![]() I am not an advocate of making larger than necessary fillet welds, but I caution inspectors not to apply requirements that cannot be substantiated by a code or contract requirement. It can cost the inspector his job when the employer or owner receives a sizable bill for unnecessary rework. Make sure you are not reading into the code requirements something that is not there. I've done it before and it can be very profitable. Should a third party inspector ask that an oversized fillet weld be reduced by grinding or otherwise, I would comply, but I would bill his employer for the cost of handling, reworking the welds, and repainting plus any additions costs incurred for unnecessary rework or repairs. There is no basis for rejecting an oversized fillet weld in any of the AWS D1.x structural welding codes. You may find Figure 5.4 and Tables 5.9 and 5.10 helpful (also found in AWS D1.1-2010) useful. However, that limitation is for the design of the weld, not the inspection or acceptance of the weld. Refer to figure 2.1 in D1.1-2010 (as an example). If the joint in question is a lap joint, the weld needs not be larger than the thickness of the member if it is less than 1/4 inch or 1/16 inch less than the thickness of the base metal if the thickness is 1/4 inch or thicker. ![]() D1.1 does not address the maximum size of a fillet weld except in the case of a lap joint.
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