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Presented by Dr. Cris Moen, Assistant Professor

Charles E. Via, Jr. Department of
Civil and Environmental Engineering
Virginia Tech
www.moen.cee.vt.edu

TRB AFH70 Committee Meeting

Fabrication and Inspection of Metal Structures
January 24, 2011

OUTLINE
Introduction
personal background, interest in cold bending fabrication
Examples-cold bending (curving) steel for bridge applications
girders
orthotropic decks
folded plate systems
Cold bending (curving) techniques and mechanics
girders, beams, plates
advantages, challenges, solutions
Research needs
connect the dots between the art of cold bending, material
science and mechanics
address the presence of cold bending residual stresses
quantify fatigue resistance
develop tools and methods that help fabricators, engineers

PERSONAL INTRODUCTION
Professional experience
J. Muller International, 1997-2002
Parsons Transportation Group, 2002-2005

PERSONAL INTRODUCTION
Academic preparation
BSCE, University of Virginia, 1995
MSCE, University of Virginia, 1997
PhD, Johns Hopkins University, 2008

Nonlinear FE modeling to collapse,

i.e. simulated tests

PERSONAL INTRODUCTION

Include plastic strains

and residual stresses
from cold bending in FE
analysis

COLD BENDING STEEL

:(/#$&%$-'(-<'$*,-%"#$%%-,5$-

2$*+&,-&."$#-677-4+5#%8%"#&'(-&1'(19

:(/#$&%$-'(-5*"';&"$%"#$(1"4-.#+;-%"#&'(-&1'(1-

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Cold bending changes steel material properties

)(*+&,-&."$#/+*,-0$(,'(1

2$*+&,-&."$#-3-4+5#

!"#&'(
Chajes, A., Britvec, S.J., and Winter, G. (1963). "Effects of cold-straining on structural steel
sheets." Journal of the Structural Division, ASCE, 89(ST2), 1-32.

Cold bending produces residual stresses.

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Quach, W.M., Teng, J.G., and Chung, K.F. (2006 ). "Finite element predictions of residual
stresses in press-braked thin-walled steel sections." Engineering Structures, 28, 1609-1619.
Key, P., and Hancock, G.J. (1993). "A Theoretical Investigation of the Column Behaviour
of Cold-Formed Square Hollow Sections." Thin-Walled Structures, 16, 31-64.

We have simplified methods for approximating cold

bending residual stress and plastic strain distributions.

Moen, C.D., Igusa, T., and Schafer, B.W. (2008).

"Prediction of Residual Stresses and Strains in ColdFormed Steel Members." Thin-Walled Structures, 46(11),
1274-1289.

OUTLINE
Introduction
personal background, interest in cold bending fabrication
Examples-cold bending (curving) steel for bridge applications
girders
orthotropic decks
folded plate systems
Cold bending (curving) techniques and mechanics
girders, beams, plates
advantages, challenges, solutions
Research needs
connect the dots between the art of cold bending, material
science and mechanics
address the presence of cold bending residual stresses
quantify fatigue resistance
develop tools and methods that help fabricators, engineers

COLD BENDING AND BRIDGES

Bill McEleney, NSBA

Horizontal curves!

COLD BENDING AND BRIDGES

Bill McEleney, NSBA

Horizontal curves!

COLD BENDING AND BRIDGES

Gergess, N.A., and Sen, R. (2008). !Cold Curving Steel Bridge Girders.! Transportation
Research Board: Journal of the Transportation Research Board, 2081, 165175.

COLD BENDING AND BRIDGES

Bend in segments to avoid web stiffeners

Gergess, N.A., and Sen, R. (2008). !Cold Curving Steel Bridge Girders.! Transportation
Research Board: Journal of the Transportation Research Board, 2081, 165175.

COLD BENDING AND BRIDGES

Gergess, N.A., and Sen, R. (2008). !Cold Curving Steel Bridge Girders.! Transportation
Research Board: Journal of the Transportation Research Board, 2081, 165175.

COLD BENDING AND BRIDGES

Orthotropic bridge decks!

McQuaid, D.L., and Medlock, R.D. (2005). "Constructability Issues in Orthotropic Steel Bridge Deck Bridges."
2005 World Steel Bridge Symposium, American Institute of Steel Construction, Orlando, FL.

COLD BENDING AND BRIDGES

Press braking steel plate!

COLD BENDING AND BRIDGES

Atorod Azizinamini, Ph.D., P.E.
Highway Bridge Services, L.L.C
402-770-6210

Folded plate bridge systems!

COLD BENDING AND BRIDGES

Folded plate bridge systems!

COLD BENDING AND BRIDGES

Cold-formed light poles!

OUTLINE
Introduction
personal background, interest in cold bending fabrication
Examples-cold bending (curving) steel for bridge applications
girders
orthotropic decks
folded plate systems
Cold bending (curving) techniques and mechanics
girders, beams, plates
advantages, challenges, solutions
Research needs
connect the dots between the art of cold bending, material
science and mechanics
address the presence of cold bending residual stresses
quantify fatigue resistance
develop tools and methods that help fabricators, engineers

BENDING METHODS (BEAMS, GIRDERS)

Easy way,
Hard way,
camber

Repair and
straightening

Alwood, T.A. (2006). What Engineers Should Know About Bending Steel. Modern Steel
Construction, American Institute of Steel Construction, May 2006.

ROLLING (COLD BENDING)

Kottler Metal Products

WintersDowney, E. (2006). A Conversation with a Bender!. Modern Steel Construction, July 2008, American
Institute of Steel Construction, Chicago, IL.

ROLLING (COLD BENDING)

Compared U.S. and European

minimum bending radii limits
for HSS sections

Kennedy, J.B., Seddeik, M., and Brady, F. (1986). "Deformations in cold-bent HSS members."
Engineering Journal, AISC, Third Quarter, 117-123.
Brady, F.J. (1978). "Determination of minimum radii for cold bending of square and rectangular hollow
structural sections." Programme 11B Final Report, Comit International pour le Dveloppment et l'Etude de
la Construction Tubulaire (CIDECT), Hamilton, Ontario.

INCREMENTAL BENDING

Bendco

Gag pressing is typically used for camber operations.

BENDING METHODS (PLATES)

Roll-forming

Press braking

COLD BENDING ADVANTAGES

and cold bending!

%Thatcher, W.M. (1967). "Horizontally Curved Steel Girders - Fabrication and Design." AISC National
Engineering Conference, American Institute of Steel Construction, San Francisco, CA.

Cut everything straight, then bend to final shape.

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COLD BENDING ADVANTAGES

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4*)#%135"+67

Shanley, F.R. (1957). Strength of

Materials, McGraw-Hill Book Company,
New York, NY.
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)&"*$%+(5,1-%13(

Increased yield stress, capacity? Engineers need to be careful about

this one!. Cold bending residual stresses can counteract increased
yield stress.

OUTLINE
Introduction
personal background, interest in cold bending fabrication
Examples-cold bending (curving) steel for bridge applications
girders
orthotropic decks
folded plate systems
Cold bending (curving) techniques and mechanics
girders, beams, plates
advantages, challenges, solutions
Research needs
connect the dots between the art of cold bending, material
science and mechanics
address the presence of cold bending residual stresses
quantify fatigue resistance
develop tools and methods that help fabricators, engineers

COLD BENDING CHALLENGES

Flexural stiffness is reduced by the presence of

cold bending residual stresses.

Beam cambered for unpropped construction

Lange, J., and Grages, H. (2009). "Influence of the Bauschinger Effect on the Deflection Behaviour of Cambered Steel
and Steel Concrete Composite Beams." Structural Engineering International, International Association of Bridge and
Structural Engineers, Zurich, Switzerland.

COLD-BENDING CHALLENGES
Residual stresses can be much different for
straight and roller bent wide flange steel beams

straight

roller bent

Spoorenberg, R.C., Snijder, H.H., and Hoenderkamp, J.C.D. (2010). "Experimental investigation of
residual stresses in roller bent wide flange steel sections." Journal of Constructional Steel Research,
66(6), 737-747.

COLD BENDING CHALLENGES

Cross-section deformation, fracture

Bjorhovde, R. (2006). "Cold Bending of Wide-Flange Shapes for Construction."

Engineering Journal, AISC, 4th Quarter, 271-286.

COLD BENDING CHALLENGES

Cross-section deformation, fracture

Brady, F.J. (1978). "Determination of minimum radii for cold bending of square and rectangular hollow
structural sections." Programme 11B Final Report, Comit International pour le Dveloppment et l'Etude de
la Construction Tubulaire (CIDECT), Hamilton, Ontario.

COLD BENDING CHALLENGES

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HMGH\M%ONM%OZNOXU%GZ%S6N]Q6]NO\%QGRQMNRS3%ORU%6LO6[S%SM\UGJ%O%HNG^\MJ>%WM[TM%NG\\MU%6LG]SORUS%GZ%HXMQMS%GZ%S6MM\%ORU%
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Ross, C. (2002). The Art of Bending. Modern Steel Construction, American Institute of Steel Construction,
October 2002.
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^MOJS%UGR[6%O\PO@S%JO6QL%6LM%QO\Q]\O_GRS>
Ricker, D.T. (1989). !Cambering Steel Beams.!
Engineering Journal, AISC, 4th Quarter, 136142.

Cold-bending can cause material fracture leading to

scrap.

WintersDowney, E. (2006). A Conversation with

a Bender!. Modern Steel Construction, July 2008,
American Institute of Steel Construction, Chicago,
IL.

AISC (2002). Meet the experts-bending steel.

Modern Steel Construction, American Institute of
Steel Construction, June 2002.

Fatigue resistance?
Fracture toughness?
Geometric limits on bending?

ENGINEERING SOLUTIONS
Mechanics-based cold bending prediction methods
Gergess, N.A., and Sen, R. (2006). !Refined analysis for cold bending steel plate girders.! Journal of
Constructional Steel Research, 61, 13531372.
Gergess, N.A., and Sen, R. (2007). !FullScale Cold Bending Demonstration Test.! Journal of
Constructional Steel Research, 63(10), 12951304.
Gergess, N.A., and Sen, R. (2008a). !Cambering structural steel Igriders using cold bending.!
Journal of Constructional Steel Research, 64, 407417.
Gergess, N.A., and Sen, R. (2008b). !Cold Curving Steel Bridge Girders.! Transportation Research
Board: Journal of the Transportation Research Board, 2081, 165175.
Bjorhovde, R. (2006). "Cold Bending of Wide-Flange Shapes for Construction." Engineering Journal,
AISC, 4th Quarter, 271-286.
Moen, C.D., Igusa, T., and Schafer, B.W. (2008). "Prediction of Residual Stresses and Strains in ColdFormed Steel Members." Thin-Walled Structures, 46(11), 1274-1289.

Cold bending simulations and experiments

Brockenbrough, R.L. (2006). !Development of Fabrication Guidelines for Cold Bending of Steel Plates.!
Engineering Journal, AISC, First Quarter, 4956.
Quach, W.M., Teng, J.G., and Chung, K.F. (2006 ). "Finite element predictions of residual stresses in
press-braked thin-walled steel sections." Engineering Structures, 28, 1609-1619.
Spoorenberg, R.C., Snijder, H.H., and Hoenderkamp, J.C.D. (2010). "Experimental investigation of
residual stresses in roller bent wide flange steel sections." Journal of Constructional Steel Research,
66(6), 737-747.

ENGINEERING SOLUTIONS
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RESEARCH NEEDS
Research needs
connect the dots between the art of cold bending, material
science and structural mechanics
use simply applied math/physics/mechanics to increase
fabrication speed, accuracy, efficiency
address the influence of cold bending residual stresses on
structural behavior deflections, strength,"
quantify fatigue resistance of cold-bent members

Thank you for your attention!

This presentation can be downloaded at
www.moen.cee.vt.edu

OUTLINE
AISC Engineering FAQ, 2006

OUTLINE

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OUTLINE

WintersDowney, E. (2006). Curved steel a reference for architects and engineers.

American Institute of Steel Construction.