Effective use of S690 to S960 high strength steel in construction: Research, development and innovative applications

By Chinese National Engineering Research Centre for Steel Construction (Hong Kong Branch), The Hong Kong Polytechnic University, and Hong Kong Constructional Metal Structures Association

 

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The use of high strength steel grades S690 to S960 in construction has advanced rapidly in Hong Kong in recent years, supported by targeted research, coordinated testing, and applications in pilot projects. The arrival of the Double Arch Steel Bridge of the Cross Bay Link in 2021 drew attention to feasible adoption of S690 steel in large civil structures.

 

This article summarises a number of research and development conducted in Hong Kong that have enabled successful applications of the S690 to S960 steel in construction with emphasis on understandings in mechanical properties and structural behaviour as well as practical means to minimise reductions in resistance and ductility of welded their sections.  Controlled welding procedures, numerical simulations, and large-scale verification tests have shown that welded sections can achieve target performance when properly designed and fabricated.

 

The Fanling North Circular Footbridge is presented as a key case study, demonstrating substantial reductions in self-weight, construction time, cost, and carbon emissions. The article also reports progress in robotic welding, workforce training, and the development of a national design standard for S690 to S960 steel structures. These outcomes show that “Effective use of S690 to S960 high strength steel” is now a practical and effective modern construction technology in Hong Kong.

 

Fig 1. Delivery of the Double Arch Steel Bridge of Cross Bay Link in Tseung Kwan O

 

Arrival of high strength steel in construction

 

After an unannounced arrival of the 10,000 tons Double Arch Steel Bridge of the Cross Bay Link at the Junk Bay in Tseung Kwan O in February 2021 (Fig 1), many of us in Hong Kong became aware of the S690 high strength steel – an advanced constructional material with a strength double to those commonly used S355 steel. This was one of the modern steel construction technology developed by Chinese National Engineering Research Centre (CNERC) since its establishment in 2015 – Effective use of S690 and S960 high strength steel in construction developed scientifically from first principles through multi-disciplinary research, and promoted widely to the construction industry through enhanced design and construction practice [1, 2]. Since then, many engineers begin to appreciate various benefits of these S690 high strength steel over the commonly used S355 steel in construction: reduced steel tonnages and welding, reduced self-weights upon supporting structures and foundation, and reduced carbon emissions [3].

 

Since 2018, the Development Bureau of the Government of Hong Kog SAR formulated a number of policies under the initiative “Construction 2.0” (psgo.gov.hk) to promote “Innovation in Construction”. Among various initiatives, the modern steel construction technology, namely, “Effective use of S690 and S960 high strength steel in construction” developed by CNERC and supported by The Hong Kong Constructional Metal Structures Association (HKCMSA), had been successfully implemented with impacts in the local construction industry. This article reports a number of major achievements on research, development and innovative applications of S690 to S960 high strength steel in the past three years. Details of a performance verification of S960 welded sections with column splices which were welded by experienced welders on site were presented, and this was an important step for preparation of the construction of a large scale circular footbridge system using S960 steel in Fanling North – the first of its kind in the world!

 

 

S690 to S960 high strength steel

 

S690 to S960 high strength steel, i.e. structural steel with yield strengths at 690 to 960 N/mm², have been available in many parts of the world since the 1990s. Their mechanical properties in terms of stress-strain curves are plotted in Fig 2 together with normal strength steel S355 and S460 steel. The excellent strengths of these high strength steel are primarily attained through engineering alloy design and heat treatments to achieve superior microstructures during steel-making. Due to high unit price and demanding welding technology of these high strength steel at these time, their applications were largely limited to large scale lifting equipment for ports and mines for many years.

 

Fig 2. Stress-strain curves of structural steel

 

For construction, these high strength steel offer highly effective structural solutions for heavily loaded members because of their excellent strength to self-weight ratios. It should be noted that a high level of ‘resistance and ductility’ for guaranteed structural safety is required not only in these steel, but also in their welded sections. Over the past 30 years, there were numerous conflicting reports in the literature which have led many structural engineers to have cautions on their mechanical properties of their welded sections, and also their fatigue performance.

 

Due to the excellent strength-to-weight ratio and favourable economic benefits of these S690 and S960 high strength steel, many engineers are eager to utilise them in construction as they are constantly required to build taller buildings and larger structures.

 

 

Challenges in effective use of S690 to S960 steel in construction

 

Possible reduction in strength and ductility after welding

For those high strength steel manufactured to EN 10025-6, GB 19879 and GB 1591, their microstructures may be modified significantly when a heating / cooling process is imposed onto these steel during welding (Fig 3). If the welding process is not properly controlled, there are often severe reductions in strength and ductility within heat affected zones of the steel plates after welding.

 

Fig 3. Effects of welding to S690 and S960 steel

 

Microstructural changes in the high strength steel will take place within the heat affected zones of the welded sections (Fig 4): phase transformations, recrystallisation, and grain growth, depending on the maximum temperatures reached, T_max, and the corresponding cooling rate from 800 to 500 ^oC, t_8/5.

 

Fig 4. Microstructural changes in S690 and S960 steel after welding

 

It should be noted that strength reductions in many welded connections and joints of these welded sections of S690 to S960 steel have been reported over the past twenty years worldwide, and typical reduction factors ranging from 0.6 to 0.8 are found.

 

Research into S690 and S960 steel

Through extensive experimental and numerical investigations, it was established to be possible to minimise reductions in both strength and ductility of the welded sections through a carefully controlled welding process, that is to control the amount of heat energy input for specific plate thicknesses and joint types.

 

Fig 5 summarises key findings of standard tensile tests on cylindrical coupons of S690 and S960 welded sections. It is demonstrated that it is practically feasible to develop suitable welding procedures for these high strength steel which will not reduce their mechanical properties due to unfavourable microstructural changes after welding.

 

Fig 5. Standard tensile tests on proportional cylindrical coupons of welded sections of S690 and S960 steel

 

In order to predict “Thermo-Metallurgical-Mechanical-Structural” responses of the high strength steel, advanced simulation was developed, which was referred as the “TMMS” approach [4, 5], to examine welded H- and Box-sections of Grades 690 and 960 steel with welded splices under axial compression, as shown in Fig 6.

 

Fig 6. Coupled modelling of phase transformation in S690 and 9S60 steel under effects of welding

 

In many cases, reduction in the compression resistances of these H- and Box-sections with welded splices under axial compression are demonstrated to be small [4] when they are welded under a proper control (Fig 7).

 

Fig 7. Deformation characteristics of welded box-sections of S690 and S960 steel plates with welded splices under axial compression

 

In order to enable effective composite construction, extensive experimental and numerical investigations have also been conducted to develop large diameter bolted shear connectors (Fig 8) to provide effective shear connections having large resistances compatible for composite beams with S690 high strength steel I-sections [6, 7].

 

Fig 8. Experimental and numerical investigations into composite beams with S690 I-sections

 

The proposed configuration of the twin shear connection, that is a pair of steel bolts with a 30 mm diameter embedded into Grade 100 concrete blocks reinforced with steel fibers, is shown to provide readily a shear resistance at about 1,500 kN and a good ductility up to a slippage of 8 mm in standard push-out tests to EN 1994-1. Typical shear resistance of headed shear studs with a 19 mm diameter is merely 100 kN.

 

In order to reduce cross-sectional dimensions of columns in building structures, it was proposed to use concrete filled structural hollow sections with increased material strengths, i.e. from S460 steel to S690 steel, and also from C60 concrete to C80 concrete. Systematic experimental and numerical investigations (Fig 9) into structural behaviour of stocky composite columns with both concrete filled circular and square hollow sections were conducted [8, 9].

 

Fig 9. Investigations into resistance enhancements in concrete-filled structural hollow sections

 

Based on the investigations into resistance enhancements in concrete-filled structural hollow sections due to confinement to concrete cores, the existing design rules are demonstrated to be readily extended to cover S690 steel and C80 concrete. Hence, their use has been adopted in the Code of Practice for the Structural Use of Steel 2011 (2023 Edition) of the Buildings Department as an amendment according to Practice Note for Authorised Persons, Registered Structural Engineers and Registered Geotechnical Engineers APP-168 in April 2026.

 

 

Performance verification of welded sections

 

Since the introduction of the high strength steel in construction in Hong Kong, many engineers have a concern on the welding quality of S690 and S960 steel sections, especially when these sections are welded on site. For some unknown reasons, over-stringent requirements on welding of these high strength steel are often specified.

 

Site welding by experienced welders
In order to address these concerns, a performance verification based on a qualified welding procedure specification (WPS) was conducted on a construction site in January 2024. Column splices of four H-sections which were fabricated with 12 and 15 mm thick S960 steel plates were welded on site according to different arrangements of wind shielding and post-weld heat treatments. Hence, there are a total of four H-sections with welded column splices (Fig 10) together with a control H-section.

 

Fig 10. Site welding of S960 H-sections with different welding conditions and post-weld heat treatments

 

It should be noted that for each column splice of these H-sections, the complete weld grooves were heated up using a flame torch to a minimum of 120^oC before commencement of welding (Fig 11a), and the surface temperature in the vicinity of the weld grooves was monitored with an infrared pointer.

 

a) Pre-heating before commencement of site welding	b) Welding according to qualified WPS
Fig 11. Site welding of S960 H-sections

 

Site welding of column splices of these four H-sections were performed by two qualified welders according to a qualified welding procedure specification (WPS) (Fig 11b) in which various details of the weld grooves, and welding sequences as well as specific values on voltage, current, wire feeding speed and welding speed have been specified. Both welders have received a proper welding training on S960 steel, and they have passed relevant welding qualification tests according to established practice. After welding, electric blankets were wrapped around the column splices of two H-sections for 2 hours, and the temperatures at the column splices were measured at close intervals using thermocouples. It should be noted that the temperatures of the column splices were maintained to 250 ^oC ± 2.5^o C for 2 hours by the use of the electric blankets, a thermal couple and a simple thermostat. After two hours, these two H-sections were air-cooled so that their temperatures dropped slowly to the ambient temperature.

 

All these H-sections were then tested under axial compression with full instrumentation (Fig 12a), and it was found that despite different arrangements of wind shielding and post-weld heat treatments, the overall load-deformation characteristics of those four H-sections with welded column splices and that of the control specimen follow each other closely along the entire deformation history.

 

Comparison among the measured cross-section resistances N_c,Rt of these four H-sections with welded column splices, and also of the control H-section confirms that there are only small differences among their resistances, i.e. 2 to 3% (Fig 12b). Hence, the effect of strength degradation due to welding in these four H-sections is demonstrated to be very small, and significantly less pronounced than commonly anticipated, especially, after allowing for their differences in geometrical dimensions.

 

a) Applied load – axial shortening curves	b) Compression resistances
Fig 12. Key results of compression tests on S960 H-sections

 

Consequently, it is demonstrated that site welding of S960 steel, when performed properly, is able to produce high quality welded sections by local welders. This performance verification is considered to be one of the many technical successes which pave the way for construction projects using S960 high strength steel in Hong Kong.

 

Robotic welding and its industrial-wide adoption
After the feasibility of quality site welding of S960 steel by local welders has been fully demonstrated, it becomes important to ensure that there are sufficient qualified welders in Hong Kong to support construction projects. Automated welding, in particular, robotic welding, is an attractive option.

Since its establishment in 2015, CNERC completed a number of research and development projects on robotic welding of high strength steel. From August 2023 to February 2025, a total of three training courses on robotic welding for S960 high strength steel for experienced structural welders was jointly organised by CNERC and HKCMSA in conjunction with a robotic welding specialist Jumbo Construction Technology (JCT). In July 2025, the first “Train-the-Trainers” programme was jointly offered by CNERC, HKCMSA and JUMBO Construction Technology at the Hong Kong Institute of Construction (HKIC) (Fig 13).

 

Fig 13. Joint industrial effort in organising training programmes for robotic welding operators

 

Moreover, with the support of the Construction Industry Council, a formal training programme for robotic welding operators was jointly developed by HKCMSA, JCT and HKIC to provide regular training courses (Fig 14). Strong support from the industry, in particular, the Hong Kong Metal Engineering Contracting Association (HKMECA), was received for a smooth operation of these training programmes.

 

Fig 14. A certificate presentation ceremony for robotic welding training in October 2025 jointly organised by HKCMSA and CIC

 

It is expected that by early 2027, a total of 200 robotic welding operators will have been trained to cope with the increase of welding work for S960 steel. It should be noted that once a welder or a robotic welding operator is certified to weld S960 steel, he is eligible to weld S690 steel as well.

 

 

Construction of a large scale circular footbridge system using S960 high strength steel

 

Led by the North Development Office of the Civil Engineering and Development Department (CEDD), the Circular Footbridge System, i.e. Footbridge F6, in Northern Metropolis (Fig 15) is a highly successful construction project about an innovative application of S960 high strength steel in Hong Kong.

 

   

Fig 15. Circular Footbridge System, Footbridge F6, at Lung Yeuk Tau Interchange, Fanling North

 

In the original design of Footbridge F6 which diameter is 40 m in plan, conventional reinforced concrete construction was adopted, and six columns were required to support the structure of about 6,250 metric tonnes. Due to the COVID-19 problem started in early 2020, the progress was seriously hit because of a long delay in land resumption, uncharted underground utilities and a shortage of workers. The discovery of multi-layers of uncharted underground utilities rendered supports to two of the 6 columns unavailable, and the foundations for the other 4 columns were also required to be reduced in sizes significantly. It became necessary for the project team to look for a lightweight footbridge system together with four compact foundations.

 

In Fig 16, details of the conforming and the alternative design of the Circular Footbridge System are illustrated, and it is shown that by replacing the reinforced concrete structure of 6,250 metric tonnes, a S960 steel circular footbridge system with 650 metric tonnes and 4 columns only, designed by YWL Engineering, was built with reduced time, costs and carbon footprint.

 

Fig 16. Comparison on conforming and alternative design of Footbridge F6

 

Key results of the comparison with various structural forms and materials are summarised in Table 1. Hence, the alternate design using S960 steel box sections by YWL Engineering is shown to have multiple advantages in terms of overall weights, fabrication and construction efforts, and carbon emissions.

 

 

Systematic experimental and numerical investigations (Fig 17) were conducted on a total of 10 no. 3 m long beams, and a total of 4 no. 16 m long beams, all of them were S960 stiffened box sections, to provide data to verify applicability of current EN design rules [10] with measured material properties and geometrical dimensions. Moreover, a technical guide [11] was compiled for structural design of the stiffened box sections adopted in the present project.

 

a) Typical beam test for 16 m long stiffened box sections under four point lateral loads b) Numerical modelling of interactive buckling at large deformations

Fig 17. Investigation into structural behaviour of S960 stiffened box sections

 

In order to prevent deterioration in mechanical properties of the S960 welded sections during shop fabrication, effective welding procedures were specifically developed for this project. A total of 40 large steel modules of S960 box sections were fabricated in Jiangsu, China, and then delivered to Hong Kong over a long-haul sea voyage. Robotic welding was also introduced to assemble some of these steel modules to form the footbridge structure on site.

The Circular Footbridge System was open to the public on 18 April 2026 (Fig 18). For full details of the design and construction of the footbridge, refer to Reference [12].

 

Fig 18. A group photo was taken by CEDD engineers, CNERC, JV engineers and YWL designers

 

When compared with the original design, the construction time had been shortened by 3 months while the construction costs had been reduced by 28%. It had also contributed to a reduction in carbon emissions by about 2,400 (tCO₂)_e , that is 65% of the entire Footbridge.

 

 

Group standard on structural design of high strength steel structures for Chinese Steel Construction Society 

In September 2023, CNERC was invited by the China Steel Construction Society (CSCS) to compile a nationwide Group Standard entitled “Design Standard for 690 to 960 MPa High Strength Steel Structures” to enable their applications throughout China. Drafting of the Standard was officially announced by CSCS in December 2023. Jointly led by The Hong Kong Polytechnic University and Tsinghua University, the Drafting Committee comprised 32 experts from Hong Kong and China, including academics, researchers and senior representatives from major design institutes and steelwork fabrication companies. The First Expert Committee Meeting for the Standard was held in Hong Kong on 16 to 17 May 2024 (Fig 19), and the Second Expert Committee Meeting was held in Beijing on 21 to 22 May 2025 (Fig 20). 

 

a) Technical presentations and discussions at PolyU b) Site visit to Cross Bay Link at Tseung Kwan O, Kowloon East     c) Ceremony for drafting of the CSCS Standard

Fig 19. First expert committee meeting. 16 to 17 May 2024. Hong Kong

 

a) Technical presentations by Ir Prof K F Chung and Prof Y J Shi b) Exchanges and discussions among steel experts, academics and fabricators

Fig 20. Second expert committee meeting. 21 to 22 May 2025, Beijing

 

The Draft Standard was submitted to CSCS in September 2025 for an industrial-wide consultation. All the comments received were discussed among members of the Drafting Committee to revise the document whenever appropriate. In February 2026, after a technical presentation and detailed discussions with the CSCS Expert Panel (Fig 21), the document was approved for publication as a CSCS Industrial Group Standard. The Standard will become effective for nationwide adoption throughout China on 1 October 2026.

 

CSCS Expert Panel led by Academician Prof Xuhong Zhou (周绪红院士)

 

Fig 21. Approval of Group Standard by China Steel Construction Society

 

This Industrial Group Standard is the first standard in China and also in the world to provide codified design rules for both steel and steel-concrete composite structures using S690 to S960 steel in construction. It should be noted that these design rules are formulated according to the methodology and formats of Chinese codes and Structural Eurocodes for cross-section and member resistances under typical actions, such as axial tension forces, axial compression forces, lateral shear forces, and bending moments, and also their interactions. Together with explanatory notes, detailed rules are available for structural engineers who are familiar with Chinese codes and Structural Eurocodes to design structural members under practical loading and support conditions.

 

 

Awards on innovative use of S960 steel in construction

 

The Circular Footbridge System was awarded a Grand Prize under Hong Kong Construction Projects of the CIC Construction Innovation Award 2025 (Fig 22). It is the top prize of the Award! It should be noted that the Construction Innovation Award was organised by the CIC every two to three years since 2015. The Award aimed to spearhead development, promotion and implementation of new construction materials, methods, technology for enhancing competitiveness of the construction industry in Hong Kong. It was widely regarded as one of the most prestige construction awards in Hong Kong, and also in Asia.

 

Fig 22. A group photo during the CIC Construction Innovation Award
(L to R) Ir William Luk, Ir Francis Leong, Ir Prof K F Chung, Ir Ricky Lau, Ir Michael Fong, Ir Joyce Lau and Ir Gavin Wong

 

Commendation of Judging Panel to the winning project:
The world's first application of S960 steel to two pedestrian bridges in the Northern Metropolitan area to reduce their structural self-weights, and also the number of piles, thereby reducing carbon emissions.

 

The construction project was also selected to receive a Winner Award in Excellence in Innovative and Technology Adoption of the Outstanding NEC Team Performance Awards 2025 organised by the Development Bureau of the Government of Hong Kong SAR (Fig 23). It should be noted that only eight projects were awarded out of about 60 entries of public projects.

 

Fig 23. A group photo of the project team during the Outstanding NEC Team Performance Awards 2025
Ir Prof K F Chung, Ir Ricky Lau, Ir Michael Fong, Ir Joyce Lau and Ir Gavin Wong and key members of the winning project

 

The Outstanding New Engineering Contracts (NEC) Team Performance Awards were organised by the Development Bureau to recognise outstanding project teams of construction / maintenance works in Hong Kong, which have exemplified the core NEC principles of mutual trust and cooperation to enhance project performance through effective collaborative partnering.

 

 

Presentation in the Opening Ceremony of the “HKIE 50th Anniversary Commemoration” Exhibition in Beijing

 

At the invitation of the HKIE, Ir Prof K F Chung, Founding Director of CNERC and HKCMSA, attended the HKIE 50th Anniversary Commemoration – “Engineering Legacy: 50 Years of Excellence” Exhibition in Beijing on 20 April 2026 (Fig 24). He was the Keynote Speaker at the Opening Ceremony of the Exhibition (Fig 25) held at the National Communication Centre for Science and Technology of the China Association for Science and Technology in Beijing. The title of the presentation of Ir Prof Chung is “Effective use of S690 to S960 high strength steel in construction – Research, Development and Innovative applications”. The Ceremony was jointly officiated by Ir Alice Chow, HKIE President for Session 2025/2026, Ms Bernadette H H Linn, Secretary for Development and Ir Ricky C K Lau, Permanent Secretary for Development (Works), both of the Government of Hong Kong SAR, and Ms Luo Hui, Vice Chairman and Co-Secretary-General of the China Federation of Engineers. Attendees included a number of HKIE Vice Presidents and Division Chairmen for Session 2025/2026, and many government officials, senior engineers, and representatives from Chinese Mainland Governments and partner organisations.

 

Fig 24. A group photo of President for Session 2025/2026 Ir Alice Chow, Ms Bernadette Linn, Ir Ricky Lau, and Chairman Luo Hui together with all attendees

 

Fig 25. Keynote presentation of Ir Prof K F Chung at the Opening Ceremony of the HKIE 50th Anniversary Commemoration – “Engineering Legacy: 50 Years of Excellence” Exhibition in Beijing

 

 

Way forward

 

With a number of highly successful construction projects  using S690 and S960 high strength steel in the past three years, the Government is determined to further develop Effective use of S690 and S960 high strength steel in construction in Hong Kong.

 

In April 2026, a Task Force was jointly established by CEDD and Highways Department to promote a wider use of S690 and S960 high strength steel in public works projects. A total of four footbridges and two vehicular bridges have already been recommended to adopt the S960 steel.

 

Effective use of S690 and S960 high strength steel in construction is a good example of Hong Kong innovation – a modern steel construction technology developed by Hong Kong engineers using high quality high strength steel made in China. Experiences gained from all these projects will be gathered and consolidated for compilation of practical design guides and codes of practice for construction projects in Hong Kong, and cities in China and in the Southeast Asia, and beyond.

 

 

Acknowledgements

 

The support of the Development Bureau and the Innovation, Technology and Industry Bureau of the Government of Hong Kong SAR is gratefully acknowledged. Special thanks are extended to Prof Shi Yongjiu of Tsinghua University and Prof Wang Zhan of South China University of Technology for their continual supports to CNERC and HKCMSA over the years.

 

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About the authors

K F Chung, H C Ho and Y F Hu are the authors of this article.

 

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