The utilization of cold-formed steel (CFS) sections in construction has become widespread due to their favorable attributes, including their lightweight properties, high strength, recyclability, and ease of assembly. To ensure their continued safe and efficient utilization, this review provides a comprehensive investigation into the factors influencing the strength of CFS members. This analysis encompasses design codes, prediction methodologies, material properties, and various structural configurations. This review uncovers discrepancies among existing design codes, particularly noting conservative predictions in AISI and AS/NZS standards for composite and built-up sections. Additionally, the effectiveness of prediction methods such as the direct strength method and effective width method varies based on specific structural configurations and loading conditions. Furthermore, this review delves into recent advancements aimed at enhancing fire resistance, connection design, and the composite behavior of CFS structures. The influence of factors such as eccentricity, sheathing materials, and bolt spacing on structural performance is also examined. This study underscores the crucial role of accurate prediction methods and robust design standards in ensuring the structural integrity and safety of CFS constructions. Through a comparative analysis, it is revealed that AISI and AS/NZS standards exhibit conservatism in predicting nominal buckling loads compared to experimental data. Conversely, a non-linear finite element analysis demonstrates a strong correlation with laboratory tests, offering a more accurate prediction of nominal buckling capacity. Overall, this review offers comprehensive insights aimed at optimizing CFS structural design practices. By identifying key areas for future research and development, this work contributes to the ongoing advancement of safe and efficient CFS construction applications.

Cold-formed steel (CFS) elements have gained significant attention in the field of structural engineering due to their numerous advantages, including high strength-to-weight ratio, cost-effectiveness, and ease of assembly and prefabrication. This review paper presents a comprehensive state-of-the-art analysis of the design and analysis of CFS structures, with a specific focus on columns and beams. The primary objectives and aims of this review paper are to provide a detailed assessment of the factors influencing the behavior and performance of CFS elements, including partial composite action, fastener spacing, bolt arrangement, web aperture, stiffeners, and connection spacing, to propose and present various formulas and methodologies that accurately estimate critical buckling loads, strength, and moment resistance for CFS members, and to emphasize the significance of proper screw and bolt placement in preventing premature failure and enhancing the overall load-carrying capacity of CFS structures. Additionally, the impact of temperature on the mechanical properties and performance of CFS members is discussed. The review paper proposes different formulas and methodologies to accurately estimate critical buckling loads, strength, and moment resistance for CFS members. Moreover, the paper highlights the importance of proper screw and bolt placement to prevent early failure and improve the overall load-carrying capacity of CFS structures. The discussion also emphasizes the need for revisions in existing standards and codes to provide more practical guidelines for designers and engineers. Overall, this state-of-the-art review paper provides valuable insights and recommendations for researchers and practitioners involved in the design and analysis of CFS elements.

The utilization of cold-formed thin-walled members as structural members has gained significant popularity due to their advantages in fabrication, cost-effectiveness, and transportation convenience. However, the reduced thickness of the used sections poses challenges such as global, local, and distortional member buckling, leading to a decrease in their axial strength. This study focuses on addressing these challenges by connecting the channels together using screws as an alternative to welding, considering the cost, time, and ease of implementation. Conducting finite element analysis on structural columns built-up from cold-formed double C steel channels and subjected to axial loads, this paper verifies the numerical models used against experimental tests known from the literature. A comparison of experimental results with nonlinear FEA and AISI & AS/NZ standards reveals commendable agreement, particularly in predicting the buckling behavior of the built-up I-shaped CFS columns. While the results of the finite element analysis show an overestimation of approximately 3.6% compared to the experimental tests, the AISI and AS/NZS standards demonstrate a conservatism of about 3.0%. Furthermore, the current study investigates the influence of screw spacing on axial strength of built-up cold-formed steel columns. The findings are derived from 175 finite element experiments, evaluating seven different cross-sectional profiles with twelve distinct screw spacings. These spacings correspond to the half-wavelength of local, distortional, and global buckling, divided by values ranging from one to four. The screw spacing determined by half the local buckling half-wavelength along the webs’ centerline resulted in enhancements of 22%, 7%, 13%, and 11% in the critical elastic local, distortional, and global column buckling loads, as well as the nominal axial strength, respectively. These increases were even more pronounced for double-lane fasteners with the same spacing, yielding improvements of 25%, 46%, 17%, and 12%, respectively. For economic considerations, it is advisable to utilize single-lane fasteners with a half-wavelength equal to half the local buckling half-wavelength.

The use of back-to-back built-up C-section beams is becoming increasingly common in CFS construction due to their cost-effectiveness and enhanced load-carrying capacity, making them suitable for longer beam spans and convenient for transportation. These built-up sections are utilized in wall studs, truss components, and floor joists, with intermediate screw fasteners placed at specific intervals to prevent the separate bowing of channels. This study reveals a ratio of 1.003 between experimental findings and finite element analysis results, and 1.002 between experimental findings and direct strength method results, indicating a strong correlation between experimental data from nonlinear finite element analysis and predictions based on the American Iron and Steel Institute and Australian and New Zealand Standards, particularly in predicting the flexural buckling strength of beam specimens. Furthermore, ongoing research is investigating the impact of screw spacing on flexural strength. This study presents results from 175 finite element tests, evaluating seven distinct cross-sections with twelve unique screw spacings. These spacings correspond to the half wavelength of local, distortional, and global buckling, divided by values from one to four. It was found that screw spacing based on half the local buckling half-wavelength along the centerline of the webs increased the critical global buckling moment capacity and the nominal flexural strength by 56 % and 27 %, respectively. For double-lane screws with the same spacing, these increases were even more substantial, reaching 65 % and 31 %, respectively. Economically, the recommended spacing for single-lane screws is half the local buckling half-wavelength.

Cold-formed steel (CFS) sections constructed with high-strength steel have gained prominence in construction owing to their advantages, including a high strength-to-weight ratio, shape flexibility, availability in long spans, portability, cost-effectiveness, and design versatility. However, the thin thickness of CFS members makes them susceptible to various forms of buckling. This study focuses on addressing and mitigating different types of buckling in columns and beams by manipulating the lip length (d) and the ratio of inside radius to thickness (Ri/t) in CFS C-sections. To achieve this objective, a comprehensive analysis involving 176 models was conducted through the Finite Element Method (FEM). The findings reveal that an increase in lip length leads to a corresponding increase in critical elastic buckling load and moment (${\mathbf{P}}_{\mathrm{c}\mathrm{r}\mathrm{l}}$, ${\mathbf{P}}_{\mathrm{c}\mathrm{r}\mathrm{d}}$, ${\mathbf{P}}_{\mathrm{c}\mathrm{r}\mathrm{e}}$, ${\mathbf{M}}_{\mathrm{c}\mathrm{r}\mathrm{l}}$, ${\mathbf{M}}_{\mathrm{c}\mathrm{r}\mathrm{d}}$, and ${\mathbf{M}}_{\mathrm{c}\mathrm{r}\mathrm{e}}$). It is recommended to utilize a lip length greater than or equal to 15 mm for both columns and beams to mitigate various buckling types effectively. Conversely, an increase in the ratio of inside radius to thickness (Ri/t) results in an increase in critical elastic local buckling load (${\mathbf{P}}_{\mathrm{c}\mathrm{r}\mathrm{l}}$) and moment (${\mathbf{M}}_{\mathrm{c}\mathrm{r}\mathrm{l}}$). Thus, lip length (d) significantly influences column and beam buckling, whereas Ri/t exhibits a relatively impactful effect. Subsequently, the experimental test results were used to verify finite element models. These insights contribute significant knowledge for optimizing the design and performance of CFS C-sections in structural applications.

Cold-formed steel channel (CFSC) sections have gained widespread adoption in building construction due to their advantageous properties, including superior energy efficiency, expedited construction timelines, environmental sustainability, material efficiency, and ease of transportation. This study presents a numerical investigation into the axial compressive behavior of CFSC section columns. A rigorously developed finite element model for CFSC sections was validated against existing experimental data from the literature. Upon validation, the model was employed for an extensive parametric analysis encompassing a dataset of 208 CFSC members. Furthermore, the efficacy of the design methodologies outlined in the AISI Specification and AS/NZS Standard were evaluated by comparing the axial load capacities obtained from the numerically generated data with the results of four previously conducted experimental tests. The findings reveal that the codified design equations, based on nominal compressive resistances determined using the current direct strength method, exhibit a conservative bias. On average, these equations underestimate the actual load capacities of CFSC section columns by approximately 11.5%. Additionally, this investigation explores the influence of eccentricity, cross-sectional dimensions, and the point-of-load application on the axial load capacity of CFSC columns. The results demonstrate that a decrease in section thickness, an increase in column length, and a higher degree of eccentricity significantly reduce the axial capacity of CFSC columns.