PRE INSTALLATION TESTING

Overview
Whenever you’re using pretensioned, high strength bolts, IE A325 & A490, ASSHTO,
the RCSC and AISC require you to test at least 3 bolt assemblies, that are
representative of what will be installed on site, all of which must meet or exceed the
values in the RCSC’s Specification for Structural Joints Using High-Strength Bolts Table
7.1. The pre-installation test was designed to verify that the bolting crew, whom will be
installing the bolts in the structure, understand and can preform the installation method
being used, and that the installation method chosen combined with the bolt assembly
will develop the minimum pretension as specified by RCSC’s Table 7.1. Pre-installation
testing shall be performed for each fastener assembly lot prior to the use of that
assembly lot in the work.

Procedure
1. Take 3 bolt assemblies consisting of 3 bolts of each diameter, length, grade,
production lot, with 3 nuts of each diameter, grade and production lot, also include the
appropriate washers of the same diameter grade and production lot, if washers are to
be used. Each bolt, nut and washer combination is referred to as an “assembly.”

2. When installing with Turn-of-Nut installation/testing method, place the bolt in the bolt
tension calibration testing device, with the bolt head in the back of the device,
securely seated in the bushing (plate.)

3. Depending on the length of bolts being tested, you may need to add hardened
spacers or flat shim plates achieve full-thread engagement of the threads, the bolt
shank and the nut After you add the nut and washer (if you’re using washer) the end of
the bolt shank must have full thread engagement prior to snug tightening the bolt, it
is allowable to have 1 to 3 threads sticking out past the end of the nut. This step will
prevent common job-site bolt testing issues, i.e. bolt shank out, among others. AT NO
POINT SHOULD YOU “STACK OUT WASHERS” TO FILL THE GRIP SPACE. Using
multiple washers, that are not going to be used in the actual connection, can cause
inaccurate results possibly failing bolts that would otherwise pass. 

4. Snug the assembly by rotating the nut (i.e. with a spud wrench) so that you can
confirm a visual indication of tension on the testing device’s dial. We do this to ensure
that all of the plys in the test assembly are in firm contact and to confirm that the head of
the bolt is not rotating and to ensure that we are starting the test from the correct
“starting line.”

Maximum Initial Tension Chart

1/2 1000 2000

5/8 2000 2000

3/4 3000 4000

7/8 4000 5000

1 5000 6000

1-1/8 6000 8000

1-1/4 7000 10000

1-3/8 9000 12000

1-1/2 10000 15000

Source: FHWA Appendix A1

5. Mark the end of the bolt shank, the nut and face plate of the testing device, mimicking
the match-marking you would do when installing bolts in the structure.
6. Use the chart below to determine how far to rotate the nut.

Turn of Nut Required Rotation Guide

1/2" Through 2" 1/3 Turn

1/2" Over 2" through 4" 1/2 Turn

1/2" Over 4" through 6" 2/3 Turn

5/8" Through 2-1/2" 1/3 Turn

5/8' 2-1/2" through 5" 1/2 Turn

5/8" over 5" through 7-1/2" 2/3 Turn

3/4" Through 3" 1/3 Turn

3/4" Over 3" through 6" 1/2 Turn

3/4" 6" through 9" 2/3 Turn

7/8" Through 3-1/2" 1/3 Turn

7/8" Over 3-1/2" Through 7" 1/2 Turn

7/8" Over 7" through 10-1/2 2/3 Turn

1" Through 4" 1/3 Turn

1" Over 4" through 8" 1/2 Turn

1" Over 8" through 12" 2/3 Turn

1-1/8" Through 4-1/2" 1/3 Turn

1-1/8" Over 4-1/2" through 9" 1/2 Turn

1-1/8" Over 9" through 13-1/2" 2/3 Turn

1-1/4" Through 5" 1/3 Turn

1-1/4" Over 5" through 10" 1/2 Turn

1-1/4" Over 10"through 15" 2/3 Turn

1-3/8" Through 5-1/2 1/3 Turn

1-3/8" Over 5-1/2" through 11" 1/2 Turn

1-3/8" Over 11" through 16-1/2" 2/3 Turn

1-1/2" Through 6" 1/3 Turn

1-1/2" Over 6" through 12" 1/2 Turn

1-1/2" Over 12" through 18 2/3 Turn

Source: RCSC Table 8.2

7. Using the table , verify the needle on the testing device’s dial shows 5% more than
the required bolt minimum pretension.

Table 7.1 Minimum Bolt Pretension for Pre-Installation Verification

1/2 13,000 kips 16,000 kips

5/8 20,000 kips 25,000 kips

3/4 29,000 kips 37,000 kips

7/8 41,000 kips 51,000 kips

1 54,000 kips 67,000 kips

1-1/8 59,000 kips 84,000 kips

1-1/4 75,000 kips 107,000 kips

1-3/8 89,000 kips 127,000 kips

1-1/2 108,000 kips 155,000 kips

Source: RCSC Section 7

All values are equal to 1.05 X the specified minimum bolt pretension in Table 8.1, rounded to the nearest kip.

8. Record the bolt tension as required and test the remaining 2 bolts. Use the average
torque value, for the 3 samples, as a guide for the torque needed to install these bolts.