This paper describes a collaborative project between the US, Ireland, and Northern Ireland (UK) to investigate advanced manufacturing cutting techniques for the creation of a new class of intermeshed steel connections that rely on neither welding nor bolting. To date, advanced manufacturing equipment has only been used to accelerate traditional processes for cutting sheet metal or other conventional fabrication activities. Such approaches have not capitalized on the equipment's full potential. This project lays the groundwork to transform the steel building construction industry by investigating the underlying science and engineering precepts for intermeshed connections created from precise, volumetric cutting. The proposed system enhances the integration between design, fabrication, installation and maintenance through building information modeling platforms to implement advanced connections. Fully automated, precise, volumetric cutting of open steel sections introduces intellectual challenges regarding the load-transfer mechanisms and failure modes for intermeshed connections. The research activity addresses knowledge gaps concerning the load resistance and design of steel systems with intermeshed connections. Physical tests, finite element simulation and multi-scale modeling are being used to investigate the mechanics of intermeshed connections including stress and strain concentrations, fracture potential and failure modes, and to optimize connection geometry.

Digital manufacturing has transformed many industries but has had only a limited impact in the construction sector. To capitalize on advanced manufacturing techniques, this paper introduces a radically new connection approach for gravity structural steel frames. The proposed intermeshed steel connection (ISC) exploits robotic abilities to cut structural steel member ends precisely to accelerate deployment and offer better disassembly options over existing approaches. Forces are transferred through common bearing surfaces at multiple contact points, and connections can be secured by small locking pieces. This paper introduces the geometry, manufacturing, and initial analysis and test results of the connection. The paper demonstrates the ability of the connection to (1) be manufactured within current industrial tolerances, (2) be erected and disassembled, and (3) perform at expected design levels.

This paper presents the work carried out on a collaborative tripartite project between the USA, Republic of Ireland and Northern Ireland to create and investigate the design, development and testing of a new class of intermeshed steel connections (ISCs) that do not rely on field welding and minimise bolting, thus targeting the facilitation of fast disassembly of steel structures and material reuse. This research took advantage of fully automated, precise, advanced manufacturing cutting technologies (e.g. laser, waterjet and high-definition plasma cutting) to achieve a connection method in steel that previously was only possible in materials such as timber, with the potential to revolutionise the steel construction industry. The paper outlines the ongoing research work by the collaborative team, focusing on the design, fabrication, finite-element analysis (FEA) and scaled experimental testing of side ISCs for the flanges of open sections, which included the use of state-of-the-art digital image correlation technology for non-contact measurements. A simplified connection design procedure is presented based on yielding of the side plates. This design procedure is refined based on the results of experimental testing and FEA of the local axial behaviour of the flange connection, addressing stress concentrations in the flange, fabrication tolerances and material overstrength.

Despite wide use of terms such as “digital manufacturing” and “digital fabrication” in the constructional steel industry, actual use to date is mostly limited to research and development activities. In contrast, other heavy industries, such as automotive and aerospace have moved much faster and implemented many aspects of digital manufacturing and fabrication in product creation and traditional workflows. As a foil to the current state of the industry, this paper presents the erection, and disassembly of a simple, two‐storey frame that employs an alternative steel connection that can be manufactured using current plasma, laser, and water jet technologies, referred to as the intermeshed steel connection (ISC). The field demonstration described in this paper shows the connection's ability to reduce on site erection time, substantially reduce the number of site bolts, eliminate site welding, and allow for easy deconstruction. The connection has been under testing and development through a consortium of the University College Dublin, Queens University Belfast and, the University of Minnesota.

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