
Figure 1.
Concept of sheet metal folding
Table 1.
Program of investigations
| Girder | hw × tw [mm] | End Stiffener [mm] | L [mm] | Girder [mm] | hw × tw [mm] | End Stiffener [mm] | L [mm] |
|---|---|---|---|---|---|---|---|
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 |
| M 1.11 | 500x2 | 300x25 | 7825 | M 1.12 | 500x2 | 300x25 | 6000 |
| M 1.21 | 1000x2.5 | 300x25 | 7825 | M 1.22 | 1000x2 | 300x25 | 6000 |
| M 1.31 | 1000x2.5 | 300x25 | 7825 | M 1.32 | 1000x2.5 | 300x25 | 6000 |
| M 1.41 | 1250x2 | 300x25 | 7825 | M 1.42 | 1250x2 | 300x25 | 6000 |
| M 1.51 | 1500x2 | 300x25 | 7825 | M 1.52 | 1500x2 | 300x25 | 6000 |
| M 2.11 | 500x2.5 | 300x25 | 5825 | M 2.12 | 500x2 | 300x25 | 3750 |
| M 2.21 | 1000x2 | 300x25+tee bar | 5825 | M 2.22 | 1000x2 | 300x25 | 3750 |
| M 2.31 | 1000x2.5 | 300x25+tee bar | 5825 | M 2.32 | 1000x2,5 | 300x25 | 3750 |
| M 2.41 | 1000x3 | 300x25+tee bar | 5825 | M 2.42 | 1000x3 | 300x25 | 3750 |
| M 2.51 | 1500x3 | 300x25+tee bar | 5825 | M 2.52 | 1500x2 | 300x25 | 3750 |

Figure 2.
Girders with corrugated webs, from which samples used in investigations into strength properties of corrugated webs were collected: a) with a flexible end stiffener; b) with a rigid end stiffener; c) cantilever girders

Figure 3.
Girders at the test stand a) beam girder M 1.41 WTA 1250/300x15; b) cantilever girder M 152 WTA 1500/300x15

Figure 4.
Girder M 1.41– box-marked site of sample collection from the girder along the fold for materials tests on the web strength

Figure 6.
Dimensions of flat samples: a) sample from 2 mm thick web; b) sample from 2.5 mm thick web; c) sample from 3 mm thick web mm

Figure 5.
Waveform shape – place of sample cutting out, along the fold, of samples from corrugated web
Table 2.
Parameters of yield strength and tensile strength tests on web samples
| Girder number | |||||||||||
|---|---|---|---|---|---|---|---|---|---|---|---|
| mm | mm | mm2 | mm | mm | % | kN | kN | MPa | MPa | ||
| 1 | 2 | 2 | 4 | 5 | 6 | 7 | 8 | 9 | 12 | 13 | 14 |
| M 1.11 | 2.0 | 20.0 | 40.0 | 70.0 | 85.0 | 21.5 | 12.2 | 16.1 | 304.4 | 403.5 | 1.33 |
| M 1.41 | 2.0 | 20.0 | 40.0 | 70.0 | 85.1 | 21.6 | 12.7 | 17.4 | 317.8 | 434.3 | 1.37 |
| M 1.51 * | 2.0 | 20.0 | 40.0 | 70.0 | 86.1 | 23.0 | 9.9 | 15.0 | 247.2 | 375.5 | 1.52 |
| M 2.21 | 2.0 | 19.7 | 39.4 | 70.0 | 83.5 | 19.2 | 13.2 | 17.2 | 334.3 | 437.5 | 1.31 |
| M 2.51 | 2.0 | 20.0 | 40.0 | 70.0 | 86.2 | 23.1 | 11.6 | 15.1 | 289.3 | 376.8 | 1.30 |
| M 1.12 | 2.0 | 20.0 | 40.0 | 70.0 | 85.5 | 22.2 | 13.6 | 17.4 | 334.7 | 430.6 | 1.29 |
| M 1.22 | 2.0 | 20.0 | 40.0 | 70.0 | 83.9 | 19.9 | 10.7 | 14.4 | 312.5 | 453.9 | 1.45 |
| M 1.42 * | 2.0 | 20.0 | 40.0 | 70.0 | 86.3 | 23.3 | 10.0 | 15.2 | 267.2 | 360.9 | 1.35 |
| M 1.52 | 2.0 | 20.0 | 40.0 | 70.0 | 86.3 | 23.3 | 10.0 | 15.2 | 299.1 | 380.5 | 1.27 |
| M 2.12 | 2.0 | 20.0 | 40.0 | 70.0 | 84.8 | 20.8 | 13.5 | 17.2 | 337.9 | 429.1 | 1.27 |
| M 2.22 | 2.0 | 20.0 | 40.0 | 70.0 | 85.9 | 22.5 | 13.5 | 17.1 | 336.3 | 427.3 | 1.27 |
| M 2.52 | 2.0 | 20.0 | 40.0 | 70.0 | 87.2 | 24.6 | 11.2 | 15.0 | 281.0 | 375.5 | 1.34 |
| Mean value for 2 mm samples: | 305.1 | 407.1 | 1.34 | ||||||||
| M 1.21 * | 2.5 | 19.8 | 49.5 | 80.0 | 96.5 | 20.7 | 13.7 | 20.6 | 275.9 | 416.0 | 1.51 |
| M 1.31 * | 2.6 | 19.7 | 51.2 | 80.0 | 96.6 | 20.7 | 13.3 | 20.6 | 260.4 | 403.0 | 1.55 |
| M 2.11 | 2.6 | 20.0 | 52.0 | 80.0 | 98.2 | 22.8 | 13.8 | 20.3 | 266.2 | 390.0 | 1.47 |
| M 2.31 | 2.5 | 20.0 | 50.3 | 80.0 | 92.0 | 15.0 | 17.3 | 24.7 | 340.8 | 487.7 | 1.43 |
| M 1.32 * | 2.6 | 20.0 | 52.0 | 80.0 | 96.2 | 20.2 | 16.3 | 23.6 | 339.4 | 435.4 | 1.28 |
| M 2.32 | 2.6 | 20.0 | 52.0 | 80.0 | 95.4 | 19.2 | 16.9 | 23.5 | 324.6 | 451.5 | 1.39 |
| Mean value for ∼2.5mm samples: | 301.2 | 430.6 | 1.44 | ||||||||
| M 2.41 | 3.0 | 20.0 | 60.0 | 90.0 | 107.9 | 19.9 | 19.5 | 25.3 | 325.5 | 422.0 | 422.0 |
| M 2.42 | 3.0 | 20.0 | 60.0 | 90.0 | 103.2 | 14.6 | 26.8 | 32.6 | 445.9 | 544.1 | 1.22 |
| Mean value for 3 mm samples: | 385.7 | 483.0 | 1.26 | ||||||||
| Mean value for all samples: | 310.2 | 419.2 | 1.36 | ||||||||

Figure 7.
View of an exemplary 2.5 mm thick sample cut out of WTB girder web

Figure 8.
Graph F – ΔL of tension of 3 mm thick steel sample cut out of the web of M 2.42 girder

Figure 9.
Graph F – ΔL of tension of type 2 mm thick steel sample cut out of the web of M 1.32 girder
Table 3.
Parameters of normal distribution of yield strength Re of steel samples of corrugated webs
| Girder number | E(R e) [Mpa] | R ek [Mpa] | D 2(R e ) | D(R e ) | f y [Mpa] | V Re | V Re235 | V Re215 | γ m | γ m235 | γ m215 |
|---|---|---|---|---|---|---|---|---|---|---|---|
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 9 | 10 | 11 | 12 |
| M 1.11 | 304.4 | 299.15 | 10.13 | 3.1826 | 294.69 | 0.0105 | 0.1390 | 0.1791 | 1.0151 | 0.7974 | 0.7296 |
| M 1.41 | 317.8 | 307.57 | 38.76 | 6.2258 | 298.85 | 0.0196 | 0.1589 | 0.1972 | 1.0292 | 0.7863 | 0.7194 |
| M 1.51* | 247.2 | 243.12 | 6.04 | 2.4576 | 239.68 | 0.0099 | 0.0301 | 0.0794 | 1.0144 | 0.9805 | 0.8970 |
| M 2.21 | 334.3 | 321.48 | 61.41 | 7.8365 | 310.50 | 0.0234 | 0.1811 | 0.2176 | 1.0354 | 0.7568 | 0.6924 |
| M 2.51 | 289.3 | 278.64 | 42.39 | 6.5108 | 269.53 | 0.0225 | 0.1144 | 0.1566 | 1.0338 | 0.8719 | 0.7977 |
| M 1.12 | 334.7 | 328.38 | 15.00 | 3.8730 | 322.96 | 0.0116 | 0.1816 | 0.2181 | 1.0168 | 0.7276 | 0.6657 |
| M 1.22 | 339.4 | 334.82 | 7.85 | 2.8018 | 330.90 | 0.0083 | 0.1876 | 0.2235 | 1.0118 | 0.7102 | 0.6497 |
| M 1.42* | 267.2 | 257.21 | 36.78 | 6.0647 | 248.72 | 0.0227 | 0.0735 | 0.1191 | 1.0341 | 0.9448 | 0.8644 |
| M 1.52 | 299.1 | 291.99 | 18.65 | 4.3186 | 285.95 | 0.0144 | 0.1307 | 0.1714 | 1.0211 | 0.8218 | 0.7519 |
| M 2.12 | 337.9 | 333.88 | 6.03 | 2.4556 | 330.44 | 0.0073 | 0.1857 | 0.2218 | 1.0104 | 0.7112 | 0.6506 |
| M 2.22 | 336.3 | 325.33 | 44.91 | 6.7015 | 315.95 | 0.0199 | 0.1837 | 0.2199 | 1.0297 | 0.7438 | 0.6805 |
| M 2.52 | 281 | 273.17 | 23.02 | 4.7979 | 266.45 | 0.0171 | 0.0998 | 0.1432 | 1.0252 | 0.8820 | 0.8069 |
| Average values 2 mm | 307.4 | 299.6 | 25.91 | 5.0906 | 292.90 | 0.0166 | 0.1388 | 0.1789 | 1.0231 | 0.8112 | 0.7422 |
| M 1.21* | 275.9 | 266.26 | 34.65 | 5.8864 | 258.02 | 0.0213 | 0.0904 | 0.1346 | 1.0319 | 0.9108 | 0.8333 |
| M 1.31* | 260.4 | 250.70 | 34.91 | 5.9085 | 242.43 | 0.0227 | 0.0595 | 0.1063 | 1.0341 | 0.9694 | 0.8869 |
| M 2.11 | 266.2 | 260.28 | 13.13 | 3.6235 | 255.21 | 0.0136 | 0.0715 | 0.1173 | 1.0199 | 0.9208 | 0.8424 |
| M 2.31 | 340.8 | 326.04 | 81.16 | 9.0089 | 313.43 | 0.0264 | 0.1893 | 0.2251 | 1.0402 | 0.7498 | 0.6860 |
| M 1.32* | 312.5 | 303.33 | 30.95 | 5.5633 | 295.54 | 0.0178 | 0.1512 | 0.1902 | 1.0264 | 0.7952 | 0.7275 |
| M 2.32 | 324.6 | 310.44 | 74.97 | 8.6585 | 298.32 | 0.0267 | 0.1683 | 0.2059 | 1.0406 | 0.7877 | 0.7207 |
| Average values 2.5 mm | 296.7 | 286.2 | 44.96 | 6.7053 | 277.20 | 0.1217 | 0.1217 | 0.1632 | 1.0322 | 0.8556 | 0.7828 |
| M 2.41 | 325.5 | 312.86 | 59.11 | 7.6883 | 302.09 | 0.0236 | 0.1695 | 0.2070 | 1.0357 | 0.7779 | 0.7117 |
| M 2.42 | 445.9 | 422.88 | 197.6 | 14.0570 | 403.20 | 0.0315 | 0.1884 | 0.3157 | 1.0488 | 0.5828 | 0.5332 |
| Average values 3 mm | 385.7 | 367.9 | 128.36 | 11.3296 | 352.70 | 0.0294 | 0.2290 | 0.2614 | 1.0422 | 0.6804 | 0.6225 |
| Average values for all samples | 312.0 | 302.4 | 41.87 | 6.4707 | 294.1 | 0.0207 | 0.1427 | 0.1825 | 1.0277 | 0.8237 | 0.7536 |

Figure 10.
Normal distribution of yield strength Re for steel samples from corrugated webs cut out of girders: a) M 2.12 having the actual thickness of 2 mm; b) M 1.31 having the actual thickness of 2.6 mm

Figure 11.
Factors of yield strength γm compared with the minimum value guaranteed by the steel mill γm235 and by the manufacturer γm215
Table 4.
| web thickness 2 mm | web thickness 2.5 mm | web thickness 2 mm | |
|---|---|---|---|
| Design yield strength f y [MPa] | 254.7 | 259.6 | 264.5 |
Table 5.
Parameters of normal distribution of geometric dimensions of steel samples from corrugated webs and of resistance obtained according to formulae (7) and (8)
| Model | D2 (A) | D(A) | V A | D2 (N) | D(N) | V N | |||
|---|---|---|---|---|---|---|---|---|---|
| mm | mm | mm2 | |||||||
| 1 | 2 | 3 | 4 | 5 | 6 | 7 | 8 | 8 | 9 |
| Mean value for 2 mm samples | 2.0 | 19.98 | 39.95 | 0.030 | 0.170 | 0.004 | 0.047 | 0.217 | 0.018 |
| Mean value for 2.5 mm samples | 2.57 | 19.92 | 51.18 | 1.111 | 1.054 | 0.021 | 0.209 | 0.457 | 0.030 |
| Mean value for 3 mm samples | 3.0 | 20.0 | 60.0 | 0.000 | 0.000 | 0.000 | 0.462 | 0.680 | 0.029 |

Figure 12.
Normal distribution of yield strength in all examined steel samples cut out of corrugated webs