This paper presents an investigation of gusset-plate welded connections in both VHS tubes and SSHS subject to tension. Tensile tests on the connections in VHS tubes were carried out. It was found that shorter weld lengths resulted in block shear tear-out (TO) or shear lag (SL) failure. The existing TO and SL design rules in various standards were examined both for welded VHS tubes and for welded SSHS from other studies. Possible modifications to the existing design rules were postulated and examined. New design rules with the corresponding capacity factors based on a FOSM reliability analysis are proposed both for TO failure and for SL failure. Critical weld lengths are also proposed to predict the failure modes.
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