06/01/2022

Technical Conference on Welding Design, Inspection,

Testing and Quality Control
17 December 2021

Introduction to Structural Welding Design:

NSCP Code Provisions and Design Examples

RODOLFO P. MENDOZA JR, D.Eng., M. ASCE, M. ASEP

Associate Professional Lecturer
Department of Civil Engineering
De La Salle University
Manila

Lecture Outline

 Introduction to structural welding

 Design provisions
 Examples
 Summation

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Learning Outcomes

 Discuss the purpose of welding and explain different welding terminologies

 Demonstrate an understanding on welding code provisions
 Apply the code provisions to actual design

Why do we weld?

 Connect structural steel

 Welding can be performed both in the
shop or in the field
 Welding provides higher flexibility of
connecting steel than bolting

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Definition: Welding

 Welding is the process of fusing

multiple pieces of metal together by
heating the filler metal to a liquid
state
 A properly welded joint is stronger
than the base metal

Key Welding Terminologies

 Tack Weld (Top picture)

 A temporary weld used to hold parts in place
while more extensive, final welds are made
 Continuous Weld
 A weld which extends continuously from one
end of a joint to the other
 Stitch Weld (bottom picture)
 A series of welds of a specified length that are
spaced a specified distance from each other

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Key Welding Terminologies

Butt
Lap Corner

Edge
Tee

 Shown above are types of structural joints which are established

by positions of the connected material relative to one another
 Lap, tee, and butt joints are most common
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Key Welding Terminologies

Fillet Full penetration Partial penetration

single bevel single bevel
groove weld groove weld

Full penetration Partial penetration

Plug double vee single J groove
groove weld weld
Weld types define the configuration of the weld and its underlying design approach
Fillet welds and groove welds are most common
Groove welds fall into two categories
Full penetration – the entire member cross-section is welded
Partial penetration – just part of the member cross-section is
welded 8
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Fillet Welds

Symbolic Profiles

Actual Profiles
Weld types define the configuration of the weld and its underlying design approach
The most commonly used weld is the fillet weld
Fillet welds are theoretically triangular in cross-section
Fillet welds join two surfaces at approximately right angles to each
other in lap, tee, and corner joints

Groove Welds

define the configuration of the weld and its underlying design approach
• Groove welds are specified when a fillet weld is not appropriate for
the job
• The configuration of the pieces may not permit fillet welding
• A strength greater than that provided by a fillet weld is required
• Groove welds are made in the space or groove between the two
pieces being welded 10
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Full Penetration Groove Welds

• The bevel or “J” preparation extends over

most of or the entire face of the material
being joined
• Complete fusion takes place

• In some types of full penetration groove

welds the material will be beveled from one
side of the plate with a separate plate on
the opposite side – called backing or a
backing bar

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Partial Penetration Groove Welds

• Partial joint penetration welds are used

when it is not necessary for the strength
of the joint to develop the full cross
section of the members being joined.

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Welding Positions

• There are four recognized welding positions:

• Flat – The face of the weld is approximately horizontal and welding is
performed from above the joint
• Horizontal – The axis of the weld is horizontal
• Vertical – The axis is approximately vertical or in the upright position
• Overhead – Welding is performed from below the joint
• The flat position is preferred because it is easier and more efficient to
weld in this position. 13

Welding Symbols
Horizontal Weld Line
Tail

Field Weld Symbol Note

(Indicating this is
a typical weld)
Leader Line

Length and Spacing of weld

Size of weld (mm)
(mm) Basic Weld Symbol
(Fillet weld symbol shown)

 Weld symbols are used to

communicate the specific details and
requirements of each weld to the
welder
 Weld symbols are included on
fabrication and erection drawings
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Welding Size

• The size of a weld must match the size

specified on the drawings
• Some welds may meet the required size after a
single pass of the welder
• Larger weld sizes may require multiple passes
to meet the size requirement
• Common single pass welds include fillet welds
up to and including 5/16 inch and thin plate
butt welds with no preparation
• Common multiple pass welds include single
bevel full penetration groove welds, single
bevel partial penetration groove welds, and
fillet welds over 5/16 inch
• The weld in the above picture is a multiple
pass fillet weld
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Weld Accessibility
• Access holes are required for some
welds, such as the welded flange
connection shown to the right
• The top access hole allows for a
continuous backing bar to be placed
under the top flange
• The bottom access hole allows for
complete access to weld the entire
width of the bottom flange
• A detail of a weld access hole for a
welded flange connection is shown
below

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How to know if the metal is weldable?

Welding in Existing Structures

Welding to existing structures during retrofit projects requires careful
consideration of numerous factors:

 Determine weldability – Identify the steel grade to establish a welding procedure

 Select and design the weld – Fillet welds are preferred and avoid over welding
 Surface preparation – Remove contaminants such as paint, oil, and grease
 Loads during retrofit – An engineer should determine the extent to which a member will be
permitted to carry loads while heating, welding, or cutting
 Fire hazards – Follow all governing fire codes, regulations, and safety rules to avoid fires

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How to know if the metal is weldable?

NSCP Requirements Sec. A5.2.3

“Where welding is anticipated for repair or modification of existing

structures, the chemical composition of the steel shall be determined
for use in preparing a welding procedure specification (WPS). Where
available, results from certified material test reports or certified
reports of tests made by the fabricator or a testing laboratory in
accordance with ASTM procedures shall be permitted for this purpose.
Otherwise, analyses shall be conducted in accordance with ASTM A751
from the samples used to determine tensile properties, or from
samples taken from the same locations.”

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Chemical Analysis of Metal

(1)Determine chemical composition (ASTM A751); and

(2)Prepare welding procedure specification per AWS D1.1

RULE:

STEELS WITH CARBON EQUIVALENT LESS THAN 0.45 ARE

GENERALLY WELDABLE
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Calculation of Carbon Equivalent

Sample Quantification of Carbon Content General Equation:
(Note: Values represent the percentage of the respective
elements in the steel.)
Principal Elements SAMPLE 1 SAMPLE 2
(Mn  Si ) (Cr  Mo V) (Ni  Cu )
Carbon 0.18 0.19 CE  C   
Manganese 0.57 0.60 6 5 15
Silicon 0.12 0.17
Chromium 0.04 0.04
Molybdenum 0.01 0.03 Sample 1
Vanadium 0.00 0.00
(0.57  0.12) (0.04  0.01 0) (0.07  0.10)
Nickel 0.07 0.07 CE  0.18  
Copper 0.10 0.16 6 5 15
CE  0.32
(0.60 0.17) (0.04  0.03 0) (0.07  0.16)
Sample 2 CE  0.19   
6 5 15
CE  0.35

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Calculation of Carbon Equivalent

Weldability of Historic Steels
– A7 and A9 (1901-1963) need to be evaluated on case-by-case
basis
– ASTM A7 and A9 Specification covered min. strength but no limits
on carbon content

– Common weldability concerns:

• Too much carbon: high hardenability, low ductility

• Too much phosphorus: increased brittleness, weld cracking
• Too much sulfur: porous welds

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Welding to Existing Metals

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Code Provisions

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Weld Strength per Weld Types

Complete and Partial Penetration Groove Welds
Weld design provisions are provided in NSCP Section 510.2. Provisions for groove
welds are given in Section 510.2.1.
Complete Joint Penetration
NSCP Table 510.2.1

Partial Joint Penetration

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SMAW Welding Process

• Shielded Metal Arc Welding (SMAW) is
also known as manual, stick, or hand
welding
• An electric arc is produced between the
end of a coated metal electrode and the
steel components to be welded
• The electrode is a filler metal covered
with a coating
• The electrode’s coating has two SMAW is the oldest Welding Process
purposes:
It forms a gas shield to prevent
impurities in the atmosphere from getting
into the weld
It contains a flux that purifies the molten
metal 25

GMAW Welding Process

• Gas Metal Arc Welding (GMAW) is also
known as MIG welding
• It is fast and economical
• A continuous wire is fed into the welding
gun
• The wire melts and combines with the
base metal to form the weld
• The molten metal is protected from the
atmosphere by a gas shield which is fed
through a conduit to the tip of the welding
gun
• This process may be automated

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FMAW Welding Process

• Flux Cored Arc Welding (FCAW) is similar
to the GMAW process
• The difference is that the filler wire has a
center core which contains flux
• With this process it is possible to weld
with or without a shielding gas
• This makes it useful for exposed
conditions where a shielding gas may be
affected by the wind

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SAW Welding Process

• Submerged Arc Welding (SAW) is usually
performed by automatic or semiautomatic
methods
• Uses a continuously fed filler metal
electrode
• The weld pool is protected from the
surrounding atmosphere by a blanket of
granular flux fed at the welding gun
• Results in a deeper weld penetration than
the other process
• Only flat or horizontal positions may be
used

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Weld Strength per Weld Types

Complete and Partial Penetration Groove Welds
Weld Strength (NSCP Sec. 510.2.4)

For Base Metal

Rn  FBM ABM
For Weld Metal
Rn  Fw Aw
FnBM = nominal stress of the base metal, (MPa)
Fnw = nominal stress of the weld metal, (MPa)
ABM = cross-sectional area of the base metal, (mm2)
Awe = effective area of the weld, (mm2)

LRFD Strength ASD Strength

 Rn   FBM ABM Rn /   FBM ABM / 

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Weld Strength per Weld Types

Complete and Partial Penetration Groove Welds
Weld Strength (NSCP Sec. 510.2.4)

For Base Metal

Rn  FBM ABM
For Weld Metal
Rn  Fw Aw
FnBM = nominal stress of the base metal, (MPa)
Fnw = nominal stress of the weld metal, (MPa)
ABM = cross-sectional area of the base metal, (mm2)
Awe = effective area of the weld, (mm2)

LRFD Strength ASD Strength

 Rn   FBM ABM Rn /   FBM ABM / 

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Weld Strength per Weld Types

Values of Resistance and Safety Factors (NSCP Table 510.2.5)

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Weld Strength per Weld Types

Values of Resistance and Safety Factors (NSCP Table 510.2.5)

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Weld Strength per Weld Types

Fillet Welds
Weld design provisions are provided in NSCP Section 510.2.2

te  0.707 w
Weld Strength (NSCP Sec. 510.2.4)

For Weld Metal

Rn  Fw Aw
  0.75 ( LRFD)   2.0 ( ASD )
Fw  0.6 FEXX Aw  0.707 wl
The force acting on a fillet weld is always a shear force 33

Weld Strength per Weld Types

Fillet Welds
Weld design provisions are provided in NSCP Section 510.2.2

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Weld Strength per Weld Types

Fillet Welds
Weld design provisions are provided in NSCP Section 510.2.2
NSCP Table 510.2.4

Section 510.2.2.2 maximum weld thickness

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Weld Strength per Weld Types

Fillet Welds
Weld design provisions are provided in NSCP Section 510.2.2.2

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Weld Strength per Weld Types

Nominal Stress of Weld Metal

Fnw  0.60 FEXX

Photo courtesy of Petro Jikken

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Weld Strength per Weld Types

Nominal Stress of Weld Metal

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Welded Connection Example

Example Problem 1
Determine the size of the fillet weld of the lap splice shown to develop the full strength
of the connection using A-36 steel and LRFD.

250
E-60 E-70
250

T T 250

T
T
Thickness = 12 mm
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Welded Connection Example

Solution
The tensile capacity of the plate using LRFD (with ø=0.90) is

T   Fy Ag  0.9(248)(12  250) 103  669.6 kN

The required weld area is (with ø=0.75 and Fexx = 483 MPa for E70 welds)
T 669.6  103
Req'd Aw    3080.74 mm 2
 * 0.6 Fexx 0.75*0.6* 483
For filler welds,
Aw  te L  2  (0.707 w)(250)(2)  3080.74 mm 2
Therefore, the required leg size is

3080.74
Req'd w   8.70 mm
0.7071* 250 * 2
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Welded Connection Example

NSCP Table 510.2.4

Section 510.2.2.2 maximum weld thickness

Referring to NSCP Table 510.2.4, Min w = 5mm
and Sec. 510.2.2.2 Max w = 12-2 = 10mm

Therefore, use w = 10mm

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Welded Connection Example

Effect of load application

Fnw  0.60 FEXX (1.0  0.5sin1.5  )

Welds are stronger when loaded at some angle.

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Welded Connection Example

Design Considerations
• Fillet welds are more economical
• Use smallest weld size if possible
• Use intermittent weld
• Avoid overhead welding

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Welded Connection Example

Cost per Number of Passes

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Fillet Weld Consideration

For fillet weld, the strength can be express in terms of 1 mm thickness of

weld per 1 mm length

 Rn  (0.75)0.6 FEXX 0.707 wl

 Rn  (0.75)(0.6)(480)0.707(1)(1)  152 N / mm / mm (0.15kN/mm/mm)

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Welded Connection Example

Example Problem 2
Design the direct-welded beam-to-column connection given the column and girder
properties below. The beam is A992 steel and the plate is A36. Mu = 678 kN-m, Vu =
266.9 kN
12 mm

37.5 mm

75 mm
W24x76
W14x109 75 mm

75 mm
37.5 mm

50 mm
37.5 mm
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Welded Connection Example

Example Problem 2
Solution:
a. Obtain beam and column properties.
W24x76

d = 607 mm
bf = 228 mm
tf = 17.3
tw = 11.2
Zx = 3280x103 mm4

Welded Connection Example

Example Problem 2
Solution:
b. Check beam capacity
W24x76

Assuming the beam is braced laterally and could develop full MP

𝜙𝑀 = 𝜙𝐹 𝑍 = 0.9 345 3280𝑥10 = 1018𝑥10 𝑁 − 𝑚𝑚

Beam capacity is higher than the demand. Okay.

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Welded Connection Example

Example Problem 2
Solution:
c. Design the flange to column weld connection
If this is part of SMF system, the connection must be design by capacity-based principles either
by amplifying the load with overstrength factor omega or by introduction of parameter Ry in
the beam capacity for computing the plastic moment. Latter option is better.

Value of Ry depends on steel grade and are provided in NSCP Table 519-1. For A992, Ry = 1.1

𝑀 = 𝑅𝑦𝐹 𝑍 = 1.1 1018 𝑘𝑁 − 𝑚 = 1120 𝑘𝑁 − 𝑚

𝑅 = 𝑀 /(𝐷 − 𝑡𝑓)

Welded Connection Example

Example Problem 2
Solution:
c. Since the weld will be CJP and the steel material and electrode used match the
values given in NSCP User note, therefore the connection will develop the full strength
of the beam flanges without tension rupture and no further calculations is required.
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Requirements after Design

NSCP Sec. 520.3

Welding shall be performed in accordance with Appendix B6. Welding shall be

performed in accordance with a welding procedure specification (WPS) as
required in AWS D1.1 and approved by the engineer of record. The WPS
variables shall be within the parameters established by the filler metal
manufacturer.

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Important References in Weld Design

Blodgett Series
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Steel Tips

Member (Wide Flange Selection)

• Sections provided are mostly the most economical sections

in the market.
• Can be used for preliminary sizing

Summation

• Welding is one way of connecting steel elements

• Welds can be grooves or fillet
• Code provisions provide checking for base metal
strength and weld metal strength
• Welding procedure and inspection is required

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Thank you for Listening

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