
Design of an Innovative CFS Purlin (Zigmax®) by Experimental Testing
Please login to view abstract download link
Cold-formed steel (CFS) elements are extremely versatile and widely used in construction, particularly for applications such as roof purlins. Optimizing the cross-section configuration of cold-formed steel purlins is essential for achieving higher industrial competitiveness by maximizing material efficiency and structural performance. ZIGMAX® is a brand new innovative cold-formed steel solution specifically designed for roof purlins stabilized by steel sheeting or sandwich panels. This new hybrid cross-section configuration leverages the advantages of conventional Z and Σ shapes, to achieve superior structural performance. Its design allows for the combination of two profiles to create a central closed core, providing enhanced strength, stiffness, and overall versatility. In this investigation the structural performance of the innovative cross-section was assessed by experimental tests, following the recommendations from the EN 1993-1-3, Annex A, clause A.3.4. Four-point bending tests were performed, incorporating lateral restraints at the connection points between the ZIGMAX® purlin and the steel sheet/sandwich panel (tension in the free flange). In the experimental campaign several parameters were assessed, such as: free spans, thicknesses, cross-section dimensions and configurations (built-up section) and lateral restraint spacing (on the restrained flange) to comprehensively assess the load bearing capacity and failure modes of 16 specimens. The experimental results were compared with design predictions following the EN 1993-1-3, Chapter 10.1 devoted to CFS beams restrained by sheeting. The obtained results demonstrate the effectiveness of the novel cross-section configuration in terms of load-bearing capacity and overall stability. The possibility of creating a thin-walled closed central core configuration combining two ZIGMAX profiles enhances the bending resistance, reducing the susceptibility to distortional buckling. Comparisons with the EN 1993-1-3 show that design predictions are conservative for all tested configurations (simply supported beams). This study confirms that the ZIGMAX® solution offers a promising alternative for modern construction applications, combining high structural performance and economic efficiency.