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Volume 46 Number 2 March 2014
Journal of the Australian Steel Institute
Structural Steel Tubular

Connection Series, 2014:
Background and Summary
3D Interactive content
Steel Construction
featured in PDF version
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STEEL CONSTRUCTIONEDITORIAL
The Tubular Connection Series is a specialist series devoted to the design of connections for structural
steel tubular members, in accordance with the current Australian Standard AS 4100 (Ref. 1). It reflects a
wealth of international best practice and the current state of knowledge of tubular connection behaviour
from test results.
The Tubular Connection Series is structured as a logical companion and in the same format as the existing
Structural Steel Connection (for predominantly open section connections), comprising two parts. Part 1,
published in 2007, covers simple connections for open sections, including connection theory, bolting and
welding related to connections. Part 2, published in 2009, covers rigid connections for open sections and
includes recommended design models for a range of rigid connections.
The Tubular Connection Series is logically grouped into a number of related connection types and, for each
connection type, provides background theory, design models, examples and Design Capacity Tables, all
heavily referenced to AS 4100 where appropriate and international best practice where necessary. As such,
the Tubular Connection Series provides a very comprehensive compendium of current cutting edge design
practice specifically related to an Australian context.
Dr Peter Key
National Technical Development Manager
Australian Steel Institute
3D INTERACTIVE CONTENT
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STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 1

ASI LIMIT STATE STRUCTURAL STEEL TUBULAR CONNECTION SERIES2014
BACKGROUND AND SUMMARY
by
Peter Key
Peter Key is National Technical Development Manager for Australian Steel Institute (ASI). His academic
achievements include a Bachelor of Engineering from The University of Sydney with 1st Class Honours and
University Medal (prox acc). Postgraduate qualifications include a Doctor of Philosophy from The University
of Sydney. Peter is a Member of the Institution of Engineers Australia and he has worked for more than
20 years in the design and construct arena, specialising in large span steel structures.
1 INTRODUCTION
This new series of connection publications by the Australian Steel Institute (ASI) covering design capacity
tables, theory and design of individual structural steel hollow section (tubular) member connections will be
known as the Structural Steel Tubular Connection Series, 1st edition, 2014 (Tubular Connection Series).
The Tubular Connection Series details the method of design and provides design capacity tables and
detailing parameters for a range of tubular connections commonly used in Australia. Connections have a
major engineering and economic importance in steel structures influencing design, detailing, fabrication and
erection costs. Standardisation of design approach integrated with industry detailing is the key to minimum
costs at each stage. The Tubular Connection Series is written in the same format as and extends the range
of the existing Structural Steel Connection Series Parts 1 and 2 for open sections (Refs. 1, 2) published by
ASI commencing 2007. Each book in the new Tubular Connection Series is numbered as a continuation
from the existing series, commencing with Tubular Design Guide 20 (TDG 20).
2 BACKGROUND
The ASI was formed in 2002 through the merger of the Australian Institute of Steel Construction (AISC) and
the Steel Institute of Australia (SIA). The former AISC published a series of design manuals giving guidance
on the design of structural connections in steelwork over the last 30 years.
Prior to consideration of tubular section connection design, the AISC published the first Steel Connection
Series in 1978 in permissible stress format, at which time connection design theories were developed for
the purpose of generating and publishing connection capacity tables for open sections. A series of editions
were published, culminating in the fourth edition Design of Structural Connections (Ref. 3) (often referred to
as the Green Book) in 1994 in limit state format.
A new Connection Series in limit state format was published in two parts, commencing 2007. Part 1 (Ref. 1),
published in 2007, covers simple connections for open sections, including connection theory, bolting and welding
related to connections. Part 2 (Ref. 2), published in 2009, covers rigid connections for open sections and includes
recommended design models for a range of rigid connections.
The former AISC published Design of structural steel hollow section connections Volume 1: Design
models (Ref. 4) (often referred to as the Blue Book) in 1996, covering design models and examples for a
range of practical connections for structural steel hollow sections (SSHS). At the time, a companion Volume
2 Standardized Structural Connections was planned to update Standardized Structural Connections, third
edition 1985, but this was never released.
The current Tubular Design Guide (TDG) series updates and significantly expands the range and depth of
models covered in the previous Blue Book and includes in addition design capacity tables (DCT) for most
common connection types. The format and structure of the TDG series follows that of the current open
section connection series, providing industry with a consistent view of both open and tubular section
connection design. The series is designed to be extended with new and updated material as required in the
future.
Each individual connection type in the tubular connection series contains in a single DESIGN GUIDE
standardised detailing and design capacity tables for the connection types covered by that publication,
derived using the recommended design models in that publication. Where different connection types are
similar in form and function, they are included as separate models within the same design guide publication.
2 STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014

3 PUBLICATIONS
The Tubular Connection Series has been published as a series of individual closely related publications
(booklets). Each covers a particular type or family of connection types. The currently available publications
are:
Tubular Design Guide 20 Background and design basis
Tubular Design Guide 21 Bolted bracing connections: covering design models for slotted SSHS end
connection, welded tee SSHS end connection and flattened end CHS connection
Tubular Design Guide 22 Bolted bracing cleats: covering design models for the bracing cleat, gusset
plate and cleat plate assembly
Tubular Design Guide 23 Plate fitments: covering design models for web side plate, moment side plate
and transverse plate
Tubular Design Guide 24 Bolted planar connections: covering design models for bolted end plate
splice and bolted moment end plate
Tubular Design Guide 25 Fully welded simple planar connections: covering design models for mitred
knee and T, Y and X connections
Tubular Design Guide 26 Fully welded gap planar connections: covering design model for K and N
gap connections and KT gap connections
Tubular Design Guide 27 Fully welded overlap planar connections: covering design models for K and
N overlap connections and KT overlap connections
4 SCOPE AND BASIS

The Tubular Connection Series is a specialist series devoted to the design of connections using SSHS in
accordance with the current Australian Standard AS 4100 (Ref 5.) where possible, reflecting the current
state of knowledge of connection behaviour based on test results, finite element analysis and related
international research. There is a large body of international research that has been and continues to be
undertaken. This research, and the international specifications and design models resulting from it, has
been selectively adopted as the basis for the aspects of the design models presented in this publication,
specifically where the behaviour is not directly addressed by AS 4100. Though substantial in various parts,
in some instances, the test evidence is sparse and in other instances the evidence is contradictory or
clouded. Each design guide in the Tubular Connection Series has been written by weighing the available
evidence to provide recommended design procedures based in part on the design procedures used in
equivalent manuals and/or published papers.
Each design guide is intended to provide a design model which gives a reasonable estimate of connection
design capacity and effort has been expended in researching and developing design models which can be
justified on the basis of the available research and current design practice. It is to be emphasised that for
the connection models presented, the design model is not necessarily the only possible model and attention
is drawn to the disclaimer at the beginning of each publication as to its applicability and use.
The connections dealt with are those generally in common use in Australia. Where relevant, the connection
elements have been standardised consistent with the earlier AISC Standardized Structural Connections
publication (Ref. 6) (now out of print) and the embodiment of this in the later ASI publications Design Capacity
Tables for Structural Steel Volumes 3 and 4 (Refs. 7, 8). An explanation of the standardisation relevant to each
connection type is included in the relevant design guide.
Tubular Design Guide 20 (TDG 20) provides the background, design basis and principles common to all the
connection types. There is an extensive range of information which forms the foundation for the design
models, together with product specific data applicable to the range of sections available from the local
manufacturers. Major sections are presented on the basis for design to AS 4100, background to SSHS
implementation, material and section properties (including international material sourcing), design
capacities for bolts, welds and components, detailing and standardisation and truss design considerations.
As a handy reference to all things SSHS for the Australian market, TDG 20 itself is a must-have reference
for the engineer.
Each of Tubular Design Guides 21 to 28 presents standardised detailing parameters, the design model
historical and theoretical basis, a series of the relevant design checks, one or more design examples and,

where possible, design capacity tables for the connection types covered by that design guide, derived using
the design models in that design guide. Each design guide contains a collection of similar connection types,
related by either configuration of the connection or the type of structural assembly in which it is used.
Each Tubular Design Guide is configured to be self-standing and able to be used independently of any
other. Each Tubular Design Guide therefore contains core data related to the material properties and
component strengths. However, where greater in-depth reference is required to the basis for the design
models or property or section information, the reader should refer to TDG 20.
5 BASIS OF SSHS CONNECTION DESIGN TO AS 4100

5.1 General considerations
The Australian Steel Structures Standard AS 4100 (Ref. 5) contains the requirements applicable to the
design of steel structures, including connections. A companion document, AS 4100 Supplement 1 (Ref. 9),
provides a commentary to the code provisions. Section 9 of AS 4100, titled Connections, defines the
design requirements specific to connection components and the connection as a whole.
In structural steel connections, there are three fundamental considerations:
(a) the connection designer requires a realistic estimate of connection strength in order that a connection
will be safe (design capacity exceeds design actions) and economical (not over-designed);
(b) the connection designer requires a realistic understanding of the serviceability and ductility
requirements of the connection, including connection stiffness, in order that the design assumptions
inherent in the analysis of the overall structure (of which the connections are a part) are consistent
with the expected behaviour of the connection; and
(c) the connection must be detailed in such a way that it is economical to fabricate and erect, while
recognising that the connection detailing may have an important impact on the strength, stiffness and
ductility of the connection and, indeed, of the overall structure.
Any design model for assessing the strength of a connection must take account of the following four
elements:
(i) the strength of the fasteners (bolts and welds);
(ii) the strength of the connection components (plates, flat bars, angles, gusset plates);
(iii) the strength of the connected (or supported) member in the vicinity of the connection (local effects);
(iv) the strength of the supporting member in the vicinity of the connection (local effects).
Connection stiffness and serviceability are particularly relevant to hollow section connections where, unlike
open section connections which generally contain secondary cleats, stiffeners and other bolted or welded
components that may be configured to condition the behaviour of the connection (pinned versus moment
behaviour for example), hollow sections are often profile cut and fully welded together to produce a
connection that contains no secondary components. The stiffness of these connections is predominantly a
function of the connection geometry and wall slenderness of the connected faces of the individual members,
with little opportunity to create the idealized pin or moment connection that is afforded by sympathetic
configuration of secondary connection components.
Standards and codes for the design of steel structures primarily deal with member design as a whole, rather
than specifically allowing for local effects, and provide only the basic information on elemental (e.g.
fastener, weld, plate) connection design. These documents typically do not specify a detailed design
procedure for any type of multi-element connection, leaving the assessment of how a connection behaves
and how its behaviour should be allowed for in design to the individual designer. AS 4100 further states that
Design shall be on the basis of a recognised method supported by experimental evidence.
The variation in behaviour between different connection types, and the need for design to be based on
experimentally substantiated methods, presents the designer with a substantial task considering the large
number of different connection types that may be encountered, each requiring individual research and
assessment. The Tubular Connection Series seeks to assist the designer by providing guidance in order to
reduce the task considerably.

5.2 Connection design models
The basic requirements that any connection design model must conform to if the design model is to be
acceptable are laid out in Clause 9.1.3 of AS 4100 (Ref. 5). These requirements are as follows:
Each element in a connection shall be designed so that the structure is capable of resisting all design
actions. The design capacities of each element shall be not less than the calculated design action
effects.
Connections and the adjacent areas of members shall be designed by distributing the design action
effects so that they comply with the following requirements:
(a) The distributed design action effects are in equilibrium with the design action effects acting on
the connection.
(b) The deformations in the connection are within the deformation capacities of the connection
elements.
(c) All of the connection elements and the adjacent areas of members are capable of resisting the
design action effects acting on them.
(d) The connection elements shall remain stable under the design action effects and deformations.
Design shall be on the basis of a recognised method supported by experimental evidence.
Residual actions due to the installation of bolts need not be considered.
The onus is placed on the structural steel designer to ensure that the actual behaviour of a connection does
not have a deleterious effect on the members of the steel frame and that the connection conforms to the
requirements specified in AS 4100.
5.3 Connection terminology
Connections are considered in the Tubular Connection Series and in AS 4100 to consist of the following
connection elements:
(A) fasteners (bolts or welds) (connectors in AS 4100 terminology);
(B) components (plates, gussets, cleats);
(C) supported members;
(D) supporting members.

These elements are defined in relation to a typical hollow section connection in Figure 1.
FIGURE 1 DEFINITION OF CONNECTION ELEMENTS

The design capacities of all of these elements must be evaluated in order to evaluate the design capacity of
the connection. TDG 20 deals with the theoretical background and design basis of these elements as
isolated elements so that the formulae derived can be used in later guides concerned with individual
connections. Design data is only repeated to a limited extent in Tubular Design Guides 21 to 27, sufficient
to establish and document element capacities for use in the design models.
The design models contained within the Tubular Connection Series are considered to be applicable only to
connections which are essentially statically loaded. Connections subject to dynamic loads, earthquake loads
or fatigue applications may require additional considerations. Fatigue loading and earthquake loading may
be the subject of later design guides.
6.0 ADVANTAGES OF SSHS FOR CONSTRUCTION

Structural steel hollow sections (SSHS) have a long history of project implementation and an equally long
history of development as a high performance building product. This pedigree is reflected in the fact that
compared to other steel products, the worldwide consumption of welded steel tubular products is increasing
in a market share sense if not an overall sense.
FIGURE 2 METRICON STADIUM ROOF ILLUSTRATING THE AESTHETIC OF EXPOSED SSHS

There are numerous reasons for the increased focus on and use of SSHS, and many speak towards the
advantages of SSHS for production, supply and building and infrastructure construction. These include:
1. A world steel industry moving from the traditional production of hot-rolled sections and plate towards
coil and strip production with attendant advantages of easier delivery from steel mill to manufacturing
plant and the capacity to supply pre-coated (galvanized or primer-painted) product in some cases.
2. Improved manufacturing technology which facilitates enhancement of the overall performance of the
product.
3. Structural steel design Standards which permit design of cold-formed SSHS sections along with hot-
rolled sections are now available in most countries around the world. These Standards have been
continually improved, enabling the design of cold-formed SSHS members and connections to take
advantage of the increased performance produced by the manufacturing process and inherent in the
products.
4. The inherent structural efficiency of the hollow section shape, which places material at the maximum
distance from the centroid of the section. Increased compression load capacity, torsional strength and
stiffness and lateral stability per unit weight are direct advantages of the hollow section shape and
lead to structures that, on a per unit area basis, are amongst the lightest that can be designed.

5. A per unit mass cost which, whilst usually higher than for hot-rolled open sections, has reduced
relative to hot-rolled sections.
6. SSHS combines resistance to wind, water or wave loading with an architecturally stimulating and
aesthetic shape, characteristics which combine to naturally lend themselves to exposure in landmark
structures with open light designs. The smaller surface area than comparable structures with open
sections and the absence of sharp corners and reduced ledges result in better corrosion protection in
these applications.
Critical to the design of structures comprising SSHS framing is the efficient and sympathetic design and
detailing of connections, often with no or minimal cleats or stiffening plates. Since the connection strength is
influenced by the geometric properties of the members, the designer must understand the nuances of
hollow section connection design and the consequent ever present conflict between member size and shape
and the desirable elimination of ancillary stiffening/strengthening plates and the like. A strong appreciation
of these issues is needed at conceptual design stage in order to ensure optimal design. The Tubular
Connection series is intended to provide the designer with the tools necessary to identify the most cost
effective and sympathetic design and detailing balance.
7 AUSTRALIAN CONTEXT
7.1 Australian production
Structural steel hollow section (SSHS) produced in Australia, comprising circular hollow sections (CHS),
square hollow sections (SHS) and rectangular hollow sections (RHS), are supplied by a number of
Australian manufacturers to the joint Australian-New Zealand Standard AS/NZS 1163 Cold-formed structural
steel hollow sections (Ref. 10). Australian produced SSHS are exclusively manufactured by a cold-forming
process with no significant pre-, intermediate or post-heat treatment, resulting in a product with enhanced
strength properties compared to the base material. Alternative manufacturing processes used in other
international markets, such as hot forming, may result in a different set of material properties and hence
section behaviour. It is therefore important to confirm the product type and reference Standard as part of the
design process.
In Australia, approximately 40% of the structural steel used each year comprises SSHS, making SSHS a
substantial component of the total market consumption. SSHS product is used as structural members in
steel construction, roadside hardware (signage gantries, guard and hand rails, pedestrian bridges), framing
components in vehicles and equipment and for recreational equipment, to name a few.
Manufacturers in Australia supply SSHS to a range of section sizes broadly corresponding to that indicated
in Table 1.
TABLE 1
RANGE OF SECTION SIZES AVAILABLE FROM AUSTRALIAN MANUFACTURERS
Minimum size Maximum size

Section (overall dimensions x wall thickness) (overall dimensions x wall thickness)
(mm) (mm)
CHS 26.9 x 2.0 508.0 x 12.7
SHS 20 x 20 x 1.6 400 x 400 x 16
RHS 50 x 20 x 1.6 400 x 300 x16
The range of standard section sizes and grades usually available in Australia is tabulated in detail in
Appendix A of TDG 20. This section size range and grades is used as the basis for input into the design
capacity tables included with each design model developed in the connection series. It is relevant to note
that Australian manufacturers also variously import some section sizes that are manufactured overseas to
Australian Standards in compliance with the particular quality and factory production control regimes of the
Australian manufacturer. These sections may be considered equal to the Australian manufactured sections
and designed utilising the section properties and design capacity tables provided by the particular
Australian manufacturer.

Availability of specific section sizes should always be checked with the manufacturers and/or
stockists/distributors, as not all section sizes are produced in all grades. In particular, individual
manufacturers may focus on production of a particular shape in one grade only. C450 material may be
available as dual graded to C350 requirements also. Check the appropriate technical literature.
The stress grades of SSHS commonly produced in Australia are 250 MPa (called C250), 350 MPa (called
C350) and 450 MPa (called C450), the C referring to cold-formed and the numeral referring to the
minimum yield stress of the product material. The C350 material has the strength enhanced from the
approximate 300 MPa feed material through cold work in the manufacturing process. The C450 grade is
achieved through use of additional alloying elements in the steel feed together with cold work from the
manufacturing process.
The material properties specified in AS/NZS 1163 are given in Table 2 for minimum values of yield stress,
tensile strength and elongation to which SSHS produced to the Standard must conform.
TABLE 2
MINIMUM SSHS MATERIAL PROPERTIES TO AS/NZS 1163
Minimum elongation as a proportion of the gauge length

Minimum Minimum %
yield tensile
strength strength Circular hollow sections Rectangular hollow
Grade
( ) ( ) sections
,
MPa MPa 15 >15 30 > 30 15 >15 30 > 30
C250, C250L0 250 320 18 20 22 14 16 18
C350, C350L0 350 430 16 18 20 12 14 16
C450, C450L0 450 500 12 14 16 10 12 14
7.2 Australian design context
The applicable Standard for SSHS design in Australia is AS 4100 Steel structures (Ref. 5). AS 4100 was
first published in limit states format in 1990. Whilst the development of AS 4100 was based largely on hot-
rolled open section members, it did permit the use of cold-formed hollow section members to AS/NZS 1163
Cold-formed structural steel hollow sections (Ref. 10). The previous permissible stress based AS 1250
(Ref. 11) had also allowed cold-formed SSHS members since an amendment in 1982.
AS 4100 specifically includes cold-formed SSHS to AS/NZS 1163 as within the scope of the Standard in
Clause 1.1.1, including members with wall thicknesses less than 3 mm, which would otherwise be excluded
according to Clause 1.1.1(a).
Section 4.5.2 of AS 4100 provides limitations for plastic analysis including, amongst other limitations, that
plastic analysis is limited to hot-formed members that are doubly symmetric I-sections. Therefore, cold-
formed SSHS sections cannot be used for plastic design to AS 4100. However, separate work undertaken
by industry has shown that, in some instances, the plastic analysis and design of cold-formed SSHS can be
undertaken.
A significant research effort on cold-formed hollow section member and connection behaviour has been
undertaken both in Australia and internationally in the last 30 years, as outlined in TDG 20. The outcomes
of these research programs have now largely been incorporated into the latest Australian Standard AS 4100
(Ref. 5) and the New Zealand Standard NZS 3404 (Ref. 12), as well as the other international standards
and specifications discussed in TDG 20.
7.3 International design context
SSHS member and connection design is firmly established internationally and draws on a pool of
international research for continuing evolution and refinement, driven by both increased understanding of
member and connection behaviour and improved manufacturing processes resulting in higher performance
sections.

In the USA, SSHS can be designed to the American Institute of Steel Construction (AISC) Specification
(Ref. 13). The current AISC Specification has merged permissible stress and limit state versions which
previously had allowed SSHS design since their 1969 and 1986 editions respectively. Ref. 14 recently
included hollow section connection design guidance in Appendix K. The AISC had also produced a specific
manual on the design of hollow structural section connections (Ref. 15).
In Canada, cold-formed SSHS is designed to the CSA-S16-01 (Ref. 16) steel structures Standard.
The British Standard BS 5950 Part 1 (Ref. 17) included design of cold-formed tubular members in the 2000
update, at which time the design of cold-formed structural hollow sections was transferred across from
BS 5950 Part 5 Code of Practice for design of cold-formed thin gauge sections (Ref. 18).
New Zealand Standard NZS 3404.1 (Ref. 12) allows design of materials to AS/NZS 1163, hence cold-
formed tubular members. Table 3 of NZS 3404.1 excludes the use of materials with a yield stress greater
than 360 MPa for category 1 and 2 seismic members, unless testing shows the specific member and
connection behaviour to be compliant with the Standards requirements.
Eurocode 3 (Ref. 19) includes design of structural hollow sections through Table 3.1 and the specification of
allowable standards and steel grades for structural hollow sections, both hot-finished and cold-formed, up to
460 MPa nominal yield stress.
7.4 Design aspects related to Australian SSHS
7.4.1 Influence of higher strength steel on SSHS connection design
The various connection design models elaborated in the Tubular Connection Series each comprise a range
of checks of different aspects of connection component behaviour. Where relevant design checks are
available in AS 4100 (Ref. 5), these are used in the design models. However, for a range of design checks,
typically those associated with the behaviour of the actual SSHS sections (as distinct from any connection
components) no corresponding design checks are available in AS 4100. In these cases, rules from
international codes and specifications, in particular the CIDECT Design Guide Series 1 and 3 (Refs. 20, 21)
have been adopted.
The CIDECT Design Guides for CHS (Ref. 20) and for SHS/RHS (Ref. 21) in Section 1.2.1 discuss
limitations on materials in respect of the range of applicability of the design models presented. The
connection resistances given in Refs. 20 and 21 are based on SSHS with a nominal yield strength up to
355 MPa. For nominal yield strength greater than 355 MPa and up to 460 MPa, the connection resistances
given in the CIDECT guides should be multiplied by 0.9. As noted in the CIDECT guides, this provision
considers the relatively large deformations that take place in joints with nominal yield strengths of
approximately 450 to 460 MPa when plastification of the connecting RHS face occurs and notes its
application to other failure modes may be conservative. The ultimate limit state load is assessed in the
CIDECT models with a deformation limit imposed corresponding to 3% of d 0 or 3% of b 0 , which is
sometimes reached with higher strength SSHS under chord face plastification failure modes.
7.4.2 Influence of yield to ultimate tensile strength ratio on SSHS connection design
The various international codes and specifications have generally adopted an allowable maximum ratio of
yield stress to ultimate tensile strength of f y /f u = 0.8. The CIDECT Design Guides 1 and 3 (Refs. 20, 21)
recommend that the allowable design yield stress used for computations should not be taken as greater
than 0.8 of the nominal ultimate tensile strength. This yield-to-ultimate limitation recognises the need for
ample material ductility for cases where less ductile modes of failure, such as punching shear failure or
local yielding of brace or plate failure, govern.
It is instructive to examine how the yield-to-ultimate tensile strength limitation is interpreted in the various
international codes and specifications. In Canada, CSA G40.20/G40.21 Grade 350W material has a nominal
yield-to-ultimate stress ratio of 350 MPa / 450 MPa = 0.78, meaning the reduction factor is not required.
This material represents less than 50% of the SSHS material produced in Canada, with the remainder to
ASTM A500 (Ref. 22). In the United States, all SSHS material is produced to ASTM A500, where the Grade
C material (nominal yield stress of 345 MPa) has a yield-to-ultimate tensile strength ratio of
50 ksi/62 ksi = 0.806, putting it marginally above the 0.8 limit. However, the AISC 360-10 Specification 2010
Edition (Ref. 14) in Tables K1.2A, K2.1A, K2.2A, K3.1A and K3.2A notes that ASTM A500 Grade C is
acceptable without further design capacity reduction.

Cold-formed tubular material to Eurocode 3 (Ref. 19) should meet the requirements for yield strength and
ultimate tensile strength given in Table 3.1 of Eurocode 3 and reproduced in Table 3 following, together with
the yield-to-tensile strength ratio. These material properties are based on EN 10219-1 (Ref. 23). A number
of product grades are above the 0.8 limit and require the reduction factor to be applied.
TABLE 3
COLD-FORMED SSHS MATERIAL PROPERTIES TO EN 10219-1
Minimum yield Minimum tensile

strength strength Yield-to-ultimate
Grade tensile strength
(f y) (f u)
fy / fu
MPa MPa
S 235 H 235 360 0.65

S 275 H 275 430 0.64
S 355 H 355 510 0.70
S 275 NH/NLH 275 370 0.74
S 355 NH/NLH 355 470 0.76
S460 NH/NLH 460 550 0.84
S 275 MH/MLH 275 360 0.76
S 355 MH/MLH 355 470 0.76
S 420 MH/MLH 420 500 0.84
S 460 MH/MLH 460 530 0.87
7.4.3 Design yield stress for Australian produced SSHS
Australian SSHS produced to AS/NZS 1163 (Ref. 10) has yield-to-ultimate tensile strength values given in
Table 4 for the C250, C350 and C450 grades. With a ratio of 0.78, Grade C250 does not require a reduction
factor to be applied. With a ratio of 0.81, Grade C350 is marginally above the limit of 0.8 but is deemed
acceptable to use without a reduction factor.
Grade C450 has a yield-to-ultimate tensile strength of 0.90 and requires a reduction factor to be applied.
The design yield stress for C450 material used for connection design for less ductile modes of failure like
punching shear failure or local yielding of brace or plate should therefore be 0.8 x 500 MPa = 400 MPa.
TABLE 4
SSHS MATERIAL PROPERTIES TO AS/NZS 1163
Minimum yield Minimum

strength tensile strength Yield-to-ultimate
Grade ( ) ( )
MPa MPa
C250, C250L0 250 320 0.78
C350, C350L0 350 430 0.81
C450, C450L0 450 500 0.90

The reduction factor discussed in Section 7.4.1 of 0.9 for ductile failure modes, which effectively equates to
a reduction in design yield stress to 0.9 x 450 = 405 MPa (since the face plastification failure mode is a
linear function of yield stress), together with the yield-to-ultimate tensile strength limiting reduction of
0.8 x 500 = 400 MPa discussed in Section 7.4.2 for the less ductile failure modes, covers the range of
failure modes normally associated with the SSHS members in the connection. Based on this rationalisation,
the recommended design yield stress ( m f y) to be used in design checks for failure modes associated with
the SSHS component of the connections in this SSHS connection series is given in Table 5 for the range of
SSHS grades produced in Australia to AS/NZS 1163, where m is the material reduction factor.
TABLE 5
DESIGN YIELD STRESS FOR SSHS RELATED FAILURE MODES
FOR SSHS TO AS/NZS 1163
Minimum yield Minimum Design yield

strength tensile strength stress
Grade (f y) (f u) (m f y)
MPa MPa MPa

C250, C250L0 250 320 250
C350, C350L0 350 430 350
C450, C450L0 450 500 400
7.4.4 Section classification
International codes and specifications classify sections according to the slenderness of the individual plate
elements that comprise the section and the consequent propensity for these to locally buckle, either
elastically or inelastically, under applied compressive or bending stress. Plate element buckling limits the
ability for the sections to carry additional load and, depending on the slenderness of the plate elements, can
instigate dramatic load shedding by the section as the plate elements buckle. This classification is therefore
a measure of the ductility of the section after first yield is reached.
Clauses 5.2.3, 5.2.4 and 5.2.5 of AS 4100 (Ref. 5) provide a classification for sections as compact, non-
compact or slender (C, N or S respectively), based on the value of plate element slenderness, ee , for the
most slender element of the cross section, compared to two slenderness limits, the yield limit, ev, and the
plasticity limit, ep .
Eurocode 3 (Ref. 19) provides a classification of sections as Class 1, Class 2, Class 3 or Class 4, based
on constituent plate slenderness.
Table 6, reproduced from Ref. 24, indicates the alignment between section classification terminology in a
number of international design standards. The alignment shown between section classifications is broadly
consistent, although there are small differences between class limits and also differences in the particular
measure of geometry used to define the element slenderness.
TABLE 6
CLASSIFICATION OF SECTIONS IN VARIOUS DESIGN STANDARDS
Specification Section classification

Eurocode 3 Class 1 Class 2 Class 3 Class 4
BS5950 Plastic Compact Semi-compact Slender
AS 4100 Compact Non-compact Slender
AISC LRFD Compact Non-compact Slender

AS 4100 does not provide specific guidance on section classification in relation to SSHS connection design.
The section classification in Clauses 5.2.3, 5.2.4 and 5.2.5 of AS 4100 relate purely to cross sectional
strength. However, the design models detailed in CIDECT Design Guides 1 and 3 (Refs. 20, 21) and on
which a number of the SSHS related failure modes in the design models described in this connection series
are based, have a validity range limited to Class 1 and Class 2 sections as defined in Eurocode 3 (Ref. 19).
Therefore, the same section class restrictions are imposed on the design rules specified in the Tubular
Connection Series.
The flange slenderness definitions and flange and CHS slenderness limits for AS 4100 and Eurocode 3 are
given in Table 7. The definition of the face slenderness varies between the two codes, and is based on the
measurements indicated in Figure 3(a) for AS 4100 and Figure 3(b) for Eurocode 3.
TABLE 7
CLASSIFICATION OF SECTIONS IN VARIOUS DESIGN STANDARDS
Element Specification Slenderness Slenderness limits

definition
Class 1, or Class 2 Class 3, or
compact non-compact
2 y
AS 4100 30 40
250
Flange
2o
Eurocode 3 33 38 42

o y
AS 4100 50 120
250
CHS
o
Eurocode 3 50 2 70 2 90 2

NOTES:
1. = 235y for use in Eurocode 3 (Ref. 19).
2. The AS 4100 slenderness limits are based on Table 5.2 of AS 4100 for cold-formed (CF) material for plate
elements with both sides supported.
3. o is the external radius of the corners of the SHS/RHS, as defined in AS/NZS 1163 (Ref. 10).
(a) AS 4100 (b) Eurocode 3
FIGURE 3 DEFINITION OF ELEMENT WIDTH FOR RHS FLANGES

The Australian section size tables provided in Appendix A to Tubular Design Guide 20 list the class
designation according to Eurocode 3 for each section size. Section sizes designated Class 3 or 4 fall
outside the limits of applicability of the design checks provided in this connection series. SSHS connection
design involving Class 3 or Class 4 sections would therefore require considerable engineering judgement
and verification and likely specific attention to stiffening or strengthening for failure modes related to local
plate stability or bending.
8 INTERNATIONAL MATERIAL SOURCING

8.1 Background
The design engineer may be faced with reviewing and approving SSHS product that has not been sourced
from Australian manufacturers and may not be certified to the relevant Australian product or design
Standards, or claims to comply but has limited certification documentation. There is a legislative
requirement that the majority of projects in Australia are required to conform to the Building Code of
Australia (Ref. 36), which calls up compliance to AS 4100 and therefore in turn the relevant Australian
product Standards for the deemed-to-satisfy route. This section provides design engineers with guidance on
the technical aspects that must be addressed in any rational review of imported product.
It must be noted that the Australian Design Standard AS 4100 (Ref. 5) relies on guaranteed values for
chemical composition, mechanical properties, dimensional tolerances, methods of manufacture and quality
control provisions for all materials used in a steel structure. These are implicit through reference to product
standards such as AS/NZS 1163 (Ref. 10) in the case of SSHS member design. AS 4100, and in particular
the capacity factors (), column curves, element slenderness ratios etc, have been calibrated through the
use of safety indices against expectations on variation in material strength, material properties, member
size and homogeneity, testing results, design model inaccuracy and assumptions, degree of ductility and
reliability of the member or connection element under the action effects, all based on Australian product
Standards and Australian design, fabrication and construction practice. Ascertaining the veracity of
substituted internationally sourced materials or fabricated products is therefore not a trivial task.
The issues discussed below draw on a body of work that has been undertaken by ASI over a number of
years, which has included significant feedback from industry, technical research and product testing. Whilst
the major thrusts of this body of work are technical, invariably regulatory and legislative overlays must be
complied with.
8.2 Material perspectives
Applicability of and equivalence in material performance is, based on the performance assumptions noted
above in relation to AS 4100 code calibration, a primary focus area when considering the appropriateness of
imported material.
The paper Effect of material properties on hollow section performance (Ref. 25) provides a current and
exhaustive comparison of the pertinent material properties from a large range of international hollow section
product standards, including examination of issues concerning corner cracking, tolerance variations
between specifications, suitability for galvanizing and the effect of the material on seismic performance. It
leaves little doubt that there are variations between product standards that must be understood and allowed
for when addressing sourcing internationally.
In addition to the issues noted in Ref. 25, there are a number of material related perspectives that the
designer must address in considering the suitability of internationally sourced material:
1. As discussed in Section 7.4, certain SSHS related failure modes adopted in the Tubular Design
Guides are based on the significant research and theoretical models presented in the CIDECT Design
Guides 1 and 3 (Refs. 20, 21). For material design yield stress over 355 MPa, CIDECT recommends
the use of a reduction factor of 0.9 on the joint resistances calculated for these failure modes. The
reduction factor of 0.9 has been adopted for the Tubular Connection Series models also. Imported
material with nominal design yield stress greater than 355 MPa should have this factor applied in the
relevant design calculations.
2. As discussed in Section 7.4.2, the relevant design models adopted from CIDECT Design Guides 1
and 3 (Refs. 20, 21) are based on a limiting yield to tensile ratio of 0.8. For imported material which
exceeds this ratio, the design yield stress used for the corresponding failure modes should be
reduced such that 0.8.

These material issues are non-trivial and must be addressed to ensure structural safety and reliability is not
compromised.
8.3 Product perspectives

There are a number of product related issues that need to be considered:
1. Tolerances on product geometry should be reviewed. Whilst a number of international product

specifications have essentially similar tolerances to AS/NZS 1163 (Ref. 10), this is not exclusively the
case. For example, Packer et al. (Ref. 25) point out that product produced to ASTM A500 (Ref. 22) is
noted for its very liberal geometric production tolerances, with a tolerance of 10% permitted on wall
thickness and no tolerance on mass, weight or cross-sectional area, resulting in tubes being produced
routinely undersize. Code calibration, such as that undertaken for AS 4100 noted above, is not
intended to accommodate liberal and systematic under sizing, the results of which therefore impinge
on the assumed safety indices.

2. Pressure pipe or line pipe is often utilised for structural applications. In fact, a proportion of the
Australian manufactured product was dual rated to both AS/NZS 1163 and also pressure pipe
Standards such as API (Ref. 26). When presented with international product that is certified to a
pressure pipe Standard but intended for use in a structural application, great care should be taken in
assessing the appropriate design yield stress based on mill or test certificates supplied with the
product. Pressure pipe is usually tensile tested in the circumferential direction (being the direction of
principal stress for pressure applications), which is also the direction of primary cold work and hence
yield stress increase resulting from the cold-forming process. Actual yield stress in the longitudinal
direction (which is the direction structural tube is tested in and reported on) can be up to
approximately 50 MPa less than the yield stress in the circumferential direction. The practical result is
that a pressure pipe with a reported yield stress of 250 MPa (in the circumferential direction) may
have an actual yield stress as usually reported for structural purposes of only 200 MPa.
3. The section classification, as discussed in Section 7.4.4, should be checked for applicability against
the limits for the connection models in the Tubular Connection Series. These are no different to the
considerations for Australian manufactured product but the designer needs to be aware that the
sections may not be classified in any property or design capacity tables received with the product and
therefore the classification will have to be calculated and checked separately.
The broader issues associated with designing to AS 4100 when imported materials are concerned have
been documented in two ASI Technical Notes:
Technical Note TN005 Guidelines for designing to AS 4100 when imported materials are involved
(Ref. 27)
Technical Note TN007 Compliance issues and steel structures (Ref. 55)
8.4 Bolt sourcing
At the time of writing, the majority of commercial (Property Class 4.6) and high strength (Property Class 8.8)
bolts used in Australia that the structural designer is likely to specify are imported. Only certain high
performance and niche market products are still manufactured in Australia. It is also a reality that price
pressures, tendering competition and a regulatory regime where normative conformance is not yet widely
implemented has resulted in both documented and anecdotal evidence that structural bolts which do not
comply with the Australian structural bolting Standard AS/NZS 1252 (Ref. 29) are regularly entering the
market.
Over a number of years ASI has undertaken awareness campaigns, producing a range of technical
information directed at the engineering and specifying community. This information has included:
Are you getting the bolts you specified? A discussion paper, Dec., 2005 (Ref. 30)
ASI Tech Note #1-06 High strength bolt assemblies. Certification to AS/NZS 12521996 Reject or
Accept?, Jan., 2007 (Ref. 31)
TN001 High strength structural bolt assemblies to AS/NZS 1252, 2011 (Ref. 32)
Section 9 of Ref. 33 which includes a discussion on certification to AS/NZS 1252

Summarising the significant issues:
Bolt suppliers (usually importers in the current Australian context) must verify and provide
documentary evidence of compliance to the relevant Australian Standards (AS/NZS 1252 Ref. 29)
and the corresponding product standards. Purchasers and certifiers must demand this documentation.
In the current market climate, the veracity of a manufacturers test certificate cannot be assumed. In
addition, a test certificate, or test report on an individual bolt (regardless of whether locally provided
by a registered laboratory), only provides a snap shot of the product quality and does not address the
necessary in-process controls during manufacture or the statistical basis on which product
conformance should be based. Therefore, locally based testing of individual or a small sample of bolts
should only be viewed as confirming the veracity of a batch of bolts that already have adequate and
proper auditable compliance documentation in place (as supplied by the importer or distributor).
The detailed requirements for proper compliance documentation are discussed in the ASI
documentation (Refs. 30, 31, 32). The confirmation of this compliance documentation is an important
and necessary task that each purchaser must undertake in order to demonstrate an adequate duty of
care. Recent Workplace Health and Safety (WH&S) legislation (Ref. 34) is placing greater
responsibility on the whole process chain to document and collaborate transparently on safety issues,
the safety aspects of non-compliant products being a relevant facet.
Compliance auditing is not a trivial task and in many cases difficult for purchasers to have the necessary
depth of understanding or resources to properly undertake. ASI is recommending to the industry that an
appropriate solution should include a rigorous third party product certification environment. Refer to
Ssection 8.8 for further details.
8.5 Welding consumables
As with bolts, the majority of welding consumables are currently imported into Australia. The necessity to
properly check certification is similar to that described in Section 8.4 for bolts, but it appears that the
propensity for non-compliance is significantly less, based on the amount of feedback received from industry.
The work of industry entities such as the Welding Technology Institute of Australia (WTIA) has helped to
ensure standards are maintained in this important area.
ASI has recently produced a Technical Note, TN008 Welding consumables and design of welds in
AS 41001998 with amendment 1, 2012 (Ref. 35) which discusses the effect of the recent harmonisation
of weld consumables on the design of welds.
8.6 Product compliance
The preceding sections have touched on some of the purely technical issues that provide the foundation for
the need to ensure product compliance with internationally sourced material (and equally applicable to
locally manufacturer material). Ref. 27 draws the distinction between two possible scenarios with regard to
internationally sourced material:
(a) Material manufactured overseas and claiming to comply with one of the Australian Standards cited in
Clause 2.2.1 of AS 4100;
(b) Material manufactured overseas and claiming to comply with one or more overseas Standards.
For type (a) material, Clause 2.2.2 of AS 4100 applies and a certificate indicating compliance to the
nominated Standard should be available in order to indicate full compliance. Engineers need to satisfy
themselves as to the veracity of these compliance certificates, which should not always be assumed.
For type (b) material, Reference 27 discusses the obligations placed on the designer and nominates five
possible paths for ensuring compliance, in summary being one or other of:
1. Obtain sufficient statistical data on the chemical and mechanical properties of the imported steels so
that they can be assigned to one of the grades for the steels cited in Clause 2.2 of AS 4100.
2. Obtain test certificates from the mill certifying that the steel intended to be used or being supplied
complies with all requirements of the relevant Standard, either AS/NZS 1163, AS/NZS 1594,
AS/NZS 3678, AS/NZS 3679.1, AS/NZS 3679.2 or AS 3597. Fully compliant test certificates should be
provided which meet the requirements of Clause 2.2.2 of AS 4100 (2012 amendment).

3. Have sufficient tests done by an independent ILAC or APLAC accredited laboratory (all Australian
NATA laboratories are ILAC accredited) under Clause 2.2.2 and obtain certification from the
accredited laboratory to enable the steel to be fitted into a grade in the relevant Standard in terms of
all parameters in the Standards. The question of what constitutes sufficient tests is discussed in
Section 8.7.
4. Treat the steel as unidentified steel as defined in Clause 2.2.3 of AS 4100, which requires the design
yield stress of unidentified steel to be down-rated to not exceeding 170 MPa. This is a severe
requirement and would usually prove uneconomic.
5. Use a modified capacity factor for the imported material, which would require carrying out statistical
studies on sufficient product and its normal distribution in order to derive new capacity factors, design
yield stress and tensile strength, using the code calibration approaches detailed in the references to
the Commentary to AS 4100. This process would be very lengthy. Note that this does not address
other non-strength related properties, such as ductility and weldability, which would still require
separate assessment.
It should be obvious that none of these paths are trivial and all require a significant investment in time and
resources to undertake properly.
8.7 Sample tests of imported product

It is currently a common practice for one or a very small number of tests to be undertaken on imported
product in order to obtain values of principal mechanical properties such as yield strength and ultimate
tensile strength. However, a single or limited testing program does not establish the required statistical data
to form the basis for the proper assessment of the necessary capacity factors and design yield strength, or
the range of other mechanical or chemical properties required to establish compliance to the Standards, as
noted above. At best, a single or limited testing regime may be used to confirm the veracity of product that
has proper compliance documentation already in place.
Single or limited test results cannot be used to change the grade of the steel. Only the steel manufacturer
can determine the grade of the steel, based on the statistical data obtained from their in-process testing
programs and the normal distribution of test results. A single test result represents a snapshot on that
normal distribution curve and may only be used to verify against the proper compliant documentation that
has been received with the product that the test result fits within the usual normal distribution expected for
that product. Where such compliant documentation does not exist and therefore the steel is essentially
unidentified, one of the five options noted in Section 8.6 must be undertaken.
BS EN 1990:2002 Basis of structural design (Ref. 36) provides a methodology in Appendix D Design
assisted by testing for utilising testing programs for a range of scenarios, including two of immediate
relevance to the current discussion:
(A) Tests to obtain specific material properties using specified testing procedures; for instance, ground
testing in situ or in the laboratory, or the testing of new materials
(B) Control tests to check the identity or quality of delivered products or the consistency of production
characteristics; for instance, testing of cables for bridges, or concrete cube testing
Ref. 36 states that for test type A the design values to be used should wherever practicable be derived
from the test results by applying accepted statistical techniques. Test type B may be considered as
acceptance tests where no test results are available at the time of design. Design values should be
conservative estimates which are expected to be able to meet the acceptance criteria at a later stage.
In essence, the difference between type A tests and type B tests lies in whether the testing samples come
from a batch of product that is not well documented (and therefore unidentified) or from a batch of product
that has proper compliance documentation, respectively. The type A testing regime relies on statistical
processes with multiple samples in order to increase confidence in the product properties. Section D5 of
Ref. 36 discusses derivation of the characteristic values from test data.
Section D6 of Ref. 36 goes on to state:
The methods given in this Annex may be used only when the following conditions are satisfied:
the statistical data (including prior information) are taken from identified populations which are
sufficiently homogeneous; and
a sufficient number of observations is available.

Whilst not precluding a single or limited tests, it is noted that: where one test only (or very few tests) is
(are) performed, no classical statistical interpretation is possible. Only the use of extensive prior information
associated with hypotheses about the relative degrees of importance of this information and of the test
results, make it possible to present an interpretation as statistical (Bayesian procedures, see ISO 12491).
Section D7 of Ref. 36 goes on to present expressions for the assessment of design values based on the
number of tests and knowledge (or otherwise) about the expected coefficient of variation of the test results.
This latter point addresses knowledge about the manufacturing processes and variability that may be
obtained from the manufacturer. In the case of steel supply from the majority of reputable manufacturers,
there should be little problem in obtaining sufficient statistical data to inform this process. In the case of bolt
supply for example, the nature of the market is such that it may be difficult to obtain useful or reliable
records.
8.8 Third-party product certification
Non-compliant steel materials and products are a significant issue for the construction industry (as it is with
other materials and industries), in particular with the changes in the supply environment and some
significant shifting toward imported materials, products and services. Industry inertia, resistance to change
and economic pressure have resulted in a dislocation between the supply side and the demand side, with
business as usual not keeping up with supply dynamics.
The technical and resource demands for rigorous compliance policing are often beyond the capacity of
product purchasers or users, who ideally should be able to rely on straightforward trusted certification
processes and deliverables. Within this context, the industry has and continues to evolve third-party
certification schemes that provide purchasers with an assurance of quality product.
Third-party product certification schemes such as that administered by the Australian Certification Authority
for Reinforcing Steels (ACRS) (http://www.acrs.net.au/ or http://www.steelcertification.com/) have provided
certification services for some time and have recently extended their range into structural steels. Other
international certification authorities also exist and may be utilised.
ASI recommends third-party certified product as an appropriate solution to ensure quality compliant and fit-
for-purpose product, whether locally produced or imported, is used on all projects to help ensure that project
stakeholders at all levels meet their duty of care responsibilities and legislated WH&S requirements. An ASI
Technical Note on third-party steel product certification (Ref. 37) provides context to this recommendation.
With third-party product certification in place, and with respect to enacting these responsibilities, the
process then becomes relatively straightforward, including:
The responsible parties obtain documentation of third-party product compliance from the relevant
certifying authority named on the product documentation received. This means more than simply
accepting statements from product suppliers but active checking of these claims with the certification
authority, the details of which may be conveniently recorded on the certifying authority website.
The various stakeholders in the process ensure their documentation includes the necessary
references to third-party certification requirements. This includes specifications, tender documents
and engineering documentation. For example, the wording ASI currently recommends on engineering
drawing notes is as follows: Structural steel shall comply with AS/NZS 1163, AS/NZS 3678,
AS/NZS 3679.1 or AS/NZS 3679.2. Acceptable manufacturers of structural steel must hold a
valid certificate of approval issued by the appropriate certifying authority e.g. ACRS. Refer to
www.steelcertification.com for current ACRS certification holders. Evidence of compliance to
this clause must be made on tendering.
9 DESIGN MODELS ADOPTED

9.1 Basis
The basis for selecting the recommended design models is detailed in Sections 2.3 and 2.4 of Tubular
Design Guide 20 (TDG 20). A detailed explanation of each recommended design model is contained in the
relevant Tubular Design Guide.
The design models meet the requirements of AS 4100 by providing a rational and recognised design model
for a range of common steel tubular connections, the design models in each design guide reflecting
engineering principles and known connection behaviour from experimental data. The emphasis in all

publications is on practical design models whose assumptions are transparent to the user, backed up with
substantial historical and current reference. The design models are related to current Australian Standards
in respect of member and fastener design and member and fastener mechanical properties, which are
presented in TDG 20.
The philosophy of each Design Guide is the same as that described in Handbook 1 (Ref. 38), being:
Take into account overall connection behaviour and carry out an approximate analysis in order to
determine a realistic distribution of forces within the connection.
Ensure that each component or fastener or section face in each action path has sufficient capacity to
transmit the applied actions, and
Recognise that this procedure can only give a connection where equilibrium is capable of being
achieved but where compatibility is unlikely to be satisfied and therefore ensure that the connection
elements are capable of ductile behaviour if so required.
The design models contained within the Design Guides are considered to be applicable only to connections
which are essentially statically loaded. Connections subjected to dynamic loads, earthquake loads or fatigue
applications may require additional considerations.
The following sections outline the essential features of each design model included in the current Tubular
Connection Series.
9.2 Slotted SSHS end connection (TDG 21)
The slotted SSHS end connection comprises a length of plate or flat bar that is slotted into the end of an
SSHS member and fillet welded on both sides to the SSHS member i.e. four fillet weld runs. Refer to
Figure 4 for typical examples of the connection. The end of the member may be either sealed with end
plates or left open. This cleat plate connection is then connected with bolts to a supporting member, usually
through another cleat or gusset plate welded to the supporting member. The supporting member may be an
SSHS member or an open section such as an I-beam or channel section.
FIGURE 4 TYPICAL SLOTTED SSHS END CONNECTION CONFIGURATIONS
Features of the connection are:

Welds are fillet welds to both sides of the cleat plate, connecting it to the member
The cleat plate is either a standard size flat bar or a plate cut to suit
The bolting category used is normally 8.8/S
The end of the SSHS member may optionally be closed with seal plates if architectural or
functional requirements dictate. Seal plates are not considered to contribute to the structural
performance of the connection and are hence not featured in the design models subsequently
discussed.

The main focus of this design model is the isolated end connection for a single brace member. Design
models specific to a connection assembly, comprising the cleat plate on the member bolted to a bracing
cleat or gusset plate on the supporting member, are provided in Tubular Design Guide 22.
Summary of design checks:

General
DESIGN CHECK NO. 1 Detailing requirements
DESIGN CHECK NO. 2 Validity limits and minimum design actions
Axial tension
DESIGN CHECK NO. 3 Design capacity of bolts in shear and ply bearing
DESIGN CHECK NO. 4 Design capacity of welds to SSHS member
DESIGN CHECK NO. 5 Design capacity due to end plate tearout in cleat plate
DESIGN CHECK NO. 6 Design capacity of cleat plate in block shear
DESIGN CHECK NO. 7 Design capacity of cleat plate in axial tension
DESIGN CHECK NO. 8 Design capacity of cleat plate due to shear lag
DESIGN CHECK NO. 9 Design capacity of SSHS member locally
Axial compression

DESIGN CHECK NO. 12 Design capacity of cleat plate due to shear lag
DESIGN CHECK NO. 13 Design capacity of SSHS member locally
DESIGN CHECK NO. 14 Design capacity of cleat plate under eccentric compression force
As well as a worked example, the following Design Capacity Tables are provided with this design model,
derived using the Design Checks stated above:
Table Member type Grade (MPa) Design actions

3.13.1(a) CHS small 250 tension; compression
3.13.1(b) CHS large 250 tension; compression
3.13.3(a) SHS small 350 tension; compression
3.13.3(b) SHS large 350 tension; compression
3.13.5(a) RHS small 350 tension; compression
3.13.5(b) RHS large 350 tension; compression

9.3 Welded tee SSHS end connection (TDG 21)
The welded tee SSHS end connection comprises a length of plate or flat bar that is welded transversely
onto a cap plate which in turn is welded onto the end of an SSHS member (refer to Figure 5 for typical
examples of the connection). The cleat plate connection is then connected with bolts to a supporting
member, usually through another cleat or gusset plate welded to the supporting member. The supporting
member may be an SSHS member or an open section such as an I-beam or channel section.
FIGURE 5 TYPICAL WELDED TEE END CONNECTION CONFIGURATIONS

Welds are fillet welds to both sides of the cleat plate, connecting it to the cap plate
The cleat plate is either a standard size flat bar or a plate cut to suit
The cap plate is welded all round to the square cut end of the SSHS with either fillet welds or a
butt weld
The cap plate is either a standard size flat bar or a plate cut to suit
The main focus of this design model is the isolated single tee SSHS end connection for a brace member.
Design models specific to a connection assembly, comprising the cleat plate on the member bolted to a
bracing cleat or gusset plate on the connected member, are provided in Tubular Design Guide 22.
General
Axial tension
DESIGN CHECK NO. 4 Design capacity of welds of cleat plate to cap plate
DESIGN CHECK NO. 5 Design capacity due to end plate tearout in cleat plate

DESIGN CHECK NO. 6 Design capacity of cleat plate in block shear
DESIGN CHECK NO. 7 Design capacity of cleat plate in axial tension
DESIGN CHECK NO. 8 Design capacity of cap plate due to punching shear
DESIGN CHECK NO. 9 Design capacity of cap plate due to plastic hinge formation (cap + tube walls)
DESIGN CHECK NO. 10 Design capacity of cap plate due to plastic hinge formation (cap only)
DESIGN CHECK NO. 11 Design capacity of welds of cap plate to SSHS
DESIGN CHECK NO. 12 Design capacity of SSHS wall local yielding

Axial compression
DESIGN CHECK NO. 14 Design capacity of welds of cleat plate to cap plate
DESIGN CHECK NO. 15 Design capacity of welds of cap plate to SSHS

DESIGN CHECK NO. 16 Design capacity of SSHS walllocal yielding
DESIGN CHECK NO. 17 Design capacity of SSHS walllocal crippling
DESIGN CHECK NO. 18 Design capacity of end plate under eccentric compression force


9.4 Flattened end CHS connection (TDG 21)
(a) Bolted (b) End cropped
FIGURE 6 TYPICAL FLATTENED END CHS CONFIGURATIONS
The flattened end CHS connection comprises a CHS bracing member which has the end flattened over a
defined length and that flattened length holed to take connection bolts (refer to Figure 6 for typical examples
of the connection). The flattened end is then connected with bolts to a supporting member, usually through
a cleat or gusset plate welded to the supporting member. The supporting member may be an SSHS member
or an open section such as an I or channel section. In some cases the end of the flattened area may be
directly welded to the supporting member or to a cleat or gusset rather than bolted.

The width of the flattened end is predominantly a function of the diameter of the CHS bracing
member.
Flattening is undertaken until the opposite faces of the CHS are approximately touching each
other.
The bolting category used is normally 8.8/S.
The main focus of this design model is the isolated end flattened connection at the end of the brace
member. Design models specific to a connection assembly, comprising the end flattening on the brace
member bolted to a cleat plate or gusset plate on the supporting member, are also presented, related back
to the cleat plate assembly detailed in Tubular Design Guide 22.
General
Axial tension
DESIGN CHECK NO. 4 Design capacity due to end plate tearout in flattened end
DESIGN CHECK NO. 5 Design capacity of flattened end in block shear
DESIGN CHECK NO. 6 Design capacity of flattened end in axial tension

Axial compression
DESIGN CHECK NO. 8 Design capacity of flattened end under eccentric compression force

5.13.1 CHS 250 tension; compression
5.13.2 CHS 350 tension; compression
9.5 Bracing cleat (TDG 22)
FIGURE 7 CONFIGURATION OF BRACING CLEAT
The isolated bracing cleat connection comprises a length of plate or flat bar that is fillet welded on both
sides to the SSHS supporting member (refer to Figure 7 for typical examples of the connection), usually
aligned with the longitudinal axis of the supporting member. The bracing cleat is usually connected with
bolts to a bracing member that is acting under tensile or compressive load.
Welds are fillet welds to both sides of the bracing cleat, connecting it to the face of the supporting
member
The bracing cleat is either a standard size flat bar or a plate cut to suit
The bracing cleat is usually aligned with the longitudinal axis of the supporting member and
positioned centrally on the face
The bracing cleat is aligned with the bracing member at an angle to the longitudinal axis of the
supporting member
The main focus of this design model is the isolated bracing cleat connected to a single brace member.
Design models specific to a connection assembly, comprising the bracing cleat on the supporting member
bolted to a cleat on the supported member, are provided in Tubular Design Guide 22. Design models
specific to multiple bracing members framing into a single bracing cleat, which in the terminology of these
design guides is called a gusset plate, are also provided in Tubular Design Guide 22.

General
DESIGN CHECK NO. 2 Validity limits and minimum
Axial tension
DESIGN CHECK NO. 4 Design capacity due to end plate tearout in end plate
DESIGN CHECK NO. 5 Design capacity of bracing cleat in block shear
DESIGN CHECK NO. 6 Design capacity of bracing cleat in axial tension
DESIGN CHECK NO. 7 Design capacity of weld to SSHS member
DESIGN CHECK NO. 8 Design capacity of SSHS member locally local shear
DESIGN CHECK NO. 9 Design capacity of SSHS member locally face yielding
Axial compression
DESIGN CHECK NO. 11 Design capacity of weld to SSHS member
DESIGN CHECK NO. 13 Design capacity of SSHS member locally face yielding
DESIGN CHECK NO. 14 Design capacity of bracing cleat under eccentric compression force

3.13.1(a) CHS small 250 compression / tension
3.13.1(b) CHS large 250 compression / tension
3.13.2(a) CHS small 350 compression / tension
3.13.2(b) CHS large 350 compression / tension
3.13.3(a) SHS small 350 compression / tension
3.13.3(b) SHS large 350 compression / tension
3.13.4(a) SHS small 450 compression / tension
3.13.4(b) SHS large 450 compression / tension
3.13.5(a) RHS small 350 compression / tension
3.13.5(b) RHS large 350 compression / tension
3.13.6(a) RHS small 450 compression / tension
3.13.6(b) RHS large 450 compression / tension

9.6 Gusset plate (TDG 22)
FIGURE 8 TYPICAL CONFIGURATIONS OF GUSSET PLATES
The gusset plate connection comprises a plate or flat bar component that is fillet welded all around to the
SSHS supporting member (refer to Figure 8 for typical examples of the connection) and usually aligned with
the longitudinal axis of the supporting member. The gusset plate is designed to accept one or more bracing
member cleat plates bolted to it in a configuration that provides load transfer between multiple members in-
plane whilst at the same time ensuring adequate clearance. The bracing members are usually acting under
tensile or compressive load.
The gusset plate is structurally similar to the isolated bracing cleat detailed in Section 3 except that since it
is usually larger to accommodate one or more bracing member cleat connections, the area of bracing cleat
contributing to the load capacity associated with each bracing cleat connection is not as well defined.
Welds are fillet welds to both sides of the gusset plate, connecting it to the face of the supporting
member.
The gusset plate is usually a plate cut to suit. Given the variation in sizes of gusset plates to suit
bracing configurations, it is usually not practical to cut gusset plates from flat bar.
The gusset plate is usually aligned with the longitudinal axis of the supporting member and
positioned centrally on the face of the SSHS (with or without any small offset to account for plate
thicknesses of the gusset or cleats on the bracing members).
The gusset plate shape is configured to the angular alignment of the bracing members framing
into the connection and the necessary clearances.
The main focus of the gusset plate model is the gusset plate with connections to single or multiple bracing
members and welded to the face of the supporting member. Design models specific to a connection
assembly, comprising the cleat plate on the brace member bolted to the gusset plate on the supporting
member, are provided in Tubular Design Guide 22.

General

Axial tension
DESIGN CHECK NO. 3 Design capacity of bolts in shear and bearing

DESIGN CHECK NO. 4 Design capacity due to end plate tearout in gusset plate
DESIGN CHECK NO. 5 Design capacity of gusset plate in block shear
DESIGN CHECK NO. 6 Design capacity of gusset plate in axial tension
Axial compression
DESIGN CHECK NO. 8 Design capacity of gusset plate under eccentric compression force
Net connection forces (tension or compression)
DESIGN CHECK NO. 9 Design capacity of gusset plate section yield

DESIGN CHECK NO. 10 Design capacity of weld to SSHS supporting member
DESIGN CHECK NO. 12 Design capacity of SSHS member locally chord face yielding
DESIGN CHECK NO. 13 Design capacity of SSHS member locally punching shear
The range of variables and number of different geometric configurations of gusset plate connections make it
difficult to rationalise a meaningful set of design capacity tables (DCT). However, the particular gusset plate
configuration can be broken down into component failure groupings and the design capacity tables
documented for the relevant design models used to find an approximate solution. Specifically:
1. Assess the local bolted connection related tension failure modes using the results for one of the cleat
connection types, such as slotted end plate or welded tee end. In most cases these will provide a
conservative (i.e. lower) estimate of capacity since the extent and edge distances of the gusset plate
may be larger than the cleat connection used in these DCTs.
2. Assess the eccentric compression failure load using the results in Tubular Design Guide 22 for cleat
assemblies. These DCTs address only the compression capacity of the cleat assembly and have been
in part configured to model the Whitmore section for one of the two cleats, thereby being applicable to
the connection of a cleat to a gusset plate.
3. Assess the net gusset plate failure modes utilising the DCTs for the moment side plate connection
given in Tubular Design Guide 23. These require the net forces on the gusset plate, which will need to
be resolved from the component forces in each member framing into the gusset plate.

9.7 Cleat plate assembly (TDG 22)
(a) Single brace connection (b) Gusset plate connection
(c) Cleat assembly (d) Whitmore section calculation
FIGURE 9 TYPICAL CONFIGURATIONS OF CLEAT PLATE ASSEMBLIES
The cleat plate assembly comprises a cleat plate on the brace member bolted to a cleat plate on the
supporting member, as shown in Figure 9(a) and (c). A cleat plate on a member bolted to a gusset plate on
the supporting member, as shown in Figure 9(b), is also considered a cleat plate assembly, where an
effective width of the gusset plate, known as the Whitmore section is used to model an equivalent cleat
plate attached to the support, as shown in Fig. 9(d).
Welds are usually fillet welds to the brace member and to the supporting member.
The cleat plates (or gusset plate) may be either a standard size flat bar or a plate cut to suit. For
the gusset plate it may be difficult to source flat bar of the required dimensions.
The cleat plates are usually aligned with the longitudinal axis of the members and positioned
centrally on the respective member faces.
The main focus of the model is the cleat plate assembly comprising single cleat plate on the bracing
member bolted to a single cleat plate connected to the supporting member. The design checks relevant only
to compression stability are presented. Design checks related to all other failure modes, such as bolt
bearing and tearout, plate tearout and block shear are described adequately in other connection models in
the Tubular Connection Series, for example, the slotted end SSHS connection.

The cleat plate assembly model is presented in a generic form as two separate cleat plates, each with their
own width, thickness, length and material properties, as shown in Fig. 10. Subscript I in Fig. 10 refers to
properties related to the cleat plate welded to the supported (brace) member, whilst subscript j refers to
properties related to the cleat or gusset plate welded to the supporting member.
Figure 10 also illustrates a cleat connected to a gusset plate, where the gusset plate properties are based
on the Whitmore Section. The generic bolted cleat plate assembly presented in this section may be used to
assess the compression capacity of the cleat to gusset connection, where the gusset is treated as a cleat
with the equivalent Whitmore section.
FIGURE 10 GENERIC CLEAT PLATE ASSEMBLY AND MODELLING OF

CLEAT-TO-GUSSET CONNECTION
General
Axial compression
DESIGN CHECK NO. 3 Design capacity of cleat plate assembly under eccentric
compression force
Cleat thickness
Table Member type Design action
(mm)
5.13.1(a) small cleat assembly 8, 10, 12 compression
5.13.1(b) large cleat assembly 10, 12, 16, 20 compression
5.13.2(a) small cleat assembly 8, 10, 12 tension
5.13.2(b) large cleat assembly 10, 12, 16, 20 tension

9.8 Web side plate (TDG 23)
(a) Web side plate to CHS (b) Web side plate to SHS
FIGURE 11 TYPICAL WEB SIDE PLATE CONFIGURATIONS
The web side plate connection consists of a length of plate or flat bar, fillet welded on both sides to the
supporting SSHS member, with bolts connecting the supported member (often a beam web) to the web side
plate (refer to Figure 11 for typical examples of the connection).
Welds are fillet welds to both sides of the cleat component, connecting it to the supporting
member
The cleat component is either a standard size flat bar or a plate cut to suit
The bolting category normally used is 8.8/S
The connection can be used with skew supported members, as shown in Fig. 11(b).
The main focus of this model is the isolated web side plate connected to an SSHS member. Hence design
checks are presented only for the connection plate and SSHS components. Design models specific to the
supported member (often an I-beam) are provided in ASI Connection Design Guide 3 (included in Ref 1).

DESIGN CHECK NO. 5 Design capacity of web side plate in shear
DESIGN CHECK NO. 6 Design capacity of web side plate in block shear
DESIGN CHECK NO. 7 Design capacity of web side plate in bending
DESIGN CHECK NO. 8 Design capacity of SSHS memberlocal shear
DESIGN CHECK NO. 9 Design capacity of SSHS memberpunching shear
DESIGN CHECK NO. 10 Design capacity of SSHS memberface yielding

Table Member type Grade (MPa) Bolt lines (n g)

3.13.1(a) CHS small 250 1, 2
3.13.1(b) CHS large 250 1

3.13.1(c) CHS large 250 2
3.13.2(a) CHS small 350 1, 2
3.13.2(b) CHS large 350 1
3.13.2(c) CHS large 350 2
3.13.3(a) SHS small 350 1, 2

3.13.3(b) SHS large 350 1
3.13.3(c) SHS large 350 2
3.13.4(a) SHS small 450 1, 2
3.13.4(b) SHS large 450 1
3.13.4(c) SHS large 450 2
3.13.5(a) RHS small 350 1, 2
3.13.5(b) RHS large 350 1
3.13.5(c) RHS large 350 2
3.13.6(a) RHS small 450 1, 2
3.13.6(b) RHS large 450 1
3.13.6(b) RHS large 450 2
9.9 Moment side plate (TDG 23)
FIGURE 12 TYPICAL MOMENT SIDE PLATE CONFIGURATIONS FOR SSHS SECTIONS

The moment side plate connection comprises a length of plate or flat bar that is welded to the side face of a
CHS or SHS/RHS member aligned with the longitudinal axis of the member and, in the case of the
SHS/RHS, usually centrally located on the face of the member. The plate is fillet welded on both sides to
the SSHS member (refer to Fig. 12 for typical examples of the connection). This moment side plate
connection is then usually connected via bolts or welds to other members. Typical applications might
include cases of truss chord to brace connections where the brace member spacing or noding of the
connection produces moment in the plane of the plate on the interface with the SSHS member.
Welds are fillet welds to both sides of the moment side plate, connecting it to the member
The side plate is either a standard size flat bar or a plate cut to suit
The bolting category used is normally 8.8/S, but may also be 8.8/T where a single member is
connected to the side plate and intended to transfer moment.
The main focus of this model is the isolated moment side plate connected to an SSHS member. Hence
design checks are presented only for the connection plate and SSHS components. Design models related to
the bolted connection of brace members to the plate are provided in Tubular Design Guide 22.

Net connection forces:
DESIGN CHECK NO. 4 Design capacity of SSHS member locallychord face yielding
DESIGN CHECK NO. 5 Design capacity of SSHS member locallypunching shear
DESIGN CHECK NO. 6 Design capacity of SSHS member locallyface shear
DESIGN CHECK NO. 7 Design capacity of side platesection yield
Table Member type Grade Design action

4.13.1 CHS 250 moment
4.13.2 CHS 350 moment
4.13.3 SHS 350 moment
4.13.4 SHS 450 moment
4.13.5 RHS 350 moment
4.13.6 RHS 450 moment

9.10 Transverse plate (TDG 23)
FIGURE 13 TYPICAL TRANSVERSE PLATE CONFIGURATIONS FOR SSHS
The isolated transverse plate connection comprises a length of plate or flat bar that is fillet welded on both
sides to the SSHS supporting member (refer to Figure 13 for typical examples of the connection), in a
direction transverse to the longitudinal axis of the SSHS member. The transverse plate may be connected
with bolts to a bracing member that is acting under tensile or compressive load.
Welds are fillet welds to both sides of the transverse plate, connecting it to the face of the
supporting member.
The transverse plate is either a standard size flat bar or a plate cut to suit.
The bolting category used (where bolts are required) is normally 8.8/S.
The plate is aligned transverse to the longitudinal axis of the supporting member and positioned
centrally on the face.
The plate may be at an angle other than 90 to the longitudinal axis of the SSHS member.
The main focus of this model is the isolated transverse plate intended to connect to a single brace member.
Design models relevant to a connection assembly, comprising the transverse plate on the SSHS member
bolted to a cleat on the supported brace member, are provided in Tubular Design Guide 22. Whilst bolted
connection details may be indicated in some diagrams, this is purely for context. Where a bolted connection
is made to a transverse plate, the relevant connection models as provided in TDG 22 should be referenced
for the additional design checks necessary.

The design checks presented for this design model relate to the unique aspects of this connection type,
primarily the action of the plate on the SSHS member to which it is connected. Where the plate is used as a
bracing cleat with a bolted connection, additional checks for plate capacity are required. Appropriate checks
for the plate acting as a bracing cleat are given in Tubular Design Guide 22.

General

Axial tension
DESIGN CHECK NO. 3 Design capacity of transverse plate in axial tension (effective width)
DESIGN CHECK NO. 5 Design capacity of SSHS member locallyface yielding

DESIGN CHECK NO. 6 Design capacity of SSHS member locallyface punching shear
DESIGN CHECK NO. 7 Design capacity of SSHS member locallychord side wall failure
Axial compression
DESIGN CHECK NO. 8 Design capacity of transverse plate in axial compression (effective width)
DESIGN CHECK NO. 10 Design capacity of SSHS member locallyface yielding
DESIGN CHECK NO. 11 Design capacity of SSHS member locallyface punching shear
DESIGN CHECK NO. 12 Design capacity of SSHS member locallychord side wall failure
Table Member type Grade Design action

5.13.1(a) CHS 250 tension
5.13.1(b) CHS 250 compression
5.13.2(a) CHS 350 tension
5.13.2(b) CHS 350 compression
5.13.3(a) SHS 350 tension
5.13.3(b) SHS 350 compression
5.13.4(a) SHS 450 tension
5.13.4(b) SHS 450 compression
5.13.5(a) RHS 350 tension
5.13.5(b) RHS 350 compression
5.13.6(a) RHS 450 tension
5.13.6(b) RHS 450 compression

9.11 Bolted end plate splice (TDG 24)
FIGURE 14 TYPICAL BOLTED END PLATE SPLICE CONNECTION CONFIGURATIONS
The bolted end plate splice connection comprises a plate that is usually fillet welded across the end of an
SSHS member, in most instances normal to the longitudinal axis of the SSHS member (refer to Figure 14
for typical examples of the connection). The end plate connection is then connected with bolts to a similarly
prepared member (in the case of a splice connection between members) or may be bolted in a number of
other configurations, usually through another plate welded to the other member. Some typical connection
assemblies are shown in Figure 15.

Welds are usually fillet welds all around the flange plate, connecting it to the member, although
where fillet welds over 8-10 mm are required, it may be more economical to use partial or full
penetration butt welds.
The end plate is usually a plate cut to suit.
The bolting category used is normally 8.8/TB.
The end plate is assumed to be uniform and continuous i.e. solid, with the member butted onto
one face of the plate. So-called ring flanges, where the plate has a hole to accept the member
slotted into it, or that have a significant hole aligned with the longitudinal axis of the member, are
not covered in this design guidance. Ring flanges are typically very thick, as the plate is designed
to remain elastic, whereas solid flange plates can be designed for plastic behaviour in structural
applications and are usually much thinner. Ring flanges would usually be required for cases where
the SSHS member is fluid filled or intended to be concrete filled. The design models presented in
this Guide are not applicable to ring flanges.
For the case of axial compression in the connection, it is assumed that the members on each side
of the connection end plates are of similar size such that there are no through thickness bending
or shearing effects caused by lack of direct bearing load paths through the thickness of the
connection.

FIGURE 15 TYPICAL CONNECTION ASSEMBLIES UTILISING BOLTED END PLATES
The bolted end plate splice is designed to resist predominantly axial tension. Where present, applied
moment is assumed to be sufficiently small such that the combined axial tension and moment does not
result in any net compression around the connection. The scope of the model also includes axial
compression, although the design checks for this case are trivial.
Where bending moments are significant, the bolted moment end plate design model described in the
following section should be adopted.

General
Axial tension
DESIGN CHECK NO. 3 Design capacity of bolts in axial tension
DESIGN CHECK NO. 5 Design capacity of end plate in bending
DESIGN CHECK NO. 6 Design capacity due to local yielding of SSHS member
Axial compression

Axial tension and bending

DESIGN CHECK NO. 11 Design capacity due to local yielding of SSHS member
End plate
Capacity
Table End plate type Member type grade Design action

(refer Note 1)
(MPa)
3.13.1(a) circular CHS Grade 250 250 axial tension 50%
3.13.1(b) circular CHS Grade 250 250 axial tension 100%
3.13.2(a) circular CHS Grade 350 250 axial tension 50%
3.13.2(b) circular CHS Grade 350 250 axial tension 100%
3.13.3 rectangular SHS Grade 350 250 axial tension 50%
2 sided
3.13.4 rectangular RHS Grade 350 250 axial tension 50%
2 sided
3.13.5 rectangular SHS Grade 450 350 axial tension 50%
2 sided
3.13.6 rectangular RHS Grade 450 350 axial tension 50%
2 sided
3.13.7(a) rectangular SHS Grade 350 250 axial tension 50%
4 sided
3.13.7(b) rectangular SHS Grade 350 250 axial tension 100%
4 sided
3.13.8(a) rectangular RHS Grade 350 250 axial tension 50%
4 sided
3.13.8(b) rectangular 4 RHS Grade 350 250 axial tension 100%
sided
3.13.9(a) rectangular SHS Grade 450 350 axial tension 50%
4 sided
3.13.9(b) rectangular SHS Grade 450 350 axial tension 100%
4 sided
3.13.10(a) rectangular RHS Grade 450 350 axial tension 50%
4 sided
3.13.10(b) rectangular RHS Grade 450 350 axial tension 100%
4 sided

9.12 Bolted moment end plate (TDG 24)
(a) Four bolt connection (b) Eight bolt connection
FIGURE 16 TYPICAL BOLTED MOMENT END PLATE CONNECTION CONFIGURATIONS
The bolted moment end plate connection comprises a solid plate that is welded across the end of an
SHS/RHS member, usually normal to the longitudinal axis of the member (refer to Figure 16 for typical
examples of the connection). This member end plate connection is then usually connected with bolts to a
similarly prepared plate welded to another member.
The design model adopted is based on tests in which the plate was full strength butt welded to the
SSHS, together with a superimposed fillet weld.
The end plate is usually a plate cut to suit.
The bolting category used is normally 8.8/TB (tensioned).
The end plate is assumed to be uniform and continuous i.e. solid, with the member butted onto
one face of the plate. So-called ring flanges, where the plate has a hole to accept the member
slotted into it, or that have a significant hole aligned with the longitudinal axis of the member, are
not covered in this design guidance. Ring flanges are typically very thick, as the plate is designed
to remain elastic, whereas solid end plates can be designed for plastic behaviour in structural
applications and are usually much thinner. Ring flanges would usually be required for cases where
the SSHS member is fluid filled or intended to be concrete filled. The design model in this Guide is
not applicable to ring flanges.
It is assumed that the members on each side of the connection end plates are of similar size such
that there are no through thickness bending or shearing effects caused by lack of direct bearing
load paths through the thickness of the end plates.
The design models adopted are valid for SHS/RHS members only. There are no models available
for CHS members.
The bolted moment end plate may be used in a number of different configurations, some of which are
shown in Figure 17. The main focus of this section is on the bolted solid end plate for RHS/SHS members
under moment loading as utilised typically in the beam splice connection shown in Figure 17(b).

(a) Rafter apex connection (b) Beam splice connection
FIGURE 17 TYPICAL CONNECTION ASSEMBLIES UTILISING BOLTED

MOMENT END PLATES
The bolted moment end plate is designed to resist predominantly moment loading. Where present, axial
load is assumed to be sufficiently small such that the combined moment and axial load does not result in a
situation where the compression or tension at any point around the connection reverses direction from that
present for the moment only case.
Where axial loads are significant, the bolted end plate splice design model described in the previous section
should be adopted.
General
Bending moment and axial tension

DESIGN CHECK NO. 4 Design capacity of welds to SHS/RHS member
DESIGN CHECK NO. 6 Design capacity of end plate due to punching shear
Shear
DESIGN CHECK NO. 8 Design capacity due to tear out in end plate
DESIGN CHECK NO. 9 Design capacity of welds to SHS/RHS member

End plate
Capacity
Table End plate type Member type grade Design action
(refer Note 1)
(MPa)
4.13.1(a) rectangular 2 sided SHS Grade 350 250 moment 50%
4.13.1(b) rectangular 2 sided SHS Grade 350 250 moment maximum
4.13.2(a) rectangular 2 sided RHS Grade 350 250 moment 50%
4.13.2(b) rectangular 2 sided RHS Grade 350 250 moment maximum
(refer Note 12)

(refer Note 12)
(refer Note 12)
(refer Note 12)
(refer Note 12)
(refer Note 12)
(refer Note 12)
(refer Note 12)

9.13 Mitred knee (TDG 25)
FIGURE 18 TYPICAL FULLY WELDED MITRED KNEE CONNECTION CONFIGURATIONS
The mitred knee connection comprises two approximately similarly sized SSHS members meeting at an
angle of 90 degrees or greater. Each member is profile cut to the mitre angle and either welded directly to
each other or via an intermediate stiffening plate. Typical examples are shown in Figure 18 for both
SHS/RHS and CHS members.
Welds are typically a combination of fillet welds and full strength butt welds, as shown in
Figure 3.2.
The stiffener plate, where specified, is either a standard size flat bar or a plate cut to suit.
The main focus of this model is the fully welded mitred knee connection in both stiffened and unstiffened
versions.
General


Combined actions
DESIGN CHECK NO. 3 Design capacity for combined moment and axial load
DESIGN CHECK NO. 4 Design capacity for shear
DESIGN CHECK NO. 5 Design capacity of welds to SSHS members
Table Member type Grade (MPa) Connection type Design action

moment
3.13.1 CHS 250 unstiffened
with axial load
moment
3.13.2 CHS 350 unstiffened
with axial load
moment
3.13.3 SHS 350 unstiffened
with axial load
moment
3.13.4 SHS 450 unstiffened
with axial load
moment
3.13.5 RHS 350 unstiffened
with axial load
moment
3.13.6 RHS 450 unstiffened
with axial load
9.14 T, Y and X connections (TDG 25)
FIGURE 19 TYPICAL T, Y AND X CONNECTION CONFIGURATIONS
Typical T and Y connections comprise a brace member profile cut and fully welded all round to the chord
member. All members are SSHS members.

Welds are usually fillet welds continuous all round the brace to chord connection. Butt welds may
be necessary in some locations due to the local plate alignments.
The end of the brace member is profile cut to ensure a good fit with minimum gap between the
brace member end and the face of the chord member at all points around the perimeter of the
brace member connection area.
A T connection is a particular variant of the Y connection with the brace member at right angles to
the chord member.
An X connection has a second brace member connected to the opposite face of the chord. Design
models for X connections generally have the two brace members collinear.
The main focus of this model is the T or Y connection subjected to pure axial load in all members or to
moment in the brace member. Interaction between axial load and moment is also presented. X connections
are treated as a variation of T and Y connections.
General
Axial tension or compression in brace member

DESIGN CHECK NO. 3 Design capacity due to chord face plastification
DESIGN CHECK NO. 4 Design capacity due to chord side wall failure
DESIGN CHECK NO. 5 Design capacity due to chord punching shear
DESIGN CHECK NO. 6 Design capacity due to local yielding of brace member
DESIGN CHECK NO. 8 Design capacity due to chord shear
Bending moment in brace member

DESIGN CHECK NO. 10 Design capacity due to chord side wall failure
Combined axial load and bending moment in brace member

DESIGN CHECK NO. 14 Combined axial load and moment interaction


4.13.1 CHS 250 T connection tension / compression
4.13.2 CHS 350 T connection tension / compression

4.13.3 SHS 350 T connection tension / compression
4.13.4 SHS 450 T connection tension / compression
9.15 K & N gap connections (TDG 26)

(a) K & N gap connections
(b) KT gap connections
FIGURE 20 TYPICAL K & N AND KT GAP CONNECTION CONFIGURATIONS
K & N gap connections comprise two brace members profile cut and fully welded all around to the chord
member, as shown in Figure 20(a). All members are SSHS members.

Features of the connection include:
Welds are usually fillet welds continuous all around the brace to chord connection. However, due
to variation in the relative angle between connected elements, in some locations butt welds are
necessary.
The ends of the brace members are profile cut to ensure a good fit with minimum gap between the
brace member end and the face of the chord member at all points around the perimeter of the
brace member connection area.
There is a defined space or gap between the brace members where they land on the connected
face of the chord member.
An N connection is a particular type of K connection where one brace member is at right angles to
the chord member.
The main focus of this section is the K or N gap connection subjected to pure axial load in all members, as
would be expected where the connection is part of a truss assembly. Any moments that occur in the
connection members are secondary, usually produced as a result of noding eccentricity.
KT connections, which are shown in Figure 20(b), are a combination of a K and T connection. The design of
KT connections is detailed, with design guidance related back to the K or T connection, as appropriate.

General
Axial tension or compression
DESIGN CHECK NO. 6 Design capacity of welds to SSHS brace members
DESIGN CHECK NO. 7 Design capacity due to chord shear

3.13.1 CHS 250 K connection tension / compression
3.13.2 CHS 350 K connection tension / compression
3.13.3 SHS 350 K connection tension / compression
3.13.4 SHS 450 K connection tension / compression

9.16 K & N overlap connections (TDG 27)
(a) K & N overlap connections
(b) KT overlap connections
FIGURE 21 TYPICAL K & N OVERLAP CONNECTION CONFIGURATIONS
K & N overlap connections comprise two (usually) brace members profile cut and fully welded all around to
the chord member, as illustrated in Fig. 21. One brace member fully or partially contacts the other brace
member. All members are SSHS members.
Features of the connection include:
Welds are usually fillet welds continuous all around the brace to chord connection.
The end of the brace members are profile cut to ensure a good fit with minimum gap between the
brace member end and the face of the chord member (and adjacent brace member) at all points
around the perimeter of the brace member connection area.
There is a defined overlap between each brace member so that at least one brace member is fully
or partially welded to the other brace member as well as to the chord member.

An N connection is a particular type of K connection where one brace member is at right angles to
the chord member.
The connection may be noded, where the centrelines of all members coincide at a point, or there
may be a defined node eccentricity. Node eccentricity is often introduced to spread or contract the
web member spacing to facilitate easier or simpler connection fabrication.
The main focus of this model is the K or N overlap connection subjected to pure axial load in all members.
Any moments that occur in the connection members are secondary, usually produced as a result of the
noding eccentricity.
KT connections, which are a combination of a K and T connection as illustrated in Fig. 21(b), are detailed,
with design guidance provided related back to the K and T connections.

General
Axial tension or compression

DESIGN CHECK NO. 3 Design capacity due to local yielding of overlapping brace
DESIGN CHECK NO. 4 Design capacity due to local yielding of chord member
DESIGN CHECK NO. 5 Design capacity due to brace shear
DESIGN CHECK NO. 6 Design capacity of welds to brace members
The development of a meaningful set of design capacity tables for K & N overlap connections involves
consideration and rationalisation of three separate members which, by virtue of the overlap present, interact
with each other, resulting in significant permutations of behaviour. For these reasons, design capacity
tables have not been produced for this connection type.
10 CONCLUSION
The use of structural steel hollow sections (SSHS) is increasing in relative terms, recognising the inherent
member efficiencies possible and the aesthetics able to be realised, in particular for architecturally exposed
structural steel (AESS) solutions. Connection design and sympathetic detailing play a significant part in
ensuring SSHS structures meet the client performance expectations, in terms of both cost and aesthetics.
The object of the Tubular Connection Series is to provide a rationalised approach to the design, detailing
and fabrication of the commonly adopted SSHS connections. The benefits of this approach include:
Provision to the competent professional person as designer, a range of reliable and economic
connections accompanied by design capacity tables (wherever possible) for each connection type
Elimination of the need for repetitive computation by structural engineers as much as practicable
Scope for the fabricator to produce connection components by production engineering methods where
possible. It is noted however that a number of the connection types have limited components.
Advantages that can be expected to flow from industry rationalisation, such as better communication,
better availability of materials and suitable components
Provide a considerable impetus towards improving the economy and therefore the competitive
position of structural steel in the Australian building industry

11 REFERENCES
1. Hogan, T.J. and Munter, S.A., Structural steel connection series for simple connections Open
sections, Australian Steel Institute, 2007.
2. Hogan, T.J. and van der Kreek, N., Structural steel connection series for rigid connections Open
sections, 1 edition, Australian Steel Institute, 2009.

st
Hogan, T.J. and Thomas, I.R., Design of structural connections, 4

th
3. edition, Australian Institute of
Steel Construction, 1994.
4. Syam, A.A. and Chapman, B.G., Design of structural steel hollow section connections Volume 1:
Design models, Australian Institute of Steel Construction, 1996.
5. Standards Australia, AS 41001998 Steel structures.

rd
6. Australian Institute of Steel Construction, Standardized structural connections, 3 edition, 1985.
7. Hogan, T.J. and Munter, S.A., Design capacity tables for structural steel, volume 3: Simple
connections Open sections, Australian Steel Institute, 2007.
8. Hogan, T.J. and van der Kreek, N., Design capacity tables for structural steel, volume 4: Rigid
connections Open sections, Australian Steel Institute, 2009.
9. Standards Australia, AS 4100 Supp11999 Steel structures Commentary (Supplement to

AS 41001998).
10. Standards Australia/Standards New Zealand, AS/NZS 1163:2009 Cold-formed structural steel hollow
sections.
11. Standards Australia, AS 12501981 SAA Steel structures code.
12. Standards New Zealand, NZS 3404: Part 1:2009 Steel structures standard. Part 1: Materials,
fabrication and construction.
American Institute of Steel Construction, Steel construction manual, 14 edition, 2011.

th
13.
14. American Institute of Steel Construction, ANSI/AISC 360-10 Specification for structural steel
buildings.
15. American Institute of Steel Construction, Hollow structural sections: Connections manual, 1997.
16. Canadian Standards Association, CAN/CSA-S16-01 Limit states design of steel structures.
17. British Standards Institution, BS 5950.1:2000 Structural use of steelwork in building. Part 1. Code of
practice for design in simple and continuous construction: hot rolled sections.
18. British Standards Institution, BS 5950.5:1998 Structural use of steelwork in building. Part 5. Code of
practice for design of cold formed thin gauge sections.
19. British Standards Institute, BS EN 1993-1-1:2005 Eurocode 3: Design of steel structures. Part 1-1:
General rules and rules for buildings.
20. Wardenier, J., Kurobane, Y., Packer, J.A., van der Vegte, G.J. and Zhao, X.-L., Design guide for
circular hollow section (CHS) joints under predominantly static loading, (Construction with hollow
nd
sections; 1), 2 edition, Comit International pour le Dveloppement et lEtude de la Construction
Tubulaire, 2008.
21. Packer, J.A., Wardenier, J., Zhao, X.-L., van der Vegte, G.J. and Kurobane, Y. Design guide for
rectangular hollow section (RHS) joints under predominantly static loading, (Construction with hollow
nd
sections; 3), 2 edition, Comit International pour le Dveloppement et lEtude de la Construction
Tubulaire, 2009.
22. ASTM International, ASTM A500/A500M - 10a Standard specification for cold-formed welded and
seamless carbon steel structural tubing in rounds and shapes, 2010.
23. European Committee for Standardization, EN 10219-1:2006 Cold formed welded structural sections
of non-alloy and fine grain steels. Technical delivery requirements.

24. Zhao, X.-L., Wilkinson, T. and Hancock, G.J., Cold-formed tubular members and connections.
Structural behaviour and design, Elsevier, 2005.
25. Packer, J.A., Chiew, S.P., Tremblay, R. and Martinez-Saucedo, G., Effect of material properties on
hollow section performance, Proceedings of the ICE Structures and Buildings, volume 163, issue 6,
2010, pp. 375-390.

26. American Petroleum Institute, API Spec 5L Specification for line pipe, 2004.
27. Hogan, T.J., Technical Note TN005 Guidelines for designing to AS 4100 when imported materials are
involved, version 3, 2012, Australian Steel Institute.
28. Hogan, T.J., Technical Note TN007 Compliance issues and steel structures, version 2, 2012,
Australian Steel Institute.
29. Standards Australia/Standards New Zealand, AS/NZS 1252:1996 High strength steel bolts with
associated nuts and washers for structural engineering.
30. Fernando, S. and Hitchen, S. Are you getting the bolts you specified? A discussion paper, Steel
Construction, Australian Steel Institute, volume 39, number 2, December 2005.
31. Munter, S., ASI TechNote #1-06 High strength bolt assemblies. Certification to AS/NZS 1252:1996
Reject or Accept? Australian Steel Institute, revision B, January 2007.
32. Hogan, T.J., Technical Note TN001 High strength structural bolt assemblies to AS/NZS 1252,
version 2, 2011, Australian Steel Institute.
33. Hogan, T.J. and Munter, S.A., Design guide 1: Bolting in structural steel connections, Australian
Steel Institute, 2007.
34. Work Health and Safety Act 2011 (Cth), sections 22, 23, 24 and 26.
35. Hogan, T.J., Technical Note TN008, Welding consumables and design of welds in AS 4100-1998 with
amendment 2012, version 1, Australian Steel Institute, 2012.
36. British Standards Institution, BS EN 1990:2002 Eurocode. Basis of structural design.
37. Hogan, T.J. and Key, P.W., Technical Note TN010, Third-party steel product certification, version 1,
Australian Steel Institute, 2012.
38. Hogan, T.J. and Munter, S.A., Handbook 1: Design of structural steel connections, Australian Steel
Institute, 2007.
12 NOTATION
b0 = overall width of SHS/RHS member
d0 = overall depth of SHS/RHS member
= diameter of CHS chord member
fu = tensile strength of SSHS member material

fy = yield stress of SSHS member material
o = external corner radius of SHS/RHS member
= thickness of material
= capacity factor, according to AS 4100
m = material reduction factor detailed in Tubular Design Guide 20 and based on the yield-to-ultimate
limiting factor of 0.8 and the reduction factor of 0.9 for yield stress greater than 350 MPa and up
to 460 MPa, both described in CIDECT Design Guides 1 and 3.
= slenderness ratio for component subject to axial compression

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ISSN 0049-2205 PRINT POST APPROVED PP255003/01614

Structural Steel Tubular

ASI CONTACT DETAILS

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 1

2 STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014

Tubular Design Guide 20 Background and design basis

4 SCOPE AND BASIS

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 3

5 BASIS OF SSHS CONNECTION DESIGN TO AS 4100

In structural steel connections, there are three fundamental considerations:

4 STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014

5.3 Connection terminology

(A) fasteners (bolts or welds) (connectors in AS 4100 terminology);

(B) components (plates, gussets, cleats);

(C) supported members;

(D) supporting members.

FIGURE 1 DEFINITION OF CONNECTION ELEMENTS

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 5

6.0 ADVANTAGES OF SSHS FOR CONSTRUCTION

FIGURE 2 METRICON STADIUM ROOF ILLUSTRATING THE AESTHETIC OF EXPOSED SSHS

6 STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014

Minimum size Maximum size

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 7

Minimum elongation as a proportion of the gauge length

7.2 Australian design context

7.3 International design context

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7.4.1 Influence of higher strength steel on SSHS connection design

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 9

Minimum yield Minimum tensile

S 235 H 235 360 0.65

7.4.3 Design yield stress for Australian produced SSHS

Minimum yield Minimum

10 STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014

Minimum yield Minimum Design yield

MPa MPa MPa

7.4.4 Section classification

Specification Section classification

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 11

CLASSIFICATION OF SECTIONS IN VARIOUS DESIGN STANDARDS

Element Specification Slenderness Slenderness limits

(a) AS 4100 (b) Eurocode 3

FIGURE 3 DEFINITION OF ELEMENT WIDTH FOR RHS FLANGES

12 STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014

plate stability or bending.

8 INTERNATIONAL MATERIAL SOURCING

8.2 Material perspectives

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 13

8.3 Product perspectives

1. Tolerances on product geometry should be reviewed. Whilst a number of international product

on the assumed safety indices.

8.4 Bolt sourcing

Section 9 of Ref. 33 which includes a discussion on certification to AS/NZS 1252

14 STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014

8.5 Welding consumables

8.6 Product compliance

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8.7 Sample tests of imported product

Section D6 of Ref. 36 goes on to state:

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8.8 Third-party product certification

9 DESIGN MODELS ADOPTED

STEEL CONSTRUCTION VOLUME 46 NUMBER 2 MARCH 2014 17