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TITLE: Doc. No.

Issue No.
SPECIFICATION FOR
FASTENERS AND WASHERS Revision
FOR OVERHEAD LINES. No.
PART 1: BOLTS AND NUTS Date of
Issue
Page 1 of 14

TABLE OF CONTENTS

0.1 Circulation List

0.2 Amendment Record

FOREWORD
1. SCOPE
2. REFERENCES
3. TERMS AND DEFINITIONS
4. REQUIREMENTS
5. TESTS AND INSPECTION
6. MARKING

ANNEX A – Technical Particulars

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Issue No.
SPECIFICATION FOR
FASTENERS AND WASHERS Revision
FOR OVERHEAD LINES. No.
PART 1: BOLTS AND NUTS Date of
Issue
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0.1 Circulation List

COPY NO. COPY HOLDER


1 Procurement Manager
2 Manager, Design
3 Manager, Construction
4 Chief Manager, Design
5 Chief Manager, Operations

0.2 Amendment Record

Rev No. Date Description of Change Prepared by Approved by


(YYYY-MM- (Name & (Name &
DD) Signature) Signature)

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Date: Date:
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Issue No.
SPECIFICATION FOR
FASTENERS AND WASHERS Revision
FOR OVERHEAD LINES. No.
PART 1: BOLTS AND NUTS Date of
Issue
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FOREWORD

This specification has been prepared by the Research and Development Department
of KPLC and the Design &Operations Departments of REA. It lays down requirements
for Bolts and Nuts (complete with washers). It is intended for use by KPLC/REA in
purchasing the items.

It shall be the responsibility of the manufacturer to ensure adequacy of the design and
good engineering practice in the manufacture of the Bolts and Nuts for KPLC/REA.
The manufacturer shall submit information which confirms satisfactory service
experience with products which fall within the scope of this specification.

1. SCOPE

1.1 This specification is for Bolts and Nuts (complete with washers) for use on overhead
power lines and associated work.

1.2 The specification covers the following:

 Pole Bolts
 Assembly Bolts
 Eye Bolts
 Tie Rods (Double and Full Threaded Bolts)
 Foundation Bolts
 Nuts
 Eye Nuts

2. REFERENCES

The following documents were referred to during the preparation of this specification.
In case of conflict, the provision of this specification shall take precedence.

ISO 1461: Metallic Coatings – Hot dip galvanized coatings on fabricated ferrous
products – Requirements

KS ISO 888: Bolts, screws and studs – Nominal lengths, and thread lengths for
general purpose bolts

BS 4190: ISO metric black hexagon bolts, screws and nuts – Specification

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Issue No.
SPECIFICATION FOR
FASTENERS AND WASHERS Revision
FOR OVERHEAD LINES. No.
PART 1: BOLTS AND NUTS Date of
Issue
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ISO 68-1: ISO general purpose screw threads – Basic profile – Part 1: Metric screw
threads

ISO 261: ISO general purpose metric screw threads – General plan

ISO 10684: Fasteners – Hot dip galvanized coatings

3. TERMS AND DEFINITIONS

For the purpose of this specification, the definitions given in the reference standards
shall apply.

4. REQUIREMENTS

4.1 SERVICE CONDITIONS

The Bolts and Nuts shall be suitable for continuous use indoors and outdoors in
tropical areas in humidity of up to 90%, average ambient temperature of +30ºC with a
minimum of -1ºC and a maximum of +40ºC and saline conditions along the coast.

4.2 Pole Bolts

4.2.1. Pole bolts shall be manufactured in accordance with BS 4190 strength grade
designation 4.6.

4.2.2. Each bolt shall be supplied complete with one full nut (as per clause 4.7 of this
specification).

4.2.3. The bolts shall be ISO metric black hexagon bolts and of hot dip galvanized finish.

4.2.4. The form of thread, diameters and associated pitches shall be in accordance with ISO
261 and BS 4190 (coarse pitch). The tolerance class shall be 8g for bolts and 7H for
nuts as per BS 4190.

4.2.5. The nominal length of the bolts shall be the distance from underside of the head to the
extreme end of the shank, including any chamfer or radius. The permissible tolerance
on the nominal lengths and finish of the ends shall be in accordance with BS 4190.

4.2.6. The length of thread on pole bolts shall be as per Table 1:

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TITLE: Doc. No.

Issue No.
SPECIFICATION FOR
FASTENERS AND WASHERS Revision
FOR OVERHEAD LINES. No.
PART 1: BOLTS AND NUTS Date of
Issue
Page 5 of 14

Table 1: Length of threads (pole bolts)

Bolt Diameter, d Bolt Length, Tolerance on Thread Length,


mm (inch) nominal length (mm) l, mm (inch)
M16 (⅝’’) 112 (4½’’) ±1.75 38 (1½’’)
M16 (⅝’’), M20 (¾’’) 175 (7’’) ±2.0 150 (6’’)
M16 (⅝’’), M20 (¾’’) 225 (9’’) ±2.30 150 (6’’)
M16 (⅝’’), M20 (¾’’) 275 (11’’) ±2.60 150 (6’’)
M16 (⅝’’), M20 (¾’’) 300 (12’’) ±2.60 150 (6’’)
M16 (⅝’’), M20 (¾’’) 325 (13’’) ±2.85 150 (6’’)
M16 (⅝’’), M20 (¾’’) 350 (14’’) ±2.85 150 (6’’)
M16 (⅝’’), M20 (¾’’) 400 (16’’) ±3.15 150 (6’’)

4.2.7. The diameter of the unthreaded portion of the shank of the bolts and other dimensions
shall be in accordance with Fig. 1 and Table 2.

Fig. 1: Dimensions for pole bolts and nuts

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Issue No.
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FOR OVERHEAD LINES. No.
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Table 2: Dimensions for Pole Bolts (before galvanizing)

Nominal size Pitch of thread Diameter of Width across Height of


and thread (coarse pitch unthreaded flats, head,
diameter series) shank dimension ‘s’ dimension ‘k’
Min. Max. Min. Max. Min. Max.
M16 (⅝’’) 2 15.30 16.70 23.16 24.00 9.55 10.45
M20 (¾’’) 2.5 19.16 20.84 29.16 30.00 12.10 13.90
All dimensions in mm u.o.s

4.3 Eye Bolts

4.3.1 Eye bolts shall be manufactured from steel to BS 4190 strength grade designation 4.6.

4.3.2 Eye bolts shall be of drop forged manufacture.

4.3.3 Each eye bolt shall be supplied complete with one full nut (as per clause 4.7 of this
specification).

4.3.4 Eye bolts shall be in accordance with fig. 2 and have dimensions shown in Table 3.

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Issue No.
SPECIFICATION FOR
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FOR OVERHEAD LINES. No.
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Fig. 2: Eye bolt

Table 3: Dimensions for Eye Bolts

Diameter Length of eye Length of Diameter of Pitch of


bolt (dimension threads, mm unthreaded thread
A as per fig. 1) (inch) part (coarse pitch
mm (inch) Min. Max. series), mm
M20 (¾’’) 250 (10’’) 150 (6’’) 19.16 20.84 2.5
300 (12’’)
325 (13’’)
350 (14’’)
400 (16’’)
450 (18’’)
550 (22’’)
600 (24’’)
All dimensions in mm u.o.s.

4.4 Assembly Bolts

4.4.1 Assembly bolts shall be ISO metric galvanized black hexagon bolts in accordance with
BS 4190 grade 4.6.

4.4.2 Each bolt shall be supplied complete with one full nut (as per clause 4.7 of this
specification).

4.4.3 The length of thread shall be in accordance with Table 4A.

Table 4A: Length of thread for Assembly Bolts

Bolt length, mm Bolt diameter


(inch) M10 & M12 M16 M20
Thread length mm
38 (1½’’) 38 - 38
50 (2’’) 30 38 46
75 (3’’) - 38 46
175 (7’’) - 44 52
‘-‘ Means size not used
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Issue No.
SPECIFICATION FOR
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4.4.4 Assembly bolts shall have other dimensions as per Table 4B.

Table 4B: Dimensions for Assembly Bolts

Nominal size Pitch of thread Diameter of Width across Height of


and thread (coarse pitch unthreaded flats head
diameter series) shank
Min. Max. Min. Max. Min. Max.
M10 (⅜’’) 1.5 9.42 10.58 16.57 17.00 6.55 7.45
M12 (½’’) 1.75 11.30 12.70 18.48 19.00 7.55 8.45
M16 (⅝’’) 2 15.30 16.70 23.16 24.00 9.55 10.45
M20 (¾’’) 2.5 19.16 20.84 29.16 30.00 12.10 13.90
All dimensions in mm u.o.s

4.5 Tie Rods (Double and full threaded bolts)

4.5.1 Tie rods (double and full threaded bolts) shall be manufactured from steel to BS 4190
strength grade designation 4.6.

4.5.2 Each tie rod shall be supplied complete with four full nuts (as per clause 4.7 of this
specification).

4.5.3 Tie rods shall be in accordance with Fig. 3 and have dimensions shown in Table 5.

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Issue No.
SPECIFICATION FOR
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FOR OVERHEAD LINES. No.
PART 1: BOLTS AND NUTS Date of
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Fig. 3: Tie rod (double and full threaded bolt)

Table 5: Dimensions for Tie Rods (Double and full threaded bolts)

Nominal size Pitch of Double threaded bolts Full threaded bolts


and thread thread (dimension as per fig 2)
diameter (coarse pitch
A B C D Length Length of
series) (length of bolt thread
of bolt)
M20 (¾’’) 2.5 450 130 160 160 550mm 550mm (22’’)
(18’’) (22’’)
550 190 180 180
(22’’)
600 200 200 200
(24’’)
All dimensions in mm u.o.s

4.6 Foundation Bolts

4.6.1 Foundation bolts shall be ISO metric galvanized black hexagon bolts in accordance
with BS 4190 grade 8.8.

4.6.2 Each bolt shall be supplied complete with one full nut. The nut shall be to BS 4190
strength grade 8.

4.6.3 The dimensions of foundation bolts shall be in accordance with Table 6.

Length of Nominal Pitch of Diameter of Width across Height of


bolt size and thread unthreaded flats head
thread (coarse shank
diameter pitch Min. Max. Min. Max. Min. Max.
series)
450 (18’’) M22 (⅞’’) 2.5 21.16 22.84 31.00 32.00 13.10 14.90
500 (20’’)
550 (22’’)
All dimensions in mm u.o.s

4.7 Nuts

4.7.1 These shall be full nuts to BS 4190 strength grade 4 and of hot dip galvanized finish.

4.7.2 The nuts shall be of dimensions indicated in Fig. 1 and Table 5.


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Issue No.
SPECIFICATION FOR
FASTENERS AND WASHERS Revision
FOR OVERHEAD LINES. No.
PART 1: BOLTS AND NUTS Date of
Issue
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Table 5: Dimensions for Nuts (before galvanizing)

Nominal size Pitch of thread Width across Width across Thickness of


and thread (coarse pitch flats, ‘s’ corners, ‘e’ Nut, ‘m’
diameter series) Min. Max. Min. Max. Min. Max.
M10 (⅜’’) 1.5 16.57 17.00 18.72 19.60 7.55 8.45
M12 (½’’) 1.75 18.48 19.00 20.88 21.90 9.55 10.45
M16 (⅝’’) 2 23.16 24.00 26.17 27.70 12.45 13.55
M20 (¾’’) 2.5 29.16 30.00 32.95 34.60 15.45 16.55
M22 (⅞’’) 2.5 31.00 32.00 35.03 36.90 17.45 18.55
All dimensions in mm u.o.s

4.7.3 The nuts shall be suitable for use with pole bolts, assembly bolts, eye bolts, tie rods
(double and full threaded bolts) and foundation bolts detailed in this specification.

4.8 Eye Nuts

4.8.1 Eye nuts shall be of drop forged manufacture, from steel to BS 4190 grade 4.6.

4.8.2 Eye nuts shall be in accordance with Fig. 4. The pitch of thread (coarse pitch series)
shall be 2.5mm to be compatible with M20 pole bolts and M20 eye bolts detailed in
clause 4.2 and 4.3 respectively.

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Issue No.
SPECIFICATION FOR
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Fig. 4: Eye nut


4.9 Galvanizing

4.9.1 All materials to be galvanized shall be of the full dimensions shown or specified and all
the removal of burrs shall be completed before the galvanizing process commences.

4.9.2 All galvanizing shall be done by the hot dip process (molten Zinc), not less than 98%
of which must be pure Zinc. The process shall be in accordance with ISO 1461.

4.9.3 The Zinc coating shall be uniform, clean, smooth and as free from spangle as
possible.

4.9.4 The minimum thickness of coating shall be in accordance with Table 6.

Table 6: Coating thickness

Nominal size and thread Local coating thickness Mean coating thickness
diameter (minimum) (minimum)
μm μm
M10 (⅜’’) 35 55

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M12 (½’’) 35 55
M16 (⅝’’) 35 45
M20 (¾’’) 45 45
M22 (⅞’’) 45 45

4.10 Strength and Safe Working Load

4.10.1 All pole bolts, eye bolts, assembly bolts and tie rods shall have a safe working shear
stress of not less than 120 N/mm² ; the ultimate shear stress shall be 75% of the
ultimate tensile strength, the factor of safety being not less than 2.5.

4.10.2 Ultimate tensile strength and tensile stress for the bolts shall be as indicated in Table 7
below:

----------THIS SPACE LEFT BLANK-------

Table 7: Tensile Strength and Safe Working Load

Bolt Sizes Ultimate Tensile Ultimate Safe Safe


Tensile Stress Area Tensile Working Working
2
Stress mm Strength Load Shear Load
2
N/mm kN kN kN
M12 (½’’) 392 84.3 33.05 13.22 9.91
M16 (⅝’’) 392 157.0 61.54 24.62 18.46
M20 (¾’’) 392 245.0 96.04 38.42 28.81

4.10.3 The safe working load of eye bolt in axial direction shall be 38.42kN minimum, the
factor of safety being at least 2.5.

4.10.4 The mechanical properties and proof loads for nuts shall be in accordance with Table
8.

Table 8: Mechanical properties and proof loads for nuts

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Issue No.
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Nominal Strength grade Tensile Brinell Rockwell Vickers


size of designation stress Hardness Hardness Hardness
nut 4 8 area of (HB) (HRC) (HV)
Stress under bolt max max max
proof load mm² (all nuts) (all nuts) (all nuts)
N/mm²
400 800
Proof load kN Grade Grade Grade Grade Grade Grade
4 8 4 8 4 8

M10 (⅜’’) 23.2 - 58.0 302 302 30 30 310 310


M12 (½’’) 33.7 - 84.3
M16 (⅝’’) 62.8 - 157
M20 (¾’’) 98.0 - 245
M22 (⅞’’) 121.0 242.0 303

5 TESTS AND INSPECTION

5.1 Bolts and Nuts shall be tested and inspected in accordance with BS 4190, ISO 1461,
ISO 10684 and this specification. It shall be the responsibility of the manufacturer to
perform or to have performed all the relevant tests.

5.2 Certified true copies of previous test reports by the relevant International or National
Testing/Standards Authority of the country of manufacture (or ISO/IEC 17025
accredited laboratory) shall be submitted with the offer for evaluation (all in English
Language). A copy of accreditation certificate for the laboratory shall also be
submitted.

Copies of test reports to be submitted shall include tensile strength, proof load,
verification of dimensions and galvanizing tests.

5.3 Routine and sample test reports for the bolts and nuts to be supplied shall be
submitted to KPLC/REA for approval before shipment/delivery of the goods.

5.4On receipt of the goods KPLC/REA may perform any of the relevant tests in order to
verify compliance with this specification. The supplier shall replace without charge to
KPLC/REA bolts and nuts which upon examination, test or use fail to meet any of the
requirements in the specification.
…………………………………………………………………………………………………………….

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Issue No.
SPECIFICATION FOR
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FOR OVERHEAD LINES. No.
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ANNEX A: Technical Particulars (to be filled and signed by the Manufacturer for all
clauses and submitted together with catalogues, brochures, drawings,
technical data and test reports for tender evaluation)

Clause Number Bidder’s offer Reference page on


Manufacturer’s catalogue,
drawing, technical data or tests
report to support the offer.

NB: - This schedule does not in any way substitute for detailed information required elsewhere in the
specification.

…………………………………………………………………………………….
Manufacturer’s Name, Signature, Stamp and Date

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Date: Date: