High Strength Bolts

2018 Bridge Construction Inspection School

Marc Stecker, P.E.

VDOT Staunton District
Project Controls Engineer

LEARNING OBJECTIVES

1. Why do we use HIGH STRENGTH bolts?

2. How do we test HIGH STRENGTH bolts?

3. How do we install HIGH STRENGTH bolts?

4. How do we inspect HIGH STRENGTH bolts?

1
3

LEARNING OBJECTIVES

1. Why do we use HIGH

STRENGTH bolts?

Typical High Strength Bolted Bridge Connections

Diaphragm

Girder Splice
Crossframe

2
5

Bolt, Nut & Washer Material Specifications

VDOT Specifications Section 407.06 and Section 226.02 are

guiding specifications for high strength bolts.

Sec. 407.06 (c): Field connections shall be made with 7/8”

diameter bolts fabricated in accordance with ASTM A325, unless
otherwise specified.

ASTM - American Society for Testing and Materials

Sec. 226.02, (h): ASTM Specifications for HS bolts, heavy

hex nuts, hardened flat washers and DTI washers

Bolts for use on ASTM A709 Grade 50W weathering steel

shall be Type 3.

Bolt Strength

• A325 (and A449) bolts twice as strong as

A307 bolts

• A325 (and A449) bolts same strength as

SAE Gr. 5 bolts (3 radial lines on bolt head)

• A490 bolts same strength as SAE Gr. 8 bolts

(6 radial lines on bolt head)

• It is NOT acceptable to substitute SAE Gr. 5

and Gr. 8 bolts for A325 and A490 bolts
respectively!

http://www.stlouisscrewbolt.com/bolt-manufacturing.html

3
7

Parts of the Nut-Bolt-Washer Assembly

Bolt & Nut Identification

4
9

Bolt Dimensions

Thread length is constant

regardless of bolt length
except for A325T bolts.

10

Bolt Holes

Section 407.04 (d):

Bolt holes shall be punched, drilled or reamed. Holes shall not be

flame cut or electrode cut.

Finished holes shall be 1/16 inch larger than the nominal bolt size.

Oversize holes will be permitted only with the permission of the

Engineer or in accordance with Section 407.06(b) which addresses
field correction of misfit holes.

5
11

Two Types of Structural Connections

“Bearing” Type Connections

• Bolts are hand tightened (“snug” tightened)
• Applied load carried by combination of bolt shear strength and plate
bearing strength.
• Used for connections in buildings

“Slip-Critical” Connections
• Bolts are pretensioned to “proof” load
• Tensioning of bolt results in clamping force applied to plates
• Applied carried by friction between plates
• Used for connections subject to load reversal, heavy impact loads or
severe vibration such as in bridges

12

“Bearing” Type Connections

6
13

“Slip-Critical” Connections

14

Vince Lombardi
Winning isn't everything, it's the only thing.

The only place success comes before work is in the dictionary.

Individual commitment to a
group effort - that is what
makes a team work,
a company work,
a society work,
a civilization work.

7
15

“Wound tighter than the

nuts on a new bridge!”
Sec. 407.06 (c) 3 – Proof Load

16

Bolt Strength

How much stress does 39,000 lb of tension produce in a bolt?

What is Stress? Stress = Force ÷ Area

Proof Strength = 39,000 lb ÷ 0.462 sq. in. = 84,400 psi

Yield Strength = 92,000 psi for A325 material

Tensile Strength = 120,000 psi for A325 material

Proof Strength = 92% of Yield Strength

Proof Strength = 70% of Tensile Strength

8
17

LEARNING OBJECTIVES

2. How do we test HIGH

STRENGTH bolts?

18
Bolt Testing to Confirm Lubrication
of Nut-Bolt-Washer (NBW) Assembly
Section 407.06 (c) 1 requires a field rotational capacity test prior to
installation according to Section 226.02 (h) 3 (and VTM 135 if using
2016 Road & Bridge Specifications!).

Contractor shall perform a field rotational capacity test on two nut,

bolt and washer assemblies for each diameter and length.

Assembly shall withstand indicated number of turns without breaking.

Check for stripping of threads after test. Must be able to turn nut
freely by hand to same point on bolt where nut was during test.

In event of failure, Contractor has option to relubricate ENTIRE LOT

of hardware BEFORE obtaining new sample to run test again.

After the tests, regardless of outcomes, the bolt sample and all
components shall be discarded in such a manner that it is impossible
to accidently use it in the structure.

9
19

Tensioning Bolts – Skidmore-Wilhelm

(Hydraulic Load Cell)

20

How Does a Skidmore Work?

Imagine a bathroom scale clamped in a bench vise.

10
21

Matchmarking for Rotational Capacity Test

4 marks required for each bolt!

2/3 turn from snug tight for bolt length

up to and including 4 diameters.

22

Homework!

Read VTM 135 and be prepared to discuss in class on Thursday!

11
23

LEARNING OBJECTIVES

3. How do we install HIGH

STRENGTH bolts?

24

Bolted Parts & Surface Prep

Section 407.06 (c) 2:

Bolted parts shall fit solidly together when assembled and shall
not be separated by gaskets or any other interposed
compressible material.

Connecting surfaces, including areas adjacent to washers,

shall be free from scale (except tight mill scale), burrs, dirt,
grease and other foreign material that would prevent solid
seating of the parts.

Surfaces for bolted splices in main units fabricated from

weathering steel and joint surfaces for other connections, when
required on the plans, shall be blast cleaned in accordance
with the requirements of 411.04 (a) 5.

12
25

Bolt Orientation

Sec. 407.06 (c) 3: Threaded ends of bolts shall be placed on inside,

where practicable, for protection from weather.

26

Bolt Orientation

13
27

Bolt Length
Bolt Length = Grip + 5/32” for each flat washer + Table Value
Grip = total thickness of all connected material, exclusive of washers.

Sec. 407.06 (c) 3: Length of bolts shall be such that point of bolt
will be flush with or outside the face of nut when installed
without over tensioning the bolt.

28

Bolt Length?

14
29

Assembling Steel
Section 407.06 (h):

Bearing surfaces that will be in permanent contact shall be cleaned

before units are assembled.

Immediately after erection, splices and field connections shall have

at least one-half of the holes filled with bolts or cylindrical pins, of
which at least half of those connections shall be bolts. Bolts shall
be evenly distributed throughout the connection.

Splices and connections carrying traffic during erection shall have

holes filled with high strength bolts that have been tensioned prior
to opening to traffic.

Erection bolts shall be same diameter as high strength bolts.

30

Bolt Installation – Step 1

Bring the members to be

joined together and align
holes with drift pins. Bolts
should not be used as drift
pins to achieve alignment.

15
31

Bolt Installation – Step 2

Fill the remaining holes with high
strength bolts, nuts and washers of
correct size and grade. Partially
tension bolts to “snug” the
connection. Work from center of
connection to the free edges.

32

Bolt Installation – Step 3

Tension the bolts working from

center of connection toward the
edges. Leave drift pins in
during this operation.
Premature removal of drift pins
can cause trapping of the bolts
by joint slippage.

16
33

Bolt Installation – Step 4

Knock out remaining drift pins and

replace with bolts. Tension these
last bolts.

34

Bolt Installation

17
35

Bolt Installation – Hole Reaming

Section 407.06 (b) covers correction of misfits during field assembly.

Hopefully, shop match drilling and pre-assembly will minimize field

misfits.

Drift pins may be used only to bring parts into position. Misaligned
holes shall be corrected by reaming where allowed by the Engineer.

No hole shall be elongated in any separate part to more than 1/8”

larger than nominal bolt size when a reamer not more than 1/16”
larger than nominal bolt size is used.

Misalignment of holes before reaming shall not be more than 1/8”.

36

Tensioning Bolts
Section 407.06 (c) 3 covers field tensioning of bolted connections.

Only as many bolts, nuts and washers as are anticipated to be

installed and tightened in a work shift shall be taken from
protected storage.

Uninstalled bolts, nuts and washers shall be returned to

protected storage at end of the work shift.

What is protected storage?

18
37

Tensioning Bolts

38

Tensioning Bolts

Storage Kegs

19
39

Tensioning Bolts
Section 407.06 (c) 3 covers field tensioning of bolted connections.

Two methods of bolt tensioning:

1. Direct Tension Indicator (DTI) washers

2. Turn-of-Nut

NOTE! Turn-of-Nut method is only allowed with

approval of the District Bridge Engineer in the
2016 Road and Bridge Specifications!

40

Tensioning Bolts

Calibrated power wrench method of tensioning is not acceptable due

to variable conditions. Last allowed in 1994 R&B Specifications!

TORQUE DOES NOT

EQUAL TENSION!
http://www.appliedbolting.com/video.php

20
41

Tensioning Bolts

An approved tension-indicating calibration device (Skidmore) shall be on

the jobsite where high-strength bolts are being installed and tightened.

When DTI washers or Turn-of-Nut methods are used, at lease three

complete bolt assemblies of each diameter, length and grade shall be
tested in the calibrating device for a pre-installation tension verification.

Power wrenches shall be of adequate capacity and sufficiently supplied

with air to perform the required tightening of each bolt in approximately
10 seconds.

Snug tight is defined as the tightness attained when a power wrench

begins to impact solidly or when the bolts are firmly hand tightened with a
spud wrench such that the complete area of connecting surfaces are
brought into firm contact with each other. Snug tight is not “finger tight.”

42

Tensioning Bolts – Skidmore-Wilhelm

(Hydraulic Load Cell)

21
43

Direct Tension Indicator (DTI) Washer

Method of Installation
Sec. 407.06 (c) 3b discusses the use of Direct Tension
Indicator (DTI) washers to install High Strength bolts.
Standard DTI bumps compress when desired tension
attained. DTI is essentially a mechanical load cell.

Iron worker visually “eyeballs” when gap has compressed.

Squirter DTI release cured orange silicone when desired

tension attained; easier for iron worker to know when to
stop. Prevents over tightening.
No match-marking required. Inspect with feeler gage.

FHWA and VDOT do not recognize squirted silicone as an inspection

method to verify bump compression. Use feeler gages.

44

Position of Flat Washer & DTI Washer

Note position of direct tension indicator in relationship to held

element. Also note position of “bumps” on direct tension indicator.

Independent of torque resistance. Easy to install and inspect.

Provide certainty of correct bolt tension.

22
45

Position(s) of Flat Washer & DTI Washer

Required gap shall be 0.015 inch
or less between DTI and bolt head
or nut when no hardened flat
washer is used against DTI.

If hardened flat washer is used,

then required gap shall be 0.010
Inch or less between DTI and
hardened flat washer.

Do not continue with additional

tightening if gap is indication gap
is closed completely!

Refer to DTI manufacturer's

recommendations and
Bridge Office!

46

Galvanized DTIs

Galvanized “Squirter” DTIs

http://www.appliedbolting.com/video.php

23
47

Cost of DTI Washers

⅞”ø Type 3 A325 ~ 75 ¢ each

⅞”ø Type 3 A325 Squirter ~ 90 ¢ each

Contractor will realize net savings based

on reduced installation and inspection
costs using DTI washers!

48

DTI Washer Manufacturer Websites

Lots of good bolt information for

inspectors including video clips!

www.appliedbolting.com

www.turnasure.com

24
49

Turn-of-Nut Tightening
Sec. 407.06 (c) 3a discusses Turn-of-Nut method of tensioning High
Strength bolts.

Note terms “turned element” and “held element” in relation to washer.

50

Turn-of-Nut Tightening

• Bolts shall be given a “suitable” match-mark.

• During tensioning, there shall be no rotation of the part
not turned by the wrench.
• 4 marks required for each bolt!

25
51

Turn-of-Nut Tightening

52

Turn-of-Nut Matchmarking
4 marks required for each bolt!

1/3 turn from snug tight for bolt length

up to and including 4 diameters.

26
53

Turn-of-Nut Matchmarking

54

Turn-of-Nut Matchmarking

27
55

Other Things to Remember!

Bolts shall be installed with a hardened flat washer under the nut or bolt head,
whichever is the turned element regardless of installation method (DTI
washers or Turn-of-Nut).

Tightening by either method (DTI washers or Turn-of-Nut) may be done by

turning the bolt head while the nut is prevented from rotating.

DTI washer is not a substitute for the required hardened flat washer under the
turned element.

“Bumps” on DTI washers shall be directed away from the girder steel.

A written record of inspection results indicating location, test dates and results
of each inspection shall be submitted to the Engineer as a condition for
payment when Turn-of-Nut method is approved and used (2016 R&B Specs!).

56

Summary of Common Problems

1. Dry/rusty threads (30% of friction) or nut faces (70% of friction)
caused by poor storage.
2. Damaged threads from forcing bolts through misaligned holes
causing nut to “freeze”.
3. Trapped bolts caused by slippage in the connection due to
removal of drift pins before enough bolts have been tensioned to
prevent slippage. Trapped bolts cannot develop tension along
their entire length.
4. Bolts that are too long causing nuts to run up against thread run-
out before bolts are properly tensioned.
5. Omission of hardened washer under the turned element.
Hardened washers significantly reduce torque required to tension
a bolt.
6. Installing DTI washers with bumps against the girder steel.
7. Waiting so long to tension installed bolts that lubricant washes off.

28
57

Summary of Air Tool Problems

1. Insufficient air pressure at the compressor.

2. Too many tools running at one time.
3. Too long an air line or leaks in the air line.
4. Blockage of the inlet or outlet filter on the tool.
5. Broken tool.

If the tool is merely sluggish, blow it out with solvent to

clean it and re-lubricate it with light oil such as SAE 5 or 10.

58

LEARNING OBJECTIVES

4. How do we inspect HIGH

STRENGTH bolts?

29
59

Inspection of High Strength Bolts Installed with DTIs

Sec. 407.06 (c) 4 discusses inspection for DTIs.

Inspection of bolt installations using DTI washers is accomplished by

checking residual gap with metal feeler gage.

Installations are considered satisfactory if average gap does not exceed

0.012 inch for DTI installed under bolt head or 0.010 inch for DTI installed
with hardened flat washer or if gap has been reduced to zero at any point
around DTI.

Refer to DTI manufacturer's recommendations and Bridge Office!

Regardless of method of bolt installation, Engineer may verify by

calibrated torque wrench that the work provides 39,000 lbs of bolt tension.

http://www.appliedbolting.com/video.php

60
Inspection of High Strength Bolts
Installed with Turn-of-Nut Method
Sec. 407.06 (c) 4 discusses inspection for Turn-of-Nut.

Contractor shall use an inspection wrench in presence of Engineer to

inspect tightening of bolts.
Inspection wrench shall be a dial torque wrench. Torque wrench
shall be checked for accuracy within 1 year by manufacturer or
approved testing agency.
No fewer than 3 typical bolts shall be placed individually in Skidmore
at least once each working day to calibrate inspection wrench and
establish job-inspection torque.
Bolts shall be inspected by applying job-inspection torque to 10% but
no fewer than 2 randomly selected bolts in each connection. If any
nut is turned this torque shall be applied to all bolts in the connection.
Loose bolts shall be tightened and reinspected or all bolts in
connection may be retightened and resubmitted for inspection.

30
61

Inspection of High Strength Bolts

Installed with Turn-of-Nut Method
Determining Job-Inspection Torque:

1. Each calibration test bolt shall be tightened in Skidmore to tension

specified in table IV-3.
2. Apply inspection wrench to the tightened bolt and determine
torque necessary to turn the nut or bolt head 5 degrees in
tightening direction.
3. Repeat process for other two calibration test bolts.
4. Job-Inspection torque is average of three test readings.
5. DO NOT use torque wrench to loosen test bolts or ANY other
bolts!!!! Measured Torque, ft-lb
Bolt
Diameter Bolt #1 Bolt #2 Bolt #3 Average
2 ¾" 600 625 625 617
3 ¼" 525 600 650 592
3 ½" 550 600 650 600
4 ¾" 580 575 585 580

62
Dial Torque Wrench

31
63

Suggestions for Inspectors

1. You are the eyes and ears of the

Bridge Office in the field!
2. Read/Study the bridge plans and
shop drawings!
3. Read/Study the VDOT R&B
Specification!
4. Read/Study the DTI
manufacturer’s installation
instructions!
5. Read/Study the RCSC
Specification for High Strength
Bolts!
6. Call your Bridge Office when you
have questions!

64

Anchor Bolts for Ancillary Structures

32
65

Ancillary Structure Anchor Bolt Failures

66

Ancillary Structure Anchor Bolts

Section 700.05 (k)

33
67

Mechanical 18x Multiplier Torque Wrench &

Hydraulic Torque Wrench

68

What the heck is that?

Remember!

You are the eyes and ears

of the Bridge Office in the field!

Call your Bridge Office when you have questions!

34
69

Missing Bolts? Matchmarking?

70

Missing Bolts?

35
71

High Strength Drift Pin Substitution?

72

High Strength Drift Pin Substitution?

36
73

Tensioned Splice?

74

Tensioned Splice?

37
75

Loose Bolts

76

Tightening Loose Bolts?

38
77

Damaged Threads

78

Splice Fill Plate Backwards?

39
79

Splice Fill Plate or Plates?

80

Oil on Weathering Steel

40
81

Splice Bolt Interference

82

Utility & Drain Connections

41
83

Thrie Beam Rail Post Connection

84

Thrie Beam Rail Post Connection

A325 or A449 Bolts Only!

Not A307!

42
85

Thrie Beam Rail Post Connection

86

Luminary Anchor Bolts Cut Off

43
87

Questions?

44
Why Do We Use Bolts to Connect Structural Steel Members?

The Framing Plan shown on Sheet 13 of the Route 11 over North River (UPC 90092) bridge plans
measures 48’-9” wide by 320’-0” long. It is simply not practical to ship this superstructure as one
complete piece due to its overall size and total weight. Refer to Sheet 13 of the referenced bridge plans
or see Figure 1 below:

Figure 1: Framing Plan for Route 11 over North River in Rockingham County
As a result, the superstructure structural steel girders are shipped with splices to accommodate shipping
length and weight limitations. The Contractor may choose to assemble the field splices in the air or on
the ground during erection of the superstructure. See Figure 2 and Figure 3 below:

Figure 2: Rolled Beam Air Splice on Route 650 over Cub Run in Rockingham County

Figure 3: Plate Girder Air Splice on Route 340 over South Fork Shenandoah River in Warren County
Structural steel members are typically connected with one of three methods:

• Welding

• Riveting

• Bolting

Shop Welding is allowed for fabrication of plate girders under controlled environmental conditions with
extensive use of robotic welding equipment. See Figure 4 and Figure 5 below:

Figure 4: Plate Girder Flange-to-Web Weld Accomplished with a Gantry Welding Machine

Figure 5: Plate Girder Flange Plates Being Prepped for Full Penetration Butt Welding
Field Welding of superstructure structural steel is allowed only as shown on the plans. Field splices of
rolled beam or plate girder sections are not allowed to be made with field welds due to the critical nature
of splices and highly variable conditions for field welding. See Figure 6 through Figure 9 for typical
examples of allowed field welding:

Figure 6: Field Welding of Pot Bearing Sole Plate to Girder Flange

Figure 7: Field Welding of Bearing Sole Plate to Truss Stringer

Figure 8: Field Welding of Washer Plate to Fixed Bearing Sole Plate

Figure 9: Field Welding of Deck Stud to Girder Flange

Up until the 1950’s, structural steel for bridges, buildings and ships was assembled with hot driven rivets.
Riveting crews typically consisted of four members:

• Heater
• Sticker-in
• Bucker-up
• Riveter

The Heater lays wooden planks across a couple of beams to make a platform for the portable, coal-
burning forge in which he heats the rivets. The three other men hang a plank scaffold by ropes from the
steel on which they are going to work. See Figures 10 through 12.

The three men climb down with their tools and take their positions on the scaffold; most often the Sticker-
in and the Bucker-up stand on one side, and the Riveter stands or kneels on the other. The Heater picks
a red-hot rivet off the coals in his forge with tongs and tosses it to the Sticker-in, who catches it in a metal
can. At this stage the rivet is shaped like a mushroom; it has a buttonhead and a stem. Meanwhile, the
Bucker-up has unscrewed and pulled out one of the temporary bolts jointing two pieces of steel, leaving
the hole empty. The Sticker-in picks the rivet out of his can with tongs and sticks it in the hole and pushes
it in until the buttonhead is flush with the steel on his side and the stem protrudes from the other side, the
Riveter's side. The Sticker-in steps out of the way. The Bucker-up fits a tool called a dolly bar over the
buttonhead and holds it there, bracing the rivet. Then the Riveter presses the cupped head of his
pneumatic hammer against the protruding stem end of the rivet, which is still red-hot and malleable, turns
on the power and forms a buttonhead on it.

This operation is repeated until every hole that can be accessed from the scaffold is riveted up. Then the
scaffold is moved. The Heater's platform stays in one place until all the work within a rivet-tossing radius
of thirty to forty feet is completed. The men on the scaffold know each other's jobs and are
interchangeable. The Riveter's job is bone-shaking and nerve-racking, and every so often one of the
others swaps with him for a while. In the days before pneumatic hammers, the riveter used two tools, a
cupped die and an iron maul; he placed the die over the stem end of the red-hot rivet and beat on it with
the maul until he squashed the stem end into a buttonhead.

Figure 10: Riveting Crew Working on Empire State Building circa 1930 (Heater member not shown.)
 Figure 11: Another Riveting Crew Working on Empire State Building circa 1930
(Sticker-in ready to catch a hot rivet tossed to him by the Heater.)

Figure 12: Two Views of a Portable, Coal-burning Forge in which the Heater member Heats Rivets
An organization called The Research Council on Riveted and Bolted Structural Joints of the Engineering
Foundation was established in 1947. This group issued its first specifications in 1951 after which the use
of high strength bolts was quickly adopted by bridge and building engineers.

High strength bolting crews typically consist of two members. See Figure 13 and 14. A bolted connection
is brought into alignment with drift pins and a few temporary erection bolts. Remaining holes are filled
with high strength bolts, nuts and washers. The bolts are tightened to snug the connection together.
Bolts are then fully tensioned by working from the center of the connection toward the edges.

One crew member typically holds the bolt head to prevent it from turning while the other member tightens
the nut, although there are exceptions depending on the method of tensioning. Any remaining drift pins
and temporary bolts are removed and replaced with high strength bolts which are then fully tensioned.

The High Strength Bolt Presentation in the Bridge Construction Inspection School will focus on testing,
installing and inspecting high strength bolts. The two methods of high strength bolt installation included in
the 2016 VDOT Road and Bridge Specifications are Direct Tension Indicator Washers (DTI) and Turn-of-
Nut.

Figure 13: Bolting Crew Working on Route 340 over South Fork Shenandoah River in Warren County
(Note hanging scaffolding, fall protection and personal protective equipment worn by crew members.)
 Figure 14: Bolting Crew Working on Route 801 over Jennings Branch in Augusta County
(Note floating work platform and personal floatation equipment worn by crew members)

Top 10 Reasons we use bolts and not rivets:

1. Faster process to install bolts.

2. Less skilled labor than riveting or welding.

3. Smaller Crews (2 person for bolting vs. 4 person for riveting).

4. Less noise than riveting.

5. Less expensive equipment used to make bolted connections.

6. No fire hazard from portable forge used for riveting.

7. No danger from tossing red-hot rivets (1,800°F).

8. Easy to remove bolts to repair structure.

9. Fewer bolts needed to provide same strength as rivets.

10. Bolts have higher fatigue strength than rivets.

Three Most Common Bolted Bridge Connections:

1) Girder Splice Bolted Connection

2) Diaphragm Bolted Connection

 3) Crossframe Bolted Connection

Now that you have an understanding why we use bolts to connect structural steel members, you are
ready for the presentation on High Strength Bolts in the Bridge Construction Inspection School.

Here are the four learning goals for the presentation on High Strength Bolts:

1. Why do we use HIGH STRENGTH bolts?

2. How do we test HIGH STRENGTH bolts?

3. How do we install HIGH STRENGTH bolts?

4. How do we inspect HIGH STRENGTH bolts?