Fillet vs. Groove Welds for Plate Girder Web-to-Flange Connections

Most plate girders are designed using fillet welds at the web-to-flange connections, but some engineers choose groove welds. Designers should be aware that while either type of weld will work — both offer the same quality — in the author’s experience, groove welds can require more than 20 times as much effort as fillet welds. This effort translates into significant time and cost. Hence, in design situations where fillet welds will work, groove welds are wasteful, and fillet welds are the prudent choice.

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