Night School 12 Session 4 Welding Wisdom

AISC Night School
November 1, 2016
Fundamentals of Bolting and Welding

Bolting Pt 4: Beyond the Bolts
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Theres always a solution in steel
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American Institute of Steel Construction
AISC Night School

November 1, 2016

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AISC is a Registered Provider with The American Institute of Architects Continuing

Education Systems (AIA/CES). Credit(s) earned on completion of this program will be
reported to AIA/CES for AIA members. Certificates of Completion for both AIA members
and non-AIA members are available upon request.
This program is registered with AIA/CES for continuing professional education. As such, it
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endorsement by the AIA of any material of construction or any method or manner of
handling, using, distributing, or dealing in any material or product.
Questions related to specific materials, methods, and services will be addressed at the
conclusion of this presentation.
Copyright Materials
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Reproduction, distribution, display and use of the presentation without written
permission of AISC is prohibited.
The American Institute of Steel Construction 2016
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AISC Night School

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Course Description
Session 4: - Bolting Pt. 4: Beyond the Bolts
November 1, 2016
This session will provide an understanding of industry specific
supplementary requirements for fasteners. Requirements for rotational
capacity testing and fastener coatings will be explained. A review of
potential issues related to bolting, such as fastener reuse and nonconformance handling, and how to address or avoid common problems
at the job site will be presented.
Learning Objectives
Learn about supplementary requirements.
Learn about Rotational Capacity Testing.
Learn about permitted structural fastener
coatings.
Review common bolting issues.
Learn about bolt reuse.
Gain an understanding of nonconformance
handling.
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November 1, 2016

FUNDAMENTALS OF BOLTING AND

WELDING
BOLTING SESSION 4: BEYOND THE BOLTS
Chad Larson
President
LeJeune Bolt Company
MANUFACTURING INSPECTION
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What gets tested?

Always
Sometimes
Dimensions Geometry
Magnetic particle
Chemistry not usually directly
Tensile Strength
Tensile Strength
Rotational capacity
Proof Load
Assembly tension testing
Surface Discontinuities
Coating thickness
Hardness
Carburization/Decarburization
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Tension Testing
(Tensile Testing)
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Hardness Testing
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Carburization/Decarburization
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Continuous Heat Treatment
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Batch Heat Treatment
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Magnetic particle inspection
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SUPPLEMENTARY REQUIREMENTS
What are F3125 S1 S4

S1. Bolts Threaded Full Length
Just like what it says, up to 4D
Special Marking T A325T
Uses and cautions Turn of Nut - Shear Strength
S2. Alternate Dimensions
Just like what it says
Special marking S A325S
Uses and cautions
S3. Lubricant
S4. Rotational Capacity Testing
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S3
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ROTATIONAL CAPACITY
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New Rotational Capacity Test - F3125 Annex A2.1.1

Details rotational capacity (RC) tests intended to evaluate the presence of
lubricant, the efficiency of lubricant and the compatibility of assemblies. The

test serves as a further quality control measure against excessively overtapped nuts, material with insufficient ductility, and generally assures the
assembly of elements (bolt, nut, and washer) will function together as a unit to
achieve required preloads.
Assemblies shall be purchased and installed as matched sets.
Intended primarily for galvanized fasteners, and fasteners that must be fully
tensioned in structural applications. When specified in contract documents this

test may also be used for field-testing.
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7/8 Diameter 3- 6 Clamp Load Analysis

75000
70000
65000
60000
55000
Clamp Load
50000
45000
40000
35000
30000
25000
20000
15000
10000
5000
0
1
11
21
31
41
51
61
71
81
91 101 111 121 131 141 151 161 171 181 191 201 211 221 231 241 251 261 271 281 291 301 311 321 331 341 351 361
Degrees of Rotation
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Rotational Capacity Test

Applicable to coated fasteners (sometimes) - ASTM
Required on all assembly lots, plain or galvanized for bridge work - AASHTO
Good, but extreme functional test of fasteners
What if connection only requires snug tight, still might be valuable (what is snug tight?)
Test generally tied to double the Turn of Nut installation requirement which is not linear, but
modified over the years
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Original Rotational Capacity Test

ASTM
Established by F16.02 for HDG bolts based on research that showed un-lubricated HDG
fasteners could not reliably reach minimum installation tension prior to torsional failure.
Expanded to cover Mechanically Galvanized fasteners when B695 was added to A325.
A means to test lubrication, which is required to prevent galling at the thread interface and
bearing surface.
Old test was a simple Pass/Fail test. You never know if you almost failed.
Vague manufacturer requirement in A325 and RCSC.
Assuming bolt meets specification the test is primarily a function of nut (or coating) lubrication but
was part of the bolt only specification.
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Rotational Capacity Testing

AASHTO and FHWA established a similar test, adding the requirement that the test be
performed on ALL structural fasteners.
Test has more specific in pass/fail criteria
Test added maximum torque at minimum design tension (via max K factor)
Minimum tension at final rotation of 1.15 design tension
This test is a good general fastener assembly performance test
But, these agencies primarily use bolts subject to full pretension
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Rotational Capacity Testing

Primary criteria tested
Strength (tensile)
Thread fit (proper oversize to avoid interference fit)
Thread strength (functional overlap)
Lubrication (too little causes torsional failure)
Ductility (extreme plastic performance or stretch beyond yield)
Quantifies lubrication effectiveness
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Problems with the current RC tests

Required by ASTM at the producer level, but should be at the distribution and end user level.
ASTM does not address plain fasteners, which can have the same issues with lack of lubrication,
particularly with Type 3 fasteners, Coatings often provide more lubricity than plain.
Nature of the test makes variability inevitable. Particularly number of washers, +/- angle tolerance,
and number of threads in the grip.

Not all fastener assemblies need this level of performance by design.
A490 previously held to the same criteria as A325, but A490 is much less ductile.
AASHTO, FHWA did not like (appropriately) the ASTM test so they maintained their own versions.
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7/8"-9 A325 Structural Bolt - 41,000 lbs. Minimum Clampload

520
480
420
Degrees of Rotation
360
300
240
180
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
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520
480
420
Degrees of Rotation
360
300
240
180
RCSC Turn of Nut Req
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
35

520
480
420
Degrees of Rotation
360
300
240
180
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
36
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520
480
420
Degrees of Rotation
360
300
Rotational Capacity Test Req
240
180
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
37

520
480
420
Degrees of Rotation
360
300
240
180
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
38
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520
Up to and Inc 4D
>4D Up to and Inc 8D
>8D
480
420
Degrees of Rotation
360
300
240
180
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
39

520
Up to and Inc 4D
>8D
480
420
Degrees of Rotation
360
300
180
240
180
120
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
40
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520
Up to and Inc 4D
>8D
480
420
Degrees of Rotation
360
320
300
240
240
180
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
41

520
Up to and Inc 4D
>8D
480
420
Degrees of Rotation
360
300
240
180
120
60
2.5
3.5
4.5
5.5
6.5
7.5
Bolt Length
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Video Rotational Capacity Testing
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COATINGS
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Coatings on Structural Bolts

B695 Zinc Mechanically Deposited Group A Only
F2329 Zinc Hot Dip Group A except Twist-Off
Research coming to permit on F2329 on Group B
F1136 Zinc/Aluminum Group A or B except Twist-Off
F2833 Zinc Rich Base Coat and Aluminum Organic/Inorganic Type Group A
or B except Twist-Off
F1941 Electrodeposited Coatings Group A Hex Only
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Other coatings possible for 120KSI (Group A)
Others coming for 150KSI Grades (Group B)
Not always done by the manufacturer
Significantly effect thread fit, K Factor, and general fastener performance
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Thickness only measured on significant surfaces
Not typically corrosion tested on a lot by lot basis
HDG on external threads only
Thread oversizing tolerances for newer coatings on A490 fasteners have been
standardized just recently
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Understanding Thread Fit - Coatings

Nut threads need to be oversized for most coatings
Oversizing the pitch diameter for clearance increases the nut minor diameter
by geometric relationship
Oversized nuts have less proof load capacity, more importantly, the increase in
minor diameter reduces the mated bolt stripping capacity
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Understanding Thread Fit - Coatings

Oversizing may change failure modes from bolt tensile failure to thread
stripping
Bolt tensile and nut proof load testing are performed with fixtures, the results
do not correlate to fastener assemblies

Care should be taken not to over-tension coated fasteners
Understand the specifics of your selected coating
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Coatings Example Zinc Aluminum Flake
Bolt
Grade 3
Washer
F1136
Grade 5
Nut
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BOLT REUSE
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Reuse
2.3.3 Reuse: ASTM A490 bolts, ASTM F1852 and F2280 twist-off-type tension
control bolt assemblies, and galvanized or Zn/Al Inorganic coated ASTM A325
bolts shall not be reused. When approved by the Engineer of Record, black
ASTM A325 bolts are permitted to be reused. Touching up or re-tightening
bolts that may have been loosened by the installation of adjacent bolts shall
not be considered to be a reuse.
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IS IT TOO TIGHT?
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Too Tight?
No
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Unfortunately This Can Happen, But.
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PROBLEMS
Most projects go as planned, but
Problems
Here is a breakdown of typical construction problems according to ENR
Magazine.
65% from Insufficient, inappropriate or conflicting information
17% from human error
8% from weather
5% from poor workmanship
5% from materials failure
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Understand the chain of command

Owner
Architect
Engineer
Inspector
Project manager
Prime or general contractor
Sub-contractor
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Regardless of the scale of the project, the owner and end user expect to get
what they pay for. This means a safe, attractive, functional structure, which
performs throughout its service life with minimal risk and maintenance. Our job
as suppliers is simply to meet their expectations.
Being prepared to respond to quality and technical questions, having the
proper knowledge of your product, and reacting in a timely and professional

manner can prevent a simple question from turning into problem or a simple
non-conformance from turning into a large claim.
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The most common problems

Be prepared and well versed in the most common of problems.
Surface discontinuities (head bursts, seams)
Low tension during preinstallation verification (equipment, training and quality)
Broken bolts or stripping during installation (often coatings and lubrication)
Storage and handling
Rotational capacity testing failing
No testing being performed
Thread damage
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The most common questions

Washer requirements
Typos and mistakes on test reports or shipping docs
Where can I get my TC tool calibrated
Can I substitute grade 5 bolts or grade 8 bolts for A325 or A490
F3125/A325 labels and certificates
What is the proper torque for installation
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What Can Happen?
Fatigue
Rust or Weathering
Coating Adhesion
Reamed Nut Threads
White Rust
Seams
Bursts
Poor Coating Thickness
Welded Parts
Storage and Handling Issues
Quench Cracks
Improper Washer Usage
Bolt Binding
Paint Adhesion
No Pre-installation Testing
Tensile Failure
Torsional Failure
Stress Corrosion Cracking
Hydrogen Embrittlement
Shank Out/Negative Stick-out
Low Tension
RC Test Failure
Inadequate Installation Tools
Lack of Installer Training
High or Low Hardness
Thread Stripping
No Control of Snug Tight
No Installation Clearance
Improper Mating Components
No Verification on Site
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A number of things
can go wrong, but
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Surface Discontinuities ASTM F788 or F812

Burst
Seam
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Bursts Are Quite Common

Head burst
Head burst
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Burst, Seam or Crack?

Seam
Quench crack
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Call Somebody!
Quench crack
Quench crack
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Other Problems
Bad threads or lack of engagement?
Adhesion or excessive impacting or bound

bolt?
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Too Brittle or Too Small?
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Or Wrong Size?
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Hot Forged, Split Die

Fin in specification
Fin profile with a bit of swell
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Misc. Problems
Coating Fixture Marks
Reamed Nut
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Workmanship
Bolt problem or hole problem?
Adhesion
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Trained Installer, Match-Marked, Witnessed, Signed-off,

didnt break.
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Rust - How Much is Too Much?

Could be OK, but need requalification
Most likely scrap
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Hole Size/Bolt Size Problem
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Bad Storage
Water
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Significant Corrosion
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Never Tightened
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Not Sure What To Say
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Not Enough Engagement
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Flatness
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Wet Storage Staining
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ARBITRATION INSPECTION
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Arbitration Inspection
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SECTION 10. ARBITRATION - RCSC

When it is suspected after inspection in accordance with Section 9.2 or
Section 9.3 that bolts in pretensioned or slip-critical joints do not have the
proper pretension, the following arbitration procedure is permitted.
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Arbitration
(1) A sample of five bolt and nut assemblies of each lot in question shall be
installed in a tension calibrator.

The material under the turned element shall be the same as in the actual
installation.
The bolt shall be partially pretensioned to approximately 15 percent of the
pretension specified in Table 8.1.
Subsequently, the bolt shall be pretensioned to the minimum value specified in
Table 8.1;
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Arbitration
(2) A torque shall be applied to the pretensioned bolt. The torque that is
necessary to rotate the nut or bolt head five degrees shall be determined.
The arbitration torque shall be determined by rejecting the high and low values
and averaging the remaining three; and,
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Arbitration
(3) Bolts represented by the sample shall be tested by applying the arbitration
torque to 10 percent of the bolts, but no fewer than two bolts, selected at
random in each joint in question.
If no nut or bolt head is turned relative to its mating component by application
of the arbitration torque, the joint shall be accepted as properly pretensioned.
93
Arbitration
If verification of bolt pretension is required after the passage of a period of
time and exposure of the completed joints, an alternative arbitration procedure

that is appropriate to the specific situation shall be used.
If any nut or bolt is turned relative to its mating component by an attempted
application of the arbitration torque, all bolts in the joint shall be tested. Those
bolts whose nut or head is turned relative to its mating component by
application of the arbitration torque shall be re-pretensioned by the Fabricator
or Erector and reinspected. The Fabricator or Erector, at their option, is
permitted to re-pretension all of the bolts in the joint and subsequently
resubmit the joint for inspection.
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RCSC Arbitration Commentary

Commentary:
Arbitrated using torque wrenches after pretensioning is subject to all of the
uncertainties of torque-controlled calibrated wrench installation. The reliability

of after-the-fact torque wrench arbitration is reduced by the absence of many
of the controls that are necessary to minimize the variability of the torque-topretension relationship, such as:
(1) The use of hardened washers;
(2) Careful attention to lubrication; and,
(3) The uncertainty of the effect of passage of time and exposure in the
installed condition.
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Arbitration Commentary
Arbitration may be based upon an arbitration torque that is determined either
using bolts that can only be assumed to be representative of the bolts used
in the actual job or using bolts that are removed from completed joints.
Ultimately, such arbitration may wrongly reject bolts that were subjected to a
properly implemented installation procedure. The arbitration procedure

contained in this Specification is provided, in spite of its limitations, as the
most feasible available at this time.
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CLOSING
Unusual Aspects of Structural Bolting

Bolts are tensioned well into yield, this is a no-no in virtually every other engineered
fastener application
Bolts are not sold as matched sets in many cases
Thread lengths are very short, bolts tend to perform better with longer threads
Acceptance testing is frequently done in the field, which is often the 1st point of
assembly
There is no industry requirement for K Factor
Snug tight as it pertains to fully tensioned bolts is highly variable - operator,
equipment, lubrication and installation procedures.

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Learning Objectives Session 1

Gain an understanding of the basics of bolting.
Gain an understanding of the background and
intent of fasteners.
Learn about bolt manufacturing steps
Become familiar with fastener terms.
Gain an understanding of functional attributes for
fasteners.
Learn about thread design and geometry
99

Learn about standards organizations responsible
for bolted connection specifications.

Learn about recent changes to fastener standards.
Gain an understanding of the basic connection.
Gain an understanding of how connection design
relates to fasteners.
Hear practical suggestions to keep costs down
and projects on schedule.
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Learn about required ordering information.
Learn about proper fastener storage and handling.
Gain an understanding of pre-installation
verification testing.
Learn about common installation methods.
Learn about inspection requirements for different
installation and joint types.
101

Learn about supplementary requirements.
Learn about Rotational Capacity Testing.
Learn about permitted structural fastener
coatings.
Review common bolting issues.
Learn about bolt reuse.
Gain an understanding of nonconformance
handling.
102
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What Else Can You Do?

Get additional fastener training, a number of options exist
Get more familiar with the standards
Ask questions
Get involved in committee work
Work with reputable contractors and suppliers
Be willing to work through problems
103
Good Reading
John H. Bickford, An Introduction to the Design and Behavior of Bolted Joints.
Industrial Fasteners Institute, Fastener Standards. Industrial Fasteners
Institute.
Geoffrey L. Kulak, John W. Fisher, John H. A. Struik, Guide to Design Criteria
for Bolted and Riveted Joints.
Geoffrey L. Kulak, High Strength Bolts: A Primer for Structural Engineers,
AISC.
PCB Load & Torque Knowledge Library
Understanding Torque-Angle Signatures of Bolted Joints
Fundamentals of Torque-Tension and Coefficient of Friction Testing
Engineering Fundamentals of Threaded Fastener Design and Analysis
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Thank You!
Brent
Christina
Nancy
Tom
Thank You
Questions?
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Individual Webinar Registrants

PDH Certificates
Within 2 business days
You will receive an email on how to report attendance from:
registration@aisc.org.
Be on the lookout: Check your spam filter! Check your junk folder!
Completely fill out online form. Dont forget to check the boxes next to each
attendees name!
Individual Webinar Registrants

PDH Certificates
Within 2 business days
Reporting site (URL will be provided in the forthcoming email).
Username: Same as AISC website username.
Password: Same as AISC website password.
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8-Session Registrants
PDH Certificates
One certificate will be issued at the conclusion of
all 8 sessions.
Quizzes
Access to the quiz: Information for accessing the quiz will be emailed to you by Thursday. It will contain a link to
access the quiz. EMAIL COMES FROM NIGHTSCHOOL@AISC.ORG
Quiz and Attendance records: Posted Tuesday mornings. www.aisc.org/nightschool - click on Current Course
Details.
Reasons for quiz:
EEU must take all quizzes and final to receive EEU
PDHS If you watch a recorded session you must take quiz for PDHs.
REINFORCEMENT Reinforce what you learned tonight. Get more out of the course.
NOTE: If you attend the live presentation, you do not have to take the quizzes to receive PDHs.
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Recording
Access to the recording: Information for accessing the recording will be emailed to
you by this Thursday. The recording will be available for two weeks. For 8-session
registrants only. EMAIL COMES FROM NIGHTSCHOOL@AISC.ORG.
PDHS If you watch a recorded session you must take AND PASS the quiz for PDHs.
Thank You
Please fill out a brief survey at the conclusion of the

webinar. Your feedback is greatly appreciated.
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AISC Night School

Fundamentals of Bolting and Welding

Thank you for joining our live webinar today.

Thank you for joining us. The presentation will begin

Theres always a solution in steel

AISC Night School

Fundamentals of Bolting and Welding

Todays audio will be broadcast through the internet.

Theres always a solution in steel

Todays live webinar will begin shortly.

Todays audio will be broadcast through the internet.

Theres always a solution in steel

AISC Night School

Fundamentals of Bolting and Welding

AISC is a Registered Provider with The American Institute of Architects Continuing

Theres always a solution in steel

Theres always a solution in steel

AISC Night School

Fundamentals of Bolting and Welding

Theres always a solution in steel

Theres always a solution in steel

AISC Night School

Fundamentals of Bolting and Welding

FUNDAMENTALS OF BOLTING AND

AISC Night School

Fundamentals of Bolting and Welding

What gets tested?

Chemistry not usually directly

Assembly tension testing

AISC Night School

Fundamentals of Bolting and Welding

AISC Night School

Fundamentals of Bolting and Welding

Continuous Heat Treatment

AISC Night School

Fundamentals of Bolting and Welding

Batch Heat Treatment

Magnetic particle inspection

AISC Night School

Fundamentals of Bolting and Welding

What are F3125 S1 S4

AISC Night School

Fundamentals of Bolting and Welding

AISC Night School

Fundamentals of Bolting and Welding

New Rotational Capacity Test - F3125 Annex A2.1.1

lubricant, the efficiency of lubricant and the compatibility of assemblies. The

tensioned in structural applications. When specified in contract documents this

7/8 Diameter 3- 6 Clamp Load Analysis

AISC Night School

Fundamentals of Bolting and Welding

Rotational Capacity Test

modified over the years

Original Rotational Capacity Test

was part of the bolt only specification.

AISC Night School

Fundamentals of Bolting and Welding

Rotational Capacity Testing

AISC Night School

Fundamentals of Bolting and Welding

Rotational Capacity Testing

Problems with the current RC tests

and number of threads in the grip.

AISC Night School