Innovative

Structural Steel
Systems
Innovative
Structural
Steel
Systems
Think, design and build with structural
steel—outside the box. There are
several innovative structural steel
systems and products that go beyond
conventional steel framing and that
have, in many cases, changed the way
designers approach projects. This list
provides a look at several of them.
Selection was based on manufacturers’
descriptions and claims; no product
testing or evaluation was performed.
Inclusion in this list does not constitute
a product endorsement by AISC.

From the cover: Learn more about the

innovative SpeedCore system on page 7.
 Connection Solutions

CAST CONNEX simplifies the design and enhances the perfor-

mance of structures by enabling architects and engineers to inte-
grate steel castings into their designs. CAST CONNEX® standard-
ized products include Universal Pin Connectors™, Architectural
Tapers™, Diablo Bolted Splices™, Timber End Connectors, High
Strength Connectors™, Cast Bolted Brackets, Scorpion Yielding
Connectors™, and High Integrity Blocks®. The company also of-
fers design-build services for custom cast steel nodes and compo-
nents. CAST CONNEX takes pride in collaborating in the creation
of safer, innovative and more beautiful built environments.
www.castconnex.com

ConX® is an innovative Chassis Based Modular™ structural steel

building system. ConX enables rapid design, fabrication and as-
sembly of robust, cost-efficient and sustainable structures for the
industrial, high-density residential, healthcare, data center and
commercial markets. ConX steel connections simply “lower and
lock”™ together in the field, allowing two- to four-times-faster as-
sembly vs. conventional steel or concrete structures. The ConX
System typically results in cutting total tonnage, eliminating waste
in the factory and field and reducing risk with a stronger, safer
structure. ConXL™ is OSHPD approved, codified by AISC and pub-
lished in AISC 358-10. ConX is LADBS approved and Cradle to
Cradle Certified CM at the silver level.
www.ConXtech.com

SidePlate is the most experienced structural steel expert in the

industry—we only work on steel building design. Our team takes
a steel lateral design, optimizes it with our patented connections
and the result is a steel tonnage reduction, erection time savings
and a performance-based design that saves money. For the gen-
eral contractor, SidePlate becomes their extension in the design
team, for the engineer, SidePlate becomes the go to source for
steel structure optimization.
Working closely with the fabricator, SidePlate supplies detailing
tools and hands-on assistance, assuring the new, lighter, easier to
erect steel package is the best job to run through the shop. In the
field, erectors like our bolted connection designs that allow faster
erection, mitigate weather delays that welded connections strug-
gle with and, of course, adds strength to the building, resulting in
high levels of resiliency. Finally, SidePlate brings a huge bonus to
owners by delivering a lighter steel package, faster erection and
multiple areas of savings. For all your steel buildings, SidePlate
Systems just makes sense.
www.sideplate.com

AISC Innovative Structural Steel Systems 3

Floor Systems

C-Beams (a division of SteelFab, Incorporated) is proud and excited to market and

manufacture Castellated and Cellular beams for your next project. The C-Beam offers
versatility, reliability and economy for all types of floor and roof structures while being
aesthetically pleasing, lightweight and structurally sound. Benefits include:
• Long span C-Beams erect faster due to fewer pieces
• Ability to pass ductwork and utilities through web openings creating lower
floor-to-floor heights
• Asymmetric sections produce the most economic composite design while
reducing material consumption and decreasing environmental impact
• Asymmetric composite design increases stiffness, therefore improving
vibration characteristics
• Eliminate columns and creates open floor space due to long span capabilities
• Less bridging compared to joist floor systems
www.c-beams.com

The GIRDER-SLAB® system is a structural steel and precast hybrid, the first to use pre-
cast hollow core planks with an integral steel girder to form a monolithic slab assem-
bly. This proven technology achieves low floor-to-floor heights, is low cost, lightweight
and offers rapid assembly and construction. The nonproprietary GIRDER-SLAB® sys-
tem is designed by the owner’s architect and structural engineer in combination with
a conventional structural steel frame. The components of the system, structural steel
(including the unique D-BEAM® girder) and precast prestressed hollow core slabs, are
manufactured and supplied by the builder’s customary subcontractors, ensuring the
owner competitive procurement of the building’s superstructure.
www.girder-slab.com

Deltabeam is a tested, proven and superior composite beam used for slim-floor de-
signs. It is the first composite steel beam that has successfully passed the UL test re-
quirements for a UL unrestrained fire rating of up to four hours without any added fire
protection materials. Deltabeam’s shallow depths, flush finish and clear spans of over
40 ft provide added design flexibility. It can support all types of slim-floor construction
including metal form deck, hollow-core plank or reinforced concrete slabs. Thanks to
its simple, economical and time-saving erection, Deltabeam has been used in over
12,000 projects worldwide.
www.peikkousa.com/product-category-deltabeam-us

4 AISC Innovative Structural Steel Systems

 Floor Systems

COMSLAB® is a long span and shallow composite floor system that helps structural
steel compete with low floor-to-floor concrete designs. With depths as low as 10½
in., it can be combined with various proprietary flush beams or conventional AISC
sections hidden in the floor section COMSLAB® is a lightweight assembly that has
UL listed UNRESTRAINED ratings of 1, 2 and 3 hours for spans of more than 30 ft. It
is ideal for all elevated concrete slab construction such as hotels, schools, parking,
office, multi-residential and medical buildings.
www.comslab-usa.com

The Ecospan® Composite Floor System is an efficient and environmentally friend-

ly steel floor system using open-web steel joists and steel deck with a concrete
topping slab. The integral component of this system is the Shearflex® HD screw,
which bonds the concrete slab to the top chord of the steel joist. The Shearflex HD
screw is a self drilling, self-tapping fastener that is attached with a Shearset® tool
(provided ) in a matter of seconds. Since it also serves as the deck attachment, no
additional welding is required.
The system is custom designed to the requirements of each project. A typical
floor with exceptional strength and serviceability will include spans up to 60 ft, with
joists spaced at 4 ft to 6 ft on center. Being a composite floor system, the maxi-
mum span-to-depth ratio of the bare joist is L/30, allowing a shallower floor-to-floor
height than traditional floor systems.
Ecospanhas both STC and IIC ratings that meet or exceed the requirements
of the International Building Code. The system has also undergone UL testing
and has fire ratings up to three hours with multiple assemblies.
www.ecospan-usa.com

Versa-Floor™ featuring Deep-Dek® Composite (DDC) is a floor system capable of

spans up to 40 ft. It integrates deep-ribbed steel profiles with a structural concrete
topping. The deck serves as formwork during construction and strengthens the slab
to support service stage loading. Versa-Floor can be placed on beam or wall bearing
frame system. Deck ends, for example, can be placed on ledger angles attached to
upturned steel beams to help reduce the depth of the beam soffit below the ceil-
ing plane. DDC’s 12-in.-wide deck sheets, available in three depths, can be spread
individually on the frame or preassembled into panels on- or off-site. DDC has facto-
ry-closed ends so end-closure angles are eliminated. A pneumatic-drive tool forms
the deck side-lap connections, which are critical to achieving composite strength.
Prior to placing concrete, longer deck lengths are line-shored at mid-span, and
unshored designs are obtainable over mid-span lengths. DDC is ICC-ES evaluat-
ed for structural conformance with the International Building Code. The system is
noncombustible and UL fire rated and responds predictably to floor vibration. The
authors of AISC’s vibration design guide customized our vibration analysis software
based on the results of extensive field and laboratory testing.
www.versafloor.com

AISC Innovative Structural Steel Systems 5

Wall Systems

The Integrity Wall™ Panel by South Shore Iron Works is the hybrid wall pan-
el solution for mid-rise projects and overbuilds up to 25 floors. The panels are
shipped and erected efficiently in less time and with better results than con-
ventional stick framing or CFS panel systems. Using the panels with a compos-
ite floor system allows designs to achieve longer free-spanning decks without
load-bearing partitions. Being an AISC-certified fabricator means that Integrity
Wall is manufactured in an experienced, high-efficiency plant under rigorous
quality-control processes to rapidly furnish consistent and precision-craft-
ed panels. The panels are shipped vertically to the job site on our fleet of
custom-built trailers for efficiency and minimization of potential transport or
weather damage. Our panels are delivered and erected without problems or
the weather delays that plague other panels systems. The panels are efficient
and cost-effective for hospitality, dormitory, multifamily, senior living, office and
retail projects, and are engineered to meet nearly any design requirement.
Panels of varying sizes in lengths up to 32 ft make it possible to start and finish
jobs in significantly less time than typical job-built systems. The panels are
available up to 12 ft, 5 in. tall and can be stacked to achieve greater heights.
In addition, they are energy-efficient and create a low amount of waste and
contribute to LEED credits by using a high percentage of recycled steel.
www.integritywallpanel.com

Pueblo Building System is an innovative yet simple structural steel framing

system for mid-rise and multistory residential projects such as apartments,
condominiums, hotels and student housing. It is a conventional system, not
requiring special code approvals or fabrication techniques. Prefabrication of
steel framing results in significantly reduced labor at the site. Advantages
over concrete construction include:
• Significant saving in construction cost and time
• About 40% lighter than a concrete structure, resulting in reduced
foundation costs
• Fits within the walls of residential units
• Floor cavities and steel joist web openings allow for horizontal air
exhaust for the units, thus eliminating need for costly fire-rated
vertical shafts and scavenger fans on the roof Advantages over wood
construction include:
• A higher-quality and more robust system at a very competitive cost
• All noncombustible materials, resulting in lower insurance costs
• No hidden problems due to dry rot
• No shrinkage or warping
• Can go taller than four or five stories, thus adding more units and
reducing cost per unit
www.pueblobt.com

6 AISC Innovative Structural Steel Systems

 Lateral Systems

The Re-Fuse Braced Frame (RFBF) is a high-performance lateral

load resisting system with enhanced reparability characteristics
resulting in a highly resilient structure. The system consists of
traditional, rolled section brace members that are connected to
gusset plates via specially engineered, proprietary steel fuse el-
ements. The fuse elements have unique geometry designed to
accommodate large inelastic deformations under extreme seis-
mic or other hazardous events while the remaining structure is
intended to remain essentially elastic, thus undamaged. The fuse
elements are intended to be replaced if damaged in a significant
hazardous event. The fuse elements vary from 26 in. to 62 in. in
length and 37 to 91 lbs in weight. The relatively compact size
of the fuse elements allows for ease of handling by one or two
people without need for a crane. In addition to the obvious ap-
plication of the primary lateral system for new construction, the
fuses can be transported through nearly any elevator, stairway, or
ladder access making the product highly suitable for renovation
and retrofit applications.
novelstructures.com

SpeedCore Pipe Sleeve for Penetration

SpeedCore is a non-proprietary revolutionary system of com-
posite structural-steel framing, aiming to replace common rein- Steel Face Plate
forced concrete core construction. The steel plate composite wall
system leverages the stiffness of concrete and the speed and ac- Tie Bar
curacy of steel. The system removes the need for reinforcement
placed on site and the additional time for concrete curing which Concrete
typically sets the pace for building construction Embeds are no Infill
longer a field-measured installation, reducing on-site coordina-
tion. Construction schedule savings and cost savings are dramat-
ically demonstrated in the Rainier Square Tower (Seattle, WA)
project, designed by Magnusson Klemencic, & Associates. Any
fabricator can produce this innovative composite system.
www.aisc.org/speedcore
Steel Face Plate

AISC Innovative Structural Steel Systems 7

Columns

ASTM A1085 Material

A new material specification for hollow structural sections (HSS) was published
in the U.S. in 2013. The AISC Specification 360-16 now includes the specifica-
tion, as well. This material provides enhanced performance and reliability for
seismic and dynamic controlled structures. The AISC Committee on Specifica-
tions allows designers to take advantage of the full nominal wall thickness when
designing with A1085—which ultimately provides more economic designs.
Highlights of the new specification include:
• Uniform minimum yield stress of 50 ksi for all shapes
• Maximum yield stress of 70 ksi for all shapes—the first material specifica-
tion in Europe or North American to provide this
• Standard Charpy notch toughness (CVN) values provided for all material,
with an option for project specific CVN if desired
• Tighter wall thickness tolerances and the addition of an overall mass
tolerance allow designers to use full nominal wall thicknesses and section
properties in design
This material will be treated as a complementary specification to ASTM A500.
Check with domestic fabricators/producers for availability.
www.aisc.org/A1085

In 2012, Atlas Tube, a division of Zekelman Industries, partnered with Nippon

and Sumikin Metal Products Co., Ltd. (NSMP), and Mitsui Co., Ltd., to supply
“jumbo” hollow structural sections (HSS) to the North American market. Typ-
ical sizes available are 10 in. to 16 in. for 0.750-in. walls and 18 in. to 22 in. for
wall thicknesses of 0.375 in. to 0.875 in. Rectangular sections are also available.
Atlas Tube continues to see an increase in demand for these products. Recent-
ly, jumbo HSS have been used in column applications in a large distribution
center, a new headquarters for a Fortune 100 company, various stadiums and
sports arenas and a large industrial project. Because of its high load carrying
capability, jumbo HSS are selected as a more efficient alternative to open sec-
tions and built-up, welded box sections. The jumbo HSS are provided via Atlas’
Chicago facility, and Atlas has also partnered with the following service centers,
who will carry inventory of the shapes:
• Totten Tubes, Los Angeles • Tubular Steel, St. Louis
www.atlastube.com/jumbo-hss

Structural Steel Core Column

Outer Steel Shell BLACK ROCK

FIREPROOF COLUMN
4K psi Concrete

Insulating Material Black Rock Fireproof Column manufactures durable, aesthetically designed
prefabricated fireproof columns. Black Rock Fireproof Columns are UL and
AISC certified and offer several types of cost savings to building owners. Black
Rock’s round, square, and rectangular shapes (along with customized shapes
and sizes) are designed for exposed exterior and interior load bearing columns.
They are utilized in hospitals, schools, dormitories, cafeterias, shopping cen-
ters, and countless other structures.
www.blackrockfireproof.com

8 AISC Innovative Structural Steel Systems

 Modular Solutions
TM

CorTek (by Nucor, Vulcraft/Verco Group) is a pre-fabricat-

ed, stay-in place, modular steel form system, which will sim-
plify and accelerate the design and construction of reinforced
concrete stair and elevator cores. This exciting new product
is custom made for each structure and delivers to the site in
modules that simply stack like building blocks. When CorTek
arrives onsite, the horizontal rebar is already placed inside the
form and the vertical rebar, which is supplied with the cores, is
simple to install. Stack the modules, drop in the vertical rebar
and place the concrete. It really is that straight forward.
No more waiting for the cores to be finished or forms
stripped. No more bulging or twisting cores. No more mis-
aligned embeds to repair or relocate. The surrounding struc-
ture can be erected simultaneously with the steel forms pri-
or to concrete placement, potentially removing the concrete
core from your project’s critical path! And since the stairs are
pre-installed inside the cores at the factory, other trades gain
immediate access to upper levels of the structure, helping to
keep the project moving forward safely, without the hassle of
temporary scaffolding, ladders or other means of temporary
vertical conveyance.
www.corteksystems.com

Z-Modular, a division of Zekelman Industries, has pioneered

a better and more innovative way to build with steel. Using
the revolutionary VectorBloc connector and steel Hollow
Structural Sections (HSS), Z-Modular can deliver modular con-
struction which is stronger, taller, faster, smarter and greener
than other current alternatives. Utilizing precise fabrication
techniques, the steel modules are built in a factory setting
allowing very tight control of fabrication and construction
tolerances. Modules are erected quickly on site without any
“tolerance creep.” Z-Modular can provide services that start
with the design and engineering of the modules, continues
with the fabrication and full fit out, and ends with the erection
and installation of a completed modular structure. Whether
you are looking to build multi-family housing, hotels, dormi-
tories, small office buildings, or datacenters, Z Modular can
deliver and take your modular project to new heights.
www.z-modular.com

AISC Innovative Structural Steel Systems 9

Thermal Breaks

Armatherm™ provides a combination of low thermal conductivity and high

compressive strength and has been used in hundreds of structural steel framing
connections transferring load in moment and shear conditions. The material is
made of a reinforced, thermoset resin which is fire resistant, does not readily
burn and has very limited creep under load, making it the ideal material for use
in structural and facade thermal break connections.
It can be used anywhere a penetration or transition exists in the building
envelope creating a thermal bridge. Situations using Armatherm™ to minimize
heat loss include balcony, canopy parapet, masonry shelf angle, cladding/Z-girt
and curtain wall mullion connections. Improvements in the effective U value of
wall assemblies can be realized by as much as 60–70%.
www.armatherm.com

Fabreeka-TIM® is a load bearing thermal break used between flanged steel

connections. The primary benefit is that it maintains structural integrity while
reducing energy loss. Made in the U.S. from a fiberglass reinforced laminate
composite, Fabreeka-TIM® is stocked in several thicknesses, including ¼-in,
½-in and 1-in. Fabreeka utilizes a water jet machine for precise cutting to any
configuration. It can be supplied with Fabreeka-TIM® washers, and Fabreeka®
bushings, which when used together in a structural connection, greatly reduce
the energy loss rate through conduction.
www.fabreeka.com

The Farrat Structural Thermal Break (FTB) is a high-performance thermal in-

sulator used between horizontal and vertical connections of internal and exter-
nal elements to prevent thermal or cold bridging. The plate provides a simple,
economical and extremely effective solution to meeting Part L of the Building
Regulations by way of reducing heat loss and the risk of internal condensation.
FTBs are available in two grades of low-thermal conductivity, high-compressive
strength material: Farrat TBK and Farrat TBL, both of which come in a variety of
thicknesses and are precision water-jet cut for custom configurations. Both ma-
terial grades are accredited by the Steel Construction Institute (SCI) under the
Assessed Product Quality Mark Scheme and are manufactured under the ISO
9001:2008 Quality Assurance system. They meet the NHBC’s technical require-
ments and are the only thermal break plates on the market holding this level of
accreditation. Unlike proprietary mechanical thermal break systems, FTBs are
simple to incorporate into most details. This flexibility means that they can be
used for a wider variety of steel-to-steel, steel-to-concrete, steel-to-timber and
concrete-to-concrete applications, including balcony, canopy, parapet, mason-
ry shelf angle, cladding and external staircase connections.
www.farrat.com

10 AISC Innovative Structural Steel Systems

 Thermal Breaks

Schöck Isokorb® is a manufactured structural thermal break (MSTB) solu-

tion to thermal bridging. The Schöck Isokorb insulating element thermally
separates and transfers the load of the exterior structure in cantilevered
steel conditions such as canopies, steel balconies, roof extensions and
steel columns. Isokorb modules consist of stainless steel inner compo-
nents and Polystyrene hard foam (Neopor®) exterior. The modules are
fully engineered and ready to install on-site, and Isokorb S22 modules
can be arranged above one another to transfer bending moments, as well
as beside each other to fit the steel member dimension and load require-
ments. Benefits include:
• Minimization of thermal bridges, thus eliminating condensation and
dew-point problems
• Increasing energy efficiency, sustainable design and possible
LEED certification
• Ease of installation with a modular stacking system
• Accommodation of a range of profile sizes and structural loads
• Independently verified thermal and structural performance
www.schock-us.com

Tnemec has combined its high-performance coatings technology with the

insulating solid, aerogel, to produce Aerolon—a spray-applied thermal
insulating coating. Aerolon is the first fluid-applied coating to act as an
effective non-structural thermal break, helping to regulate heat transfer
and control condensation within and in-board of the building envelope.
With a low thermal conductivity of 35 mW/mK, Aerolon helps keep
surface temperatures above the dew point, reducing condensation and
inhibiting moisture inside walls. When applied to common thermal bridg-
ing areas—such as pass-through I-beams, fins, canopies, roof davits or
window frames—the insulating coating reduces the thermal conductivity
of the substrate, limiting the transfer of exterior temperatures through
building penetrations.
Aerolon is a low VOC, water-based coating that can be spray-applied
onsite or offsite and, if needed, can be touched-up in the field during
new construction or retrofit projects. Its application is more versatile than
structural thermal breaks and can limit overall labor and material expens-
es for projects focused on green building and holistic design.
www.tnemec.com/thermalbreak

For the latest and greatest innovations, visit www.aisc.org/innovations. And to add one to our list or learn more about
how to use any of these options on your next project, visit www.aisc.org/solutions or contact us at solutions@aisc.org. F127-18
Your project just got easier.
With almost 125,000 project teams assisted to date,
AISC’s Steel Solutions Center is a free resource made just for you.

SSC Project AISC steel experts assisted

#83301 the project team with the
original structural concept.
Godfrey Hotel For the full story, visit
Chicago, IL www.aisc.org/godfrey.

Photo courtesy of the Godfrey Hotel Chicago.

STEEL SOLUTIONS
CENTER
866.ASK.AISC | solutions@aisc.org
www.aisc.org/askaisc