Hello, again, DaveViking. You make some good points, and I'll do my best to respond.
1. Kind of glue: A high-strength glue like PL-2000, which develops 200#/in^2. If I were sure of (low) moisture conditions, I would use a good aliphatic resin. These glues are stronger than the lignins in the wood, so on the interface, the truss fibres would tear before the glue gave out. Due to cost and fabrication time, I would stay away from resorcinal or epoxy. Cracking of the glue bond under rotation is not something I have seen. Since both the wood truss member and the ply gusset are checked under Limit States Design codes (CSA 086.1-94 here in Canada) for axial tension and compression, as well as the various types of bending and shear if applicable, these aspects of the loading are considered. As far as fatique loading goes, no, I have not considered it - and perhaps I should. On the other hand, I would be surprised if the standard stamped metal gussets have ever been analysed for fatique either. If anyone has any information on this topic, please post.
2. Nailing requirements: This is, indeed my difficulty, and it is why I need to know what moments are developed in each gusset. Designing nailing for axial tension is not a problem. For example, one unclinched common wire nail (3" long, gauge # 9) will have a factored lateral resistance of 0.6 kN in Spruce-Pine-Fir if wood side plates are used (and a few other conditions are met). This is fine if the gussets are modeled as pure pin-connected, for then a simple Method of Joints or Sections analysis of the axial forces is all that is required under static loading. But if not pin-connected, I must have a way to compute the moments that is less onorous than the one developed by Suddarth that I mentioned in my first post. Knowing the M(max) in the gusset can be translated into shear on individual nails - which might change the number of nails needed....
3. No, I have not contacted the Wood Truss Council of America. I believe I had visited their website in my search, and, if memory serves, found no mention of plywood gussets - only the regular ones, all of which, I believe are proprietory anyway. I did contact the Canadian Plywood Association (which is how I received a copy of Suddarth's paper). Other than that, I have struck out, because, I believe, no one uses ply gussets any more.
4. Lags: A possibility, but, again, moments will develop, and I am back to square one - with the added reduction in cross-sectional area that the use of lags necessitates.
5. Ply cut on site: Well, perhaps. Most contractors have smaller portable table and radial arm saws for on-site work. Many have shops with heavier-duty equipment, where the mass cutting of the gussets would take place. This is the easy part. Air-nailing and glueing too (even clinching, which increases the lateral resistance by a factor of 1.6, is easy). Knowing construction as I do, using ply is somewhat easier than the use of metal plates - just a matter of air-nailing and spreading glue. Even hand-nailing is not too time-consuming, and a crew can have a good time doing it.
Moments.....
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