WELDED CONNECTIONS

1
 Welding
Welding is the method of connecting two
metal parts by establishing a metallurgical
bond between them by heating or pressure
or both. The parts to be connected are
brought to a liquid state either through an
electric arc or the oxy-acetylene gas flame
along with welding electrode which adds
metal to the joint.
After cooling, the liquid state becomes a
solid state and hence metal parts are joined
together.
 Advantages of Welded Connections
over bolted connections
• Welded connections is airtight and
watertight. Hence, welded connections is
employed in the construction of water/oil
storage tanks, ships, etc.
• Welded connections are more rigid.
• Due to the fusion of two metal pieces
jointed, a continuous structure is obtained,
which gives a good aesthetic appearance
than bolted joints.
 Advantages of Welded Connections
over bolted connections
•Welded connections eliminate the need for
making holes, except for a few holes
required for erection purposes. Since the
holes at the ends govern the design of
bolted connections (end and edge distance),
a welded connection results in a member
with a smaller gross section.
•Due to elimination of operations such as
drilling and punching, welding results in less
fabrication costs.
 Advantages of Welded Connections
over bolted connections

• Welded joints are economical, This is

because the splice plates and bolt material
are eliminated. Also, the required size of
gusset plates is also smaller.

•Labour cost is also less as only one person

is required to do the welding whereas at
least two persons are required for bolting
and four for welding.
 Advantages of Welded Connections
over bolted connections
• Total overall savings by employing welding
over bolting may be up to 15%.
• Welding offers more freedom to the
designer in choosing sections. The designer
is not bound by the available rolled sections,
but may build up any cross section, which
may be economical and advantageous.
• Alterations can be made with less expense
in case of welding as compared to bolting.
 Advantages of Welded Connections over
bolted connections
• It is easy to correct mistakes in fabrication
during erection, whereas mismatch of holes
in a bolted connection is very difficult to
correct.
• Noise produced in welding process is
relatively less.
•Due to the elimination of holes, stress
concentration effect is considerably less in
welded connections.
 Advantages of Welded Connections over
bolted connections

•Process of welding requires less safety

precautions for public in the vicinity.
• With welding, it has become possible to
connect tubular sections, which are
structurally very economical
• Due to the simple design details, time is also
saved in detailing, fabrication and field
erection.
 Advantages of Welded Connections over
bolted connections
•The efficiency of a welded joint is more than a
bolted joint. In fact 100% efficiency can be
obtained using welding.
• Process of welding is quicker in comparison
to bolting.
• Due to the fact that the strength of a welded
joint is the same as that of the parent metals,
even a smallest piece of the metal which
otherwise is a scrap can be used, bringing
overall economy.
Disadvantages of Welded Connections over
bolted connections
• High skilled person is required for welding
• The inspection of welded joints is difficult
and expensive. Moreover, non-destructive
testing is required in important structures.
• costly equipment is necessary to make
welded connections.
• Members jointed by welding may distort,
due to the heat during welding process.
Disadvantages of Welded Connections over
bolted connections

• Welded connections are prone to cracking

under fatigue loading.
• Proper welding may not be done in field
conditions, especially in vertical and
overhead positions.
• The possibility of brittle fracture is more in
the case of welded joints than in bolted
connections.
Disadvantages of Welded Connections over
bolted connections
• The welding performed in the field is
expensive than performed in the shop.
• welding at the site may not be feasible due
to lack of power supply.
 Welding Electrodes
Welding electrodes are classified on the basis
of mechanical properties of weld metal,
Welding position, type of coating, and type of
Current required.

Classification of electrodes shall be indicated

by the coding system of letters and numerals
to indicate the specified properties or
characteristics of the electrodes. IS 814:1991
has classified the coated electrodes using
letters and Four digits coding (i.e., ERXXXX)
13
 Coding
It consists of the following letters and numerals and
shall be followed in the order stated:

a) A prefix letter ‘E' shall indicate a covered electrode

for manual metal arc welding, manufactured by
extrusion process;

b) A letter indicates the type of covering;

c) first digit indicates ultimate tensile strength in

combination with the yield stress of the weld metal
deposited;
14
d) Second digit indicates percentage elongation in
combination with the impact values of the weld
metal deposited;

e) Third digit indicates welding position(s) in which

the electrodes may be used and;

f) Fourth digit indicates the current conditions in

which the electrode is to be used .

15
 Example

E R 4 2 1 1
COVERED ELECTRODE

TYPE OF COVERING - (RUTILE)

STRENGTH CHARACTERISTICS – (UTS =

410-510 Mpa AND YS = 330 Mpa min.)

ELONATION AND IMPACT PROPERTIES – (ELONGATION =

22 % min. AND IMPACT = 47J min. AT 0°C)

WELDING POSITION – (ALL POSITIONS)

WELDING CURRENT AND VOLTAGE

CONDITIONS – (D± AND A50)

16
 Type of covering

Type of covering shall be indicated by the following letters

A Acid

B Basic

C Cellulosic

R Rutile

RR Rutile, heavy coated

SB Semibasic

17
Designation of Strength Characteristics

Designating Digit Ultimate Tensile Yield Strength (Mpa)

Strength (Mpa)

4 410-540 330

5 510-610 400

18
 Welding positions
The welding position or positions in which the electrode can be
used as recommended by the manufacturer shall be indicated by
the appropriate designating digits as follows:

1. All positions;

2. All positions except vertical down;

3. Flat butt weld, flat fillet weld and horizontal vertical fillet weld;

4. Flat butt weld and flat fillet weld;

5. Vertical down, flat butt. Flat fillet and horizontal and vertical-
fillet weld; and

6. Any other position or combination of positions not clarified

19
above.
Percentage Elongation and Impact Strength

20
Welding Current and Voltage Conditions

21
 Size and length of electrode
The size of an electrode shall be designated by the
nominal diameter of the core wire expressed in
millimetres.
Size (mm) Length (mm)

1.6 150 or 200 or 250

2.0 200 or 250 or 300 or 350

2.5 250 or 300 or 350

3.15 350 or 450

4.0 350 or 450

5.0 350 or 450

6.3 350 or 450

8.0 350 or 450

22
 Welding processes

1. Electric arc welding

2. Gas welding
3. Thermit welding
4. Forged welding
5. Resistance welding
 Electric arc welding
Arc welding is used in most of the structural welding
operations. Here, electric energy which is used as the
heat source is produced by electric arc. The base metal
and welding rod (or electrode) are heated to fusion
temperature by the electric arc. The welding rod is
connected to one terminal of the current source and the
object to be welded is connected to the other terminal.
The temperature in the region of welding ranges from
3300º C to 5500º C.
Different processes of Electric arc welding
There are many welding processes; few common
processes typically used in the structural steel
fabrications are explained.
•Shielded Metal Arc Welding (SMAW)
•Submerged Arc Welding (SAW)
•Gas-shielded Metal Arc Welding (GMAW)
•Flux Cored Arc Welding (FCAW)
•MIG Welding
•TIG welding
•Electrogas welding (EGW)
•Electro slag Welding (ESW)
•Stud Welding (SW), etc.
 Shielded Metal Arc Welding (SMAW)
Shielded Metal Arc Welding (SMAW) is also called “stick
welding”.
Arc welding equipments and accessories
This is the most popular method of arc welding.
Heating is done by means of electric arc between a
coated electrode and the material being joined. If
uncoated or bare wire electrodes are used, the
molten metal gets exposed to atmosphere and
combines chemically with oxygen and nitrogen and
forms defective welds.

The coating on the electrode forms a gaseous

shield that helps to exclude oxygen and protects
the molten metal from oxidation.
The flux of the electrode coating, being lighter
than molten metal, hardens at the surface of
the weld. This can be removed by gentle
tapping or by brushing.

SMAW is a manual process that is typically used

when welding in the field. The main advantage of
SMAW is that high quality welds can be made rapidly
at a low cost.
 Submerged Arc Welding (SAW)
A semi automatic or an automatic welding process
that usually limited to welding in fabrication shop. In
this process, the arc is submerged under granular
flux and thus hidden from the view and no eye
protection devices are required. This flux material
acts to improve weld quality and to protect it from
the air.
 Gas-shielded Metal Arc Welding (GMAW)

The electrode is fed constantly through a spool, and

the protection is provided constantly by some gas
mixture.
Initially, inert gases were used such as Argon, hence
called “MIG” process. Carbon Dioxide (CO2) is a
popular gas with this process.
Recently, mixture of Argon, Helium and CO2 are
used for better weld characteristics.
 Flux Cored Arc Welding (FCAW)

• It utilizes the heat of an arc between a

continuously fed consumable flux cored electrode
and the work.
• The heat of the arc melts the surface of the base
metal and the end of the electrode.
• The metal melted off the electrode is transferred
across the arc to the work piece, where it
becomes the deposited weld metal.
• Shielding is obtained from the disintegration of
ingredients contained within the flux cored
electrode.
Weld base metal
(steel)

1mm

Inner flux
Metal-Arc Inert Gas (MIG) Welding

MIG Welding refers

to the wire that is
used to start the arc.

It is shielded by inert
gas and the feeding
wire also acts as the
filler rod.
 Tungsten-Arc Inert Gas (TIG) Welding
The arc is started with a tungsten electrode shielded by
inert gas and filler rod is fed into the weld puddle
separately.

The gas shielding that is required to protect the molten

metal from contamination is supplied through the torch.
Gas Welding

It is also called as oxy-acetylene

welding. Here the mixture of
gases namely acetylene and
oxygen is burned at the tip of a
torch, which produces a very hot
flame. This heats the metal
pieces for cutting and welding
process. Though gas welding is
simple and inexpensive, it is
slow and hence it is generally
used for repair and maintenance
work only.
 Thermit welding
In this method, a mixture of iron oxide and
aluminum called thermit is ignited and the iron oxide
is reduced to molten metal which is deposited by a
mould placed around the joint.
 Forged welding
In forged welding the parts to be joined are heated
to plastic stage and then joined by applying high
external pressure.
 Resistant welding
Metal parts are joined by means of heat and
pressure which causes fusion of parts.

Heat is generated by electrical resistance to a

current of high amperage & low voltage passing
through small area of contact between parts to be
connected.
 Types of weld

• Fillet weld
• Butt or groove weld
• Plug weld
• Slot weld

Of these welds, fillet weld is used to a large

extent (about 80%). Groove welds are used to
a lesser extent (15%). However, slot and plug
welds are rarely used (less than 5%).
 Fillet weld
Fillet weld is a weld of approximately triangular
cross-section joining two surfaces approximately at
right angles to each other in lap-joint or tee joint.
Fillet welds are widely used due to their economy,
ease of fabrication and adoptability at site.

Fillet weld
Since they do not require any edge preparation,
they are cheaper than groove welds.

Fillet welds are usually assumed to fail in shear,

where the shear failure occurs along a plane
through the throat of the weld.

Failure Plane

43
A fillet weld is termed as concave fillet weld or
convex fillet weld or mitre fillet weld depending on
the weld face is concave or convex or
approximately flat.

Convex Concave
Surface Surface

Leg Leg

Leg Throat Leg

Throat Unequal leg fillet weld
 Nomenclature of welds
Size of the weld (s) : The size of fillet weld is
specified as the minimum leg length of the weld. s
≥ 3mm.
Throat : The weakest section in the fillet weld
cross-section is known as the throat whose length
is the perpendicular distance from the right angle
corner to the hypotenuse of the largest isosceles
right-angled triangle that can be inscribed within
the weld cross-section.

Effective Throat thickness = K × size of weld = K × s

where K is a constant and s is a size of the weld in
mm 45
The effective throat thickness of a fillet weld shall
not be less than 3 mm and shall generally not
exceed 0.7t and 1.0t under special circumstances
where t is thickness of thinner part.
Effective length of the fillet weld : It is taken equal
to actual length minus twice the weld size but not
less than four times the size of the weld.
End return : Fillet welds terminating at the ends or
sides of parts should be returned continuously
around the corners for a distance of not less than
twice the size of the weld.

End return are made to relieve the weld length

from high stress concentrations at their ends.
Effective area: The effective area of a fillet weld is
taken as the product of effective length and
effective throat thickness.
A few examples of application of fillet weld are
shown in Figure.

48
Types of fillet weld

Diagonal fillet weld

End fillet weld

Side fillet weld

49
Side fillet weld: A fillet weld, the axis of which is
parallel to the direction of applied load. It is
also termed as longitudinal fillet weld.

End fillet weld: A fillet weld, the axis of which is

at right angles to the direction of applied load. It
is also termed as transverse fillet weld.

Diagonal weld: A fillet weld, the axis of which is

inclined to the direction of applied load

50
 Types of joints

BUTT JOINT
LAP JOINT

CORNER JOINT

T JOINT

EDGE JOINT 51
 BUTT JOINTS

The butt joint is typically used for connecting two

butted plates together as is generally required to
provide a plate longer than the commonly
available from the rolling mill or to spice a plate of
different thickness or width. These joints are
formed by either by a full or a partial penetration
groove weld.
52
 LAP JOINTS
A lap joint is extensively used as it is simplest
type of welded connection to fabricate. It is made
when two members with flat surfaces overlap
each other. No special plate preparation is
necessary and fit-up errors can be easily
accommodated.
The connection is normally made with fillet welds
along the edges of the connected parts. The joints
can be used to splice tension members, connect
various members to gusset plates or other
members and in any situation where force
transferred through the connection is not required
to change direction. 53
 TEE JOINTS
Tee joint is used to connect plates at right angles
forming a tee. It is commonly used to connect
flange plates to the web of built up beam section.
Typically fillet weld, balanced on both sides of the
web plate, is used for ease of application and
economy. In case heavy, thick plate cross
sections, it might be necessary to use partial
penetration, or full penetration groove welds.

54
 CORNER JOINTS
Corner joints are a special type of joint. This
connection is provided at the edge of two plates
by a butt or a fillet weld. If fillet weld is used, it is
necessary to extend one plate out beyond the
corner in order to provide a shelf for the weld.
They are commonly used in fabricating box
sections.

EDGE JOINTS
In this type of joint, the edges of the two plates
are connected together. The connection is made
with partial penetration weld; the edges with
prepared grooves help weld to penetrate deeper.
55
Find the size and length of the side fillet
weld for the lap joint to transmit a factored
load of 120 kN as shown in Fig. Assume
site welds, Fe 410 grade steel and E41
electrode. The cross-sections of two plates
to be connected are 75 × 8 mm and 125 × 8
mm.

75 mm 125 mm

56
Minimum size of weld for 8 mm thick section =
3 mm (Table 21, Cl. 10.5.2.3)

Maximum size of weld = 8 – 1.5 = 6.5 mm

(Cl. 10.5.8.1)

Choose the size of weld, s = 6 mm

Effective throat thickness = te = 0.70s = 4.2

mm
57
Strength of 6 mm weld / mm length = 4.2 x
410 / (√3 x 1.5) = 662.7 N/mm (Cl. 10.5.7.1.1)

Assuming only two longitudinal welds

along the sides

Required length of weld = 120 x 103 /662.7

= 181 mm

Length to be provided on each side = 181/2

= 90.5 mm> 75 mm (width of plate) (Cl.
10.5.1.2)
58
Hence, provide 90.5 mm weld on each side
with an end return of 2x 6 = 12 mm

Overall length of the weld provided = 2 x

(90.5 + 2 x 6) = 205 mm

59
A tie member 100 mm × 8 mm is to transmit
a pull equal to the full strength of small
plate. Design fillet welds. The steel used is
of grade Fe410. Assume gusset plate to be
12 mm.
Minimum size of weld for 12 mm thick gusset
plate = 5 mm (Table 21, Cl. 10.5.2.3)

Maximum size of weld for 8 mm thick section

= 8 – 1.5 = 6.5 mm
(Cl. 10.5.8.1)

Choose the size of weld, s = 5 mm

Effective throat thickness = te = 0.70 ×5 = 3.5

mm
Full design strength of smaller plate,

Tdg = Agfy/γm0

Tdg = 8 × 100 × (250/1.1) × 10-3 = 181.82 kN

Design Strength of 5 mm weld / mm length
= 3.5 x 410 / (√3 x 1.25) = 662.8 N/mm (Cl.
10.5.7.1.1)
 Assuming only two longitudinal welds along the
sides
Required length of weld = 181.82 x 103 /662.8
= 274.32 mm

Length to be provided on each side = 274.32 /2 =

137.16 mm ≈ 140 mm > 100 mm (Cl. 10.5.1.2)

Hence, provide 140 mm weld on each side with an

end return of 2 x 5 = 10 mm

Overlap required = 140 mm

Total length of the weld provided = 2 x (140 + 2 x 5) =

300 mm
 Over lap Gusset Plate
140 mm

10 mm

100
mm

Tie member

64
Assuming fillet weld on three sides (i.e.
along length and width of tie member)

Total weld length required as found above =

274.32 mm

The weld length accommodated on the

transverse side = 100 mm

274.32 = 2 × overlap + 100

Overlap = 87.16 mm ≈ 90 mm > 40 mm
(Clause 10.5.1.2)
 Assuming fillet weld on three sides

Gusset Plate
Over lap
90 mm In the case of lap joints,
10 mm
the minimum lap should
not be less than four
times the thickness of
the thinner part joined or
40 mm, whichever is
100 more (Clause 10.5.1.2).
mm
In our case, minimum
lap = 4×8 = 32 mm and
40 mm

Tie member Hence, minimum lap in

our case is 40 mm.
66
Total length of the weld provided = 2 x (90 +
10) +100 = 300 mm

Assuming fillet weld on four sides

Total weld length required as found above =
274.32 mm

274.32 = 2 × overlap + 2 ×100

Overlap = 37.16 mm ≈ 40 mm (Clause 10.5.1.2)

Total length of the weld provided = 2 x (40 +

100) = 280 mm
 Assuming fillet weld on four sides
Gusset Plate
Overlap
40 mm

100
mm

Tie member

68
Two plates are connected to form a fillet
joint using 6mm weld. Welding is provided
on three sides with a lap of 300mm as
shown in Fig. Find the strength of the
joint. If welding is provided on all four
sides (Fig.), determine the strength of the
joint. Also find the percentage increase in
the strength. Use Fe 410 steel with yield
stress 250 MPa. Assume shop welding.

69
 300 × 12 mm 300 mm
200 × 12 mm

200 mm

Lap joint connection with weld on three sides

70
Case (i) : Welding on three sides

Lw = 300 + 200 + 300 = 800 mm

Design strength of fillet weld joint,

P1 = 0.7s Lw fwd / γmw (Cl. 10.5.7.1.1)

= 0.7 x 6 x 800 x (410 /√3) / 1.25

= 6,36,286 N

Hence, allowable load = 6,36,286 / 1.5

= 4,24,191 N
71
 300 × 12 mm 300 mm
200 × 12 mm

200 mm

Lap joint connection with weld on four sides

72
Case (ii) : Welding on four sides
Lw = 300 + 200 + 300 + 200 = 1000 mm

Design strength of fillet weld joint,

P2 = 0.7s Lw fwd / γmw (Cl. 10.5.7.1.1)
= 0.7 x 6 x 1000 x (410 /√3) / 1.25
= 7,95,358 N

Hence, allowable load = 7,95,358 / 1.5

= 5,30,239 N

Percentage increase in strength

= (P2 – P1) / P1 x 100 = 25 % 73
A tie member of a roof truss consists of an
ISA 100 × 75 mm × 8 mm. The angle is
connected to a 10 mm thick gusset plate
and the member is subjected to a working
pull of 300 kN. Design the welded
connection. Assume connections are made
in the workshop.
Working load = 300 kN
Factored load = 300 × 1.5 = 450 kN
Minimum size of weld for 10 mm thick
gusset plate = 3 mm (Table 21, Cl. 10.5.2.3)
At the rounded toe of the angle section,
size of weld should not exceed = (3/4) × t
= (3/4) × 8
= 6 mm
Hence provide size of weld = 6 mm.
Effective throat thickness = te = 0.70 × 6 =
4.2 mm
 Gusset Plate

ISA 100 × 75 × 8 mm
176 mm
P2
100 mm 69 mm
450 kN
31 mm
P1
391 mm

Cxx = 31 mm taken from SP6

Fillet weld along length 76
 Gusset Plate

ISA 100 × 75 × 8 mm
157 mm
P2
31 mm 100 mm 69 mm
450 kN
31 mm 31 mm
P1
348 mm

Fillet weld symmetrical about c.g. of angle

to avoid eccentricity of loading. 77
 Gusset Plate

ISA 100 × 75 × 8 mm
126 mm
P2
P3 100 mm 69 mm
450 kN
31 mm
P1
341 mm

Fillet weld along length and width of angle 78

Design Strength of 6 mm weld / mm length
= 4.2 x 410 / (√3 x 1.25) = 795.4 N/mm (Cl.
10.5.7.1.1)
Let P1 and P2 be the resisting forces
exerted by the weld at the heel and toe of
an angle section, respectively. They are
assumed to act along the edges of the
angle.
Taking moment of forces about P2,
P1 × 100 = 450 × (100 - 31)
P1 = 310.5 kN
P2 = 450 – 310.5 = 139.5 kN
Effective length L1 of the weld required =
(310.5 ×1000)/795.4 = 390.4 ≈ 391 mm
Provide 6 mm weld 391 mm long at the heel
of the angle

Effective length L2 of the weld required =

(139.5 ×1000)/795.4 = 175.4 ≈ 176 mm

Provide 6 mm weld 176 mm long at the toe

of the angle
If transverse weld added at the end of the
angle, it should be applied symmetrically
about the C.G. of the section to avoid
eccentricity of loading.

Length of transverse weld = 2 × 31 = 62 mm

Therefore, force resisted by 62 mm length of 6

mm weld

= 0.7 × 6 × 62 × 410 / (√3 x 1.25 x 1000)

= 49. 31kN
Balance load = 450 – 49.31 = 400.69 kN

P1 × 100 = 400.69 × (100 - 31)

P1 = 276.48 kN
P2 = 400.69 – 276.48 = 124.21 kN
Effective Length L1 = 276.48 × 1000/795.4
= 347.6 mm (say 348 mm)
Effective Length L2 = 124.21 × 1000/795.4
= 156.2 mm (say 157 mm)
Fillet weld along length and width of angle
Force resisted by weld P3 = 795.4× 100× 10-3
= 79.54 kN
Taking moment of forces about P1

P2 ×100 + P3 ×100/2 = 450 × 31

P2 = (450×31 – 79.54 × 100/2)/100 = 99.73kN

P1 = 450 – 99.73 – 79.54 = 270.73 kN

Length of weld L1 = (270.73 × 103)/795.4

= 340.37 mm say 341 mm

83
Length of weld L2 = (99.73 × 103)/795.4

= 125.38 mm say 126 mm

Length of weld L3 = (79.54 × 103)/795.4

= 100 mm

Total length of weld required =

341 + 126 + 100 = 567 mm

84
 A tie member of a roof truss consists of an
2ISA 100 × 75 mm × 8 mm. The angles are
connected to either side of a 10 mm thick
gusset plate and the member is subjected
to a working pull of 300 kN. Design the
welded connection. Assume connections
are made in the workshop.
Working load = 300 kN
Factored load = 300 × 1.5 = 450 kN
Each angle carries a factored pull of 450/2 = 225 kN
85
Design Strength of 6 mm weld / mm length
= 4.2 x 410 / (√3 x 1.25) = 795.4 N/mm (Cl.
10.5.7.1.1)
Let P1 and P2 be the resisting forces
exerted by the weld at the heel and toe of
an angle section, respectively. They are
assumed to act along the edges of the
angle.
Taking moment of forces about P2,
P1 × 100 = 225 × (100 - 31)
P1 = 155.25 kN 86
P2 = 225 – 155.25 = 69.75 kN
Effective length L1 of the weld required =
(155.25 ×1000)/795.4 = 195.2 ≈ 196 mm
Provide 6 mm weld 196 mm long at the heel
of the angle

Effective length L2 of the weld required =

(69.75 ×1000)/795.4 = 87.7 ≈ 88 mm

Provide 6 mm weld 88 mm long at the toe

of the angle 87
 Gusset Plate

2ISA 100 × 75 × 8 mm
88 mm
P2
69 mm
450 kN
Cxx=31 mm
P1
196 mm

88
The 10 mm thick bracket shown in Fig. is
connected with the flange of the column
ISHB 300 @ 577 N/m. Determine the size of
the weld required to transmit a factored load
of 250 kN. Assume shop welding.

89
 y
250 kN
e
180mm 120mm
A B
θ
q2 200mm
400mm
x θ q q
c.g. 1 x
42.63 mm
10 mm
D C thick plate

ISHB 300
90
y
 2W

ISHB 300
10 mm
thick plate
91
Let ‘t’ be the throat thickness of the weld required.

Total area of the weld (Ignoring end return) = 180t + 400t

+180t = 760t

x = Distance of c.g. of weld from vertical weld

= 2 × 180 t × 90/760t = 42.63 mm

y = 400 / 2 = 200mm
1
I xx = × t × 400 + 180t × 200 × 2
3 2

12
= 19733333t mm 4
92
 1 2
I yy = 400t × 42.63 + 2  × t × 180 + 180t × (90 − 42.63) 
2 3

12 
= 2506737t mm4

J zz = I xx + I yy = 22240070t mm 4

Distance of extreme point of the weld from c.g.

rmax = 200 + (180 − 42.63) = 242.63 mm

2 2

93
 200
tan θ = = 1.4559
180 − 42.63
θ = 55.517 o

Eccentricity, e = 120 + 180 - 42.63 = 257.37 mm

250 × 103
328.95
Direct shear stress, q1 = = N / mm 2
760t t

94
 P × e × rmax
Shear due to torsion at B, q 2 =
J zz

250 × 10 × 257.37 × 242.63

3
q2 =
22240070t
701.950
= N / mm 2

q= (q2
1 + q + 2q1q2 cosθ
2
2 )
95
   328.95  2  701.95  2 328 .95 701 .95 
q =   +  + 2× × cos 55.517 
 t   t  t t 
 

928.656
q= N/mm 2

t
Strength of weld = 410 / (√3 x 1.25) s = t/0.7

= 189.37 N/mm2 t
Equating maximum shear to it,
s
we get 928.656/t =189.37, t = 4.904 mm
Size of normal fillet, s = 4.904/0.7 = 7.005 mm
Therefore, provide 8 mm fillet weld. 96
 Welding Symbols
The information concerning type, size, position,
welding process etc. of the welds in welded joints
is conveyed by standard symbols in drawings.

The symbolic representation includes elementary

symbols along with a) supplementary symbol, b) a
means of showing dimensions, or c) some
complementary indications.

IS: 813 - 1986 “Scheme of Symbols for Welding”

gives all the details of weld representation in
drawings. 97
Symbols comprises of the following:

a) an arrow line (1) for each joint

b) a dual reference line, consisting of two parallel

lines, one continuous and one dashed (2); and

c) a certain number of dimensions and

conventional signs.

A knowledge of welding symbols is essential for

a site engineer to be able to read the drawings.
Symbols save lot of space as descriptive notes
can be omitted.
 Method of Representation

1 2a
3

Joint

2b

1 = arrow line
2a = reference line (Continuous line)
2b = identification line (dashed line)
3 = welding symbol
99
Elementary symbols represent the various
categories of the weld and look similar to the shape
of the weld to be made. Combination of elementary
symbols may also be used, when required.

The symbol shall be placed either above or beneath

the reference line, in accordance with the following:

a)The symbol is placed on the continuous line side of

the reference line if the weld (weld face) is on the
arrow side of the joint

b) The symbol is placed on the dashed line side if the

weld (weld face) is on the other side of the joint
100
To be welded on To be welded on
the arrow side the other side

For symmetrical
welds only
The main dimensions relative to the cross section
are written on the left-hand side (that means before)
of the symbol. Longitudinal dimensions’ are written
on the right-hand side (that means after) of the
symbol.

s l s l

t5 300
s7 300
Indication of Field or Site weld

23

Indication of weld process

Elementary welding symbols
Examples on use of Elementary symbols
Examples of combinations of Elementary
and supplementary symbols
Indication of Peripheral weld
 Intermittent fillet weld
t n × l (e)
l l l t
e e

l l l
e e

Unless otherwise specified, the intermittent fillet

welding shall have an effective length of not less than
four times the weld size, with a minimum of 40 mm
(Clause 10.5.5.1).
 Staggered intermittent fillet weld

t n × l (e)
l l l t n × l (e)
e e

l e l

The clear spacing between the effective lengths of intermittent

fillet weld shall not exceed 12 and 16 times the thickness of
thinner plate joined, for compression and tension joint
respectively, and in no case be more than 200 mm (Clause
10.5.5.2).
113
 Fillet weld on arrow side. Weld’s leg size is 10 mm.
s10 200 Weld length is 200 mm.

Intermittent fillet weld on arrow side. Weld’s leg size is

s12 3×125 (75) 12 mm. Weld length is 125mm. Number of weld
elements is 3. Distance between adjacent weld
elements is 75 mm.
s6 200
Field fillet welds on both sides. Weld’s leg size is 6
200
s6 mm 6 mm. Weld length is 200 mm.

s12
3×125 (75) Staggered intermittent Fillet welds on both sides. .
3×125 (75)
Weld’s leg size is 12 mm. Weld length is 125mm.
s12 Number of weld elements is 3. distance between
adjacent weld elements is 75 mm.

Weld all around joint

23 Tail used to reference certain specification or weld

process (project welding)
114
ISMB 350 @52.4 kg/m transmits a service reaction
of 130 kN to the flange of the column ISHB250 @
54.7 kg/m using end plate. Design the framed
connection when the normal field fillet welds are
applied directly on both sides of the beam web.
All the rolled beam and column section are in
Fe410 grade steel.

115
 w

ISMB 350

ISHB 250
 5 mm weld
8 mm weld

ISHB 250
210 mm ISMB 350 350 mm

50mm

Thickness of plate 12 mm
8.1 mm
250 mm

140 mm

50mm
250 mm
For a field welded connection, partial safety factor, γmw
=1.5 and for Fe410 grade steel, fy = 250 MPa

For ISMB 350, bf = 140 mm, tw = 8.1 mm

Factored Vertical Reaction, V = 1.5 × 130 = 195kN

Try with two plates of 50 x 12 mm

Moment = V × L

where L = distance between the welds

Moment = 195 × 50 = 9750 kN-mm

Minimum size of weld for 12 mm thick plate = 5 mm
(Table 21, Cl. 10.5.2.3)

Maximum size of the weld = 12-1.5 = 10.5 mm

Adopt 8 mm fillet weld

Design Strength of 8 mm weld / mm length = 0.7x 8 x
410 / (√3 x 1.5) = 883.73 N/mm (Cl. 10.5.7.1.1)
6M
Required depth of the weld on each side =
2tf wd

6 × 9750 × 10
3
Required depth of the weld = = 181.93mm
2 × 883.73
About 10 % extra depth is to be provided to take care of
shear also. However, it should not be more than 2/3 the
depth of the beam in order to allow rotation at the end of
the beam.

Provide depth of the weld = 210 mm

Vertical shear/mm = 195 × 103/(2 × 210)

= 464.29 N/mm
6M
Horizontal shear due to bending =
2th 2
6 × 9750 × 103
Horizontal shear due to bending/mm =
2 × 210 2

= 663.27 N / mm120
Resultant stress/mm = ((464.29)2
+ (663.27 )
2
)
= 809.6 N / mm〈883.73N / mm

Hence, provide two plates of 50 × 12 mm

Let us find out size of weld connecting plate with
column ISHB
Design strength of weld =
0.7x s x (410 / (√3 x 1.5)) x 2 x 210 = 195 x 103
s = 4.20 mm
Provide 5 mm weld
Determine the load, V that can be applied
on the bracket shown in Fig. Use 6 mm field
fillet welding.

Bracket connection showing load out of plane

Shear stress due to direct force, q = V/ (2 x 200 x 1) =
0.0025 V N/mm2

Moment on weld, M = 200 V N-mm

Considering unit thickness of weld at root,

Moment of inertia I = 2 (1x 2003) / 12 = 1.33 x 106 mm4

Normal stress due to bending in tension, fa = M y / I

Here, M = 200 V N-mm, y = 100 mm, I = 1.33 x 106

mm4

Hence, fa = 0.015 V
Equivalent stress, fe is computed as (cl. 10.5.10.1.1)

fe = ( fa2 + 3q2 )0.5 = 0.0152 V

For 6 mm fillet weld (field weld)

Strength of weld/mm , fwd =0.7 x 6 (410 / √3) / 1.50 =

662.8 N/mm

Equating the equivalent stress, fe with the strength of

6 mm weld, fwd

fe = fwd
0.0152 V = 662.8

Hence, V = 43605 N = 43.605 kN

For the current bracket a load of 43.605 kN can be

safely applied.
 Butt or Groove Welds
In this type of weld, grooves are generally made in
the base metal before welding and hence are called
as groove weld. Groove welds is used to weld
members aligned in the same plane. The weld should
have the same strength of the base material (or even
greater).

126
 TYPES OF BUTT OR GROOVE WELDS

(c) Double V
(a) Square (b) Single V

(d)Single Bevel (e)Double Bevel (f) Single U

(g) Double U (h) Single J (i)Double J

Two plates of size 200 x 10 mm and 200 x 8 mm
are connected by a weld groove having

(i) Single – V groove weld joint, and

(ii) Double – V groove weld joint.

Determine the maximum tension which the joints

can resist. The steel plates are of grade Fe 410
grade with yield strength of 250 MPa. Assume
shop welding.
Case (i) : Single – V groove weld
In this case, incomplete penetration results due to
single – V groove

Single V is an incomplete penetration welding.

Hence the throat thickness is 5/8th of the thickness of

thinner plate (IS 816-1969).

te = 5/8 t = (5/8) x 8 = 5 mm

Effective length of weld Lw = width of plate = 200 mm.

Strength of weld, P = L x te x fy / γmw

= 200 x 5 x 250/1.25 = 200,000 N = 200 kN
Case (ii) : Double – V groove weld

In this case, complete penetration results due to

Double – V groove.

Effective throat thickness is 8mm which is the

thickness of the thinner plate.

te = 8 mm

Strength of weld, P = L x te x fy / γmw

= 200x 8 x 250/1.25 = 320,000 N = 320 kN
Slot Weld

They can be
used in addition
to fillet welds
when more areas
of weld are
required.

132
Plug Weld

133
Slot and Plug Weld in combination
with fillet welds

134
A tie member consists of two ISMC 250. The
Channels are connected on either side of a 10
mm thick gusset plate. Design the welded joint
to develop the full strength of the tie, if the
overlap is limited to 400 mm.

For ISMC 250, tf = 14.1 mm, tw = 7.1 mm, A = 3867

mm2

Tensile strength of each channel = Ag fy/γmo

= (3867×250× 10-3)/1.1

= 878.864kN
135
Minimum size of weld = 3 mm

Maximum size of weld = 7.1 – 1.5 = 5.6 mm

Provide s = 4 mm weld

Effective Throat thickness, te = 0.7 × 4 = 2.8 mm

Design Strength of 4 mm weld / mm length =

2.8 x 410 / (√3 x 1.25) = 530.24 N/mm (Cl.
10.5.7.1.1)
136
Total length of fillet weld required to connect the
channel section
= 878.864 × 10-3 / 530.24 = 1657.48 mm (say
1658 mm)
The overlap is limited to 400 mm
The maximum length of the weld that can be
provided in the channel = 2 × 400 + 250 = 1050
mm.

137
Width of the slot should not be less than (i)
three times the thickness of the plate = 3 × 7.1 =
21.3 mm and (ii) 25mm (IS 816-1969)
Provide two slots of 30 mm
Let x be the length of the slot,
Total length of the weld required = 2 × 400 +
(250-2×30) + 4x = 1658
x = 167 mm (say 170 mm)
Provide two 30 mm wide slots of 170 mm
length.
138
 Gusset Plate

ISMC250

60 mm
30 mm
70 mm x 250 mm
30 mm
60 mm

Slots

139
Total length of the weld provided = 400 +
400 + 170 × 4 + 60 × 2+ 30 × 2+ 70 = 1730
mm > 1658 mm

140
Design the welded connection to connect
two plates of width 200 mm and thickness
10 mm for 100 % efficiency.

Strength of plates = Ag fy/γm0

= 200 × 10 × 250/1.1

= 454545N

Minimum size of the weld = 3mm

Maximum size = 10-1.5 = 8.5 mm 141

Use s = 8 mm weld
Design strength of fillet welds =
0.7x 400 x 8 x (410 / (√3 x 1.25)) =424191 N
Slot welds are to be provided to resist a force of =
454545 -424191 = 30354N
Strength of the slot weld =
410 / (√3 x 1.25) =189.37MPa
Area of the slot weld required = 30354/189.37
= 160.3 mm2
Provide two slots of size 10 mm x 10 mm = 200 mm2
142
10 mm thick plate Slots

8 mm weld
10
10

10 200
10
8 mm weld

10 mm
10 mm

143
144