This paper describes welded connection tests that were performed on sq
uare (SHS) and rectangular hollow sections (RHS) with a thickness rang
ing from 1.6 to 3.0 mm. Longitudinal fillet welds were tested. The tes
t results are compared with existing American, Australian, Canadian, a
nd European design formulas. The effect of the direction of loading, t
he weld length, the end return welds, and the orientation of an RHS on
the weld strength are studied. Proposed design formulas are given. Th
e reliability analysis method is used to calibrate the existing and pr
oposed design formulas.