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This paper describes an investigation into the use of advanced manufacturing techniques for the creation of a new class of intermeshed steel connections that rely on neither welding nor bolting. The project detailed herein lays the groundwork to transform the steel building construction industry by advancing the underlying science and engineering precepts for intermeshed connections created from precise, volumetric cutting. The proposed system enhances the integration between design, fabrication, and installation. Fully automated, precise, volumetric cutting of open steel sections poses challenges regarding the load-transfer mechanisms and failure modes for intermeshed connections. Implementation of the intermeshed connection would cause a discontinuity in the beam; therefore, the effects of such a configuration on the behavior of the steel frame are investigated in the current paper. Load resistance and design of these connections are also explored with physical tests and finite element modeling to investigate the mechanics of intermeshed connections, including stress and strain concentrations, fracture and failure modes, and connection geometry optimization. [ABSTRACT FROM AUTHOR]

Digital manufacturing has transformed many industries but has had only a limited impact in the construction sector. To capitalize on advanced manufacturing techniques, this paper introduces a radically new connection approach for gravity structural steel frames. The proposed intermeshed steel connection (ISC) exploits robotic abilities to cut structural steel member ends precisely to accelerate deployment and offer better disassembly options over existing approaches. Forces are transferred through common bearing surfaces at multiple contact points, and connections can be secured by small locking pieces. This paper introduces the geometry, manufacturing, and initial analysis and test results of the connection. The paper demonstrates the ability of the connection to (1) be manufactured within current industrial tolerances, (2) be erected and disassembled, and (3) perform at expected design levels. [ABSTRACT FROM AUTHOR]

Advanced manufacturing techniques, such as plasma, waterjet, and laser can facilitate field assembly and disassembly of steel structural components, and therefore potentially transform how steel structures are designed and constructed. These techniques have opened up an opportunity to create a new class of steel connections that rely on intermeshed (i.e. interlocked) components in lieu of traditional connectors such as weld and bolt. This paper presents an experimental investigation on the mechanics of such intermeshed steel connections manufactured by high-definition plasma and waterjet cutting. Four full-scale specimens with an intermeshed connection were designed to resist gravity loading in steel frames. The experimental testing program focused on the behavior of intermeshed connections under vertical loads including pure flexural and combined flexural-shear loading. Both global load-deflection response and local deformation were measured to provide insights into the complex load transfer mechanisms. The experiments demonstrated ample load carrying capacity, approaching the beam plastic moment, and ample ductility, approaching a deflection over span length ratio of 1/60 to 1/40, through the interaction of individual components. Analysis of the test data also raises important questions that must be addressed for the practical design of these connections. • Advanced cutting techniques could help eliminate welding or bolting in steel connections. • The intermeshed connection transfers loads through interlocking pieces. • Waterjet and plasma cutting could meet the precision of the intermeshed connection. • The intermeshed steel connection exhibits ample load carrying capacity and ductility. • The angles and shear plates contribute in both moment and shear load transfer. [ABSTRACT FROM AUTHOR]