Chapter 2 – Welded Connections

I. Introduction
In welded connections, different elements are connected by heating their surfaces to a plastic
or fluid state. There may or may not be pressure, and there may or may not be filler material.
Arc welding is the general term for the many processes that uses electrical energy in the form
of an electric arc to generate the heat necessary for welding.

Process of Welding
Welded connections in steel structures are ordinarily done by arc welding. Arc welding is
a welding process that is used to join metal to metal by using electricity to create enough heat
to melt metal, and the melted metals when cool result in a binding of the metals. It is a type of
welding that uses a welding power supply to create an electric arc between a metal stick
(electrode) and the base material to melt the metals at the point of contact. Arc welders can
use either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes.

**Molten steel must be protected from the surrounding air otherwise, gases contained in the
molten steel can combine chemically with oxygen and nitrogen in the air. This chemical
reaction leaves small pockets of gases in the weld after it has cooled down, making it porous.
The resulting weld will be brittle with very little resistance to corrosion.
To prevent this undesirable brittleness weld, 2 types of arc welding is commonly used, shielded
metal arc welding (SMAW) and submerged arc welding (SAW).

II. Types of Welding

Consumable Electrode Methods
1. Shielded Metal Arc Welding (SMAW)
2. Submerged Arc Welding (SAW)
3. Gas Metal Arc Welding (GMAW)
4. Flux Cored Arc Welding (FCAW)

Non-consumable Electrode Method

1. Gas tungsten Arc Welding (GTAW)
Shielded Metal Arc Welding (SMAW)

One of the most common types of arc welding is shielded metal arc welding (SMAW), which is
also known as manual metal arc welding (MMAW) or stick welding. An electric current is used
to strike an arc between the base material and a consumable electrode rod or stick. The
electrode rod is made of a material that is compatible with the base material being welded and
is covered with a flux that gives off vapors that serve as a shielding gas and provide a layer of
slag, both of which protect the weld area from atmospheric contamination. The electrode core
itself acts as filler material, making a separate filler unnecessary. The process is very versatile,
requiring little operator training and inexpensive equipment.

The process is generally limited to welding ferrous materials, though specialty electrodes have
made possible the welding of cast iron, nickel, aluminum, copper and other metals. The
versatility of the method makes it popular in a number of applications including repair work and
construction.

**Welding slag is a form of slag, or vitreous material produced as a byproduct of some

arc welding processes, most specifically shielded metal arc welding (also known as
stick welding), submerged arc welding, and flux-cored arc welding. Slag is the solidified
remaining flux after the weld area cools.
Submerged Arc Welding (SAW)

It is a high-productivity welding process in which the arc is struck beneath a covering layer of
granular flux. This increases arc quality, since contaminants in the atmosphere are blocked by
the flux. The slag that forms on the weld generally comes off by itself and, combined with the
use of a continuous wire feed, the weld deposition rate is high. Working conditions are much
improved over other arc welding processes since the flux hides the arc and no smoke is
produced. The process is commonly used in industry, especially for large products. As the arc is
not visible, it is typically automated.

Gas Metal Arc Welding (GMAW)

It commonly called MIG (for metal/inert-gas), is a semi-automatic or automatic welding process

with a continuously fed consumable wire acting as both electrode and filler metal, along with
an inert or semi-inert shielding gas flowed around the wire to protect the weld site from
contamination.
Constant voltage, direct current power source is most commonly used with GMAW, but
constant current alternating current are used as well. With continuously fed filler electrodes,
GMAW offers relatively high welding speeds; however the more complicated equipment
reduces convenience and versatility in comparison to the SMAW process.
Originally developed for welding aluminum and other non-ferrous materials in the 1940s,
GMAW was soon economically applied to steels. Today, GMAW is commonly used in industries
such as the automobile industry for its quality, versatility and speed.

Flux Cored Arc Welding (FCAW)

It is a variation of the GMAW technique. FCAW wire is actually a fine metal tube filled with
powdered flux materials. An externally supplied shielding gas is sometimes used, but often the
flux itself is relied upon to generate the necessary protection from the atmosphere. The process
is widely used in construction because of its high welding speed and portability.

Gas Tungsten Arc Welding (GTAW)

Gas Tungsten Arc Welding (GTAW), or tungsten/inert-gas (TIG) welding, is a manual welding
process that uses a non-consumable electrode made of tungsten, an inert or semi-inert gas
mixture, and a separate filler material. Especially useful for welding thin materials, this method
is characterized by a stable arc and high quality welds, but it requires significant operator skill
and can only be accomplished at relatively low speeds. It can be used on nearly all weldable
metals, though it is most often applied to stainless steel and light metals. It is often used when
quality welds are extremely important, such as in bicycle, aircraft and marine applications.
The electrode used in GTAW is made of tungsten or a tungsten alloy, because tungsten has the
highest melting temperature among pure metals, at 3,422 °C (6,192 °F). As a result, the
electrode is not consumed during welding.

III. Electrodes used for Welding (under American Welding Society – AWS)

Process
Minimum
Minimum
SMAW SAW GMAW FCAW tensile
yield stress,
AWS A5.1 or AWS A5.17 or AWS A5.18 AWS A5.20 strength, Fu
Fy (MPa)
A5.5 A5.23 or A5.28 or A.5.29 (MPa)

E60XX E6XT-X 345 415

F6XX-EXXX 345 415-550
E70XX ER70S-X E7XT-X 415 485
F7XX-EXXX 415 485-655
E80XX 460 550
F8XX-EXXX E8XT 470 550-690
ER80S 450 550
E100XX 600 690
F10XX-EXXX 605 690-895
ER100S 620 690
E10XT 605 690-830
E110XX 670 760
F11XX-EXXX 675 760-895
ER110S 675 760
E11XT 675 760-860

IV. Electrode Classifications

a. For SMAW (Electrodes with 4 digits)

E – stands for Electrode

XX – First 2 X designates the minimum tensile strength in ksi
X – 3rd X designates position for which the electrode can be used.
1 – Flat, Vertical, Overhead, and Horizontal (all position)
2 – Horizontal-fillet and Flat
3 – Flat, Horizontal, Overhead, and Vertical-downwards
XX – Last two X shows two things: Polarity in which electrode can be used and Flux composition

(Electrodes with 5 digits)

Flux Composition Details

b. For SAW (Carbon Steel)

F6XX–EXXXX

F – Flux
6 – Tensile Strength (6*10= 60ksi)
1st X – either A (Arc weld) or P (Post Weld Heat Treatment)
2nd X – Low temperature; Impact Value (digit)
E – Electrode
1st X – Manganese content either M (Medium), L (Low), or H (High)
2nd and 3rd X – Carbon content (%)
4th X – Manufacturer’s Initial

(Low Alloy Steel)

F6XX–EXXX

F – Flux
6 – Tensile Strength (6*10= 60ksi)
1st X – either A (Arc weld) or P (Post Weld Heat Treatment)
2nd X – Low temperature; Impact Value (digit)
E – Electrode
1st and 2nd X – Corrosion characteristic and Molybdenum Content (letter and number)
3rd X – Supplementary designation

**Manganese is a chemical element with the symbol Mn and atomic number 25. It is not found
as a free element in nature; it is often found in minerals in combination with iron. Manganese is
a transition metal with a multifaceted array of industrial alloy uses, particularly in stainless
steels.
Molybdenum is a silvery-white metal that is ductile and highly resistant to corrosion. It has one
of the highest melting points of all pure elements — only the elements tantalum and tungsten
have higher melting points. Molybdenum is also a micronutrient essential for life.

c. For GMAW

ER – Electrode or filler rod

XX – Tensile Strength
S – Solid Wire
Y – Designates the chemical composition of the additives such as deoxidizing agent or cleansing
agent used on electrode.

Sample 1
ER70S-6
where,
ER – Designates a welding electrode or filler wire
70 – Designates the minimum tensile strength of the deposited weld metal shall be 70 ksi or
70,000 Psi
S – Stands for solid wire
6 – Reflects the amount of oxidizing agent and cleansing agent on the electrode. In particular
the number 6 means that more deoxidizers have been added to the wire, which is helpful when
welding on dirty or rusty steel.

Sample 2 (For Stainless Steel)

Stainless steel electrodes are designated in a slightly different way. Some of the commonly used
stainless steel electrodes are ER308L and ER309L etc. Meaning of these symbols is explained
below.

ER308L
where,
ER – Stands for electrode or filler wire
308 – Designates the grade of stainless steel of the electrode or filler wire
L – Designates that it is a low carbon electrode

Sample 3 (For Aluminum)

For Aluminum, electrodes are designated as ER4043, ER5350 etc. These electrodes are
designated in a different way.

ER4043
where,
ER – Stands for electrode or filler wire
4 – Designates series of Aluminum of which the electrode is made from. In this case it’s a 4000
series Aluminum
043 – Reflects the amount of silicone added to the electrode

d. For FCAW
V. Advantages of Welding
1. In welded connections, in general, fewer pieces are used. This will speed up the detailing and
fabrication process.
2. In welded connections, gusset and splice plates may be eliminated. Bolts or rivets are not
needed either. Thus, the total weight of a welded steel structure is somewhat less than that of
the corresponding bolted structure.
3. Connecting unusual members (such as pipes) is easier by welding than by bolting.
4. Welding provides truly rigid joint and continuous structures.

**One possible drawback of welding is the need for careful execution and supervision. For this
reason, welding is sometimes done in the shop and bolting in the field. In other words, shop-
welding is complemented by the bolting in the field.

VI. Common types of weld in welded steel structures

The two common types of weld in welded steel structures are groove welds and fillet welds.
Fillet welds are much more popular in structural steel design than groove welds.

1. Groove Welds
There are two different types of groove welds – partial-joint-penetration (PJP - single V) groove
weld and complete-joint-penetration (CJP - double V) groove weld. Groove welds can be used
when the pieces to be connected can be lined up in the same plane with small tolerances.

Partial-joint-penetration (PJP) Complete-joint-penetration (CJP)

2. Fillet Welds
Depending on the direction of the applied load and the line of the fillet weld, fillet welds are
classified as longitudinal or transverse fillet weld. In longitudinal fillet weld, the shear force to
be transferred is parallel to the weld line; in transverse fillet weld, the force to be transmitted is
perpendicular to the weld line.
VII. Forms of Welded Joints

a. Butt Joint
This type of joint is the most commonly used welding joint. It’s relatively easy to prepare and
there are many variations that can be applied to manipulate the desired result. Those variations
include the shape of the groove, the width of the gap, layer variation, and any other process.
Basically, both metal in this joint is configured to align on the same plane and the side of each
base metal will be joined by welding.

b. Tee Joint
Tee joint is a joint on which the base metal is perpendicularly configured to each other and
the welding is done as fillet weld on one side or both sides of the joint. Tee joint and any other
fillet joints are not usually prepared with groove unless the base metal is thick and welding on
both sides is not sufficient to withstand the load imposed on the joint.
c. Lap Joint
A modification of the butt joint, where the material that resides on the same plane is
configured to overlap each other and then fillet welded. However, there is also another welding
method that can be applied to lap joints such as slot weld, plug weld, and spot weld.

The application for this joint is mostly on sheet metal while it’s also rarely used on thicker
material such as plates and pipe (socket weld). The base metal is not usually grooved when fillet
welded. Though in another welding method such as slot and plug weld a special preparation is
required to give some kind of pathway for welding.

a. Simple single lap joint

b. Tapered lap
c. Scarf joint
d. Stepped lap
e. Strap joint

d. Corner Joint
Corner joint is very similar to the tee welding joint, the difference is the location of the metal.
For tee joint, it’s positioned rather far from the corner or simply said in the middle, but in
corner joint the corner of both metals meets in either closed or open manner. It kind of looks
like the corner of a box where the two perpendicular metal meet.
That being said, the application of this joint is mostly on a metal box construction or any
construction that resembles a box. The joint can only be fillet welded with any welding process
that can reach the connection.
e. Edge Joint
This one is similar to lap joint where parts of the base metal overlapping each other, but instead
of fillet welded this joint is butt welded on the thickness side where the end of the material
meets.
This welding joint is also similar to the flanged corner joint and flanged butt joint, where part of
the base metal is bent and welded on the end side. Because there’s a contact area of the two
metal, corrosion is a problem. So does defects like porosity, slag inclusion, and lack of fusion
just like in any other type of joint.
VIII. Section 510.2 Welds

510.2.1 Groove Welds

A groove weld is a weld on a work piece surface, between work piece edges, between work
piece surfaces, or between work piece edges and surfaces. The actual weld groove is a channel
in the surface of the work piece or an opening between two joint members providing space
to contain weld metal.

Types of Groove Joints

V-groove Flare Bevel Groove

J-groove Flare V-Groove
U-groove Square Groove
Scarf

Anatomy/Nomenclature of a Grove Weld

510.2.1.1 Effective Area of Groove Welds
The effective area of groove welds shall be considered as the length of the weld times the
effective throat thickness.

The effective throat thickness of a complete-joint-penetration (CJP)/double V groove weld shall

be the thickness of the thinner part joined.

The effective throat thickness of a partial-joint penetration (PJP) grove weld shall be shown in
the table below:

Welding Position
F (flat); H (horiz);
Welding Process Groove Type Effective Throat
V (vert); OH
(overhead)
Shielded Matal
All
Arc (SMAW)
Gas Metal Arc J or U Groove 60
(GMAW) degrees V
All Depth of Groove
Flux Cored Arc
(FCAW)
Submerged Arc J or U Groove 60
F
(SAW) degrees Bevel or V
Gas Metal Arc
(GMAW)
F, H 45 degrees Bevel Depth of Groove
Flux Cored Arc
(FCAW)
Shielded Metal Depth of Groove
All 45 degrees Bevel
Arc (SMAW) Minus 3 mm
Gas Metal Arc
(GMAW) Depth of Groove
V, OH 45 degrees Bevel
Flux Cored Arc Minus 3 mm
(FCAW)

**The effective throat size of a partial-joint-penetration groove weld is dependent on the

process used and the weld position. The contract documents should either indicate the
effective throat required or the weld strength required, and the fabricator should detail the
joint based on the weld process and position to be used to weld the joint.

The effective weld size for flare groove welds, when filled flush to the surface of a round bar, a
90 degrees-bend in a formed section, or a rectangular Hollow Structural Section (HSS) shall be
shown in “Effective Weld Sizes of Flare Groove Welds” table, unless other effective throats are
demonstrated by tests. The effective size of flare groove welds filled less than flush shall be
shown too in the table, less the greatest perpendicular dimension measured from a line flush to
the base metal surface to the weld surface.

Effective Weld Sizes of Flare Groove Welds

Welding Process Flare Bevel Groove* Flare V Groove

GMAW and FCAW-G 5/8 R 3/4 R
SMAW and FCAW-S 5/16 R 5/8 R
SAW 5/16 R 1/2 R
*For Flare Bevel Groove with R < 10mm use only reinforcing
fillet weld on filled flush joint. General Note: R = radius of joint
surface (can be assumed to be 2t for HSS), mm

Larger effective throat thickness than those in “Effective Weld Sizes of Flare Groove Welds”
table are permitted, provided the fabricator can establish by qualification the consistent
production of such larger effective throat thickness. Qualification shall consist of sectioning the
weld normal to its axis, at mid-length and terminal ends. Such sectioning shall be made on a
number of combinations of material sizes representative of the range to be used in the
fabrication.

510.2.1.2 Limitations of Groove Weld

The minimum effective throat thickness of a partial-joint-penetration groove weld shall not be
less than the size required to transmit calculated forces nor the size shown in the table for
“Minimum Effective Throat Thickness of PJP Groove Welds.” Minimum weld size is determined
by the thinner of two parts joined.
Minimum Effective Throat Thickness of Partial-Joint-Penetration Groove Welds
Material Thickness of Thinner Part Joined Minimum Effective Throat Thickness
To 6mm inclusive 3mm
Over 6mm to 13mm 5mm
Over 13mm to 19mm 6mm
Over 19mm to 38mm 8mm
Over 38mm to 57mm 10mm
Over 57mm to 150mm 13mm
Over 150mm 16mm
510.2.2 Fillet Welds
Fillet welds can be either equal-leg or unequal-leg. The intersection points of the original faces
of the steel elements being connected is called the root of the weld. The surface of the weld
should have a slight convexity. In computation of the strength of the weld, however, this
convexity is not taken into account and the theoretical flat surface is used. The normal distance
from the root to the theoretical face of the weld is called the throat of the weld.

Anatomy/Nomenclature of a Fillet Weld

Experiments performed on fillet welds indicate that they are weaker in shear than in tension
and compression. Also, equal-leg fillet welds fail in shear through the throat (at angles of about
45 degree with the legs of the welds).

Thus, shear stress is the controlling factor in the design of fillet welds; it is customarily
calculated by dividing the force P acting on the weld by the effective throat area of the weld.

510.2.2.1 Effective Area of Fillet Welds

The effective area of a fillet weld shall be the effective length multiplied by the effective throat.
The effective throat of a fillet weld shall be the shortest distance from the root to the face of
the diagrammatic weld. An increase in effective throat is permitted if consistent penetration
beyond the root of the diagrammatic weld is demonstrated by tests using the production
process and procedure variables.

Values of Theoretical Throat for Fillet Weld (SMAW)

a. For equal-leg fillet welds, the relation between the dimensions of the leg “w” and the throat
“t” is:
𝑇ℎ𝑟𝑜𝑎𝑡, 𝑡 = 0.707𝑤

b. For unequal leg fillet, the throat, t is:

𝑤ℎ
𝑇ℎ𝑟𝑜𝑎𝑡, 𝑡 =
√𝑤 ! + ℎ!
Values of Theoretical Throat for Fillet Weld (SAW)
When w (leg) < 10mm
𝑇ℎ𝑟𝑜𝑎𝑡, t = w

When w (leg) > 10mm

𝑇ℎ𝑟𝑜𝑎𝑡, 𝑡 = 0.707𝑤 + 3𝑚𝑚

510.2.2.2 Limitations of Fillet Welds

The minimum size of fillet welds shall not be less than the size required to transmit calculated
forces, nor the size as shown in the table below. These provisions do not apply to fillet weld
reinforcements of partial- or complete-joint-penetration groove welds.

Minimum Size of Fillet Welds

Material Thickness of Thinner Part Joined Minimum Size of Fillet Weld

To 6mm inclusive 3mm
Over 6mm to 13 mm 5mm
Over 13mm to 19mm 6mm
Over 19 mm 8mm

The maximum size of fillet welds of connected parts shall be:

a. Along edges of material less than 6mm thick, not greater than the thickness of the material.
thickness of plate < 6mm ∴ 𝑡"#$%& = 6𝑚𝑚
b. Along edges of material 6mm or more in thickness not greater than the thickness of the
material minus 2mm, unless the weld is especially designated on the drawings to be built out to
obtain full-throat thickness. In the as-welded condition the distance between the edge of the
base metal and the toe of the weld is permitted to be less than 2mm provided the weld size is
clearly verifiable.
thickness of plate > 6mm ∴ 𝑡"#$%& = 𝑡" ()*+,-) − 2𝑚𝑚

The minimum effective length of fillet welds:

The minimum effective length of fillet welds designed on the basis of strength shall not be less
than four times the nominal size (leg size), or less the size of the weld shall be considered not to
exceed ¼ of its effective length.
𝑙
𝑙 ≥ 4𝑤 𝑜𝑡ℎ𝑒𝑟𝑤𝑖𝑠𝑒 𝑤,// =
4

The maximum effective length of fillet welds:

a. For end-loaded fillet welds with a length up to 100 times the leg dimension, it is permitted to
take the effective length equal to the actual length.

𝑙 ≤ 100𝑤 ∴ 𝑙$%&. ,// = 𝑙

b. When the length of the end-loaded fillet weld exceeds 100 times the weld size, the effective
length shall be determined by multiplying the actual length by the reduction factor, 𝛽.

𝑙
𝛽 = 1.2 − 0.002 A B ≤ 1.0
𝑤
where,
l = actual length, mm
w = weld leg size, mm
𝑙 > 100𝑤 ∴ 𝑙$%&. ,// = 𝛽𝑙

c. When the length of the weld exceeds 300 times the leg size, the value of 𝛽 shall be taken as
0.60.
𝑙 > 300𝑤 ∴ 𝑙$%&. ,// = 0.60𝑙

510.2.3 Plug and Slot Welds

The principal use of plug or slot welds is to transmit shear in a lap joint when the size of the
connection limits the length available for fillet or other edge welds. Slot and plug welds are also
useful in preventing overlapping parts from buckling.
510.2.3.1 Effective Area of Plug and Slot Welds
The effective shearing area of plug and slot welds shall be considered as the nominal cross-
sectional area of the hole or slot in the plane of the faying surface.

510.2.3.2 Limitations of Plug and Slot Welds

a. Plug or slot welds are permitted to transmit shear in lap joints or to prevent buckling of
lapped parts and to join component parts of built-up members.

b. The diameter of the hole for a plug weld shall not be less than the thickness of the part
containing it plus 8mm, rounded to the next larger even mm, nor greater than the minimum
diameter plus 3mm or 2 ¼ times the thickness of the weld.
∅"12) > 𝑡"1%3, + 8𝑚𝑚
∅"12) > 𝑡"1%3, (𝑟𝑜𝑢𝑛𝑑𝑒𝑑 𝑡𝑜 𝑛𝑒𝑥𝑡 𝑙𝑎𝑟𝑔𝑒𝑟 𝑒𝑣𝑒𝑛 𝑚𝑚)
∅"12) < ∅$*-. + 3𝑚𝑚
1
∅"12) < 2 × 𝑡ℎ𝑟𝑜𝑎𝑡
4

c. The minimum center-to-center spacing of plug welds shall be four times the diameter of the
hole.
𝑠$*- ≥ 4𝐷

d. The length of the slot weld shall not exceed 10 times the thickness of the weld. The width of
the slot shall not be less than the thickness of the part containing it plus 8mm, nor shall it be
larger than 2 ¼ times the thickness of the weld. The ends of the slot shall be semicircular or
shall have the corners rounded to a radius not less than the thickness of the part containing it,
except those ends which extend to the edge of the part.
𝑙4153 ≤ 10 × 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑤𝑒𝑙𝑑
1
2 × 𝑡ℎ𝑖𝑐𝑘𝑛𝑒𝑠𝑠 𝑜𝑓 𝑤𝑒𝑙𝑑 ≥ 𝑤4153 ≥ 𝑡"1%3, + 8𝑚𝑚
4
𝑟,-6 5/ 4153 ≥ 𝑠𝑒𝑚𝑖𝑐𝑖𝑟𝑐𝑢𝑙𝑎𝑟 𝑜𝑟 𝑡"1%3,

e. The minimum spacing of lines of slot welds in a direction transverse to their length shall be 4
times the width of the slot. The minimum center-to-center spacing in a longitudinal direction on
any line shall be 2 times the length of the slot.
𝑠37%-4+,74, ≥ 4 × 𝑤𝑖𝑑𝑡ℎ 𝑜𝑓 𝑠𝑙𝑜𝑡
𝑠$*-. 8#3#8 ≥ 2 × 𝑙𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑠𝑙𝑜𝑡

f. The thickness of the plug or slots welds in material 16mm or less in thickness shall be equal to
the thickness of the material. In material over 16mm thick, the thickness of the weld shall be at
least ½ the thickness of the material but not less than 16mm.
For 16mm or less thickness of plate,
𝑡"12) 57 4153 = 𝑡"1%3,
For greater than 16mm thickness of plate,
1
𝑡"12) 57 4153 ≥ 𝑡"1%3,
2
𝑡"12) 57 4153 > 16𝑚𝑚

510.2.5 Combination of Welds

If two or more of the general types of welds (groove, fillet, plug and slot) are combined in a
single joint, the strength of each shall be separately computed with reference to the axis of the
group in order to determine the strength of the combination.

510.2.7 Mixed Weld Metal

When Charpy V-notch toughness is specified, the process consumables for all weld metal, tack
welds, root pass and subsequent passes deposited in a joint shall be compatible to ensure
notch-tough composite weld metal.

**The Charpy impact test, also known as the Charpy V-notch test, is a standardized high strain-
rate test which determines the amount of energy absorbed by a material during fracture.
Absorbed energy is a measure of the material’s notch toughness.
IX. Section 510.2.4 Strength

9
The design strength 𝜙𝑅- and the allowable strength :! , of welds shall be the lower value of the
base material and the weld metal strength determined according to the limit states of tensile
rupture, shear rupture or yielding as follows,

For the Base Metal:

𝑅- = 𝐹;< 𝐴;<

For the Weld Metal:

𝑅- = 𝐹= 𝐴=

where,
FBM = nominal strength of the base of metal per unit area, MPa
FW = nominal strength of the weld metal per unit area, MPa
ABM = cross-sectional area of the base metal, mm2
AW = effective area of the weld, mm2

The values of 𝜙, Ω, 𝐹;< , 𝐹= and limitation thereon are given in the table below:

Available Strength of Welded Joints, N

Load Type Required

Nominal Effective
and Direction Pertinent Filler Metal
𝜙 𝑎𝑛𝑑 Ω Strength (FBM Area (ABM or
Relative to Metal Strength
or FW), N AW), mm2
Weld Axis Levela,b
COMPLETE-JOINT-PENETRATION GROOVE WELDS
Matching
filler metal
shall be used.
For T and
corner joints
with backing
Tension left in place,
Normal to Strength of the Joint is controlled by the base metal notch tough
weld axis filler metal is
required.
(See Filler
Metal
Requirements
Section
510.2.6)
 Filler metal
with a
strength level
equal to or
Compression
one strength
Normal to Strength of the joint is controlled by the base metal
level less
weld axis
than
matching
filler metal is
permitted
Filler metal
with a
Tension or strength level
Tension or compression in parts joined parallel to a weld
Compression equal to or
need not to be considered in design of welds joining the
Parallel to less than
parts
weld axis matching
filler metal is
permitted
Matching
filler metal
Shear Strength of the joint is controlled by the base metal
shall be
used.c
PARTIAL-JOINT-PENETRATION GROOVE WELDS INCLUDING FLARE VEE GROOVE AND FLARE
BEVEL GROOVE WELDS
𝜙 = 0.90 See Section
Tension Base Fy
Ω = 1.67 510.4
Normal to
𝜙 = 0.80 See Section
weld axis Weld 0.60FEXX
Ω = 1.88 510.2.1a
Compression
Column to
Filler metal
base Plate
with a
and column Compressive stress need not to be considered in design of
strength level
splices welds joining parts
equal to or
designed per
less than
Section
matching
510.1.4(1)
filler metal is
Compression 𝜙 = 0.90 See Section
Base Fy permitted
Connections Ω = 1.67 510.4
of members
designed to
𝜙 = 0.80 See Section
bear other Weld 0.60FEXX
Ω = 1.88 510.2.1a
than columns
as described
 in Section
510.1.4(2)
Compression 𝜙 = 0.90 See Section
Base Fy
Connections Ω = 1.67 510.4
not finished- 𝜙 = 0.80 See Section
Weld 0.90FEXX
to-bear Ω = 1.88 510.2.1a
Tension or
Tension or compression in parts joined parallel to a weld
Compression
need not to be considered in design of welds joining the
Parallel to
parts.
weld axis
Base Governed by Section 510.4
Shear 𝜙 = 0.75 See Section
Weld 0.60FEXX
Ω = 2.00 510.2.2a
PLUG AND SLOT WELDS
Base Governed by Section 510.4
Shear 𝜙 = 0.75 See Section
Weld 0.60FEXX
Ω = 2.00 510.2.3a
a For matching weld metal see AWS D1.1, Section 3.3
b Filler metal with a strength level one strength level greater than matching is permitted
c Filler metals with a strength level less than matching may be used for groove welds
between the webs and flanges of built-up section transferring shear loads, or in applications
where high restraint is a concern. In these applications, the weld joint shall be detailed and
the weld shall be designed using the thickness of the material as the effective throat, 𝜙 =
0.80, Ω = 1.88 𝑎𝑛𝑑 0.60𝐹>?? as nominal strength
d Alternatively, the provisions of Section 510.2.4(1) are permitted provided the deformation
compatibility of the various weld elements is considered.
Alternatively, Sections 510.2.4(2) and 510.2.4(3) are special applications of Section 510.2.4(1)
that provide for deformation compatibility.

Alternatively, for fillet welds loaded in-plane the design strength 𝜙𝑅𝑛 and the allowable
strength, 𝑅- /Ω, of welds is permitted to be determined as follows:

𝜙 = 0.75 (𝐿𝑅𝐹𝐷)
Ω = 2.00 (𝐴𝑆𝐷)
Design of Welded Connections (Fillet Welds)
1. Fillet welds are most common and used in all structures.
2. Weld sizes are specified in 1/16 in. increments
Size of Weld
in mm
3/16 4.76
1/4 6.35
5/16 7.94
3/8 9.52
½ 12.7
5/8 15.9
3/4 19.2

3. A fillet can be loaded in any direction in shear, compression, or tension. However, it always
fails in shear.
4. The shear failure of the fillet weld occurs along a plane through the throat of the weld:

a. Process/Method: SMAW; Theoretical throat for Equal Legs

𝑇ℎ𝑟𝑜𝑎𝑡, 𝑡 = 0.707𝑤

b. Process/Method: SMAW; Theoretical throat for Unequal Legs

𝑤ℎ
𝑇ℎ𝑟𝑜𝑎𝑡, 𝑡 =
√𝑤 ! + ℎ!
c. Process/Method: SAW; When w < 10mm
𝑇ℎ𝑟𝑜𝑎𝑡, t = w
d. Process/Method: SAW; When w > 10mm
𝑇ℎ𝑟𝑜𝑎𝑡, 𝑡 = 0.707𝑤 + 3𝑚𝑚

5. Shear Stress in fillet weld of length, L, subjected to load P

𝑃
𝐹+ 𝑜𝑟 𝛿4@,%7 =
𝐴

wherein,
𝐹+ 𝑜𝑟 𝛿4@,%7 𝑓𝑜𝑟 𝐿𝑅𝐹𝐷 = 0.60𝐹A
𝐹+ 𝑜𝑟 𝛿4@,%7 𝑓𝑜𝑟 𝐴𝑆𝐷 = 0.30𝐹A
𝐹A = 𝑚𝑖𝑛𝑖𝑚𝑢𝑚 𝑡𝑒𝑛𝑠𝑖𝑙𝑒 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ 𝑜𝑓 𝑒𝑙𝑒𝑐𝑡𝑟𝑜𝑑𝑒𝑠
𝐴 = 𝑎𝑟𝑒𝑎 𝑓𝑖𝑙𝑙𝑒𝑡 𝑤𝑒𝑙𝑑 (𝑡ℎ𝑟𝑜𝑎𝑡 × 𝐿)
𝑃 = 𝑙𝑜𝑎𝑑 𝑜𝑟 𝑙𝑜𝑎𝑑 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦

6. Required Strength
a. For LRFD (keywords: Ultimate strength/ Design strength)
𝑅2 ≤ 𝜙𝑅-

wherein,
𝑅2 = 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝐿𝑅𝐹𝐷)
𝜙 = 0.75 (𝑓𝑜𝑟 𝑓𝑖𝑙𝑙𝑒𝑡 𝑤𝑒𝑙𝑑)
𝑅- = 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝐿𝑅𝐹𝐷) = 𝐹+ 𝐴
b. For ASD (keywords: Allowable strength)
𝑅-
𝑅% ≤
Ω

wherein,
𝑅% = 𝑟𝑒𝑞𝑢𝑖𝑟𝑒𝑑 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝐴𝑆𝐷)
Ω = 2.00 (𝑓𝑜𝑟 𝑓𝑖𝑙𝑙𝑒𝑡 𝑤𝑒𝑙𝑑)
𝑅- = 𝑛𝑜𝑚𝑖𝑛𝑎𝑙 𝑠𝑡𝑟𝑒𝑛𝑔𝑡ℎ (𝐴𝑆𝐷) = 𝐹+ 𝐴

7. Shear Strength for Base Metal (Section 507 Design of Members for Shear)
𝜙+ = 0.90 (𝐿𝑅𝐹𝐷)
Ω+ = 1.67 (𝐴𝑆𝐷)
𝐹+ 𝑜𝑟 𝛿4@,%7 𝑓𝑜𝑟 𝐿𝑅𝐹𝐷 = 0.60𝐹A
𝐹+ 𝑜𝑟 𝛿4@,%7 𝑓𝑜𝑟 𝐴𝑆𝐷 = 0.40𝐹A
8. Balanced Weld Group

In some cases, members subjected to direct axial stresses are themselves unsymmetrical and
cause eccentricities in welded connections. An example is an angle section welded to a gusset
plate below.

(Balancing the welds on a tension member connection)

To avoid any eccentricity, the following equations must be satisfied

𝑃 = 𝑃B + 𝑃! + 𝑃C

cd 𝑀8) = 0f 𝑃B 𝑦B + 𝑃C 𝑦C = 𝑃! 𝑦!

where P1, P2, and P3 are capacities of each weld.

**If all these welds are equal-leg fillet and have the same size, the following equations may be
used:
𝑃 = 0.707𝑤𝐿𝐹+

𝐿 = 𝐿B + 𝐿! + 𝐿C

𝐿B × 𝑦B + 𝐿C × 𝑦C = 𝐿! × 𝑦!
9. Eccentrically Loaded Welded Connection

Direct Load:
𝐹&
𝑃D& =
𝐿

𝐹A
𝑃DA =
𝐿

𝐿 = d 𝐿 = 𝐿B + 𝐿! + 𝐿C

Load due to moment:

𝑇 = 𝐹& 𝑒A + 𝐹A 𝑒&

𝑇𝑦
𝑃E& =
𝐽

𝑇𝑥
𝑃EA =
𝐽

𝐿!
𝐽 = d 𝐿 h + 𝑥F ! + 𝑦F ! i
12

Total Load per millimeter length of the weld:

𝑇𝑜𝑡𝑎𝑙 𝑙𝑜𝑎𝑑, 𝑃 = j(𝑃D& + 𝑃E& )! + (𝑃DA + 𝑃EA )!

10. Connections with Shear and Bending Stresses

A welded connection that must support both direct shear and bending,

Nominal Shear Stress

𝑃
𝑓+ =
𝐿353%1

Nominal Bending/Flexural Stress

𝑀𝑐 𝑀 𝑃𝑒
𝑓G = = =
𝐼 𝑆 𝑆

*Section Modulus, S is at Properties of Weld Group (treated as lines) table*

Resultant Stress (N/mm)

𝑅 = j𝑓+ ! + 𝑓G !

𝑅 = 𝐹+ 𝑡,

where,
te = effective weld size
te = 0.707w for equal-leg weld
Fv = allowable shearing stress of the weld metal
11. Properties of Weld Group (treated as lines)

Sample Calculation for S:

1(𝑑)C 𝑑C
𝐼8& = h i×2=
12 6
𝑑C
𝐼8& A 6 B
𝑆= =
𝑐 𝑑
(2)
𝑑!
𝑆=
3