Know Your HSS Welds ATTENDANCE

VERIFICATION
CODE:
By Cathleen Jacinto, PE, SE
_______________
Steel Tube Institute /
FORSE Consulting

SEU Core Session, May, 2023 www.LearnWithSEU.com

 Learning Objectives

 Identify factors that contribute to difficult HSS fabrication

and how to avoid them.
 Understand how and when HSS member access affects
weld choices.
 Compare suitability of CJP vs. PJP welds in HSS
sections.
 Review welding positions and qualifications.

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Agenda

 What’s the big deal?

 General Considerations
 HSS Weld Design
 Effective Weld Lengths
 With Examples
 Welder Considerations
 AESS
Brother James Gaffney, FSC, Student Center, Lewis University
Courtesy: Wight & Co.

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Terminology

• Branch
• Chord
• AWS D1.1 – 2020
 Clause 10 – Tubular
• SMAW – shielded metal arc welding
• FCAW – flux cored arc welding
• GMAW – gas metal arc welding
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 What’s the big deal?
• Load path
• “Provide a path for the force to
enter into the part (or section)
that lies parallel to the force
(Blodgett, 1982)
• “A good welded connection has
a clear and direct load path.”
(Miller, 2017)
• “…dependent on the stiffness of
the elements in the structural
system.” (Drucker, 2014)
• Flexibility of HSS wall Spec Fig. C-K1.2
• Uneven load distribution

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What’s the big deal?

• Member selection tied to connection capacity

 Chord member thickness

IF YOU
REMEMBER
• Weld from one side only
ONE THING…..
 Larger weld sizes

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General Considerations

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Design Philosophy

• Develop the yield strength of the plate / HSS branch

• Upper limit
• Conservative
• Not recommended unless required

• Weld sizes to resist applied forces in plate / HSS branch

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Matched versus Stepped

Matched Stepped Stepped

Connection Connection Connection

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Matched versus Stepped

• Matched connections require a flare bevel groove weld that,

depending on the corner radius of the supporting member, may
require a special backing weld or steel backing—inefficient weld

• Stepped connections are more economical because they allow us to

use a fillet weld as long as the branch member and its weld are
small enough to fit on the flat part of the chord member’s wall

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Gapped versus Overlapped K-
 Gapped  Overlapped
• Less expensive because • Stronger joint
easier to fabricate • Higher percentages of overlap,
the higher the joint strength →
stiffer truss

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Cutting HSS - Rectangular

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Cutting HSS - Round

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Vernon Tool

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Rectangular HSS Truss

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Round HSS Truss

Can’t insert this

member

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Weld Effective Lengths
• For elements transverse to the HSS face
• Due to the variation of flexural stiffness of
the HSS wall across the section width, the
force transmitted through the weld is not
uniform
• Reduced effective weld length
• Load is highest at ends close to sidewalls
and lowest in the middle

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HSS Weld Design

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HSS Welds
• Fillet welds
• PJP
• Flare bevel and
Flare-V-groove
welds
• CJP

Tousignant and Packer, 2014

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Fillet Weld
• Least expensive and
easiest
• 1.5 increase
• Single sided, leg size
often exceeds HSS wall
thickness

Tousignant and Packer, 2014

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Fillet Weld

AISC 360-22, Eq J2-5

AISC DG24, 1st Ed.

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Misuse of Spec J2.2b and D1.1 Clause 2.4.2.9
• Limitation on size of weld applied to edges
• Possible to melt away the top edge of a
member
• Max fillet = t – 1/16”
• HSS to base plate – not an edge – does
not apply

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Directional Strength Increase Factor

• AISC 360 Section J2.4(a) permits the use of directional

strength increase factor, kds, “for fillet welds where strain
compatibility of the various weld elements is considered.”

• Based on research on lap splice connections loaded in

shear

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 Directional Strength Increase Factor
• Single-sided welds to a HSS wall in tension
are partially unrestrained and are prone to
bending about the local axis leading to an
opening of the weld root
• Actual failure plane is closer to the HSS fusion
face and has a longer failure line. Packer, 2015

Conservative to use the weld effective throat

thickness as defined by Spec (min distance
between root of the fillet welds and the face of
the triangular weld profile).
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Directional Strength Increase Factor
• The restraint provided to the fillet weld depends on the HSS
wall thickness and shape, weld size and penetration
• Effect is much more severe on rectangles than rounds
• Not applicable for rectangular HSS to rigid plates
• Permitted for double sided fillet welds (ie plates) to HSS
• And HSS branches under compression only

Yes! No. Rectangular

Round HSS HSS in tension or
in tension to effective lengths in
See AISC 360-22,
rigid plate. K5. J2.4 Commentary
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Fillet Weld Design
• Check weld metal and base metal for shear

ASTM Material Fy, ksi Fu, ksi Fy / Fu Limit State Deff

Base metal
A53 Grade B 35 60 0.583
yielding

A500 Grade C 50 62 0.806 Base metal rupture

AISC DG24, 1st Ed.,

A1085 50 65 0.769 Base metal rupture Table 2-2

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Fillet Weld Design
• Effective weld size
HSS Minimum Thickness, tmin, to Develop FEXX Strength, in.

Weld Size, in A53 Grade B A500 Grade C A1085

3/16 0.199 0.150 0.143

1/4 0.265 0.200 0.190
5/16 0.331 0.250 0.238
3/8 0.398 0.300 0.286
7/16 0.464 0.350 0.333
1/2 0.530 0.400 0.381 AISC DG24, 1st Ed.,
Table 2-3
9/16 0.596 0.450 0.428
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Specification Comm. K5 & SCM Part 8

• Rule of thumb that a fillet weld = 1.1tb develops yield

strength of branch member
• From IIW 2009 or CEN 2005 (Eurocode 3)
• Confirmed for rounds
• For rectangular sections → 1.3tb

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 Partial Joint Penetration Welds
• Welding full thickness for an HSS is complicated
• When fillet exceeds ½” consider a PJP
• Effective throat given in Spec Table J2.1

Miller, 2017 29
AISC 360-22
Reinforced PJP
• Capacity ≠ sum of individual capacities
• (E) = least dimension from the weld root to the weld face
• No allowance for weld face convex reinforcement
• Considering Z loss at root for 45° bevels

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AWS D1.1-2020
Flare Bevel & Flare V Groove Welds
• Effective throat, E, is a function of
outside radius, 2t
• Spec Table J2.2
• D1.1 Clause 4.4.1.4 (Table 4.1)

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Flare Bevel & Flare V Groove Welds
• Assumes filled flush to outside of HSS
• Takes into account typical Z loss at root and typical HSS
corner radii
• These are maximums!

AISC 360-22 32
Flare Bevel & Flare V Groove Welds
• Underfilled joint is ok and can save money!
• AWS D1.1 requires contract
documents specify the effective
throat for PJP groove welds
• Varying corner radii on square tubing
affects the amount of weld required to fill
the joint.
• Unfilled edges are also ok if the required
throat is achieved
• Exception: AESS
Miller, 2017
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Flare Bevel Groove Weld example

5.5 4.1

inch
https://app.aws.org/forum/topic_show.pl?pid=280695:hl=flare%20bevel

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Flare Bevel Groove + Reinforcement
• Increase beyond filled-flush
• Similar to situation for PJP + reinforcement

AWS D1.1-2020

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Matched Connection
• Root gap limited to 1/16” as detailed, 1/8” as fitted up

Tube Profiling Weld Backing / Steel Backing

Build up
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Complete Joint Penetration Weld

• Exception, rather than the rule.

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 Unbacked CJP

• Try to never specify

• May be a good application for a casting
• Backup weld at root must be placed from outside which
requires precise root preparation to ensure proper gap
• Requires a 6GR certification
• CJP weld on tubular members in T-, Y-, or K-connection
from one side, w/o backing, in all positions.

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 CJP - Backing

• Normally must be continuous to avoid

creating a stress riser perpendicular to
stress field
• D1.1-2010 allowed discontinuous backing
for statically loaded HSS end connections
(D1.1-2020 clause 10.22)
• Discontinuity cannot be in the Miller, 2017

corners or be more than 2 pieces

• Discontinuity parallel to primary
stresses

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CJP - Backing

• Usually cannot be removed

• Statically loaded – can be left in place
• Seismic – some cases where backing must be removed
• Removal not required for base plates
• Cyclical – typically remove transverse backing
• AESS – exposed backing removed
• Difficult to provide for round HSS

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Welding End to End
• Bending radius is dependent
on the thickness of the HSS
wall
• Will vary from producer to
producer

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Effective Weld Lengths

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Weld Effective Lengths
• If designing to resist actual loads, must
account for non-uniform loading of the weld →
weld effective lengths / properties = reduced
effective lengths
• Transverse elements
• Extrapolates from effective width Be
• Elements (elements and welds) parallel to
longitudinal axis of member are considered
fully effective.
• Development of effective Sip, Iip, Sop, Iop →
STI, updated DG24, 2022 Spec Commentary
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Square/Rect HSS Welds
• AISC 360 Table K5.1
Effective Weld Lengths
• Transverse Plate
• T-, Y-, X- Connections
• Gapped K-
• Overlapped K-

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 Round HSS Welds
• AWS D1.1 clause 10.5.5 gives
axially loaded round HSS
effective weld length
(Qz) = 1/1.5 of total weld length
• Transverse plate to round HSS
• Round HSS to round HSS

Saddle
Packer, 202X
Crown
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Round HSS Welds
• New to AISC 360-22
• Round-to-Round HSS
Effective Weld Lengths
• Tousignant and
Packer, 2017, 2018

AISC 360-2022 Specification

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Round HSS welds
• Round HSS to Round
HSS – fillet weld if
possible but…
• Machine ends to
saddle the chord
but no edge bevel
• Likely only small b

AWS D1.1-2020 47
Poll Question #1
HSS connection capacity is most closely tied
to what parameter?
 A. Length of the chord member
 B. Angle of the attached branch member
 C. Chord member thickness
 D. Welding process/type

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 Weld Design Example:
Transverse Plate to HSS

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 Example: Transverse Plate Weld Design

• Transverse Plate to Square HSS

• Axial load of Pu=60k to HSS 8x8x1 2 COLUMN
A500C
Fy = 50 ksi
W18x35 BEAM
column using top and Fu = 62 ksi pu=30k A992, Fy=50 ksi, Fu=65 ksi,

bottom flange plates.

• Assume each plate takes Pu=60k
½ the load.
pu=30k

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MOMENT CONNECTION
 Example: Transverse Plate to HSS
HSS 8x8x1 2 COLUMN
A500C
Fy = 50 ksi
W18x35 BEAM
Fu = 62 ksi

• Connection Limit States A992, Fy=50 ksi, Fu=65 ksi,

• Local Yielding of Plate: Spec 360-16 Eq. J4-1 Pu=60k

• Local Yielding of HSS Sidewalls: Spec 360-16

Eq. J10-2
• Plastification: 15th Ed. Manual Eq. 9-30
MOMENT CONNECTION
• Punching Shear of HSS: 15th Ed. Manual Eq. 9-29
• Local Crippling of HSS Sidewalls: Spec 360-16 Eq. J10-4
• Plate-to-HSS Weld: Spec 360-16 Table K5.1

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HSS Limit State Tables
Summarize limit state equations to consider in HSS connections

• Code map between

SHEAR AISC 360-10 and
AISC 360-16 HSS
Provisions
AXIAL

TRUSS

MOMENT

https://steeltubeinstitute.org/limitstates
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STI Limit State Table – Axial – Transverse Plate

and more limit states.. 53

 Example: Transverse Plate Weld Design

• Transverse Plate to Square HSS

• HSS8x8x1/2, A500C HSS 8x8x1 2 COLUMN
A500C
Fy = 50 ksi
W18x35 BEAM
Fu = 62 ksi pu=30k A992, Fy=50 ksi, Fu=65 ksi,

• 3/8” x 6-1/2” Plate, A572-50 Pu=60k

branch = plate
pu=30k

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MOMENT CONNECTION
 Example: Transverse Plate Weld Design

plate

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 Example: Transverse Plate Weld Design

• Effective Weld Length

• AISC Spec 360-22 Table K5.1, Eq. K5-4
• Welds on both sides of transverse plate
(Eq. K5-4)

AISC 360-2022 Specification 56

 Example: Transverse Plate Weld Design
• Transverse weld design
• For ¼” weld, 2 sides
• Per AISC 360-22 Commentary, directionality strength increase
factor of 1.5 permitted for transverse plate branches with
double-sided fillet welds
(Manual Eq. 8-2a)

OK

• Therefore, ¼” double-sided fillet weld is adequate.

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Effective Weld Length Example:
Round HSS Cross-Connection

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 Example: Round HSS Truss Weld Design


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 Example: Round HSS Truss

• Cross-Connection Limit States

• Chord Plastification
• Shear Yielding (Punching)
• Plate-to-HSS Weld
• Spec 360-22 Eq. K5-1 and
Table K5.2

AISC 360-22 Specification 60

Example: Round HSS Truss Weld Design

(Eq. K5-17)

AISC 360-2022 Specification

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Example: Round HSS Truss Weld Design

(Eq. K5-16)

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 Example: Round HSS Truss Weld Design
• Determine weld size:
(Eq. K5-1)

• Effective weld throat, tw

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Welder Considerations

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Distortion & Shrinkage
• It’s going to happen – how do you plan for it
• A lot of factors:
• Thickness of weld
• Number of passes
• Distance of weld from neutral axis
• Restraint by connected members
• Welding sequence
• Welding method
• What steps can you take
• Truss – start in center and work out
• Local heating
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Weld Positions & Process
• Shop
• Rectangular shapes can often be
positioned horizontally
• Round shapes – position always changes
• Field
• All position capability
• Truss connections – think about access
• SMAW provides access but slow
• FCAW-S

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Weld positions and Sequences
• 360° rolling weld – Flat • Vertical weld

• 180° vertical weld • Horizontal weld – upright

position

CIDECT, DG7
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Architecturally Exposed
Structural Steel

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 AESS
• Preferred
connection
• Location of
longitudinal
seam
• Flare bevel
groove welds

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Acknowledgements

• Kim Olson, Nucor

• Dr. Duane Miller, Lincoln Electric
• Dr. Jeff Packer, University of Toronto

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Poll Question #2
Welders qualified to perform an unbacked
complete joint penetration weld are common
throughout the United States?
 A. True
 B. False

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Resources

• DG 21: Welded Connections

• Upcoming DG 24 – Second Edition: HSS Connections
• AWS D1.1-2020
• Steel Tube Institute

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HSS Connex
Online tool to check HSS wall adequacy at connections

Free to access
https://steeltubeinstitute.org/hss-connex-tool 73
STI Excel Design Aid Spreadsheets
Online tool to check HSS wall adequacy at connections
• Fillable field Excel files
• ASCE 7-10
• AISC 360-10
• AISC Design Guide 24

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STI HSS Design Manuals

https://steeltubeinstitute.org/hss-manuals/ 75
HSS Design Resources
www.steeltubeinstitute.org
• Webinars – Live and Recordings

• Resource Library

• Capability Tool

• Limit State Tables

• HSS Design Manuals

• HSS Excel Design Tools

• HSS Connex

• Professional Membership / eNews

Brookfield Place Entry Pavilion, Image credit: Plaza Construction
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 Learning Objectives

 Identify factors that contribute to difficult HSS fabrication

and how to avoid them.
 Understand how and when HSS member access affects
weld choices.
 Compare suitability of CJP vs. PJP welds in HSS
sections.
 Review welding positions and qualifications.

77
 Questions?
Cathleen Jacinto, PE, SE
cjacinto@steeltubeinstitute.org
HSS Consulting Engineer
Steel Tube Institute / FORSE Consulting, LLC

78
 ATTENDANCE VERIFICATION CODE: _____________

CHALLENGE QUESTION

Which of the following related to connections is the

answer to this session’s challenge question?
• Matched
• Stepped
• Gapped
• Overlapped

Please circle the answer that is announced so that you can use the information to
complete your quiz for PDH.