This report provides a comprehensive update of key considerations and drivers that will influence FCAW-S weld performance. The major focus has been toughness, specifically in understanding the causes of seemingly large variation in measured toughness. Analysis of the data indicates that improving welding practice is an effective tool for reducing the toughness variation and enhancing overall weld performance. Comparisons are made with the performance of other welding processes commonly used for pipeline girth welding, such as SMAW.