WAAM Integrated Plug‐and‐Play Beam‐to‐Column Connection

Abstract This paper presents the development and evaluation of a novel plug‐and‐play beam‐to‐column connection for steel structures, designed to facilitate rapid on‐site assembly, enable structural reuse, and reduce material usage. The connection concept was refined through an iterative design process focused on minimizing material consumption while maintaining structural performance. Finite element analysis was employed at each iteration to evaluate the joint's stiffness and moment resistance, with validation based on experimental data. The final plug‐and‐play connection was compared to a conventional single extended end‐plate bolted connection using equivalent beam and column sections. Results show that the plug‐and‐play joint achieves a 26.1% reduction in material use while offering higher stiffness and moment capacity. Yielding behavior differs between the two connections, with the plug‐and‐play joint developing plasticity at higher loads, thereby extending potential for reuse. Classified as semi‐rigid and partial strength, the connection supports moment‐resisting frame applications. The proposed design demonstrates a viable and efficient alternative to traditional bolted joints, with opportunities for further optimization and expanded applications.