IEEE Standard for Fasteners for

Overhead Line Construction

IEEE Power and Energy Society

Sponsored by the
Transmission and Distribution Committee

IEEE
3 Park Avenue
New York, NY 10016-5997
USA

IEEE Std C135.80-2012

26 November 2012

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for

Overhead Line Construction
Sponsor

Transmission and Distribution Committee

of the

IEEE Power and Energy Society

Approved 19 October 2012

IEEE-SA Standards Board

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Abstract: The requirements of inch-based: (1) zinc-coated ferrous carriage bolts, machine bolts,
double-arming bolts, double-end bolts, washer-head bolts, eye bolts, eye nuts, and washer nuts;
(2) zinc-coated ferrous lag screws of the fetter drive, gimlet point, and twist drive type;
(3) washers; and (4) staples, commonly used in overhead line construction, are covered. Metric
bolts, nuts, and lag screws are not covered by this standard.
Keywords: bolt, hardware, IEEE C135.80, line, nut, overhead, screw, staple, washer

The Institute of Electrical and Electronics Engineers, Inc.

3 Park Avenue, New York, NY 10016-5997, USA
Copyright 2012 by The Institute of Electrical and Electronics Engineers, Inc.
All rights reserved. Published 26 November 2012. Printed in the United States of America.
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Participants
At the time this IEEE standard was completed, the Overhead Lines, Structural Materials, and Hardware
Working Group had the following membership:
Keith E. Lindsey, Chair
Thomas McCarthy, Vice Chair
Dick Aichinger
Mehmet Arslan
Gordon Baker
Tony Baker
Yair Berenstein
Allen Bernstorf
Nelson G. Bingel, III
Tom Bozeman
Derrick Bradstreet
Michael Brucato
Dave Bryant
Bill Calhoun
Steve Casteel
John Chan
Neal Chapman
Jerry Cheeks
Allen Clapp
Eric Cleckley
Mike Clodfelder
Rich Collins
Len Consalvo
Lena Cordell
Glenn Davidson
Mike DellaVecchia
Nicholas J. DeSantis
Tony DiGioia
Keith E. Dinsmore
Corrine Dimnik
Seydou Diop
Doug Dodson
Michael Dolan
Dennis Doss
Michael Fick
Alan Fleissner
Bruce Freimark
Ross Gableman
Michael Garrels
Jeff Giffen

Kyle Gilbreath
Erich Gnandt
Waymon Goch
Tom Grisham
Asim Haldar
Joe Hallman
Bryan Hanft
Doug Harms
Linda Harrison
Steve Harrison
Ibrahim Hathout
Jennifer Havel
Donald G. Heald
Randy Hopkins
Michael Hudgens
Magdi F. Ishac
Mark Isom
Arjan Jagtiani
Doug Jones
Jacob Joplin
Mark Jurgemeyer
Peter Kapinos
Tim Kautz
Kenneth Keller
Robert Kluge
Samy Krishnasamy
Brian Lacoursiere
Hong-To Lam
Ling Lan-Ping
Jim Larkey
Ming Lu
Otto Lynch
Gary McAllister
Ray McCoy
Casey Miller
Steven Miller
May Millies
Robert J. Millies

Scott Monroe
Roger Montambo
George B. Niles
Juan Nuo
John J. Olenik
Carl Orde
Bob Oswald
Mohammad Pasha
Jason Payne
Chad Pederson
Robert Peters
Douglas Proctor
Brian Reed
Rafael Rios
Jack Roughan
Karen Rowe
Ron Rowland
Robert Santarsiero
Brian Share
David Shibilia
Ross Smith
Steve Smith
Brent Smolarek
Paul Springer
Eric Stemshorn
Andrew H. Stewart
Carl R. Tamm
Phu Trac
Vinh N. Tran
Larry Vandergriend
Jack Varner
Bruce Vaughn
Jeff Wang
Nathan Washburn
Ed West
Bob Whophom
Dan Wycklendt
Nancy Zhu

vi

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The following members of the individual balloting committee voted on this standard. Balloters may have
voted for approval, disapproval, or abstention.
Saleman Alibhay
Harvey Bowles
William Byrd
James Chapman II
Robert Christman
Glenn Davidson
Gary Donner
Randall Dotson
Gary Engmann
Fredric Friend
David Gilmer
Waymon Goch
Edwin Goodwin
Randall Groves
Timothy Hayden

Jeffrey Helzer
Lee Herron
Werner Hoelzl
Magdi F. Ishac
Mark Jurgemeyer
Gael Kennedy
Robert Kluge
Joseph L. Koepfinger
Jim Kulchisky
Chung-Yiu Lam
Keith E. Lindsey
William McBride
Thomas McCarthy
Arthur Neubauer
Michael S. Newman
Nick S.A. Nikjoo

Gary Nissen
Carl Orde
Lorraine Padden
Bansi Patel
Robert Peters
Douglas Proctor
Keith Reese
Michael Roberts
Stephen Rodick
Bartien Sayogo
Jerry Smith
Gary Stoedter
John Toth
John Vergis
Daniel Ward

When the IEEE-SA Standards Board approved this standard on 19 October 2012, it had the following
membership:
Richard H. Hulett, Chair
John Kulick, Vice Chair
Robert M. Grow, Past Chair
Konstantinos Karachalios, Secretary
Satish Aggarwal
Masayuki Ariyoshi
Peter Balma
William Bartley
Ted Burse
Clint Chaplin
Wael Diab
Jean-Philippe Faure

Alexander Gelman
Paul Houz
Jim Hughes
Young Kyun Kim
Joseph L. Koepfinger*
David J. Law
Thomas Lee
Hung Ling

Oleg Logvinov
Ted Olsen
Gary Robinson
Jon Walter Rosdahl
Mike Seavy
Yatin Trivedi
Phil Winston
Yu Yuan

*Member Emeritus

Also included are the following nonvoting IEEE-SA Standards Board liaisons:
Richard DeBlasio, DOE Representative
Michael Janezic, NIST Representative
Don Messina
IEEE Standards Program Manager, Document Development
Erin Spiewak
IEEE Standards Program Manager, Technical Program Development

vii

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Introduction
This introduction is not part of IEEE Std C135.80-2012, IEEE Standard for Fasteners for Overhead Line Construction.

This standard combines the following standards for fasteners for overhead line construction:

IEEE Std C135.1, IEEE Standard for Zinc-Coated Steel Bolts and Nuts for Overhead Line
Construction. a, b

IEEE Std C135.3, IEEE Standard for Zinc-Coated Ferrous Lag Screws for Overhead Line
Construction.

ANSI C135.4, American National Standard for Zinc-Coated Ferrous Eyebolts and Nuts for
Overhead Line Construction. c

ANSI C135.5, American National Standard for Zinc-Coated Ferrous Eyenuts and Eyelets for
Overhead Line Construction.

ANSI/NEMA C135.10, ANSI/NEMA Standard for Galvanized Ferrous Washers. d

ANSI C135.14, American National Standard for Staples with Rolled or Slash Points for Overhead
Line Construction.

ANSI C135.38, American National Standard for Zinc-Coated Ferrous Washerhead Bolts and
Washer Nuts.

IEEE publications are available from The Institute of Electrical and Electronics Engineers (http://standards.ieee.org/).
The IEEE standards or products referred to in this clause are trademarks of The Institute of Electrical and Electronics Engineers, Inc.
c
ANSI publications are available from the American National Standards Institute (http://www.ansi.org/).
d
NEMA publications are available from Global Engineering Documents (http://global.ihs.com/).
b

viii

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Contents
1. Overview .................................................................................................................................................... 1
1.1 Scope ................................................................................................................................................... 1
1.2 Purpose ................................................................................................................................................ 1
2. Normative references.................................................................................................................................. 2
3. Zinc-coated steel bolts and nuts.................................................................................................................. 2
3.1 Material................................................................................................................................................ 2
3.2 Dimensions .......................................................................................................................................... 3
3.3 Threads ................................................................................................................................................ 9
3.4 Strength.............................................................................................................................................. 10
3.5 Sizes................................................................................................................................................... 11
3.6 Corrosion protection .......................................................................................................................... 11
3.7 Finish ................................................................................................................................................. 11
3.8 Marking of fasteners .......................................................................................................................... 12
4. Zinc-coated ferrous lag screws ................................................................................................................. 12
4.1 Lag screws ......................................................................................................................................... 12
4.2 Dimensions ........................................................................................................................................ 12
4.3 Strength.............................................................................................................................................. 12
5. Zinc-coated ferrous eyebolts, eye nuts, and eyelets.................................................................................. 17
5.1 Material.............................................................................................................................................. 17
5.2 Eyebolts ............................................................................................................................................. 18
5.3 Eye nuts and eyelets .......................................................................................................................... 20
6. Zinc-coated ferrous washers..................................................................................................................... 22
6.1 Material.............................................................................................................................................. 22
6.2 Dimensions ........................................................................................................................................ 23
7. Zinc-coated corrosion protection.............................................................................................................. 26
8. Aluminum alloy washers.......................................................................................................................... 27
8.1 Material.............................................................................................................................................. 27
8.2 Dimensions ........................................................................................................................................ 27
9. Staples with rolled or slash points ............................................................................................................ 27
9.1 Material.............................................................................................................................................. 27
9.2 Dimensions ........................................................................................................................................ 28
9.3 Strength and rigidity .......................................................................................................................... 31
9.4 Protective coatings............................................................................................................................. 31
10. Finish...................................................................................................................................................... 31
11. Marking .................................................................................................................................................. 32
12. Definitions for acceptability and sampling ............................................................................................. 32
13. Requirements.......................................................................................................................................... 33
14. Determination of acceptability ............................................................................................................... 33
Annex A (informative) Bibliography ........................................................................................................... 34

ix

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IEEE Standard for Fasteners for

Overhead Line Construction
IMPORTANT NOTICE: IEEE Standards documents are not intended to ensure safety, health, or
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Concerning IEEE Documents. They can also be obtained on request from IEEE or viewed at
http://standards.ieee.org/IPR/disclaimers.html.

1. Overview

1.1 Scope
This standard covers the requirements of inch-based: (1) zinc-coated ferrous carriage bolts, machine bolts,
double-arming bolts, double-end bolts, washer-head bolts, eye bolts, eye nuts, and washer nuts; (2) zinccoated ferrous lag screws of the fetter drive, gimlet point, and twist drive type; (3) washers; and (4) staples,
commonly used in overhead line construction. Metric bolts, nuts, and lag screws are not covered by this
standard.

1.2 Purpose
This combined standard will provide a one-source standard for fasteners commonly used in overhead
distribution and transmission lines. It will replace several active and archived standards that are currently in
use to specify these fasteners.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

2. Normative references
The following referenced documents are indispensable for the application of this document (i.e., they must
be understood and used, so each referenced document is cited in text and its relationship to this document is
explained). For dated references, only the edition cited applies. For undated references, the latest edition of
the referenced document (including any amendments or corrigenda) applies.
ANSI/ASME B1.1, American National Standard for Unified Inch Screw Threads (UN and UNR Thread
Form). 1, 2
ANSI/ASME B18.2.1, American National Standard for Square and Hex Bolts and Screws (Inch Series).
ANSI/ASME B18.2.2, American National Standard for Square and Hex Nuts (Inch Series).
ANSI/ASME B18.5, American National Standard for Round Head Bolts (Inch Series).
ASTM A153/A153M, Standard Specification for Zinc Coating (Hot-Dip) on Iron and Steel Hardware. 3

3. Zinc-coated steel bolts and nuts

3.1 Material
3.1.1 Bolt material
All bolts shall be made from one of the following materials:
a)

Hot-headed bolts, double-arming bolts, double-end bolts, and washer-head bolts shall be made from
hot-rolled steel that has been produced by the open-hearth, basic-oxygen, or electric-furnace process
and that is of a grade and quality suitable to meet the requirements of this standard.

b) Cold-headed carriage bolts, machine bolts and washer-head bolts shall be made from steel coldheading rod or wire, produced by the open-hearth, basic-oxygen, or electric-furnace process, that is
of a grade and quality suitable to meet the requirements of this standard, and shall be reheated if
necessary to meet the requirements.
c)

Washers welded to square-head machine bolt heads to form washer-head bolts shall conform to
Clause 6 of this standard.

3.1.2 Nut material

Nuts for bolts made from steel, in accordance with item a) and item b) in 3.1.1, shall be made from hotrolled steel that has been produced by the open-hearth, basic-oxygen, or electric-furnace process, and that is
of a grade and quality suitable to meet the requirements of this standard.

ANSI publications are available from the American National Standards Institute (http://www.ansi.org/).
ASME publications are available from the American Society of Mechanical Engineers (http://www.asme.org/).
3
ASTM publications are available from the American Society for Testing and Materials (http://www.astm.org/).
2

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

3.1.3 Washer-nut material

Washer nuts shall be made of hot-rolled steel that has been produced by the open-hearth, basic oxygen, or
electric furnace process, or of malleable or ductile type ferrous castings. All of these materials shall be of
grades and qualities suitable to meet the requirements of this standard. Washers welded to form the washer
nuts shall conform to Clause 6 of this standard.

3.2 Dimensions
3.2.1 Bolt length
The length of semicone-pointed bolts shall be measured from the underside of the head to the last thread at
the end of the bolt. The length of all other bolts shall be measured from the underside of the head to the end
of the bolt. The points of double-arming and double-end bolts shall not be included in the length.
3.2.2 Machine bolt heads
All machine bolt heads shall be regular square or hexagonal, and shall be in accordance with ANSI/ASME
B18.2.1. 4 The dimensions of machine bolt heads before zinc coating shall be as given in Table 1 and
Table 2.
3.2.3 Carriage bolt heads
All carriage bolt heads shall be in accordance with ANSI/ASME B18.5. The dimensions before zinc
coating shall be as given in Table 3.
3.2.4 Washer-head bolt heads
All washer-head bolt heads shall have wrench-fit dimensions, be regular square, and shall be in accordance
with ANSI/ASME B18.2.1. The dimensions of washer-head bolt heads before zinc coating shall be as
given in Figure 1.
3.2.5 Nut dimensions
All nuts shall be square or hexagonal in accordance with ANSI/ASME B18.2.2. The dimensions prior to
zinc coating are given in Table 4 and Table 5.
3.2.6 Washer nut dimensions
Washer nuts shall be square in accordance with ANSI/ASME B18.2.2. The dimensions prior to zinc
coating are given in Figure 2.

Information on references can be found in Clause 2.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Size

A
Min

1/2

1-1/2

47/64

5/8

1-7/8

59/64

3/4

2-1/4

1-7/64

1-1/8

Min

C
Max

Min

Max

Min

3/4

9/32

11/32

15/16

11/32

13/32

7/16

1/2

1/4

F
Min

Max

Length of bolts
(in)

Max

Min

Max

5/32

9/32

1/32

5/32

1/8

1/4

6, 7, 9, 11

7/32

11/32

1/16

3/16

3/16

5/16

6 1/2, 10, 12, 14

3/8

1/16

7/16

5/16

7/16

5, 9, 10, 14, 16, 20

Min thread
length
(in)
3
4
6

Bolt length
(in)
4 to less than 8
8 to less than 12
12 and over

Figure 1 Dimensions for washer-head bolts

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Size
1/2
5/8
3/4

A
Min
1-1/2
1-7/8
2-1/4

B
Min
51/64
63/64
1-7/64

C
Max
13/16
1
1-1/8

Min
3/8
31/64
19/32

D
Max
7/16
39/64
23/32

Min
3/32
3/16
3/16

E
Max
7/32
5/16
5/16

Min
1/16
1/8
1/8

Max
5/32
7/32
7/32

Figure 2 Dimensions for washer nuts

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 1 Dimensions of square-head bolts (in inches)

3/8

Basic
9/16

Max
0.562

Min
0.544

Width across
corners
Max
Min
0.795
0.747

1/2

3/4

0.750

0.725

1.061

0.995

21/64

5/8

15/16

0.938

0.906

1.326

1.244

27/64

0.444

0.400

0.062

3/4

1-1/8

1.125

1.088

1.591

1.494

1/2

0.524

0.476

0.062

7/8

1-5/16

1.312

1.269

1.856

1.742

19/32

0.620

0.568

0.062

Nominal
bolt size

Width across flats

Height

Maximum radius
of fillet

Basic
1/4

Max
0.268

Min
0.232

0.348

0.308

0.031

0.031

1-1/2

1.500

1.450

2.121

1.991

21/32

0.684

0.628

0.093

1-1/4

1-7/8

1.875

1.812

2.652

2.489

27/32

0.876

0.812

0.093

NOTE 1The top of the head is to be flat and chamfered. The diameter of the chamfer circle is to be equal to
the maximum width across flats, within a tolerance of 15%.
NOTE 2The maximum width across flats applies at all points. No transverse section through the head
between 25% and 75% of head height, as measured from the bearing surface, is to be less than the minimum
width across flats.
NOTE 3The bearing surface is to be at right angles to the axis of the body within a tolerance of 3 for sizes
1 in and smaller and 2 for sizes larger than 1 in.
NOTE 4The axis of the head is to be concentric with the axis of the body (determined by one diameter
length of the body under the head) within a tolerance equal to 3% [6% full indicator reading (FIR)] of
maximum width across flats.
NOTE 5Any swell, fin under the head, or die seam on the body shall not exceed the basic bolt diameter by
the following:
0.030 in for sizes up to 1/2 in, inclusive
0.050 in for sized 5/8 in and 3/4 in
0.060 in for sizes 7/8 in to 1-1/4 in, inclusive

3.2.7 Semicone points

Machine bolts that are 1/2 in, 5/8 in, and 3/4 inch in diameter, 8 in and longer, shall have semicone points
with the nominal dimensions shown in Table 6. The thread end of bolts not requiring semicone points shall
be chamfered or rounded.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 2 Dimensions of hex-head bolts (in inches)

3/8

Basic
9/16

Max
0.562

Min
0.544

Width across
corners
Max
Min
0.650
0.620

1/2

3/4

0.750

0.725

0.866

0.826

11/32

5/8

15/16

0.938

0.906

1.083

1.033

27/64

0.444

0.378

0.062

3/4

1-1/8

1.125

1.088

1.299

1.240

1/2

0.524

0.455

0.062

7/8

1-5/16

1.312

1.269

1.516

1.447

37/64

0.604

0.531

0.062

Nominal
bolt size

Width across flats

Height

Maximum radius
of fillet

Basic
1/4

Max
0.268

Min
0.226

0.364

0.302

0.031

0.031

1-1/2

1.500

1.450

1.732

1.653

43/64

0.700

0.591

0.093

1-1/4

1-7/8

1.875

1.812

2.165

2.066

27/32

0.876

0.749

0.093

NOTE 1The top of the head is to be flat and chamfered. The diameter of the chamfer circle is to be equal to
the maximum width across flats, within a tolerance of 15%.
NOTE 2The maximum width across flats applies at all points. No transverse section through the head
between 25% and 75% of head height, as measured from the bearing surface, is to be less than the minimum
width across flats.
NOTE 3The bearing surface is to be at right angles to the axis of the body within a tolerance of 3 for sizes
1 in and smaller and 2 for sizes larger than 1 in.
NOTE 4The axis of the head is to be concentric with the axis of the body (determined by one diameter
length of the body under the head) within a tolerance equal to 3% (6% FIR) of maximum width across flats.
NOTE 5Any swell, fin under the head, or die seam on the body is to not exceed the basic bolt diameter by
the following:
0.030 in for sizes up to 1/2 in, inclusive
0.050 in for sizes 5/8 in and 3/4 in
0.060 in for sizes 7/8 in to 1 1/4 in, inclusive

Table 3 Dimensions of carriage bolt heads (in inches)

Nominal
bolt
size
3/8

13/16

1/2

1-1/16

5/8

1-5/16

Diameter of head
Basic

Max

Height of head

Min

Basic

.844

0.782

1.094

1.032

1.344

1.219

Depth of square

Width of square

Max

Min

Max

Min

Max

Min

3/16

0.208

0.188

0.219

0.188

0.388

0.368

1/4

0.270

0.250

0.281

0.250

0.515

0.492

5/16

0.344

0.313

0.344

0.313

0.642

0.616

3/4

1-9/16

1.594

1.469

3/8

0.406

0.375

0.406

0.375

0.768

0.741

7/8

1-13/16

1.844

1.719

7/16

0.469

0.438

0.469

0.438

0.895

0.865

2-1/16

2.094

1.969

1/2

0.531

0.500

0.531

0.500

1.022

0.990

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 4 Dimensions of square nuts (in inches)

3/8

Basic
5/8

Max
0.625

Min
0.606

Width across
corners
Max
Min
0.884
.832

1/2

13/16

0.812

0.788

1.149

1.082

7/16

Nominal
bolt size

Width across flats

Thickness
Basic
21/64

Max
0.346

Min
0.310

0.458

0.418

5/8

1.000

0.969

1.414

1.330

35/64

0.569

0.525

3/4

1-1/8

1.125

1.088

1.591

1.494

21/32

0.680

0.632

7/8

1-5/16

1.312

1.269

1.856

1.742

49/64

0.792

0.740

1-1/2

1.500

1.450

2.121

1.991

7/8

0.903

0.847

1-1/4

1-7/8

1.875

1.812

2.652

2.489

1 3/32

1.126

1.062

NOTE 1The maximum width across flats applies at all points. No transverse section through the nut between
25% and 75% of the nut thickness, as measured from the bearing face, shall be less than the minimum width
across flats.
NOTE 2The tops of nuts are to be flat and chamfered or washer crowned. The diameter of the chamfer circle
is to be equal to the maximum width across flats within a tolerance of 15%.
NOTE 3The bearing surface is to be at right angles to the axis of the threaded hole within a tolerance of 3 for
size 1 in nuts or smaller, and 2 for nuts larger than 1 in.
NOTE 4The axis of the tapped hole is to be concentric with the axis of the nut body within a tolerance equal
to 5% (10% FIR) of the maximum width across flats.

Table 5 Dimensions of hex nuts (in inches)

3/8

Basic
5/8

Max
0.625

Min
0.606

Width across
corners
Max
Min
0.884
.832

1/2

13/16

0.812

0.788

1.149

1.082

7/16

0.458

0.418

Nominal
bolt size

Width across flats

Thickness
Basic
21/64

Max
0.346

Min
0.310

5/8

1.000

0.969

1.414

1.330

35/64

0.569

0.525

3/4

1-1/8

1.125

1.088

1.591

1.494

21/32

0.680

0.632

7/8

1-5/16

1.312

1.269

1.856

1.742

49/64

0.792

0.740

1-1/2

1.500

1.450

2.121

1.991

7/8

0.903

0.847

1-1/4

1-7/8

1.875

1.812

2.652

2.489

1 3/32

1.126

1.062

NOTE 1The maximum width across flats applies at all points. No transverse section through the nut between
25% and 75% of the nut thickness, as measured from the bearing face, shall be less than the minimum width
across flats.
NOTE 2The tops of nuts are to be flat and chamfered or washer crowned. The diameter of the chamfer circle
shall be equal to the maximum width across flats within a tolerance of 15%.
NOTE 3The bearing surface is to be at right angles to the axis of the threaded hole within a tolerance of 3
for size 1 in nuts or smaller, and 2 for nuts larger than 1 in.
NOTE 4The axis of the tapped hole is to be concentric with the axis of the nut body within a tolerance equal
to 5% (10% FIR) of the maximum width across flats.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 6 Dimensions of semicone points (in inches)

Approximate length
of point beyond
last thread
3/16
3/16
1/4

Bolt size
1/2
5/8
3/4

Approximate
included angle of
point
60
60
60

3.3 Threads
3.3.1 Kind of thread
Bolt threads shall be machine rolled or cut.
3.3.2 Dimensions and class of external thread for bolts
The threaded portion of all bolts shall, before zinc coating, be in accordance with Class 2 of ANSI/ASME
B1.1 and Table 7.
Table 7 Dimensions of unified screw threads (in inches)
Major diameter a

Bolt threads
Nominal
bolt size

Pitch diameter b

Minor
diameter c

3/8

16

Stress
area
(in2)
0.077

1/2

13

0.142

0.499

0.488

0.482

0.449

0.443

0.404

5/8

11

0.226

0.623

0.611

0.605

0.564

0.559

0.512

3/4

10

0.334

0.748

0.735

0.729

0.683

0.677

0.625

7/8

0.462

0.873

0.859

0.852

0.801

0.795

0.737

0.606

0.998

0.983

0.975

0.917

0.910

0.845

1-1/4

0.969

1.248

1.231

1.223

1.155

1.148

1.072

Number
per in

Max

Min

Min d

Max

Min

Nominal

0.374

0.364

0.359

0.333

0.329

0.297

On a straight thread, the major diameter is the diameter of the coaxial cylinder, that would bound the crest of an
external thread or the roots of an internal thread.
b

On a straight thread, the pitch diameter is the diameter of the coaxial cylinder, the surface of which would pass
through the thread profiles at such points as to make the width of the groove equal to one-half the basic pitch. On
a perfect thread, this occurs at the point where the widths of the thread and groove are equal.
c

On a straight thread, the minor diameter is the diameter of the coaxial cylinder, which would bound the roots of
an external thread or the crests of an internal thread.
d

For unfinished hot-rolled material.

3.3.3 Threads of zinc-coated bolts

The external threaded portion of all bolts shall, after zinc coating, be in a condition such that nuts, tapped in
accordance with Table 8, will fit the zinc-coated bolt so that the nut can be run the entire length of the
thread without the use of tools.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

3.3.4 Dimensions for nuts and tapped parts

After zinc coating, all nuts and internally threaded parts shall be tapped oversize in accordance with the
dimensions given in Table 8.
Table 8 Dimensions for nuts and tapped parts (in inches)
Internal threads

Nominal
bolt size

Number of
threads per
inch

3/8

16

Min
0.351

Max
0.357

Min
0.324

Max
0.338

Major
diameter
Min
0.392

1/2

13

0.468

0.475

0.435

0.452

0.518

0.518-13

5/8

11

0.586

0.593

0.547

0.566

0.645

0.645-11

3/4

10

0.705

0.713

0.663

0.683

0.770

0.770-10

7/8

0.825

0.833

0.777

0.800

0.897

0.897-9

0.943

0.952

0.889

0.914

1.024

1.024-8

1-1/4

1.181

1.191

1.119

1.147

1.274

1.274-7

Pitch diameter

Minor diameter

Nominal
tap size
OD
0.392-16

3.3.5 Length of threads

Unless otherwise stated, all bolts shall have thread lengths as given in Table 9.
Table 9 Thread length of bolts (in inches)a
Minimum thread
length excluding
points
Carriage
3/8
3 up to less than 8
1-3/4
Carriage
1/2, 5/8, 3/4, 7/8, 1
4 up to less than 8
3
Machine
3/8, 1/2, 5/8, 3/4, 7/8, 1
4 up to less than 8
3
Machine
1/2, 5/8, 3/4, 7/8, 1, 1-1/4
8 up to less than 12
4
Machine
1/2, 5/8, 3/4, 7/8, 1, 1-1/4
12 and over
6
Double-arm
1/2, 5/8, 3/4
All lengths
Full thread
Double-arm
7/8, 1
All lengths
3 at each end
a
Bolts shorter or smaller, or both, than those listed shall have minimum thread lengths in
accordance with ANSI/ASME B18.2.1.
Kind of bolt

Size

Bolt lengths

3.4 Strength
3.4.1 Tensile strength
Bolts with nuts assembled shall meet the minimum tensile requirements listed in Table 10. Failure shall
occur in the shank or threaded section and not at the junction of the head and shank. Threads shall not strip
below the minimum specified tensile strength shown in Table 10.
3.4.2 Shear strength
Bolts shall meet the minimum shear requirements listed in Table 10.

10

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 10 Strength of bolts (in pounds-force)

Size and kind of bolt
3/8 in carriage or machine bolt
1/2 in carriage, machine or double-arming bolt
5/8 in machine or double-arming bolt
3/4 in machine or double-arming bolt
7/8 in machine or double-end bolt
1 in machine or double-end bolt
1-1/4 in machine or double-end bolt

Minimum tensile
strength
4 250
7 800
12 400
18 350
25 400
33 500
53 300

Single shear
through threads
3 050
5 200
8 330
12 440
17 270
22 690
36 590

Single shear
through shaft
4 580
7 950
12 420
17 890
24 350
31 800
49 700

3.4.3 Cold bend test

The non-threaded portion of bolts shall be capable of being bent while at room temperature at any point
through an angle of 180, about a diameter equal to the diameter of the bolt without cracking the steel on
the outside bent portion. In the case of completely threaded bolts, the threads shall be removed and the 180
bend shall be about a diameter equal to the reduced diameter of the bolt.

3.5 Sizes
Bolt sizes and lengths are given in Table 11.
Table 11 Sizes and lengths of bolts (in inches)
Kind of bolt
Carriage
Machine
Machine
Machine
Machine
Double-arm
Double-end

Sizes
3/8, 1/2
3/8
1 /2
5/8
3 /4, 7/8, 1, 1-1/4
5/8, 3/4, 7/8, 1, 1-1/4
7/8, 1, 1-1/4

Lengths
4, 4-1/2, 5, 6
4-1/2, 5, 6
4-1/2, 5, 6, 8, 10, 12
6, 8, 10, 12, 14, 16, 18, 20
8, 10, 12, 14, 16, 18
12, 14, 16, 18, 20, 22, 24
12, 14, 16, 18, 20, 22, 24, 26, 28, 30, 32, 34, 36

Unless otherwise specified, each machine bolt and carriage bolt shall be furnished with one nut assembled
thereon, each double-arming bolt shall be furnished with four nuts assembled thereon, and each double-end
bolt shall be furnished with two nuts assembled thereon.

3.6 Corrosion protection

Fasteners shall be zinc coated. The coating shall be applied by the following:
a)

The hot-dip process in accordance with ASTM A153/A153M, or

b) Any other method producing a zinc coating that meets the requirements of ASTM A153/A153M for
adhesion, purity, and thickness application to the class of material being coated.

3.7 Finish
Bolts shall be free from burrs, seams, laps, and irregular surfaces that affect serviceability.
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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

3.8 Marking of fasteners

All fasteners shall bear the manufacturers symbol or identification mark in accordance with Clause 11.

4. Zinc-coated ferrous lag screws

4.1 Lag screws

All lag screws shall be made from one of the following materials:
a)

Hot-headed lag screws shall be made from hot-rolled steel that has been produced by the open
hearth, basic oxygen, or electric-furnace process and that is of a grade and quality suitable to meet
the requirements of this standard.

b) Cold-headed lag screws shall be made from steel cold-heading wire that has been produced by the
open hearth, basic-oxygen, or electric-furnace process and that is of a grade and quality suitable to
meet the requirements of this standard, and shall be reheated (stress relieved) if necessary to meet
the requirements of this standard.

4.2 Dimensions
All dimensions are in inches prior to zinc coating.
All lag screws shall be square or hex and in accordance with ANSI/ASME B18.2.1, as specified in Figure 3
through Figure 7.
Lag screw threads shall be machine-rolled or cut as specified in the data sheets.

4.3 Strength
Lag-screw heads shall be of sufficient strength to develop the body tensile strength of the screws. Failure
shall occur in the shank or threaded section and not at the junction of the head and shank. In no case shall
the strength be less than shown in Table 12.
Table 12 Strength of lag screws (in pounds-force)
Normal diameter of screw
(in)
1/4
5/16
3/8
1/2

Minimum tensile strength

1500
2300
3500
6500

4.3.1 Cold bend test

After removal of the threads to the root diameter, the unthreaded portion of the lag screw shall be capable
of being bent at room temperature (10 C to 30 C) at any point through an angle of 180, about a diameter
equal to the normal diameter of the screw without cracking the steel on the outside bent portion.

12

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Body dimensions
D

Diameter
of screw

Length

Min. thread

Shoulder

1/4

2-1/2

1-3/4

0.94

2-1/2

1-3/4

2-1/2

4-1/2

2-3/4

3/8

1/2

Threads
per inch

Root
diameter

Depth of
thread

10

0.18

0.01

0.125

8 or 9

0.30

0.02

0.156

6 or 7

0.41

0.02

Figure 3 Dimensions for fetter drive lag screws rolled threads

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Diameter
of screw

Length

Min
thread
length

1-1/2

2-1/2

1-3/4

2-1/2

1-3/4

1/4

5/16

S
Shoulder

Threads
per inch

Threads dimensions
Pitch

Flat at
root

Depth of
thread

Root
diameter

0.100

0.043

0.020

0.160

0.094

10

0.111

0.048

0.020

0.210

0.125

0.9

Figure 4 Dimensions for gimlet point lag screws rolled or cut threads

14

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Nominal size
or basic
product
diameter
No. 10 0.1900

Body or
shoulder
diameter

Width across flats

Width across
corners

Height

Shoulder
length

Radius of
fillet

Max

Min

Basic

Max

Min

Max

Min

Basic

Max

Min

Min

Max

Min

0.199

0.178

9/32

0.281

0.271

0.398

0.372

1/8

0.140

0.110

0.094

0.03

0.01

1/4

0.2500

0.260

0.237

3/8

0.375

0.362

0.530

0.498

11/64

0.188

0.156

0.094

0.03

0.01

5/16

0.3125

0.324

0.298

1/2

0.500

0.484

0.707

0.665

13/64

0.220

0.186

0.125

0.03

0.01

3/8

0.3750

0.388

0.360

9/16

0.562

0.544

0.795

0.747

1/4

0.268

0.232

0.125

0.03

0.01

7/16

0.4375

0.452

0.421

5/8

0.625

0.603

0.884

0.828

19/16

0.316

0.278

0.156

0.03

0.01

1/2

0.5000

0.515

0.482

3/4

0.750

0.725

1.061

0.995

21/64

0.348

0.308

0.156

0.03

0.01

5/8

0.6250

0.642

0.605

1-5/16

0.938

0.906

1.326

1.244

27/64

0.444

0.400

0.312

0.06

0.02

3/4

0.7500

0.768

0.729

1-1/8

1.125

1.088

1.591

1.494

1/2

0.524

0.476

0.375

0.06

0.02

7/8

.08750

0.895

0.852

1-5/16

1.312

1.269

1.856

1.742

19/32

0.620

0.568

0.375

0.06

0.02

1.0000

1.022

0.976

1-1/2

1.500

1.450

2.121

1.991

21/32

0.684

0.628

0.625

0.09

0.03

1-1/8

1.1250

1.149

1.098

1-11/16

1.688

1.631

2.386

2.239

3/4

0.780

0.720

0.625

0.09

0.03

1-1/4

1.2500

1.277

1.223

1-7/8

1.875

1.812

2.652

2.489

27/32

0.876

0.812

0.625

0.09

0.03

Figure 5 Dimensions for square lag screws

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Nominal size
or basic
product
diameter

Body or
shoulder
diameter

Width across flats

Width across
corners

Height

Shoulder
length

Radius of
fillet

Max

Min

Basic

Max

Min

Max

Min

Basic

Max

Min

Min

Max

Min

No. 10

0.1900

0.199

0.178

9/32

0.281

0.271

0.323

0.309

1/8

0.140

0.110

0.094

0.03

0.01

1/4

0.2500

0.260

0.237

3/8

0.375

0.362

0.505

0.484

11/64

0.188

0.156

0.094

0.03

0.01

5/16

0.3125

0.324

0.298

1/2

0.500

0.484

0.577

0.552

13/64

0.220

0.186

0.125

0.03

0.01

3/8

0.3750

0.388

0.360

9/16

0.562

0.544

0.650

0.620

1/4

0.268

0.232

0.125

0.03

0.01

7/16

0.4375

0.452

0.421

5/8

0.625

0.603

0.722

0.687

19/16

0.316

0.278

0.156

0.03

0.01

1/2

0.5000

0.515

0.482

3/4

0.750

0.725

0.866

0.862

21/64

0.348

0.308

0.156

0.03

0.01

5/8

0.6250

0.642

0.605

1-5/16

0.938

0.906

1.083

1.033

27/64

0.444

0.400

0.312

0.06

0.02

3/4

0.7500

0.768

0.729

1-1/8

1.125

1.088

1.299

1.240

1/2

0.524

0.476

0.375

0.06

0.02

7/8

0.08750

0.895

0.852

1-5/16

1.312

1.269

1.516

1.447

37/64

0.604

0.531

0.375

0.06

0.02

1.0000

1.022

0.976

1-1/2

1.500

1.450

1.732

1.653

43/64

0.700

0.625

0.625

0.09

0.03

1-1/8

1.1250

1.149

1.098

1-11/16

1.688

1.631

1.949

1.859

3/4

0.780

0.658

0.625

0.09

0.03

1-1/4

1.2500

1.277

1.223

1-7/8

1.875

1.812

2.165

2.066

27/32

0.876

0.749

0.625

0.09

0.03

Figure 6 Dimensions for hex lag screws

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

3.000

2.250

4.000

2.625

4.500

2.625

5.000

3.000

Unspecified dimensional tolerances 0.31, unspecified angular tolerances 2.

Figure 7 Dimensions for twist drive lag screws

5. Zinc-coated ferrous eyebolts, eye nuts, and eyelets

5.1 Material
All eye nuts and eyelets shall be made of hot-rolled steel that has been produced by the open-hearth, basic
oxygen, or electric furnace process, or of malleable or ductile type ferrous castings. All of these materials
shall be of grades and qualities suitable to meet the requirements of this standard.
All eyebolts shall be made from hot-rolled steel that has been produced by the open-hearth, basic oxygen,
or electric furnace process and shall be of grades and qualities suitable to meet the requirements of this
standard.
Nuts shall comply with the requirements of 3.1.2.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

5.2 Eyebolts
5.2.1 Dimensions

Bolt diameter

Rmin

Min

Max

Min

Max

Min

Min

Max

Min

Max

5/8

5/8

3/4

21/32

23/32

5/16

33/64

37/64

1/4

5/16

3/8

3/4

5/8

3/4

21/32

23/32

5/16

33/64

37/64

27/32

29/32

3/4

Figure 8 Dimensions for straight, thimble eyebolts for single stranded wire

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Bolt diameter

Rmin

Min

Max

Min

Max

Min

Min

Max

Min

Max

5/8

5/8

3/4

21/32

23/32

5/16

33/64

37/64

1/4

5/16

3/8

3/4

5/8

3/4

21/32

23/32

5/16

33/64

37/64

27/32

29/32

3/4

Figure 9 Dimensions for angle, thimble eyebolts for single stranded wire eyebolts

Bolt diameter

Rmin

Min

Max

Min

Max

Min

Max

Min

Max

5/8

1-7/16

1-9/16

1-15/16

2-1/16

1-7/8

2-1/8

31/64

39/64

5/16

3/4

1-7/16

1-9/16

1-15/16

2-1/16

1-7/8

2-1/8

31/64

39/64

3/4

Bolt length tolerances are plus in and minus in.

Figure 10 Eyebolt

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

5.2.2 Tensile strength

Eyebolts with nuts assembled shall meet the minimum tensile requirements listed in Table 13. Failure shall
occur in the shank or threaded section and not at the junction of the head and shank. Threads shall not strip
below minimum specified tensile strength shown in Table 13.
5.2.3 Shear strength
Bolts shall meet the minimum shear requirements listed in Table 13.
Table 13 Strength of eyebolts (in pounds-force)
Size
5/8 in diameter
3/4 in diameter

Minimum tensile
strength
12 400
18 350

Single shear
through threads
8 330
12 440

Single shear
through shaft
12 420
17 890

5.2.4 Cold bend test

The non-threaded portion of eyebolts shall be capable of being bent while at room temperature at any point
through an angle of 180, about a diameter equal to the diameter of the bolt, without cracking the steel on
the outside bent portion. In the case of completely threaded bolts, the threads shall be removed and the 180
bend shall be about a diameter equal to the reduced diameter of the eyebolt.

5.3 Eye nuts and eyelets

5.3.1 Material
Eye nuts and eyelets shall be made of hot-rolled steel that has been produced by open-hearth, basic oxygen,
or electric-furnace process, or of malleable or ductile type ferrous castings. All of these materials shall be
of grades and qualities suitable to meet the requirements of this standard.
5.3.2 Threading
Eye nuts shall be tapped after galvanizing according to Table 14.
5.3.3 Dimensions
All dimensions before galvanizing shall be in accordance with Figure 11.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 14 Eye nut tapped threads dimensions

Eye nut tapped threads

Bolt threads

Pitch diameter

Minor diameter

Major nominal

Nominal
bolt size

Threads per
inch

Min

Max

Min

Max

Dia. min

Tap size OD

5/8

11

0.587

0.594

0.548

0.567

0.646

0.646-11

3/4

10

0.706

0.714

0.663

0.684

0.771

0.771-10

0.635

0.643

0.596

0.615

0.694

0.695-11

Anchor rod threads

Nominal
rod size

Threads per
inch

5/8

11

5.3.4 Strength
Eye nuts and eyelets shall have sufficient strength to develop the minimum tensile strength of the bolts or
anchor rods for which they are intended and in no case less than the following:
Eye nut or eyelet designation

Minimum load (pounds-force)

5/8 in bolt

12 400

5/8 in anchor rod

16 000

3/4 in bolt

18 350

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Figure 11 Eye nut and eyelet dimensions

6. Zinc-coated ferrous washers

6.1 Material
All washers shall be made of hot-rolled steel that has been produced by the open-hearth, basic oxygen, or
electric furnace process, or of malleable or ductile type ferrous castings. All of these materials shall be of
grades and qualities suitable to meet the requirements of this standard.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

6.2 Dimensions
The basic dimensions before galvanizing are shown in Figure 12 through Figure 18.
Dimensions for type A flat round washers (Figure 12) shall conform to ANSI B18.22.1 [B1]. 5

Bolt size
1/4
3/8
1/2
1/2
5/8
3/4
1
1

A
Min
5/16
7/16
9/16
9/16
11/16
13/16
1-1/16
1-1/16

B
Max
3/8
1/2
5/8
5/8
3/4
7/8
1-1/4
1-1/4

Min
3 /4
1
1-1/4
1-3/8
1-3/4
2
2
2-1/2

T
Max
49/64
1-1/32
1-9/32
1-13/32
1-25/32
2-1/32
2-1/32
2-17/32

Min
3/64
1/16
1/16
5/64
3/32
7/64
7/64
7/64

Max
1/8
9/64
9/64
11/64
3/16
13/64
15/64
15/64

Figure 12 Type A flat round washers

The numbers in brackets correspond to those of the bibliography in Annex A.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Bolt size
5/8
3/4
3/4
7/8
1

A
Min
11/16
13/16
13/16
15/16
1-1/16

B
Max
3/4
7/8
7/8
1
1-1/8

Min
2-3/16
2-15/16
3-3/16
3-15/16
5-15/16

T
Max
2-5/16
3-1/16
3-5/16
4-1/16
6-1/16

Min
11/32
13/32
17/32
17/32
27/32

Max
7/16
1/2
9/16
9/16
15/16

W
3/16
5/32
3/16
3/16
3/16

Figure 13 Type B round washers

Bolt size
5/8
5/8
3/4

A
Min
11/16
11/16
13/16

Max
3/4
3/4
7/8

Min
1-7/8
2-1/8
2-1/8

B
Nominal
2
2-1/4
2-1/4

Max
2-1/8
2-3/8
2-3/8

Min
7/64
11/64
11/64

T
Nominal
1/8
3/16
3/16

Max
5/32
7/32
7/32

Figure 14 Type A flat square washers

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Bolt size
5/8
3/4

A
Min
11/16
13/16

Max
3/4
7/8

Min
2-1/8
2-1/8

B
Nominal
2-1/4
2-1/4

Max
2-3/8
2-3/8

Min
7/32
7/32

T
Nominal
9/32
9/32

Max
11/32
11/32

Figure 15 Type B flat square washer

Bolt
size
5/8
5/8
5/8
3/4
7/8

A
Min
11/16
11/16
11/16
13/16
15/16

Max
3/4
3/4
3/4
7/8
1

Min
2-1/8
2-3/8
2-7/8
2-7/8
3 7/8

B
Nominal
2-1/4
2-1/2
3
3
4

Max
2-3/8
2-5/8
3-1/8
3-1/8
4-1/8

Min
11/64
11/64
15/64
15/64
15/64

T
Nominal
3/16
3/16
1/4
1/4
1/4

Max
7/32
7/32
9/32
9/32
9/32

Min
4
4
4
4
4

R
Nominal
4-1/2
4-1/2
4-1/2
4-1/2
4-1/2

Max
5
5
5
5
5

Figure 16 Type A curved square washers

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Bolt
size
5/8
5/8
3/4
3/4

A
Min
11/16
11/16
13/16
13/16

Max
3/4
3/4
7/8
7/8

Min
2-1/8
2-7/8
2-7/8
3 7/8

B
Nom
2-1/4
3
3
4

Max
2-3/8
3-1/8
3-1/8
4-1/8

Min
7/32
9/32
11/32
13/32

T
Nom
1/4
5/16
3/8
7/16

Max
5/16
3/8
7/16
1/2

R
Nom
4
4
4
4

Min
3-1/2

3-1/2
3-1/2
3-1/2

Max
4-1/2

4-1/2
4-1/2
4-1/2

W
Min
1/8
1/8
1/8
3/16

Figure 17 Type B curved square washers

Bolt
size
3/4

Min
13/16

A
Max
7/8

Min
2-1/8

B
Nom
2-1/4

Max
2-3/8

7/8

15/16

2-7/8

3-1/8

Min
31/8
37/8

C
Nom
3-1/2

Max
3-3/8

Min
9/32

T
Nom
5/16

Max
3/8

Min
4

R
Nom
4-1/2

Max
5

W
Min
1/8

4-1/8

13/32

7/16

1/2

4-1/2

3/16

Figure 18 Type B curved rectangular washers

7. Zinc-coated corrosion protection

All ferrous bolts, lag screws, washers, and nuts covered in Clause 3 through Clause 6 shall be zinc coated.
The coating shall be applied by the following:
a)

The hot-dip process in accordance with ASTM A153/A153M, or

b) Another method producing a zinc coating that meets the requirements of ASTM A153/A153M for
adhesion, purity, and thickness applicable to the class of material being coated.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

8. Aluminum alloy washers

8.1 Material
Aluminum washers shall be made of aluminum alloy AA number A-356.0 heat treated to T-6 temper.

8.2 Dimensions
The basic dimensions of aluminum alloy washers are shown in Figure 12 through Figure 17 and Figure 19.
Dimensions for type A flat round washers (Figure 10) shall conform to ANSI B18.22.1 [B1].

Bolt
size

A
Min

Max

3/4

13/16

7/8

7/8

15/16

7/8

15/16

Min
21/8
27/8
27/8

B
Nom

Max

2-1/4

2-3/8

3-1/8

3-1/8

Min
31/8
37/8
47/8

C
Nom

Max

Min

T
Nom

Max

Min

R
Nom

Max

3-1/2

3-3/8

17/32

9/16

5/8

4-1/2

4-1/8

17/32

9/16

5/8

4-1/2

5-1/8

17/32

9/16

5/8

4-1/2

Figure 19 Cast aluminum curved rectangular washersRecommended for

wood structures only

9. Staples with rolled or slash points

9.1 Material
All staples shall be made of the following materials.
9.1.1 Ferrous staples
Ferrous staples shall be made of hot-rolled, open hearth, basic oxygen, or electric furnace steel of a grade
and quality suitable to meet the requirements.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

9.2 Dimensions
All dimensions of ferrous, copper-coated, and aluminum clad staples shall be in accordance with Figure 20,
Table 15, and Table 16.

Figure 20 Staples with rolled or slash points

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 15 Preferred sizes and types

Size
L

1
1-1/4
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-1/2
1-3/4
1-3/4
1-3/4
1-7/8
2
2
2
2
2
2
2-1/4
2-1/2
3
3
3

1/4
1/4
1/4
5/16
3/16
1/4
3/8
1/2
3/8
1/4
3/8
11/16
3/8
1/4
1/2
5/8
5/8
1-1/16
7/8
1-1/16
3/4
1
1-1/16

0.114
0.114
0.120
0.144
0.148
0.148
0.148
0.162
0.144
0.148
0.148
3/16
0.144
0.148
0.162
0.162
3/16
3/16
3/16
3/16
1/4
1/4
1/ 4

Copper coated
Rolled
Slash
point
point
X

X
X

Types
Hot-dip galvanized
Rolled
Slash
point
point

X
X

X
X
X

X
X

X
X
X

Electro galvanized
Rolled
Slash
point
point

X
X
X

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Table 16 Staples with rolled or slash points

Tolerances
Size
L
L

Min

Max

Rolled point
S
Min
Max

Min

Max

Min

Max

Slash point
S
Min Max

P
Min

Max

Wire size
Tolerance
Pos
Neg

1/4

0.114

1-1/16

1/4

9/32

7/32

9/32

0.114

0.002

0.001

1-1/4

1/4

0.114

1-1/4

1-5/16

1/4

9/32

7/32

9/32

0.114

0.002

0.001

1-1/2

1/4

0.120

1-1/2

1-9/16

1/4

9/32

7/32

9/32

0.120

0.002

0.001

1-1/2

5/16

0.144

1-1/2

1-9/16

5/16

11/32

15/32

9/16

0.144

0.002

0.001

1-1/2

3/16

0.148

1-7/16

1-9/16

3/16

7/32

7/32

5/16

0.148

0.002

0.001

1-1/2

1/4

0.148

1-7/16

1-9/16

1/4

9/32

7/32

5/16

0.148

0.002

0.001

1-1/2

3/8

0.148

1-1/2

1-9/16

3/8

13/32

15/32

9/16

0.148

0.002

0.001

1-1/2

1/2

0.162

1-1/2

1-9/16

1/2

17/32

17/32

5/8

0.162

0.002

0.001

1-3/4

3/8

0.144

1-3/4

1-13/16

3/8

13/32

15/32

9/16

1-11/16

1-13/16

3/8

13/32

7/32

5/16

0.144

0.002

0.001

1-3/4

1/4

0.148

1-11/16

1-13/16

1/4

9/32

7/32

5/16

0.148

0.002

0.001

1-3/4

3/8

0.148

1-3/4

1-13/16

3/8

13/32

15/32

9/16

1-11/16

1-13/16

3/8

13/32

7/32

5/16

0.148

0.002

0.001

1-7/8

11/16

3/16

1-13/16

1-15/16

11/16

3/4

5/16

1/2

3/16

0.003

0.002

3/8

0.144

1-31/32

2-1/16

3/8

13/32

7/32

5/16

0.144

0.002

0.002

1/4

0.148

1-31/32

2-1/16

1/4

9/32

7/32

5/16

0.148

0.002

0.002

1/2

0.162

2-1/8

1/2

17/32

17/32

5/8

1-31/32

2-1/16

1/2

17/32

1/4

7/16

0.162

0.003

0.002

5/8

0.162

2-1/8

5/8

21/32

17/32

5/8

1-31/32

2-1/16

5/8

11/16

1/4

7/16

0.162

0.003

0.002

5/8

3/16

2-1/8

5/8

21/32

17/32

5/8

3/16

0.003

0.002

1-1/16

3/16

2-1/8

1-1/16

1-1/8

9/16

3/4

3/16

0.003

0.002

2-1/4

7/8

3/16

2-3/16

2-3/8

7/8

15/16

7/32

5/16

3/16

0.003

0.002

2-1/2

1-1/16

3/16

2-1/2

2-5/8

1-1/16

1-1/8

9/16

3/4

3/16

0.003

0.002

3/4

1/4

3-1/8

3/4

25/32

13/16

0.243

0.005

0.003

1/4

3-1/8

1-1/16

13/16

1/4

0.005

0.003

1-1/16

1/ 4

3-1/8

1-1/16

1-1/8

13/16

1/ 4

0.005

0.003

30

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

9.3 Strength and rigidity

All staples shall be of sufficient strength and rigidity to resist bending and distortion beyond the point of
usability when installed by normal driving methods under normal conditions.

9.4 Protective coatings

9.4.1 Ferrous staples
All ferrous staples shall be hot-dip or electro-galvanized. The points of cut or slash point staples need not
be galvanized
9.4.1.1 Hot-dip galvanizing
Hot-dip galvanizing shall be in accordance with ASTM A153/A153M for class D hardware, the minimum
thickness on significant surfaces to be 0.001445 in (0.85 oz/ft2).
9.4.1.2 Electro-galvanizing
Electro-galvanizing shall be in accordance with ASTM B633-11 [B8] for type R. S. coating or heavier, the
minimum thickness on significant surfaces to be 0.00015 in (0.09 oz/ft2).
9.4.2 Copper-coated staples
Copper-coated staples shall consist of a steel wire core with a copper coating thoroughly bonded thereto so
that the interlocking crystalline union is secured between the two metals. The copper thickness at any point
on the wire before forming into staples shall be not less than 6% of the wire radius. The steel core wire
shall be of a grade and quality suitable to meet the requirements of this standard.
9.4.3 Aluminum-clad staples
Aluminum-clad staples shall consist of a steel wire core with an aluminum coating permanently and
integrally bonded thereto. The aluminum thickness at any point on the wire before forming into staples
shall not be less than 10% of the wire radius. The steel core wire shall be of a grade and quality suitable to
meet the requirements of this standard.

10. Finish
All bolts, nuts, screws, washers, and staples covered in this standard shall be free from burrs, seams, laps,
and irregular surfaces that affect serviceability.

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

11. Marking
All bolt heads, eyebolt shanks, nuts, washers, and lag screw heads shall bear the manufacturers symbol or
identification mark. Each shipping package of fasteners covered in this standard shall be marked with the
vendor's name and catalog number.

12. Definitions for acceptability and sampling

acceptance quality level (aql): The maximum percent defective (maximum number of defects per
100 units) that, for the purpose of a sampling inspection, can be considered satisfactory as a process
average.
average test value ( X n ):
X n = (X 1 + X 2 + X 3 + ... + X n )/n

where
X 1 , X 2 , ..., X n , are individual test values and n is the total number of units tested.

defect: Any nonconformance with specified requirements of the tested unit of product. For purposes of
this standard, a defect is defined as a unit of product that, when tested, falls below its specified rated
ultimate strength.
lot: A quantity of line fasteners selected and agreed upon by the manufacturer and customer as being
representative of a homogeneous population. Each lot, as far as is practicable, shall consist of units of
product of a single type, grade, class, size, and composition that are manufactured at essentially the same
time and under essentially the same conditions. Consideration should be given to limit the lot size, where
applicable, to each heat-treating and/or annealing process of a group of units. As necessary, the manufacturer
shall provide adequate and suitable storage space for each lot and means for proper identification. Any
lot shall not exceed 35 000 units.
major defect: A unit of product that, when tested, falls below 85% of its specified rated ultimate
strength.
sample: One or more units of product drawn from a lot, the units of sample being selected at random
without regard to their quality.
sample size: Based on the lot size. Minimum sample sizes are given in Table 17.
Table 17 Minimum sample size
Lot size
1 to 15
16 to 50
51 to 150
151 to 500
501 to 3 200
3 201 to 35 000

Sample size
2
3
5
8
13
20

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

13. Requirements
The inspection criteria used in this standard correspond to sample size code S-3 with a double
sampling plan for normal inspection having an aql of 2.5% (see ANSI/ASQC-1993).

14. Determination of acceptability

The acceptability of a lot shall be determined by the use of Table 18.
Table 18 Acceptance/rejection criteria
Test sample
Single
Single
Single
First
Second
First
Second
First
Second

Sample size
2
3
5
8
8
13
13
20
20

Cumulative sample size

8
16
13
26
20
40

Accept
0
0
0
0
1
0
1
1
3

Reject
1
1
1
2
2
2
2
3
4

The lot shall be considered acceptable when the number of defects found in the first (or single) sample
is equal to or less than the first acceptance number from Table 18. If this acceptance criterion is met on the
first sampling, a second sampling is not needed. If the number of defects found in the first or single
sample is equal to or greater than the first rejection number, the lot shall be rejected without a second
sampling being allowed. If the number of defects found in the first sample is between the first acceptance
and rejection numbers, a second sampling of the size given in Table 17 shall be tested. The number of
defects found in the first and second samples shall be accumulated. If the cumulative number of defects is
equal to or less than the second acceptance number, the lot shall be considered acceptable. If the
cumulative number of defects is equal to or greater than the second rejection number, the lot shall be
rejected.
Both the manufacturer and the end user shall reserve the right to reject the entire lot if a tested unit of
product is found to have a major defect (i.e., falls below 85% rated ultimate strength).

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IEEE Std C135.80-2012

IEEE Standard for Fasteners for Overhead Line Construction

Annex A
(informative)
Bibliography
Bibliographical references are resources that provide additional or helpful material but do not need to be
understood or used to implement this standard. Reference to these resources is made for informational use
only.
[B1] ANSI B18.22.1, American National Standard for plain washers. 10
[B2] ASTM A197, Specification for cupola malleable iron. 11
[B3] ASTM A394, Standard Specification for Steel Transmission Tower Bolts, Zinc-Coated and Bare.
[B4] ASTM A569, Hot-rolled steel, carbon (0.15 max percent) sheet and strip, commercial quality.
[B5] ASTM A570, Hot-rolled carbon steel sheet and strip, structural quality.
[B6] ASTM A575, Merchant quality hot-rolled carbon steel bars.
[B7] ASTM A635, Steel sheet and strip, carbon, hot-rolled commercial quality, heavy-thickness coils.
[B8] ASTM B633-11, Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel.

10
11

ANSI publications are available from the American National Standards Institute (http://www.ansi.org/).
ASTM publications are available from the American Society for Testing and Materials (http://www.astm.org/).

34

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