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Revision 00

Date 15/05/2008

Revision description First issue

Prepared by:

Giancarlo Brunori Vincenzo Ruggieri

signature:

signature:

Verified by:

signature: Approved by:

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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EN 1993-1-1 EN 1993-1-8 EN 1090-1 EN ISO 12944

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

Rules quoted in this document

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

Alstom control procedures

Final documentation check and inspection Identification and retrievability

1. API E0063.0 2. API E0064.0

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.

In compliance with EN 1090-1 8.3:

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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3.1.1 Normal bolts (resistance classes 5.6/6)

Bolts (class 5.6) shall be in compliance with ISO 4014 for tolerance category A and B and ISO 4016 for tolerance category C (ISO 8765 for category A fine pitch bolts), material in compliance with EN ISO 898-1, nuts (class 6) shall be in compliance with ISO 4032 category A and B and ISO 4034 for category C (or ISO 8673 for category A-B with fine pitch), material in compliance with EN 20898-2. The resistant class and geometrical data are specified in contract drawings. Normal bolts used in API constructions, usually belong to the resistance class 5.6/6.

3.1.2 High resistance bolts (resistance classes 8.8 and 10.9)

There are in Europe two bolt systems, between them comparable, HR from France and HV from Germany, codified in EN 14399 parts 16. Their primary differences are: Height of nuts: nuts of HR system are slightly more height than HV system nuts (0.90.85 bolt diameter of HR system versus 0.8330.8 bolt diameter of HV system, in function of bolt diameter); Length of threaded part of bolts: bolts of HR system have threaded length longer than bolts of HV system (2.52.16 bolt diameter of HR system versus 1.91.45 bolt diameter of HV system, in function of bolt diameter); Mechanical property class: 8.8 or 10.9 for HR system bolts, 10.9 for HV system bolts. In addition, there are a lot of other small differences that enforce the EN 14399 to codify:
This document on structural bolting reflects the situation in Europe where two technical solutions exist to achieve the necessary ductility of bolt/nut/washer assemblies. These solutions utilize different systems (HR and HV) of bolt/nut/washer assemblies. Both systems are well proved and it is up to the experts responsible for structuring bolting whether they use the one or the other system. It is, however, important for the performance of the assembly to avoid mixing up the components of both systems. Therefore, the bolts and nuts for both systems are standardized in one single part of this European Standard each and the marking of the components of the same system is uniform. Table 1 Systems of bolt/nut/washer assemblies Bolt/nut/washer assembly Bolt/nut/washer assembly System HR System HV General EN 14399-1 requirements Bolt/nut assembly EN 14399-3 EN 14399-4 Marking HR HV Property classes 8.8/8 10.9/10 10.9/10 Washer(s) EN 14399-5 or EN 14399-6 EN 14399-5 or EN 14399-6 Marking H H Suitability test for EN 14399-2 EN 14399-2 preloading Preloaded bolted assemblies are very sensitive to differences in manufacture and lubrication. Therefore it is important that the assembly is supplied by one manufacturer who is always responsible for the function of the assembly. For the same reason it is important that coatings of the assembly is under the control of one manufacturer.

Bolt system required, geometrical data and resistance class (only for HR system) are specified in contract drawings.

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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.

3.2.1 Conditioning of coupling surfaces

The connections carried out with bolts are differentiated in not pre-loaded and preloaded. In the not pre-loaded joints, bolts work nearly exclusively by shear; in the pre-loaded connections the coupling is guaranteed by friction between the surfaces under pre-loaded bolts working in tension (may also work under shear if some yielding happens).

3.2.1.1 Not pre-loaded shear-connections

The contact surfaces must be cleaned, free of grease, dirtiness, foreign materials, etc. They may be painted or shop primer preserved.

3.2.1.2 Pre-loaded shear-connections

The contact surfaces in the sliding resistant connection must be prepared according to the requirements of the following par. 4.1. If not immediately assembled (not within the next 12 hours after the sandblasting) and the bolts tightened, on the contact surfaces may be applied a painting product with suitable friction coefficient. This product must have the friction coefficient qualified by test performed by a qualified test institute and certified by a third party (Notified body); see para. 2.4. 4. SURFACES CONDITIONING AND BORING

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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From EN 1090-1 8.8: Prospect 7: Friction surfaces classification Class A Treatment

Sandblasted surfaces, with removed any free rust, not painted; Sandblasted surfaces, spray metallized with aluminum; Sandblasted surfaces, metallized with a zinc based product and subjected to friction factor test to have a friction factor not lesser than 0,5. Zinc-alkali silicate paint 5080 m, applied on sandblasted surfaces. Surfaces cleaned with wire brushing or with flame cleaning, with all free rust removed. Not treated surfaces.

B C D

4.1.1 Contact surfaces protection over painting

1) Contact surfaces for slip-resistant connections shall be preserved, during the element painting, by covering it with suitable adhesive papers treated with antirust products or painting it with a stripping or cereous antirust film. Alternatively they can be painted with a, suitable for friction factor, primer. 2) After assembly the contact surfaces shall be protected against infiltration of water, oil and other contaminants. This may be made by: a) Application of silicon rubber along all the junction perimeter; b) When specified in contract documents, bolting the contact surfaces with interposed fresh paint and, then, painting the junction perimeter to close any possible opening.

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.

4.2.1 Shear bolts joints

Where it is allowed a joint subsidence under load, the hole-bolt gap may be defined according to EN 1090-1 8.1 point Dimension and location of holes: normal holes. We recall the 4.2 points

4.2.2 Friction bolts joints

Misalignments of holes that not permit the bolt passing are not allowed in any case. See 4.2.

4.2.3 Bolts in precision bores

When the joint subsidence under load is not allowed, bolts shall work in shear with a precision coupling, with gap between hole-bolt not exceeding 0.3 mm (see EN 10901 8.10 Bolts in precision bore and pins). This situation is typical for pinned connections. Holes for this type of bolting/pinning must be drilled with a diameter suitably reduced (at least 2 mm) and successively they shall be bored (or reamed) to the final diameter after that the truss to build shall be assembled finished in every parts, with the aid of suitable assembling pins and bolts. 5. BOLTING PROCEDURE

5.1

Determination of bolts length

Figures represent the characteristic quantities of a bolt and its clamp length.

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Figure 1 - Bolt representation

Figure 2 - Clamp length

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.

Table 1 HR type bolt length in function of Clamp Length

Thread d l nom 35 40 45 50 55 60 65 70 75 80 85 90 95 100 110 120 130 140 150 160 170 180 190 200 min 33,8 38,8 43,8 48,8 53,5 58,5 63,5 68,5 73,5 78,5 83,3 88,3 93,3 98,3 108 118 128 138 148 158 168 178 188 198 max 36,3 41,3 46,3 51,3 56,5 61,5 66,5 71,5 76,5 81,5 86,8 91,8 96,8 102 112 122 132 142 152 164 174 184 195 205 min. 16 16 20 25 30 35 40 45 50 55 60 65 70 75 max. 21 26 31 36 41 46 51 56 61 66 71 76 81 86 19 19 19 19 27 32 37 42 47 52 57 62 67 77 87 97 107 117 21 26 31 36 41 46 51 56 61 65 70 75 80 90 100 110 120 130 24 24 24 24 24 30 35 40 45 50 55 60 70 80 90 100 110 22 27 32 37 42 47 52 57 62 67 72 77 87 97 107 117 127 25 25 25 25 25 31 36 41 46 51 56 66 76 80 90 100 26 31 36 41 46 51 56 60 65 70 75 85 95 105 115 125 28 28 28 28 28 28 38 43 48 53 63 73 77 87 97 107 117 127 137 147 28 33 38 43 48 53 57,8 62,8 67,8 72,8 82,8 92,8 103 113 123 133 143 153 162 172 30 30 30 30 30 30 37 42 47 57 67 71 81 91 101 111 121 131 141 31 36 41 46 51 55 60 65 70 80 90 100 110 120 130 140 150 160 170 34 34 34 34 34 34 42 52 62 66 76 86 96 106 116 126 136 38 43 48 53 58 63 68 78 88 98 108 118 128 138 148 158 168 39 39 39 39 39 51 55 65 75 85 95 105 115 125 47 52 57 62 72 82 92 102 112 122 132 142 152 162 min. max. min. max. M12 M16 M20 M22 min. max. M24 min. max. M27 min. max. M30 min. max. M36 min. max. S t min and S t max

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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5.1.1.2 Bolts according to EN 14399-4 (HV type)

For joints bolted with bolts type HV according to EN 14399-4 the suitable bolt length in function of the clamp length may be defined with the following table (extracted from the Appendix 1 of EN 14399-4 Table 2 - HV type bolt length in function of Clamp Length

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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

Presentation (shop pre-assembly)

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.

5.3.1 Support and fixing devices

The required material, the extensions and the modalities for carrying out the preassembling, when required, shall be discussed with API who will reserve the right to accept or reject the Constructors proposals. Tack welding use is forbidden for pieces assembling in preassembling or erection phase.

5.3.2 Holes correspondence check and spinning

Any adaptation and/or adjustment activity of prefabricated elements during the assembling on site (due to misalignment of holes, cuts, addition of materials, over tolerances, etc.), if attributable to the responsibility of the Manufacturer, shall be charged to him.

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.

5.4.1 Shear bolting

Bolts only subject to shear: it is allowed a tightening reduction to the 80% of the design preload as quoted in EN 1090-1 8.6 on condition that the suitable measure against the auto- screwing off is specified. In any case vertical axis bolts must be assembled with upwards head. Bolts also subject to axial load (preloaded bolts): bolts must be tightened to 100% of the value quoted in EN 1090-1 8.6.

5.4.2 Friction bolts

All bolts must be tightened to 100% of the value quoted in EN 1090-1 8.6. 6. CHECK

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.