Corrugated Sheet Metal Research Articles

Developable forming of high-strength corrugated sheet metal

The classical theory of folded developables suggests that curved crease folding can be applied to sheet metal of high strength to manufacture parts with complex geometries. However, its application has been limited to sheet metals with low strength and requires grooving or perforation of the material at the fold lines. Applying the geometrical concept otherwise remains unexplored despite its potential in sheet metal-intensive industries like automotive, transportation, and construction. The current study introduces a novel sheet metal forming technique called developable forming. The theory of folded developables is applied to design a die tool for flange drawing a developable-shaped steel sheet. A developable connection is produced from high-strength material without resorting to thickness accommodation techniques. Experimental findings establish that the novel process does not follow the premises of the theory of folded developables. New shape effects are observed and the terms curving and coning are introduced to describe these. Additionally, significant redundant strains are identified in the flange, highlighting the different deformation modes in the developable forming process. A higher formability is achieved for a material with limited uniaxial elongation highlighting the need for further investigation on the mechanisms involved in the novel process.

Enhancing productivity through work study - A case of electric power pole cross arm fabrication

In the area of globalization any manufacturing industry must be competent in terms of productivity, quality, cost and delivery. A fundamental improvement in production is necessary to succeed in the international markets. Work study is one of the earliest scientific management methods used to determine the best way to perform production tasks in order to reduce idle time and worker fatigue as a result, increase productivity. Kombolcha Steel Products Industry, the member of MIDROC Ethiopia Technology Group, producing a variety of metal and engineering products, such as steel poles, steel structures, structural hot dip galvanization, corrugated sheet metal, etc. The company's main focus was meeting the delivery deadlines, with little attention to implementing standard working method and procedures during the production. The inefficient method of piercing the holes in the u-channels to fabricate the electric pole cross arms is causing a drop in productivity.The primary objective of the current study is to identify the bottlneck in the process of electric power poles cross arms fabrication, to set standard time for the process and reduce the cycle time. Time and method studies were used to identify the flaws in the current fabrication process and layout design. The efficient technique to manufacture the product has been replaced by redesigning and implementing a new layout. This arrangement accelerated the process by reducing the idle time for the three punching machines that undertake the piercing operations. The modified layout raised production from the target daily production of 420 pieces to 720 pieces in 8 h, resulting in a 71 % reduction in the previous work cycle from 65 to 39 s. After a time and method study, a simple change in the layout with no capital investment not only increased the company's productivity and profitability, but it also reduced worker fatigue due to extra material handling operations of raw materials and intermediate products.

Study of Innovative Connector for Steel–Concrete Composite Structures

The paper presents an analysis of the innovative connector for manufacturing a steel–concrete composite beam. The connector consists of a corrugated metal sheet in the shape of a dovetail and shot nails. The nails are shot through the sheet fold into the flange of the steel I-section. Experimental studies of push-out tests were carried out. The conducted tests proved that the proposed solution can be applied as the fastener for steel–concrete composite beams for the construction of ceilings in utility public buildings with small beam’s span. Considering the criteria presented in the Eurocode 4 standard and the results of the experiments, it was proven that all analyzed types of fasteners are ductile. The connector made of sheet with a thickness of 1.00 mm and 2 nails is characterized by a breaking load of 30.83 kN. The load-bearing capacity of the fastener can be adjusted by changing the corrugated sheet thickness and changing the number of nails shot in the single fold of the sheet.

Assessing Green Features of “Phumdi” as a Sustainable Material: A Comparative Analysis with Bamboo, Wood, Metal, and Plastic

Sustainable materials and their potential application in building industries are gaining attention; however, there is still largely unexplored floating biomass, notably “Phumdi”, as a sustainable floating building material. Phumdi, a distinctive floating biomass, is observed in specific wetland habitats in the Loktak Lake located in Manipur, India. This heterogeneous mass of vegetation, organic matter, and soil has been utilised by several communities for various purposes, such as medicine, food, forage, and material for building houses, handicrafts, and aquaculture activities. Such floating bodies serve as a sanctuary for a wide range of flora and fauna. The study aims to conduct a comprehensive comparative analysis of phumdi as a sustainable floating material in comparison with other widely recognized construction materials such as recycled plastics, bamboo, corrugated metal sheets, and wood by evaluating the “green feature” chart. The research and experiments carried out on phumdi have underscored the highest sustainability level for its use, i.e., 15 green features, followed by wood and bamboo with 14 features, and the other two materials with low sustainability performance: plastic barrels with seven features and corrugated zinc metal sheets with eight features. Further investigation is necessary for the advancement of this material as a viable alternative for biomass-based building materials.

Flexural Behavior of Pultruded GFRP–Concrete Composite Beams Strengthened with GFRP Stiffeners

The utilization and incorporation of glass fiber-reinforced plastics (GFRP) in structural applications and architectural constructions are progressively gaining prominence. Therefore, this paper experimentally and numerically investigates the use of GFRP I-beams in conjunction with concrete slabs to form composite beams. The experimental design incorporated 2600 mm long GFRP I-beams which were connected compositely to concrete slabs with a 500 mm width and 80 mm thickness. The concrete slabs are categorized into two groups: concrete slabs cast using normal-strength concrete (NSC), and concrete slabs prepared using high-strength concrete (HSC). Various parameters like the type of concrete (normal and high-strength concrete), type of stiffeners bonded to the composite section (bolt–epoxy or bolt only), and inclusion of corrugated metal sheets were investigated. To obtain the full shear connection between the GFRP I-sections and concrete slabs, two rows of shear connectors in the form of bolts were utilized. These shear connectors were erected to the top flange of the GFRP I-sections to compositely connect between the GFRP I-beams and the concrete slabs as well as the corrugated metal sheets. The strengthening of the shear webs of GFRP I-beams with GFRP T-section stiffeners resulted in an enhancement in the flexural and shear strength. The failure loads in the case of the bolt–epoxy connection for the stiffeners were 8.2% and 10.0% higher than those in the case of bolt only when the concrete compressive strengths were 20.1 MPa and 52.3 MPa, respectively. Moreover, the effect of the concrete compressive strength was vital where the failure loads increased by 79.9% and 77.1% when HSC was used instead of NSC for the cases of bolt–epoxy and bolt only, respectively. The epoxy adhesive used in conjunction with mechanical connectors, specifically bolts, resulted in sufficient composite action and delayed shear failure within the web of the GFRP beam. For the specimens with bolt–epoxy connection, strain levels in the concrete slabs were consistently higher than in the other specimens with bolts alone at the same loading level. The concrete slabs integrated with HSC registered strain levels that were 20.0% and 21.8% greater for bolt–epoxy and bolt-only connections, respectively, when compared to those using normal-strength concrete (NSC). This discrepancy can likely be credited to the enhanced composite interaction between the concrete slabs and the GFRP I-beams. In addition, ABAQUS software (version 6.2) was used to develop FE models to analyze the tested composite beams and provide a parametric study using the verified models.

PERFORMANCE EVALUATION OF SOLAR PHOTOVOLTAIC PANEL MOUNTED ON SLOPED CORRUGATED METAL SHEET ROOF IN KANO STATE NORTHWEST NIGERIA

Installation of solar photovoltaic system on roof has advantages of proper utilization of space, help in avoiding shading effects and reduction of dust accumulation on the panels. However, electrical efficiency and lifespan of solar photovoltaic panel tends to decrease due to the increase in surface temperature above the operation temperature of the panels due to its contact with the roofing sheets. The performance of solar photovoltaic panels was experimentally investigated on corrugated metal sheet (CMS) roof at four different heights (0, 100, 200, and 300mm). Four polycrystalline silicon photovoltaic panels of 10 watts each were selected from the same manufacturer. The temperatures on the roof and on the photovoltaic panels’ surfaces were measured at different solar hours. Also, the outputs of the solar panels together with the irradiance available were measured at same hours using an electronic data logger and imported to an Excel software. Irradiance variation, gap between roof and photovoltaic panels, and heating effect on panels were found to be the parameters affecting the photovoltaic system’s performance. The highest temperature attained by the photovoltaic panel is when it was directly mounted on the roof as 76.5°C while the other photovoltaic panels mounted at a gap height of 100mm, 200mm and 300mm attained the highest temperature of 71.8oC, 69,6oC and 68.0oC respectively. The panels’ extra heat was originating from CMS roof vicinity. Output powers from the panels were unequal throughout the experiment whilst exhibited similar behavior. The panels’ temperature dropped...

Analysis of the Possibility of Elimination of Threats Resulting from the Modification of Bullet Trajectory after Hitting the Target in Garrison Shooting Ranges

. During shooting operations in garrison shooting ranges, a phenomenon of random deflection of the bullet flight path was noticed which may cause secondary reflections from accidentally hit technical and ballistic shooting range elements and the ground of the actual plane of the shooting range (ricochets posing a threat to people and property within the shooting range and safety zones). Minimisation of this phenomenon must be considered during the design and operation of the shooting ranges. In 20202022 the Military Institute of Armament Technology (Zielonka, Poland) carried out tests with the aim of determining the impact of the shooting target or military target material or design (hereinafter referred to as the targets) on the risk of occurrence of modifications of bullet trajectory that cause the bullets to leave the shooting zone. The paper presents example results of these tests that show, but are not limited to, that the reasons to modify the direction of the bullet path after target penetration and any ricochets include: target material (flat or corrugated sheet metal, cardboard, plywood, etc.), target wooden legs, and even metal elements fixing the legs to the target. On the basis of the test it was shown that the metal targets prohibited on intermediate lines may cause significant deflections of the bullet flight path after penetration and dangerous ricochets. Due to the reason presented above, the metal targets are placed on the last line of targets before the main bullet trap only where the technical and ballistic parameters of the bullet trap ensure that any ricochets are captured. It was stated that the contact targets used on intermediate target lines and provided with wooden legs may cause bullet trajectory changes comparable to or even greater than in the case of the prohibited metal targets. To this end it is advisable to establish legal framework covering the ballistic inspection of the target materials to be used in garrison shooting ranges.

Dynamic bearing capacity of point fixed corrugated metal profile sheets subjected to blast loading

Blast loading scenarios and the corresponding hazards have to be evaluated for infrastructure elements and buildings especially at industrial sites for safety and security issues. Point fixed corrugated metal sheets are often applied as façade elements and can become a hazard for humans if they are pulled off. This paper investigates the dynamic bearing capacity of such structural members in terms of their general bending behavior in the middle of the span and pull-out behaviors at the fixing points. The elements are fixed at two sides and the load transfer is uniaxial. An experimental series with static and dynamic tests forms the basis to identify the predominant failure modes and to quantify the maximum stress values that can be absorbed until the investigated structural members fail. The experimental findings are applied to create and to optimize an engineering model for the fast and effective assessment of the structural response. The aim is the derivation of a validated model which is capable to predict the blast loading behavior of metal sheets including arbitrary dimensions, material properties, and screw connections. Results of this study can be integrated into a systematic risk and resilience management process to assess expected damage effects and the evaluation of robustness.

Contact interactions between soil and a corrugated metal sheet in soil-shell structures under construction

Abstract During the construction of soil-shell objects, large deformations of the shell, which is made of corrugated metal sheet, occur. This enables geodetic techniques to be used when monitoring such objects. On this basis, displacements of selected points of the shell are determined, and it is then possible to obtain bending moments, as shown in this paper. Based on measurements using strain gauges in the circumferential band of the shell, internal forces in steel are estimated. The algorithm given in the paper enables the impact of soil on the shell in the examined objects to be analysed. The proposed method of analysing forces in the contact layer becomes especially useful when the static conditions of the model of a shell, which is considered as a bar submerged unilaterally in the soil medium, are met. The paper indicates the possibility of using both measuring techniques. Calculations include a smaller share of axial forces on the contact impact during the laying phase of the backfill. The paper provides examples of the analysis of built shells and record-breaking objects, with an assessment of the effectiveness of the proposed algorithm. Good mapping of contact forces, which were calculated on the basis of bending moments, was indicated even when there was not a dense grid of measuring points. An important advantage of the algorithm involves reduction of the circumferential band that is separated from the soil-shell system to the bar, which is an element resulting from the division of the structure into subsystems.

Analysis of Stressed Skin Behaviour of a Steel Façade Frame Under Varying Structural Conditions

Steel structures are traditionally designed neglecting the in-plane bearing capacity of the cladding. However, the cladding can act in coordination with the main structure, behaving as a diaphragm and contributing to its spatial stability, enabling the so-called stressed skin concept design. The subject of this paper was an analysis of behaviour of a sample steel frame cladded with corrugated sheet metal, and connected to each other by self-tapping screws. Various conditions regarding the set and the number of fastening devices, as well as method of numerical modelling of fasteners, type of the corrugated sheet metal, and overall dimensions of the frame were analysed using FEM and ANSYS workbench software, including geometric and material nonlinearity. Results can serve as useful and reliable design guidelines, and as an argument for further propagation of the stressed skin concept design as a rational design approach for steel structures.

Design of distillation reactor with novel catalysts distribution pattern for n-amyl acetate synthesis in industrial scale

Reactive distillation combining reaction and separation has been increasingly employed in fuel synthesis, such as biodiesel, Fischer-Tropsch synthesis, and so on. However, most of the applications in this field remain at the laboratory level, so it is difficult to industrialize them. As one of the most important steps in the industrialization of reactive distillation, the design of the distillation reactor with catalytic packing has never been published. Therefore, this article derives an integral model to systematical design and optimizes the Seepage Catalytic Packing Internal (SCPI) developed by our previous works. The solution procedure of the integral model is outlined and illustrated in a case study that n-amyl acetate synthesis on an industrial scale. Additionally, it is illustrated how the internal structure is optimized with the aim of the minimum total annual cost. When the mixed feed volume is 2.95 kmol/h, the radius of the reactive distillation column (R) is 0.129 m, the width ratio of the catalyst containers to the corrugated metal sheet (m) is 1.9 the total annual cost (TAC) is the lowest. These results show that the integral model can be satisfactorily applied to design and optimize the SCPI. This research content has a guiding role in the industrialization of the reactive distillation of fuel synthesis.

The Use of the Collocation Algorithm for Estimating the Deformations of Soil-Shell Objects Made of Corrugated Sheets

Abstract The algorithm presented in this paper is intended for the analysis of deformations of shells in the construction phase of soil-shell objects when strain gauges and geodetic measurements are used. During the construction of such an object, large displacement values occur and the impact of axial forces on the displacement of a corrugated metal sheet is small. Internal forces (strain gauges), as well as the displacements of a selected circumferential band of the shell are determined directly from such observations. The paper presents two examples of the analysis of large span shell structures of constructed objects, as well as the assessment of the effectiveness of the finite difference method (FDM) in beam schemes. Good deformation mapping was indicated using the collocation algorithm and the differential approach to the solution when there is a dense mesh and regular distribution of measuring points. In the analysed examples, a significant divergence between the support conditions adopted in the FEM calculation models and the actual static conditions in the objects was indicated. The collocation algorithm is especially designed for such situations. Collocation points in such a solution are used to consider a beam – separated from a structure and without boundary constraints, but with specific changes in curvature – as a reference system, which is determined from the geodetic measurements of two collocation points.

Design development and evaluation of the efficiency of the regular separation pack

Practically all enterprises of gas and petrochemical industry use separation packs, which can be used as separators and as be an element of heat of mass exchange equipment. The article presents the design of a regular separation pack composed of corrugated metal sheets, as well as the method of measuring its main technological parameters using the finite element method. Dependence of energy consumption and separation quality on design features of the pack is established.

Research of efficiency of regular separation pack made of corrugated metal sheets

The separation of heterogeneous systems, of which gas is the solid medium, is a common process of the chemical and oil and gas industries. The quality of gas flow separation affects the efficiency of the entire process. This paper provides a research of the effect of the geometrical dimensions of a regular separation pack composed of corrugated sheets on the efficiency of fine particle capture. Information-measuring system based on simulation using computer simulation using finite element method is proposed for evaluation.

Ocena ryzyka stosowania metalowych blach falistych do budowy drogowych konstrukcji gruntowo-powłokowych

The process of construction involves a risk of non-compliance of the construction works with the basic requirements of both Polish and European regulations. In order to mitigate the consequences of events related to the above-mentioned risk the products are subject to standardisation or technical evaluation prior to their placement on the market. The risk assessment methods are designed to identify the essential characteristics of construction products by analysing their effect on compliance of the construction works in which they are incorporated with the basic requirements. This article presents risk assessment related to incorporation in the works of a set of corrugated metal sheet products designed for construction of road bridges, overpasses and tunnels. An original qualitative method of risk assessment related to incorporation of a construction product in the works was conceived and its usefulness was confirmed. It has been demonstrated that while it is indispensable to carry out the risk assessment at the technical assessment stage, it is not, however, sufficient for efficient managing the risk of placing construction product on the market.

A study of the effects of climatic temperature changes on the corrugated structure

The study provides the results of experimental tests on temperature distribution throughout the surface of a corrugated metal sheet. Mathematical models are proposed for calculating the thermal conductivity and the thermal stress state of a fragment of the corrugated metal frame of a transportation facility whose lateral surfaces are heated to different temperatures. It is assumed that the temperature depends on two spatial variables. As a possible criterion for choosing the desired function of temperature distribution throughout the construction, it is assumed that the functional defined by a set of admissible functions is minimized in the form of an integral throughout the region of the body from the expression given by the production of entropy. In the study of the temperature field, the differential equation of thermal conductivity is used, and the stress-strain state is measured by the equation of the theory of thermal elasticity. To solve the differential heat equation, the method of finite differences is used, and for the solution of the equations of the theory of thermal elasticity, the finite element method is applied. It has been established that the temperature is distributed unevenly throughout the corrugated metal sheet. There is a temperature difference between the lower and upper surfaces of the corrugated metal sheet. The temperature difference between the bottom and top sides of the sheet is +7.1 °C at the highest atmospheric temperatures and –5.5 °C at the lowest atmospheric temperatures. It has been determined that the magnitude of the stresses that appear on corrugated metal sheets due to the atmospheric temperature difference is up to 25 % of the permissible stress. Therefore, when designing corrugated metal structures, it is necessary to calculate the effect of climatic temperature changes. The obtained data of the thermal stress state of corrugated metal structures are important for design enterprises. It is because taking into account the action of the temperature field on the stress state of the structure as a whole at the design stage helps select materials to reduce the temperature stresses that have a direct influence on the development of corrosion damage to the metal of the pipe.

Design of Transverse Stiffeners in Plate Girders with Corrugated Web

This study reports investigations into the effect of relative flexural stiffness of intermediate stiffeners γ on the failure zone location in the corrugated web. The study also aimed at obtaining stiffness criterion for intermediate stiffeners that depends on the magnitude of the plate geometry parameter α. To achieve the goals of the study, experimental investigations were conducted into load displacement paths of four exemplary SIN girders. They were simply supported girders, made to full scale, and composed of pre-assembled units. The phenomena occurring in the experiment were represented using the Finite Element Method. For FEM numerical analysis of girders with intermediate stiffeners, models with the web height of 1000, 1250 and 1500 mm, made from 2; 2.5 and 3 mm thick corrugated sheet metal were used. Due to the analysis of 52 girder numerical models, it was possible to propose the stiffness criterion of intermediate stiffeners. The criterion was based on the assessment of shear buckling strength of the corrugated web. Using the regression method, dimensionless coefficients of the stiffener stiffness ks dependent on the optimum stiffness γ were determined. Based on estimated coefficients of the stiffener stiffness ks, the absolute minimum stiffness of intermediate stiffeners Ismin used in corrugated web plate girders was calculated. It was demonstrated that the use of an intermediate stiffener, the stiffness of which is greater than Ismin , additionally leads to a change in the location of the site of the web shear buckling.

PREDICTING THE STRUCTURAL PERFORMANCE OF SANDWICH CONCRETE PANELS SUBJECTED TO BLAST LOAD CONSIDERING DYNAMIC INCREASE FACTOR

The safety of the civil structures could be significantly improved against shock waves and blast loads by using steel concrete steel (SCS) protective walls. A numerical study has been performed to simulate the response of SCS wall subjected to a near-field blast load. A conventional SCS panel subjected to near-field blast load and its structural performance is evaluated in terms of maximum damage and deformation. The simulations performed using ABAQUS\EXPLICIT finite element package and built-in concrete damage plasticity concrete constitutive formulation. The maximum deformation, plastic strain, and failure mode under different loading scenarios have been investigated. The aim of this study is predicting the structural response of the SCS panel with different blast charge and identification of optimum configuration in terms of concrete strength and plate thickness. In the second part of the study, two novel sandwich configurations consisting of a corrugated metal sheet and the concrete core are proposed and compared with the conventional protective walls. The optimum parameters for each structural component are identified using an optimization procedure. Based on this study, using the proposed wall configuration will results in superior performance compared to the conventional walls while the extra cost of fabrication is insignificant.

Experimental and Analytical Investigation of Point Fixed Corrugated Metal Sheets Subjected to Blast Loading

Besides the primary threats of a blast loading scenario, flying fragments from nonstructural elements could be a further threat to exposed humans. Point fixed corrugated metal sheets are often applied as facade elements. This paper focuses on the analysis of the dynamic bearing resistance and related pull-out behaviour of such elements. In a first step, the dynamic bearing capacity is investigated by an experimental study. Different sheet thicknesses and dimensions are examined for different loading levels using shock tube experiments. Based on the experimental results an engineering model is applied to predict the overall bearing capacity of the investigated corrugated metal sheet elements using mathematical optimisation methods. In a second step, the comparison to an analytical approach to quantify the prognostic capacity of the theoretical assessment method is addressed. Obtained results enable fast and effective quantification of expected damage effects and can be integrated into an overall risk and resilience analysis scheme.

English

English