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RE: 5/16 Fillet Weld

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The number of passes for a given weld is a function of process and position. As a general rule, stick welding in the shop will yield a maximum single pass fillet weld of 5/16". In the field the general rule is the maximum single pass fillet weld is 1/4". A fast freeze rod is generally used in the field and a fast fill rod is generally used in the shop. (Commonly called a mud rod)

With wire (either shielded or inner shield) single passes can result in significantly larger single pass welds.

Harold Sprague

From: "dave lowen" <jatech(--nospam--at)>
Reply-To: <seaint(--nospam--at)>
To: <seaint(--nospam--at)>
Subject: RE: 5/16 Fillet Weld
Date: Wed, 11 Jan 2006 20:08:44 -0500


No, I didn't mean more passes would be required. Bill was correct in stating
that a 5/16 fillet is a single pass weld. I am saying that the cross
sectional area of a 5/16 fillet is 3 times larger than that of a 3/16 fillet
requiring 3 times more filler metal to be deposited. A welding operator
cannot move the arc 3 times faster in order to deposit filler metal at the
same speed he would for a smaller weld.

Bills' thinking is wise because it provides sacrificial material for the
corrosion process. This is done all the time in steel mills, particularly in
the by-products area, where the "more is better" theory prevails.

My intent was to point out that engineers who specify larger than required
welds on their projects dramatically increase the cost of the job. I was
taught that the second highest outlay of a fab shop was hydro, and welding
consumes a lot of hydro.




From: Neil Moore [mailto:nmoore(--nospam--at)]
Sent: January 11, 2006 6:26 PM
To: seaint(--nospam--at)
Subject: RE: 5/16 Fillet Weld


Dave's comment is good.  What he might of meant was that more weld passes
would be required.  We weren't interested in a particular job but the
overall economy of any project where welds larger than really required will
increase the costs.

It might be of value to read  Section 7.5 in Blodgett's "Design of Welded
Structures", one of  the structural engineers bibles.

Neil Moore, SE, SECB
neil moore and associates
consulting structural engineers
shingle springs, ca

distressed structures investigations

At 02:04 PM 1/11/2006, you wrote:

Dave -

Yep, that was me.

I understand your point about the difference in the quantity of weld metal
deposed. I'm not a welder, and I'm not sure the deposition rate is the same.

The bottom line: The welder on this job says this about the proposed change:
"No Biggie".

T. William (Bill) Allen, S.E.
Consulting Structural Engineers
-----Original Message-----
From: dave lowen [ mailto:jatech(--nospam--at) <mailto:jatech(--nospam--at)> ]
Sent: Wednesday, January 11, 2006 11:34 AM
To: seaint(--nospam--at)
Subject: 5/16 Fillet Weld

I think it was Bill Allen who posted a message this morning (I deleted it
already) regarding changing a fillet weld size from 3/16 to 5/16 because it
only amounted to a little more electrode.
In fact, a 5/16 fillet requires approximately 3 times the electrode as a
3/16 weld.

One could assume that if the deposition rate in pounds per hour were the
same for both welds then the larger weld would take 3 times as long, a
substantial labor cost.

Dave Lowen
V 519 587 5797
F 519 587 5138
E jatech(--nospam--at)

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