Abstract: A cost-effective orthotropic deck bridge panel which is capable of being standardized to facilitate the use of orthotropic decks on short span bridges. Inclusion of a concrete deck in the panel simplifies fabrication details, thereby increasing the economic viability of the disclosed orthotropic deck panel in short span bridge projects. Shortcomings in fabrication of steel support ribs of the panel are overcome by using a cold roll-forming process instead of a press brake to form longitudinal bends in sheet material. The cold roll-forming process further allows camber to be introduced in the support ribs, thereby eliminating an extra manufacturing step.

Abstract: A shallow single plate cold roll formed steel tub girder member is fabricated from unheated steel plate material by a cold roll-forming process which eliminates longitudinal welds and induces camber in the tub girder member.

Abstract: A method of manufacturing a railroad car tank head includes the steps of providing a circular blank of steel plate material, cold-forming the circular blank to form an intermediate ellipsoidal dish, cold-forming a peripheral flange region of the intermediate ellipsoidal dish to form a flanged ellipsoidal dish, and heat treating the flanged ellipsoidal dish. The heat treatment may be either a thermal stress relieving heat treatment or a normalizing heat treatment. The two cold-forming steps may be carried out at room temperature. The present invention provides a method of making a railroad car tank head that is more efficient than prior methods, avoids the challenges of hot-forming and single-stage cold-forming, is easily adaptable to different tank head diameters using the same forming equipment, and yields a railroad car tank head that meets safety standards.

Abstract: A new method of manufacturing a railroad car tank head having the steps of providing a circular blank of steel plate material, cold-forming the circular blank to form an intermediate ellipsoidal dish, cold-forming a peripheral flange region of the intermediate ellipsoidal dish to form a flanged ellipsoidal dish, and heat treating the flanged ellipsoidal dish. The heat treatment may be either a thermal stress relieving heat treatment or a normalizing heat treatment. The two cold-forming steps may be carried out at room temperature. The present invention provides a method of making a railroad car tank head that is more efficient than prior methods, avoids the challenges of hot-forming and single-stage cold-forming, is easily adaptable to different tank head diameters using the same forming equipment, and yields a railroad car tank head that meets safety standards.

Abstract: A cylindrical shell for a tank of a railway tank car is made using roll-forming technology and straight longitudinal weld seams. The cylindrical shell has a longitudinal axis and a uniform cross-sectional shape in a plane normal to the longitudinal axis. The cylindrical shell includes a plurality of elongated segments welded together along weld seams extending parallel to the longitudinal axis of the cylindrical shell. Each elongated segment forms a portion of the cross-sectional shape of the shell and is formed by passing a flat piece of metal plate stock material through a roll-forming machine configured to progressively bend the piece of stock material. In one embodiment, exactly three identical elongated segments, each defining an arc of 120 degrees, are welded together along adjacent longitudinal edges to form a cylindrical shell having a circular cross-section.

Abstract: A highway guardrail post comprises an elongated one-piece roll-formed metal body including a front wall defining an attachment face, a pair of opposing side walls orthogonal to the front wall, a first pair of inverted corners respectively connecting the pair of side walls to the front wall, and a second pair of inverted corners respectively extending from the pair of side walls and terminating in a pair of spaced rear edges to define a rear access opening opposite the front wall. The guardrail posts may be manufactured by roll-forming a metal sheet or coil and cutting the roll-formed metal sheet or coil into lengths.

Abstract: A trailer floor assembly includes a pair of longitudinally extending side rails supporting a plurality of self-mating transverse panels. The plurality of transverse panels includes extruded aluminum panels interspersed with roll-formed steel panels at locations where extra strength is desired (e.g., king pin, landing dollies, and rear door). The extruded panels include T-shaped slots in a bottom wall thereof to allow the extruded panels to be fastened to the side rails by fasteners engaging the bottom wall of the panel but not the top wall the panel. The assembly eliminates transverse cross-beams used to support longitudinal panels in the prior art, and thereby provides improved aerodynamics.

Abstract: A highway guardrail post comprises an elongated one-piece roll-formed metal body including a front wall defining an attachment face, a pair of opposing side walls orthogonal to the front wall, a first pair of inverted corners respectively connecting the pair of side walls to the front wall, and a second pair of inverted corners respectively extending from the pair of side walls and terminating in a pair of spaced rear edges to define a rear access opening opposite the front wall. The guardrail posts may be manufactured by roll-forming a metal sheet or coil and cutting the roll-formed metal sheet or coil into lengths.

Abstract: A prefabricated panel assembly for use in constructing a marine vessel comprises a plurality of elongated, roll-formed metal panels fixed sided to side by longitudinal weld seams. The panels include a plate portion and an angle portion adjoining the plate portion along a longitudinal primary bend, the plate portion having a generally flat panel segment, the angle portion having a web generally orthogonal to the panel segment and a flange generally parallel to the panel segment and adjoining the web along a secondary bend. The panel assembly provides a more efficient and cost-effective alternative to using individual structural steel angles welded to individual steel plate in constructing a marine vessel.