Ti SPC Ohe Fasteners 0120

Page 1 oI 31 EIIective Irom
September 2012
SpeciIication No. TI/SPC/OHE/ FASTENERS/0120
GOVERNMENT OF INDIA
MINISTRY OF RAILWAYS
RESEARCH DESIGNS AND STANDARDS ORGANISATION
MANAK NAGAR, LUCKNOW-226011
Specification for Steel Fasterners & Stainless Steel Fasterners for
25 kV A.C. Traction Overhead Equipment
1. SCOPE
1.1 This Specification covers the requirements of Steel Fasterners and
Stainless Steel Special Head/Hexagon straight Bolts and Screws, Flat
Countersunk Nib Bolts and Screw, U-Bolts, J-Bolts, Hexagon Nuts
and Lock Nuts and Plain and Spring Washers used on 25 kV A.C.
Traction Overhead Equipment. The term Fasteners shall include
Bolts, Nuts, Lock Nuts and washer. The term nut shall include lock
Nuts. The term Bolt shall include Screws, Special head Bolts/Screws.
1.2 This Specification supersedes RDSO Specification No.ETI/OHE/
18(4/84) with A&C Slip No. 1 to 5.
2. GOVERNING SPECIFICATIONS
2.1 The fasteners shall generally conform to the respective Indian
Standards unless specified otherwise herein. The provisions of the
governing Specifications shall be applied in the manner
altered/amended or supplemented by this Specification.
2.2 In preparation of this Specification reference has been made to the
following Specifications.
Sl.No. Specification No. Specification Title.
i) IS: 1363-2002 Black hexagon bolts nuts and lock
nuts (Dia 6 to 39) & black hexagon
screws (Dia 6 to 24 mm).
ii) IS: 1367 (Pt.2, 3, 5, 6, 7,
9, 10, 13, 18).
Technical supply conditions for
threaded Steel fasteners
iii) IS: 1570 (Pt. 5) - 1985 Schedule for wrought steels
(Stainless & heat resisting steels)
iv) IS: 2016- 1967 Plain washers
v ) IS: 3063 - 1994 Spring washer for bolts, nuts &
screws.
vi ) BS: 2061 - 1953 Phosphor bronze spring washer for
General engineering purposes.
September 2012
Sl.No. Specification No. Specification Title.
vii) IS: 549 - 1974 Split pines.
viii) IS: 9549 - 1980 Dimension for split pin holes, wire
holes and head slots for bolts.
ix) IS: 9519 - 2005 Dimensions for width across flats
for hexagon head bolts & nuts.
x ) IS: 8353 - 1977 Flat countersunk nib bolts.
xi ) IS: 730 - 1978 Hook bolts for corrugated sheet
roofing.
xii) IS: 1368 - 1987 Dimensions for ends of bolts and
screws.
xiii) IS: 4172 - 1987 Dimension for radii under the head
of bolts and screws.
xiv) IS: 5369 - 1975 General requirements for plain
washers and lock washers.
xv ) IS: 4206 - 1987 Dimensions for nominal lengths
and thread lengths for bolts screws
and studs.
xvi ) IS: 4213 - I, II, III, IV, V ISO metric screws threads.
xvii) IS: 2334 - 2001 Gauging practice for ISO metric
screw threads.
xviii) IS: 1369 - 1995 Dimensions for screw thread run
out sand undercuts.
xix) IS: 2614 - 1969 Methods for sampling of fasteners
xx ) IS: 2629 - 1985 Recommended practice for hot dip
galvanising of iron and steel.
xxi ) IS: 4211 - 1993 Thread pitch gauges for ISO metric
screws threads ( Pitch range
0.25 to 6.0 mm ).
xxii) IS: 6745 - 1972 Methods for determination of mass
of zinc coating on zinc coated
iron & steel articles.
xxiii) IS: 2633 - 1986 Method for testing uniformity of
coating on zinc coated articles.
xxiv) IS: 9141 - 1979 Code of practice for packing of
fasteners
xxv) IS: 3203 - 1982 Methods of testing local thickness
of electroplated coatings.
September 2012
3. DEVIATION FROM SPECIFICATION
3.1 Any deviation from this Specification calculated to improve the
performance, efficiency and utility of fasteners proposed by the
tenderer will be given due consideration provided full particulars with
justification thereof are furnished.
4. SERVICE CONDITIONS
4.1 The fasteners are used in conjunction with various
fittings/components of Traction Overhead Equipment including those
carrying current.
4.2 Weather Conditions
The fasteners are used very widely under the severe Weather
conditions. The limiting conditions which have to be withstood in
service are indicated below :
Maximum temperature of Air in shade - 45 C
Minimum temperature of Air in shade - 0 C
Maximum temperature attainable by an - 65.5 C
object exposed to Sun.
Maximum relative Humidity - 100%
Average annual Rainfal - 1750 to 6250 mm
Average number of Dust - 35 days. Max.
Storm days per annum
Number of Thunder storm days - 35 days Max.
per annum.
No. of Rainy days per annum - 120 days Max
Maximum Wind pressure - 200Kg/Sq. meter.
Altitude - Not exceeding 1000 m.
4.3 The fasteners are also subjected to chemical pollution from the
effluent gases of Chemical Plants, exhaust of Steam/Diesel
locomotives and to saline atmosphere in coastal areas.
September 2012
5. MATERIAL
5.1 Ferrous fasteners
Steel Fasteners shall conform to Grade-C Specification in
IS:1367 (Part-2) -2002. Bolts/Screws shall comply with mechanical
property class 4.6 of IS: 1367 (Part-3) - 2002. Nuts shall comply
with the mechanical property class 4.6 of IS:1367(Part 3) -2002.
Nuts comply with the mechanical property class 04, 4 or 5 (as
applicable) of IS:1367 shall (Part-6) - 1994.
5.2 Stainless Steel Fasteners
The Stainless Steel Bolts, Nuts, Lock Nut & Washers shall conform to
AISI 316.
5.3 Plain Washers
Plain Washers shall conform to IS: 2016 - 1967. Galvanised Steel
Plain Washers (Punched, Type A) shall be used with galvanised Steel
Bolts, Bronze, Stainless Steel or Copper Washers (punched, Type A)
shall be used with Stainless Steel Bolts.
5.4 Spring Washers
The Spring Washers shall conform to IS: 3063 - 1994. Galvanised
Steel Spring Washers with flat ends (type B) shall be used with
Galvanised Steel Bolts. Phosphor Bronze Spring Washers,
conforming to BS: 2061- 1953, shall be used with Stainless Steel
Bolts.
6. GENERAL REQUIREMENTS
6.1 Workmanship
The Bolts and Nuts shall be clearly finished, sound & free from
defects which may effect their serviceability, and shall be consistent
with the grade prescribed. The fasteners shall have full surfaces and
edges in keeping with the method of manufacturing used. These shall
be free from burrs, although barely perceptible thin burrs which
results for example, from slotting and trimming operations, may be
left out.
The Black Grade Bolts may have reasonable die - seem on the
shank; but in no case the shank diameter with such seams shall
exceed the maximum permissible diameter. The Stainless Steel
Bolts, Nuts, Locknut, Plain Washer, Spring Washer shall be supplied
in natural finish.
September 2012
The Washers shall be free from cracks, burrs, pits and other
defects. The holes of Plain Washers shall be reasonably concentric
with the outer periphery. All sharp edges shall be removed.
The surfaces of Washers shall be free from die marks and shall
be finished smooth. The ends shall be so severed as to prevent
tangling.
6.2 Bolts end Nuts shall be classified by their nominal diameter. The
dimensions of hexagons, chamfers, shank diameter and other
dimensions for different nominal sizes of Bolts and Nuts, whether
ferrous or stainless steel shall be in accordance with Table 1.
6.3 Unless otherwise shown in the Purchasers drawings, the Nuts shall
have single chamfer, and Lock Nuts shall have double chamfer.
6.4 Bolts shall be drilled for Split Pins wherever shown in the Purchasers
drawings. Split Pin holes shall be at right angles to the axis of Bolts.
The dimensions for Split pin holes for a particular size of Split pin
shall be according to IS: 549 - 1974.
6.4.1 The tolerance in the location of split pin holes shall be according to
IS: 9549 - 1980.
7. DIMENSIONS
7.1 The dimensions for hexagon Bolts, Screw and Nuts shall be in
accordance with Table 1 read in conjunction with the relevant
Purchasers Drawings and IS:9519 - 2005 "Specification for modified
dimensions of width across flats for hexagonal Bolts/ Screws and
Nuts normal series.
7.2 The dimensions for special head Bolts and Screws, U-Bolts, J-Bolts
shall be as shown in the purchasers drawings.
7.3 Dimensions of flat countersunk nib Bolts/Screws shall conform to
IS: 8353 - 1977 and those of J Bolts shall conform to IS:730 - 1978.
7.4 Dimensions of ends of Bolts and Screws shall be as per
IS: 1363 - 2002 and the dimensions for radii under the head of Bolts
and Screws shall be as per IS: 4172 - 1987. The cone point/
turncated cone point ends of Bolts and Screws shall be as shown in
purchasers drawings.
September 2012
7.5 Dimensions of Plain and Spring Washers shall be as shown in
IS:2016 -1967 and IS: 3063-1994 respectively. The permissible
deviations from dimensions of plain washers shall be in accordance
with Table 3 and 4 of IS: 5369 -1975.
7.6 The dimensional tolerances for Galvanised Steel and Stainless Steel
Bolts, Screws and Nuts shall be as per Table 1.
8. LENGTHS AND THREADED LENGTHS
8.1 The lengths and threaded lengths of Bolts/Screws shall be generally
as per IS: 4206 - 1987. However, exact lengths and threaded
lengths shall be as shown in Purchasers Drawings.
9. THREADS (INTERNAL AND EXTERNAL)
9.1 The threads shall be ISO metric. The internal and external thread
profile shall be in accordance with IS : 4213 (Part I) - 1976.
September 2012
Table - 1 (Refer Fig.1)
INDICATING THE DIMENSIONS AND TOLERANCES ON BOLTS AND NUTS AND THREADS OF BOLTS AND NUTS
Sl.No. Size
Dimen
sion
M10 M12 M14 M16 M18 M20 M22 M24 Remarks
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
1. NOM
d MAX
MIN
10
11.24
(10.90)
9.79
(9.64)
12
13.44
(13.10)
11.72
(11.57)
14
15.44
(15.10)
13.72
(13.57)
16
17.44
(17.10)
15.72
(15.57)
18
19.44
(19.10)
17.72
(17.57)
20
21.64
(21.30)
19.63
(19.48)
22
23.64
(23.30)
21.63
(21.48)
24
25.64
(25.30)
23.63
(23.48)
2. NOM
s MAX
MIN
16
16.34
(16.00)
15.72
(15.57)
18
18.34
(18.00)
17.72
(17.57)
21
21.34
(21.00)
20.31
(20.16)
24
24.34
(24.00)
23.31
(23.16)
27
27.34
(27.00)
26.31
(26.16)
30
30.34
(30.00)
29.31
(29.16)
34
34.34
(34.00)
33.15
(33.00)
36
36.34
(36.00)
35.15
(35.00)
3. c MIN 17.76
(17.59)
20.02
(19.85)
22.95
(22.78)
26.34
(26.17)
29.73
(29.56)
33.12
(32.95)
37.46
(37.29)
39.72
(39.55)
4. NOM
k MAX
MIN
7
7.79
(7.45)
6.70
(6.55)
8
8.79
(8.45)
7.70
(7.55)
9
9.79
(9.45)
8.70
(8.55)
10
10.79
(10.45)
9.70
(9.55)
12
12.89
(12.55)
11.60
(11.45)
13
13.89
(13.55)
12.60
(12.45)
14
14.89
(14.55)
13.60
(13.45)
15
15.89
(15.55)
14.60
(14.45)
5. da MAX 12.54
(12.2)
15.54
(15.2)
17.54
(17.2)
19.54
(19.2)
21.54
(21.2)
24.74
(24.4)
26.74
(26.4)
28.74
(28.4)
6. a MAX 5.0 6.0 7.5 7.5 9.0 9.0 9.0 11.0
September 2012
Sl.No. Size
Dimen
sion
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
7 b b1 MIN
b2 MIN
b3 MIN
26
32
-
30
36
49
34
40
53
38
44
57
42
48
61
46
52
65
50
56
69
54
60
73
8 NOM
m MAX
MIN
8
8.79
(8.45)
7.70
(7.55)
10
10.79
(10.45)
9.70
(9.55)
11
11.89
(11.55)
10.60
(10.45)
13
13.89
(13.55)
12.60
(12.45)
15
15.89
(15.55)
14.60
(14.45)
16
16.89
(16.55)
15.60
(16.45)
18
18.89
(18.55)
17.60
(17.45)
19
19.99
(19.65)
18.50
(18.35)
9 NOM
f MAX
MIN
5
5.62
(5.38)
4.77
(4.62)
7
7.69
(7.45)
6.70
(6.55)
8
8.69
(8.45)
7.70
(7.55)
8
8.69
(8.45)
7.70
(7.55)
9
9.69
(9.45)
8.70
(8.55)
9
9.69
(9.45)
8.70
(8.55)
10
10.69
(10.45)
9.70
(9.55)
10
10.69
(10.45)
9.70
(9.55)
10 r MIN 0.3
(0.4)
0.5
(0.6)
0.5
(0.6)
0.5
(0.6)
0.5
(0.6)
0.7
(0.8)
0.7
(0.8)
0.7
(0.8)
11 l 150
>150
10.90
11.80
10.90
11.80
10.90
11.80
10.90
11.80
10.90
11.80
11.05
12.10
11.05
12.10
11.05
12.10
12 Pitch P 1.5 1.75 2 2 2.5 2.5 2.5 3
13
Pitch Bolt MAX
Dia MIN
Meter
Nut MAX
MIN
8.994
8.782
9.250
9.026
10.829
10.593
11.113
10.863
12.663
12.413
12.966
12.701
14.663
14.413
14.966
14.701
16.334
16.069
16.656
16.376
18.334
18.069
18.656
18.376
20.334
20.069
20.656
20.376
22.003
21.668
22.386
22.051
September 2012
Note :-
1. Use b1 for l 130, b2 for 130 < l l 200 and b3 for l > 200.
2. Modified dimensions for width across flats (Normal series) for M10, 12, 14 and 22mm as per
IS:9519-1980 shall also be acceptable.
3. The tolerances on the last four dimension i.e. Sl.No. 12 to 15 are applicable in black condition for
ferrous nuts and bolts and these for Sl. No. 1 to 11 are applicable after galvanising.
4. Figures in brackets wherever shown indicate the dimensions for SS fasteners.
Sl.No. Size
Dimen
sion
(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)
14
MAJOR Bolt MAX
Dia MIN
Meter
Nut MAX
MIN
9.968
9.593
-
10.00
11.966
11.541
-
12.00
13.962
13.512
-
14.00
15.962
15.512
-
16.00
17.958
17.428
-
18.00
19.958
19.428
-
20.00
21.958
21.428
-
22.00
23.952
23.352
-
24.00
15
Minor Bolt MAX
Dia MIN
Meter
Nut MAX
MIN
8.128
7.808
8.751
8.376
9.819
9.457
10.531
10.106
11.508
11.114
12.310
11.835
13.508
13.114
14.310
13.835
14.891
14.446
15.854
15.294
16.891
16.446
17.854
17.294
18.891
18.446
19.854
19.294
20.271
19.740
21.382
20.752
September 2012
9.2 The diameter and pitch and combination shall be according to IS:
4213(Part II)- 1976. The pitch shall be coarse.
9.3 The basic dimensions for profiles of ISO metric screw threads
shall be as per IS: 4213 (Part III) - 1976.
9.4 The tolerance class for ISO metric screws threads shall be coarse
as given in table 5 of IS:4213(Part IV)-1976.
9.5 The deviations from basic dimensions for nut and bolt threads of
the tolerance class specified in clause 9.4 shall be as tabulated in
table - 1. The tolerance class shall be 7H for nuts and 8g for bolt
threads. The limits of sizes for tolerance class 7H for nut threads
and 8g for bolt threads are given in table-1. These limits are
applicable to ferrous fasteners in black condition and to stainless
steel fasteners in finished condition.
9.6 The thread run outs and undercuts shall be as per IS: 1369-1995.
10. GALVANISING OF FERROUS FASTNERS
10.1 Dimensions
10.1.1Fasteners with internal Threads -Prior to galvanising and
subsequent tapping the dimensions of fasteners with internal
threads shall conform to the relevant standards. Internal threads
shall be tapped over-size after galvanising and they shall be oiled
for corrosion protection.
10.1.1.1 The oversize tapping allowance shall be as given in Table
below. These allowances are applicable to major, pitch and
minor diameters, the amended diameters being subject to the
same manufacturing tolerances of the appropriate grade of
threads stated in the relevant fastener standard.
TABLE: ALLOWANCES FOR INTERNAL THREADS TO
ACCOMMODATE GALVANIZED EXTERNAL THREADS.
Nominal Size Internal Diametral Allowances
Threads. mm
Below M16 +0.40
M16 to M22 +0.50
Over M22 and
up to and including M36 +0.65
September 2012
10.1.2 Fasteners with External Threads - Prior to galvanising, the
dimensions of fasteners with external threads shall conform to
the relevant standards including thread sizes.
10.1.2.1The thickness of galvanized coating on external threads shall be
so controlled in the galvanising process that galvanised
fasteners with external threads can be assembled by hand with
internally threaded fasteners complying with 10.1.1.
10.1.2.2Galvanised external threads shall not be recut.
10.1.3 Coating Requirements
10.1.3.1Mass of Coating - The mass of coating per square meter of
the surface shall comply with the minimum average and
minimum individual sample coating given in Table below. The
mass of coating shall be determined by one the following
methods:
a) The stripping test described in Append-ix B; or
b) Magnetic or electronic thickness measuring devices as
covered in IS: 3203-1965 `Method of testing local thickness
of electroplated coatings. The mass of coating in g/m
2
is
found by multiplying the thickness in micrometers by 7.0.
10.1.3.2 In case of dispute, the stripping test shall be the referee
test.
TABLE: MASS AND EQUZAVALANT THICKNESS OF COATING
Minimum Average Minimum Individual
Mass Thickness Mass Thickness
g/m
2
m g/m
2
m
375 54 300 43
September 2012
10.1.4 Uniformity of Coating - The uniformity of zinc coating shall
be such that the coating shall withstand the copper sulphate
test as given in IS : 2633- 1986. Methods of testing
uniformity of coating on zinc coated articles (first revisions )
`without showing any adherent red deposit of metallic
copper upon the base metal with the following exceptions.
a) A fine line of copper on the crest of the screw threads or on
sharp edges of Bolt/Nut or at or adjacent to any cut of
abrasion present in the original fastener shall not be
considered a defect to cause rejection, and
b) Any deposit of metallic copper with threads of fasteners
which have been re-thread rolled after galvanising, is
allowable.
10.1.5 Adhesion of Coating - The coating shall withstand the knife test
as covered in IS: 2629-1985.
10.2 All ferrous fasteners including washers shall be hot dip
galvanized for electro-galvanised to achieve a uniform adherent
coating of zinc. The minimum thickness of zinc coating shall be of
400 g/m
2
(55 microns).
11. TESTS
11.1 The manufacturers shall carry out the specified tests, during
production on the samples, taken at regular intervals, separately
for the different sizes, grade & material, which are being
manufactured under similar processes of productions to ensure
conformity to relevant specifications as also to maintain proper
control over the process of manufacture. The manufacturer shall
at the time of inspection, produce a certificate showing the
records of various inspections/tests which have been exercised
during manufacture.
11.2 When the purchaser requires additional tests, related to his order
but not specified hereunder, such tests shall be subject of
agreement between the purchaser and the manufacturer.
11.3 All the tests on the fasteners shall be carried out at manufacturers
works. The manufacturer shall arrange, without making claim or
charge, all the necessary machinery, apparatus, labour,
assistance etc. required to get the prescribed tests conducted in
the presence of purchasers representative.
September 2012
11.4 Type Tests
i) Visual examination ( 12.1)
ii) Measurement of dimensions (12.2)
iii) Gauging of threads ( 12.3)
iv) Chemical composition (12.4)
v) Mechanical tests (12.5)
a) Tensile test (12.5.1)
b) Elongation after fracture (12.5.2)
c) Hardness test (12.6)
d) Proof load test (12.7)
(for ferrous bolts and nuts
and stainless steel nuts).
e) 0.2% permanent strain test (12.8)
(For S.S. bolts only)
f) Head soundness test ( 12.9)
g) Crushing test on nuts (12.10)
(SS nuts only)
h) Bend test on straight bolts (12.11)
(SS bolts only).
i) Torsion test on bolts & nuts (12.12)
(for SS bolts & nuts only)
vi) Galvanising test on ferrous fasteners (12.13)
vii) Inter-crystalline corrosion bend test (12.14)
for SS fasteners, or Micro examination of
SS fasteners (12.15)
viii) Permanent set test on spring washers (12.16)
ix) Twist test on spring washers (12.17)
11.5 Routine tests
Visual examination (12.1)
September 2012
11.6 Acceptance tests
i) Visual examination ( 12.1)
ii) Measurement of dimensions (12.2)
iii) Gauging of threads (12.3)
iv) Chemical composition (12.4)
(only for stainless steel fasteners)
v) Mechanical tests (12.5)
a) Tensile test (12.5.1)
b) Percentage elongation after fracture (12.5.2)
c) Hardness test (12.6)
d) Proof load test (12.7)
(for ferrous bolts & nuts and for stainless steel nuts).
e) Stress at 0.2% permanent strain test (12.8)
f) Head soundness test for bolts (12.9)
g) Crushing test on nuts (12.10)
(SS nuts only)
h) Bend test on straight bolts (12.11)
( SS bolt only)
i) Torsion test on bolts & nuts (12.12)
(for SS bolts & nuts only)
vi) Galvanising test on ferrous fasteners (12.13)
vii) Inter-crystalline corrosion bend test on (12.14)
stainless steel fastners.
Or
Micro examination of stainless steel (12.15)
Fasteners.
viii) Permanent set test on spring washers (12.16)
ix) Twist test on spring washers(12.17)
11.6.1 Sampling procedure
11.6.1.1 Lot : All the fasteners in a consignment belonging to the
same size, grade, material and manufactured under similar
process of production and submitted for inspection at one
instance shall constitute a lot.
September 2012
11.6.2 Scale of sampling
11.6.2.1 Samples shall be selected at random and examined for each
lot separately for ascertaining their conformity to the
requirements of this specification. Only one set of samples as
indicated in 11.6.2.2 shall be drawn from a lot for all the
characteristics.
September 2012
TABLE 2
SCALE OF SAMPLING AND CRITERIA FOR CONFORMITY FOR INSPECTION
( Clause 11.6.1, 11.6.2, 11.6.3 )
Lot size VISUAL CHARACTERISTICS DUDS DIMENSIONAL CHARACTERISTICS STAINLESS STEEL
FASTERNERS
Sample Sam
ple
size
Cum
ulati
ve
size
Ac Re Ac Re Sample Sa
m
ple
size
Cumu
lative
size
BLACK FASTNERS
Major
deIect
Major
deIect
Major
deIects
Minor
deIects
Ac Re Ac Re Ac Re Ac Re
AQL 4.0 0.65 2.5 4.0 1.5 2.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
Upto 100
First
Second
20
20
20
40
1
4
4
5
0
1
2
2
First
Second
8
8
8
16
0
1
2
2
0
1
2
2
0
1
2
2
0
1
2
2
101300
First
Second
32
32
32
64
2
6
5
7
0
1
2
2
First
Second
13
13
13
26
0
1
2
2
0
3
3
4
0
1
2
2
0
1
2
2
301500
First
Second
50
50
50
100
3
8
7
9
0
1
2
2
First
Second
20
20
20
40
0
3
3
4
1
4
4
5
0
1
2
2
0
3
3
4
5011000
First
Second
80
80
80
160
5
12
9
13
0
3
3
4
First
Second
32
32
32
64
1
4
4
5
2
6
5
7
0
3
3
4
1
4
4
5
10013000
First
Second
125
125
125
250
7
18
11
19
1
4
4
5
First
Second
50
50
50
100
2
6
5
7
3
8
7
9
1
4
4
5
2
6
5
7
September 2012
Note:- ClassiIication oI major and minor deIect is given in Appendix A oI IS: 2614 1969. | LEGEND AQL Acceptable quality
Level|
Lot size VISUAL CHARACTERISTICS DUDS DIMENSIONAL CHARACTERISTICS STAINLESS STEEL
FASTERNERS
Sample Sam
ple
size
Cum
Ulati
ve
size
Ac Re Ac Re Sample Sam
ple
size
Cum
Ulati
ve
size
BLACK FASTNERS
Major
deIect
Major
deIect
Major
deIects
Minor
deIects
Ac Re Ac Re Ac Re Ac Re
AQL 4.0 0.65 2.5 4.0 1.5 2.5
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19
300110000
First
Second
200
200
200
400
11
26
16
27
2
6
5
7
First
Second
80
80
80
160
3
8
7
9
5
12
9
13
2
6
5
7
3
8
7
9
1000135000
First
Second
315
315
315
630
11
26
16
27
3
8
7
9
First
Second
125
125
125
250
5
12
9
13
7
18
11
19
3
8
7
9
5
12
9
13
Over 35000
First
Second
500
500
500
1000
11
26
16
27
5
1
2
9
13
First
Second
200
200
200
400
7
18
11
19
11
26
16
27
5
12
9
13
7
18
11
19
September 2012
11.6.2.2 Samples shall be drawn from each lot in accordance with Cols. 1,
2,3 of table 2 for visual and dimensional verifications and for
inspection of physical and other properties.
11.6.3 Criteria for conformity
11.6.3.1 Visual characteristics : All the fasteners drawn in accordance
with clause 11.6.2.2 shall be first examined for visual
characteristics like type, finish, workmanship, duds, visual
surface discontinuities and identification mark. To ascertain the
conformity of the lot to the requirements of all visual
characteristics, except duds, the procedure given in 11.6.3.1.1
shall be followed. For duds, procedure given in 11.6.3.1.2 shall
be followed.
11.6.3.1.1 Visual characteristics ( other then duds) :If in the first sample
the number of defective fasteners with respect to all visual
characteristics, except duds, is less than or equal to the
corresponding acceptance number (Ac) given in Col.5 of table 2
the lot shall be declared as conforming to the requirements for
these characteristics. If the number of defectives is greater then
or equal to the corresponding rejection number (Re) given in
Col.6 of table 2 the lot shall be deemed as not meeting the
requirements for these characteristics. If the number of
defectives is greater than the acceptance number but less than
the rejection number a second sample of the same x number of
fasteners selected as the first sample shall be taken to
determine the conformity or otherwise of the lot. The number of
defectives found in the first and second sample shall be
combined and if the combined number of defectives is less than
or equal to the corresponding acceptance number the lot shall be
declared as conforming to the requirements; otherwise not.
11.6.3.1.2 Duds: If the number of defective fasteners in respect of duds is
less than or equal to the corresponding acceptance number
given in col.7 of table 2, the lot shall be declared as conforming
to the requirements for duds. If the number of defective
fasteners is greater than or equal to the rejection number given
in col.8 of table 2, the lot shall be declared as not conforming to
the requirements for duds. If the number of defective fasteners
is greater than the acceptance number but less than the
rejection number, a second sample of the same number of
fasteners selected as the first sample shall be taken to
September 2012
determine the conformity or otherwise of the lot. The number of
defective fasteners found in the first and second samples shall
be combined and if the combined number of defective fasteners
is less than or equal to the corresponding acceptance number,
the lot shall be declared as conforming to the requirements for
duds, otherwise not.
11.6.3.2 Dimensional characteristics
The lot which has been found satisfactory in respect of visual
characteristics (See 11.6.3.1) shall be tested for dimensional
characteristics like diameter, length etc. except pitch, basic
dimensions of threads which will be tested as per clause 12.3
after stripping / case of ferrous fasteners. The fasteners for this
purpose shall be taken at random in accordance with col.9 and
10 of table 2, from those already drawn for inspection of visual
characteristics ( see 11.6.3.1) and tested for dimensional
characteristics. If the number of fasteners failing to satisfy the
requirements for these characteristics is less than or equal to the
corresponding acceptance number given in col. 12,14,16 or 18
of table 2, the lot shall be declared as to have not the
requirements of the specification in respect of these
characteristics. If the number of defectives is greater than or
equal to the corresponding rejection numbers given in col.
13,15,17 or 19 of table 2 the lot shall be deemed as not
confirming to these characteristics. In case the number of
defective lies in between the acceptance and rejection number, a
second sample of the same size shall be taken and inspected for
dimensional characteristics and inference drawn accordingly.
11.6.3.3 Physical chemical & galvanising requirements
11.6.3.3.1 From the samples taken in accordance with 11.6.2.2 end which
have been subjected to the visual and dimensional tests,
samples in multiples of 5 or 6, as the case may be shall be
drawn at random for mechanical, chemical and galvanising tests
in case of bolts and nuts. In case of spring washers, samples in
multiples of 4 shall be selected for twist test and permanent set
test.
September 2012
11.6.3.3.2 Galvanized Fasteners
i) BOLTS : - The samples selected in accordance with clause
11.6.3.3.1 shall be divided in 6 equal parts. Each part shall
be subjected to one of the following tests:
a) Tensile / elongation test ( Cl.12.5.1 and 12.5.2 )
b) Proof load test (Cl.12.7)
c) Head soundness test ( Cl. 12.9)
d) Hardness test ( Cl.12.6)
e) Galvanising test ( Cl.12.13)
f) Gauging of threads ( Cl. 12.3)
and visual examination after stripping ( 12.1)
ii) NUTS : - The samples selected in accordance with clause
11.6.3.3.1 shall be divided into 4 equal parts. Each part shall
be subjected to one of the following tests.
a) Proof load test ( 12.7)
b) Hardness test (12.6)
c) Gauging of threads (12.3)
d) Galvanising test and visual examination.
after stripping ( 12.13 & 12.1 )
11.6.3.3.3 Stainless steel fasteners
(i) BOLTS : - The samples selected in accordance with clause
11.6.3.3.1 shall be divided in 6 equal parts. Each part shall be
subjected to the following tests:
a) Tensile strength / Extension ( 12.5.1 & 12.5.2)
b) Stress at 0.2% permanent strain ( 12.8)
c) Head soundness test (12.9)
d) Bend test (12.11)
e) Gauging of threads end Torsion test ( 12.3 & 12.12)
f) Micro examination, hardness & Chemical.
Composition ( 12.15, 12.6 & 12.4 )
ii) NUTS : - The samples selected in accordance with clause
11.6.3.3.1 shall be divided into 4 equal parts. Each part shall be
subjected to following tests.
a) Proof load test ( 12.7)
b) Gauging of threads and Crushing test ( 12.3 and 12.10)
c) Micro examination ( 12.15 )
d) Chemical composition (12.4)
e) Hardness test (12.6)
September 2012
11.6.3.3.4 Should more than one sample fail in any test(s), the lot shall be
rejected. If only one sample fails in any test, twice the number of
samples shall be drawn and the test, twice the number of samples
shall be repeated. The lot shall be accepted if there is no failure in
the re-test.
12. METHOD OF TESTS
12.1 Visual Examination
All the bolts & nuts shall be visually examined for finish,
workmanship, chamfers and identification mark and for visual
surface discontinuities referred in IS: 1367 (Part 9) - 1993 and IS:
1367(Part.10) - 2002. The bolts shall be examined for straightness
of shank and for any eccentricity of shank with respect to head.
Nuts & washers shall be examined for eccentricity of the holes,
crack, burrs, pits and other defects. Zinc coating on ferrous
fasteners shall be examined for defects defined in Appendix A of
IS: 2629 - 1985.
12.2 Measurement of dimensions
The dimensions of fasteners including lengths and threaded
lengths of bolts shall be measured with the help of suitable
gauges/devices and shall be within the limits specified in clause 7
& 8 of this specification or these specified in purchasers drawings.
12.3 Gauging of threads
These tests shall be done in black condition of galvanised fasteners
after stripping. The thread pitch for particular diameter
combination [See Table 1 of IS:4213 (Part -II - 1976)] shall be
measured with the help of thread pitch gauges conforming to
IS:4211-1993. The thread profile shall be checked with the help of
gauges in accordance with IS: 2334-2001. The limits of sizes of
nut and bolt threads for tolerance class7H and 8g respectively are
specified in Table -1.
September 2012
12.4 Chemical composition
12.4.1Ferrous fasteners: Chemical analysis of the galvanised steel bolts
shall be carried out in accordance with IS: 228 -1987 and parts and
shall conform to Clause 4 of IS : 1367(Part 3) - 2002 i.e. Carbon shall
not exceed 0.55%, sulphure 0.06% and phosphorus 0.05% for bolts.
The chemical composition for ferrous nuts shall be as follows:
Property Class C Mn P S
%Max. %Min. %Max. %Min.
4,5 0.50 - 0.110 0.150
04 0.53 0.25 0.060 0.150
12.4.2 Stainless steel fasteners shall be analyzed in accordance with IS:
228-1987 and parts. The chemical composition shall conform to
Grades Mentioned clause 5.2.
12.5 Mechanical Tests
12.5.1 Tensile Test for Bolts
12.5.1.1 G.S. Bolts: The tensile test shall be carried out on all sizes of bolts
in finished condition where a. free threaded length equal to one
diameter of bolt shall also be subjected to tensile load. The fracture
shall occur in the shank or thread of bolt and not at the junction of
the head and the shank. The calculation of the tensile strength is
based on the stress area. The tensile strength shall not be less than
400 N/mm
2
.
12.5.1.2 Stainless Steel Bolts and Studs: The Tensile Test shall be carried
out on all sizes of Bolts and Studs in finished condition where a free
threaded length equal to one diameter of bolt shall also be
subjected to tensile load. The fracture shall occur in the shank or
thread of bolt and not at the junction of the head and the shank.
The calculation of the tensile strength is based on the stress area.
The tensile strength shall not be less than 500 N/mm
2
.
12.5.1.3 Test Rig: For the purpose of tensile test the rig shall be designed
accordingly. The speed of testing shall not exceed 25 mm/min. The
grips of testing machine should be self aligning to avoid side
thrust on the specimen".
September 2012
12.5.2 Determination of percentage elongation after fracture
12.5.2.1 G.S. bolts: The elongation test shall be carried out on full size
bolts in finished condition where it is possible to mark the gauge
length equal to 5.65 \So on the shank. Where it is not possible to
mark the gauge length on the shank, machined test pieces shall be
used for the purpose of determination of percentage elongation after
fracture as per clause 8.1 IS:1367 (Part 3):2002. The load shall be
applied in the manner as in 12.5.1.3. The elongation after fracture
in both the cases shall not be less than 22%. The applicability of the
elongation test on the full size bolts in finished condition and on
machined test pieces (refer Drg. No. ETI/C/0073 Mod. A) Shall be
as under:-
Nominal thread /
shank diameter
(mm)
Dimensions for bolts as per Drg. No.
ETI/C/0073 Mod. A
Machined test pieces In finished condition.
12 60/30 and below 120/36 and above.
14 All sizes
18 All sizes
24 All sizes
12.5.2.2 Stainless Steel Bolts and Studs: The extension after fracture of
stainless steel bolts and studs shall be measured during the tensile
test (see sub- clause 12.5.1.2). The extension shall not be less than
0.6 d (where d is nominal diameter of bolt).
12.6 Hardness Test :
12.6.1 Hardness test for galvanised steel fasteners shall be carried out after
removal of zinc coating. On steel bolts, the test shall be carried out
in accordance with Clause 8.4 of IS:1367(Part 3)-2002 and on steel
nuts in accordance with 8.2 of IS:1367(Part.6)-1994. On stainless
steel bolts and nuts this test shall be carried out in accordance with
IS:1586-2000 or latest version. The values of hardness shall be
within the ranges given in Table 3 below.
September 2012
Table 3
[Ref : IS:1367 (Part-V)-1994 or Latest]
Fastener
Property
class
Nominal size Hardness
Minimum Maximum
Steel Bolts 4.6 All 120 HV 220 HV
Steel Nuts 04 All 188 HV 302 HV
4 Over M16 to
M39
117 HV 302 HV
5 M10 - M 16 130 HV 302 HV
Over M16 to
M39
146 HV 302 HV
Stainless steel
Bolts & Nuts
- All - 95 HRB
12.7 Proof load test on Bolts and Nuts
12.7.1 Proof load test on Bolts and Nuts shall be carried out in accordance
with Clause 8.5 of IS:1367 (Part 3) - 2002 and Clause 8.1 of IS:1367
(Part.6)-1994 respectively. The Stainless Steel Bolts shall be capable
of being fully loaded upto the proof load, as prescribed in Table 4.
Steel and Stainless Steel Nuts shall be capable of being fully loaded
upto proof loads indicated in Table 5.
Table 4 - PROOF LOADS FOR STEEL BOLTS ISO METRIC
COARSE TIREAD
Nominal
Thread
Pitch
of the
Nominal
Stress
Property
Class
Diameter
(mm)
Threads
(mm)
Area
(mm
2
)
4.6 of IS:1367(Part-6)-1994
(Proof load N)
6 1 20.1 4520
7 1 28.9 6500
8 1.25 36.6 8240
10 1.5 58.0 13000
12 1.75 84.3 19000
14 2 115 25900
16 2 157 35300
18 18 1818 2.5 192 43200
20 2.5 245 55100
22 2.5 303 68200
24 3 353 79400
27 3 459 103000
September 2012
TABLE 5 - PROOF LOAD VALUES FOR NUTS - ISO METRIC COARSE TIREADS
Nominal
Size
Pitch of
the
thread
mm
Nominal
stress
area
of
Mandrel
Mm
2
Proof load N
Steel Nuts Stainless
Steel
Nuts,
(Proof
Stress
500
N/mm
2
)
Property
Class 04
Property
Class 4
Property
Class 5
M6 1 20.1 7640 ---- 11700 10000
M7 1 28.9 11000 ---- 16800 14500
M8 1.25 36.6 13900 ---- 21600 18300
M10 1.5 58 22000 ---- 34200 29000
M12 1.75 84.3 32000 ---- 51400 42200
M14 2 115 43700 ---- 70200 57500
M16 2 157 59700 ---- 95800 78500
M18 2.5 192 73000 97900 121000 96000
M20 2.5 245 93100 125000 154400 122500
M22 2.5 303 113100 154500 190900 152000
M24 3 353 134100 180000 222400 476500
M27 3 459 174400 234100 289200 229500
M30 3.5 561 213200 286100 353400 280500
M33 3.5 694 263700 353900 437200 347000
M36 4 817 310500 416700 514700 408500
M39 4 976 370900 497800 614900 488000
12.8 Stress at 0.2% Permanent Strain Test (For Stainless Steel Bolt only)
12.8.1 This test shall be conducted in accordance with IS:1608 - 2005 or
latest version. The stress at 0.2% permanent strain shall not be
less than 205 N/mm
2
.
Nominal
Thread
Pitch
of the
Nominal
Stress
Property
Class
Diameter
(mm)
Threads
(mm)
Area
(mm
2
)
4.6 of IS:1367(Part-6)-1994
(Proof load N)
30 3.5 561 126000
33 3.5 694 156000
36 4 817 184000
39 4 976 220000
September 2012
12.9 Head soundness test for Bolts
12.9.1 This test is not applicable to U Bolts, J Bolts and Flat Countersunk Nib
Bolts.
12.9.2 This test shall be carried out as illustrated in figure 2 (enclosed) and
in Fig. 4 of IS:1367(Part-3) - 2002.
12.9.3 The Bolt shall be inserted in a special Steel Die of the dimensions
given in Table II of IS:1367(Part-3)-2002. The hole in the die shall
be at an angle of 60
0
to its upper surface.
12.9.4 When struck several blows with a hammer the head of Bolt or Screw
should be bent to an angle (90-60)
0
without showing any sign of
cracking at the fillet between Shank and head.
12.9.5 Where Screws are threaded upto the head the test will be regarded
as established even if a crack should appear in the first thread,
provided that head does not snap off.
12.10 Crushing test on Nuts (Stainless Steel only)
12.10.1 The Nut under test shall be placed edgewise on an anvil and
crushed by hammering till its threads come in contact with a mandrel,
the diameter of which shall be 0.9 D
1
where D
1
is the minor diameter
of Nut described in figure 1 of IS:4213(Part.I):1976. After crushing,
the Nut shall not exhibit any fracture or crack at any point. The Nut
may then be broken for further chemical analysis and inspection of
structure.
12.11Bond Test on Straight Bolts (Stainless Steel only)
12.11.1 This test is applicable only to straight Bolts.
12.11.2 The threaded part of the bolt shall be so held in the jaws of a vice
that the threaded part projects for a distance equal to at least half the
nominal diameter. The projecting part shall then be bent by
hammering so that the axis of free portion is at an angle of 165
degree to the axis of the portion held in the vice. On examination, the
bend shall not exhibit any crack (see figure-3).
12.12 Torsion test on Bolts and Nuts (For Stainless Steel Bolts & Nuts only)
12.12.1 A torsion test shall be conducted on Stainless Steel Bolts and Nuts.
The test shall be conducted as described in 12.12.2 in case of straight
Bolts and as described in 12.12.3 in case of U Bolts. The ultimate
torsional strength shall be not less than that specified in Table 6.
September 2012
TABLE - 6
ULTIMATE TORSIONAL MOMENT FOR
STAINLESS STEEL BOLTS AND NUTS
Diameter of Bolt
mm
Ultimate Torsional Strength (Minimum)
(kg-m)
10 6.5
12 12
14 16
12.12.2 The head of the Bolt shall be gripped in a Vice and a Steel Plate
slipped over the thread, the diameter of the hole drilled in this steel
plate being 11 mm in case of 10mm diameter Bolts, 14 mm in case of
12 mm diameter Bolts and 16 mm in the case of 14 mm diameter
Bolts. A Flat Steel Washer is then placed between the Steel Plate and
the Nut (but none between Plate and head of Bolt). The total
thickness of the Steel Plate and the Washer shall be so chosen that
the position of Nut on the threaded portion of Bolt is the same as
when the Bolt is in actual use. The test shall be carried out without
lubrication of the parts in contact with each other. The torque shall be
applied by means of Torque Spanner, the design of which is subject to
the approval of the purchaser. The torque shall be increased in steps
until the Bolt fractures. After each increment of torque, the Nut shall
be unscrewed and the threads on both Bolt and Nut examined.
12.12.3 The torsion test on U bolts shall be conducted in a manner similar to
that described in 12.12.2, but the U bolt shall be prevented from
deforming in the course of the test by seating it on a mandrel, the
radius of curvature of which is equal to that of the inner edge of the U
bolt. A Steel Plate with two drilled holes shall be slipped over the two
limbs of the U bolt, the diameter of the holes in the Steel Plate
bearing the same relationship to the diameter of the Bolt as in the
case of straight Bolts. The steep Plate may be integral with the
mandrel. A Flat Steel Washer shall then be placed between the Steel
Plate and the Nut on each limb(Fig 4). The torsion test shall then be
carried out as described in 12.2.2 after gripping the mandrel in a
Vice. It is sufficient if the test is conducted on one limb of the U-Bolt.
12.12.4 The test shall result in fracture of the Bolt, but not of the Nut. The
values of torque at fracture shall be not less then that indicated in
September 2012
Table-3. Further, on unscrewing the Nut at any value of torque below
the value specified in Table 3, the threads on Bolt and Nut shall be
found to be undamaged and it shall be possible to work the nut along
the entire threaded length of the Bolt.
12.13 Galvanising test
The zinc coating on galvanised fasteners shall be tested for
adherence, uniformity and mass. The mass of zinc coating shall be
measured on the unthreaded portion by stripping method (IS:6745 -
1972) or by previously calibrated Elcometer (magnetic method). The
uniformity shall be checked by Preece Test (IS:2633-1986) on the
threaded portion of Bolts. It shall withstand at least five successive
dips in one minutes. Adherence shall be checked on the shank or
head by any one of the methods prescribed in clause 6.4 of IS 2629-
1985.
12.14 Inter-Crytallic Corrosion Bend Test (For stainless steel only)
12.14.1 The Bend Test pieces shall not be larger than 12.5 mm (1/2 inch)
diameter. The test piece shall be sensitized by heating to a
temperature of 650
0
C for the period stated in the relevant material
specification, followed by cooling in air. All test pieces shall be
immersed for 72 hours in boiling solution having the following
composition:
111 grams Copper Sulphate (CuSo
4.
5 H
2
O),
98 grams Sulphuric acid [Relative Density (d) = 1.84]
made upto 1 litre with distilled water.
Precautions shall be taken during the boiling to prevent concentration
of the solution due to evaporation.
After this preparation each test piece shall be bent through 90
round a radius equal to three times the diameter and thickness of the
test piece, and shall withstand this treatment without cracking on the
outer, convex surface.
12.15 Micro examination of Stainless Steel Fasteners
(Test for freedom from Carbide precipitation)
12.15.1 Micro examination on transverse section of Stainless Steel Bolts and
Nuts shall be carried out to ascertain freedom from Carbide
precipitation at grain boundaries. In case any sample shows evidence
of Carbide precipitation, the lot represented by the same may be
September 2012
reheat treated, and resubmitted as a new lot at the discretion of the
purchaser. Otherwise the lot shall be rejected.
12.16 Permanent Sat Test on Spring Washers
12.16.1The Spring Washers under test shall be compressed flat for
3 Minutes duration and released between two Plates having a
hardness of 60 HRC, Minimum on release if the pressure, the free
height (h
2
= 2S indicated in IS:3063 1994) of the washer shall not be
less then that given in Table 2 A & 2 B of IS:3063-1994. This
compression and removal of pressure shall then be repeated 20
times in quick succession after which the free height shall not have
further reduced.
12.17 Twist Test on Spring Washers
12.17.1 A portion of the Washer shall be gripped in Vice jaws and then
equal portion shall be gripped in wrench jaws as shown in Fig. 1 of
IS:3063-1994. Edges of the Wrench jaws shall be sharp and parallel
to Vice jaws. The Wrench shall than be rotated in a direction that
increases the free height of the Spring Washer till the Washer is
twisted through on angle of 90
0
. The Washer shall show no sign of
fracture.
13. MARKING AND MODE OF DELIVERY
13.1 The Bolts shall be delivered assembled with their Nuts and Lock Nuts
and Washers (wherever required). The Nuts and Lock Nuts shall be
fully screwed on by hand.
13.2 Bolts, Screws and Nuts shall be provided with identification marking
as laid down in IS: 1367 (Part.18)-1996. The marking of the
manufacturers trade mark of name is mandatory for all products
covered by the obligatory marking requirements for property classes.
For Stainless Steel Fasteners, AISI 316 should be marked as
property class.
13.2.1 If the Fasteners are not properly marked by the manufacturers
according to clause 13.2, then the whole lot shall be rejected.
13.3 The fasteners shall be packed as described in IS:9141-1979.
September 2012
13.4 Each package shall contain only one grade and dimension of
fasteners.
13.5 The packages shall be marked clearly and legibly with the following
information.
a) The product designation,
b) A pictorial representation of the product,
c) Total number of pieces in the package,
d) Net and gross mass of package,
e) Name or identification symbol of the manufacturer,
f) Purchase order No. and consignee,
g) Date of inspection and inspecting authority and
h) Any other information as required by Purchaser.
September 2012

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