Chapter 7
Welded Connections For
Tension Members
•Welding Processes
•Weld Types for Civil Engineering Structures
•Details of Fillet Welds
•Matching Weld Electrodes
•Failure Mode in Fillet welds
•Design Strength of Fillet Welds
•Design of Fillet Welds
•Connecting Elements in welded Connections of
Tension Members
Welding Definition and Process
• Structural Welding is the process whereby the parts to be
connected are heated and fused with supplementary molten
metal added to the joint.
• There are many different welding techniques used in the civil
engineering applications.
• The most commonly used welding techniques are :
(1) Shielded Metal Arc Welding (SMAW)
(2) Submerged Arc Welding (SAW)
Welding Processes
(1) Shielded Metal Arc Welding (SMAW):
• Commonly used for field welds.
• In SMAW process, the electrode (coated wire) tip is brought close to
the base metal until an arc is formed between them.
• As the electrode melts, the coating forms a gaseous shield to protect
the molten metal from the air (to prevent oxidation and to stabilize
the use of the arc energy)
Welding Processes
(2) Submerged Arc Welding (SAW):
• Commonly used for shop welds.
• In SAW process, the electrode tip and the arc are submerged in a
granular flux that melts to form a gaseous shield.
• The SAW process provides more penetration into the base metal and
higher strength than the SMAW process.
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Weld Types for Civil Engineering
Structures
1. Fillet Welds (about 80% of all
welds)
Those welds placed in a corner
formed by two parts in contact (the
parts to be welded) Longitudinal Welds
Transverse
Welds
Pu
Weld Types for Civil Engineering
Structures
2. Groove Welds (about 15% of all welds)
Those welds deposited in a gap (groove) between the two
parts be connected.
Weld Types for Civil Engineering
Structures
3. Slot & Plug Welds (about 5% of all welds)
Used when available length of fillet weld is not sufficient.
Details of Fillet Welds
•For SMAW: te = 0.707 Sw
Details of Fillet Welds
•For SAW: te is increased beyond its actual value to reflect the
higher quality weld.
For Sw 3/8”: te = Sw (i.e., 0.293Sw increase);
For Sw > 3/8”: te = 0.707Sw + 0.11”
where: 0.11” = 0.293*3/8” = the max. increase.
Matching Weld Electrodes
The tensile strength of the weld metal should
be ≥ the tensile strength of the base metal.
According to the American Welding Society
(AWS), the electrode grades used for SMAW
are E60, E70, E80, etc..., where “E” denotes
electrode and the numerals are the tensile
strength of the electrode metal in ksi.
The following table can be used for SMAW
matching weld electrodes:
AISC LRFD p.16.1-102
Failure Mode in Fillet welds
For longitudinal weld, the Failure mode is shear
fracture in the weld along the throat.
For transverse weld, the failure mode is
combined shear and tension fracture in the
weld, also along the throat.
Pu /2 Pu /2
Pu
Pu
Pu /2 Pu /2
Before weld fracture After weld fracture
Combined shear and tension
fracture plane
Tn Pu /2
Vn
Pu /2
Vn
Pu /2 Pu /2 Tn
Before weld fracture As weld fracture occurs
Design Strength of Fillet Welds
Tests showed that a transverse weld is 50%
stronger than a longitudinal weld of the same
length and size. Therefore, using the design
strength in the LRFD manual that accounts for
this fact (p. 16.1-100) we get:
Rn ≥Pu
Where Rn is the design strength of the weld
group, and;
For each weld in the weld group;
Rn = 0.75 (0.6 FEXX) (te) (1 + 0.5 sin1.5) (Lw)
Where:
FEXX = electrode tensile strength;
= angle between Pu and weld longitudinal axis
Lw = weld length
te = effective throat of fillet weld
therefore, for a long. weld in a tension member
connection, = 0
Rn = 0.75 (0.6 FEXX) (te) (Lw)
and for a transverse weld in a tension member
connection, = 90º;
Rn = 0.75 (0.6 FEXX) (te) (Lw)(1.5)
Design Strength of Fillet Welds (Cont’d)
Note: In computing the design strength of fillet welds in tension
member connections, we should observe the following limits:
i. For Longitudinal welds:
The design strength per inch due to weld fracture should not
exceed the design strength due to shear rupture in the
connected member or in the gusset plate [0.75 (0.6 Fu) (t)]
Design Strength of Fillet Welds (Cont’d)
ii. For Transverse welds:
The design strength per inch due to weld fracture should not
exceed the design strength due to tensile rupture in the
gusset plate [0.75 (Fu) ([Link].)]
Example 1
E60 electrodes are used for the ¼ in. fillet welds;
the member is a pair of L3x2x5/16; and, the 5/8-
in.-thick gusset plate is 5 in. wide. A36 steel is
used for the member and gusset plate. Find the
design strength of the fillet welds for L1= 4.50 in.,
L2= 1.50 in., and L3= 3.00 in. Use SMAW process.
Gusset plate: 5x5/8
L2 Member: pair of L3x2x5/16
Pu
5 in.
3 in.
L3
Pu y = 1.02 in.
L1 Fillet welds: L1 = 4.50 in.
0.25 in. welds L2 = 1.50 in.
E60 electrodes L3 = 3.00 in.
Solution
For a longitudinal weld
1- Weld fracture:
Rn/in= 0.75 (0.6 FEXX) (0.707Sw)
Rn/in=0.75(0.6)(60)(0.707)(0.25)=4.77 k/in
2- Shear rupture of the member alongside a
weld:
Rn/in= 0.75 (0.6 Fu) (t)
Rn/in=0.75(0.6)(58)(0.3125)=8.16 k/in
3- Shear rupture of the gusset alongside two
welds:
Rn/in= 0.75 (0.6 Fu) (t)
Rn/in=0.75(0.6)(58)(0.625)=16.3 k/in
Since 16.3 > [2(4.77)=9.54], weld fracture governs
For a transversal weld
1- Weld fracture:
Rn/in= (4.77 k/in) (1.5) = 7.16 k/in
2- Tension rupture of the gusset alongside
two welds
Rn/in = 0.75 (Fu) (t)
Rn/in = 0.75(58)(0.625) = 27.2 k/in
Since 27.2 > [2(7.16)=14.3], weld fracture governs
For For the fillet weld group, the design
strength is:
[(Rn/in.) Lw] = 2[(4.77)(4.50+1.50) +
(7.16)(3.0)] = 100.2 kips
Design of Fillet Welds
• Choosing the weld electrodes:
Use the matching weld electrodes table
presented earlier for that purpose.
• Choosing the weld size:
It is preferable to use a single pass weld,
since it is cheaper than multi-pass weld.
However, the maximum fillet weld size that
can be deposited in one pass is 5/16 inches.
Keeping this in mind, the weld size should be
chosen between the minimum and the maximum
values allowed, which are defined as follows
(LRFD p. 16.1-96):
A. The minimum fillet weld size is
specified in the LRFDM Table J2.4,
p.16.1-96, as a function of the thinner
part being connected, in order to
ensure that enough heat is available to
minimize residual stresses.
B. The maximum weld size along the edges
of a connected part should not exceed
the part thickness, when that thickness
is less than 1/4 in When the part’s
thickness is ≥ 1/4 in, the max. weld
size is the connected part’s thickness
minus 1/16.
• Choosing the weld length:
The lengths of different weld segments should
be computed such that the design strength of
the weld group is ≥ Pu . However, the following
limits should be observed:
Lw ≥ 4 Sw for all fillet welds.
Lw 100Sw for longitudinal fillet welds.
If If Lw > 100Sw : use Lw-eff = Lw*b
where: b = 1.2-0.002 (Lw/w) < 1
Lw= actual length of end-loaded weld (in)
w = weld leg size (in)
Note:
End returns are not
required, but they
increase the connection
ductility. Ler should be ≥
2Sw; however its strength
could be neglected in
computing the weld-group
design strength, unless
Ler is ≥ 4 Sw. If end
returns are not used,
then Lw should stop at a
distance of at least Sw
from the connection end.
AISC LRFD p.16.1-96
Example 2
• Use SMAW process, and E70 electrodes.
• Use A36 steel for the tension member and G. Pl.
• Find the weld size and weld length L2 required to form a safe
connection for the hatched tension member shown below.
Example 2 (Cont’d)
Solution:
(1) Weld Size:
• For tmin = 5/16” of the angle section,
minimum Sw=3/16” (LRFD Table J2.4, pp.16.1-96), )
• For tmin = 5/16” of the angle section,
maximum Sw=5/16 – 1/16 = ¼” (LRFD pp.16.1-96), )
• Let’s use Sw = ¼ in.
(2) Strength of Longitudinal weld:
• Weld fracture:
Rn/in. = 0.75 (0.6 FEXX)(0.707Sw)
= 0.75 (0.6) (70)(0.707)(0.25) = 5.57*2 = 11.14 kips/in
Example 2 (Cont’d)
• Shear rupture of the member:
Rn/in. = 0.75 (0.6 Fu) tmember
= 0.75 (0.6)(58)(0.3125*2) = 16.32 kips/in
• Shear rupture of the gusset plate:
Rn/in. = 0.75 (0.6 Fu) [Link].
= 0.75 (0.6)(58)(0.375) = 9.79 kips/in
11.14 kips/in (2 weld sides)
R n / in min. of 16.32 kips/in (2 angles) 9.79 kips/in
9.79 kips/in ([Link])
Example 2 (Cont’d)
(3) Strength of transverse weld:
• Weld fracture:
Rn/in. = (11.14 kips/in)(1.5) = 16.7 kips/in
• Tension rupture of the gusset plate:
Rn/in. = 0.75 Fu [Link].
= 0.75 (58)(0.375) = 16.3 kips/in
16.7 kips/in (2 weld sides)
R n / in min. of 16.3 kips/in
16.3 kips/in ([Link])
Example 2 (Cont’d)
The design strength of the weld group:
(16.3)(2.5) + (9.79)(2L2) = (40.75 + 19.58 L2) kips
• The strength design requirement is:
40.75 + 19.58 L2 ≥ [Pu = 84.9] L2 ≥ 2.25 in.
• However, For fracture on Ae of the member,
Lc ≥ 2.19 in. is required for Pn ≥ 84.9 kips.
• And for BSR of the gusset,
Lv ≥ 3.00 in. is required for Pn ≥ 84.9 kips.
• Therefore, the BSR strength of the G. Pl. requires that Lv ≥ 3 in.
use L2 = L3 = Lv = 3 in.
Example 3 => Example 1 (Cont’d)
In the figure below, E60 electrodes are used to connect a pair of
L3x2x5/16; and the 5/8”-thick gusset plate. The gusset plate is 5”
wide and A36 steel is used for the member and gusset plate.
Knowing that the weld size is 1/4”, find the design strength of the
Gusset plate.
Example 3 (Cont’d)
(1) Based on Yielding on Ag:
• Ag = 5 (5/8) = 3.125 in2
• Rn = 0.9 Fy Ag = 0.9 (36)(3.125) = 101.25 kips
(2) Based on Tensile Rupture on Ae:
• Ae = 0.85Ag
• Rn = 0.75 Fu (0.85Ag)
= 0.75 (58)(0.85 * 3.125) = 115.55 kips
Example 3 (Cont’d)
(3) Based on BSR:
• LT = 3.5 + (5-3.5)/2 = 4.25 in
• LV = 4.5 + 0.25 = 4.75 in
Example 3 (Cont’d)
(3) Based on BSR:
• FuAt = (58)(4.25)(0.625) = 154.06 kips
• 0.6FuAv = 0.6(58)(4.75)(0.625) = 103.3 kips
• Since FuAt > 0.6FuAv
Thus, tension fracture governs the design
• Rn = 0.75 [Fu At + 0.6Fy Av ]
= 0.75 [154.06 + 0.6(36)(4.75)(0.625)]
= 163.64 kips
• The governing design strength of the [Link]. is 101.25
kips.
Example 4
Replace the weld arrangement in the previous
example with the one shown in Figure (e), and
find the weld lengths length L2 and L3.
Solution
From Example 2 above:
P1 = (16.3)(2.5) = 40.75 kips
P2 = 9.79L2 & P3 = 9.79L3
Use the equilibrium equation M = 0 @ P3 to
get:
P2 (2.5) + P1 (1.25) – Pu (1.69) = 0
9.79 L2 (2.5) + 40.75 (1.25) – 84.9 (1.69) = 0
L2 = 3.78 in
Then use the equilibrium equation P1 + P2 + P3 =
Pu to get:
40.75 + 9.79(3.78) + 9.79 L3 = 84.9
L3 = 0.73 in.
But since min. weld length should be ≥ 4 Sw =
4(0.25) = 1.0” :
Therefore, use L2 = 3.75” and L3 = 1.0”
Design of Connecting Elements in Welded
Connections of Tension Members
• If the tension member is connected to a gusset plate, then the
design strength of the gusset plate is the lowest of the following
failure modes:
1) Yielding on Ag: Rn = 0.9 Fy Ag
2) Fracture on An: Rn = 0.75 Fu (0.85Ag)
3) Block Shear Rupture (see figure in the next slide):
Rn = 0.75 (Fu At + 0.6Fy Av) when Fu At ≥ 0.6Fu Av
Rn = 0.75 (0.6Fu Av + Fy At) when 0.6Fu Av > Fu At
Design of Connecting Elements in Welded
Connections of Tension Members (Cont’d)
Finally, the strength design requirement is: Rn ≥ Pu
Example 5
Find the design strength of the A36 steel
Gusset Plate shown in figure.
Solution
1. Based on yielding of Ag
Ag = 5 (5/8) = 3.125 in2
Rn = 0.9 Fy Ag = 0.9(36)(3.125) = 101.25 kips
2. Based on fracture of Ae
Ae = 0.85 Ag
Rn = 0.75 Fu (0.85Ag)=0.75 (58)(0.85 * 3.125)
= 115.55 kips
3. Based on BSR (see Figure below)
FuAt = (58)(4.25)(0.625) = 154.06 kips
0.6FuAv = 0.6(58)(4.75)(0.625) = 103.3 kips
Rn = 0.75 [Fu At + 0.6Fy Av ]
= 0.75 [154.06 +
0.6(36)(4.75)(0.625)]
= 163.64 kips
Therefore, the governing design strength of
the [Link]. is 101.25 kips.