Flexural behaviour and design of hybrid cold-formed steel built-up I-section beams

The current study investigates the flexural performance and design of hybrid cold-formed steel built-up I-section beams, which are increasingly popular in the construction industry. These beams combine the benefits of both an "I" section and a closed-box section in their cross-section profile. They are constructed from two identical plain channels placed back-to-back with space between them and top and bottom cover plates, fastened together by screws. A nonlinear finite element (FE) model was developed to consider initial geometric imperfections, material and geometric non-linearities. The model was validated against the test results of cold-formed steel (CFS) built-up beams from the companion paper and literature. Once validation was successful, a comprehensive parametric study using finite element modelling was conducted to generate data on hybrid cold-formed steel built-up I-section beams across a broader range of cross-sectional slenderness, hybrid ratio, aspect ratio of the cross section and thickness of the cover plates. The parametric results were used to analyse the influence of key parameters on the moment carrying capacity and buckling modes. The applicability of the current Direct Strength Method in the AISI S100–16 specifications was evaluated based on these results, revealing that it is unconservative. Additionally, modified design procedures and equations were suggested for hybrid CFS built-up I-section beams vulnerable to local buckling in major axis bending, which were then evaluated through reliability analysis.