Design of Butt Welds

Butt / Groove welding

Butt weld is used when the plates to be joined are in the same plane or when T
joint is desired.
Butt welding
A butt weld is specified by the size of the weld. Size is defined by the
effective throat thickness.

Specification:

1. Size of the weld

2. Effective length of the butt weld

3. Effective area of the butt weld

4. Reinforcements
1. Size of the weld
Size of the weld is specified by the effective throat thickness
as follows:

(a) The size of the butt weld is the thickness of the thinner plate.
(b) The effective throat thickness in case of complete penetration
is taken as the thickness of the thinner part.
Double-V, Double-U, Double-J & Double Bevel butt joints are the
examples of completely penetrated butt weld.
(c) In case of incomplete penetration of butt weld the effective
throat thickness is taken as the 7/8th of the thickness of the
thinner part. But for purpose of stress calculation the effective
throat thickness should not exceed 5/8th of the thickness of the
thinner part.

(d)The difference in thickness between the two plates should

not be more than 25% of the thickness or 3mm whichever is
more.

(e) If difference is more than 25% tapering less than 1 in 5 is

to be done.
2. The effective length of the butt weld

It is the area of the butt weld for which the specified size (i.e. the
throat thickness) of the weld exists.

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.

Note:- In drawing only effective lengths are shown, the

welder must provide an additional length of 2S to get the
overall depth.
Reinforcements :
Reinforcement is the extra weld metal
which make the throat dimension at least
10% greater than the thickness of the
weld material. The extra deposit of
metals above the thinner plate between 1
mm to 3 mm is not considered for stress
calculation or design. The reinforcement
is provided to increase the efficiency of
the joint.

Stress in the butt weld : The stresses of the butt weld should be taken
equal to the stresses of the parent metal in the case of shop weld.

These values are reduced to 80% in case of field weld.

Design strength of butt weld
The design strength of butt weld in tension or compression is
governed by yield f y Lw te
T dw =
γmw
Lw = effective length of weld in mm
fy = smaller of yield stress of weld and parent material in MPa
te = effective throat thickness in mm
γmw = partial safety factor
= 1.25 for shop welding and
= 1.5 for site welding

The design strength of butt weld in shear is also governed by yield

f y Lw te
Vdw =
3 γmw
Stresses due to individual forces

When subjected to either compressive or tensile due to axial force

or shear force alone, the stress in the weld is given by
P
fa o r q 
t e lw

Where,
fa = calculated normal stress due to axial force in N/mm2
q = shear stress in N/mm2
P = force transmitted (axial force N or shear force Q)
t e = effective throat thickness of weld in mm
l w= effective length of weld in mm
Combination of stresses
Fillet welds
While subjected to a combination of normal stress (due to axial
tension/compression or bending tension/compression) and shear
stresses, the equivalent stress fe should satisfy the following

2 2 fu
fe  f  3q
a

3  mw
Where,

fa = normal stress, compression or tension, due to axial force or

bending moment.
q= shear stress due to shear force or tension.
Combined bearing, Bending and shear
If bearing stress, (fbr) is combined with bending stress (fb)
(tensile or compressive) and shear stresses (q) under the most
unfavourable conditions of loading, the equivalent stress (fe) is
obtained from the following formula:

2 2 2
fe  f  f  f b f br  3 q
b br

fe = equivalent stress
fb = calculated stress due to bending in N/mm2
fbr = calculated stress due to bearing in N/mm2
q = shear stress in N/mm2
Example:
Two plates of thickness 12 mm and 10 mm are to be jointed by a
groove weld. The joint is subjected to a factored tensile force of 250
kN. Assuming an effective length of 150 mm, check the safety of the
joint for
a) Single-V groove weld joint and,
b) Double-V groove weld joint.
Assume Fe 410 grade steel plates and that the welds are shop welded.

12 mm 10 mm

Single-V groove weld

12 mm 10 mm

Double-V groove weld

(a) Single-V groove weld:
5 5
Throat thickness, te  t  10  6.25 m m
8 8
Effective length of weld, L w  150 m m

Lw te f y 150  6.25  250 3

Strength of weld=   10  187.5 kN  250 kN
 mw 1.25

Hence the joint is not safe.

(b) Double-V groove weld:

Throat thickness = thickness of thinner plate = 10 mm
Lw te f y 150  10  250 3
Strength of weld =   10  300 kN  250 kN
 mw 1.25

Hence, the joint is safe.

Example:
A joint is subjected to a factored shear force of 300 kN. Assuming
single-V groove weld joint find the effective length of the weld if the
thickness of thinner plate is 8 mm. Assume Fe 410 grade steel plates
and that the welds are shop welded.

Solution:

For single-V groove weld, effective throat thickness =

5 5
te  t  8  5 mm
8 8
3
3 γmw V dw 3 1.25 300 10
Length of the weld, L w 520 m m
fy te 250 5

Thus, the effective length of the weld will be 520 mm.

Design of Plug and Slot Weld
 Plug and Slot Weld

A slot is cut in one of the overlapping member and the welding

metal is filled in the slot.
If the slot is small and completely filled with weld metal, it is called
plug weld.
If the periphery of the slot is filled with weld metal, it is called as
slot weld.
Following specifications are for the design of plug or slot weld as
per IS816-1969:

1. The width or diameter of the slot should not be less than three
times the thickness of the part in which the slot is formed or 25
mm, whichever is greater
2. The distance between edge of the part and edge of slot or plug or
between adjacent slots or plugs should not less than 3 times
thickness of thinner member or 25mm, whichever is greater.

3. Corners at the enclosed ends should be rounded to a radius not

less than one and a half times the thickness of the upper plate or
12 mm which ever is greater.
The design shear stress on a plug or slot weld will be same as that
in fillet weld and is specified in 10.5.7.1.1 of IS 800:2007
Example: An ISMC 300 @ 363 N/mm is used to transmit factored
force 800 kN. The channel section is connected to a 12mm thick
gusset plate. Design a fillet weld connection if the overlap is limited
to 300 mm. Use slot welds if required. Assume site welding.
Solution
The properties of ISMC 300 are,
A= 4630 mm2 , tf = 13.6 mm , tw= 7.8 mm
maximum size of weld= 7.8 - 1.5 = 6.3 mm. (Cl. 10.5.8.1)
Minimum size of the weld = 3 mm (Table 21 IS 800:2007)
Adopt a 6-mm size weld.
Throat thickness = KS = 0.7 x 6 = 4.2 mm
fu
Strength of the weld per mm = t e
3  mw
= 4.2  410 / ( 3  1.5 )
= 663 N/mm
Required length of weld = 800  1000 / 663  1207m m

The maximum length of weld that can be provided in the

channel = 300  2  300  900m m  1207m m

Hence, use two slots welds of width 25 mm

( 3 t  3  7.8  23.4 or 25 mm whichever is greater

Assume the length of the slot weld is x mm, then,

1207  2  300  300  4 x
or, x  76.75 mm
Hence, provide 80 mm x 25 mm slots , two in numbers as
shown in the figure.
Example
A pipe of 100 mm diameter and 8 mm thick is connected
to a 16 mm thick plate with fillet weld. It is subjected to
a vertical factored load of 10 kN at a distance of 0.5 m
from the welded end. It is also subjected to a factored
twisting moment of 3 kNm. Find the size of the weld
assuming shop welding and steel of grade to be Fe410
Solution:
Here, fu = 410 MPa , ymw = 1.25
fu 410
Permissible shear stress = = =189.37 N/mm2
3×γmw 3×1.25
Hence, P = 10 kN
M = P. e = 10 x 0.5 = 5 kNm
T = 3 kNm
Polar moment of inertia, Ip = 2πr3 ×t = 2π×503 ×t
= 785398t mm4
Izz= Ip/2 = 392699t mm4
3
P 10×10
(1) Shear stress due to direct load, q1 = =
2πrt 2×π×50×t
31.83
= N/mm2
t
 T
(2) Shear stress due to twisting moment, q2 = ×r
Ip

6
3×10 ×50 191
= = N/mm2
785398t t
M
(3) Normal stress due to bending, fa= ×r
Izz
6
5×10 636.62
= ×50 = N/mm2
392699t t

Resultant shear stress, 𝑞 = 𝑞1 2 + 𝑞2 2

31.83 2 191 2 193.6

= + = N/mm2
t t t
Equivalent stress due to normal and shear stress,

636.62 2 3×193.6 2 861.75

fe = fa 2 +3q2 = + = N/mm2
t t t
fu
fe ≤ = 189.37
3 ×γmw

861.75
≤ 189.37
t

So, t = 4.55 mm

t
Hence, s = = 6.4 ≈ 7 mm
0.707
So, the size of the weld will be 7 mm.
ECCENTRIC CONNECTION
Load lying in plane of bolted joint
Load lying in plane of bolted joint
Analysis
• Acting shear force (P) is replace by a Force acting through the
centroid of the bolt group and a moment (M=P×e) where e is
the eccentricity of the load

P
(passing through centroid)
P
e

M=Pe
Load lying in plane of bolted joint
If, Direct load =P, Bending moment, M = Pe
Therefore, Direct axial shear, Fa = P/n
Where
n No of bolts in the group
Fa Force on each bolt due to axial load

Fa Fm Fa Fm

+ =

Direct Force Combined direct

Moment Force & moment
Again, Rotational shear or shear due to moment on each bolts,
Fm  r
Where,
r  Radial distance of the bolts from the CG of the group
Fm
 Fm  kr  k  Here k Proportionality constant
r
Moment due to Fm in each bolt = (kr).r = kr2
Hence, the total moment will be:
F r    kr  r M t   kr k  r
2 2
m

Fm
But, k 
r
Fm
 M   kr  r
2 2

Mr P er
 Fm  
r r
2 2
For extreme bolt

P Mr P er
Fa  ;  Fm  
 
2 2
n r r

R  Fa  Fm  2 Fa Fm co s 
2 2
Resultant force,
Example: Calculate the safe load F that can be carried by the
connection as shown in the figure below. HSFG bolts of grade 8.8
with 20 mm diameter are used. Assume the thickness of the bracket
plate as 12 mm and column used is ISWB 350. Assume no slip is
permitted and slip factor (μf) as 0.5. All dimensions in the figure
below are in mm.
Solution:
HSFG 8.8 bolt, Ø = 20 mm, μf = 0.5.
ISWB 350, tf = 11.4 mm
Proof load, 𝐹𝑜 = 𝐴𝑛𝑏 × 0.7𝑓𝑢𝑏
𝜋
= 0.78 × × 202 × 0.7 × 800 × 10−3 = 137 kN
4

(1) Slip resistance of bolt in bearing, 𝑉𝑑𝑠𝑓 = 𝜇𝑓 𝑛𝑒 𝑘ℎ 𝐹𝑜 /γ𝑛𝑓

= 0.5×1×1×137/1.25 = 55 kN

(2) Strength of bolt in bearing,

2.5𝑘𝑏 𝑑𝑡𝑓𝑢
𝑉𝑑𝑝𝑏 =
𝛾𝑚𝑏
 𝑒 40
= = 0.606,
3𝑑𝑜 3×22
𝑝 60
− 0.25 = − 0.25 = 0.66,
𝑘𝑏 = least of 3𝑑𝑜 3×22
𝑓𝑢𝑏 400
= = 0.975,
𝑓𝑢 410
1
= 0.606

Here, thickness, t will be the thickness of flange of ISWB350 = 11.4

mm.

410
So, 𝑉𝑑𝑝𝑏 = 2.5 × 0.606 × 20 × 11.4 × × 10−3
1.25
= 113 kN

Hence, Bolt Value= least of (55 & 113) = 55 kN

 𝑟1 = 502 + 602 = 78.1 𝑚𝑚, 𝑟2 = 50 𝑚𝑚

𝑟 2 = 4𝑟12 + 2𝑟22 = 4 × 78.12 + 2 × 502

= 29398 𝑚𝑚2
𝐹
𝐹𝑎 =
6
𝐹 × 180
𝐹𝑚1 = × 78.1 = 0.478𝐹
29398
𝐹 × 180
𝐹𝑚2 = × 50 = 0.306𝐹
29398
−1
50
𝜃1 = 𝑡𝑎𝑛 = 50.19° ; 𝜃2 = 0
60
 𝐹𝑟1 = 𝐹𝑎2 + 𝐹𝑚21 + 2𝐹𝑎 𝐹𝑚1 𝑐𝑜𝑠𝜃1

1 2 1
=𝐹 + 0.4782 + 2 × × 0.478 × 𝑐𝑜𝑠50.19
6 6

= 0.599𝐹

1 2 1
𝐹𝑟2 = 𝐹 + 0.3062 +2× × 0.306 × 𝑐𝑜𝑠0
6 6

= 0.473𝐹
∴ 𝐹𝑟 = max 𝑜𝑓 𝐹𝑟1 & 𝐹𝑟2 = 0.599𝐹
∴ 0.599𝐹 = 55

𝑜𝑟 𝐹 = 92 kN
DESIGN OF ECCENTRIC CONNECTION
Load lying in plane of bolted joint
Design procedure for eccentric load lying in plane of bolt
groups:
•Assume a suitable diameter ‘d’ for the bolt.

•Find strength of one bolt in shear, bearing and get bolt value, Bsd.

•If moment coming on the joint is much less compare to the direct
load, use formula: n = P/ Bsd to find approximate numbers of
bolts.

•Increase the number of bolts to a certain percentages (say 50%)

and then arrange the total number of bolts in two or more vertical
lines at a suitable spacing, edge and pitch.

•If moment on the joint is much high compare to the direct load,
use formula:n  6M
n ' p  B sd
Design procedure for eccentric load lying in plane of bolt
groups:
Here, n = number of bolts per line.
p = pitch of the bolt.
n' = number of bolt lines.

•Increase the number of bolts to a certain percentages (say 50%)

and then arrange the number of bolts per line.

•The resultant force for the critical bolt is to be calculated.

•If resultant force in the critical bolt is less than the bolt value,
then the joint is safe.

•Otherwise, increase the number of bolts per line.

Example: Design a bolted bracket connection to transfer an end
reaction of 300 kN with an eccentricity of 170 mm, due to factored
load as shown in the figure. The steel used is of grade FE 410. Use 20
mm diameter bolt of grade 4.6. The thickness of bracket plate is 10
mm and the column section is ISHB 200 @ 365.91 N/m.

eo =170 mm

ISHB 200 300 kN

Bracket plate
Example: Design a bolted bracket connection to transfer an end
reaction of 300 kN with an eccentricity of 170 mm, due to factored
load as shown in the figure. The steel used is of grade FE 410. Use 20
mm diameter bolt of grade 4.6. The thickness of bracket plate is 10
mm and the column section is ISHB 200 @ 365.91 N/m.

eo =170 mm

ISHB 200 300 kN

Bracket plate
Solution: For Fe 410 grade of steel: f u  410 M Pa
For bolts of grade 4.6: f ub  400 N / m m 2
Partial safety factor for the material of bolt:  m b  1.25
For column section ISHB 200 @ 365.91 N/m,
Gauge, g  100 m m
Thickness of flange, t f  9.0 m m
Diameter of bolt, d  2 0 m m
Diameter of hole, d 0  22 mm [Table 19 IS 800]
Minimum edge distance, e = 1.5×22 = 33 mm [cl. 10.2.4.2 –IS 800]
Net shear area of the bolt at threads,

Anb  0.78   20  245 m m
2 2

4
Minimum pitch, p = 2.5×20 = 50 mm

Provide e = 35 mm and p = 60 mm
 f ub
Strength of bolt in single shear, V dsb   n n Anb  n s A sb 
3   mb
3
400  10
 1  245  0   45.26 kN
3  1.25

2.5  k b  d  t  f u
Strength of bolt in bearing, V dpb 
 mb

kb is smaller of 35/(3×22), 60/(3×22)-0.25, 400/410, 1

Hence, kb = 0.53
3
2.5  0.53  20  9  410  10
V sd   78.23 kN
1.25

Hence, the strength of the bolt, V sd  45.26 kN

Let us provide bolts in two vertical rows.

Moment due to eccentricity, M = 170×300 = 51000 kN-mm
number of row, n   2
Number of bolts required in one row,
6M 6  51000
n   7.51  8
pn V sd 60  2  45.26

Provide 16 bolts on each bracket plate with 8 bolts in each vertical

line.
eo =170 mm

ISHB 200 300 kN

50 mm

θ rn
c/c distance
@ 60 mm

Bracket plate
Force on critical bolt A
P 300
The direct force, F1    18.75 kN
n 16
P e 0 rn
The force in the bolt due to twisting moment, F2 
r
2

Eccentricity, eo = 170 mm
rn  210  50  215.87 m m
2 2

 r  4  [(210  50 )  (150  50 )  (90  50 )  (30  50 )]

2 2 2 2 2 2 2 2 2

 342400 m m
2

300  170  215.87

F2   32.15 kN
342400
 50
cos    0.232
210  50
2 2

Resultant force on the critical bolt,

F  F1  F2  2 F1 F2 co s 
2 2

F  18.75  32.15  2  18.75  32.15  0.232

2 2

 40.8 kN  45.26 kN

Hence, connection is safe.

ECCENTRIC CONNECTION
Load lying in plane of welded joint
 Load lying in plane of welded joint

e b
y

d r

x

Maximum stress will be, where r is maximum and

angle between the two force is minimum
Let us consider a weld of size = S
Throat thickness, t  0.707S

If
P  Total vertical load
e  Eccentricity
L  total length of the weld = 2b + d

Then, the direct shear stress in the weld,

Also, the stress due to bending,

 Where,
M  Moment = Pe
r  The radial distance of the welding point
from the CG of the weld
Ip Polar moment of inertia of the weld = Ixx + Iyy

At any point the resultant stress is given by

Where,  the angle between them

For critical condition, developed stress should be
less than the permissible stress in weld.
Example:
A bracket is subjected to a load of 50 kN and is connected to a
stanchion by welding. Find the size of the weld so that the load can
be carried safely.
50 kN

mm

X Distance of the CG of the welded area from BC

 Solution :
Eccentricity of the load = 150 + 100 – 25 = 225 mm

mm4

Similarly,
mm4

mm4

Area =
Maximum radial distance, mm
Moment, kNm

Maximum shear stress due to bending,

Direct shear stress,

Resultant stress,
Strength of weld = 410/ (√3×1.25) = 189.37MPa

Therefore, 539.88/t = 189.37, Thus t = 539.88/189.37 = 2.85 mm

Size of the weld, s= t/0.707 = 4.03 mm

Hence, provide 5 mm size of the weld.