11 COLD-FORMED CONNECTIONS

11.1 Connections
A variety of joining methods is available for thin-walled structures. In comparison with thicker
connections (t > 3 mm) the behaviour of connections in thin-walled elements is characterised by the
small plates stiffness [Davies, 1991]. Therefore, additional effects may appear in the ultimate limit
state and serviceability state and the level of safety may be more depend on the quality control. Such
effects are, for example, the tilting of the fastener in hole bearing failure or the big distortion of the
sheet when the fastener is loaded in tension and the sheet is pulled over the head of the fastener. This
is the reason why design procedures for connections in cold-formed elements have been developed
which are, in a number of cases, different from the procedures for thicker steel. Connections to thin
walled members are used for:
• connecting steel sheets to the supporting structure, e.g. to a purlin;
• interconnecting two or more sheets, e.g. longitudinal seams of sheets;
• assemble linear cold-formed sections, e.g. in storage racking.

11.2 Fastenings
For thin-walled constructions three types of fastenings can be identified [Toma et al, 1993]
and [Yu, 2000]:
• fastenings with mechanical fasteners;
• fastenings based on welding;
• fastenings based on adhesive bonding.

Table 11.1 Global survey of application field for mechanical fasteners

Thin Steel Thin
to to to Fastener Remark
thick wood thin

X X Bolts M5-M16

Self-tapping screw φ 6,3 with washer ≥ 16 mm, 1 mm

X
thick with elastomer

Hexagon head screw φ 6,3 or 6,5 with washer ≥ 16

X X
mm, 1 mm thick with elastomer
Self-drilling screws with diameters:
φ 4,22 or 4,8 mm
X X
φ 5,5 mm
φ 6,3 mm

Thread-cutting screw φ 8 mm with washer ≥ 16 mm,

X
1 mm thick with or without elastomer

Blind rivets with diameters:

φ 4,0 mm
φ 4,8 mm
φ 6,4 mm
X Shot pins

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Mechanical fasteners
Table 1 shows a global field of application of the different mechanical fasteners according to
Toma [Toma et al, 1993]. In the following part some short information is given concerning the
different mechanical fasteners. Bolts with nuts are threaded fasteners, which are assembled in
preformed holes through the material elements to be joined [Hancock, 1998]. Thin members will
necessitate the use of bolts threaded close to the head [Wong, Chung, 2002]. For thin-walled sections
the bolt diameter is usually M5-M16. The preferred property classes are 8.8 or 10.9. Results of tests
indicate that the following four basic types of failure usually occur [Fan, 1995] in the cold-formed
steel bolted connections:
• longitudinal shearing of the sheet along two parallel lines, see Figure 11.1a;
• bearing or piling up of material in front of the bolt, see Figure 11.1b;
• tearing of the sheet in the net section, see Figure 11.1c;
• shearing of the bolt, see Figure 11.1d.
In many cases, a joint is subject to a combination of different types of failure. The tearing of
the sheet is often caused by the excessive bolt rotation and dishing of the sheet material. Screws can
provide a rapid and effective means to fasten sheet metal siding and roofing to framing members and
to make joints in siding and roofing, as shown in Figure 11.2. They can also be used in steel framing
systems and roof trusses and to fasten drywall panels to metal channels and runners. Two main types
of screws can be distinguished:
• self tapping screws, i.e. thread-forming screws and thread-cutting screws,
• self-drilling screws.
Most of the screws will be combined with washers to improve the load-bearing capacity of the
fastening and/or to make the fastening self-sealing. Some types have plastic heads or plastic caps are
available for additional corrosion resistance and colour matching.

a) Ribbed siding
a) Longitudinal shear failure of sheat

b) Flat siding
b) Bearing failure of sheet

c) V - beam roofing
c) Tensile failure of sheet,

d) Shear failure of bolt d) Corrugated roofing

Figure 11.1 Failures of bolted connections Figure 11.2 Application of self-tapping screws

Figure 11.3 shows the thread types for thread-forming screws. Type A is used for fastening
thin-to-thin sheets. Type B is used for fixings to steel base of a thickness greater than 2 mm. Type C
is usually used for fixings to thin steel bases of a thickness up to 4 mm. Thread-forming screws
normally are fabricated from carbon steel (plated with zinc and lubricant).

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 Figure 11.4 shows some examples of thread and point of thread-cutting screws. Thread-
cutting screws are used for fastening to thicker metal bases. Self-drilling screws drill their own hole
and form their mating thread in one operation. Figure 11.5 shows two examples of self-drilling
screws.

Type A Type B Type C

Figure 11.3 Figure 11.4
Thread types for thread-forming screws Thread and point of thread-cutting screws

drill flute
thread
drill point screw
length
drill diameter drill
7,7
Figure 11.5 Examples of self-drilling screws

Blind rivets and tubular rivets are often used in cold-formed steel construction [Kaitila et al,
2001]. They are used to simplify assembly, improve appearance, and reduce the cost of connection.
A blind rivet is a mechanical fastener capable of joining work pieces together where access to the
assembly is limited to one side only. Based on the method of setting, blind rivets can be classified
into
• pull-stem rivets, see Figure 11.6;
• explosive rivets (with a chemical charge in the body, which is expanded by applying heat to
the rivet head),
• drive-pin rivets (two-piece rivets, which consist of a rivet body and a separate pin installed
from the head side of the rivet).

Tubular rivets are often used to fasten sheet metal. The strength in shear or compression is
comparable to that of solid rivets. Nominal body diameters range from 0,8 to 7,9 mm. The
corresponding minimum lengths range from 0,8 to 6,4 mm.

Cut at rivet head and grind

Self plugging Pull through Open end Closed end

a) pull-stem rivets

Open end Closed end c) drive-pin rivets

b) explosive rivets
Figure 11.6 Blind rivets

Shot pins, examples are shown in Figure 11.7, are fasteners driven through the connecting
plate into the base metal by powder shot or by air.

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 Powder actuated fasteners Air driven fasteners
Figure 11.7 Shot pins

Figure 11.8 Sequence of forming press-joint

Press joining is a relatively new technique for joining cold-formed steel sections. The joint is
formed using the parent metal of the sections to be connected [Kolari K., 1999]. The tools used to
form a press-joint consist of a male and female punch and die. Figure 11.8 shows the sequence of
forming a press-joint.
Rosette-joining, see Figure 11.9, is also a new automated approach for fabricating cold-formed steel
components such as stud wall panels and roof trusses. It is formed in pairs between prefabricated
holes in one jointed part and collared holes in the other part. The joining process is shown in
Figure 11.9.

Figure 11.9 Rosette-joint and rosette-joining process [Makelainen et al, 1999]

Welding
Cold-formed sections joints can be made by the open arc process as well as by resistance welding.
The following welding procedures are used for thin-walled sections, see [Toma et al, 1993]:
• GMA – welding (gas metal arc welding),
• manual arc welding (welding with covered electrodes),
• TIG welding (tungsten-inert gas welding),
• plasma welding.
The following types of arc welds are generally used in cold-formed steel constructions, see
Figure 11.10 [Yu, 2000]:

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 • groove welds,
• arc spot welds (puddle welds),
• arc seam welds,
• fillet welds,
• flare groove welds.

Resistance welding is done without open arc. In contrary to the open arc welding process there is
no need of protection of the molten metal by shielding gas slag. Figure 11.11 demonstrates the
resistance welding procedures.

a) groove welds in butt joints b) arc spot welds

c) arc seam welds d) fillet welds.

end view

e) flare bevel groove weld f) flare V-groove

Figure 11.10 Arc welds

electrodes projection
electrodes or electrodes or welds
or dies
welding tips welding tips

Before After
welding welding
a) spot welding b) seam welding c) projection welding
Figure 11.11 Resistance welding procedures

Adhesive bonding
For fastening by means of bonding it is important to realise that a bonded connection possesses a good
shear resistance and mostly a bad peeling resistance, see Figure 11.12. For that reason a combination
of bonding and mechanical fastening may be chosen. Adhesives used for thin walled steels are as
follows:
• epoxy adhesive types – best hardening will appear under elevated temperature (order of
magnitude 80-120°C);
• acrylic adhesive types – more flexible than the epoxy types.

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Advantages of bonded connections are a uniform distribution of forces over the connection and
a good repeated load behaviour. Some disadvantages are that the surface should be flat and clear and
there is a hardening time.

Loaded by shear

Loaded by peeling

Figure 11.12 Shear and peeling of connections by means of adhesive bonding

11.3 Design considerations

Design considerations for cold-formed members are specified in Chapter 8 of standard
prEN 1993-1-3 [prEN 1993-1-3, 2003]. Concerning the Mechanical fastenings, it has to underline that
bearing resistance, shearing resistance, tension resistance and net section resistance of connected
members are calculated in the same way as for thick sections, for any type of connector. There are
differences at the numerical coefficients from formulas, which are specified by the standard. Specific
failure modes are checked for the pull through and pull out resistance. Connections with mechanical
fasteners are treated in paragraph 8.4 of the norm like blind rivets (Table 8.1), self-tapping screws
(Table 8.2), cartridge fired pins (Table 8.3) and bolts (Table 8.4). Concerning the welded
connections, spot welds represent a fastening technology, which is specific for thin walled metal
structures and specific design provisions have been developed. They are specified in Eurocode 3-1-3.
Design resistances for spot welds connections are given in paragraph 8.5, Table 8.5, while for lap
welds in paragraph 8.6, with fillet welds in (8.6.2) and arc spot welds in (8.6.3), respectively.
Specifications for connections based on adhesive bonding are included in the standard for aluminium
structures ENV 1999-1. Special mechanical connections, press- and rosette-joints are in the same
situation and they have to be treated in the same way as the previous ones. When design by testing is
used, provisions of ENV 1993-1-3, Chapter 9 and Annex Z of ENV 1993-1-3 has to be used.

Q&A 11.1 Increased Yield Strength by Cold-Forming

Can the increase in yield strength due to cold working be utilized in the design of connections that are
welded after the member is formed?
__________________________________________________________________________

In the design formula for the weld strength in prEN 1993-1-3, however, the strength
parameter for the material is the ultimate strength fu of the plate material, which is not influenced by
cold forming. It is noted that due to the heat input during welding, the increased yield strength near
the welds disappears, which means that at those cross sections no positive effect of the cold forming is
allowed to be taken into account.

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Q&A 11.2 Deformation Capacity of Shear Connections
Why is the limit Fy,Rd ≥ 1,2 Fu,Rd in the standard prEN 1993-1-3?
___________________________________________________________________________

This question refers to prEN 1993-1-3, Table Design resistance for self-tapping screws. The
design criterion for shear deformation capacity of connection is expressed as:
FV ,Rd ≥ 1,2 Fn ,Rd , (11.1)

where Fv,Rd is the shear resistance, see Figure 11.1, or evaluated by testing and
A f
Fn ,Rd = net u (11.2)
γ M2

is the net section resistance.

The multiplier 1,2 in formula (11.1) is to ascertain that the failure mode of the connection is
bearing or net section failure and not failure of the screw. Failure of the screw gives brittle behaviour
of the connection, because of the small deformation capacity of the screw in shear [LaBoube, Yu,
1999].
The factor 1,2 is taken into account the possible unfavourable mechanical properties of the
steel compared to the screw (the real strength of the steel may be much higher than the nominal value,
while the strength of the screw may be just the nominal value). The required conditions should be
fulfilled when deformation capacity of the connection is needed. When these conditions are not
fulfilled it should be proved that the required deformation capacity will be provided by other parts of
the structure.

Q&A 11.3 Screws in Sandwich Panels

How is the resistance of bolts in sandwich panels subject to shear and tension evaluated?
___________________________________________________________________________

Self-tapping screws are used to connect sandwich panels [prEN 14509, 2002]. The
loading by temperature, wind and dead load is mostly cyclic. The screws of austenitic steels
with special shapes are used to prevent the fracture under serviceability loading, see 11.13a.
The flexibility of the structure (stress skin method) is taken into account to prevent the collapse
under loading by the differences of temperature [Davies, 1986] and [De Matteis, Landolfo, 1999]. The
distribution of forces into the internal and external plate of the sandwich panel may be taken into
account using the component method, see 11.13b [Mareš et al, 2000]. Two failure modes of
bolted connection of sandwich panel were observed the bearing in the internal hole, see
Fig. 11.14a, and the fracture of the screw shank, see Fig. 11.14b. By the horizontal loading of
panels the membrane forces due to deflection of sandwich panel, see [ECCS 66, 2000], are
taken into account including the prying forces caused by additional fixing moments, see
Fig. 11.14c,.
Bolt in bending
Bolt in shear
Plastic hinge Plate in bearing
Bolt in shear
Fd
Plate in bearing

a) deflection curve of traditional screw and of b) component model of bolt in sandwich panel
screw with notches on shank [Mareš et al, 2000]

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 Figure 11.13 Bolted connection of sandwich panel
r1 r2

a) failure mode bearing of the b) failure mode fracture of the c) prying forces caused by
internal hole screw shank additional fixing moments
Figure 11.14 Bolted connection of sandwich panel

Q&A 11.4 Bearing of Thin Plates

What is the difference between the bearing resistance of thick and of thin (thin walled) plates?
___________________________________________________________________________

The prediction models for the bearing resistance are based on the experimental evidence. The
formula for bolts in thick plates (for thickness larger or equal to 3 mm) is included in Table 3.4 of
prEN1993-1-8 and for bolts in thin plates in Table 8.1 of prEN 1993-1-3, where rivets, self taping
screws and pins are also included. The bearing resistance of thick plates takes into account the spacing
into the perpendicular direction, by using the factor k1,

k1 α b f u d t
Fb ,Rd = , (11.3)
γM2

where αb is the smallest of αd ; fub / fu or 1,0. In the direction of load transfer for end bolts
αd = e1 /(3 d0) and for inner bolts αd = p1 /(3 d0) – 0,25. Factor k1 is for edge bolts the smallest of
2,8 (e2 / d0) - 1,7 or 2,5 and for inner bolts the smallest of 1,4 (p2 / d0) - 1,7 or 2,5. e1, e2, p1, p2 are end
distance, edge distance and spacing for fasteners. d0 is diameter of the hole, d is the bolt diameter and
t is the sum of thickness of connected plates in the checked direction. The bearing resistance of thin
plates uses the factor kt to take into account the thinners of the plate,

2 ,5 α b kt f u d t
Fb ,Rd = , (11.4)
γM2

where αb is smallest of αb = e1 / (3 d) and αb = 1,0; while kt for 0,75 mm ≤ t ≤ 1,25 mm is

kt = (0,8 t + 1,5) / 2,5 and for t > 1,25 mm is kt = 1,0. The resistance for the thickness beyond this
range of validity is determined from the tests.

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