Copyright Materials May 23, 2013 Fatigue of Welded Connections: A Primer, Part I
Using AISC 360 Appendix 3, this live webinar examines the basic
concepts behind fatigue including the definition, application and
This presentation is protected by US and International Copyright causation; as well as welded connections and variables affecting
laws. Reproduction, distribution, display and use of the fatigue. The presentation then reviews the aspects of the design
presentation without written permission of AISC is prohibited. model including fatigue testing, categories of connection details and
predictive model.
The American Institute of Steel Construction 2013
Learning Objectives
Fatigue of Welded
To learn and understand the provisions included in Appendix 3 of
Connections: A Primer, Part I
the 201 AISC Specification for Structural Steel Buildings. written and presented by
To learn and understand the concepts behind the fatigue design Duane K. Miller, Sc. D., P.E.
requirements.
Manager, Engineering Services,
Become familiar with fatigue testing, categories of connection details The Lincoln Electric Company,
and predictive models. Cleveland, OH.
To understand the implementation of the fatigue design
requirements for welded connections.
This session is specifically geared toward The basic concepts behind fatigue-resistant steel
Engineers and Contractors involved with bridge structures are considered, explaining the
construction, but is equally applicable to interrelated variables of stress range, connection
individuals involved with the design and geometry and the expected life of the welded
fabrication of crane girders and supports, and connection. The role of dead load stress versus
other weldments subject to cyclic loading. live load stress are discussed, as are the variable
of weld quality and steel strength.
Using AISC 360 Appendix 3, weld geometries are Fatigue enhancement methods are presented. The
considered in detail with a practical focus on how role of material toughness on fatigue life is
to increase the fatigue resistance of welded discussed. Case studies, including the bad and
connections. ugly, are presented.
AISC 360-10
APPENDIX 3
SPECIFICATION
For Structural DESIGN FOR FATIGUE
Steel Buildings
14
GLOSSARY
Fatigue.
17 18
APPENDIX 3
Fatigue is the process of cumulative damage in a benign
environment that is caused by repeated fluctuating loads DESIGN FOR FATIGUE
and, in the presence of an aggressive environment, is
known as corrosion fatigue .
This appendix applies to members and connections subject
to high cycle loading within the elastic range of stresses of
frequency and magnitude sufficient to initiate cracking and
progressive failure, which defines the limit state of fatigue.
Barsom and Rolfe User Note: See AISC Seismic Provisions for Structural
Steel Buildings for structures subject to seismic loads.
APPENDIX 3
APPENDIX 3 Commentary
DESIGN FOR FATIGUE
3.1. GENERAL PROVISIONS
3.1. GENERAL PROVISIONS (contd)
In general, members or connections subject to less than a
No evaluation of fatigue resistance of members consisting few thousand cycles of loading will not constitute a fatigue
of shapes or plate is required if the number of cycles of condition except possibly for cases involving full reversal of
application of live load is less than 20,000. loading and particularly sensitive categories of details. This
is because the applicable cyclic allowable stress range will
be limited by the static allowable stress.
APPENDIX 3
APPENDIX 3 Commentary
DESIGN FOR FATIGUE
.Issues of fatigue are not normally encountered in
This appendix applies to members and connections subject building design; however, when encountered and if the
to high cycle loading within the elastic range of stresses of severity is great enough, fatigue is of concern and all
frequency and magnitude sufficient to initiate cracking and provisions of Appendix 3 must be satisfied.
progressive failure, which defines the limit state of fatigue.
25 26
CHAPTER J
DESIGN OF CONNECTIONS
Fatigue APPENDIX 3
Omer W. Blodgett
Globally elastic 32
Richard W. Hertzberg
33 34
75
Plastic
Stress (ksi)
50
30 kips
1
25
Elastic 1
75
50
30 kips
0
kt = maximum/nominal = max/nom
Strain 37 38
75
Stress (ksi)
50
30 kips
41
MPa
36 Ksi, 250 MPa 50 Ksi, 350 MPa 100 Ksi, 690 MPa 690
Welding technology is complex and fabrication by welding
encompasses characteristics that should be understood to
different levels by the design engineer, the fabricator, and
350
the welder. Some of these characteristics pertinent to the
present discussion are residual stresses, imperfections,
and stress concentrations.
0
Barsom and Rolfe
47 48
From Economical and Fatigue Resistant Steel Bridge Details, National Highway Institute Course No. 13049
Imperfections Imperfections
49 50
Imperfections Imperfections
51 52
Imperfections Imperfections
53 54
Imperfections Imperfections
55 56
Weld Toes
57 58
Unfused Root of Single Sided PJP Groove Weld Unfused Root of Double Sided PJP Groove Weld
59 60
tp 2a
62
61
Ends of Intermittent Fillet Welds Ends of Fillet Welds at Partial Length Cover Plates
63 64
APPENDIX 3
APPENDIX 3 Commentary
DESIGN FOR FATIGUE
3.5. GENERAL PROVISIONS
3.1. GENERAL PROVISIONS (contd)
Extensive test programs using full-size specimens,
substantiated by theoretical stress analysis, have Stress range is defined as the magnitude of the change in
confirmed the following general conclusions (Fisher et al., stress due to the application or removal of the service live
1970; Fisher et al., 1974): load.
(1) Stress range and notch severity are the dominant stress
variables for welded details and beams;
65 66
Stress Range
Applied Stress
total load
max. stress, max
= max - min
Stress range,
Time
67 68
-10 -5
0 -15
0 (1) Stress range and notch severity are the dominant stress
variables for welded details and beams;
-5 Stress range, = 10 ksi
-10 74
75
Residual Stresses: Tensile Load RemovedSome Stress Reduction Residual Stresses: After Welding
Residual Stresses: Compressive Load Applied Residual Stresses: Compressive Load RemovedNo Reduction
y y
Stress
Stress
0 0
Time Time
83 84
y y
Stress
Stress
0 0
Time Time
85 86
APPENDIX 3 Commentary
(1) Stress range and notch severity are the dominant stress
variables for welded details and beams;
87 88
APPENDIX 3 Commentary
20
APPENDIX 3 Commentary
20
y
y
Stress
Stress
0 0
Time Time
93 94
Stress range,
FRACTURE and FATIGUE CONTROL in STRUCTURES FRACTURE and FATIGUE CONTROL in STRUCTURES
97 98
APPENDIX 3 Commentary
APPENDIX 3 Commentary
99 100
103 104
90o
45o
22 1/2o
11 1/4o
Threshold value
20
Detail 5
UNWELDED STEEL
A B D F A B D F
C E C E
111 112
Longitudinal Fillet
Longitudinal CJP
A B D F
C E
113 114
Category C Details
A B D F
C E
115 116
Category E Details
Coverplated Beam
Transverse Stiffener
A B D F
C E
117 118
3
Log Stress Range (SR, ksi)
1
Category A Category A
Category B Category B
Category E Category E
1 1
20x103 105 106 107 108 20x103 105 106 107 108
Coverplated Beam
Transverse Stiffener
Category A
Category B
Category B
Category F Category C
10
Category G Category D
Category E
Category E
A B D F
1 C E
20x103 105 106 107 108
APPENDIX 3
123 124
where
(a) For stress categories A, B, B, C, D, E and E the
allowable stress range, FSR, shall be determined by Cf = constant from Table A-3.1 for the fatigue category
Equation A-3-1 or A-3-1M, as follows:
0.333 FSR = allowable stress range, ksi (MPa)
Cf
FSR = FTH (A-3.1) FTH = threshold allowable stress range, maximum stress
n
SR range for indefinite design life from Table A-3.1,
ksi (MPa)
0.333
C f x 329 nSR = number of stress range fluctuations in design life
FSR = FTH (S.I.) (A-3.1M) = number of stress range fluctuations per day 365
n SR years of design life
125 126
1
(a) For stress categories A, B, B, C, D, E and E the
allowable stress range, FSR, shall be determined by Category A
Equation A-3-1 or A-3-1M, as follows: Category B
0.333 Category B
Cf 10
Category F Category C
Category E
0.333 Category E
C f x 329
FSR = FTH (S.I.) (A-3.1M) 1
0.167 1 Category B
Cf 10
Category F
6
Category C
Category E
FSR =
(
C f 11 x 10 4 ) 0.167
(c) For tension-loaded plate elements connected at their (a) For stress categories A, B, B, C, D, E and E the
end by cruciform, T or corner details with complete-joint- allowable stress range, FSR, shall be determined by
penetration (CJP) groove welds or partial joint-penetration Equation A-3-1 or A-3-1M, as follows:
(PJP) groove welds, fillet welds, or combinations of the
0.333
preceding, transverse to the direction of stress, the
Cf
allowable stress range on the cross section of the tension- FSR = FTH (A-3.1)
loaded plate element at the toe of the weld shall be n
SR
determined as follows:
0.333
C f x 329
FSR = FTH (S.I.) (A-3.1M)
n SR
131 132
SECTION 1 SECTION 2
PLAIN MATERIAL AWAY FROM ANY WELDING CONNECTED MATERIAL IN
MECHANICALLY FASTENED JOINTS
135 136
SECTION 3 SECTION 4
WELDED JOINTS JOINING COMPONENTS OF LONGITUDINAL FILLET WELDED END CONNECTIONS
BUILT-UP MEMBERS
137 138
SECTION 5 SECTION 6
WELDED JOINTS BASE METAL AT WELDED
TRANSVERSE TO DIRECTION OF STRESS TRANSVERSE MEMBER CONNECTIONS
139 140
SECTION 7 SECTION 8
BASE METAL AT SHORT ATTACHMENTS MISCELLANEOUS
141 142
SECTION 1PLAIN MATERIAL AWAY FROM ANY WELDING SECTION 1PLAIN MATERIAL AWAY FROM ANY WELDING
1.2 B 1.3 B
Description: Noncoated weathering steel base metal with rolled or Description: Member with drilled or reamed holes. Member with
cleaned surface. Flame-cut edges with surface roughness value of re-entrant corners at copes, cuts, block-outs or other geometrical
1,000 in. (25 m) or less, but without re-entrant corners. discontinuities made to requirements of Appendix 3, Section 3.5,
except weld access holes.
Potential Crack Initiation Point: Away from all welds or Potential Crack Initiation Point: At any external edge or at
structural connections. hole perimeter.
145 146
SECTION 2CONNECTED MATERIAL IN MECHANICALLY FASTENED JOINTS SECTION 2CONNECTED MATERIAL IN MECHANICALLY FASTENED JOINTS
2.1 B 2.3 D
Description: Gross area of base metal in lap joints connected by Description: Base metal at the net section of other mechanically
high-strength bolts in joints satisfying all requirements for slip- fastened joints except eye bars and pin plates.
critical connections.
Potential Crack Initiation Point: Through gross section near Potential Crack Initiation Point: In net section originating at
hole. side of hole.
149 150
SECTION 3WELDED JOINTS JOINING COMPONENTS OF BUILT-UP MEMBERS SECTION 3WELDED JOINTS JOINING COMPONENTS OF BUILT-UP MEMBERS
3.1 B 3.2 B
Description: Base metal and weld metal in members without Description: Base metal and weld metal in members without
attachments, built up of plates or shapes connected by continuous attachments, built up of plates or shapes, connected by continuous
longitudinal CJP groove welds, back gouged and welded from longitudinal CJP groove welds with backing bars not removed, or by
second side, or by continuous fillet welds. continuous PJP groove welds.
Potential Crack Initiation Point: From surface or internal Potential Crack Initiation Point: From surface or internal
discontinuities in weld away from end of weld. discontinuities in weld, including weld attaching backing bars.
153 154
SECTION 3WELDED JOINTS JOINING COMPONENTS OF BUILT-UP MEMBERS SECTION 3WELDED JOINTS JOINING COMPONENTS OF BUILT-UP MEMBERS
3.3 D 3.4 E
Description: Base metal at weld metal terminations of longitudinal Description: Base metal at ends of longitudinal intermittent fillet
welds at weld access holes in connected built-up members. weld segments.
Potential Crack Initiation Point: From the weld termination into Potential Crack Initiation Point: In connected materials at start
the web or flange. and stop locations of any weld deposit.
155 156
SECTION 3WELDED JOINTS JOINING COMPONENTS OF BUILT-UP MEMBERS SECTION 3WELDED JOINTS JOINING COMPONENTS OF BUILT-UP MEMBERS
3.5a E 3.5b E
Description: Base metal at ends of partial length welded Description: Base metal at ends of partial length welded
coverplates narrower than the flange having square or tapered coverplates narrower than the flange having square or tapered
ends, with or without welds across the ends. Coverplates wider ends, with or without welds across the ends. Coverplates wider
than the flange with welds across the ends. than the flange with welds across the ends.
Flange thickness (tf) < 0.8 in. (20 mm). Flange thickness (tf) > 0.8 in. (20 mm).
Potential Crack Initiation Point: In flange at toe of end weld or Potential Crack Initiation Point: In flange at toe of end weld or
in flange at termination of longitudinal weld or in edge of flange in flange at termination of longitudinal weld or in edge of flange
with wide coverplates. 157 with wide coverplates. 158
SECTION 4LONGITUDINAL FILLET WELDED END CONNECTIONS SECTION 4LONGITUDINAL FILLET WELDED END CONNECTIONS
4.1a E 4.1b E
Description: Base metal at junction of axially loaded members with Description: Base metal at junction of axially loaded members with
longitudinally welded end connections. Welds shall be on each side longitudinally welded end connections. Welds shall be on each side
of the axis of the member to balance weld stresses. of the axis of the member to balance weld stresses.
Thickness t < 0.5 in. (12 mm). Thickness t > 0.5 in. (12 mm).
Potential Crack Initiation Point: Initiating from end of any weld Potential Crack Initiation Point: Initiating from end of any weld
termination extending into the base metal. termination extending into the base metal.
161 162
SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS
5.2a B 5.2b B
Description: Weld metal and base metal in or adjacent to CJP Description: Weld metal and base metal in or adjacent to CJP
groove welded splices with welds ground essentially parallel to the groove welded splices with welds ground essentially parallel to the
direction of stress at transitions in thickness or width made on a slope direction of stress at transitions in thickness or width made on a slope
no greater than 1:2 1/2 and with weld soundness established by RT no greater than 1:2 1/2 and with weld soundness established by RT
or UT. or UT.
Fy < 90 ksi (620 MPa) Fy 90 ksi (620 MPa).
Potential Crack Initiation Point: From internal discontinuities in Potential Crack Initiation Point: From internal discontinuities in
weld metal or along fusion boundary. weld metal or along fusion boundary or at start of transition when
165 Fy 90 ksi (620 MPa). 166
SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS
5.2b B 5.4 C
SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS
6.1a B 6.1b C
Description: Base metal at details attached by CJP groove welds Description: Base metal at details attached by CJP groove welds
subject to longitudinal loading only when the detail embodies a subject to longitudinal loading only when the detail embodies a
transition radius, R, with the weld termination ground smooth and transition radius, R, with the weld termination ground smooth and
with weld soundness established by RT or UT. with weld soundness established by RT or UT.
R 24 in. (600 mm). 24 in. > R 6 in. (600 mm > R 150 mm)
Potential Crack Initiation Point: Near point of tangency of Potential Crack Initiation Point: Near point of tangency of
radius at edge of member. radius at edge of member.
171 172
SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS
6.1c D 6.1d E
Description: Base metal at details attached by CJP groove welds Description: Base metal at details attached by CJP groove welds
subject to longitudinal loading only when the detail embodies a subject to longitudinal loading only when the detail embodies a
transition radius, R, with the weld termination ground smooth and transition radius, R, with the weld termination ground smooth and
with weld soundness established by RT or UT. with weld soundness established by RT or UT.
6 in. > R 2 in. (150 mm > R 50 mm) R < 2 in. (50 mm)
Potential Crack Initiation Point: Near point of tangency of Potential Crack Initiation Point: Near point of tangency of
radius at edge of member. radius at edge of member.
173 174
SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS
6.1 6.2a B
SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS SECTION 6BASE METAL AT WELDED TRANSVERSE MEMBER CONNECTIONS
6.2e C 6.3a D
Description: Base metal at details of equal thickness attached by Description: Base metal at details of unequal thickness attached
CJP groove welds subject to transverse loading with or without by CJP groove welds subject to transverse loading with or without
longitudinal loading when the detail embodies a transition radius, R, longitudinal loading when the detail embodies a transition radius, R,
with the weld termination ground smooth and with weld soundness with the weld termination ground smooth and with weld soundness
established by RT or UT. Weld reinforcement is not removed. established by RT or UT. Weld reinforcement is removed.
R 24 in. (600 mm) R > 2 in. (50 mm).
Potential Crack Initiation Point: At toe of the weld either along Potential Crack Initiation Point: At toe of weld along edge of
edge of member or the attachment. thinner material.
177 178
SECTION 7BASE METAL AT SHORT ATTACHMENTS SECTION 7BASE METAL AT SHORT ATTACHMENTS
7.1a C 7.1b D
Description: Base metal subject to longitudinal loading at details Description: Base metal subject to longitudinal loading at details
with welds parallel or transverse to the direction of stress where with welds parallel or transverse to the direction of stress where
the detail embodies no transition radius and with detail length in the detail embodies no transition radius and with detail length in
direction of stress, a, and thickness of the attachment, b. direction of stress, a, and thickness of the attachment, b.
a < 2 in. (50 mm) 2 in. (50 mm) a 12b or 4 in. (100 mm)
Potential Crack Initiation Point: Initiating in base metal at the Potential Crack Initiation Point: Initiating in base metal at the
weld termination or at the toe of the weld extending into the base weld termination or at the toe of the weld extending into the base
metal. 181 metal. 182
SECTION 7BASE METAL AT SHORT ATTACHMENTS SECTION 7BASE METAL AT SHORT ATTACHMENTS
7.1c E 7.1d E
Description: Base metal subject to longitudinal loading at details Description: Base metal subject to longitudinal loading at details
with welds parallel or transverse to the direction of stress where with welds parallel or transverse to the direction of stress where
the detail embodies no transition radius and with detail length in the detail embodies no transition radius and with detail length in
direction of stress, a, and thickness of the attachment, b. direction of stress, a, and thickness of the attachment, b.
a > 4 in. (100 mm) when b > 0.8 in. (20 mm) a > 12b or 4 in. (100 mm) when b 0.8 in. (20 mm)
Potential Crack Initiation Point: Initiating in base metal at the Potential Crack Initiation Point: Initiating in base metal at the
weld termination or at the toe of the weld extending into the base weld termination or at the toe of the weld extending into the base
metal. 183 metal. 184
a
a < 2 in.
a < 50mm
C
a < 2 in. (50 mm) C
185 186
SECTION 7BASE METAL AT SHORT ATTACHMENTS SECTION 7BASE METAL AT SHORT ATTACHMENTS
7.2a D 7.2b E
Description: Base metal subject to longitudinal stress at details Description: Base metal subject to longitudinal stress at details
attached by fillet or partial-joint-penetration groove welds, with or attached by fillet or partial-joint-penetration groove welds, with or
without transverse load on detail, when the detail embodies a without transverse load on detail, when the detail embodies a
transition radius, R, with weld termination ground smooth. transition radius, R, with weld termination ground smooth.
Potential Crack Initiation Point: Initiating in base metal at the Potential Crack Initiation Point: Initiating in base metal at the
weld termination, extending into the base metal. weld termination, extending into the base metal.
187 188
SECTION 8MISCELLANEOUS
SECTION 8
8.1 C
MISCELLANEOUS
8.2 F 8.3 E
Description: Shear on throat of continuous or intermittent Description: Base metal at plug or slot welds.
longitudinal or transverse fillet welds.
Potential Crack Initiation Point: Initiating at the root of the fillet Potential Crack Initiation Point: Initiating in the base metal at
weld, extending into the weld. the end of the plug or slot weld, extending into the base metal.
191 192
8.4 F 8.5 G
Description: Shear on plug or slot welds. Description: Snug-tightened high-strength bolts, common bolts,
threaded anchor rods, and hanger rods with cut, ground or rolled
threads. Stress range on tensile stress area due to live load plus
prying action when applicable.
Potential Crack Initiation Point: Initiating in the weld at the Potential Crack Initiation Point: Initiating at the root of the
faying surface, extending into the weld. threads, extending into the fastener.
193 194
0.333
B 61 x 108 12
Cf C 44 x 108 10
FSR = FTH (A-3.1)
n
SR D 22 x 108 7
E 11 x 108 4.5
0.333
C f x 329 E 3.9 x 108 2.6
FSR = FTH (S.I.) (A-3.1M)
n F 150 x 1010 8
SR
G 3.9 x 108 7
195 196
For Imperial Units (ksi)
3. Determine fatigue category from illustration. Find Cf Note 2: For nsr = infinite, FSR < FTH
coefficient for the fatigue detail.
4. Calculate FSR.
5. For all Categories except Category F, for a given live
load, select a member geometry that results in a
stress range less than FSR. For Category F, modify
weld size.
6. Consider alternative connection details with
increased fatigue resistance and recalculate FSR. 197 198
DESIGN EXAMPLE
100,000 cycles
1. Determine the number of cycles the connection must
endure (nsr). 1, 2 100,000 cycles
Grade 50
2. Determine the forces on the connection due to live CJP, reinforcement
and dead loads. Fdead = - 20 K, Flive = + 80 K left in place, UT
6.2h E
0.333
Cf
FSR = FTH
n
SR
201 202
6.2h E
0.333 0.333
11x10 8 11x10 8
FSR =
3
4.5 FSR =
3
4.5
100x10 100x10
203 204
6.2h E 6.2h E
0.333 0.333
Fmax Fmin 11x10 60 - 20 11x10
8 8
FSR = =
3
4.5 FSR = =
3
4.5
A 100x10 A 100x10
205 206
80
FSR = = 22.17
80
FSR = = 11x10 3( )0.333
4.5 A
A Amin = 3.6 in2
207
Use 4 in2 208
6.2h D 6.2h D
80
0.333 FSR = = 27.93
22x10 8
A
FSR =
3
7
100x10 Amin = 2.9 in2
211
Use 3 in2 212
8 A
0
100,000 cycles required Weld receives UT 100,000 cycles required Weld receives UT
3
5
.
1
8
0.333 FSR = =
44x10 8
FSR =
3
10
100x10 Amin = 2.27 in2
215
Use 2.5 in2 216
Category E
6.2h 2.5 wide C
Category D Category C
R = 2
R = 6
W = 3 W = 2.5
219 220
6 7
CategoryC
= 2(1) + 4 = 2(2) + 3
14.5
= 2(6) + 2.5 222
Category A
A B D F
C E
225 226
Category B Category B
227 228
Category B Category B
Category B Category C
231
UT or RT inspected 232
Category C Category C
Category D Category E
Eye bars
235 236
Category E Category E
Category E Category F
Category D Category D
Category B
A B D F
C E
Category E Category G
APPENDIX 3
249 250
where
(a) For stress categories A, B, B, C, D, E and E the
allowable stress range, FSR, shall be determined by Cf = constant from Table A-3.1 for the fatigue category
Equation A-3-1 or A-3-1M, as follows:
0.333 FSR = allowable stress range, ksi (MPa)
Cf
FSR = FTH (A-3.1) FTH = threshold allowable stress range, maximum stress
n
SR range for indefinite design life from Table A-3.1,
ksi (MPa)
0.333
C f x 329 nSR = number of stress range fluctuations in design life
FSR = FTH (S.I.) (A-3.1M) = number of stress range fluctuations per day 365
n SR years of design life
251 252
(b) For stress category F, the allowable stress range, FSR, (c) For tension-loaded plate elements connected at their
shall be determined by Equation A-3-2 or A-3-2M, as end by cruciform, T or corner details with complete-joint-
follows: penetration (CJP) groove welds or partial joint-penetration
(PJP) groove welds, fillet welds, or combinations of the
0.167
Cf preceding, transverse to the direction of stress, the
FSR = FTH (A-3.2) allowable stress range on the cross section of the tension-
n
SR
loaded plate element at the toe of the weld shall be
determined as follows:
(
C f 11 x 10 4
FSR =
) 0.167
Inside Corner
T (tee)
(c) For tension-loaded plate elements connected at their (i) Based upon crack initiation from the toe of the weld on
end by cruciform, T or corner details with complete-joint- the tension loaded plate element the allowable stress
penetration (CJP) groove welds or partial joint-penetration range, FSR, shall be determined by Equation A-3-3 or A-3-
(PJP) groove welds, fillet welds, or combinations of the 3M, for stress category C as follows:
preceding, transverse to the direction of stress, the
allowable stress range on the cross section of the tension- 0.333
loaded plate element at the toe of the weld shall be 44 x 10 8
determined as follows: FSR = 10 (A-3.3)
Three options follow, labeled i, ii, and iii. n SR
0.333
14.4 x 1011
FSR = 68.9 (S.I.) (A-3.3M)
261 n SR 262
(i) Based upon crack initiation from the toe of the weld on Category C
the tension loaded plate element the allowable stress Condition i
range, FSR, shall be determined by Equation A-3-3 or A-3-
3M, for stress category C as follows:
0.333
44 C
x 10 8
FSR = f
10
FTH (A-3.3)
n SR
0.333 Toe Cracks
14.4 1011
Cf xx329
FSR = F
68.9
TH (S.I.) (A-3.3M)
n SR 265
(ii) Based upon crack initiation from the root of the weld where
the allowable stress range, FSR, on the tension loaded RPJP, the reduction factor for reinforced or non-reinforced
plate element using transverse PJP groove welds, with or transverse PJP groove welds, is determined as follows:
without reinforcing or contouring fillet welds, the allowable
stress range on the cross section at the toe of the weld shall 0.65 0.59 2a + 0.72 w
be determined by Equation A-3-4 or A-3-4M, for stress t t
= p p 1.0
category C as follows: RPJP 0.167 (A-3.5)
0.333 tp
44 C
x 10 8
FSR = RPJP f
(A-3.4)
nSR Note: no value for FTH 2a w
1.12 1.01 + 1.24
0.333 t t
14.4 p p 1.0 (S.I.) (A-3.5M)
1011
Cf xx329 RPJP =
FSR = RPJP (S.I.) (A-3.4M) tp
0.167
n SR 271 272
273
w 1.0
Domain of practical
0
.
7
2
2a
w
0
.
6
5
0
.
5
9
0
.
7
2
2a
0.2 + 2a
+
tp
1
.
0
tp
w increases RPJP = Tp = 1
0
.
1
6
7
t t
1
.
0
tp
p p
RPJP =
0
.
1
6
7
0
tp 0 1/8 1/4 3/8 1/2 5/8 3/4 7/8 1 1-1/8
5/16 Fillet Weld Leg Size (w)
275
Minimum fillet size for 1 steel (AWS)
276
Minimum contouring fillet size (AISC)
APPENDIX 3 where
RPJP, the reduction factor for reinforced or non-reinforced
transverse PJP groove welds, is determined as follows:
DESIGN FOR FATIGUE
DK Miller Commentary
3.5. SPECIAL FABRICATION AND ERECTION The term reduction factor may be non-intuitive. A
REQUIREMENTS large reduction factor (a high number) is good in
this case; a small reduction factor is bad.
In transverse complete-joint-penetration T and corner
joints, a reinforcing fillet weld, not less than 1/4 in. (6 mm)
in size shall be added at re-entrant corners.
277 278
REVIEW APPENDIX 3
(a) For stress categories A, B, B, C, D, E and E the
allowable stress range, FSR, shall be determined by
DESIGN FOR FATIGUE Equation A-3-1 or A-3-1M, as follows:
0.333
3.3. PLAIN MATERIAL AND WELDED JOINTS Cf
FSR = FTH (A-3.1)
In plain material and welded joints the range of stress at n
SR
service loads shall not exceed the allowable stress range
computed as follows: 0.333
C f x 329
Three options follow, labeled a, b, and c.
FSR = FTH (S.I.) (A-3.1M)
n SR
279 280
(b) For stress category F, the allowable stress range, FSR, (c) For tension-loaded plate elements connected at their
shall be determined by Equation A-3-2 or A-3-2M, as end by cruciform, T or corner details with complete-joint-
follows: penetration (CJP) groove welds or partial joint-penetration
(PJP) groove welds, fillet welds, or combinations of the
0.167
Cf preceding, transverse to the direction of stress, the
FSR = FTH (A-3.2) allowable stress range on the cross section of the tension-
n
SR
loaded plate element at the toe of the weld shall be
determined as follows:
(
C f 11 x 10 4
FSR =
) 0.167
nSR
281 282
(ii) Based upon crack initiation from the root of the weld
the allowable stress range, FSR, on the tension loaded
(i) Based upon crack initiation from the toe of the weld on
plate element using transverse PJP groove welds, with or
the tension loaded plate element the allowable stress
without reinforcing or contouring fillet welds, the allowable
range, FSR, shall be determined by Equation A-3-3 or A-3-
stress range on the cross section at the toe of the weld shall
3M, for stress category C as follows:
be determined by Equation A-3-4 or A-3-4M, for stress
category C as follows:
0.333
44 x 10 8 44 x 10 8
0.333
FSR = 10 (A-3.3)
FSR = RPJP (A-3.4)
n n
SR
SR
0.333 0.333
14.4 x 1011 14.4 x 1011
FSR = 68.9 (S.I.) (A-3.3M) FSR = RPJP (S.I.) (A-3.4M)
n SR 283 n SR 284
(iii) Based upon crack initiation from the roots of a pair of where
transverse fillet welds on opposite sides of the tension RFIL is the reduction factor for joints using a pair of
loaded plate element, the allowable stress range, FSR, on transverse fillet welds only.
the cross section at the toe of the welds shall be
determined by Equation A-3-6 or A-3-6M, for stress 0.06 + 0.72 w
t
category C as follows:
= p 1.0
0.333
RFIL 0.167 (A-3.7)
tp
44 x 10 8
FSR = RFIL (A-3.6)
nSR
Note: no value for FTH
0.10 0.72 w
0.333 t
14.4 x 1011 RFIL = p 1.0
(S.I.) (A-3.7M)
FSR = RFIL (S.I.) (A-3.6M) t p
0.167
n SR
285 286
If RFIL = 1.0, use stress category C.
determined as follows:
0.06 + 0.72 w
0.2 t 2a
= p 1.0
Three options follow, labeled i, ii, and iii. RFIL
tp
0.167
Tp = 1
i. CJP groove welds 0
0 1/8 1/4 3/8 1/2 5/8 3/4 7/8 1 1-1/8
ii. PJPs without or with fillet welds 5/16 Fillet Weld Leg Size (w)
iii. Fillet welds Minimum fillet size for 1 steel (AWS)
289 290
Minimum contouring fillet size (AISC)
Fillets Fillets
w = (3/4) tp (2a = tp) Select w to obtain RFIL = 1
w w
RFIL > 0.50 for tp < 3 Divide w by tp to obtain multiplier
tp tp
Results in very large fillets
2a 2a
0.8 2
Reduction Factor RFIL
1 t
tp 0.9 2
p
2a 0.7
E = 0.35 tp 0.6
0.5
0.4
0.3
PJP effective throat (E) = fillet weld leg size (w)
0.2
2a = tp 2E = 0.3 tp w = E =0.35 tp 0.1
0
tw = effective throat of combined PJP/fillet
0 1 2 3 4 5
2tw = tp 295 Steel Thickness (in.) 296
SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS
Description: Base metal and weld metal at transverse end Description: Base metal and weld metal at transverse end
connections of tension-loaded plate elements using PJP groove connections of tension-loaded plate elements using PJP groove
welds in butt or T- or corner joints, with reinforcing or contouring welds in butt or T- or corner joints, with reinforcing or contouring
fillets. FSR shall be the smaller of the toe crack or root crack allowable fillets. FSR shall be the smaller of the toe crack or root crack allowable
stress range. stress range.
Crack initiating from weld toe. Crack initiating from weld toe.
Potential Crack Initiation Point: Initiating from geometrical Potential Crack Initiation Point: Initiating from geometrical
discontinuity at toe of weld extending into base metal. discontinuity at toe of weld extending into base metal.
297 298
SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS
Description: Base metal and weld metal at transverse end Description: Base metal and weld metal at transverse end
connections of tension-loaded plate elements using PJP groove connections of tension loaded plate elements using a pair of fillet
welds in butt or T- or corner joints, with reinforcing or contouring welds on opposite sides of the plate. FSR shall be the smaller of the
fillets. FSR shall be the smaller of the toe crack or root crack allowable toe crack or root crack allowable stress range.
stress range.
Crack initiating from weld root. Crack initiating from weld toe.
Potential Crack Initiation Point: Initiating at weld root subject to Potential Crack Initiation Point: Initiating from geometrical
tension extending into and through weld. discontinuity at toe of weld extending into base metal.
299 300
SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS SECTION 5WELDED JOINTS TRANSVERSE TO DIRECTION OF STRESS
5.6b C 5.7 C
Description: Base metal and weld metal at transverse end Description: Base metal of tension loaded plate elements and on
connections of tension loaded plate elements using a pair of fillet girders and rolled beam webs or flanges at toe of transverse fillet
welds on opposite sides of the plate. FSR shall be the smaller of the welds adjacent to welded transverse stiffeners.
toe crack or root crack allowable stress range.
Potential Crack Initiation Point: Initiating at weld root subject to Potential Crack Initiation Point: From geometrical discontinuity at
tension extending into and through weld. toe of fillet extending into base metal.
301 302
304
(a) For stress categories A, B, B, C, D, E and E the (b) For stress category F, the allowable stress range, FSR,
allowable stress range, FSR, shall be determined by shall be determined by Equation A-3-2 or A-3-2M, as
Equation A-3-1 or A-3-1M, as follows: follows:
0.333 0.167
Cf Cf
FSR = FTH (A-3.1) FSR = FTH (A-3.2)
n
SR n
SR
C f x 329
0.333
(
C f 11 x 10 4
FSR =
) 0.167
(c) For tension-loaded plate elements connected at their (i) Based upon crack initiation from the toe of the weld on
end by cruciform, T or corner details with complete-joint- the tension loaded plate element the allowable stress
penetration (CJP) groove welds or partial joint-penetration range, FSR, shall be determined by Equation A-3-3 or A-3-
(PJP) groove welds, fillet welds, or combinations of the 3M, for stress category C as follows:
preceding, transverse to the direction of stress, the
allowable stress range on the cross section of the tension- 0.333
loaded plate element at the toe of the weld shall be 44 x 10 8
determined as follows: FSR = 10 (A-3.3)
n SR
0.333
14.4 x 1011
FSR = 68.9 (S.I.) (A-3.3M)
307 n SR 308
(ii) Based upon crack initiation from the root of the weld (iii) Based upon crack initiation from the roots of a pair of
the allowable stress range, FSR, on the tension loaded transverse fillet welds on opposite sides of the tension
plate element using transverse PJP groove welds, with or loaded plate element, the allowable stress range, FSR, on
without reinforcing or contouring fillet welds, the allowable the cross section at the toe of the welds shall be
stress range on the cross section at the toe of the weld shall determined by Equation A-3-6 or A-3-6M, for stress
be determined by Equation A-3-4 or A-3-4M, for stress category C as follows:
category C as follows: 0.333
0.333 44 x 10 8
44 x 10 8 FSR = RFIL (A-3.6)
FSR = RPJP (A-3.4)
n SR
n SR Note: no value for FTH
0.333
14.4 x 1011
14.4 x 10 11
0.333
FSR = RFIL (S.I.) (A-3.6M)
FSR = RPJP (S.I.) (A-3.4M) n SR
nSR 309 310
1
20x103 105 106 107 108