Minimum weight of cold-formed steel sections under compression

Abstract This paper presents a combined theoretical and experimental study on the minimum weight and the associated optimal geometric dimensions of an open-channel steel section with given length subjected to a prescribed axial compressive load. Sections both with and without lips are analyzed. The results obtained using a nonlinearly constrained optimization method are compared with those estimated from a simple-minded optimization procedure that assumes the simultaneous occurrence of all failure modes in a minimum weight structure. The types of failure mode considered include yielding, flexural buckling, torsional–flexural buckling, and local buckling. The failure criterion is based purely on compressive strength, with other possible design constraints (e.g. bending stiffness, minimum gauge and cost) ignored. The effects of end support conditions and restraint on torsional buckling are examined. The load capacity of a C-section calculated according to the 1998 British Standard Institution’s specifications on Structural Use of Steelwork in Building is used to check the validity of theoretical predictions. Finally, two new C-sections with lips were designed and manufactured based on the optimal results, and tested. Test results confirm the analytical predictions, with the optimal C-sections performing much better than the existing ones.