Metal-Plated Connections in Sustainable Lightweight Construction: A Weak Link in Fire Conditions?

Lightweight engineered trusses support sustainable construction with the benefits of mass production and fast construction at lower costs. However, the truss system has raised concerns due to premature failure in fire conditions. This study investigates the effect of a thin soot layer on the surface of the gusset plate and the teeth of the gusset plate on the temperature development within lightweight wood specimens in fire conditions. A 10 cm long, 8.9 cm wide, and 3.8 cm thick dimensional lumber (often called 2 by 4) partially covered by a gusset plate was exposed to a constant incident radiant heat flux. A total of 12 experiments were conducted with four different configurations, bare gusset plates with and without teeth and soot-coated gusset plates with and without teeth, at three different external radiative heat fluxes of 10, 15, and 20 kW/m2. The exposure durations were set to be 60, 40, and 30 min, respectively, to allow the total applied amount of radiant energy for each specimen to be identical. Three thermocouples were installed at a depth of 13 mm from the exposed wooden surface: two beneath the gusset plate and one below the uncovered wooden surface, and an additional thermocouple was between the gusset plate and the wood surface. The obtained temperature data showed that soot-coated gusset plates absorb significantly more radiation and record higher temperatures within the specimens than the specimens with the bare gusset plates. It was also found that the bare gusset plate works as a protective layer for the wood at 20 kW/m2, but not at 10 and 15 kW/m2. The teeth certainly contributed to heat transfer increasing the temperatures within the wood higher than those without teeth, but the effect was only meaningful for the soot-covered specimens. Connection strength was also qualitatively analyzed and it was discovered that the bare specimen retained a strong connection between the gusset plate and wood. In contrast, the soot-coated specimen was easily removed by hand, even when exposed to the same heat flux. Applying these results to a realistic scenario, this loss in connection strength could result in truss failure and structural collapse, which may result in injury to or even death of the responding firefighters. Additional gusset plate protection measures may be necessary to prolong the connection strength and prevent structural collapse.