Experimental and numerical study of one-sided branch plate-to-circular hollow section connections

Connections to circular hollow steel sections (CHS) are considered one of the most complex and time consuming connections in steel construction. Such connections are usually composed of gusset plates welded to the outside of the steel tube or penetrating the steel tube. Design guides, accounting for the effect of connection configuration on the strength of the connection, are not present. This study aims to investigate, through experimental testing and a parametric study, the influence of connection configuration on the strength of one sided branch plate-to-CHS members. A notable effect was observed on the behavior of the connections due to its detailing changes with respect to capacity, failure mode, ductility, and stress distribution. A parametric study is performed using the calibrated analytical model to include a wider range of parameters. The study involves 26 numerical analyses of finite element models including parameters of the diameter-to-thickness (D/t) ratio, length of gusset plate, and connection configuration. Accordingly, a modification to the formulas provided by the current design recommendations was suggested to include connection configuration effects for the one sided branch plate-to-CHS members.