HSS Insider – June 2026 – HSS Welding

June 2026 | Issue #45

In this issue of HSS Insider, learn how AWS D1.1 welding qualification requirements apply to common HSS connections and explore a new quick-reference guide for weld qualification testing. We also highlight the 2026 Mastering HSS Connections webinar series, July’s webinar on atypical HSS connections, and registration details for the 2026 HSS Summit.

Not All Tubular Connections are Welded Equal

AWS D1.1 packs a lot into a few clauses — and the logic of plate versus tubular qualification isn’t obvious on a first read. This article unpacks it: how AWS D1.1 organizes its welding requirements, what each position designation (1F through 6GR) demands of the welder, why tubular T-, Y-, and K-connections are so difficult to weld, and the everyday HSS connections that don’t need tubular qualifications at all.

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HSS Welding Position Reference

Plate test or tubular? For HSS connections, the answer isn’t always obvious — and an unnecessary tubular requirement costs time and money. This quick-reference chart lays out the qualification requirements side by side, with test setups and real connection examples, so the right path is clear.

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Webinar

The Mastering HSS Connections Series

STI is continuing the Mastering HSS Connections webinar series in 2026 with a comprehensive, multi-session program focused on HSS connection design. Building on the 2025 series launch, this series combines live and on-demand learning to give you the tools and confidence to design a wide range of connections.

From fundamental principles to more advanced design topics, each session is built to help you take on real-world challenges.

Earn Continuing Education Credits – Earn up to 12 PDH credits, with 1 PDH available per webinar. 

Click below for series packages and pricing. Receive discounts as an HSS Professional Member. Click here to become an HSS Professional Membership.

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Outside the Manual: Designing Atypical HSS Connections Beyond Standard Guidelines

Take a closer look at one-sided bolting options for HSS connections as alternatives to welding and through-bolting, with discussion on connection behavior, load transfer, and detailing considerations. This June webinar also examines applicable design references and key limit states to check in the supporting HSS wall that often governs connection capacity. Participants can earn 1.0 PDH upon completion.

This live webinar has already been presented. Click below to watch other HSS recorded webinars on demand.

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2026 HSS Summit
Special Launch Pricing Ends Today!

The Steel Tube Institute’s 2026 HSS Summit brings together fabricators, service centers, and engineers November 10–12 in Huntsville, Alabama. This exclusive 2.5-day event features expert-led educational sessions and collaborative discussions focused on the latest opportunities, challenges, and innovations in Hollow Structural Sections (HSS).

Attendees can also take part in guided tours of the Nucor Steel Decatur hot roll mill and Nucor Tubular Products facility, plus enjoy a special reception and dinner at the U.S. Space & Rocket Center beneath the Saturn V Apollo moon rocket.

• Continuing Education: Learn about material availability, connection detailing, design and fabrication, software, manufacturing equipment, and sustainability. Sessions are eligible for PDH credits.
• Roundtable & Panel Discussions: Exchange ideas and best practices with industry leaders and peers.
• Breakout Sessions: Participate in targeted discussions tailored to your role and interests in the industry.

Register now to receive the launch pricing of $200 (available through June 30). Pricing will increase to $300 starting tomorrow.

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Related Resources

Welding of Hollow Structural Sections

This article explores how connection geometry, weld selection, and load distribution affect HSS joint performance, while outlining practical approaches for designing economical and effective welded connections. It also highlights when fillet, PJP, and CJP welds are appropriate and the impact each has on fabrication complexity and cost.

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Welding in HSS Corners

Welding in HSS corners is generally not recommended but is sometimes necessary for full-width and moment-connected applications, despite the challenges posed by rounded corner geometry. This article reviews flare-groove weld behavior, effective throat calculations, and practical fabrication solutions for matched-width HSS connections and other demanding details.

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Structure: Know Your HSS Welds

Explore key factors in weld design for HSS, including the flexibility of the HSS wall, the size of the corner radius, and the effects of single-sided welds. Understanding weld type selection and design is key to maximizing the benefits of HSS framing while minimizing fabrication/erection costs.

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