EUROSTEEL 2017, September 13–15, 2017, Copenhagen, Denmark

Experimental tests and model study on self‐drilling screws

connections subjected to shear
Marcin Gryniewicz*,a, Jerzy Kazimierz Szlendaka
a
Technical University of Bialystok, Faculty of Civil and Environmental Engineering, Poland
marcin.gryniewicz@gmail.com, jerzy.szlendak@gmail.com

ABSTRACT
Research on shear resistance of the steel sheeting plates with thickness from 0,50 to 1,50 mm
connected by self-drilling screws is undertaken and presented in this paper. One screw type with
one diameter has been used. This kind of the single lap fastening is commonly used in a steel
sheeting. Experimental and theoretical data about a connections slip and shear stiffness is a one of
most important issue in case of a stressed skin diaphragm action problems. At the present practice
the linear model of connections is effectively used however for more advanced analyses, the non-
linear models have to be taken into consideration. These are necessary in case of the advanced
design and implementation of the stressed skin action in the steel structures covered by the
corrugated metal sheeting. Such a model study is presented herein which intend to investigate the
general connection behaviour where the main selected variable is the plate thickness. The test are
performed according to the current standards EN 1990 and ECCS handbooks. It leads to a statistical
evaluation of proposed functions for the design slip of fasteners and its limits. The theoretical basis
of experimental tests under the shear load is presented.

Keywords: cold formed steel design, self-drilling screws shear connections, theoretical models,
experimental tests

1 INTRODUCTION
Most popular in a design applications of the cold formed steel sheeting is its utilization to the
stabilization of single structural elements, e.g. roof cold formed purlins. A further way to take
advantage of the cold formed steel covering is a stressed skin diaphragm action. Such design
advantage is not commonly known between designers. The reason of this are advanced and
complex design procedures, which required sufficient knowledge and experience [1]. These issues
have been also undertaken by authors recently [2, 3]. The general conclusion is that behavior of
connections is very important in such skin diaphragm structures and their theoretical modelling
have to be examined according the current practice. So, the experimental investigations of the shear
self-drilling screws connections of thin plates has been carried out.
Many studies describe the behavior of light gauge steel structures connections. Some works about
screwed and with blind bolts connections has been presented e.g. by Wuwer W. [4, 5]. Usually
complete joints in frames made of cold formed profiles were investigated like it is described in [6].
Some research is undertaken in the field of such connections subjected to fire [7, 8]. For the studies
presented in this paper, set of the statically loaded single lap self-drilling screws connections for
normal conditions according to design codes [10,11] are under consideration. These considerations
have an effect in a proposition of the typical linear model for every connection (as an alternative for
value given generally in [1] as 0.25 mm/kN for all screws with overall diameter from 4.1 mm to
4.8 mm). Extension for special purposes in form of a bi-linear function is developed.

© Ernst & Sohn Verlag für Architektur und technische Wissenschaften GmbH & Co. KG, Berlin · ce/papers 1 (2017), No. 2 & 3
https://doi.org/10.1002/cepa.100 wileyonlinelibrary.com/journal/cepa 619
620 |

2 THEORETICAL BASIS

2.1 Connectors in FEM analysis of shear diaphragms

In a literature the connectors model consist of two perpendicular springs with an appropriate
stiffness [9]. These springs connects two nodes having the same coordinates. One node is a part of a
sheeting plate discrete model while another one is connected with structural element or adjacent
sheet. Authors propose another model. Every connector in a system will be replaced by the
equivalent cantilever frame finite element [2] which can be reasonably usable in an almost every,
even non advanced, scientific software. Fig. 1 presents the idea of a discussed mathematical
connection model.

Fig. 1. Presentation of the model of a single shear connection: s – connection slip; leq – chosen length of a cantilever
frame element; Ieq – equivalent moment of inertia of the element [2]

2.2 Failure modes of connections under shear

It is important to predict and record the failure mode of a connection during the tests. Thus, it is
necessary to characterize typical failure modes as it is done in the ECCS manual [10] which is
presented in Table 1 (“applied symbol” in the table is added by the authors for the research
purposes). The experiment described in this paper has been especially prepared to avoid a specific
type of a joint capacity loss which is the tilting and pull-out. It was achieved by using two screws in
a single connection.
Table 1. Characteristics of the failure modes of connections for fasteners loaded in shear [10]
Applied Failure mode Elongation Pilling of Necking / Pull-out of
symbol of hole material Tearing fastener
BF bearing failure x x
NF net section failure x x x
SF shear of fastener
EF end failure x x x
TF tilting and pull-out x

3 TESTS OF CONNECTIONS SUBJECTED TO SHEAR

3.1 Requirements for shear tests
Requirements for shear test are introduced in the recent version of the ECCS publication [10]. The
recommendations covers all necessary problems in details and are consistent with the Eurocode
rules concerned with the design assisted by testing [12]. All the detailed data can be found in these
references. General rules are described below.
First of all, properties of steel samples and fasteners should be determined. Basic values for steel
samples are: yield stress (0,2% proof stress), ultimate tensile strength and percentage elongation at
fracture. At least three tensile tests shall be carried out. For fasteners (including metal and rubber
washers), nominal dimensions shall be verified. Mechanical properties of the fasteners are also
recommended to check in accordance with referred manuals.
Manufacturing of the steel samples should be performed in a consistent manner in accordance with
the producer’s recommendations and site practice (e.g. depth setting control, tightening torque, type
of tool, strength and thickness of substrate). Fasteners should be fixed within 1 mm of the positions
specified on the test samples.
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Detailed requirements about the numbers of test are also specified in relation to specimens
properties. The minimum number of five tests allows the variability of the fastening to be
established, but tests series will be improved if the number of tests increases.
Fig. 2 presents arrangement of the test specimen with two fasteners. Tests with one fastener are also
possible but in cases where curling or distortion of the connection is expected the test with two
fasteners may provide result with a lower variation.
Deformation should be measured using an appropriate extensometer (one or two separate
extensometers if necessary). Relative travel of the grips shall not be used unless there is no slip of
the specimen in the testing machine grips and deformation readings are corrected to account for the
elastic extension of the specimen beyond the extensometer length.

Fig. 2. Shear test specimen with two fasteners (for fastener diameter not larger than 6.5 mm)

The rate of loading shall not exceed 1 kN/min and the rate of deformation shall not exceed
1 mm/min. Deformation shall be measured beyond 3 mm of relative displacement.
The ultimate resistance of the fastening shall be taken as the maximum load recorded during the
test. It is recommended to define a failure load in a deformation of 3 mm. Peak load beyond the
3 mm limit should be recorded during the test. Fig. 3 illustrate the idea of failure load recognition.

Fig. 3. Connections failure limits criteria

3.2 Shear resistance and flexibility

The characteristic resistance of a fastening follows from a statistical evaluation of test results [10]:
Rk  Rm  k  s k (9)
where Rm is a mean value of the test results obtained from a minimum of five tests,
k is the fractile factor which can be taken from [12] Annex D,
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sk is a standard deviation.
Mean value of the test result has to be adjusted by taking into account the actual measured
resistance of the material in comparison to nominal one. Fractile factor k equals 2.33 for five tests if
the coefficient of variation in not known from prior knowledge.
The design shear resistance of connection is defined with the formula below:
Rk
Rd  (1)
 M2

where Rd is the design resistance of a fastening,

Rk is the characteristic resistance of a fastening under static load,
γM2 is the partial factor for resistance (see appropriate Eurocode [11]).
The shear flexibility of a fastening should be determined from:

ch 
1

a h
(10)
Rd  1 n
where ah is the slip of a fastening at a load equivalent to Rd / γ1
Rd is the design resistance of a fastening,
γ1 is an appropriate factor,
n is a number of test specimens.
In example, for fastening sheets to the substructure with one fastener test, appropriate value of γ1 is
1.5 (corresponds to factors used for wind action).
3.3 Preparation of main experiment
The main purpose of the research was the experimental verification of a real behavior of a simple
lap joints made of thin plates and self-drilling screws. Results can be useful for building
mathematical models of connections e.g. for roofs with sheeting acting as a diaphragm. In a range
of variety types of joints, lap connections with the same two thin plates was chosen to investigate.
Such joints can be identified with seam connections between two separate roof sheets e.g. made of
cold formed trapezoidal sections. It was intended to use several plates thicknesses to build a
complete and practical set of data. Exact dimensions, chosen thicknesses and marking concept is
presented in Fig. 4.

Fig. 4. Test specimens dimensions and marking

Plates with thickness from 0.50 mm to 1.25 mm are made of DX51 steel according to EN 10327
[13]. One exception are plates of thickness 1.50 mm which have been delivered with S350 material
(according to EN 10326 [14]). This difference is a consequence of a production process established
by the supplier (Pruszyński). Such variation is treated as a practical accent and was not removed
 | 623

from the research intentionally. Five specimens assemblies per one thickness have been prepared
(the complete set of the 70 plates was necessary to build the 35 assemblies). All the specimens have
been protected by hot-dip galvanizing.
The used connectors was HILTI self-drilling screws: S-MS type for plates 0.50 mm and S-MD for
other ones. All screws had the same diameter 4.8 mm and was equipped with steel and sealing
washers. S-MD screws are not practically suitable to use in the thin plates. On the other hand, type
of S-MD screws are commonly used by contractors at site. This practical reason decided on the
application of this exact type of connectors for the major connections. Material for screws was
stainless steel 1.4301 (according to EN 10088-2 [15]).
All specimens has been prepared with special care according to the manual and the producer
delivery conditions. The specimens assemblies has been manufactured with usage of a metal
construction screwdriver ST 1800 provided by HILTI. This kind of the tool is commonly used by
contractors e.g. for decking applications. Torque clutch helps prevent over-driving or a screw head
breakage. Depth gauge function controls compression of the sealing washer for optimum sealing.
Through the high precision and suitable control all the specimens assemblies was prepared
identically. Fig. 5 presents the example of the connected plates as side view.

Fig. 5. Example of the one connection as side view

3.4 Description of the performed tests

As it is suggested by the ECCS manual, tests for mechanical properties was undertaken as a first
step. The most applicable are tensile tests according to ISO 6892-1 [16]. Fig. 6 is a graph with an
example of a readings for the one specimens set made of DX51 material. Graph can be useful e.g.
for creating an idealized stress – strain relationship for calculations with this steel material.
Statistics results are listed in Table 2 (symbols in the table and the graph according to [16]).

Fig. 6. Experimental stress – strain relationship for the DX51 steel test series and the values for the one representative
specimen as an example
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Table 2. Statistics results for the tests series based on DX51 steel samples according to ISO 6982-1 [16]
mE Rp0.2 Rm Ag Agt RB At a0 b0 S0
n=3 [GPa] [MPa] [MPa] [%] [%] [MPa] [%] [mm] [mm] [mm2]
x 114 327 392 34.1 34.4 279 61.6 1 20 20
s 44.8 11.9 2.29 0.4 0.3 49 1.5 0 0 0
 [%] 39.25 3.,65 0.58 1.28 0.88 17.55 2.38 0 0 0

All experiments have been undertaken with usage of a Zwick / Roell test machine controlled by
a computer unit with a dedicated software testXpert II. For the main tests, rates of loading and
displacement was controlled during the whole loading process as it is suggested by the manual
(rates of 1 kN/min and 1 mm/min were not exceeded). The testing procedure was terminated
automatically by the computer system by force and displacements controls for given high
thresholds, thus investigations have been performed till the complete break of connection.

Fig. 7. Example of the connection failure

Usually the first, main failure mode of a connection was the bearing failure BF (see Table 1), as it
was expected by choosing a shear test with two fasteners (see Fig. 7). Shear of fasteners SF, end
failures EF or tilting and pull-out failures TF was not occurred at a characteristic resistance level.
There were no net section tension failures NF of the plates. Fig. 8 shows the example graphs for a
complete observations periods of the selected thicknesses to express an indicative range of the
performed tests. Each graph consists of the five curves for each assembly of specimens. Table 3
summarises performed research as statistical evaluation according to ECCS manual [10] and
Eurocode [12]. All presented results are calculated as for the one connector.

a) b)
Fig. 8. Selected example graphs of complete tests processes for thicknesses (five tests/curves per thickness):
a) 0.80 mm; b) 1.00 mm; (vertical axis – force in N, horizontal axis – displacement in mm)
 | 625

Table 3. Statistical results of the shear tests according to [10] (fractile factor k = 2.33 [12])
Series A B C D E F G
Nominal thickness t [mm] 0.50 0.60 0.70 0.80 1.00 1.25 1.50
Mean value of the test results Rm [N] 1462 1519 1948 2698 3490 5073 5853
Standard deviation sk [-] 27.29 123.99 80.25 68.39 86.00 134.46 144.81
Shear resistance Rk [N] 1398 1230 1761 2539 3740 4760 5516
Shear flexibility (γ1 = 1.0 ) ch [mm/N] 1.05 0.26 0.29 0.30 0.344 0.19 0.17
Shear flexibility (γ1 = 1.5 ) ch.15 [mm/N] 0.50 0.14 0.18 0.17 0.12 0.10 0.09

4 PREPOSITIONS OF CONNECTIONS MODELS

4.1 The linear model of connections
The linear model of connections can be simply build using a shear strength and a flexibility of a
connection obtained from presented tests. It is important to take the appropriate value of the
flexibility corresponding to the analysis method and purpose of the design. It means that the
deformation should be taken at the working load level, e.g. the design resistance of the fastener
divided by the partial factor for the particular load used e.g. in the ULS combination [10]. This is
the reason why two values of ch are presented in Table 3. With respect to the experimental results,
the values with γ1 = 1.0 will be used for building the analytical models (predicted for calculations
with unfactored loads). The examples of a comparison of the analytical linear model and a real
behavior of the connections according to tests are presented in Fig. 9 (consequently, in relation to
the one screw). It should be noted, that the calculated flexibility has a larger value than the
connection in its linear part of a real behavior, which is a safe assumption in case of the design
practice (it can be more clear comparing curves in Fig. 9b).

a) b)
Fig. 9. Comparison of the analytical linear model and a real behaviour of connections according to tests:
a) 0.80 mm; b) 1.00 mm (vertical axis – force in N, horizontal axis – displacement in mm)

For the all connections, complex graph in Fig. 10 can be useful. It can be noticed that connections
from B to E have nearly similar shear stiffness (refer to Table 3). In that case, the mean value of the
calculated stiffness was adopted as simplification (ch,mean = 0.30 mm/kN). The dashed curves in
Fig. 10 indicate results with a different configuration than the others in the experimental set (as it
was described previously). The dotted line, marked as “EC”, represents the general linear model
obtained from ECCS recommendations [1] given here for comparison.
626 |

Fig. 10. Proposition for analytical linear models of tested connections

4.2 The extended, bi-linear model of connections

It can be seen in the graphs presented in Fig. 9 that force – displacement curves should be described
rather by bi-linear than linear functions. For a current design practice such model is not used and the
“strengthening” of connection resistance is the additional “safety factor”. However, such models are
usually dedicated for more complex numerical analyses. In the scope of a computational methods,
most of the convergence problems can be solved using advanced, comparable to real ones,
mathematical models of materials, supports, elements and connections. The described bi-linear
screwed connections models would allow such an analysis of the connections, if will be applied e.g.
in stressed skin static models like presented by the authors in [2, 3]. Additionally, potential
instabilities during mathematical calculations can be reduced as the result of a continuity of a force
– displacement function at the ultimate load level (deformation constraints is not suddenly
interrupted after reaching Rd).
Moreover, according to the ECCS manual for testing of such connections [10] it is recommended to
define a failure load as peak load in a deformation of 3 mm, and it is limited to this range of
deformation (see Fig. 3). Although it is clarified that in certain cases, under extreme loading
conditions (e.g. earthquake loads) this requirement may not be applied and the peak load may be
taken as the ultimate load without deformation restrictions. This consideration expands the range of
a practical application of the presented bi-linear model.
Table 10. Values used to obtain second part of the bi-linear connection model
Series A B C D E F G
Nominal thickness t [mm] 0.50 0.60 0.70 0.80 1.00 1.25 1.50
Mean value of the ultimate loads Rm,max [N] 1503 1519 1948 2759 4458 6685 7425
Second shear flexibility ch,II [mm/N] 2.20 0.89 0.90 1.38 1.27 1.08 0.87

The second shear flexibility ch,II can be obtained by modifying the formula (10) using the ultimate
load without reduction by the partial factor (see Table 10). Thus, the corresponding displacements
shall be taken:

ch 
1

a h , max
(11)
R m, max n

where ah,max is the slip of a fastening at a load equivalent to Rm,max

 | 627

Rm,max is the ultimate resistance of a fastening,

n is a number of test specimens.

Examples of the analytical bi-linear models and a real behavior of connections according to test
results are presented in Fig. 11. The extended version of the previously presented graph for the
linear model as the bi-linear behavior of joints can be seen in Fig. 12 (with the “EC” dotted line for
comparison, similar to the shown in the linear chart).

a) b)
Fig. 11. Comparison of the analytical bi-linear model and a real behaviour of connections according to tests:
a) 0.80 mm; b) 1.00 mm (vertical axis – force in N, horizontal axis – displacement in mm)

Fig. 12. Proposition for analytical extended, bi-linear models of tested connections

5 SUMMARY AND ACKNOWLEDGMENT

1. Linear models of connections commonly used in an engineering practice has been extended by
bi-linear one and presented for a selected range of the tested connections.
628 |

2. Different solutions in the connections A (other type of the screw) and G (other steel material)
shows boundaries of a solutions for a chosen range of used connections in practice.
3. The one screw diameter for the several, most popular plates thicknesses has been used. Future
researches should be carried out to check the behaviour of connections with other fasteners and
different plates thicknesses.

ACKNOWLEDGMENTS
The authors gratefully acknowledge the test specimens provided by the company PRUSZYŃSKI
and the fasteners with the tools provided by HILTI.
Studies were carried out in the framework of works S/WBiIS/2/2012 and W/WBiIS/2/2017 at
Bialystok University of Technology and financed by funds for science provided by the Ministry of
Science and Higher Education (MNiSW), Poland.

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[1] ECCS-TWG 7.5 “European Recommendations for the Application of Metal Sheeting Acting as a
Diaphragm”, 1995
[2] Gryniewicz M., Szlendak J.K. “FEM model of the steel building roof includes stressed skin diaphragm
action effects”, The International Conference on Metal Structures, Zielona Góra, 2016
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nica-Bydgoszcz, 2015 ( in Polish)
[4] Wuwer W. “Elasto-kinematic behaviour of screw connection in lightweight steel structures”, European
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[5] Swierczyna Sz., Wuwer W. “Evaluation of bearing resistance of blind bolt lap joints”, Proceedings of
the 7th European Conference on Steel and Composite Structures, Napoli, EUROSTEEL 2014
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Connections”, International Scholarly Research Network, ISRN Civil Engineering, Volume 2012
[7] Wei Lu, Mäkeläinen P., Outinen J., Ma Z. “Investigation on Screwed Connection in Fire in Cold-
Formed Steel Sheeting”, Proceedings of the 6th European Conference on Steel and Composite
Structures, Budapest, EUROSTEEL 2011
[8] Kallerová P., Wald F., Sokol Z. “Connections of Trapezoidal Sheets under Fire”, Acta Polytechnica,
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[9] Bródka J., Garncarek R., Miłaczewski K. „Blachy fałdowe w budownictwie stalowym”. Arkady,
Warszawa, 1999 (in Polish)
[10] ECCS TC7 TWG 7.10 “The Testing of Connections with Mechanical Fasteners in Steel Sheeting and
Sections”, 2nd Edition, No. 124, 2009
[11] EN 1993-1-3 Eurocode 3: Design of steel structures - Part 1-3: General rules - Supplementary rules for
cold-formed members and sheeting
[12] EN 1990 Eurocode - Basis of structural design
[13] EN 10327 Continuously hot-dip coated strip and sheet of low carbon steels for cold forming. Technical
delivery conditions
[14] EN 10326 Continuously hot-dip coated strip and sheet of structural steels. Technical delivery conditions
[15] EN 10088-2 Stainless steels. Technical delivery conditions for sheet/plate and strip of corrosion
resisting steels for general purposes
[16] ISO 6892-1 Metallic materials. Tensile testing. Method of test at room temperature