Leroy Gardner

Imperial College London | Imperial · Department of Civil and Environmental Engineering

The direct analysis method (DAM), featuring second order elastic analysis with two stiffness reduction factors-τb and τg, is the primary means of stability design for steel structures in AISC 360 and AISI S100. The equivalent provisions for stainless steel structures, which are due to be incorporated into the upcoming AISC 370 and ASCE-8 Specificat...

Although additive manufacturing (AM) has been maturing for some years, it has only recently started to capture the interest of the cost-sensitive construction industry. The research presented herein is seeking to integrate AM into the construction sector through the establishment of an automated end-to-end framework for the generation of high-perfo...

Wire arc additive manufacturing (WAAM) is a metal 3D printing method that allows the cost-effective and efficient production of large-scale elements, and has thus gained great interest from architects and structural engineers. Integration of this novel technology into the construction industry, however, requires the development of a clear understan...

Physical experiments are widely used in structural engineering for the validation of finite element models and the establishment and assessment of design provisions. However, while there exists an abundance of member-level test data, there is a clear need for further benchmark frame-level test data, particularly given the growing trend for advanced...

Although still in its infancy, metal additive manufacturing (AM) or 3D printing has now arrived at a scale suitable for use in construction. The new technology offers the potential for improved economy, sustainability, safety and productivity through greater automation, enhanced customisation, reduced material usage and reduced wastage. In this pap...

Although additive manufacturing (AM) continues to gain widespread adoption, the overhang problem remains a critical issue affecting printing quality. The design of self-supporting structures via topology optimisation approaches has been extensively studied. However, current optimisation research predominantly focuses on 3-axis AM machines, overlook...

An energy formulation employing total potential energy principles is presented to derive a governing equation for strength predictions of struts made from materials following the Ramberg-Osgood constitutive law such as stainless steel, cold-formed steel, and aluminium alloys. The formula is generic and applicable to arbitrary cross-sections and all...

Cold-working can occur during production of flat sheet products and during fabrication of structural cross-sections. In both cases, when the material is cold-worked, plastic deformations result in material strength enhancements. These strength enhancements are particularly significant for materials such as stainless steel, which exhibit rounded str...

Wire arc additive manufacturing (WAAM) is a method of metal additive manufacturing (AM) that can be used to fabricate optimised large‐scale structural elements of complex form in a cost‐effective manner, opening up opportunities to unleash the true potential of structural optimisation. To demonstrate this potential, two optimised steel cantilever t...

The primary aim of the present study is to explore the use, advantages and potential of two advanced data acquisition techniques – 3D scanning and digital image correlation (DIC), in the testing of metallic structures. 3D scanning is a novel method for capturing the full outer geometry of an object. It is being increasingly used in experimental stu...

Design by GMNIA (Geometrically and Materially Nonlinear Analysis with Imperfections) allows the key behavioural features of structures to be directly captured in the analysis, dramatically reducing the need for subsequent design checks. Since the analysis of frames typically employs beam finite elements, which do not explicitly account for local bu...

This paper presents an experimental study into the effect of moment gradients on the local buckling behaviour of hot‐rolled high strength steel square hollow section (SHS) beams. The influence of moment gradients was investigated by testing 20 beam specimens, ranging from Class 2 to Class 4 according to the cross‐section classification limits given...

The application of design by finite element analysis (FEA) is becoming increasingly prevalent in applied engineering; however, codified provisions remain scarce. The vision of CEN/TC 250/SC 3 was to develop a new comprehensive document based on the existing provisions currently distributed throughout the different Eurocode 3 parts, and with extensi...

This paper presents an experimental investigation into the structural response of wire arc additively manufactured (WAAM) steel T‐stub connections subjected to tension. A total of fifty‐two T‐stub specimens of different printing strategies and geometric configurations were tested to failure. 3D laser scanning was employed to determine the specimen...

The behaviour and design of cylindrically‐pinned stainless steel equal‐leg angle section members under compression and compression combined with strong‐axis bending are investigated herein. Numerical models are developed by means of shell finite element modelling formulated within ABAQUS and validated against experimental data. A numerical parametr...

The use of wire arc additive manufacturing (WAAM) in conjunction with topology optimisation enables the production of structural components with significantly higher strength‐to‐weight ratios than conventional structural components. However, owing to the additional production stages involved in WAAM ( e.g . arc welding), a common question arises re...

Wire arc additive manufacturing (WAAM) is a method of metal 3D printing which, when strategically combined with traditional methods of manufacture, has the potential to make a significant impact on the construction sector. To illustrate this potential, an experimental investigation into the flexural buckling response of 13 hot‐rolled I‐section colu...

An experimental investigation into the structural behaviour of steel frames made up of hybrid steel welded I‐section members is presented in this paper. The tested hybrid steel welded I‐section profile had quenched and tempered S690 steel flanges and an S355 steel web. The experimental programme comprised four two‐dimensional, single storey, single...

The design and performance of optimised wire and arc additively manufactured (WAAM) rectangular hollow section (RHS) beams, with varying material strengths and thicknesses along their lengths, are investigated in this study. Simply‐supported beams under three‐point bending were considered. Size optimisation of the RHS beams was carried out by fixin...

The behaviour and design of homogeneous and hybrid high strength steel (HSS) beams are addressed in the present study. Six in‐plane three‐point bending tests on three different welded I‐sections were first conducted. Following the experimental investigation, a finite element (FE) modelling programme was performed, which included a validation study...

Three types of geometric imperfection need to be considered in the design of structural systems: global frame out‐of‐plumbness, also referred to as sway imperfections, member out‐of‐straightness, also known as bow imperfections, and local cross‐section imperfections. For modelling convenience, equivalent geometric imperfections are often employed t...

An experimental study into the flexural buckling response of wire arc additively manufactured (WAAM) columns is presented in this paper. A total of six square hollow section (SHS) columns were tested under axial compression with pin‐ended boundary conditions. The lengths of the members were varied to achieve a wide range of member slendernesses. Ow...

Powder bed fusion (PBF) additive manufacturing has the potential for significant impact in a range of engineering applications due to its ability to produce complex and free-form components in a precise manner. The size of components, however, is limited by the internal build volume of the employed PBF machines. Using laser welding, small individua...

Wire arc additive manufacturing (WAAM), a method of directed energy deposition (DED) for metal 3D printing, is capable of producing intricate parts at a relatively high rate and low cost. Despite the great potential of WAAM for applications in construction, knowledge of the performance of WAAM structural elements is still lacking, and the geometric...

This paper presents an experimental investigation into the structural response of wire arc additively manufactured (WAAM) steel T-stub connections subjected to tension. A total of eighty T-stub specimens featuring different printing strategies, bolt arrangements and geometric configurations were tested to failure. 3D laser scanning was employed to...

Wire-arc directed energy deposition (DED), also known as wire-arc additive manufacturing (WAAM), is a metal 3D printing technique that is recognised for its high efficiency, cost-effectiveness, flexibility in build scales and suitability for the construction sector. However, there remains a lack of fundamental data on the structural performance of...

The behaviour and design of pin-ended stainless steel equal-leg angle section members under compression and compression plus minor-axis bending are investigated herein. The studied members are cylindrically pinned about the minor axis. An experimental investigation, including material testing, initial geometric imperfection measurements and physica...

Combining welding technology with robotics, wire arc additive manufacturing (WAAM) is emerging as a viable method of construction. To facilitate its wider application, in particular with structural integrity in mind, an improved understanding of the fatigue properties of WAAM materials is needed. Hence, an experimental investigation into the fatigu...

This paper presents a comprehensive numerical study into the in-plane member stability and design of normal and high strength steel (NSS and HSS) non-slender welded I-section beam-columns subjected to compression plus uniaxial bending. Finite element (FE) models were firstly developed to replicate the structural performance of welded I-section beam...

A comprehensive numerical investigation into the cross-sectional behaviour and ultimate capacity of non-slender welded I-sections, made of both normal and high strength steels (NSS and HSS), under combined compression and uniaxial bending is presented. Finite element (FE) models were initially established and validated against test results collecte...

The flexural buckling behaviour and design of homogeneous and hybrid welded I-section columns, considering a wide range of steel grades, are investigated in the present study. Residual stresses are first examined through the statistical analysis of 71 existing experimental results collected from the literature; on the basis of the findings, a new r...

Prestressed stayed columns (PSCs) are structural systems whose compressive load-carrying capacity is enhanced through pre-tensioned cable stays. Much research has demonstrated that PSCs buckle subcritically when their prestressing levels maximize the critical buckling load of the theoretically perfect arrangement. Erosion of the pre-tensioned cable...

The structural behaviour of sheathed cold-formed steel lipped channel section columns (studs) subjected to combined compression and major axis bending is investigated herein by means of numerical modelling. Finite element (FE) models of single studs, set in tracks and connected to oriented strand board (OSB) and gypsum plasterboard sheathing under...

Design by GMNIA (Geometrically and Materially Nonlinear Analysis with Imperfections) allows the key behavioural features of structures to be directly captured in the analysis, improving accuracy and dramatically reducing the need for subsequent design checks. Since the analysis of frames typically employs beam elements, in which local buckling of c...

Interest in the use of wire arc additive manufacturing (WAAM) in construction has increased rapidly in recent years. Key to facilitating wider application is an improved understanding of the material behaviour. In particular, with structural design by finite element analysis in mind, constitutive models to describe the full range stress-strain resp...

A study into the mechanical behaviour and design of steel equal-leg cruciform section members subjected to axial compression is presented. Experimental data from the literature are used to validate shell finite element models developed within the commercial package ABAQUS for their load-deformation and ultimate behaviour. A numerical parametric stu...

Formulae for calculating the elastic local buckling stresses of doubly-symmetric thin-walled I-section girders subjected to combined shear and direct stresses, accounting for the interaction between the plate elements are presented. The interaction between the plate elements (i.e. the flanges and web) is bounded by a theoretical lower-bound, where...

An experimental investigation into the structural performance of wire arc additively manufactured (WAAM) steel single-lap shear bolted connections is presented in this paper. The steel wire had a nominal yield stress of 420 MPa. Sixty specimens of different thicknesses, printing strategies and geometric features including end distances and plate wi...

The data available in this article include 3D mechanical designs used for the computer-aided fabrication of metal honeycombs produced by additive manufacturing and studied in [1]. In addition, the force-displacement data utilized to evaluate the mechanical performance of the metal used in this study are available via the digital image correlation t...

The behaviour and design of high strength steel (HSS) beams are addressed in the present study. Six in-plane three-point bending tests on three different welded I-sections − two homogeneous S690 steel welded I-sections and one hybrid welded I-section with S690 steel flanges and an S355 steel web, were first conducted. The beam tests were carried ou...

The Continuous Strength Method (CSM) is a deformation-based approach to the design of structures that enables a continuous, rational and accurate allowance for material nonlinearity (i.e. the spread of plasticity and strain hardening). Central to the method is the application of strain limits, determined on the basis of the local slenderness of ful...

Initial geometric imperfections have been identified as the main cause for the large discrepancies between experimental and theoretical buckling loads of thin-walled circular cylindrical shells under axial compression. The extreme sensitivity to imperfections has been previously addressed and mitigated through the introduction of stiffeners; howeve...

Axially compressed circular cylindrical shells with large diameter-to-thickness ratios are highly susceptible to local buckling, and their load-carrying capacities are known to be very sensitive to initial geometric imperfections. Hence, severe knock-down factors on their theoretical buckling loads are typically prescribed in design specifications,...

In the framework of the revision of Eurocode 3, Part 1–1, several amendments have been proposed and accepted in order to improve the rules for the resistance to member buckling. For clarification, a flow chart connecting the global analysis (first or second order), the imperfections and the type of verification has been implemented for ease of use....

Wire arc additive manufacturing (WAAM) is a promising metal 3D printing technique in the construction industry for its ability to produce large and complex-shaped elements, with reasonable printing accuracy, time and costs. There is currently, however, a lack of fundamental test data on the structural performance of WAAM elements. To address this,...

The MX3D Bridge is the world’s first additively manufactured metal bridge. It is a 10.5m-span footbridge, and its dynamic response is a key serviceability consideration. The bridge has a flowing, sculptural form and its response to footfall was initially studied using a 3D finite element (FE) model featuring the designed geometry and material prope...

Powder bed fusion (PBF) is an additive manufacturing method that enables complex metallic components to be manufactured with high precision. The microstructure, mechanical properties and cross‐sectional behaviour of PBF additively manufactured stainless steel circular hollow sections are investigated through experiments in this paper, with a view t...

Portal frames are a common form of structural system used to create efficient wide‐span enclosures. Over the past few decades, the design of portal frames has evolved in the direction of longer, lighter and taller structures, while cladding systems have become more substantial. Although this allows larger spaces, it can also result in heightened st...

An accurate and consistent approach to the out‐of‐plane stability design of steel beams and structures utilising geometrically and materially nonlinear analysis with imperfections (GMNIA) and strain limits is proposed. The method is implemented using computationally efficient beam elements, with the ultimate structural resistance defined either by...

In the framework of the revision of Eurocode 3 Part 1‐1, several amendments have been proposed and accepted in order to improve the rules for the resistance to member buckling. For clarification, a flow‐chart connecting the global analysis (1st or 2nd order), the imperfections and the type of verification has been implemented for ease of use. Since...

Cold‐working can occur during the production of flat sheet products and the fabrication of structural cross‐sections. In both cases, when the material is cold‐worked, plastic deformations result in material strength enhancements. These strength enhancements are particularly significant for materials such as stainless steel, which exhibit rounded st...

There are a number of scenarios in which structural members experience torsion, including under the direct application of torsional loading, when transverse loading is applied at an eccentricity to the shear centre and as a second order effect arising from lateral torsional instability. To date, the torsional rigidity of concrete-filled steel tubul...

In this paper, the flexural‐torsional buckling response of austenitic stainless steel I‐section beam‐columns is investigated. Finite element simulations are performed with the aim of analysing the parameters affecting the behaviour of the studied members. The accuracy and safety of the existing design provisions of the European structural stainless...

Recent disruptive technological advances, including wire arc additive manufacturing (WAAM) and the concept of digital twins, have the potential to fundamentally transform the way in which we design, build and manage structures. WAAM is a method of metal 3D printing that is well suited to the price‐sensitive construction industry and has been used t...

An experimental investigation into the structural performance of wire arc additively manufactured (WAAM) steel single‐lap shear bolted connections is presented in this paper. Sixty specimens of different thicknesses, printing strategies and geometric features, including end distances and plate widths, were manufactured using steel wire of a nominal...

The revision of the Eurocodes effectively started in 2015 with the creation of project teams. EN 1993-1-1 is the main part of Eurocode 3 since it includes the general rules for steel structures, and more specifically rules for the strutural analysis and the verification of its members. With EN 1993-1-8 (design of joints), it has been revised in the...

Powder bed fusion (PBF) additive manufacturing has the potential for significant impact on the construction industry due to its ability to produce complex and free-form components with high-precision. However, the size of components is limited by the build envelope of PBF machines. Laser welding offers a means of joining small individual PBF parts...

Aluminium alloys are gaining increasing use in the construction industry, underpinned by extensive research and the growing availability of codified structural design rules at room temperature. More recently, considering that the material properties of aluminium alloys degrade significantly at elevated temperatures, a substantial number of studies...

Recent disruptive technological advances, including wire arc additive manufacturing (WAAM) and the concept of digital twins, have the potential to fundamentally transform the way in which we design, build and manage structures. WAAM is a method of metal 3D printing that is well suited to the price-sensitive construction industry and has been used t...

Honeycomb structures have a wide range of applications, from medical implants to industrial components. In addition, honeycombs play a critical role when passive protection is required due to their low density and high energy absorption capabilities. With the transition of additive manufacturing from a rapid prototyping approach to a manufacturing...

Wire arc additive manufacturing (WAAM) is a metal three-dimensional (3D) printing method that enables large-scale structural elements with complex geometry to be built in a relatively efficient and cost-effective manner, offering revolutionary potential to the construction industry. Fundamental experimental data on the structural performance of WAA...

An experimental and numerical study into the behaviour of concrete-filled double skin tubular (CFDST) stub columns is presented. A total of eight axial compression tests were carried out, four utilising conventional concrete and four with recycled aggregate concrete. The stub columns were circular in cross-section and each comprised an austenitic s...

This paper presents an experimental and numerical investigation into the post-fire behaviour and residual capacity of S700 high strength steel circular hollow section (CHS) beam–columns. The experimental investigation was performed on ten S700 high strength steel CHS beam–columns and included heating and cooling of the specimens as well as post-fir...

The use of numerical models in the advanced analysis and design of steel structures, particularly under extreme loading conditions, is becoming increasingly widespread. A crucial component of such models is an accurate description of the material response. A systematic study into the dynamic constitutive modelling of structural steels is presented...