BOLTING

Basics, Tips

& Best Practices

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SmartBolts®

Direct Tension Indicating Fasteners™

Address:
202 Perry Parkway, Suite 7
Gaithersburg, MD 20877
United States

Phone: +1 (240) 631-7246

Fax: +1 (240) 750-6025

Email: [email protected]

URL: www.smartbolts.com
www.stressindicators.com

Stress Indicators Incorporated is a solutions-driven engineering and manufacturing

firm based in Maryland, USA. Formed in 1992, we provide innovative Visual
Indication Systems™ solutions for customers worldwide.

Stress Indicators Incorporated invented and developed SmartBolts® technology and

commercialized the products to enable broad industry acceptance. All SmartBolts®
are manufactured from quality fasteners at our USA facility.

Disclaimer
While we try to make sure that all data/information posted in this report is accurate at all times, we are not
responsible for typographical and other errors that may appear. Data/Information is subject to change
without notice. Stress Indicators assumes no responsibility or liability for any damages incurred directly or
indirectly as a result of any data errors, omissions, or discrepancies.
 BOLTING Basics, Tips & Best Practices

Table of Contents
Introduction ................................................................................................................................................. 4

Part One: Basics of Specifying a Bolt

Step One: Specifying the Basics of a Fastener .......................................................................................... 6
Selecting a Head Type .............................................................................................................................. 6
Select Your System of Units ..................................................................................................................... 6
Choose Your Material ............................................................................................................................... 7
Step Two: Pick Your Bolt Dimensions & Thread Length ....................................................................... 8
Specify Your Bolt Dimensions ................................................................................................................. 8
Select Your Preferred Thread Type .......................................................................................................... 8
Step Three: Optimize Your Bolt .............................................................................................................. 10
Select a Finish ......................................................................................................................................... 10
Upgrade to a Tension Indicating Fastener .............................................................................................. 11

Part Two: The Torque-Tension Relationship

The Torque-Tension Relationship ........................................................................................................... 13
Gasket Creep ............................................................................................................................................. 15

Part Three: Special Feature

Advantages of Using SmartBolts ............................................................................................................. 18

Part Four: FAQs & Bolting Terms

Frequently Asked Questions (FAQs)....................................................................................................... 20
Units of Measure used in Bolting ............................................................................................................. 23
Bolting Terms ............................................................................................................................................ 24
Resources ................................................................................................................................................... 26

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Introduction
This Special Report contains three parts and one feature. BOLTING Basics, Tips & Best Practices
includes a three-step guide on the basics of specifying your bolt, it breaks down the different type
of bolt heads, threads, finishes, materials, and everything you need to consider when designing
your bolt. In the second part, we dive into the torque-tension relationship: what it is, the factors
that affect it, and the variability of torque charts. This part also includes a brief discussion on gasket
creep: what it is, and the factors that affect it. We’ve also included a special feature on SmartBolts
and the advantages associated with using the SmartBolts Visual Indication System. In part four,
you will find ten frequently asked questions on bolting, a list of bolting terms, and units of measure
in relation to bolts.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
 Part One
Basics of Specifying a Bolt

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Step One: Specifying the Basics of a Fastener
Selecting a Head Type
Hex Bolt (HXBT): A hex headed threaded fastener. It is commonly used in conjunction with a
washer and a nut.

Hex Head Cap Screw (HHCS): In addition to the features of a hex bolt, these threaded fasteners
have a washer face beneath the head and a chamfered thread point. The flat washer face provides
a higher quality bearing surface than Hex Bolts. These ‘screws’ are designed for use in tapped
holes, but are still and excellent choice for through bolting applications. This is the most
commonly found head type in industrial applications.

Hex Flange Bolt (HFLB): These bolts also contain an external hex drive, and
feature an enlarged bearing surface that extends beyond the hex head like a built
in washer.

Heavy Hex Cap Screw (HVCS): Similar to hex head cap crews, these structural fasteners have
an increased width across the flats. They also commonly have a unique thread length.

Socket Head Cap Screw (SHCS): These fasteners with a cylindrical head have an internal hex
drive into which the hexagonal ends of an Allen wrench will fit. Often, these fasteners are used in
applications requiring the fastener to be counterbored.1

Studs: These headless fasteners

are threaded on both ends or The Importance of Using Correct
along the entire length. When Units
fully threaded they are referred Confirm which standard system of units
to as either studs or threaded your project requires before purchasing
your bolts. This is very important to
rods. When used with a blind
verify – a multi-million dollar project
hole they may contain a drive to assist with installation.2 can fail with the miscalculation of a
single fastener type. In 1999, NASA lost
Select Your System of Units an unmanned space mission as a result
The two main system of units are inch and metric. In most of a mix-up between metric and
imperial units. Its $125 million Mars
cases the system of units required is set because the Climate Orbiter probe was destroyed
mating thread is already established. It is important to because its altitude-control system used
ensure that the proper size thread be specified in order to imperial units but its navigational
avoid unsafe and improper threading. software used metric units.

If you have the opportunity to design your bolted joint from scratch, consider what the most
convenient units are for you and your customers.

1
Image Source – Socket Screws from Armafix. (n.d.).
2
Image Source – Steel Bolts. (n.d.).

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
It is generally best practice to use a consistent system of units throughout your machinery.

Choose Your Material

Steel: Steel is the most common fastener material and is available in plain as well as various
surface finishes.

When selecting steel fasteners it is important to consider the grade or class of material. In metric
systems, material strength is organized into classes. With imperial systems, material strength is
organized into various grades. Low grade steels like grade 2 or class 4.8 are not commonly heat
treated. The use of these grades should be limited to none critical low performance bolted joints.
When additional strength and performance is needed, a common choice is to use grade 5 or class
8.8 fasteners with a hardness of 27-33 HRC. For even greater strength, grade 8 or class 10.9
fasteners can be specified. These fasteners have a hardness from 33-39 HRC. ASTM A574 OR
Class 12.9 rated material can commonly be found when using socket head cap screws. For more
information on some of the most commonly used grades/classes see the chart below.

Units Grade Description

SAE J429 Grade 5 is an inch property grade of medium
Grade 5
carbon (or alloy) steel.
Inch
SAE J429 Grade 8 is an inch property grade of medium
Grade 8
carbon alloy steel.
ISO 898-1 Class 8.8 is a metric property class of medium
Class 8.8
carbon steel.
Metric
ISO 898-1 Class 10.9 is a metric property class of carbon
Class 10.9
alloy steel.

Stainless Steel: Stainless steel is a special steel alloy containing at least 18% chromium and 8%
nickel which provide significant corrosion resistance. Since stainless steel cannot USUALLY be
hardened through heat treating it is commonly cold worked to gain its strength. Two
frequently used grades are A2 vs. A4 stainless steels. These classifications represent 304
and 316 materials, respectively. While both materials offer corrosion resistance, 316
stainless steels are preferred for use in marine environments. A4 is also available in
higher strength options than A2, with some special grades approaching strengths
of grade 5 fasteners.3

Other Alloys: When steel and stainless steel fasteners don’t meet design requirements other types
of alloys may be used. Aluminum for instance, is a lightweight with an impressive strength to
weight ratio. However, due to strength limitations and a susceptibility to fatigue use of aluminum
in critical applications should be carefully considered. Other high nickel alloys are commonly used
when high temperature resistance is a requirement.

3
Image Source – Stainless Steel Hex Bolt In MM Multibrand 6x35 6mm Dia 35mm Length. (n.d.).

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Step Two: Pick Your Bolt Dimensions & Thread Length
Specify Your Bolt Dimensions
The following table provides a description for different bolt dimensions:
Bolt Dimension Description
Standard (Rounded) size of the unthreaded body or major diameter of the
Nominal Diameter
threads.
The pitch is the distance between two successive thread crests or roots. Pitch
TPI/Pitch is usually specified for metric fasteners. TPI stands for “threads per inch” and
is used with inch fasteners. Pitch is equal to the reciprocal of TPI.

Length The length of a bolt as measured from underneath the head (Bearing surface).

Metric Fasteners: Nominal diameter – Pitch x Length (i.e. M24 – 3.0 x 90mm)
US Fasteners: Nominal diameter – Threads Per Inch (TPI) x Length (i.e. 3/4″ – 10 x 3.5″)

The illustration below details these measurements:

Select Your Preferred Thread Type

There are two standard thread styles, coarse and fine. Coarse threads have a stronger thread
stripping resistance but a lower tensile strength to an equivalent bolt size with a fine thread. With
adequate thread engagement, fine threads benefit from an increase in tensile strength. Another
benefit to choosing fine threads is when tapping a relatively thin-walled material.
Another aspect to consider is full vs. partial thread lengths. Thread length is measured from the
end of a fastener to the last fully formed thread.

Finish Description
The fastener shank is partially threaded to a standardized thread length
Partial
based on the nominal diameter and length of the fastener.

Full The fastener shank is fully threaded for the total length of the fastener.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Threads can be manufactured by two methods – cut or roll-forming. Cut threads are created with
a machine that physically removes the
material using cutting tools.

Rolled threads use pressure to form threads

between special threading dies. Since
material is not removed, rolled threads offer
a continuous grain structure which can
improve a threads fatigue resistance.

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Step Three: Optimize Your Bolt
Select a Finish
It is generally important to choose a finish that can withstand your anticipated environment.
Plain (Black) – Plain, or black finishes are bare metal with a simple cosmetic black coating and
should have a light coating of oil to resist corrosion. The cosmetic coating does not provide
increased corrosion protection.

Zinc Plated – Zinc plated finishes offer galvanic protection by acting as a

sacrificial layer to protect the underlying steel. Clear and yellow
chromate finishes are commonly used to preserve the life of the zinc
plating.4

Hot Dipped Galvanized – Hot dip galvanizing is generally specified for

outdoor application and is a thick zinc based finish. It is necessary to ensure
the use of compatible components that can tolerate the thicker finish.5

Aluminum Zinc Flake – Commonly supplied under proprietary brands, this newer coating
provides significant corrosion protection without the risk of hydrogen embrittlement. It can also
be sourced with or without the use of chromium.
Other Finishes – Sometimes it is necessary to use custom coatings that provide even greater
corrosion protection, cosmetic appeal, or more consistent friction performance, for example.

4
Image Source – HHC 5/8. (n.d.).
5
Image Source – Tin Zinc Plating. (n.d.).

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Upgrade to a Tension Indicating Fastener
1) Customize your fastener with a Visual Tension Indicator & gain the benefits of the
SmartBolts Visual Indication System.
SmartBolts are unique in that they allow users to visually inspect fasteners at-a-glance. An
indicator located on the bolt head indicate whether a bolted joint is loose or tight with a clear,
visible display that gradually darkens from bright red to black as the fastener is tightened.
SmartBolts are simple: the indicator works on the most accurate principle for tension
measurement – actual fastener elongation under load.

2) Specify fastener preload.

Fastener preload is the tensile force to be developed during installation. It can be designated
using klbf, KIPS, or kN (for additional information on these units, refer to the units of measure
on page 22). SmartBolts are designed to produce a clear and repeatable shift in color from red
to black as an installer tightens the fastener to the designated preload. In addition to making
technicians’ maintenance jobs easier and more efficient, they act as an extra source of security
for machinery, structures and the personnel responsible for operating and maintaining these
critical joints.

3) Identify the project type and include a mention of environmental concerns.

SmartBolts are often used in harsh and hazardous conditions. We include these concerns in our
analysis to ensure that SmartBolts will perform in accordance with our stringent quality goals.

4) Visit the SmartBolts website

To order your SmartBolts go to http://www.smartbolts.com/find-your-smartbolt/. There you
will find the option of picking between pre-engineered bolts and custom bolts.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
 Part Two
The Torque-Tension
Relationship

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
The Torque-Tension Relationship
What is the torque-tension relationship and how do the two
properties relate? Torque is the rotational force used to turn the nut
or fastener head in a bolted joint. As torque is applied to the nut, it
attempts to climb up the threads of the bolt reducing the grip length;
however, when the components within the grip resist, the bolt is
forced to stretch. As the bolt elongates, it behaves like a spring and
develops tension, also known as preload. The tension developed
with the bolt has an equal and opposite reaction6 on the bolted
components, which creates the all-important clamp force, the
compressive force holding the bolted joint members together. Torque = Rotational Force
Measuring torque gives variable
The torque value is actually a calculated quantity from the short results because friction is
unknown.
form torque-preload equation. Bickford (1995) states the equation
as T  K  F  D , where T, K, F, and D are the input torque, the
“nut factor,” the achieved preload, and bolt’s nominal diameter,
respectively (Bickford, 1995, p. 226).
The torque-tension relationship is hard to predict when you take into
consideration all the factors that affect the nut factor (An expansion
on this topic can be found in the article: The Torque-Tension
Relationship Gets Stretched.)

Measure Tension not Torque

Since torque is a rotational force, it’s only an indicator of how hard Tension = Stretching Force
it is to turn a bolt. Tension, on the other hand, is the stretch in a bolt Measuring direct tension takes into
account everything you need to
that provides the clamping force. It is necessary to develop adequate know.
tension in order to provide bolted joint security. In torque chart 1, it
should be noted that whether the
bolt is lubricated or not, this
should not change the tension
that needs to be applied. In the
lubricated column, this torque
chart is assuming a nut factor (k)
of 0.1, it is only when this
assumption holds true that an
application of 75 ft. lbs. of
torque would develop 18,000
lbs. of tension. In the dry bolt
column, for the same amount of
Torque Chart 1 - A torque chart for an ASTM A490 indicating the tightening
tension, we now have to apply 150 ft. torque range for both lubricated and plain bolts.

6
Usually, but not always. See p. 182 of Bickford for more information on the exceptions..

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
lbs. of torque to develop the same amount of tension (18,000 lbs.) because it is assuming a nut
factor (K) of 0.2.
In torque chart 2, the lubricated column is assuming a nut factor (K) of 0.15, and the dry column
is again assuming a nut factor (K) of 0.2. Thus, the reliability of the torque-tension relationship is
highly dependent on the nut factor. What is the nut factor?
The nut factor is a grouping of the
assumptions associated with the torque-
tension relationship into one number. It
exists to streamline and simplify all of
the many factors affecting the use of
torque measurement to achieve the
desired result – precise clamp force on
the joint. The many factors influencing
the torque-tension relationship include
the material, size, plating, surface finish,
thread lubricants, corrosion and wear of
fasteners, nuts and washers, among other
things. The nut factor conveniently
summarizes all of these variables. It is an
empirical value that linearly models the
rate at which tension is developed within
a fastener when torque is applied.
A point of caution when using torque
charts is to make sure that you
understand the nut factor being implied.
For instance, if you were to use the
lubricated torque value from torque
chart 1, but the actual torque-tension
relationship ends up behaving more like the Torque Chart 2 – A torque chart for an SAE Grade 5 bolt.
lubricated bolt from torque chart 2 then the tension that is actually developed will undershoot the
target designed tension of 18,000 lbs. by approximately 6,000 lbs. To reiterate, this means that
even though you may think that 18,000 lbs. of tension has been created, in reality only 12,000 lbs.
has been developed.
You may be wondering why each torque chart implied different nut factors for lubricated bolts.
Well, an experiment was conducted by the Department of Mechanical Engineering at Oakland
University, examining this very factor.
The experiment was conducted using three
types of lubricants (Solid Film, Grease,
and Oil) to better understand the effect of lubricant on the friction and torque-tension relationship.
To learn more about the experiment click here to read the Effect of Lubrication on Friction and
Torque-Tension Relationship in Threaded Fasteners.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
In conclusion, using the measurement of torque to ensure bolted joint security is not the most
reliable way to guarantee that your bolts are properly tensioned. Keep in mind that many factors
can affect the amount of torque applied to a bolt. Therefore, it is critical for us to work to identify
and control the nut factor (K) for a bolted joint when using torque control methods to avoid
undershooting or overshooting the target designed tension.

Gasket Creep7
What is Gasket Creep?
Gaskets have many mechanical characteristics which have an important effect on joint behavior.
One important mechanical characteristic is creep relaxation a.k.a. gasket creep. This occurs when
a bolt preload is being developed, during assembly of a joint, and the gasket is compressed. The
change in the thickness of the gasket will depend on its “compressibility” and on the amount of
bolt load created during assembly. When the compressive stress is maintained for a long time, the
gasket will slowly continue to get thinner and slightly wider, which allows the bolts’ clamping the
joint to relax. According to Bickford, gasket creep is measured in several different ways, including:
Pure Creep, which is the loss of thickness of the gasket under a constant compressive stress load.
This can only be measured in a test rig, since the clamping force exerted by the bolts in a
conventional flange will decrease as the gasket creeps.
Pure Relaxation, is the loss of compressive stress on a gasket loaded under constant deflection
conditions. Measuring pure relaxation would require very high-tech equipment.
Creep Relaxation, occurs under a steadily reduced compressive load on the gasket. Creep
relaxation is a combination of both pure creep and pure relaxation. For example, the gasket is
loaded by tightening bolts, when the gasket creeps it becomes thinner. This results in the bolts
relaxing which leads to a domino effect of loss in bolt elongation, bolt tension, clamping force,
and, therefore, stress on the gasket.

Factors Affecting Creep

There is no way to avoid gasket creep, because “a good gasket material must have some plasticity
to allow it to mate intimately with all the imperfections of the flange surfaces.” The amount of
creep that will occur depends on the materials it is made of, and its construction. Furthermore,
there a number of other factors that can affect gasket creep, including:
Initial Thickness, creep relaxation is relative to the thickness of the gasket. For example, a ¼
inch thick fiber gasket will relax almost 4 times as much as a 1/16 inch thick gasket made from
the same material.
Time, most creep relaxation occurs within the first 15-20 minutes after preloading. It will also
continue to creep slowly for several hours, and maybe even forever.
Temperature, this is one of the major factors that affects creep relaxation. High temperatures
can increase the amount of creep by a factor of 10 or more.

7
Source – Bickford, J. H. (1995) p 655 - 662.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Applied Loads, the amount of initial stress place on the gasket affects its creep rate. The higher
the load, the higher the amount of creep produced.

Bolt Stiffness, does not affect a gasket’s creep-relaxation properties, it will however affect the
relationship between the loss of thickness of the gasket and the loss of clamping force or
compressive stress on the gasket.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
 Part Three
Special Feature: Advantages of
SmartBolts

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Advantages of Using SmartBolts
A SmartBolt is an ordinary bolt that has been embedded with a Direct Tension Indicator that allows
you to measure bolt tension. This technology uses color to indicate tension. The changes in color
are proportional to bolt stretch, which ensures accurate and reliable measurements. Our customers
have reported that visual bolt inspections offer cost-savings and performance benefits compared
to traditional maintenance methods which require that workers check each bolt with a torque
wrench.
 SmartBolts improve the safety and reliability of your equipment.
 The real-time visual alert of tension allows for hands-free inspection.
 Service life is extended with full repeatability, reusability, and no wearable parts.
 Install and inspect on-the-go with no training required.
 Avoid costly downtime with SmartBolts.
 Any bolt can virtually be made into a SmartBolt.
Visual bolt inspections are up to 10 times faster. When many bolts need to be inspected, there
is considerable value in reducing the time required to inspect each bolt.
Visual bolt inspections are hands-free. In cases where bolts are difficult to access, visual
inspection enables a worker to perform inspection without touching the bolts.
Visual bolt inspections promote safe work practices. Sometimes, bolts are in hazardous places.
While security of these bolts is critical to operations, it’s also critical to ensure personnel are not
placed in harm’s way.
Visual bolt inspections are more accurate. Traditional inspection methods often use torque
measurement, which can be unreliable because of hidden friction factors. SmartBolts bypass this
limitation by measuring bolt tension directly.
Visual bolt inspections provide increasing value over time. A regular and
comprehensive bolted joint inspection plan can ensure that your equipment remains
reliable, high-performing and safe for many years to come. Visual
bolt inspections provide immediate benefits that reduce
both the short and long-term costs associated with
maintenance, and improve your operations so they
can perform at their optimal level.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
 Part Four
FAQs & Bolting Terms

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Frequently Asked Questions (FAQs)
1) What happens as a bolt is tightened?
When using a traditional wrench to tighten a bolt,
the torque applied to the nut causes it to slide up
the inclined plane of the threads. This relative
motion between the nut and the bolt attempts to
reduce the distance between the bearing surfaces of
the bolt and nut. This dimension is the grip
length of the bolted joint. When the joint members
within the grip resist, the bolt begins to stretch like
a stiff spring, developing tension and
simultaneously compressing the components
together creating the all-important clamp force.8

2) Should I tighten the bolt head or the nut?

Either is acceptable, however a torque value defined for tightening the head does not
necessarily apply to tightening the nut. Tightening the head vs. the nut can result in
different nut factors and therefore change the torque required to achieve
proper preload.

3) What is the difference between tension and torque?

Tension is the stretch or elongation in a bolt that provides the clamping force in a joint.
On the other hand, torque is an indirect indication of tension; it is the amount of
rotational force required to spin the nut along the threads of a bolt.9

4) What is the torque to yield tightening method?

The torque to yield tightening method is the concept of tightening a fastener so that a
high preload is achieved by tightening the yield point of the fastener’s material. In
order to do this accurately, special equipment is required; the equipment monitors the
tightening process. Ultimately, as the fastener is being tightened the equipment will
monitor the torque verses the angle of rotation of the fastener. If it were to deviate
from the specified gradient by a certain amount the tool halts the tightening process.
The deviation is an indication that the fastener material has been yielded.

5) What is bolt preload and why is it important?

Preload is the tension created in a fastener when it is tightened. This tensile force in
the bolt creates a compressive force in the bolted joint known as clamp force. For
practical purposes, the clamp force in an unloaded bolted joint is assumed to be equal
and opposite of the preload.10 If proper preload, and thus clamp force, is not developed
or maintained, the likelihood of a variety of problems such as fatigue failure, joint

8
Image Source – Torque Information. (n.d.).
9
Image Source – Torque Device & DIGI-TORC Series. (n.d.).
10
Usually, but not always. Review Bickford (p. 192, Bickford, 1995) for more information on the exceptions.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
separation, and self-loosening from vibration can plague the bolted joint leading to joint failure.

6) Why do bolts come loose?

There can be many possible causes for bolts to loosen in service. When we say “loosen” here we
mean lose their tension, or preload. Here are five major causes:

 Vibration which can create relative

transverse movement of the bolted materials
leading to self-loosening of the nut.
 Relaxation of the bolted joint after tightening
due to embedment or gasket creep.
 Elastic interactions occur when multiple
bolts are present in a bolted joint. The
additional force applied to the joint members
by tightening a bolt can affect the amount of
tension on the other previously tightened
bolts. Elastic interactions can either increase
or decrease bolt preload making it even more
difficult to predict.
 Temperature fluctuation of the components.
 Insufficient initial preload developed at
installation
Bolts have to operate in all kinds of conditions

The design of the bolted joint can minimize relaxation and embedment, and ensuring sufficient
preload at installation can reduce the effects of vibration and likelihood of relative transverse
movement. In other words, properly designed bolted joints that are properly preloaded should not
self-loosen!

7) What is proof load & how is it different from yield strength & ultimate strength?
Each of these are basic mechanical properties that help define the expected tensile strength11
performance of a specific fastener and can be measured in units of force. In USCS and SI systems,
force is measured in pound-force (lbf) and Newtons (N), respectively. Since the strength of
fasteners is generally quite large, it is also common to see these forces listed in kilopound-force
(klbf) and kilonewton (kN).
Proof load is defined as the maximum tensile force that can be applied to a bolt that will not result
in plastic deformation. In other words, the material must remain in its elastic region when loaded
up to its proof load. Proof load is typically between 85-95% of the yield strength. Yield
strength can be defined as the tensile force that will produce a specified amount of permanent
deformation (most commonly 0.2%) within a specific fastener.

11
The term strength in this context differs from stress by being defined for a specific bolt’s stress area and presented
in units of force. Worth mentioning is that “strength” is also commonly used interchangeably with stress and
presented in units of pounds per square inch (psi) for USCS or Megapascals (MPa) for SI. In this case, the value
represents a more general property that can be applied to a variety of stress areas to derive the limits of applied
forces. In other words, the ultimate tensile strength of the fastener material (MPa) can be presented as the ultimate
tensile strength (kN) of a specific size fastener.

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Ultimate tensile strength can be defined as the maximum force a specific fastener must withstand
before fracture.

8) How do coatings or platings affect the torque-tension relationship?12

A coating/plating will change the surface of the fastener; most coatings increase the lubricity of
the fastener. This will reduce the amount of friction or surface roughness, which leads to more
energy going into stretching the bolt when tightened, rather than losing energy to friction between
the threads.

9) How does one prevent thread galling?13

There is no way to completely eliminate/prevent galling, however there are different methods used
to minimize it:
 Lubricating threads
 Adding a PTFE coating
 Reducing the class of fit
 Reducing the rotational speed during installation
 Avoid using prevailing torque locknuts
 Use of rolled threads instead of cut threads
 Use proper installation torque14

10) What are the benefits of using thread lubrication on bolts?

 Controlling Friction – When tightening a bolt, this could cause galling, seizing, and
fastener wear. A properly lubricated bolt will prevent these events from occurring by
reducing the overall amount of friction.
 Assisting with Proper Tension – Unexpected nut factors can radically reduce fastener
preload, even when following prescribed torque. Selecting the proper lubricant that will
overcome one nut factor, will allow you to be closer to achieving proper preload.
 Reduces Corrosion – Using the correct lubricant, you can reduce and prevent corrosion
from moisture and chemicals. The lubricant will create a barrier on the bolt to protect it
from corrosion.
 Aids in Break-out – Bolts assembled using lubricant are easier to break-out. By using
lubricant during installation, you can avoid galling that is associated with bolt break-out.
 Reduces Damage – If a bolt fails in a critical joint, the consequences can be severe.
Anything from loss of production, financial damage, material leaks, to hazardous
emissions, and worker injury can occur. These events can be reduced by adding the proper
lubricant to your bolting procedure, since it assists in achieving proper preload.

That being said, please keep in mind that different types of bolts require different lubricants. It is
important to take the time to find the right lubricant for the bolt you are using. The one-size-fits-
all approach is not appropriate in this particular context.

12
Source – Engineering Frequently Asked Questions. (2016).
13
Source – Engineering Frequently Asked Questions. (2016).
14
Image Source – Thread Galling. (n.d.).

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Units of Measure used in Bolting
KIPS: A non-SI unit. It is an Imperial unit of force. It equals 1,000 pounds-force, used primarily
by American architects and engineers to measure engineering loads.

Kilopounds-force (klbf): A measure of tensile force or clamp force on a bolt as it is tightened.

The symbol klbf is used when it is necessary to clearly distinguish it as a unit of force rather than
mass. The name comes from combining the words “kilo” and “pound”; it is occasionally called a
kilopound.

kN (kilonewtons): A measure of tensile force or clamp force on a bolt as it is tightened. Design

Tension, Proof Strength, and Ultimate Strength are expressed in kN for Metric series SmartBolts®.

SI: The International System of Units, an evolution of the metric system.

Stress: An engineering value that is defined as force per unit area. For bolts, it is often expressed
in PSI (pounds per square inch). The metric parallel measure is MPa (Mega Pascals).

USCS: The U.S. Customary System, an evolution of the British Imperial System.15

15
Image Source – CDI Dial Torque Wrench Dual Scale. (n.d.).

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BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Bolting Terms
Clamp Force: The compressive force on the joint
members that occurs from the developed tensile force when
a bolt is tightened. Clamp force is what holds your bolted
joint together, not torque.16

Creep Strain: The tendency for a bolt to move slowly or

deform permanently under the influence of constant
mechanical stresses or high temperature levels.

Design Tension: The tensile force on the bolt, measured in klbf or kN, at which SmartBolts® are
designed to indicate the “Tight” color, black. “Tight” shows the bolt has been properly installed
and Preload is established.

Elastic Interaction: In a bolted joint with multiple fasteners, as each fastener is tightened a
variation in individual fastener preload will occur.

Embedment: Localized yielding of bolted joint components resulting in a change of grip length
consequently causing relaxation of the bolted joint.

Galling: This occurs during installation when pressure and friction cause bolt threads to seize to
the threads of a nut or tapped hole. If a fastener has seized up from galling it is almost impossible
to remove without cutting the bolt.

Grip Length: The combined thickness of all

components joined together between the bolt head and
nut.

Minimum Grip Length: With respect to SmartBolts®,

if a Minimum Grip Length is denoted, there is a limit to
how far the nut can be run up the shank during
installation before it begins to impact the accuracy of the
SmartBolts® indicator. Customers may contact the
factory to learn what the specified minimum grip length is for a particular SmartBolts® model, if
it applies.

Modified Proof Strength: The proof strength of the bolt after conversion into a SmartBolt. In all
but the shortest bolt lengths, this strength is identical to the bolt proof strength before modification.

Nut Factor: A constant (K) that attempts to model all of the many variables (such as friction) that
affect the torque-tension relationship. Torque charts depend on an assumption of the nut factor,

16
Image Source – Clamping Force. (n.d.).

24
BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
but it is very difficult to predict and measure. (A full explanation of the nut factor problem can be
found in our blog post: Torque Measurements and the Nut Factor Problem.)

Preload: The tensile force developed during installation (tightening) of a bolt.

Proof strength: The tensile strength of a bolt beyond which permanent elongation of the bolt may
occur. SmartBolts® are designed to operate in tensile loads from zero up to proof strength. This is
called the elastic region of the bolt.

Strain: With respect to bolts under tensile force, strain is the measure of elongation of the bolt as
it is stretched.

Stress Area: The effective cross sectional area of the threaded region in a bolt.

Tension: The stretch or elongation in a bolt that provides the clamping force.

Torque: The amount of energy it takes to spin the nut up along the threads of a bolt. A twisting or
rotational force given in units of pound-feet (lb-ft) or Newton-meters (Nm). Torque is related to
bolt tension by the nut factor, which is difficult to predict.

Ultimate Strength: The maximum tensile load that a bolt can withstand before breaking.

25
BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Resources
Bickford, J. H. (1995). An introduction to the design and behavior of bolted joints (3rd ed.)
New York, NY: Taylor & Francis Group

Bolt Torque Chart. (2016). Retrieved July 13, 2016, from

http://www.portlandbolt.com/technical/bolt-torque-chart/

Bolted Joint Design. (2016). Retrieved July 08, 2016, from

https://www.fastenal.com/en/69/bolted-joint-design

CDI Dial Torque Wrench Dual Scale. (n.d.). Retrieved July 28, 2016, from
http://www.probandsawblades.com/prod-18-1-553-447/cdi-dial-torque-wrench-dual-scale-3-8-
dr-0-75-in-lbs.htm

Clamping Force. (n.d.). Retrieved July 28, 2016, from

https://www.carrlane.com/catalog/index.cfm/29425071f0b221118070c1c513906103e0b05543b0
b012009083c3b285351444a2d020609090c0015312a36515f534458

Engineering Frequently Asked Questions. (2016). Retrieved July 07, 2016, from
https://www.fastenal.com/en/82/engineering-frequently-asked-questions

Fastenal. (2009). [Illustration of Tensile: Stress-Strain Relationship] Bolted Joint Design:

Mechanical Properties of Steel Fasteners in Service.

Fastener Torque Charts. (2011, May 18). Retrieved July 19, 2016, from
https://www.imperialsupplies.com/pdf/a_fastenertorquecharts.pdf

Gedeon, M. (2010, January). Factors Affecting Stress Relaxation and Creep [Editorial].
Materion. Retrieved July 08, 2016, from
https://materion.com/~/media/Files/PDFs/Alloy/Newsletters/Technical Tidbits/Issue No 13 -
Factors Affecting Stress Relaxation and Creep.pdf

HHC 5/8. (n.d.). Retrieved July 25, 2016, from

https://www.acmetool.com/index.jsp?path=product

Industrial Thread Lubricants. (August 12). Retrieved July 08, 2016, from
http://www.fastorq.com/uncategorized/industrial-thread-lubricants/
Liquid Wrench | Products. (n.d.). Retrieved July 27, 2016, from
http://www.liquidwrench.com/products/

New MLP Solid Film Lubricant in Pen Applicator. (2015, August 11). Retrieved July 27,
2016, from http://bulletin.accurateshooter.com/2015/08/new-mlp-solid-film-lubricant-in-pen-
applicator/

26
BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
Signs. (n.d.). Retrieved July 27, 2016, from
http://stonehousesigns.com/category/type/signs?page=45

Socket Screws from Armafix. (n.d.). Retrieved July 25, 2016, from
http://www.armafix.com/products/threaded-fasteners/socket-screws

Stainless Steel Hex Bolt In MM Multibrand 6x35 6mm Dia 35mm Length. (n.d.). Retrieved
July 25, 2016, from http://www.gajsupply.com/Multibrand-Stainless-Steel-Hex-Bolt-In-MM-
6x35-6mm-Dia-35mm-Length

Steel Bolts. (n.d.). Retrieved July 26, 2016, from http://www.pipetubefittings.net/steel-bolt.html

Thread Galling. (n.d.). Retrieved July 26, 2016, from https://www.boltdepot.com/fastener-

information/Materials-and-Grades/Thread-galling.aspx

Tin Zinc Plating. (n.d.). Retrieved July 25, 2016, from http://www.platingtech.com/plating-
specifications/tin-zinc-plating/

Tips for Loosening Nuts, Bolts and Screws (2016). Retrieved July 07, 2016, from
http://www.familyhandyman.com/workshop/tips-for-loosening-nuts-bolts-and-screws/view-all

Torque Device & DIGI-TORC Series. (n.d.). Retrieved July 27, 2016, from
http://www.hanstool.com/product/class/?23.html

Torque Information. (n.d.). Retrieved July 27, 2016, from http://www.gedore-

torque.com/service-centre/torque/
Vila, B. (n.d.). What Would Bob Do? Rusty Bolts, Non-Slip Tubs, and House Wrap. Retrieved
July 25, 2016, from http://www.bobvila.com/articles/what-would-bob-do-nails-non-slip-tubs-
house-wrap/#.V5ZtVrgrK00

Zou, Q., Sun, T., Nassar, A., Barber, G., & Gumul, A. (2015, May 26). Effect of Lubrication
on Friction and Torque-Tension Relationship in Threaded Fasteners [Editorial]. Research Gate.
Retrieved July 12, 2016, from
https://www.researchgate.net/publication/245314459_Effect_of_Lubrication_on_Friction_and_T
orque-Tension_Relationship_in_Threaded_Fasteners

27
BOLTING Basics, Tips & Best Practices Stress Indicators, Inc. © 2016
SmartBolts
®

Visual Indication System

TM

Get Peace of Mind when you...

Know at a Glance your Bolted Joints are Secure™
TORQUE is NOT
Always TIGHT
Measuring torque only
tells you how difficult it is
to turn the bolt. It provides
little information about bolt
LOOSE TIGHT tension, the force that is
actually holding your critical

T he SmartBolts built-in visual tension indicator turns from red to black when proper
tension has been reached and is completely reversible for the life of the fastener.
joints together.

SmartBolts are on the Job Worldwide...

Keeping production up and running Saving inspection time and maintenance Helping prevent accidents

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Wind turbine Robotic arc welders Slewing bearings Injection molding Mobile stacking conveyor
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Pump assembly for Excavator drilling Multiple applications NEXRAD Doppler radar Heavy duty truck
hydraulic fracturing equipment Chicago Transit Authority National Weather Service suspension assembly
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Put SmartBolts to Work for You...

Go to smartbolts.com/shop to search our catalog of
Pre-Engineered SmartBolts or request Custom SmartBolts
manufactured to your specifications.

SmartBolts
Stress Indicators Incorporated
®
(240) 631-7246
[email protected]
Visual Indication System
TM
www.smartbolts.com