Design of

Fillet Welds
Design strength of fillet weld
The design strength of fillet weld is calculated on its throat area.
f u Lw te
Pd w =
3 γmw

Lw = length of weld in mm
fu = ultimate stress of weld in MPa
te = effective throat thickness = 0.7S
γmw = partial safety factor
= 1.25 for shop welding and
= 1.5 for site welding
S = size of weld in mm
Example:
A tie member of a roof truss consists of ISA 100×75×8 of Fe410
grade, is welded to a 10 mm gusset plate. Design the welded
connection to transmit a tensile load, T. Assume connection are made
in the workshop.

Lw1
10 mm

100 T

Lw2

10 mm gusset plate ISA 100 × 75 × 8

Solution : Minimum weld size = 3 mm [Table 21, IS 800]
3
Maximum weld size =  8  6mm [clause 10.5.8.2, IS 800]
4
Therefore, Let us adopt 5 mm thick fillet weld.
Throat thickness, t e  0.7  5  3.5 m m

For ISA 100×75×8, Gross area, Ag = 1336mm2 , Cz = 31mm

f y Ag 250 × 1336
Full strength of the angle 10
3

γm0 1.1
303.64 kN
3.5  410
Strength of 5-mm weld =  662.8 N / m m
3  1.25
Force to resist by weld at 100 mm side of angle,
3
P2  662.8  100  10  66.28 kN

Force to resist by weld at upper side of angle,

Ty P2 303.64  31 66.28
P1      61kN
d 2 100 2

Force to resist by weld at lower side of angle,

P3  T  P1  P2  303.64  61  66.28  176.36 kN

61  10
3

Length required at upper side of angle, L w1   92 m m

662.8

176.36  10
3

Length required at upper side of angle, Lw 3   266m m

662.8
Total Length (effective) of weld = 266 + 92+100 = 458 mm
Note: Add twice the weld size at the ends.
Thus total length = 458+2S = 468 mm
Example. Design a suitable fillet weld to connect web plate to flange
plate and flange plate to flange cover plate of a built-up girder as
shown in the figure, for the following data. Assume shop welding.
Web plate: 1200 mm × 12 mm
Flange plate: 450 mm × 20 mm
Flange cover plate: 350 mm × 16 mm
Maximum Factored shear force: 1600 kN
 450 mm

350 mm

16 mm
20 mm

1200/2=600 mm

12 mm

Centroidal axis
Solution: For Fe 410 steel: f u  410 M Pa

For shop weld:  m w  1.25

fu 410
Permissible shear stress    189.37 N / m m
2

3   mw 3  1.25

Connection of web plate to flange plate:

Size of weld: Minimum = 5 mm [Table 21, IS 800]

Maximum = 12 – 1.5 =10.5 mm [clause 10.5.8.1, IS 800]
Let us provide 7 mm size of fillet weld.
Effective throat thickness of weld t e  K S  0.7  7  4.9 m m
 t e  2  4.9  9.8 m m
A y  450  20  (600  10)  350  16  (600  20  8)

 900.68  10 m m
4 3
 350  16 450  20 12  1200
3 3 3

I zz  2  [  350  16  628   450  20  610 ] 

2 2

12 12 12
 12.8  10 m m
9 4

1600  10  (900.68  10 )
3 4
VAy
Shear stress:   114.9 N / m m  189.37 N / m m
2 2

I zz   t e 12.8  10  9.8
9

Hence, the weld is safe.

Connection of flange plate to flange cover plate:
Adopt a 7 mm fillet weld.
t e  K S  0.7  7  4.9 m m
 t e  2  4.9  9.8 m m
Ay  350  16  (600  20  8)  351.68  10 mm
4 3

1600  10  (351.68  10 )
3 4
VAy
Shear stress:   44.86 N / m m  189.37 N / m m
2 2

I zz   t e 12.8  10  9.8
9

Hence, the weld is safe.

 Design of
Ordinary Black Bolts
Types of Bolted Connections

(i) Bearing Type Bolt

(Clause 10.3)
(i) Friction Type Bolt
(Clause 10.4)

(i) Lap Joints

(ii) Butt Joints

 Design of Ordinary Black Bolts

1. Shearing strength of bolts

2. Bearing strength of bolts
3. Tensile strength of bolts
4. Tensile strength of plate
5. Combined shear and tension
 Design of Ordinary Black Bolts (Clause 10.3)
f ub
1) Bolts in Shear V nsb n n Anb n s A sb lj lg pkg
3
Vnsb = nominal capacity of bolts in shear
fub = ultimate tensile strength of bolts
nn = no. of shear planes with threads intercepting the plane
ns = no. of shear planes without threads intercepting the
plane
βlj = reduction factor which allows for overloading of end
bolts that occur in long connections
βlg = reduction factor for large grip lengths
βpkg = reduction factor for packing plates thicker than 6mm
Anb = net tensile area of bolt to be considered at the root of
the threads = 0.78×π×d2/4
Asb = nominal plain shank area of the bolt;
Threads excluded from shear plane

Threads included in shear plane

 V dsb V nsb mb

Vdsb = design shear force

γmb = partial safety factor for the material of bolt = 1.25

Reduction Factor for Long Joints

If length of joint lj > 15d, where d = nominal diameter of

bolts,

then βlj = 1.075 – lj/ (200d), 0.75 ≤ βlj ≤ 1.0

Reduction Factor for Large Grip Length

If total thickness of connected plates lg > 5d, then βlg = 8d/

(3 + lg)
Note: βlg < βlj and lg < 8d

Reduction Factor for Packing Plates

If thickness of packing plates tpkg > 6mm, then
βpkg = 1 – 0.0125tpkg
2) Bolts in Bearing
V npb 2.5 k b dt f u

Vnpb = nominal bearing strength of bolt

fu = ultimate tensile stress of plate

d = nominal diameter of bolt

t = summation of thickness of connected plates

experiencing bearing stress in same direction
 e p
kb = smaller of , 0.25, f ub f u ,1
3d 0 3d 0
fub = ultimate tensile stress of bolts

d0 = diameter of bolt hole

p = pitch of fastener along bearing direction

e = edge distance
V dpb V npb mb

Vdpb = design shear force

γmb = partial safety factor = 1.25

3) Bolts in Tension
mb
Tnb 0.9 f ub Anb f yb Asb
m0
Tnb = nominal capacity of a bolt in tension
fub = ultimate tensile stress of bolts
An = net tensile stress area
Asb = shank area of bolt
fyb = yield stress of bolt
γm0 = partial safety factor = 1.1
γm1 = partial safety factor = 1.25

T db T nb mb

Tdb = design tensile force

γmb = partial safety factor = 1.25

4) Tension Capacity of Plate

0.9 f u An
Where An b nd 0 t T nd
m1
Tnd = tension capacity of plate

fu = ultimate tensile stress of plate

An = net effective area of plate

γml = partial safety factor = 1.25

b = width of plate

n = number of holes along width perpendicular to the direction of load

d0 = hole diameter

t = thickness of plate
5) Bolts with combined Shear and Tension
2 2
V Te
1.0
V sd T nd

V = applied shear force

Vsd = design shear capacity

Te = externally applied tension

Tnd = design tension capacity

6) Strength of Solid Plate
0.9 f u Asp
T sp
m1

where Asp = b×t

b = width of plate
t = thickness of plate
fu = ultimate tensile stress of plate
γm1 = partial safety factor = 1.25

Efficiency of Joint
stre n g th o f jo in t p e r p itch le n g th
100
stre n g th o f so lid p la te p e r p itch le n g th
 Example: Calculate the shear strength of 16 mm diameter
bolt of grade 4.6. The bolt is under triple shear as shown
in the figure below.

f ub
Solution: V dsb 3
n n Anb n s A sb lj lg pkg
mb
nn = no. of shear planes with threads intercepting the plane =1
ns = no. of shear planes without threads intercepting the plane
=2
Nominal diameter of bolt, d =16 mm
Diameter of hole, d 0  18 mm (Ref. Table 19)
For grade 4.6 bolts; f ub  400 M Pa

For Fe 410 grade of steel; f u  410 M Pa

Partial safety factor for bolt,  m b  1.25
For 16 mm diameter bolt;

Net shear area of bolt at threads is, Anb  0.78   d 2  157 m m 2
 4
And Ans   d  201 m m
2 2

4
Thus, f ub 400 3
V dsb n n Anb n s A sb 1 157 2 201 103 10 N
3 mb
3 1.25

Therefore, the design shear strength, Vdsb = 103 kN

Worked out Examples
on Design of
Ordinary Black Bolts
Example: Design the following joints using ordinary black bolts between two
plates of width 200 mm and thicknesses 10 mm and 18 mm respectively to
transmit a factored load of 150 kN.

a) Lap joint
b) Single cover butt joint with cover plate of 8 mm.
c) Double cover butt joint with 8 mm covers plates.
Use plates made of Fe 410 grade steel and 16 mm diameter bolt of grade
4.6.
Example: Design the following joints between two plates of width 200 mm
and thicknesses 10 mm and 18 mm respectively to transmit a factored load
of 150 kN.

a) Lap joint
b) Single cover butt joint with cover plate of 8 mm.
c) Double cover butt joint with 8 mm covers plates.
Use plates made of Fe 410 grade steel and 16 mm diameter bolt of grade
4.6.
Solution: Nominal diameter of bolt, d  1 6 m m
Diameter of hole, d 0  18 mm (Ref. Table 19)
For grade 4.6 bolts; f ub  400 M Pa
For Fe 410 grade of steel; f u  410 M Pa
Partial safety factor for bolt,  m b  1.25
a) Lap joint:
The bolts will be in single shear.
n  1 ns  0
Assuming threads in the shear plane, n ;
For 16 mm diameter bolt; Net shear area of the bolt at threads is,
Anb  157 m m
2
 f ub
Design shear strength per bolt , V dsb   n n Anb  n s A sb 
3   mb
3
400  10
 1  157  0   29 kN
3  1.25

Minimum pitch, p  2.5 d  2.5  16  40

Minimum end distance, e = 1.5 d0 (for rolled edge) =1.5×18=27 mm
= 1.7 d0 (for hand-flame cut edge) = 1.7×18=30.6 mm
Provide p=50 mm and e= 31 mm
2.5  k b  d  t  f u
Design bearing strength per bolt, V dpb 
 mb

kb is smaller of 31/(3×18), 50/(3×18)-0.25, 400/410, 1

Kb = 0.57
 3
2.5  0.57  16  10  410  10 kN
V dpb 
1.25

= 74.78 kN
Therefore, bolt value = 29 kN.
Number of bolts required = 150/6 = 5.2
Provide 6 bolts.
Arrange the bolts in two lines.
18mm Direction of load
10mm 150 kN

31mm

138mm 200 mm

31mm
b) Single cover butt joint:
50mm 50mm

The bolts also will be in single shear.

So V dsb  29 kN
 2.5  k b  d  t  f u
Design bearing strength per bolt, V dpb 
 mb
p = 50 mm, e = 31 mm, Kb = 0.57, t = 8 mm
3
2.5  0.57  16  8  410  10
V dpb 
1.25
=59.83 kN

Therefore the bolt value is 29 kN. 150

Number of bolts required for this connection   5.1
29

Provide 6 bolts and arranging it in three lines.

Direction of load
18mm 10mm
150 kN

31mm

69mm
69mm 200 mm

31mm

50mm
c) Double cover butt joint:
The bolts will be in double shear.
Assuming threads in the shear planes. Therefore n n  2 ; n s  0
Since the two plates of thicknesses 18 mm and 10 mm are to be jointed,
packing plate of thickness (18-10) = 8 mm will be required.
As per clause 10.3.3.3 of IS:800 2007,
Design shear capacity of bolts will be decreased by factor  pk
 pkg  (1  0.0125 t pkg )
 (1  0 .0 1 2 5  8)
 0 .9
f ub
Design strength of bolt in double shear, V dsb  ( n n Anb  n s A sb )  pk
3   mb
3
400  10
  2  157  0.9
3  1.25
= 52.21 kN
Design bearing strength per bolt, 2.5  k b  d  t  f u
V dpb 
 mb
p = 65 mm, e = 31 mm, Kb = 0.57, t = 10 mm
3
2.5  0.57  16  10  410  10
V dpb 
1.25
=74.78 kN
Therefore the bolt value is 52.21 kN.
150
Number of bolts required for this connection  2.87
52.21

Using 4 bolts to arrange the joint as single bolted double cover butt joint.
8mm cover plates
Direction of load
18mm 10mm
150 kN

Packing plate(8mm)
31mm

138mm 200 mm

31mm

65mm
Example: Two plates 10 mm thick are joined by 16mm diameter bolts in
a triple staggered lap joint. Find efficiency of the joint.

18

10
10

1-1 2-2 3-3

25
20
20
20
20

25

40
dh = 16+2=18mm
fu 400
n n Anb n s A sb 1 157 0
Psingle shear = V dsb
3 3
29.0 kN
mb
1.25

Pbearing V dpb 2 .5 k b d tf u mb

e p
kb = smaller of , 0.25, f ub f u ,1
3d g 3d g

Here, e = 25 mm, p=40mm

kb = 25/(3×18), 40/(3×18)-0.25, 400/410, 1

kb = 0.46
 2.5 0.46 16 10 410
Pbearing 60.35 K N
1.25

Bolt value = 29.0 KN

Strength of joint based on bolt value = 7×29.0 = 203 KN

Strength of joint along 1-1 0.9 f u b nd h t ml

= 10-3 × 0.9×410×(130-2×18)×10/1.25 = 277.49 KN

Strength of joint along 2-2 0.9 f u b nd h t ml

2 Bv
= 10-3 × 0.9×410×(130-3×18)×10/1.25 + 2×29
= 282.35 KN

Strength of joint along 3-3 0.9 f u b nd h t m l 5 B v

= 10-3 × 0.9×410×(130-2×18)×10/1.25 + 5×29
= 422.49 KN
Strength of joint = 203 KN

Strength of solid plate 0.9 f u b t ml

= 0.9×410×130×10/1.25

=383.75 KN
203
Efficiency, 100 52.9%
383.75
Design of High Strength
Friction Grip Bolts
1) Shear strength of HSFG Bolts

V nsf f
n e K h F0

Vnsf = nominal shear capacity of bolt

µf = coefficient of friction Ref. Clause 10.4.3, Table 20

Kh = 1.0 for fasteners in clearance holes

= 0.85 for fasteners in oversized and short slotted holes and long slotted
holes loaded perpendicular to the slots

= 0.7 for fasteners in long slotted holes loaded parallel to the slots

ne = number of effective interfaces offering frictional resistance to slip

F0 = proof load = Anbf0

f0 = proof stress = 0.7 fub

Anb = net area of bolts at threads

fub Ultimate tensile stress in bolt

V dsf V nsf mf

Vdsf = design shear force

γmf = partial safety factor

= 1.1 if slip resistance is designed at service load

= 1.25 if slip resistance is designed at ultimate load

Reduction Factor for Long Joints

If length of joint lj > 15d, where d = nominal diameter of

bolts,

then βlj = 1.075 – lj/ (200d), 0.75 ≤ βlj ≤ 1.0

Vnsf is reduced by a factor βlj

2) Bolts in Bearing

V npb 2.5 k b dtf u

Vnpb = nominal bearing strength of bolt

fu = ultimate tensile stress

d = nominal diameter of bolt

t = summation of thickness of connected plates

experiencing bearing stress in same direction
 e p
kb = smaller of , 0.25, f ub f u ,1
3d 0 3d 0

fub = ultimate tensile stress of bolts

d0 = diameter of bolt hole

p = pitch of fastener along bearing direction

e = edge distance
V dsb V npb mb

Vdsb = design shear force

γmb = partial safety factor = 1.25

 m1
3) Bolts in Tension Tnf 0.9 f ub Anb f yb Asb
m0

Tnf = design tensile strength of bolt

fub = ultimate tensile stress of bolts
Anb = net tensile stress area of bolt
Asb = shank area of bolt
fyb = yield stress of bolt
γm0 = partial safety factor = 1.1
γm1 = partial safety factor = 1.25

T df T nf mb

Tdf = design tensile force

γmb = partial safety factor = 1.25

4) Bolts with combined Shear and Tension
2 2
V sf Tf
1.0
V sdf T sdf

Vsf = applied shear force at service load

Vsdf = design shear capacity

Tf = externally applied tension at service load

Tsdf = design tension capacity

5) Prying forces
(Clause 10.4.7)

4
lv f 0 be t
Q Te 2
2 le 27 l e l v

Q = additional force of fastener due to prying action

lv = distance from bolt centre line to toe of fillet weld or to

half the root radius of a rolled section

le = distance between prying force and bolt centre line

 le 1.1t f0 f y

β = 2 for non pre-tensioned bolts

1 for pre-tensioned bolts

η = 1.5

f0 = proof stress

t = thickness of end plate

t m in 4.4 M p
f y be

where Mp = Telv/2 = Qle

Example:
An ISA 110 mm ×110 mm ×10 mm carries a factored tensile force of 150
kN. It is to be jointed with a 10 mm thick gusset plate. Design the joint
using HSFG bolt when (a) no slip is permitted, (b) when slip is permitted.
Assume steel is Fe 410 grade.

Solution:
Let us provide HSFG bolts of grade 8.8 and of diameter 20 mm.

For 8.8 grade bolts: f ub  800 M Pa


Net tensile stress area of bolt, Anb  0.78   20  245 m m
2 2

4
For Fe 410 grade of steel: f u  410 M Pa
(a) Slip-critical connection (slip is not permitted ):
3
proof load, F0  Anb  0.7 f ub  245  0.7  800  10  137.2 kN

Slip resistance of bolt   f n e k h F0 /  m f

here,  f = 0.5 (assuming)

n e = number of effective interfaces offering frictional resistance to slip
=1
 m f = 1.25 at ultimate load

k h = 1.0 (assuming bolts in clearance holes)

137.2
Slip resistance of bolt  0.5  1  1   54.88 kN
1.25

150
Number of bolts required   2.73
54.87
Thus provide 3 nos. HSFG bolts.
(b) Bearing type connection: (slip is permitted )
Strength of bolt in single shear,

Anb f ub 245  800 3

V dsb    10  90.53 kN
3 m b 3  1.25

Strength of bolt in bearing, 2.5 k b dtf u

V dpb 
 mb
Assume e = 40 mm [Minimum e = 1.7d0 = 37.4 mm]
p = 60 mm [Minimum p = 2.5d = 50 mm]

kb is smaller of 40/(3×22) , 60/(3×22) - 0.25 , 400/410, 1

Therefore, kb = 0.61
3
So, 2.5  0.61  20  10  410  10
V dpb   100.04 kN
1.25
Hence, strength of bolt = 90.53 kN
Number of bolts required 150
  1.66
Thus provide 2 HSFG bolts 90.53
WELD CONNECTION
Welding is the process of connecting metal pieces by application
of heat (i.e. fusion) with or without pressure.

Types of Welding Process

•Forge Welding
•Thermit Welding
•Gas Welding
•Resistance Welding
•Electric-arc Welding
Advantages of weld connections

1. As no hole is required for welding, hence no reduction of area. So,

structural members are more effective in taking the load.

2. In welding, filler plates, gusseted plates, connecting angles etc.

are not used, which leads to reduced overall weight of the
structure.

3. Welded joints are more economical as less material is required.

4. The efficiency of welded joints is more than that of the

riveted/bolted joints.

5. The welded joint look better than the bulky riveted/bolted joints
Advantages of welding
6. The speed of fabrication is faster in comparison with the riveted
joints.

7. Complete rigid joints can be provided with welding process.

8. The alteration & addition to the existing structure is easy as

compare to rivet joints.

9. No noise is produced during the welding process as in the case of

riveting.

10. The welding process requires less work space in comparison to

riveting.

11. Any shape of joint can be made with ease.

Disadvantages of welding joints
• Welded joints are brittle & therefore their fatigue strength is less
than the members joined.

• Due to uneven heating & cooling of the members during the

welding, the members may distort resulting in additional stresses.

• Skilled labor & electricity are required for welding

• No provision for expansion & contraction is kept in welded

connection & therefore, there is possibility of cracks.

• The inspection of welding work is more difficult & costlier than

the riveting work.

• Defects like internal air pocket, slag inclusion & incomplete

penetration are difficult to detect.
Types of Welds
Classified according to their formations:

• Fillet Weld

• Butt Weld

• Plug Weld
 Basic types of welds and their symbols

Form of weld Section Symbol

Fillet

Square butt

Single-V-butt
Basic types of welds and their symbols

Double-V-butt

Single-U-butt

Double-U-butt

Single-bevel-
butt
Basic types of welds and their symbols

Double -bevel-
butt

Single-J-butt

Double-J-butt
Shape of weld Symbol
Flat
Convex
Concave
Fillet welding
When two lapped plates are to be joined fillet welding is
used.
Design of Fillet Welds
Few terms are used while designing a fillet weld:

1. Size of fillet weld

2. Throat of fillet weld
3. Effective length of the fillet weld
4. End return
5. Overlap
6. Side fillet
7. Intermittent fillet weld
8. Single fillet weld
9. Permissible stress & strength of fillet weld
Size of Fillet weld

Toe
Weld face

Toe
Fusion Zone

Leg
Root
1. Size of the weld :

The sides containing the right angle of the fillet weld

are called legs. The size of the weld is specified by
the minimum leg length. The length is the distance
from the root of the weld to the toe of the weld,
measured along the fusion face.
Table: Minimum size of first run or single run fillet weld
(Clause 10.5.2.3; Table 21)

Thickness of thicker part Minimum size of

Weld (mm)
Over (mm) Up to and
Including(mm)
- 10 3
10 20 5
20 32 6
32 50 8 of first run
10 for minimum size
of weld
Note :
1. When the minimum size of the fillet weld is greater than the
thickness of the thinner part, the minimum size of the weld should
be taken as the thickness of the thinner part.
2. When the thicker part is more than 50 mm thick, special
precaution like preheating etc. will have to be taken.

As per Clause 10.5.2.1 of IS 800:2007 for deep penetration welds,

where the depth of penetration beyond the root run is a minimum
of 2.4 mm, the size of the fillet weld is minimum leg size plus 2.4
mm.
The maximum size of the fillet weld
= Thickness of the thinner plate – 1.5mm
= ¾ of nominal thickness of angle
Effective throat thickness
The effective throat thickness of a fillet weld is the
perpendicular distance from the root to the hypotenuse joining
the two ends of the legs, while reinforcement is neglected.

BA  BC  S A
 AC  2S
D
AB  AD  BD
2 2 2
S
T
 BD  AB  AD
2 2
B
2 S C
 S  S
 BD  S    BD 
2

 2 2

 BD  T  0.707S  0.7S
 For the angle other than right-angled fillet weld the value of
throat thickness is given as:

T = KS

Where,
T = Throat thickness of weld
KA constant depends upon the angle between fusion face
S Thickness of the weld

Effective throat thickness shall not be less than 3 mm and generally

not exceeding 0.7t or 1.0t under special circumstances where t is the
thickness of the thinner plate(Clause 10.5.3.1 of IS 800)
Values of K for different angles between fusion faces
(Table 22 of IS 800:2007, Clause 10.5.3.2)

Angle between Constant, K

fusion face

600-900 0.7
910-1000 0.65
1010-1060 0.6
1070-1130 0.55
1140-1200 0.5
Effective length of fillet: - The effective length of the fillet
weld is the area of the weld for which the specified size & the
effective throat thickness of the weld exist.

Effective length (l) = Overall length (L) – 2S

The effective length should not be less than four times the size
of the weld. Otherwise size of the weld must be taken as the
one fourth of the effective weld length.

i.e.
Design strength of fillet weld
The design strength of fillet weld is calculated on its throat area.
f u Lw te
Pd w =
3 γmw

Lw = length of weld in mm
fu = ultimate stress of weld in MPa
te = effective throat thickness = 0.7S
γmw = partial safety factor
= 1.25 for shop welding and
= 1.5 for site welding
S = size of weld in mm
 Design Procedure
1. Assume size of weld based on thickness of members to be joined.

2. By equating design strength of weld to external factored load,

effective length of weld is calculated. If length exceeds 150te, reduce
design capacity of weld as prescribed in clause 10.5.7.3 and is as
given below.

The design strength of weld will be reduced by a factor as follows.

0.2l j
lw
= 1.2 -
150t e
Where, lj = length of joint in the direction of force transfer
te = throat thickness of the weld.

3. End returns of length equal to twice the size of weld are provided
at each end of longitudinal fillet weld.
End return:
The fillet weld terminating
at the end or side of a
member should be
returned around the
corner whenever
practicable for a distance
not less than twice the
weld size as shown in the
figure:

Overlap
The overlap of a lap joint should not be less than four times the
thickness of the thinner plate or 40 mm which ever is more.