The Lincoln Electric Company
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1 2004 The Lincoln Electric Company
2 Customer Assistance Policy The business of The Lincoln Electric Company is manufacturing and selling high quality welding equipment, consumables, and cutting equipment. Our challenge is to meet the needs of our customers and to exceed their expectations. On occasion, purchasers may ask Lincoln Electric for advice or information about their use of our products. We respond to our customers based on the best information in our possession at that time. Lincoln Electric is not in a position to warrant or guarantee such advice, and assumes no liability, with respect to such information or advice. We expressly disclaim any warranty of any kind, including any warranty of fitness for any customer s particular purpose, with respect to such information or advice. As a matter of practical consideration, we also cannot assume any responsibility for updating or correcting any such information or advice once it has been given, nor does the provision of information or advice create, expand or alter any warranty with respect to the sale of our products. Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in applying these types of fabrication methods and service requirements. Document Updates The information contained in this document is believed to be accurate at the time of printing and is subject to change as additional information and data become available. Examples of such modifications include, but are not limited to, the incorporation of additional product data. The reader is encouraged to check the Lincoln Electric website for updates. (2)
3 Background In September 1995 the SAC Joint Venture received funding through the Federal Emergency Management Agency (FEMA) to address both immediate and long-term needs related to solving performance problems with welded, steel moment-frame connections discovered following the 1994 Northridge, California earthquake. The Recommended Specifications and Quality Assurance Guidelines for Steel Moment-Frame Construction for Seismic Applications (FEMA 353) 1 was one of the final products of the SAC project. For the remainder of this document it will be referred to simply as FEMA 353. FEMA 353 contains recommended specifications and quality assurance guidelines, incorporating the knowledge gained from the now-completed SAC project, that are deemed necessary to achieve the design objectives for steel moment-frame buildings subject to seismic loading. The document was prepared in two parts. Part I, Recommended Specifications, provides recommended supplemental recommendations for typical steel projects subject to seismic loading, which are intended to be included in the job specifications. Despite the fact that FEMA 353 has not been subjected to a formal consensus adoption process, these recommendations have received extensive review by practicing engineers, researchers, fabricators and erectors. The American Institute of Steel Construction (AISC) and the American Welding Society (AWS) are currently in the process of considering incorporating various portions of FEMA 353 into the AISC Seismic Provisions and the AWS Structural Welding Code. It is anticipated that many of these recommendations will be included in AISC and AWS documents over the next couple of years. Part II, Recommended Quality Assurance Guidelines, was prepared to provide design professionals, building officials, and contractors with recommended procedures for performing quality control and quality assurance functions. As with Part I, these recommendations are not mandatory but are deemed appropriate to achieving the construction standards. (1) Available at no charge in the United States from FEMA, (800) (3) SM
4 FEMA 353 is not intended to be a stand-alone specification. Rather, it is meant to be used as a supplement to, and in coordination with, a complete specification for steel construction. For example, when included in contract documents, FEMA 353 may augment the AWS Structural Welding Code for Steel (AWS D1.1). The requirements of AWS D1.1 would govern in addition to the recommendations in FEMA 353. Although FEMA 353 is a recommendation as written, its standards can become requirements if they are incorporated into a contract. Therefore, for FEMA 353 to be required, the Engineer must specify it in the contract documents. Much of the technical background for the FEMA 353 is contained in FEMA 355B, State of the Art Report on Joining and Inspection. 2 In addition, the Fabricators and Erectors Guide to Welded Steel Construction, published by the James F. Lincoln Arc Welding Foundation, contains information on seismic and other structural welding issues. 3 What s New? The following is a summary of FEMA 353 recommendations related to procurement of arc welding consumables. This does not, however, include the topics of design, quality control, quality assurance, joint details, or other fabrication/erection issues. As a cross-reference, FEMA 353 page numbers are listed in parentheses. 1. Weld Categories The Engineer must specify the Seismic Weld Demand Category and the Seismic Weld Consequence Category of certain welded joints. Once specified, these classifications must be included on the shop and erection drawings (Part I: p.1-7). A and B Weld Demand Categories are intended for connections that are expected to experience service stresses equal to or beyond the yield level. For example, beam-to-column complete joint penetration (CJP) groove welds are generally considered to be in either A or B category (Part II: p.5-10). (2) State of the Art Report on Joining and Inspection (FEMA 355B). Federal Emergency Management Agency. (3) Fabricators and Erectors Guide to Welded Steel Construction. The James F. Lincoln Arc Welding Foundation, (4) SM
5 2. The Filler Metal Trade Name is an Essential Variable It is recommended that the Welding Procedure Specification (WPS) include the welding electrode and/or flux manufacturer s name and the product trade name (Part I: p.1-11). 3. Electrode Diameter is an Essential Variable It is recommended that the WPS list the electrode diameter to be used, which is considered an essential variable (Part I: p.1-11). 4. Weld Strength It is recommended that all welds be made with E70 type filler metals (nominal 70 ksi tensile strength). However, if A913 Grade 65 is used, an E80 type filler metal shall be used for matching strength (Part I: p.2-3). 5. Charpy V-Notch Toughness FEMA 353 recommends that all filler metals in the Seismic-Force-Resisting System meet the following CVN levels (Part I: p.2-3): a. 20 ft-lb at 0 F (in accordance with the appropriate AWS filler metal specification) b. 40 ft-lb at 70 F (using the test method prescribed in Appendix A of FEMA 353) 6. Appendix A Test Method (CVN Toughness) FEMA 353 has two options for certifying that the product meets the 70 F CVN recommendations. One option calls for testing to be conducted for each production lot. Two test plates are to be welded for each electrode diameter used, one at a low heat input and one at a high heat input. 4 In addition to the heat input, the preheat and interpass temperatures are prescribed to obtain relatively fast and slow cooling rates. FEMA 353 recommends that 30 kj/in (70 F preheat and 200 F interpass temperature) and 80 kj/in (300 F preheat and 500 F interpass temperature) heat inputs be used. However, a wider or narrower range of heat inputs can be tested, which may be a function of the operating characteristics of the electrode. The WPS used must fall within the range of heat inputs and interpass temperatures tested. (4) The Errata to FEMA 353 dated March 16, 2001, states that two test plates, one for each heat input level, shall be used and 5 CVN test specimens shall be made per plate. (5) SM
6 Alternatively, the testing per each lot may be waived if that manufacturer produces products that meet the AWS Filler Metal Procurement Guidelines (AWS A5.01) and if the manufacturer s quality assurance program is approved by the Engineer. An example of a quality assurance program can be found in the AWS Bridge Welding Code (AWS D1.5) Fracture Control Plan, where lot testing requirements can be waived for fracture critical members. The Bridge Welding Code states that welding consumables produced under continuing quality assurance programs audited and approved by one or more of the following agencies shall be exempt from heat and lot testing (1) American Bureau of Shipping (ABS), (2) Lloyd s Register of Shipping, or (3) American Society of Mechanical Engineers (ASME) (Section , AWS D1.5-95). The Lincoln Electric Company is audited and certified by ABS and ASME, as well as to ISO 9001 (see Appendix A for examples of these quality certificates). With the Engineer s approval, the typical certificates of conformance (see Appendix B for an example) along with the Toughness Verification Test Results (see Appendix C) should suffice as verification that the product meets the recommendations (Part I: p.a-1). 7. Hydrogen Level It is recommended that filler metal for use on Seismic Weld Demand Category A or B welds meet the requirements for H16 (maximum 16 ml diffusible hydrogen per 100 grams deposited weld metal), as defined by AWS A4.3. The typical certificate of conformance showing diffusible hydrogen test results shall be adequate proof that the electrodes meet this recommendation (Part I: p.2-4). 8. Packaging It is recommended that FCAW electrodes be received in moisture-resistant packages that are undamaged (Part I: p.2-4). 9. Intermixing FCAW When self-shielded FCAW electrodes are to be used in Seismic Weld Demand Category A or B (6)
7 welds in combination with other processes (including gas-shielded FCAW), Appendix C testing is recommended (Part I: p.3-6). 10. Intermixing FCAW Tests (Appendix C) Appendix C recommends a supplemental filler metal test when self-shielded FCAW is to be mixed in the same joint with other welding processes. In the test, the first (or root) filler metal is used to fill one-third of the joint and then the second one is used to complete the joint. Five CVN specimens are taken from the mid-thickness location in order to ensure maximum mixing of the two filler metals. The average CVN toughness of the specimens shall equal or exceed 40 ft-lb at 70 F (Part I: p. C-1). 11. FCAW Ambient Air Exposure Limits a. It is recommended that the exposure time for FCAW electrodes be based on Appendix D tests (Part I: p.3-6). b. In lieu of testing - If welding ceases for more than 8 hours, the coil shall be removed from the machine and stored in an oven at 250 to 550 F, or as recommended by the manufacturer. - If the electrode sees more than 24 hours of total exposure (outside of closed or heated storage), then the coil cannot be used for Category A or B welds. However, if testing shows that drying is effective at removing moisture and restoring the electrodes to less than 16 ml of diffusible hydrogen, then the electrode can be heated as described above (Part I: p.3-6). 12. FCAW Exposure Testing (Appendix D) To qualify for an extended exposure time limit for FCAW, it is recommended that the electrode be exposed to an environment of 80 F and 80% relative humidity for the exposure limit desired. After the exposure time, diffusible hydrogen tests shall be performed for each diameter for which qualification is sought. Based on the test results, it is recommended that the manufacturer provide (7)
8 recommendations for storage and atmospheric exposure to ensure that the diffusible hydrogen level will not exceed an H16 classification (Part I: p. D-1). 13. Contractor s Responsibility - Contractor s Responsibility: Should supplemental certifications for the welding material not be available from the manufacturer, it is recommended that the Contractor have the necessary testing performed and provide the applicable test reports (Part I: p.1-10). - Contractor Submittals: It is recommended that the submitted shop and erection drawings contain the weld demand and consequence categories, as well as identification of the applicable WPS for each weld. For other non-welding issues see FEMA 353, Part I: p.1-6 and Certificates of Compliance: It is recommended that the Contractor submit a letter stating that the manufacturer s certifications and test reports have been reviewed, and that the materials being furnished for the project are in conformance with the applicable standards, specifications and project documents (Part I: p.1-8). - Manufacturer s Test Reports: It is recommended that the Contractor submit copies of the manufacturer s certificates of conformance to the Engineer (Part I: p.1-10). -Welding Procedure Specifications (WPSs): It is recommended that the Contractor submit all WPSs to be used by the Contractor on the project to the Engineer. For WPSs that are not prequalified, the supporting Procedure Qualification Record (PQR) should be submitted with the WPS. In addition, all the product data sheets for the welding consumables to be used on the project should be submitted (Part I: p.1-11). -Welding Performance Qualification Records (WPQRs): It is recommended that the Contractor submit written Welding Performance Qualification Records (WPQRs) for all welding personnel under the Contractor s supervision who will be welding on the project (Part I: p. 1-12). - Supplemental Welding Personnel Testing: It is recommended that the welders and welding operators performing work on category A or B welds pass a Supplemental Welder Qualification Test on a special mock-up joint per Appendix B (Part I: p. 3-5). -Welder Stamps: It is recommended that each welder mark or stamp a unique symbol at each completed weldment (Part I: p.3-2). - Ultrasonic Testing Mark: It is recommended that a visible mark for UT, be placed on (8)
9 the steel approximately four inches away from the weld for all welds that are to be ultrasonic tested (Part I: p.3-2). -Wind Velocity Limits: It is recommended that the wind velocity in the immediate vicinity of the weld not exceed three miles per hour for GMAW, FCAW-G, GTAW and EGW (Part I: p. 3-6). - Minimum Preheat and Interpass Temperature: It is recommended that the preheat and interpass temperatures be in the range as tested in accordance with Appendix A for welds in Seismic Demand Categories A, B, or C. The AWS D1.1 Structural Welding Code minimum preheat temperatures should also be followed (Part I: p. 3-6). - Maximum Preheat and Interpass Temperature: The maximum preheat and maximum interpass temperature permitted is 550 F, measured one inch away from the weld (Part I: p.3-7). - Ceramic or Copper Backing: It is recommended that the welder pass a qualification test with the specific type of backing to be used in production. This includes the use of non-fusible backing materials, including ceramic or copper (Part I: p.3-7). - Controlled Cooling: Controlled cooling after welding is not required per FEMA 353 (Part I: p. 3-8). - Post Weld Heat Treatment: PWHT is not required per FEMA 353 (Part I: p. 3-6). Compliance with FEMA 353 1) Lincoln Electric has created a new line of seismic products that are intended for use in applications subject to FEMA 353 (See Table 1). Each product and electrode diameter has been tested and is packaged in accordance with the FEMA 353 recommendations. a) These products have been tested at the heat input ranges listed (using the test method prescribed in Appendix A of FEMA 353) 5 and meet the recommended CVN levels of 20 ft-lb at 0 F and 40 ft-lb at 70 F under the prescribed conditions. Test reports for each product are located in Appendix B of this document. Lincoln Electric will publish additional or updated reports as new data become available. (5) Appendix A of FEMA 353 requires a 3/4 in. test plate with a 1/2 in. root opening and a 45 included angle. Most of these tests in Table 1 were conducted with this geometry; however, for some the root opening and included angle varied due to the operating characteristics of the product. All of the test plates were 3/4 in. (9) SM
10 b) These products are shipped in either hermetically sealed plastic containers or vacuumsealed foil bags that are resistant to damage and moisture, helping to ensure that the packaging requirements are satisfied. Other ED0 numbers for the same product will not necessarily have the special packaging. Therefore, these ED0 numbers should be ordered if the products must comply with the FEMA 353 packaging recommendations. Outershield XLH70 is shipped in 500 lb. drums. Testing has demonstrated that XLH70 will become rusty prior to exceeding diffusible hydrogen limits as outlined in FEMA 353. The product at this point would be very difficult to feed through a conventional welding gun and liner. c) As with other Lincoln FCAW products, these meet the H16 diffusible hydrogen requirement. Additionally, FEMA 353 does not mandate the position in which the test plates are to be welded. The tests were welded in the flat and vertical up positions. (10)
11 Table 1. Electrodes Intended for Applicatons Subject to FEMA 353. Sealed Package AWS Shielding Diameter Heat Input Extended Sealed Package With Lot Testing Trade Name Classification Gas (in.) Range (kj/in.) Exposure Time Package Without Lot Control & Lot Controlled Innershield NR-232 E71T Week 13.5# Coil (54# Herm. Seal Pail) ED ED Innershield NR-232 E71T Week 33# Steel Spool in Foil Bag ED ED Innershield NR-232 E71T Week 13.5# Coil (54# Herm. Seal Pail) ED ED Innershield NR-232 E71T Week #25 Plastic Spool in Foil Bag ED ED Innershield NR-232 E7IT-8-5/ Week 13.5# Coil (54# Herm. Seal Pail) ED ED Innershield NR-232 E7IT-8-5/ Week 25# Steel Spool in Foil Bag ED ED Innershield NR-305 E70T-6-3/ Week 25# Plastic Spool in Foil Bag ED ED (1) Innershield NR-305 E70T-6-3/ Week 50# Coil in Foil Bag ED ED Innershield NR-550-H E81T8-N.21 5/ Weeks 25# Plastic Spool in Foil Bag ED Outershield 71 Elite E71T-1, -9 CO Weeks 33# Steel Spool in Foil Bag ED ED Outershield 71 Elite E71T-1, -9 CO Weeks 33# Steel Spool in Foil Bag ED ED Outershield 71 Elite E71T-1, -9 CO2 1/ Weeks 25# Plastic Spool in Foil Bag ED ED Outershield XLH70 E70T-1, -9 CO2 3/ Weeks 50# Coil in Foil Bag ED ED Outershield XLH70 E70T-1, -9 CO2 3/ Weeks 500# Fiber Drum ED ED All product numbers subject to change without notice. (1) Readi-Reel Footnote: 1 The following additional products have been tested and meet the FEMA 353 mechanical testing requirements. These products may be special ordered through your local Lincoln Electric office for further information. 1/16 NR-233 5/64, 3/32, 7/64 NR-311Ni 5/64, 3/32 NR-203 Ni 1%.045, 1/16 Outershield 81Ni1-H.045,.052, 1/16 Outershield 71M.068, 5/64 NR-203MP (11)
12 2) The Fabricators and Erectors Guide to Welded Steel Construction 6 contains data and a technical discussion regarding intermixing of self-shielded FCAW filler metals with other processes. For specific Lincoln Electric electrode combinations, the reader is advised to review this document. If data for the combination in question is not available, contact the regional Lincoln Electric sales office. 3) FEMA 353 has two options regarding FCAW storage and exposure limits. Until further testing is conducted, it is recommended that the requirements outlined in FEMA 353 be followed (see FCAW Ambient Air Exposure Limits). What s Next? The FEMA 353 guide is not an ANSI consensus document as is the case with other standards such as the AWS D1.1 Structural Welding Code. Therefore, in the near future it is anticipated that other organizations (e.g., AWS and AISC) will incorporate appropriate provisions into the codes and standards under a consensus process. FEMA 353 is not a living document and will not be updated. The SAC project has finished its tasks and has been dissolved. As FEMA 353 is being implemented, there will likely be provisions in the document requiring interpretation and adjustment. It will be the responsibility of the Engineer and the Contractor to understand the requirements of the particular job and specify the appropriate material. For information on welding products suitable for applications subject to FEMA 353, contact the regional Lincoln Electric sales office in your area. Information is also available online at (6) Table 6-1, page 35. (12) SM
13 References 1. Federal Emergency Management Agency, July 2000, Recommended Specifications and Quality Assurance Guidelines for Steel Moment-Frame Construction for Seismic Applications (FEMA 353), FEMA, Washington, D.C. 2. Federal Emergency Management Agency, May 2000, 100% Draft - State of the Art Report on Joining and Inspection (FEMA 355B), FEMA, Washington, D.C. (final version has not been printed as of June 2001). 3. The James F. Lincoln Arc Welding Foundation, August 1999, Fabricators and Erectors Guide to Welded Steel Construction, Cleveland, OH. 4. American Welding Society, 2000, Structural Welding Code for Steel (AWS D1.1), Miami, FL. 5. American Welding Society, 1995, Bridge Welding Code (AWS D1.5), Miami, FL. 6. American Welding Society, 1993, Filler Metal Procurement Guidelines (A5.01), Miami, FL. 7. American Institute of Steel Construction, Inc., April Seismic Provisions for Structural Steel Buildings, AISC, Chicago, IL. (13)
14 Appendix A: Lincoln Electric Quality Certifications (14)
15 (15)
16 (16)
17 Appendix B: Certificate of Conformance Example (17)
18 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (18)
19 Appendix C: Test Reports (19)
20 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (20) SM
21 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (21) SM
22 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (22) SM
23 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (23)
24 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (24) SM
25 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (25) SM
26 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (26) SM
27 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (27)
28 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (28)
29 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (29)
30 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (30)
31 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (31) SM
32 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (32)
33 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (33)
34 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (34)
35 The Lincoln Electric Company St. Clair Avenue Cleveland, OH (35)
36 LINCOLN NORTH AMERICA DISTRICT SALES OFFICES U.S.A. ALABAMA BIRMINGHAM (205) MOBILE (251) ALASKA Contact VANCOUVER, WA (360) ARIZONA PHOENIX (480) ARKANSAS LITTLE ROCK (501) CALIFORNIA FRESNO (559) LOS ANGELES (562) SACRAMENTO (916) SAN DIEGO (760) SAN FRANCISCO (925) COLORADO DENVER (303) CONNECTICUT NORTH HAVEN (860) FLORIDA JACKSONVILLE (904) MIAMI (305) ORLANDO (407) TAMPA (813) GEORGIA ATLANTA (770) SAVANNAH (912) HAWAII Contact LOS ANGELES, CA (562) IDAHO BOISE (208) ILLINOIS CHICAGO (630) PEORIA (630) INDIANA EVANSVILLE (812) FT. WAYNE (260) SOUTH BEND (219) INDIANAPOLIS (317) IOWA CEDAR RAPIDS (319) DAVENPORT (563) DES MOINES (515) KANSAS KANSAS CITY (913) WICHITA (316) KENTUCKY LOUISVILLE (502) LOUISIANA BATON ROUGE (225) LAFAYETTE (337) SHREVEPORT (318) MARYLAND BALTIMORE (443) MASSACHUSETTS BOSTON (508) MICHIGAN DETROIT (248) FLUSHING (810) GRAND RAPIDS (616) MINNESOTA MINNEAPOLIS (763) MISSISSIPPI JACKSON (601) MISSOURI KANSAS CITY (KS) (913) ST. LOUIS (314) SPRINGFIELD (417) MONTANA Contact VANCOUVER, WA (360) NEBRASKA OMAHA (402) NEW JERSEY EDISON (732) NEW MEXICO ALBUQUERQUE (505) NEW YORK ALBANY (518) BUFFALO (716) NEW YORK CITY (888) SYRACUSE (315) NORTH CAROLINA CHARLOTTE (704) RALEIGH (919) OHIO AKRON (330) CINCINNATI (513) CLEVELAND (216) COLUMBUS (614) DAYTON (937) TOLEDO (419) OKLAHOMA OKLAHOMA CITY (405) TULSA (918) PENNSYLVANIA PHILADELPHIA (610) PITTSBURGH (724) HARRISBURG (717) SOUTH CAROLINA GREENVILLE (864) COLUMBIA (803) SOUTH DAKOTA SIOUX FALLS (605) TENNESSEE KNOXVILLE (865) MEMPHIS (901) NASHVILLE (615) TRI-CITIES (423) TEXAS DALLAS (817) HOUSTON (281) SAN ANTONIO (830) UTAH MIDVALE (801) VIRGINIA HERNDON Washington, D.C. (703) DANVILLE (434) HAMPTON ROADS (757) WASHINGTON VANCOUVER (360) SPOKANE (509) WASHINGTON DC HERNDON, VA (703) WEST VIRGINIA CHARLESTON (304) WISCONSIN GREEN BAY (920) MILWAUKEE (262) CANADA ALBERTA CALGARY (403) /(877) 600-WELD EDMONTON (780) WINNIPEG (204) BRITISH COLUMBIA VANCOUVER (604) MARITIMES NEW BRUNSWICK (506) MANITOBA WINNIPEG (204) ONTARIO MISSISSAUGA (905) TORONTO (416) /(800) QUEBEC MONTREAL (450) LATIN AMERICA Miami, Florida U.S.A. Phone: (305) LINCOLN INTERNATIONAL HEADQUARTERS EUROPE Barcelona, Spain Phone: RUSSIA, AFRICA & MIDDLE EAST Cleveland, Ohio U.S.A. Phone: (216) HARRIS CALORIFIC DIVISION 2345 Murphy Blvd., Gainesville, Georgia U.S.A. Phone: Fax: (770) Web Site: ASIA PACIFIC Singapore Phone: Australia Phone: THE WELDING EXPERTS THE LINCOLN ELECTRIC COMPANY St. Clair Ave. Cleveland, Ohio TEL: FAX: Consumables C1.60 8/04
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