The aim of this thesis is to assess the suitability of cold-formed rectangular hollow sections (RHS) for plastic design. The project involved an extensive range of tests on cold-formed Grade C350 and Grade C450 (DuraGal) RHS beams, joints and frames. A large number of finite element analyses was also carried out on models of RHS beams. The conclusion is that cold- formed RHS can be used in plastic design, but stricter element slenderness (b/t) limits and consideration of the connections, are required. Further research, particularly into the effect of axial compression on element slenderness limits, is required before changes to current design rules can be finalised. Bending tests were performed on cold-formed RHS to examine the web and flange slenderness required to maintain the plastic moment for a large enough rotation suitable for plastic design. The major conclusions of the beam tests were: (i) Some sections which are classified as Compact or Class 1 by current steel design specifications do not maintain plastic rotations considered sufficient for plastic design. (ii) The current design philosophy, in which flange and web slenderness limits are independent, is inappropriate. An interaction formula is required, and simple formulations are proposed for RHS. Connection tests were performed on various types of knee joints in RHS, suitable for the column - rafter connection in a portal frame. The connection types investigated were welded stiffened and unstiffened rigid knee connections, bolted plate knee joints, and welded and bolted internal sleeve knee joints, for use in RHS portal frames. The ability of the connections to act as plastic hinges in a portal frame was investigated. The most important finding of the joint tests was the unexpected fracture of the cold-formed welded connections under opening moment before significant plastic rotations occurred. The use of an internal sleeve moved the plastic hinge in the connection away from the connection centre- line thus eliminating the need for the weld between the RHS, or the RHS and the stiffening plate, to carry the majority of the load. The internal sleeve connections were capable of sustaining the plastic moment for large rotations considered suitable for plastic design. Tests on pinned-base portal frames were also performed. There were three separate tests, with two different ratios of vertical to horizontal point loads, simulating gravity and horizontal wind loads. Two grades of steel were used for comparison. The aims of the tests were to examine if a plastic collapse mechanism could form in a cold-formed RHS frame, and to investigate if plastic design was suitable for such frames. In each frame, two regions of highly concentrated curvature were observed before the onset of local buckling, which indicated the formation of plastic hinges and a plastic collapse mechanism. An advanced plastic zone structural analysis which accounted for second order effects, material non-linearity and member imperfections slightly overestimated the strength of the frames. The analysis slightly underestimated the deflections, and hence the magnitude of the second order effects. A second order plastic zone analysis, which did not account for the effects of structural imperfections, provided the best estimates of the strengths of the frames, but also underestimated the deflections. While cold-formed RHS did not satisfy the material ductility requirements specified for plastic design in some current steel design standards, plastic hinges and plastic collapse mechanisms formed. This suggests that the restriction on plastic design for cold-formed RHS based on insufficient material ductility is unnecessary, provided that the connections are suitable for plastic hinge formation, if required. A large number of finite element analyses were performed to simulate the bending tests summarised above, and to examine various parameters not studied in the experimental investigation. To simulate the experimental rotation capacity of the RHS beams, a sinusoidally varying longitudinal local imperfection was prescribed. The finite element analysis determined similar trends as observed experimentally, namely that the rotation capacity depended on both the web slenderness and flange slenderness, and that for a given section aspect ratio, the relationship between web slenderness and rotation capacity was non-linear. The main finding of the finite element study was that the size of the imperfections had an unexpectedly large influence on the rotation capacity. Larger imperfections were required in the more slender sections to simulate the experimental results. There should be further investigation into the effect of varying material properties on rotation capacity.

Although it offers a wide variety of interesting properties such as fire resistance or durability, stainless steel has been used in limited amount in structures. It is a known fact that the design rules don't properly account for the additional benefits of stainless steel properties and are largely based on the specifications for carbon steel. Indeed, a number of similarities exist between stainless steel and ordinary carbon steel but there is sufficient differences to afford a specific treatment in design standards. And since stainless steel is an expensive material, it is important to accurately predict the resistance of structural members. The present research work is dedicated to the study of cold-formed stainless steel profiles. It actually follows the life of a stainless steel construction element and falls on three fundamental topics: the material behavior, the through-thickness residual stress distribution and mechanical enhancement due to the cold-forming process and, last, the strength of concentrically compressed thin-walled columns. Firstly, several constitutive models are characterized such as Teodosiu-Hu's micro-structural based hardening model, capable of predicting the behavior of the studied stainless steel grade submitted to biaxial loading causing plastic strain. This model accounts for the nonlinear hardening behavior, the anisotropy, the Bauschinger effect and more complex behavior such as the observed work-hardening stagnation under reversed deformation at large strains. For this purpose, a collection of tests is carried out including multiaxial tests such as tensile-shear tests and successive simple shear tests and plane-strain tests. Secondly, the effects of the forming process on the mechanical properties are studied. To begin with, on the basis of the constitutive models developed previously, an analytical method that calculates the biaxial residual stress distribution in the walls and in the corners of cold-formed profiles is established. Based on the conclusions drawn from this theoretical analysis, a new formula for the evaluation of the actual mechanical properties is established. This formula is not restricted to a single alloy or type of cross-section. Current design standards are then used to calculate the strength of lipped-channel section columns failing by combined distortional and overall flexural-torsional buckling and the results are compared to tests. Indeed, full-scale tests on cold-formed stainless steel lipped channel section columns were achieved in the Structures Laboratory of the University of Liège. And, once verified against the test results, finite element models were used to generate additional results when necessary. The author then presents a new Direct Strength Method taking into account this phenomenon. Finally, a wide amount of reference results are gathered from the literature, without limiting oneself to any kind of cross-section or stainless steel grade. This database is used to propose an improved formulation for the design of stainless steel thin-walled section columns failing by distortion, local or combination of local and overall buckling in the low slenderness range.

The importance of fire safety design has been realised due to the ever increasing loss of properties and lives caused by structural failures during fires. In recognition of the importance of fire safety design, extensive research has been undertaken in the field of fire safety of buildings and structures especially over the last couple of decades. In the same period, the development of fire safety engineering principles has brought significant reduction to the cost of fire protection. However the past fire research on steel structures has been limited to heavier, hot-rolled structural steel members and thus the structural behaviour of light gauge cold-formed steel members under fire conditions is not well understood. Since cold-formed steel structures have been commonly used for numerous applications and their use has increased rapidly in the last decade, the fire safety of cold-formed steel structural members has become an important issue. The current design standards for steel structures have simply included a list of reduction factors for the yield strength and elasticity modulus of hot-rolled steels without any detailed design procedures. It is not known whether these reduction factors are applicable to the commonly used thin, high strength steels in Australia. Further, the local buckling effects dominate the structural behaviour of light gauge cold-formed steel members. Therefore an extensive research program was undertaken at the Queensland University of Technology to investigate the local buckling behaviour of light gauge cold-formed steel compression members under simulated fire conditions. The first phase of this research program included 189 tensile coupon tests including three steel grades and six thicknesses to obtain the accurate yield strength and elasticity modulus values at elevated temperatures because the deterioration of the mechanical properties is the major parameter in the structural design under fire conditions. The results obtained from the tensile tests were used to predict the ultimate strength of cold-formed steel members. An appropriate stress-strain model was also developed by considering the inelastic mechanical characteristics. The second phase of this research was based on a series of more than 120 laboratory experiments and corresponding numerical analyses on cold-formed steel compression members to investigate the local bucking behaviour of the unstiffened flange elements, stiffened web elements and stiffened web and flange elements at elevated temperatures up to 800°C. The conventional effective design rules were first simply modified considering the reduced mechanical properties obtained from the tensile coupon tests and their adequacy was studied using the experimental and numerical results. It was found that the simply modified effective width design rules were adequate for low strength steel members and yet was not adequate for high strength cold-formed steel members due to the severe reduction of the ultimate strength in the post buckling strength range and the severe reduction ratio of the elasticity modulus to the yield strength at elevated temperatures. Due to the inadequacy of the current design rules, the theoretical, semi-empirical and empirical effective width design rules were developed to accurately predict the ultimate strength of cold-formed steel compression members subject to local buckling effects at elevated temperatures. The accuracy of these new design methods was verified by comparing their predictions with a variety of experimental and numerical results. This thesis presents the details of extensive experimental and numerical studies undertaken in this research program and the results including comparison with simply modified effective width design rules. It also describes the advanced finite element models of cold-formed steel compression members developed in this research including the appropriate mechanical properties, initial imperfections, residual stresses and other significant factors. Finally, it presents the details of the new design methods proposed for the cold-formed steel compression members subject to local buckling effects at elevated temperatures.

The aim of this thesis is to assess the suitability of cold-formed rectangular hollow sections (RHS) for plastic design. The project involved an extensive range of tests on cold-formed Grade C350 and Grade C450 (DuraGal) RHS beams, joints and frames. A large number of finite element analyses was also carried out on models of RHS beams. The conclusion is that cold- formed RHS can be used in plastic design, but stricter element slenderness (b/t) limits and consideration of the connections, are required. Further research, particularly into the effect of axial compression on element slenderness limits, is required before changes to current design rules can be finalised. Bending tests were performed on cold-formed RHS to examine the web and flange slenderness required to maintain the plastic moment for a large enough rotation suitable for plastic design. The major conclusions of the beam tests were: (i) Some sections which are classified as Compact or Class 1 by current steel design specifications do not maintain plastic rotations considered sufficient for plastic design. (ii) The current design philosophy, in which flange and web slenderness limits are independent, is inappropriate. An interaction formula is required, and simple formulations are proposed for RHS. Connection tests were performed on various types of knee joints in RHS, suitable for the column - rafter connection in a portal frame. The connection types investigated were welded stiffened and unstiffened rigid knee connections, bolted plate knee joints, and welded and bolted internal sleeve knee joints, for use in RHS portal frames. The ability of the connections to act as plastic hinges in a portal frame was investigated. The most important finding of the joint tests was the unexpected fracture of the cold-formed welded connections under opening moment before significant plastic rotations occurred. The use of an internal sleeve moved the plastic hinge in the connection away from the connection centre- line thus eliminating the need for the weld between the RHS, or the RHS and the stiffening plate, to carry the majority of the load. The internal sleeve connections were capable of sustaining the plastic moment for large rotations considered suitable for plastic design. Tests on pinned-base portal frames were also performed. There were three separate tests, with two different ratios of vertical to horizontal point loads, simulating gravity and horizontal wind loads. Two grades of steel were used for comparison. The aims of the tests were to examine if a plastic collapse mechanism could form in a cold-formed RHS frame, and to investigate if plastic design was suitable for such frames. In each frame, two regions of highly concentrated curvature were observed before the onset of local buckling, which indicated the formation of plastic hinges and a plastic collapse mechanism. An advanced plastic zone structural analysis which accounted for second order effects, material non-linearity and member imperfections slightly overestimated the strength of the frames. The analysis slightly underestimated the deflections, and hence the magnitude of the second order effects. A second order plastic zone analysis, which did not account for the effects of structural imperfections, provided the best estimates of the strengths of the frames, but also underestimated the deflections. While cold-formed RHS did not satisfy the material ductility requirements specified for plastic design in some current steel design standards, plastic hinges and plastic collapse mechanisms formed. This suggests that the restriction on plastic design for cold-formed RHS based on insufficient material ductility is unnecessary, provided that the connections are suitable for plastic hinge formation, if required. A large number of finite element analyses were performed to simulate the bending tests summarised above, and to examine various parameters not studied in the experimental investigation. To simulate the experimental rotation capacity of the RHS beams, a sinusoidally varying longitudinal local imperfection was prescribed. The finite element analysis determined similar trends as observed experimentally, namely that the rotation capacity depended on both the web slenderness and flange slenderness, and that for a given section aspect ratio, the relationship between web slenderness and rotation capacity was non-linear. The main finding of the finite element study was that the size of the imperfections had an unexpectedly large influence on the rotation capacity. Larger imperfections were required in the more slender sections to simulate the experimental results. There should be further investigation into the effect of varying material properties on rotation capacity.