Preloading the high strength bolt using hydraulic extension method is a fast and efficient method for

bolt installation. Hydraulic bolt tension device can guarantee the initial tension of bolt well. However, if
the relation of initial tension and the final remaining preload of bolt cannot be determined, the preload
on the bolts still cannot be guaranteed. This paper uses theoretical analysis method to research the
relation between the eventual preload and the initial tension of high strength bolts on Heavy-duty
Gantry beams. Then we proposes a set of calculation method of bolt installation preload and the initial
tension and provides theoretical basis for the installation of heavy-duty segmented beam.

Innovative Ways to Solve Difficult Bolting Problems Tripp Fulmer Nord-Lock Inc. 1000
Gregg St, Carnegie, Pennsylvania, USA, 15106 Phone: 412-279-1149 Email:
Tripp.Fulmer@Nord-Lock.com Keywords: Bolting, Tension, Multi-Jackbolt Tensioner,
Hydraulic Tensioner INTRODUCTION When designing mechanical systems or heavy
equipment, the main thought is typically the way in which this system function and
perform. The thought of how this system will be held together or connected, to
other application components is often overlooked or considered a predetermination.
The two options for connecting metal are welding and bolting of a joint. Since
weldings use is limited to non-gasket connections with the same materials, bolting
becomes the most common method in industry. Drilling it down to the simplest
concept, the joining of two or more materials is needed because those materials are
trying to separate when subjected to a working load. Every connection experiences
a working load during operation which acts as a separation force on the joint. The
goal of bolting is to maintain the integrity and lifespan of a joint. To achieve this
goal, the clamping force, preload, must be greater than the working load, and any
peak loads. With a clamping load larger than the working load, the bolt will see a
consistent force, and will not feel the effects of the working load. Therefore, the joint
will not experience cyclic loading that leads to fatigue failure. At the same time, the
clamping load cannot exceed the bolts or joint capacity (Bickford 1990, p. 424).
Sometimes, the acceptable range of clamp load above working load and below the
bolt capacity is small, increasing the importance of accuracy. There are many
variables to consider when designing a bolted connection. These include, but are
not limited to, quantity and size of bolts, space restrictions, grip length to diameter
ratio, bolt stress, compression of joint materials and gaskets, application
environment, and bolt mechanical properties. Once these variables have been
factored into the design, the final options are limited and the method of creating
preload will have to adapt to the design of the overall application. Since the method
of tightening can lead to issues during installation and removal for maintenance,
these options and the innovative methods used to prevent issues that occur in the
field that lead to unnecessary downtime or failures will be discussed. DISCUSSION
Issue of Friction On smaller applications, issues with tightening are not as critical,
but as the applications and bolting become larger, the number of issues increases.
The reason behind this is simple: friction. It is known that approximately 90% of the
input torque is used to overcome friction and 10% overcomes the inclined plane of
the thread. This can be shown in Figure 1 (Bickford 1990, p. 134). Figure 1:
Magnitudes of forces opposing input torque applied to a nut. As the bolting
diameter, or main thread size, increases, the thread and bolt head surface areas

increase exponentially. This growth in surface areas translates into larger metal to
metal friction as the nut or bolt is turned on the thread. To overcome this larger
friction a higher force is required to turn the nut. As the load increases through
tightening, turning of the nut becomes even more difficult as the load is distributed
on the surface area. The torque to bolt diameter relationship is shown below in
Figure 2 (Bickford & Nassar 1998, p. 513). Figure 2: Input torque increases
exponentially to reach same bolt stress, 60ksi Figure 3 below (Bickford 1990, p.
149), shows a comparison of the use and non-use of lubrication with a bolted joint.
First, with the lubrication used, the coefficient of friction reduced and the bolt
stretch is higher with less torque. This means that friction reduces the load output
given a certain torque input. Additionally, without a lubricant there is a higher
coefficient of friction and the loading is less accurate shown by the scatter of group
B in Figure 3. Figure 3: Torque-preload tests on lubricated (group A) and unlubricated
(group B). 2.25-8x12, B16 studs. Methods Over the history of bolting, many
methods have been developed to reach a specific preload. Most of these methods
involve one or more of the following issues: expensive, slow, and worst of all,
dangerous. The first method to review is turning with a wrench; often custom made
for larger diameters to fit the application space. The way in which these wrenches
are turned is dangerous. Some wrenches are pulled by heavy equipment or
overhead cranes, some are hit with sledge hammers, and sometimes the workers
try to turn it themselves. Since the goal is to reach a certain stretch, which can be
converted into an angle of turn, these methods can be accurate but are slow and
dangerous. Another method is to use hydraulic torqueing equipment. This method
also turns the nut, in the same way a wrench does, but with the use of hydraulic
pressure to turn a socket. This method does reduce installation time but, due to
high pressure hydraulic lines and large sockets with risk of breaking, safety is a
concern. Hydraulic equipment tends to be expensive and costly to maintain as well.
Both wrenching and hydraulic torqueing methods must overcome the friction of the
threads and under the head of the bolt, a task that proves increasingly difficult as
the bolt diameter increases. Bolts can also be tightened using heat, this method
eliminates the issue of friction. By using heating rods, a bolt can be heated to
expand and the nut turned down. Once the bolt cools, it will contract to tighten the
joint. Depending on the equipment, this method can have any combination of the
three issues. Less expensive equipment takes longer to heat the bolt. If the nut is
not properly turned in place, the process must be repeated. Additionally, having a
bolt or group of bolts that are at elevated temperatures for extended period of time
causes a hazardous environment and leads to safety concerns. The most costly
equipment heats using induction, which is much faster in heating and cooling of the
bolts, and is safer however the cost difference is large. Removal Issues Not only are
there issues in the installation of large bolting applications, but removal can be even
more difficult. Over years of service, the joints may become corroded, the threading
damaged, experience cyclic loading and fatigue, and many other problems. If a
large bolt or nut were to seize and needs to be turned off, then it must be cut off.
This is unsafe, time consuming and costly, as the bolt may also need to be drilled

out. Solution It seems like there is not a torqueing/tightening method that is

accurate, timely, safe and inexpensive. However, there are methods that do not
require turning of the nut and do not involve heat. These methods apply clamping
load by tensioning the bolt. In tensioning, a tool is used to stretch the bolt in pure
tension. This not only eliminates the frictional forces that resist turning, torqueing,
of the bolt or nut, but it also eliminates any torsional stresses placed on the bolt
during tightening. Without turning of either the bolt or nut, issues with galling in the
threads and under the head of the bolt or nut are eliminated. While tensioning a
stud, a flange is drawn together and gaskets crushed smoothly while taking up joint
settlement and relaxation. This allows bolting to be installed with less interfering
variables, therefore increasing accuracy and consistency. For couplings that see a
torque during operation or where alignment is a concern and difficult to achieve,
tensioning provides an axial pull on the stud. This axial pull can be used with a
tapered stud and matching tapered sleeve, which expands in the hole, to create a fit
bolt and a radial load to counteract the shear forces in the joint. This can be referred
to as an expansion bolt. Expansion bolts can eliminate the need for fit bolts that
have a high manufacturing cost, due to timely machining and high tolerances to
simply reduce in diameter once stretched in loading. Also, alignment does not have
to be perfect since the tapered sleeve will be sized smaller than the bore of the
through hole. This eliminates the needs for reaming of the flange holes to match.
Tensioning can be accomplished in two ways, mechanically and hydraulically. Both
methods have pros and cons depending on the application requirements, customer
needs and space restrictions. Mechanical tensioners, Multi-Jackbolt Tensioners
(MJTs), tension a large stud or bolt by using a radial array of smaller bolts,
jackbolts, in the nut body of the tensioner assembly. The combined force of the
jackbolts creates the overall preload needed. The jackbolts press against a
hardened washer to pull, tension, the stud or bolt, and remain in place, due to
compression, to maintain the load. The advantage of using smaller jackbolts is that
a much smaller torque is required because the load is divided among multiple bolts
(Bickford & Nassar 1998, p. 507). This leads to advantages of using simple tooling,
including standard torque wrenches, for larger diameter bolts like shown in Figure 2
earlier. This reduces costs, setup time, and safety concerns. Installation time may
be longer depending on which torqueing method the MJT is compared to, but can
easily be made up by increasing man power for a short period of time. Instead of
three workers setting up and installing one bolt at a time, each can torque a
tensioner with a torque wrench. There is a sequence to tightening the jackbolts that
takes some extra time, but this procedure provides gradual loading that helps
compensate for joint settlement, relaxation and gasket crush. This also increases
the accuracy as the jackbolts are tightened to the provided torque. Hydraulic
tensioning, uses hydraulic fluid pressure to stretch the stud and provide the proper
preload. There is a hydraulic tensioner tool that stretches the stud, then utilizes a
hex or round nut under a bridge that is turned down, to maintain preload. This
allows for the tool to be removed and reused. Alternatively, there is a hydraulic nut
that has shims or a locking collar that can be turned down to maintain the preload.

The advantage of hydraulic tensioning is that these tensioners or tools can be

connected in series, allowing one operator to tighten many studs at once. The setup
time is longer, but the installation time is fast and loading over a flange or gasket
joint is even. The costs of equipment is high, but the components and tools are
reusable. Lastly the method of tightening is safe. Concern with hydraulic pressure is
present, but when used with proper care and training, this issue is eliminated.
CONCLUSIONS There are many methods and tooling that can be used in the
tightening of a bolted joint. The difficulty is that the variables involved in tightening
the joint are often overlooked. The best way to improve issues with bolting is to
eliminate as many variables as possible. The largest variable that leads to issues
with accuracy, safety, time, and cost is friction. By tensioning a larger bolt or stud,
mechanically or hydraulically, friction is eliminated and the joint can be tightened in
a simple and safe method. REFERENCES 1. John H. Bickford, An Introduction to the
Design and Behavior of Bolted Joints 2nd Edition, Marcel Dekker, Inc., Madison Ave.,
New York, New York, 1990. 2. John H. Bickford and Sayed Nassar, Handbook of Bolts
and Bolted Joints, Marcel Dekker, Inc., Madison Ave., New York, New York, 1998.