Case Study: Cast Connex achieves validated, weld-free sliding cast-steel connections for exposed mass-timber roofs with Altair

Cast Connex’s Innovative Connection Design Meets Aesthetics, Functionality, and Assembly Needs

Castconnex, a leader in architectural and structural cast steel connection components, needed a custom, exposed “tree‑like” connection to transfer roof loads to mass timber (Glulam) columns at a University of Victoria student hall. The design called for four cantilevered steel arms that must slide together on site with an extremely tight 1.5 mm gap (no welds or fasteners) that closes under load; Castconnex needed to ensure the assembled connection’s deflections and stresses stayed within allowable limits.

Using Altair’s simulation suite—Altair HyperWorks with HyperMesh and OptiStruct—Altair performed detailed FEA of the upper and lower castings and the assembled system, modeling contacts, nonlinear materials, and the 1.5 mm sliding gap. Analysis showed the upper casting experienced an additional 7 mm displacement until the gap closed (around half service load), after which cantilever stiffness matched, and ULS results from OptiStruct confirmed all components remained elastic with principal tensions well below material limits. Altair’s work validated the flat‑pack sliding assembly concept, confirmed structural performance, and enabled on‑site assembly without welds or bolts.

Castconnex

Jennifer Pazdon

VP