FEMA Manual

The Lincoln ElectricCompany

2004

SM

FEMA 353 Welding Manual

One Source For All Your Welding & Cutting Needs

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)

(1)Available at no charge in the United States from FEMA, (800) 480-2520.



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 recom-

mended 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 profes-

sionals, 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.

(3)SM

(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, 1999.



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 infor-

mation 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).

(4)SM

(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 testspecimens shall be made per plate.”



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.

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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 12.6.1.1, 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 prod-

uct 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

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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

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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 1-7.

- 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)

(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 inTable 1 were conducted with this geometry; however, for some the root opening and included angle varied due to the operating char-acteristics of the product. All of the test plates were 3/4 in.



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.

(9)SM

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Additionally, FEMA 353 does not mandate the position in which the test plates are to be welded. The tests were welded in the flatand vertical up positions.



b) These products are shipped in either hermetically sealed plastic containers or vacuum-

sealed 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.

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(6)Table 6-1, page 35.



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

http://www.lincolnelectric.com.

(12)SM

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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 1997. Seismic Provisions for Structural Steel

Buildings, AISC, Chicago, IL.

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Appendix A: Lincoln Electric Quality Certifications

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Appendix B: Certificate of Conformance Example

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Appendix C: Test Reports

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THE LINCOLN ELECTRIC COMPANY

22801 St. Clair Ave.Cleveland, Ohio 44117-1199

TEL: 216.481.8100 • FAX: 216.486.1751

www.lincolnelectric.com

THE WELDING EXPERTS

ConsumablesC1.60 8/04

LINCOLN NORTH AMERICADISTRICT SALES OFFICES

U.S.A.ALABAMABIRMINGHAM 35124-1156 (205) 988-8232MOBILE 36582-5209(251) 443-6524

ALASKAContact VANCOUVER, WA (360) 693-4712

ARIZONAPHOENIX 85260-1745(480) 348-2004

ARKANSASLITTLE ROCK 72032-4371(501) 764-0480

CALIFORNIAFRESNO 93722-3949(559) 276-0110LOS ANGELES 90670-2936(562) 906-7700SACRAMENTO 95819-3111(916) 452-1425SAN DIEGO 92065-4165(760) 787-1970SAN FRANCISCO 94551-4847(925) 443-9353

COLORADODENVER 80112-5115(303) 792-2418

CONNECTICUTNORTH HAVEN 06238-1090(860) 742-8887

FLORIDAJACKSONVILLE 32216-4634(904) 642-3177MIAMI 33178-1175(305) 888-3203ORLANDO 32714-1974(407) 788-8557TAMPA 33594(813) 477-5817

GEORGIAATLANTA 30076-4914(770) 475-0955SAVANNAH 31324-5180(912) 727-4286

HAWAIIContact LOS ANGELES, CA(562) 906-7700

IDAHOBOISE 83616-6646(208) 938-2302

ILLINOISCHICAGO 60527-5629(630) 920-1500PEORIA 60527-5629(630) 920-1500

INDIANAEVANSVILLE 47630(812) 454-3428FT. WAYNE 46825-5547(260) 484-4422SOUTH BEND 46561-9160(219) 674-5523INDIANAPOLIS 46250-5536(317) 845-8445

IOWACEDAR RAPIDS 52402-3160(319) 362-6804DAVENPORT 52806-1344(563) 386-6522DES MOINES 50265-6218(515) 963-1778

KANSASKANSAS CITY 66214-1625(913) 894-0888WICHITA 67037-9614(316) 788-7367

KENTUCKYLOUISVILLE 47112-7025(502) 727-7335

LOUISIANABATON ROUGE 70808-3150(225) 922-5151LAFAYETTE 70507-3126(337) 886-1090SHREVEPORT 75692-9313(318) 518-4099

MARYLANDBALTIMORE 21050-3067(443) 831-0416

MASSACHUSETTSBOSTON 01701-7726(508) 788-9353

MICHIGANDETROIT 48034-4005(248) 353-9680FLUSHING 48433-1855(810) 487-1310GRAND RAPIDS 49512-3924(616) 942-8780

MINNESOTAMINNEAPOLIS 55447-4743(763) 551-1990

MISSISSIPPIJACKSON 39212-9635(601) 372-7679

MISSOURIKANSAS CITY (KS) 66214-1625(913) 894-0888ST. LOUIS 63045(314) 291-5877SPRINGFIELD 65804(417) 841-2779

MONTANAContact VANCOUVER, WA(360) 693-4712

NEBRASKAOMAHA 68046-2826(402) 339-1809

NEW JERSEYEDISON 08837-3939(732) 225-2000

NEW MEXICOALBUQUERQUE 87008(505) 890-6347

NEW YORKALBANY 12304-4320 (518) 469-8222BUFFALO 14075-2520(716) 646-8414NEW YORK CITY (888) 269-6755SYRACUSE 13057-9313(315) 432-0281

NORTH CAROLINACHARLOTTE 28273-6200(704) 588-3251RALEIGH 27604-8456(919) 303-1972

OHIOAKRON 44236-4680(330) 342-8009CINCINNATI 45242-3706(513) 554-4440CLEVELAND 44117-2525(216) 383-2662COLUMBUS 43221-4073(614) 488-7913DAYTON 45458(937) 885-6964TOLEDO 43528-9483(419) 867-7284

OKLAHOMAOKLAHOMA CITY 73139-2432(405) 616-1751TULSA 74146-1622(918) 622-9353

PENNSYLVANIAPHILADELPHIA 19008-4310(610) 543-9462PITTSBURGH 15001-4800(724) 857-2750HARRISBURG 17104-1422(717) 213-9163

SOUTH CAROLINAGREENVILLE 29681-4724(864) 967-4157COLUMBIA 29209(803) 783-2851

SOUTH DAKOTASIOUX FALLS 57108-2609(605) 339-6522

TENNESSEEKNOXVILLE 37922-1736(865) 966-9648MEMPHIS 38115-5946(901) 363-1075NASHVILLE 37027(615) 236-1144TRI-CITIES 37659-5693(423) 753-8098

TEXASDALLAS 76051-7602(817) 329-9353HOUSTON 77060-3143(281) 847-9444SAN ANTONIO 78133-3502(830) 964-2421

UTAHMIDVALE 84047-3759(801) 233-9353

VIRGINIAHERNDON 20170-5227Washington, D.C.(703) 904-7735DANVILLE(434) 489-3222HAMPTON ROADS 23693-4171(757) 870-5508

WASHINGTONVANCOUVER 98661-8023(360) 693-4712SPOKANE 99005-9637(509) 468-2770

WASHINGTON DCHERNDON, VA 20170-5227(703) 904-7735

WEST VIRGINIACHARLESTON 25526-8864(304) 757-9862

WISCONSINGREEN BAY 54302-1829(920) 435-1012MILWAUKEE 53186-0403(262) 650-9364

CANADAALBERTACALGARY(403) 253-9600/(877) 600-WELDEDMONTON(780) 436-7385WINNIPEG(204) 488-6398

BRITISH COLUMBIAVANCOUVER(604) 945-7524

MARITIMESNEW BRUNSWICK(506) 849-4474

MANITOBAWINNIPEG(204) 488-6398

ONTARIOMISSISSAUGA(905) 565-5600TORONTO(416) 421-2600/(800) 268-0812

QUEBECMONTREAL(450) 654-3121

LINCOLN INTERNATIONAL HEADQUARTERS

HARRIS CALORIFIC DIVISION2345 Murphy Blvd., Gainesville, Georgia 30504 U.S.A.

Phone: 1-800-241-0804 • Fax: (770) 535-0544 • Web Site: www.harriscal.com

LATIN AMERICAMiami, Florida U.S.A.Phone: (305) 888-3203

EUROPEBarcelona, Spain Phone: 34 91 816 4266

RUSSIA, AFRICA & MIDDLE EASTCleveland, Ohio U.S.A.Phone: (216) 481-8100

ASIA PACIFICSingaporePhone: 65 6773 6689AustraliaPhone: 61 2 9772 7222

Documents

FEMA Manual