Plug Weld Sizing Calculator

Calculate plug weld diameter, spacing, and shear capacity per AWS D1.1 structural welding code

Input Parameters

Results

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Minimum Plug Diameter
in
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Capacity per Plug
lb
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Minimum Center Spacing
in
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Total Joint Capacity
lb
Note: Plug welds are used to connect lapping members when fillet welds are impractical. Per AWS D1.1, plug weld holes must be filled flush. Maximum plate thickness for plug welds is the depth of the hole.

Reference

AWS D1.1 Section 2.4.5 Plug Weld Requirements: Min diameter for t < 5/8 in: d >= t + 5/16 in Min diameter for t >= 5/8 in: d >= t + 3/8 in Min center-to-center spacing: 4 x diameter Shear capacity = 0.60 * FEXX * filler area * reduction factor Depth of fill: minimum = plate thickness