Connection Checks — Engineering Reference
AISC 360 demand-to-capacity checks for steel connections: bolt shear, bearing, block shear, weld throat, and tearout limit states explained.
Overview
Every steel connection must be checked against a series of limit states to confirm that the demand-to-capacity ratio (DCR) does not exceed 1.0 for any failure mode. A DCR = R_u / (phi x R_n), where R_u is the required strength (factored demand) and phi x R_n is the design strength (factored capacity). The connection is adequate when every DCR <= 1.0. The governing DCR (the highest ratio) identifies the controlling limit state and the remaining reserve in the connection.
AISC 360-22 Chapter J provides the limit state equations for bolts (J3), welds (J2), and connecting elements (J4). A typical bolted shear connection requires checking 6-10 limit states; a moment connection may require 12-15 checks including column-side verifications.
Complete limit state checklist
Bolted connection checks
| # | Limit State | AISC Section | Equation | phi |
|---|---|---|---|---|
| 1 | Bolt shear | J3.6, Table J3.2 | R_n = F_nv x A_b x n_s | 0.75 |
| 2 | Bolt bearing | J3.10 | R_n = 1.2 x L_c x t x F_u (per bolt) | 0.75 |
| 3 | Bolt tearout | J3.10 | R_n = 1.5 x d x t x F_u (upper limit) | 0.75 |
| 4 | Bolt tension | J3.6, Table J3.2 | R_n = F_nt x A_b | 0.75 |
| 5 | Combined shear-tension | J3.7 | F'_nt = 1.3F_nt - (F_nt/(phi x F_nv)) x f_rv | 0.75 |
| 6 | Slip resistance | J3.8 | R_n = mu x D_u x h_f x T_b x n_s | 1.00 or 0.85 |
Connecting element checks
| # | Limit State | AISC Section | Equation | phi |
|---|---|---|---|---|
| 7 | Gross section yielding | J4.1(a) | R_n = F_y x A_g | 0.90 (tension), 1.00 (shear) |
| 8 | Net section rupture | J4.1(b) | R_n = F_u x A_e | 0.75 |
| 9 | Block shear rupture | J4.3 | R_n = 0.6F_u x A_nv + U_bs x F_u x A_nt | 0.75 |
| 10 | Plate flexure | F11 or J4 | M_n = F_y x Z (compact) | 0.90 |
| 11 | Plate buckling | E3 (Thornton) | P_n = F_cr x A_whitmore | 0.90 |
Weld checks
| # | Limit State | AISC Section | Equation | phi |
|---|---|---|---|---|
| 12 | Fillet weld shear | J2.4 | R_n = 0.60 x F_EXX x t_e x L | 0.75 |
| 13 | Base metal at weld | J2.4 | R_n = 0.60 x F_u x t x L (shear) | 0.75 |
| 14 | CJP weld (tension) | J2.3 | Same as base metal | per base metal |
Column-side checks (moment connections)
| # | Limit State | AISC Section | Equation | phi |
|---|---|---|---|---|
| 15 | Column flange bending | J10.1 | Yield line / T-stub | 0.90 |
| 16 | Web local yielding | J10.2 | R_n = F_yw x t_w x (5k + l_b) | 1.00 |
| 17 | Web crippling | J10.3 | Per AISC Eq. J10-4 | 0.75 |
| 18 | Web panel zone shear | J10.6 | R_v = 0.60 x F_y x d_c x t_w | 0.90 |
Worked example — DCR summary for a shear tab
Given: W21x44 beam, R_u = 55 kip, 3/8 in. x 9 in. A36 shear tab, three 3/4 in. A325-N bolts at 3 in. spacing, 5/16 in. fillet weld (E70XX) to W14x48 column.
| Check | phi x R_n (kip) | R_u (kip) | DCR | Status |
|---|---|---|---|---|
| Bolt shear (3 bolts) | 53.7 | 55 | 1.02 | NG — need 4 bolts |
| Bearing on tab (3 bolts) | 58.2 | 55 | 0.94 | OK |
| Block shear (beam web) | 112 | 55 | 0.49 | OK |
| Block shear (tab) | 98 | 55 | 0.56 | OK |
| Tab gross shear yielding | 72.9 | 55 | 0.75 | OK |
| Tab net shear rupture | 66.7 | 55 | 0.82 | OK |
| Weld (2 x 9 in. lines) | 111.5 | 55 | 0.49 | OK |
| Column web yielding | 185 | 55 | 0.30 | OK |
Revised with 4 bolts (12 in. tab): Bolt shear = 4 x 17.9 = 71.6 kip. DCR = 55/71.6 = 0.77. All checks pass. Governing limit state: bolt shear at DCR = 0.77.
Demand-to-capacity ratio interpretation
| DCR Range | Interpretation |
|---|---|
| 0.00 - 0.50 | Significantly over-designed — consider reducing plate/bolt size |
| 0.50 - 0.85 | Efficient design — good balance of economy and reserve |
| 0.85 - 0.95 | Tight design — acceptable but limited reserve for field changes |
| 0.95 - 1.00 | Marginally adequate — reconsider if loading assumptions change |
| > 1.00 | Fails — must revise connection |
Code comparison — connection check approach
| Feature | AISC 360 | AS 4100 | EN 1993-1-8 | CSA S16 |
|---|---|---|---|---|
| Bolt shear check | Table J3.2 (F_nv tabulated) | Clause 9.2.2 (V_f) | Table 3.4 (alpha_v x f_ub x A) | Clause 13.12.1 |
| Block shear model | Combined shear + tension planes | Clause 9.1.9 | Not explicit (use Annex) | Clause 13.11 |
| Bearing model | 1.2 L_c t F_u per bolt | 3.2 d t f_up | k_1 x alpha_b x f_u x d x t | 3 x phi x n x t x d x F_u |
| Weld directional strength | 1.0 + 0.50 sin^1.5(theta) | Not permitted | k_w directional factor | Not permitted |
| Base metal check required | Yes (J2.4) | Yes (implicitly) | Yes (Table 4.1) | Yes |
Common mistakes to avoid
- Checking bolt shear but skipping bearing/tearout — bearing on thin plates (shear tabs, gussets) with short edge distances frequently governs over bolt shear. This is the single most commonly missed check in practice.
- Not checking block shear on the beam web — at coped beams, the beam web block shear capacity can be 30-50% lower than the bolt group shear capacity. This check must be performed for every coped beam connection.
- Using gross area for net section rupture — the net area deducts bolt holes (nominal diameter + 1/16 in. per AISC B4.3). Forgetting hole deductions overestimates the rupture capacity.
- Ignoring base metal capacity at welds — the weld may be stronger than the base metal it connects to. Both the weld throat and the base metal at the weld must be checked. For thin plates with large welds, base metal shear rupture often governs.
- Not presenting a DCR summary — a well-organized DCR table is essential for peer review and building permit approval. Presenting only the governing check without showing all limit states makes it impossible for the reviewer to verify completeness.
AISC Chapter J connection design checklist
AISC 360-22 Chapter J governs the design of all steel connections. The chapter is organized by connection element type, and each section contains the limit state equations that must be satisfied. The following checklist summarizes the key sections and the checks required for each connection type.
| Chapter J Section | Scope | Primary Checks | Typical Application |
|---|---|---|---|
| J1.1 | Joint terminology | Definitions | All connections |
| J2 | Welds | Fillet weld throat, CJP strength, PJP effective throat, base metal at weld | Welded shear tabs, moment connections, brace gussets |
| J3 | Bolts | Shear, tension, combined shear-tension, bearing, tearout, slip resistance | Bolted shear tabs, moment end plates, base plates |
| J4 | Connecting elements | Gross yielding, net rupture, block shear, compression buckling | Gusset plates, shear tabs, angle clips, tee stems |
| J5 | Filler plates | Thicker filler requirements, filler contribution | Bolted splices with different member depths |
| J10 | Flanges and webs | Flange local bending, web local yielding, web crippling, web panel zone shear | Moment connections, concentrated forces on columns |
A complete connection design must address every applicable section of Chapter J. For a typical simple shear connection (single-plate shear tab), Sections J2, J3, and J4 cover the majority of limit states. For a fully welded moment connection, Sections J2 and J10 are the primary references, with J4 for the end plate or flange plate.
Connection design workflow
- Determine the required strength from the structural analysis (R_u for LRFD or R_a for ASD).
- Select a preliminary connection configuration (bolt count, plate size, weld size).
- Check all applicable bolt limit states (shear, bearing, tearout, tension, combined loading, slip).
- Check all applicable weld limit states (fillet weld throat capacity, base metal capacity).
- Check all connecting element limit states (gross yielding, net rupture, block shear, plate buckling).
- Check the supported member (beam web block shear, coped section capacity).
- Check the supporting member (column web yielding, web crippling, panel zone shear).
- Tabulate DCR values for all limit states and confirm the governing DCR is less than or equal to 1.0.
Bolt limit states in detail
Bolt shear (AISC J3.6)
Bolt shear capacity is the most fundamental bolt check. The nominal shear strength per bolt is:
R_n = F_nv * A_b * n_s
where F_nv is the nominal shear stress from AISC Table J3.2, A_b is the nominal bolt area (pi * d^2 / 4), and n_s is the number of shear planes (1 for single shear, 2 for double shear).
| Bolt Grade | F_nv (ksi) Single Shear | F_nv (ksi) Double Shear | Thread Condition |
|---|---|---|---|
| A325-N | 54 | 54 | Threads in shear plane |
| A325-X | 68 | 68 | Threads excluded from shear plane |
| A490-N | 68 | 68 | Threads in shear plane |
| A490-X | 84 | 84 | Threads excluded from shear plane |
| A307 | 27 | 27 | N/A (no X condition) |
The phi factor is 0.75 for bolt shear. Note that double shear does not change Fnv — it simply provides two shear planes, doubling the total capacity per bolt. For example, a 3/4 in. A325-N bolt in double shear: phi * Rn = 0.75 * 54 _ 0.4418 _ 2 = 35.8 kip per bolt.
Bolt bearing and tearout (AISC J3.10)
Bolt bearing capacity depends on the clear distance between the edge of the hole and the adjacent hole or material edge (L_c). When deformation at the bolt hole is a design consideration (which is the usual case), the nominal bearing strength per bolt is the lesser of:
R_n = 1.2 * L_c * t * F_u (bearing deformation limit)
R_n = 2.4 * d * t * F_u (upper bound — tearout limit)
where L_c is the clear distance in the direction of force, t is the connected material thickness, F_u is the tensile strength of the connected material, and d is the nominal bolt diameter.
For a bolt at the edge of a plate with edge distance L_e and standard hole diameter d_h = d + 1/16 in.:
L_c = L_e - d_h / 2 = L_e - (d + 1/16) / 2
For interior bolts at spacing s:
L_c = s - d_h = s - (d + 1/16)
Bearing often governs for thin plates (shear tabs, gussets) with large bolts and close spacing. The phi factor is 0.75 for both bearing and tearout.
Bolt tension and combined loading (AISC J3.6, J3.7)
When bolts are loaded in tension only (e.g., anchor bolts, hanger connections), the nominal tensile strength per bolt is:
R_n = F_nt * A_b
| Bolt Grade | F_nt (ksi) |
|---|---|
| A325 | 113 |
| A490 | 141 |
| A307 | 60 |
When a bolt is simultaneously loaded in shear and tension (e.g., prying action in a moment end plate, bracket connections), the interaction equation applies:
F'_nt = 1.3 * F_nt - (F_nt / (phi * F_nv)) * f_rv <= F_nt
where f*rv is the required shear stress in the bolt. The modified tensile capacity is then phi * F'_nt _ A_b. This interaction check prevents the bolt from failing simultaneously in both shear and tension.
Slip resistance (AISC J3.8)
Slip-critical connections use pretensioned bolts to clamp the connected plies together, preventing slip under service loads. The nominal slip resistance is:
R_n = mu * D_u * h_f * T_b * n_s
where mu is the slip coefficient (0.30 for Class A, 0.50 for Class B surfaces), D_u is a factor reflecting the ratio of mean installed pretension to minimum pretension (1.13 per the AISC Commentary), h_f is a factor for fillers (1.00 for no filler), T_b is the minimum bolt pretension from AISC Table J3.1, and n_s is the number of slip planes.
| Bolt Diameter (in.) | A325 Min. Pretension T_b (kip) | A490 Min. Pretension T_b (kip) |
|---|---|---|
| 5/8 | 19 | 24 |
| 3/4 | 28 | 35 |
| 7/8 | 39 | 49 |
| 1 | 51 | 64 |
| 1-1/8 | 64 | 80 |
| 1-1/4 | 81 | 102 |
The resistance factor for slip is 1.00 at the service load level (LRFD) or 0.85 at the factored load level (when slip is checked at the strength limit). Slip-critical connections are required for connections subject to fatigue, connections with oversized holes, connections with slotted holes loaded perpendicular to the slot, and connections where slip would compromise the structural integrity.
Weld limit states in detail
Fillet weld shear (AISC J2.4)
The nominal shear strength of a fillet weld per unit length is:
R_n = 0.60 * F_EXX * t_e * L
where F_EXX is the weld electrode tensile strength (70 ksi for E70XX), t_e is the effective throat thickness (0.707 * w for equal-leg fillet welds with leg size w), and L is the weld length.
For E70XX fillet welds, the capacity per inch of weld per sixteenth of leg size is approximately:
phi * R_n per inch = 0.75 * 0.60 * 70 * 0.707 * w = 22.3 * w (kip/in., w in inches)
Or equivalently, 1.39 kip per inch per sixteenth of leg size. A 5/16 in. fillet weld (5 sixteenths) has a capacity of 5 * 1.39 = 6.95 kip per inch of weld.
Weld length limitations
AISC J2.2b imposes the following limits on fillet welds:
- Minimum effective length: 4 times the weld size (w). If the length is less than 4w, the effective weld size is reduced to L/4.
- Maximum effective length for longitudinal welds: For flat-bar-to-plate connections loaded in tension, the effective length is limited to 70w (to account for nonuniform strain distribution along very long welds). Transverse welds do not have this limit.
- Minimum weld size: Per AISC Table J2.4, the minimum fillet weld size depends on the thinner connected part: 1/8 in. for material up to 1/4 in. thick, 3/16 in. for material 1/4 to 1/2 in., 1/4 in. for material 1/2 to 3/4 in., and 5/16 in. for material over 3/4 in. thick.
- Maximum single-pass weld size: 5/16 in. for flat position, 1/2 in. for horizontal/vertical. Larger welds require multiple passes.
Directional strength increase (AISC J2.4)
When the load on a fillet weld is not parallel to the weld axis, the weld capacity increases due to the directional strength effect. The nominal strength becomes:
R_n = 0.60 * F_EXX * t_e * L * (1.0 + 0.50 * sin^1.5(theta))
where theta is the angle between the weld axis and the line of force. For a transverse weld (theta = 90 degrees), the increase factor is 1.0 + 0.50 * sin^1.5(90) = 1.50, giving a 50% increase in capacity. This is a significant advantage when using transverse fillet welds instead of longitudinal welds.
Limit state priority table
The following table ranks the most common limit states by how frequently they govern in practice, based on typical building connection configurations:
| Priority | Limit State | Frequency of Governing | Common Scenario |
|---|---|---|---|
| 1 | Bolt shear | Very High | Shear tabs, double-angle connections, end plates |
| 2 | Bearing on connected material | High | Thin shear tabs, gusset plates with close bolt spacing |
| 3 | Block shear rupture | High | Coped beam webs, gusset plates, angle legs |
| 4 | Net section rupture | Moderate | Angles with multiple bolt lines, plates with many holes |
| 5 | Fillet weld shear | Moderate | Welded shear tabs, bracket connections |
| 6 | Slip resistance | Moderate | Slip-critical connections, connections with slotted holes |
| 7 | Gross section yielding | Low | Thick plates, stocky gussets |
| 8 | Tearout | Low | Connections with short edge distances |
| 9 | Column web yielding | Low | Light columns with heavy connections |
| 10 | Panel zone shear | Low | Moment connections in seismic frames |
Worked example: simple shear connection for W18x50 beam
Given: W18x50 beam (t_w = 0.355 in., d = 18.0 in., F_y = 50 ksi, F_u = 65 ksi) framing into a W14x61 column. Required shear R_u = 45 kip. Use a single-plate shear tab (A36, F_y = 36 ksi, F_u = 58 ksi) with 3/4 in. A325-N bolts and 5/16 in. fillet weld (E70XX) to the column flange.
Step 1 -- Preliminary configuration: Select a 3/8 in. x 8 in. shear tab with three 3/4 in. A325-N bolts at 3 in. spacing. Edge distance at top and bottom = 1.0 in. Weld length = 8 in. (two vertical lines, one each side of tab).
Step 2 -- Bolt shear: phi _ R_n = 0.75 _ 54 _ 0.4418 _ 3 bolts = 53.7 kip. DCR = 45 / 53.7 = 0.84. OK.
Step 3 -- Bolt bearing on shear tab: Standard hole diameter d*h = 3/4 + 1/16 = 13/16 in. Clear distance at edge bolt: L_c = 1.0 - 13/32 = 0.594 in. Bearing at edge bolt: R_n = 1.2 * 0.594 _ 0.375 _ 58 = 15.5 kip. phi _ R_n = 11.6 kip. Clear distance at interior bolts: L_c = 3.0 - 13/16 = 2.188 in. Bearing at interior bolt: R_n = 1.2 _ 2.188 _ 0.375 _ 58 = 56.9 kip. phi _ R_n = 42.7 kip. Check tearout at edge bolt: R_n = 2.4 _ 0.75 _ 0.375 _ 58 = 39.2 kip. phi _ R_n = 29.4 kip. Total phi * R_n = 11.6 + 42.7 + 42.7 = 97.0 kip. DCR = 45 / 97.0 = 0.46. OK.
Step 4 -- Block shear on shear tab: Gross shear area Anv = 2 * (1.0 + 2 _ 3.0) _ 0.375 = 5.25 in.^2 Net shear area Anv_net = A_nv - 2.5 * (13/16 + 1/16) _ 0.375 = 5.25 - 2.5 _ 0.875 _ 0.375 = 5.25 - 0.820 = 4.43 in.^2 Gross tension area A_nt = 1.5 _ 0.375 = 0.563 in.^2 (approximate, from last bolt to edge) Net tension area A*nt_net = A_nt - 0.5 * 0.875 _ 0.375 = 0.563 - 0.164 = 0.399 in.^2
phi _ R_n = 0.75 _ (0.6 _ 58 _ 4.43 + 1.0 _ 58 _ 0.399) = 0.75 _ (154.2 + 23.1) = 0.75 _ 177.3 = 133.0 kip. DCR = 45 / 133.0 = 0.34. OK.
Step 5 -- Shear tab gross shear yielding: phi _ R_n = 1.00 _ 36 _ 8.0 _ 0.375 = 108.0 kip. DCR = 45 / 108.0 = 0.42. OK.
Step 6 -- Shear tab net shear rupture: Net area = (8.0 - 3 _ 0.875) _ 0.375 = (8.0 - 2.625) _ 0.375 = 2.016 in.^2 phi _ R*n = 0.75 * 58 _ 2.016 = 87.7 kip. DCR = 45 / 87.7 = 0.51. OK.
Step 7 -- Fillet weld capacity: Two 8 in. lines of 5/16 in. fillet weld (E70XX): phi _ R_n = 0.75 _ 0.60 _ 70 _ (0.707 _ 5/16) _ 2 _ 8 = 0.75 _ 0.60 _ 70 _ 0.221 * 16 = 111.5 kip. DCR = 45 / 111.5 = 0.40. OK.
Step 8 -- Block shear on beam web (assuming cope at top flange): This check is required when the beam is coped. For an uncoped beam with the shear tab bolted through the beam web, the beam web block shear is generally adequate for typical configurations but must be verified per project conditions.
Summary DCR table:
| Limit State | phi * R_n (kip) | DCR | Status |
|---|---|---|---|
| Bolt shear (3 bolts) | 53.7 | 0.84 | Governs |
| Bearing on tab | 97.0 | 0.46 | OK |
| Block shear (tab) | 133.0 | 0.34 | OK |
| Gross shear yielding | 108.0 | 0.42 | OK |
| Net shear rupture | 87.7 | 0.51 | OK |
| Fillet weld (2 x 8 in.) | 111.5 | 0.40 | OK |
Governing limit state: bolt shear at DCR = 0.84. The connection has adequate reserve and does not require revision.
Run this calculation
Related references
- Steel Connection Design
- Bolt Capacity Table
- How to Verify Calculations
- Bolted Connection Types
- Weld Joint Types
- Gusset Plate Design
- steel connection capacity calculator
- weld capacity for connection design
- bolt grade properties
- weld electrode reference
- bolt group capacity calculator
Disclaimer
This page is for educational and reference use only. It does not constitute professional engineering advice. All design values must be verified against the applicable standard and project specification before use. The site operator disclaims liability for any loss arising from the use of this information.
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