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Weld Wars 

Lincoln loses control over study to prevent collapse of skyscrapers

Wednesday, May 12 1999
Photo by Slobodan Dimitrov

In the beginning, the mysterious seismic-retrofit project in San Bernardino bore the unmistakable aroma of congressional pork. Through an intense, clandestine lobbying campaign, Lincoln Electric, America’s largest maker of welding materials, got Congress to set aside $5 million to solve the company’s biggest corporate dilemma: brittle Lincoln welds — in thousands of buildings — that could cause high-rises to collapse in earthquakes. The federal money seemed to be virtually under Lincoln’s control, a boon to help the company research an escape from liability for its product.

But something strange happened on the way to the federal feedbag. Word of the impending study leaked out to top engineering professionals across the country, and as a result, Lincoln has now been edged out of the driver’s seat, while a scientific donnybrook has erupted over who should control the research project and what it ought to accomplish.

At stake here is more than just a company’s profits or the fate of its welds. This particular Lincoln glue is a fundamental part of nearly every modern skyscraper built over the last 30 years, as basic to the construction job as the steel itself. All the updated building codes, all the high-tech earthquake-proofing, may be for naught when the Big One — or even the Medium One — hits these brittle welds. The cost of fixing these buildings is staggering. The cost of not doing so is unthinkable. But five years after the problem was discovered, not thinking about it is mostly what’s been done. And so the federal research money that Lincoln maneuvered for, to salvage its own product, was just too important to leave in the hands of a multibillion-dollar corporation with a vested interest.

The San Bernardino project is not only an opportunity to learn something before an earthquake hits, but a chance to save lives and prevent billions of dollars in property damage, says Thomas Sabol, an L.A.-area engineer widely viewed as an expert on steel-frame retrofitting. Sabol is among an assertive but loosely organized collection of scientists, bureaucrats and college professors who want to extract public value from these unanticipated research dollars.

Joining the fray is a government-funded advisory council called SAC; it was previously created by Congress to propose solutions to the problem of brittle welds, but members of SAC’s executive committee complained that they had no knowledge of the San Bernardino project until learning about it from the Weekly. Now SAC is trying to make up for lost time by forwarding its own bid to direct the project.

The research will take place under the auspices of Cal State San Bernardino, so its administrators figure they are in charge. And they’ve made one thing clear: They won’t take direction from Lincoln. For the moment, the welding company has retired to the sidelines, but that hasn’t silenced critics such as George Soneff, a Santa Monica attorney currently suing Lincoln over its welds. "If Lincoln had been working honestly, if its motive had been pure, it would have alerted the engineering community" about the San Bernardino project, he says.

The Northridge quake in 1994, followed by the Kobe, Japan, quake one year later, exposed an unsuspected structural calamity-in-waiting. In seismic zones around the world — including downtown L.A. — brand-new skyscrapers are in danger of collapsing (in Kobe several did) because their steel frames are cemented together with a cheap-and-easy weld material that cracks under moderate earthquake vibrations.

This disturbing reality especially worried Cleveland-based Lincoln Electric, which supplied the questionable weld metal, called NS-3M, to Southland builders. Representatives from Lincoln continued to sell NS-3M in seismically vulnerable areas long after industry tests indicated that the product was prone to fracture in earthquakes. In fact, a year after welds cracked by the Northridge temblor were discovered, Duane Miller, Lincoln’s top weld expert, sold the same product to builders of the San Bernardino County Medical Center, located about a mile away from the San Andreas and San Jacinto faults. San Bernardino County authorities insist that these welds, some of which actually cracked during the hospital’s construction without any seismic pressure, have now been either replaced or reinforced at a cost of $6 million in public funds, but the documentation is inconclusive.

Other former Lincoln clients are not so sanguine. Since the Northridge quake, Lincoln has been sued by 16 separate building owners over its welds. In some cases, buildings had to be completely evacuated when severe fractures in major support columns were discovered. Nearly all of these suits have been settled out of court for undisclosed sums. And Lincoln insists that other factors, such as poor workmanship, are really to blame for the cracked connections.

But Lincoln remains legally vulnerable, and in 1997, the company launched a million-dollar lobbying campaign through the "Seismic Safety Coalition." According to federal lobbyist reports, Lincoln is the only dues-paying member of this coalition, which hired California’s own Leon Panetta, former Clinton chief of staff and congressman, to knock on congressional doors.

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