A Structural Analysis of Column Gusset Plates on the Production Module Support Structures

Andi Ardianti; Muhammad Najib Sadikin Daerobi; Muhammad Zubair Muis Alie

doi:10.48084/etasr.16645

Authors

Andi Ardianti Department of Naval Architecture, Hasanuddin University, Makassar, Indonesia
Muhammad Najib Sadikin Daerobi Department of Naval Architecture, Hasanuddin University, Makassar, Indonesia
Muhammad Zubair Muis Alie Department of Ocean Engineering, Hasanuddin University, Makassar, Indonesia

Volume: 16 | Issue: 2 | Pages: 33576-33581 | April 2026 | https://doi.org/10.48084/etasr.16645

Received: 2 December 2025 | Revised: 20 January 2026 | Accepted: 28 January 2026 | Online: 4 April 2026

Corresponding author: Andi Ardianti

Abstract

Floating Production Storage and Offloading (FPSO) units are complex offshore production facilities, whose topside modules are supported by multicolumn structures. A main component of this system is the gusset plate, which connects and reinforces the joints between the columns and other structural members while distributing internal forces. Under combined static and dynamic loading, gusset plates are prone to localized deformation, which may reduce joint stiffness and compromise structural stability. This study analyzes the mechanical behavior of the gusset plates in production module support structures using numerical analysis based on the Finite Element Method (FEM). Three different gusset plate configurations were developed and compared to evaluate the influence of geometry on the stress distribution, deformation patterns, and safety factors under identical operational and environmental load cases. The results indicate that gusset geometry significantly affects stress concentration, with the Corner model exhibiting the highest Von Mises stress (647 MPa), the Round model showing moderate improvement (567 MPa), and the Flat model achieving the lowest stress (474 MPa) and the most uniform distribution. These findings highlight the importance of geometric optimization in enhancing the structural reliability and load-transfer performance of production-module support systems.

Keywords:

topside module, supporting column, gusset plate, finite element method

Downloads

Download data is not yet available.

References

U. Bhardwaj, A. P. Teixeira, C. Guedes Soares, A. K. Ariffin, and S. S. Singh, "Evidence based risk analysis of fire and explosion accident scenarios in FPSOs," Reliability Engineering & System Safety, vol. 215, Nov. 2021, Art. no. 107904. DOI: https://doi.org/10.1016/j.ress.2021.107904

Y. Huang, Y. He, Y. Liu, M. Qiu, and M. Li, "Design and numerical simulation of the elastomeric support for the topside modules of an FPSO," Ocean Engineering, vol. 307, Sept. 2024, Art. no. 118203. DOI: https://doi.org/10.1016/j.oceaneng.2024.118203

Y. Huang, Y. He, Y. Liu, M. Qiu, M. Li, and Z. Luo, "Application and analysis of elastomeric supporting style for topside modules of a spread mooring FPSO," Ocean Engineering, vol. 261, Oct. 2022, Art. no. 112183. DOI: https://doi.org/10.1016/j.oceaneng.2022.112183

Y.-S. Shin and H.-J. Kim, "A comprehensive method for evaluating compressive strength and buckling behavior of corner gusset plates with various shapes," Engineering Structures, vol. 333, June 2025, Art. no. 120158. DOI: https://doi.org/10.1016/j.engstruct.2025.120158

C. Wang, J. Yang, G. Li, T. Xie, K. Deng, and T. Xu, "Experimental study and analysis of UHPC-RC composite multi-column frame piers," Structures, vol. 82, Dec. 2025, Art. no. 110479. DOI: https://doi.org/10.1016/j.istruc.2025.110479

G. A. Bisinotto, J. V. Sparano, A. N. Simos, F. G. Cozman, M. D. Ferreira, and E. A. Tannuri, "Sea state estimation based on the motion data of a moored FPSO using neural networks: An evaluation with multiple draft conditions," Ocean Engineering, vol. 276, May 2023, Art. no. 114235. DOI: https://doi.org/10.1016/j.oceaneng.2023.114235

D.-S. Kwon, C. Jin, M. Kim, A. Guha, O. E. Esenkov, and S. Ryu, "Data-driven inverse estimation of ocean wave parameters using field-measured FPSO motion and environmental data," Ocean Engineering, vol. 341, Dec. 2025, Art. no. 122683. DOI: https://doi.org/10.1016/j.oceaneng.2025.122683

M. Ghaderi-Garekani and S. Maleki, "Experimental and numerical investigations of block shear failure in gusset plates welded to double angle members," Structures, vol. 48, pp. 1356–1372, Feb. 2023. DOI: https://doi.org/10.1016/j.istruc.2023.01.047

Y. Huang, Y. He, M. Qiu, Y. Liu, and M. Li, "Study of the wet-towing transportation of an FPSO with elastomeric-supporting topside modules," Ocean Engineering, vol. 293, Feb. 2024, Art. no. 116602. DOI: https://doi.org/10.1016/j.oceaneng.2023.116602

S. D. Pham, A. Karamanli, N.-D. Nguyen, and T. P. Vo, "Vibration and buckling analysis of laminated and bio-inspired helicoidal composite curved beams," Structures, vol. 82, Dec. 2025, Art. no. 110480. DOI: https://doi.org/10.1016/j.istruc.2025.110480

S. D. Dillen and C. Mittelstedt, "Efficient post-buckling analysis of laminated plates with bending–twisting coupling using a novel algorithmic implementation," Composite Structures, vol. 373, Dec. 2025, Art. no. 119646. DOI: https://doi.org/10.1016/j.compstruct.2025.119646

A. Kohli, M. Mathad, S. V Hosamani, M. K. Adagimath, and B. B. Kotturshettar, "Finite element analysis of knee joint implant for varying bio material using ANSYS," Materials Today: Proceedings, vol. 59, pp. 941–950, Jan. 2022. DOI: https://doi.org/10.1016/j.matpr.2022.02.017

D. Y. Ali and R. A. Mahmood, "Influence of Slenderness Ratio and Sectional Geometry on the Behavior of Steel braced Frames," Engineering, Technology & Applied Science Research, vol. 14, no. 3, pp. 14282–14286, June 2024. DOI: https://doi.org/10.48084/etasr.7314

T. Nguyen-Van and T. Bui-Tien, "Investigation of the Eigenvector of Stochastic Finite Element Methods of Functionally Graded Beams with Random Elastic Modulus," Engineering, Technology & Applied Science Research, vol. 13, no. 4, pp. 11253–11257, Aug. 2023. DOI: https://doi.org/10.48084/etasr.5991

W. Wang et al., "Interfacial bonding stress transfer and failure mechanism between corrugated steel plate and reinforced concrete," Engineering Failure Analysis, vol. 153, Nov. 2023, Art. no. 107555. DOI: https://doi.org/10.1016/j.engfailanal.2023.107555

J. Xie and W. Zhang, "Numerical analysis on steel bracing members with bolted gusset plate connections," Journal of Constructional Steel Research, vol. 222, Nov. 2024, Art. no. 108960. DOI: https://doi.org/10.1016/j.jcsr.2024.108960

Y.-S. Shin and H.-J. Kim, "Net-section fracture resistances of bolted gusset plates with various connection details," Journal of Constructional Steel Research, vol. 227, Apr. 2025, Art. no. 109350. DOI: https://doi.org/10.1016/j.jcsr.2025.109350

Y. Cao, Y. Zhou, G. Zhong, and K. Jiang, "Structural performance of cruciform butted connected gusset plates under tensile loading," Journal of Constructional Steel Research, vol. 235, Dec. 2025, Art. no. 109934. DOI: https://doi.org/10.1016/j.jcsr.2025.109934

Y. Zarei, A. Afsari, S. M. R. Nazemosadat, and M. Mohammadi, "Simulation and Thermo-Mechanical Analysis of AA6063-T5 in FSW by FEM," Journal of Modern Processes in Manufacturing and Production, vol. 2, no. 2, Sept. 2024, Art. no. 5.

M. Mohammadi, S. M. R. Nazemosadat, D. Fazel, and Y. Bazargan Lari, "An integrated approach for structural modeling, modal analysis, and aerodynamic evaluation of an electric vehicle body shell using finite element method and computational fluid dynamics," Materials Today Communications, vol. 45, Apr. 2025, Art. no. 112331. DOI: https://doi.org/10.1016/j.mtcomm.2025.112331

S. M. R. Nazemosadat, D. Ghanbarian, M. Naderi-Boldaji, and M. A. Nematollahi, "Structural analysis of a mounted moldboard plow using the finite element simulation method," Spanish Journal of Agricultural Research, vol. 20, no. 2, pp. e0204–e0204, Mar. 2022. DOI: https://doi.org/10.5424/sjar/2022202-18157

M. Mohammadi, S. M. R. Nazemosadat, and A. Afsari, "Modeling and Analysis of a Tractor Diesel Engine Test Stand Structure Using the Finite Element Method," Biomechanism and Bioenergy Research, vol. 3, no. 2, pp. 75–87, Dec. 2024.