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Revision 00
Date 15/05/2008
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1. 2. 3. 4. 5. 6. 7.
PURPOSE AND SPECIFIC APPLICABILITY DOCUMENTATION BOLTING CHARACTERISTICS SURFACES CONDITIONING AND BORING BOLTING PROCEDURE CHECK FINAL DOCUMENTATION
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1. PURPOSE AND SPECIFIC APPLICABILITY This specification provides the API requirements for the manufacture of bolted joints, to be assembled in support structure and in frames supporting environmental plants. The term bolted joints as used in this specification is intended to cover fabricated junctions, which are part of support structures and frameworks. Particularly, the supply covers the following activities: 1. Supply of the component, able to be assembled or erected; Manufacturing of the compound column or beam and relevant examination and test, marking, cleaning an painting (covered by the procedure E0052); 2. Completion of the column/beam (welding of end plates, etc.), Boring the holes for bolts, Working of the contact surfaces; 3. Procurement of bolting; 4. Assembly the components.
1.1
Definition
Alstom Power Italia S.p.A. Environment Control System South Europe or its designated representative. Final client or its designated representative. Firm to which order is awarded. Firm invited to issue a proposal for the scope herein specified.
The following definitions shall apply to the specification: API (ECS SE): Client: Vendor, Manufacturer: Bidder:
1.2
API documents
All documents and drawings furnished by API shall be treated as proprietary information and shall not be used for others than their original purpose without written permission by API
1.3
Applicability
This specification is applied to all contracts requiring application of EUROCODE 3 (EN 1993). This specification is an integral part of the order. Derogation from the order or from this specification shall be required in writing, with the adequate forewarning, and are only admitted if accepted by API with written notification. 2. DOCUMENTATION
2.1
Reference documentation
The Constructor shall follow the requirements of Code and Standards below listed and that specified in contract documents. EN 1990 Basis of structural design.
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Eurocode 3: Design of steel structures, Part 1-1: General rules and rules for buildings. Eurocode 3: Design of steel structures, Part 1-8: Design of joints. Execution of Steel Structures General rules and rules for buildings. Paints and varnishes Corrosion protection of steel structures by protective paint systems. Mechanical properties of fasteners made of carbon steel and alloy steel Mechanical properties of fasteners Nuts with specified proof load values Coarse thread Hexagon head bolts Product grades A and B Hexagon head bolts Product grade C Hexagon nuts, type 1 Product grades A and B Hexagon nuts Product grade C
EN 14399-1 to 6 High-strength structural bolting assemblies or preloading. EN ISO 898-1 EN 20898-2 EN ISO 4014 EN ISO 4016 EN ISO 4032 EN ISO 4034
2.2
Moreover the above mentioned rules and codes, the following are quoted in this document. ISO 4759 ISO 7089 If not diversely stated in relevant job documents, the last edition of Code and specifications shall be used. ISO 8501
2.3
2.4
Manufacturing documentation
The supplier shall submit to API, for information or approval, the following documents: 1) Bolt materials certificate EN 10204 2.2, attesting their adherence to the specified rule. 2) Certificate of statistical tightening test, according to EN 14399-2, on high strength (8.8/8 and 10.9/10) bolt/nut/washers assemblies for checking the behavior of the fastener assemblies so to ensure the required preload. The result of test shall be: a) Rotation/bolt force curve, with noted the angles pi, 1i, 2i; b) Torque/bolt force curve with determination of the torque at the design preload and the mean value km and its standard deviation sk;
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c) Elongation/bolt force curve with determination of the bolt force corresponding to the 0.2% of permanent bolt elongation. 3) Certificate of testing for conformity evaluation according to EN 14399-1, para. 5. a) Testing for dangerous substances, b) Testing of dimensional requirements of the components, c) Testing of mechanical characteristics of components, d) Testing of functional characteristics of assembly: Torque/bolt force curve for the individual values of the bolt force at a specified value of the applied torque. The torque applied shall be that determined on basis of the tests performed at point 2.b above; the obtained Fbm shall be the minimum preload required for the bolt assembly tested. e) Certificates must show the obtained test values, not a generic conformance. 4) Certificate of test, according to EN 1090-1 Appendix A, to determine the slipping factor under pre-load bolts: a) Purpose of this test is determining the class of friction after a particular surface treatment. Usually, it has to be verified the slipping of the coating surface under a friction load. b) The test results shall be exposed as detailed in EN 1090-1 Appendix 2, A.2.6. Manufacturer has to require above documentation at the purchasing. In case it was not available, he has to include tests in his activities before delivery material to site. Manufacturing documentation will be produced according to the job Material Requisition (MR). 3. BOLTING CHARACTERISTICS
3.1
Bolts
The bolt shank must stick out from the nut after the tightening. Use of bolts nominal length in excess of about one thread pitch should be usual. For not preloaded bolts, at least one whole thread pitch (more the sort out threading) must remain free between the nut support surface and the part not threaded of the shank. For preloaded bolts, at least four whole thread pitch (more the sort out threading) must remain free. Bolts must not be welded. With pre-loaded bolts, washers are required under both bolt and nut. With not preloaded bolts their use is not mandatory but recommended. Washers must be bevelled and the bevel must be toward the bolt head/nut.
Generally, for carpentry use, are used bolts with tolerance category C (bolts with large tolerances [grade C h14/15] on non threaded parts and rough manufacturing on the threaded parts [g8/H7]. Where a better coupling between bolts and bores is required, it must be used bolts of tolerance category AB, i.e. h12/13 for non-threaded parts, g6/H6 for threaded parts. For more details see ISO 4759.
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Bolt system required, geometrical data and resistance class (only for HR system) are specified in contract drawings.
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BOLTED STEEL JOINTS (in compliance with EN codes) Coupling surfaces conditions before assembling
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3.2
Columns and beams must arrive in shop/yard finished in every their part, included end plates and T-squares. In case the coupling surfaces are ready for bolted joint, they must have been protected with corrosion preserving paper or equivalent; in case they have been painted, or non protected or eventually the preservation is failed, they must be conditioned as specified on the following.
4.1
Contact surfaces
The contact surfaces shall arrive in shop/yard prepared as defined in the above paragraphs; in any case they must be according to the contract drawings. If not prepared and in lack of specification the following instruction shall be applied. 1) Shear connection Bearing type. No special provision for the contact surfaces is required. Surface must be plane, machine worked, and must be cleaned by wire brushing or flame with removal of all the free rust. 2) Shear connection Slip-resistant. If not otherwise required by contract drawings, surfaces shall be in accordance with EN 1993-1-8 3.9.1 Table 3.7 and EN 1090-1 8.8 Prospect 7: class of friction surfaces C (for a design slip factor = 0.3). The surfaces of the contact joints shall be accepted when, at the workshop preassembling test, the contact effective surface shall be, at least, 80% of the total joint surface. The check shall be made by thickness gauges. For convenience we show the table and prospect before mentioned. From EN 1993-1-8 3.9.1:
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B C D
4.2
Boring
All the drills shall be made by drilling machine, being excluded the punching machine use. After drilling and/or boring the holes edges must be free of burr (beveled). When it is possible, holes should be drilled with a diameter suitably reduced (at least 2 mm) and successively they should be bored (or reamed) to the final diameter. After
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that the pre-assembled elements shall be assembled finished in every part, with the aid of suitable assembling pins and bolts (as under mentioned for Bolts in precision bores). In any case, misalignments of holes that not permit the bolt passing are not allowed. In such cases it is necessary to bore the hole at a greater diameter with a suitable substitution of the interested bolts. The use of over sizing or slotting of holes must be authorized in writing by API. Drilling/boring diameter/distances shall be in accordance with contract drawings; in lack of specifications the following instructions shall be applied. 1. Diameters: a) Nominal tolerances for hole-bolt assembly is required according to EN 1090-1 8.1 point Dimension and location of holes: normal holes (1 mm M12/14, 2 mm M16-24, 3 mm M27 and larger). b) In those joints in which the bolts work in shear with a precision coupling, the hole-bolt tolerances must not exceed 0.3 mm, included the tolerances (in accordance with EN 1090-1 8.10 the hole-bolt coupling may be h13-H11). c) The orthogonality between the hole axes and the bolted surface must be within 1. If it is greater for contingent reason (e.g. a joint interesting a laminated shape) it shall be made use of angulated washers. 2. Distances Spacing and distances must respect the specification of EN 1993-1-8 3.5 Positioning of holes for bolts and rivets.
5.1
Figures represent the characteristic quantities of a bolt and its clamp length.
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5.1.1.1 Bolts according to EN 14399-3 (HR type) and EN 4014 EN 4016 (normal bolts)
For joints bolted with bolts type HR according to EN 14399-3 the suitable bolt length in function of the tightening thickness may be defined with the following table.
It must be put attention when the threaded part of the bolt has been required to not be included in the shear plane; in such case, the bolt length must be chosen accepting a greater length sticking out the nut. It must be selected the minimum bolt length for required clamped part.
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5.2
The Manufacturer, after has made the temporary shop assembling and has made the boring, must perform (with the API witness as by QC) the following test: Geometries and design correspondence check, Boring check, Working check, Visual and dimensional check of the contact between the elements to join, After the test, trusses or girders that shall be dismantled before erection in site, must be assembled by temporary bolts and pins for shipping. The Manufacturer shall directly provide the bolts and nuts, and every other material, required for pre-assembling. A dimensional check report shall be issued and send to API.
5.3
When explicitly required by the contract and/or by the job material requisition, the platforms of at least two elevations, chosen by API, shall be pre-assembled in the workshop. Any reduced pre-assembling shall be agreed upon with API.
5.4
Bolt tightening
Bolts must be tightened until the minimum specified preload. In lack of specification in contract documents adopt (EN 1090-1 8.6): Fp = 0.7fubAs where Fp = minimum preload [N], fub= bolt ultimate tensile strength [MPa] As = tensile stress area [mm2]. Tightening shall be carried out using one of the following methods, if not otherwise specified in contract documents: 1. Turning moment check method, according to EN 1090-1 8.7.2 (preferred), 2. Part-turn method, according to EN 1090-1 8.7.3, 3. Direct tension indicator method, according to EN 1090-1 8.7.4, 4. Combined method, according to EN 1090-1 8.7.5.
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The greater difficulty to verify the preload depends from the tightening moment which 90% is need to win the friction resistance among the rubbing surfaces during the tightness. A simple formula is the following: M = (kdFu)/1000 where:
M = Tightening moment [mN], d = nominal diameter of bolt [mm], Fu= preload [N], k = torsion coefficient depending from: Dimensions and shape of the rubbing surfaces, Friction coefficient among the surfaces, Screwing up method. In first approximation it may be taken: k = 0.21 0.17 the greater values for small diameter bolts. GENERAL NOTE: If a bolt set, tightened at minimum preload, is unscrewed, it must be removed and the whole set permanently discarded, if not diversely, and explicitly, specified in contract documents. For convenience the following tables for bolting tests, could be used.
6.1
Visual examination
Bolted joints shall be subjected to a visual examination; in this check shall be made use of instruments and examined: Tightening of bolts, by a torque wrench;
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Tightening of bolted plates, by thickness gauge: surfaces between which the 0.1 mm thickness gauge does not pass will be considered in contact.
6.2
Dimensional Examination
A dimensional check of bolting shall be performed according to contractual drawings. 7. FINAL DOCUMENTATION The documentation that the Constructor shall send to API for approval or information is listed in the relevant MR, defining also the times when the documents shall be issued (see 2.4). API reserves to send his comments within 21 days from the date when the documents have been received. API approval shall not hover the Constructor from his responsibility as regards the correct execution of the drawings supplied to the effects of a good erection and assembling. The supply shall not be deemed completed unless all the documents listed in the MR relevant to this specification have been issued. The documents sent together with the material shall show the quantity, the mark number of pieces dispatched and the relating construction drawing number. Any charge due to wrong filling out of the shipping documents shall be at the Constructor's expenses. Final documentation shall be inspected and checked by API for compliance to its specification E0063.0.