You are on page 1of 39

BS-111 (Revision 5) Page 1/39

Research Design and Standards Organization, Lucknow


Report no BS-111 (Revision 5)
Guidelines for use of High Strength Friction Grip (HSFG) bolts on bridges on
Indian Railways

Typical splice joint with HSFG bolts


April 2016
BS-111 (Revision 5) Page 2/39

Foreword to BS-111 (Revision 5)


HSFG bolts are being adopted on steel bridges widely since last two years and this document is being
referred for guidance by the field as well as design engineers. An important feedback was received from field that
the Quality Control of bolts is not covered properly in the earlier versions of the report even though the codal
references had been given. To address this issue, a new annexure V has been added to specify not only the tests
required for quality control but also their frequency and their independent verification etc. It is hoped that this
will help the field engineers in ensuring the quality of bolts. Few other changes in this document include:
1. A & C slip no 10 of IRS B1 has been issued which incorporates the provisions regarding DTI washers and
length of bolts, which were already included in this report vide Revision 4. Accordingly, the references
have been changed to reflect the same.
2. IS:1367 Part 8 has revised version 2012 has been incorporated for torque to be given in the nuts.
3. The FAQs have been numbered Annexure III and Dos and Dont as Annexure IV.
RDSO extends hearty thanks for Mr Avadhesh and Mr Gautam Bose from M/S Panchsheel Fasteners, Mr
Rupesh Patel from M/S Loyal Enterprises And Mr Sumit Kumar Udehra from M/S Udhera Mechanical Works who
have given feedback on the report which has formed the basis of the changes in the document. The Inspection
wing for steel girders at RDSO (B & S as well as M & C dtes) have also given their feedback on practicality of
provisions, whose contribution is acknowledged here.
All the users, designers as well as field engineers are once again requested to give further feedback on
HSFG bolts to RDSO at e mail ID directorsteel2@gmail.com so that the codal provisions can be improved and
practical difficulties, if any, in implementing the guidelines are taken care of.

Executive Director (B&S) RDSO


April 2016
*********
Foreword to BS-111 (Revision 4)
The knowledge in the field of HSFG bolts is expanding as the use of these is becoming progressively more
prevalent. RDSO has already issued/ revised drawings for 25 T loading plate, composite and open web steel girders
with HSFG bolts. Issues pointed out by the users, fabricators, manufacturers are being addressed on day-to-day
basis by RDSO, but some issues have necessitated the revision of this document. Few minor changes are required
in codal provisions for which draft correction slips have been sent to Railway Board. Important changes in this
document include:
1. Codal specifications for DTI washers which were not given earlier. Now the relevant codes have been
mentioned for better quality control. 0.25 mm feeler gauge which is required for some cases of DTI
washer applications has now been incorporated.
2. Removal of ambiguity in provisions regarding projection of threads beyond the end of the bolt. The EN
code and IS code provisions are differing in this respect. The ambiguity has been resolved.
3. The sequence of tightening has been better explained pictographically. The provisions for feeler gauges to
be used with DTI washers has been changed as per provisions of EN 1090-2.
4. Some typographical errors have been rectified.
Hope the above changes and the newly added section Frequently Asked Questions to include some of
the most commonly asked questions from field and design offices will help further clarify the matter. Ms Sheela
Makwana, DyCE/ NW Rly, Dr Sanjeev Garg, DyCE/ N Rly and M/S Unbrako Fasteners deserve thanks for their
feedback and correspondence.
BS-111 (Revision 5) Page 3/39

All the users, designers as well as field engineers are once again requested to give further feedback on
HSFG bolts to RDSO at e mail ID directorsteel2@gmail.com so that the codal provisions can be improved and
practical difficulties, if any, in implementing the guidelines are taken care of.
Executive Director (B&S) RDSO
*********
Foreword to BS-111 (Revision 3)
HSFG bolts are evolving field for Indian Railways. Since the version 2 was issued, HSFG bolts have been
included in Indian Railway Codes vide:
1) Correction Slip No. 19 to IRS Steel Bridge Code.
2) Correction Slip no. 6 to IRS B1-2001.
3) Correction Slip no. 27 to IR Bridge Manual.
4) Correction Slip no. 20 to IRS Steel Bridge Code.
5) Correction Slip no. 9 to IRS B1-200
The codal/manual provisions shall apply to HSFG bolts. This report may be referred to as explanatory
handbook only and in case there is any contradiction, the codes/manuals will prevail.
This third revision of BS-111 has been necessitated to give guidance regarding torque to be applied for
tightening of bolts. The correction slips already issued have been referenced as required. Special thanks to field
engineers giving feedback, especially Girish Kumar Rao, AXEN/Con, Visakhapatnam, E. Co. Railway.
All the users, designers as well as field engineers are once again requested to give further feedback on
HSFG bolts to RDSO at e mail ID directorsteel2@gmail.com so that the codal provisions can be improved and
practical difficulties, if any, in implementing the guidelines are taken care of.

Executive Director (B&S) RDSO

*********

Foreword to BS-111 (Revision 2)


The guidelines (no BS-111) for use of High Strength Friction Grip Bolts (HSFG) on bridges on Indian
Railways was issued in June-2012. The same was revised in July 2013 to incorporate the feedback received from
the various railways. A matter regarding the thickness of aluminium metallising was raised by CBE, Northern
Railway and this led to discovery of a few bugs in the previous version, so the version 2 of the BS-111 is being
issued
RDSO has already proposed correction slips to IRSB1, IRBM and Steel Bridge Code on the basis of this
report. It may be noted that BS-111 was issued as a compilation of the codal provisions in the field of High Strength
Friction Grip bolts. After the issue of the correction slips to the various codes/manuals, the provisions therein will
govern. This document, however, will still remain useful in the form of commentary for the codal provisions.
All the users, designers as well as field engineers are requested to give further feedback on HSFG bolts to
RDSO at e mail ID directorsteel2@gmail.com so that the codal provisions can be improved and practical
difficulties, if any, in implementing the guidelines are taken care of.

Executive Director (B&S) RDSO


BS-111 (Revision 5) Page 4/39

Foreword to BS-111(Revision1)
The guidelines for use of High Strength Friction Grip Bolts (HSFG) on bridges on Indian Railways
was issued in June-2012. This is a new field for Indian Railways and lots of issues have been raised by the
users, designers and field engineers. There has been need to modify certain provisions to ensure smooth
field working and so a need for revision in the original guidelines issued has arisen.
The following major changes have been made in the revised guidelines:-
1. In para 7.II. the nominal diameter of hole has been changed from 2mm to 1.5mm more than
bolt diameter for bolts having diameter less than 25mm and 2mm more than the bolt
diameter for larger diameter bolts. This para has been added so that hole diameter is same
as used for rivets.
2. Para 8, sub-para VII has been modified to cover different cases of provision of washers in
field including DTI washers as old provisions were creating some confusion.
3. In para 10.I.c). a sub-clause vi is added describing Personnel for Tightening. This para has
been added for better quality control.
4. In para 10.II.b).iv, the 0.1mm feeler gauge has been specified to be used for checking and
term refusal has been defined.
5. In para 12.II.(c), the para regarding use of HSFG bolts for repair/rehabilitation work has been
reworded to make it more clear.
6. In para 12.III, the para on painting has been replaced by a para specifying Painting during
initial installation and Painting in service. This is as per feedback received.
7. Table 2 and Annexure D of IS:4000 have been provided at the end of report for ready
reference of engineers.
8. In addition, minor changes have been made in wordings etc. in paras 8.II.a), para 9, para
10.I.c).iii, para 10.III.iii and para 10.VI for making these clearer.

RDSO is proposing correction slips to IRSB1, IRBM and Steel Bridge Code on the basis of these
revisions. All the users, designers as well as field engineers are requested to give further feedback on
HSFG bolts to RDSO at e mail ID directorsteel2@gmail.com so that the codal provisions can be improved
and practical difficulties, if any, in implementing the guidelines are taken care of.

Executive Director (B&S) RDSO


*************
BS-111 (Revision 5) Page 5/39

Foreword
Steel is an important material for construction of bridges. The connections in shop are now being made
by submerged arc welding. But for field connections, rivets have been traditionally used. The riveted
connections have served us well for over 150 years. But the rivets pose some difficulties:
1. In difficult and inaccessible areas, making rivets is difficult and often quality of rivets in such
locations is very poor.
2. For large grips, longer rivets are required. The shanks of these rivets are difficult to be heated
uniformly and while transporting the hot rivets, the same get differentially cooled and the rivets are
not able to completely fill up the annular space all round.
3. With changing times, Indian Railways and the only major organization in India still using
structural rivets and the availability of skilled labour required for riveting is diminishing.
RDSO has been seized of these issues and has been looking for replacement of the rivets with some
other type of connections and High Strength Friction Grip (HSFG) bolts have been found suitable for the
same. These can be used in road bridges as their use has been permitted by IRC codes. For railway
bridges, the relevant codes are required to be changed (clauses pertaining to design of HSFG bolts for
railway loading need to be introduced) before the HSFG bolts can be used for the same.
While preparing these guidelines IS codes, Eurocodes, American codes and literature on the subject
have been referred. The drawings issued by zonal railways incorporating HSFG bolts for ROBs were also
studied. RDSO has tried to make the guidelines comprehensive and cover the design, installation and
maintenance aspects in the same. The concerns of engineers about theft and sabotage have also been
addressed in the guidelines. The draft guidelines were published on internet for comments at RDSO
website as well IRICEN website and lots of comments have been received. RDSO is thankful to Shri
Gautam Bose from Panchsheel fasteners, Shri A Ghoshal from M/S STUP Consultants, Shri Naresh
Lalwani, SPB2, IRICEN, Shri Y S Hooda, Director ( B & S) RDSO, Shri Murthy Raju, DyCE/C/D S W Rly and
Shri Radhakrishan, SSE(B), S Rly, for their very useful comments. The comments from Shri Lalwani and
Shri Ghoshal were in detail and RDSO is thankful to them for devoting so much time for studying the
draft guidelines closely.
The comments received have been incorporated in the guidelines. All the users, designers as well as
field engineers are requested to give the feedback on HSFG bolts to RDSO at e mail id
directorsteel2@gmail.com so that the codal provisions can be improved and practical difficulties, if any,
in implementing the guidelines are taken care of.

Executive Director ( B& S) RDSO


June 2012
*************
BS-111 (Revision 5) Page 6/39

Basics about HSFG Bolts


1. Introduction: Rivets have been used historically for making field connections in steel girders
subject to railway and highway loadings. Rivets, however, require skilled workers and elaborate
equipment/arrangements. With passage of time, the availability of such labour and equipment
for small quantum of work is becoming difficult and Indian Railways (IR) is looking for
alternatives to rivets. Also, rivets are difficult to make when the grip length increases as the
uniform heating of longer rivets and also ensuring that rivets do not cool down before the same
is driven becomes problematic in field. One option for substitute for rivets, namely High
Strength Friction Grip (HSFG) bolts is covered in these guidelines. HSFG bolts are high strength
structural bolts which have been tightened such as to induce predefined tension in the bolt
shank. Due to the tension in the bolt, the interface between the plies (steel members in a joint)
cannot move relative to each other because of the frictional resistance. The bolts act differently
than normal bolts or rivets as explained below:

Ordinary Bolt action 1: Bearing of bolt/ plate

Ordinary Bolt action 2: Shearing of bolt

HSFG Bolt Action: Friction along interface transmits shear load


2. Scope: These guidelines cover the use of HSFG bolts in friction type joints for bridges covered by
IRS Steel Bridge Code, from sizes M16 to M36. Galvanized bolts are not covered in these
guidelines. These guidelines are intended to help better understanding of the codal provisions.
BS-111 (Revision 5) Page 7/39

For actual design/ use, the source codes shall be referred to and followed. These guidelines
cover the use of HSFG bolts in Road Over Bridges as well as Railway Bridges. At the moment, IRC
codes allow use of HSFG bolts and with issue of correction slips to codes for incorporating
provisions related to HSFG bolts, HSFG bolts can be used as an alternative to the rivets in all
types of railway bridges. RDSO is modifying all standard drawings from rivets to HSFG bolts. Due
to different actions, HSFG bolts cannot be used in conjunction with rivets/ welds in same joint
without considering the structural action
3. Hierarchy of Codes: The guidelines have been prepared based on IS and EN codes, with
modifications to suit the conditions for Indian railways. The hierarchy of codes shall be as
follows:
I. Provisions of IRS codes.
II. Where IRS codes are silent, relevant IS codes may be referred.
III. Where both IRS and IS codes are silent, EN codes may be referred.
4. Reference Codes:
I. IS 4000: 1992 High Strength Bolts in Steel structures code of Practice.
II. IS 3757 1985 (reaffirmed 2003) Specifications for high strength structural bolts.
III. IS 6623:2004 - High Strength Structural Nuts - Specifications
IV. IS 6649:1985 - Specification for Hardened and Tempered Washers for High Strength
Structural Bolts and Nuts.
V. IS 1367 (Part 8): 2012 Prevailing Torque type Steel Hexagon Nuts - Mechanical and
Performance properties.
VI. IS 1367 (Part XII):1983(reaffirmed 2001) Phosphate coatings for threaded fasteners.
VII. IS 1367 (Part 6) 1994 (reaffirmed 2004) Mechanical properties and test methods for
nuts with specified proof loads
VIII. EN 1993-1-8: 2005 Design of Steel Structures design of joints
IX. EN 14399 Part 1 to 10High strength structural bolting for preloading.
X. EN-1090-2: 2008, Execution of Steel Structures and Aluminium Structures part 2
Technical Requirements for Steel Structures.
5. Types of Bolts: For the purpose of HSFG connections, only high strength structural bolts can be
used. IS 4000 gives two property classes: 8.8 and 10.9 for the same. Bolts shall conform to IS
3757. The bolts have the following characteristics:
I. Property class: A property class has two parts separated by a decimal in the form x.y.
The first part, x, indicates 1/100 of the nominal tensile strength in Newton per sq mm
and y indicates ten times the ratio of the lower yield stress and nominal tensile
strength.1 For example, property class 8.8 means that the bolt will have nominal
Ultimate Tensile strength of 800 N/mm2, and lower yield stress of 80% of 800 N/mm2,
i.e. 640 N/mm2.
II. Identification: The property class of bolts (8.8 or 10.9) shall be embossed or indented as
8S or 10S respectively on the top of head along with the manufacturers identification

1
Clause 3 of IS 1367(Part 3).
BS-111 (Revision 5) Page 8/39

symbol.2Alternately, marking 8.8 S or 10.9 S are also acceptable. The suffix S here
denotes that the bolt is high strength structural bolt with a large series hexagon.

(a)

(b) (c)
Figure: (a)A bolt assembly (b)Typical Marking on bolt-heads (c) Actual bolt head with
markings
III. Diameter: IS 4000 gives diameters of HSFG bolts as M16, M20, M24, M30 and M36.
Other sizes given in IS1367 includeM18, M22 and M27 (Referred to as non-preferred
sizes also). For bridge works, these can be used and M22 size is readily available in the
market.
Bolt head DTI Washer

Plies or
members

2nd Washer Threads inside the


member
Packing Washer(s), if any
Threads projection
Nut

Fig: Typical Assembly of HSFG bolt

2
Clause 9 of IS 3757.
BS-111 (Revision 5) Page 9/39

IV. Length: The length of bolt shall be chosen such as to hold the steel members in position,
with provision for the nut, washer(s) and some projection beyond the bolt. Along with
the overall length of the bolt, the thread length has to be specified. At least 4 full
threads shall remain clear between the bearing surface of the nut and unthreaded part
of the shank3 (This means that at least 4 threads shall extend into the members being
joined by the bolt). The minimum length of bolt shall be worked out on the basis of
maximum grip length covering maximum limits of ply thickness (covering ply thicknesses
and all washers minus one standard washer) plus an additional allowance4 given in table
1 of IS 4000. Table 1 of IS 4000 is reproduced below:
Nominal Size of Bolt Nominal Dia of Bolt Allowance for Grip in mm
M 16 16 26
M 20 20 31
M 24 24 36
M 30 30 42
M 36 36 48
Table 1 of IS 4000
For M 22 bolts, the allowance for grip shall be 34 mm. Most manufacturers have ready
tables for the bolt lengths depending upon the steel plates to be gripped. Still, it will be
prudent on the part of the field engineer to cross check the computations before
ordering the bolts. Maximum grip length of all plies, including packings and packing
washers, shall not exceed 10 times the nominal diameter of the bolt.
V. Surface Finish: All bolts shall be supplied with coating consisting of zinc phosphate that
is used in conjunction with suitable oil of rust preventive type as per IS 1367 (Part XII).
VI. Other Types of Bolts: There are other types of bolts, called twist-off bolts which have an
additional stem at the end, which are tightened using double acting torque wrenches
and the additional leg twists off when the desired torque is reached. The twist off occurs
due to the torque applied and is not a direct indicator of the force in the bolt. For rusted
bolts, the value of force in bolt may be appreciably less than that indicated by torque,
hence these bolts has not been favoured for use on Indian Railways.
6. Nut: Each bolt shall be tightened using a high strength nut, conforming to IS 6623. The nut has
to be strong enough to be able to impart the necessary torque to the bolt and also withstand
the force during the life of the structure. Further, the threads in nut shall be matching with the
threads in the HSFG bolt and the nut shall be free running on the threads of the HSFG bolts.
I. Property Class:5Nuts are designated by property class designation, which is equal to
1/100 of the minimum tensile strength in Newton per square mm of the bolt. For HSFG
bolts, the property classes to be used are 8, and 10 as specified in IS 1367 (Part 6),
suitable for bolts of property class 8.8 and 10.9 respectively. The nuts shall be hardened

3
Clause 28.9.4(ii) of IRS B1.
4
Clause 28.9.4 (iii) of IRS B1 and clause 4.1.1 of IS 4000.
5
IS 3767 (Part 8).
BS-111 (Revision 5) Page 10/39

and then tempered at a temperature of at least 4250C.6 Normal height of nut shall be
more than 0.8 times the nominal bolt diameter.
II. Identification of Nut: The nuts have the following markings:7
a) Manufacturers identification symbol.
b) Property class, marked as 8S or 10S. (The suffix S denotes a high strength
structural nut with a large series hexagon.) Alternately, 8.8 S or 10.9 S are
also acceptable.

Fig: Typical markings on nuts


The marking shall be either on the top or the bottom face of double chamfered nuts and
shall be either indented or embossed on non bearing surface of washer faced nuts.
III. Surface of Nut: All nuts shall be supplied with coating consisting of zinc phosphate that
is used in conjunction with suitable oil of rust preventive type as per IS:1367 (Part XII).
IV. Position of nut in bolt: HSFG bolt cannot be easily opened out except by use of torque
wrench. Still, as an additional precaution, it may be ensured that the nut is not easily
accessible for opening out by anti-social elements, the same shall be provided
preferably as follows:
a) In girder web: Towards outside of the girder.
b) In flanges: Towards bottom (Except when in composite construction).
c) In composite construction: Towards inside of concrete.
d) In bracing: Towards the rolled section side so that the space for rotation of the
nut is not readily available.
e) Where Tapered washer is used, the nut shall preferably be on the other side.
7. Holes for HSFG Bolts: Normal holes in the steel members being connected by the rivets shall be
used for HSFG bolts also, subject to the following:
I. Making of holes: The holes shall be made by drilling only.
II. Nominal Diameter of Hole: The actual diameter of hole shall be 1.5 mm more than the
bolt diameter8 for less than 25mm dia. bolts and 2 mm more than nominal dia. of HSFG
bolts for larger diameters i.e. for 20 mm dia HSFG bolt, the hole shall be 21.5 mm in
diameter.

6
Clause 5.1 of IS 6623.
7
Clause 10 of IS 6623.
8
Clause 6.1 of IS 4000 provides for 2mm extra for friction type joints. However, the same has been kept as 1.5mm
till 25mm for uniformity with holes made for rivets.
BS-111 (Revision 5) Page 11/39

III. Oversize Holes: In case the bolts are to be provided in existing structure, the maximum
size of hole shall not exceed 1.25 d or d + 4 mm whichever is less i.e. for 16 mm dia bolt,
the maximum diameter of hole shall not exceed 20 mm and for 24 mm dia bolt, the
maximum diameter shall not exceed 28 mm.9
IV. Use of Hardened Washers: In case the hole diameter exceeds the bolt diameter by 2
mm, hardened washers shall be used in place of normal washers.
8. Washer: Annular rings which are provided between the bolt head/ nut and the members being
joined are called washers. Washers for HSFG bolts shall conform to IS 6649. The washers have
the following characteristics:
I. Types: Three types of washers have been specified in IS 6649, clause 2:
a) Type A: Plain hole circular washers.
b) Type B: Square taper washers for use with channels (60 taper)
c) Type C: Square taper washers for use with I-beams (80 taper)
Identification: Type A washers shall be identified by provision of two nibs (small
projections) and manufacturers identification symbol in indented character. The type B
and C washers shall be identified by the type identification symbol, B or C and the
manufacturers identification symbol.10

Nib

Fig: Typical markings/shapes on plain and tapered washers

Photo: Typical hardened washer


II. Categories of washers:
a) Plain washer: Plain washers are used where other washers are not being used.

9
As per para 7.12.5 of IRS Steel Bridge Code.
10
Clause 12 of IS 6649.
BS-111 (Revision 5) Page 12/39

b) Packing washers: If the bolt is longer than required, plain washers may be used as
packing washers. However, the maximum number of packing washers shall be
limited to 3, with maximum total combined thickness of 12 mm.11
c) Hardened washer: For oversize holes, hardened washers shall be used.12 These
washers are required to prevent punching of the nut in the annular space around the
bolt shank.
Note: IS 6649 specifies only one type of washers, which are through hardened and
tempered13, so all the terms a), b) and c) above refer to the same type of washer only.
d) Tapered Washer: Where the angle between the axis of bolt and the joint surface is
more than 3 degree off normal, a tapered washer shall be used against the tapered
surface. Non rotating surface shall preferably be placed against tapered washer.14
III. Surface Finish: All washers (except DTIs) shall be supplied with coating consisting of zinc
phosphate that is used in conjunction with suitable oil of rust preventive type as per IS
1367 (Part XII).
IV. Dimensional Deviation for washers: All washers shall be flat with a maximum deviation
not exceeding 0.25 mm from straight edge laid along a line passing through the center
of the hole.15
V. Direct Tension Indicators (DTI): The Direct Tension Indicators are special type of
washers with projections which get pressed when tension is applied. The pressing of
projections to required level indicates that the required tension has been applied in the
bolts. Resemblance of DTIs with washers is incidental. In fact, these are precision
engineered mechanical load cell which is the most reliable method for checking HSFG
bolt tensioning. As shown in figure below, DTIs have multiple projections, between
which the feeler gauge is to be inserted to check if the bolt has been sufficiently
tightened or not. Complete closing of the projections, however, may indicate either
overtightening or poor quality material in DTI.
DTIs are very good method of ensuring that the bolts are tightened properly, and this
method of tightening shall be preferred over the method with plain washers. The DTIs
normally are patented products and shall be supplied preferably with zinc phosphate
coating, but alternatively can be with any other corrosion prevention treatment given to the
surface as specified by the manufacturer. The code which covers specifications of DTI
washers is EN 14399 Part 9, where these are referred to as Auto Torque Indicating washers.
Measuring the amount by which the indentations have been pressed indicate if the
bolts have been tightened to the desired tension level. The DTIs used shall be the ones
which are compatible metallurgically and also suitable for the bolts of property class 8.8 and

11
Clause 8.2.4 of EN 1090-2
12
Clause 6.3.2 (a) of IS 4000
13
Clause 6 of IS 6649.
14
Clause 7.1.2 of IS 4000.
15
Clause 3.1 of IS 6649
BS-111 (Revision 5) Page 13/39

10.9.Suitable markings identifying the bolt manufacturer, property class of DTI and its
diameter shall be engraved suitably on the DTI. Action of DTIs is as indicated below:

Two faces of DTI

VI. Other Types of Tension Indicators: There are other proprietary tension indicators such
as those having squirting action in which material squirts off and those having rubber
projections which shear off when required tension load is applied. These tension
indicators have not been considered in these guidelines.
VII. Number of washers to be provided:
a) For HSFG bolts, minimum two washers shall be provided, one against head and one
against the nut.16 The two washers are required because of very high tension is
imparted to the bolt, which can damage the steel members, especially softer mild
steel members used on Indian Railways most commonly.
b) One DTI shall be used in one bolt. In case DTI is being provided, the same will count
as one washer, i.e. one DTI and one plain washer shall be provided.
c) DTIs shall normally be provided below the head of the bolt (with projections
towards bolt head) in case nut is rotated. In case the bolt is to be rotated, DTI shall
normally be provided under nut (with projection towards nut). In case other side is
not accessible for measuring projection gap in DTI, the DTI may be provided under
nut which is being rotated. In this case, an additional washer shall be provided on the

16
As per para 28.10.2 (iii) (a) of IRS B1.
BS-111 (Revision 5) Page 14/39

DTI side to protect the projections from damage due to the abrasion during bolt
tightening.
The same is shown in figures below:

Stationary
Head/nut

Moving
Nut/Head Stationary
Head

9. Surface preparation for steel interface before providing HSFG bolts: The steel interface
between the plies which form a joint having HSFG bolts shall have special surface preparation so
that sufficient slip factor as assumed by designer in design is available. The following surface
preparation shall be done:
I. New construction: The interface between the plies which are connected together by the
HSFG bolts shall be Aluminium metallised without any over coating. The aluminium
metallising shall be as per para 39.2.1 of IRS B1.17
II. Existing structures: The interface of plies which are to be included in the HSFG bolts
shall be cleaned by wire brushing/ flame cleaning equivalent to the surface specified in
IRBM para 217, 1 (b), (i) to (iv).18The surfaces shall be cleaned to remove all loose rust
and paint layers (Only isolated patches of coatings/ rust can remain). If, however, in
existing structures, rivets are to be replaced by bolts but no surface preparation is
possible, the slip factor shall be suitably reduced.
10. Installation of bolts:
I. Basic principles: The HSFG bolts work on the principle of applying a specified pre-load on
the joint such that the plies in the joint are joined together without any gap.
a) Basic principle of tightening: The tightening of HSFG bolts is to be done at stress level
which is beyond the yield point, i.e. the plastic flow of material shall take place. This is
important because the yield point of bolt material is well defined and after this level, the
strain increases without increase in stress, as shown in figure below:

17
IRS B1 specifies that metallising be done in two layers. The same will constitute only one coat, which shall not be
painted over.
18
As per para 28.10.3 (ii) of IRS B1.
BS-111 (Revision 5) Page 15/39

The effort through the tightening procedures is to lead the bolt into the horizontal part of the bolt
tension/ elongation curve as shown above.

Fig: Manual Torque wrenches of two different sizes


b) Tension to be given: The bolt shall be tightened to minimum loads specified in
IS:4000. For bolts subject to only tension, the force shall be Pto as specified in table 2
of IS:4000. For other joints, the same shall be as per table 3 of IS:4000, reproduced
below:
Nominal Size of Bolt Minimum Bolt Tension in kN for Bolts of property class
8.8 10.9
M 16 94.5 130
M 20 147 203
M22 182 251
M 24 212 293
M 30 337 466
M 36 490 678
Based on Table 3 of IS 4000
c) Sequence of tightening: The following steps shall be followed for
tightening of bolts:
i. The holes shall be brought in alignment by using drifts etc
such that the bolt threads are not damaged during insertion of
bolts. Drifting shall not distort the metal or enlarge the
holes.19
ii. The members being joined shall be held in position by
insertion of few HSFG bolts (tightened to first stage

19
Clause 7.1.4 of IS 4000.
BS-111 (Revision 5) Page 16/39

only).These bolts shall not be tightened to second stage till all the bolts in a joint
are inserted and tightened to first stage.
iii. After the alignment/ geometry of members is verified to be correct as per
drawings, balance bolts shall be inserted and tightened upto first stage of
tightening. The drifts inserted as above shall also be replaced by HSFG bolts one
by one.
iv. The final tightening shall not proceed until the gap between
the plates has been closed such that the residual gap, if any,
is less than 2 mm at edges.20 There shall, however, be no gap
in the central portion. In case the central portion is not in
close contact or gap at edges is more than 2 mm,
straightening of members may be done after opening out
the bolts inserted and the entire procedure i) to iii) above
shall be repeated.
v. During tightening of bolts also, the steel members can
continue to deform and hence the tightening of subsequent
bolts can lead to loosening of already tightened bolts. In
order to minimize the loosening of already tight bolts, tightening in the two stages
shall be done starting from the stiffest part to the free edges.21 Stiffest parts of
joint are generally towards the center of the joint. Bolt tightening sequence for
typical flange/web splices, based on above principles, is shown below:

vi. Personnel For Tightening: The tightening of HSFG bolts is a technical procedure.
Only trained personnel who understand the procedure shall carry out the
installation of HSFG bolts. Before any person is deployed for installation, his
knowledge of the procedure for tightening shall be checked and if found
20
Clause 8.5.1 and 8.3 of EN 1090-2
21
Clause 7.1.5 of IS 4000
BS-111 (Revision 5) Page 17/39

satisfactory, a competency certificate shall be issued by an engineer not below the


rank of ADEN or equivalent. The competency certificate once issued shall be valid
for six months. Any person deployed for installation of HSFG bolts must possess a
valid competency certificate.
II. Procedure for Installation of HSFG Bolts Using Direct Tension Indicator: This is the
preferred method of installation of HSFG bolts.
a) Calibration of Direct Tension Indicator: Before the DTI are brought to site, the same
shall be tested in the presence of engineer. Three nos. bolts of similar diameter and
property class as shall be used in the work shall be taken and installed with DTI. The
installation procedure to be followed shall be similar to the one given for plain
washers. On full tightening, the projections on DTI washers shall meet the
requirements of checks specified after second stage tightening using DTIs. Only the
DTIs which satisfy the calibration shall be brought to site for work.
b) Procedure:22The tightening is done in two stages so that the bolts already tightened
do not get loose when the subsequent bolts are tightened.
i. First Stage of Tightening: As a first stage, all bolts in the joint shall be tightened to
snug tight condition. Snug tight condition means the nut is tightened using an
ordinary wrench by an average worker, applying maximum force on the wrench.
This stage is required to bring the plies in close contact.
ii. Checks after First stage tightening: After first stage of tightening, the joint shall be
checked to see if the plies are in close contact and the clearances are not exceeded.
iii. Second Stage of Tightening: During the second stage of tightening, torque wrench
is used to tighten the bolts until the indentations on the DTI indicate full tightening.
iv. Checks after Second stage tightening:23 0.40 mm/0.25 mm thick feeler gauge shall
be used to check 100% of the bolts for proper tightening. If the DTI is provided on
the part (nut/bolt head) not being rotated, then 0.40 mm thick feeler gauge shall be
used. Else if the DTI is being provided under the part (nut/bolt head) being rotated,
0.25 mm feeler gauge shall be used. If this gauge cannot be inserted in the space
between indicator positions on a DTI, it is called a refusal. If a 0.10 mm thick feeler
gauge cannot be inserted in the space between indicator positions on a DTI, it is
called full compression of the indicator. The feeler gauge shall be used to
determine if the bolt has been sufficiently tightened, as follows:
Number of indicator Minimum number of feeler gauge
positions in DTI washer refusals*
4 3
5 3
6 4
7 4
8 5

22
Based on clause 8.5.6 of EN 1090-2.
23
Clause 28.10.6 (d) of IRS B1 and Annexure J of EN 1090-2.
BS-111 (Revision 5) Page 18/39

9 5
*No more than 10% of the indicators in a connection bolt group
shall exhibit full compression of the indicator.

The procedure for checking the proper tightening of bolt using DTI is shown in the figures below.

Fig: Inserting feeler gauge in space between indicator positions

Fig: Method of checking the correct tensioning using DTI


The total number of indicators in a bolt connection shall be counted and it shall be ensured that not
more than 10% exhibit full closure i.e. zero gap after tightening.
III. Procedure for Installation of HSFG Bolts Without DTI washers: If there is some problem
with availability of DTIs, plain washers may be used for installation of HSFG bolts after
approval of SAG officer in-charge of the work, using the following procedure:
Procedure:24The tightening is done in two stages so that the bolts already tightened do not get
loose when the subsequent bolts are tightened.
i. First Stage Tightening: In the first stage, a calibrated wrench with an accuracy of 10%
shall be set to 75% of the torque computed for the complete tightening of the bolt. All
the bolts in the joint shall be tightened to this torque. After checking all bolts after the
first stage, permanent marks shall be made with suitable marker on the bolt as well as

24
Based on clause 8.5.4 of EN 1090-2.
BS-111 (Revision 5) Page 19/39

nut to indicate the relative position of the two. The mark shall be such that the same
shall be visible for inspection upto 1 year after the date of installation.
ii. Checks after first stage: After the first stage of tightening, following shall be checked:
a) The steel members that make up the plies of the joint with HSFG bolts shall be
checked for proper contact.
b) 10 % bolts shall be checked with a separate calibrated wrench set at 75% of the proof
load for the bolt and any bolt turning by more than 150 during the same shall be
rejected. If the loose bolts thus found are more than 5 but less than 1% of the total,
another 10% of the bolts shall be checked. If the total loose bolts thus found exceed
1% of the total, the torque wrench shall be calibrated afresh and the entire lot shall
be checked for tightness.
iii. Second Stage Tightening: Then the bolts shall be turned by a further amount in proper
sequence of tightening as specified below:
Total nominal thickness t of Further rotation to be applied, during
parts to be connected the second stage of tightening
(including all packing and Degrees Part turns
washers), d = dia of bolt
t < 2d 60 1/6
2d t < 6d 90 1/4
6d t 10d 120 1/3
iv. Checks after second stage tightening: After the second stage of tightening, following
shall be checked:
a) 100% bolts shall be checked and certified to have been turned through the requisite
amount by verifying the permanent marks on the nut and the bolt.
b) 1% of the bolts, subject to minimum of 10 per size of bolts shall be checked for gross
under-tightening as per procedure given in Annexure D of IS 4000.25
Annexure D of IS4000 is reproduced at Annexure I.
IV. Retensioning of bolts:
a) The HSFG bolts are tightened beyond yield stress level and undergo plastic
deformation once tightened fully. If the bolt is opened out after complete tightening,
its length gets increased permanently as compared with the initial length. The initial
few threads which transfer the load from the nut to the bolt suffer the maximum
damage. Therefore, a bolt completely tightened shall not be reused under any
circumstances.26
b) The bolt tensioned completely can be identified by damage to the threads especially
near the front end of nut where most of the load is transferred. The coating, if any,
may also show signs of damage. The free running of the nut on the threads may also
be affected.

25
As per clause no. 28.10.7 (iv) b) to IRS B1.
26
As per clause no. 28.10.9 (i) of IRS B1.
BS-111 (Revision 5) Page 20/39

c) A fully tensioned bolt, opened out for any reason whatsoever, needs to be rejected
and removed from the site of work. Along with the bolt, the nut, washer(s) and
DTI(s) used on that bolt also need to be rejected and removed from the site of
work.
d) A bolt which has been snug tightened or partially tightened and then opened out will
not be considered to have been retensioned and reuse of such bolts will be
permissible in the same or different holes, as required.
V. Specifications of torque wrench: Except for works of minor nature where number of
HSFG bolts to be installed is very less, only mechanical torque wrenches (pneumatic,
hydraulic, electronic etc) shall be used for tightening of bolts.27 For small quantum of
work, manual torque wrenches may be used.
VI. Calibration of torque wrench: Calibrated torque wrenches, accompanied with a
certificate to the effect, shall be brought to site. Torque wrenches shall be calibrated
periodically once in a year to an accuracy of 10%. These shall be re-calibrated in case of
any incidence involving the wrench during use resulting in heavy impact (such as fall,
mishandling etc.) or if the joint is found to have been improperly tightened using the
same. The procedure for calibration of torque wrench shall be as specified by the
manufacturer.
VII. Setting of torque in the Torque Wrench28: Torque shall be set in torque wrench as per
recommendations of bolt fabricator. The same shall be within limits specified in table 5
of IS 1367 part 8 (2014) for property class 8 nuts and table 7 of IS 1367 part 8 (2012) for
property class 10 nuts. In absence of bolt manufacturer recommendations, torque to be
applied shall be computed as 10% below the maximum value of torque given in tables of
IS: 1367 part 8 referred above. Extract of the tables are reproduced below:

27
As per clause no. 28.10.10 of IRS B1.
28
As per clause no. 28.10.7 i of IRS B1 after incorporating A&C Slip no. 9.
BS-111 (Revision 5) Page 21/39

performance
BS-111 (Revision 5) Page 22/39
BS-111 (Revision 5) Page 23/39

VIII. Other methods of Tensioning: There are other methods of tensioning, but only the two
methods outlined above have been found to be suitable as per the field conditions
prevailing on Indian Railways.
11. Economics of HSFG bolts: The HSFG bolts are direct replacements of rivets and with proper
design, the number HSFG bolts in a joint/ splice shall be less than or equal to the number of
rivets. At current prices, the cost of rivets and HSFG bolts are comparable to each other. Cost of
HSFG bolts is likely to go down as the volume of work grows and multiple manufacturers are
available. HSFG bolts bring other benefits to the railway, namely:
I. Reduced time of assembly/ erection.
II. Reduced requirement of scaffolds.
III. Less skilled manpower requirement.
IV. Less rejections and easier supervision.
V. Providing quality HSFG bolts is feasible as compared to other alternatives: welds in field
are non feasible, whereas rivets are getting difficult to execute day by day.
12. Maintenance of HSFG bolts:
I. Anti-theft and Anti-sabotage measures: Where it is apprehended that theft/sabotage
might take place, the bolt threads may be destroyed by applying welding tack to the
bolt projection beyond the nut after final tightening and inspection. The tack shall not
be more than 5 mm long and not more than 3 mm in size. It shall be especially ensured
that too much heat is not imparted to the bolt as to alter its metallurgical properties.
Alternatively, use of proven bonding agent to seize or lock the bolt in position may be
applied to the threads projecting beyond the nut29. Experimentally, RDSO has found
that HSFG bolts upto 20 mm diameter can be opened, especially in the bracing/ cross
frames near the supports or in accessible girder locations. Larger bolt diameters require
considerable force to open and cannot be opened by stealth. It may be noted that
hammering of bolts to damage its threads is likely to affect the entire bolt assembly
and is not recommended.
II. Inspection: During inspection, the bolts shall be seen for the following:
a) Broken/ missing bolts.
b) Loose bolts: The identification of loose bolts shall not normally require testing by
hitting etc. Looseness shall be identified by looking at the signs such as water ingress
in the joint, signs of rust coming from inside the joint and fine powdery material
coming out of joint etc. If it is suspected that the bolts are loose, the same shall be
checked as per procedure given in Annexure D of IS 4000. If loose bolts are found,
the same shall be marked by a round circle all around and shall be replaced
expeditiously. HSFG bolts are one time use item and retightening of these bolts is
not allowed.

29
Any bonding agent must increase the torque required for opening of bolt by minimum 200 Nm (RDSO report no.
C-226 was referred for this)
BS-111 (Revision 5) Page 24/39

III. Use of HSFG bolts for repair/rehabilitation works: Where any girder component/joint is
to be replaced, HSFG bolts shall be used as follows:
(a) Complete joint shall have HSFG bolts. HSFG bolts cannot be used for replacement of
isolated loose rivets.
(b)Proper surface preparation shall be done and joint design shall be done based on
design provisions as per para 7.12 of Steel Bridge Code. Particular care shall be taken
regarding use of appropriate slip factor for the surface preparation done.
IV. (i) Painting during initial installation: In case of HSFG bolts with Direct Tension
Indicating device, the final coat in field applied on complete structure may be applied
on HSFG bolts also. In case part turn method of tensioning is used without Direct
Tension Indicating device, the HSFG bolts shall not be painted and the permanent
location marks made on the bolts shall be visible after one year of installation.
(ii) Painting in service: HSFG bolts shall be painted as per normal painting schedules and
painting methodologies as specified in the Indian Railways Bridge Manual for the girder
as a whole.
BS-111 (Revision 5) Page 25/39

Provisions for DESIGN of HSFG Bolts (as per IRS Steel Bridge Code)
IS:4000 provides for both bearing type joints which work more or less like rivets and friction type joints
which act on friction between plies. Bearing type joints as defined in IS 4000 shall not be provided using
HSFG bolts on bridges covered by IRS Steel Bridge Code. Only friction type joints shall be provided using
HSFG bolts for all structures covered under IRS Steel Bridge Code.
1. Plies: The plates/ members joined together through HSFG bolts are called plies. To join dis-
similar members, suitable packing shall be provided if the difference in thickness is more than 1
mm. From maintenance considerations, too thin packing plates are not desirable. In design, no
additional factor need be considered for the packing thickness.30
2. Diameter of bolt: Normally, for structural design, 20 mm or 22 mm dia bolts shall be chosen.
However, if the joints are to be made smaller and for better detailing 24 mm and larger
diameter bolts can be used. The bracing can also be design with 20 mm/ 22 mm dia bolts.
However, if the load is too less, such as in foot over bridges, smaller diameter bolts can be used.
3. Diameter of hole: The nominal diameter of hole shall be 1.5 mm more than the bolt diameter31
i.e. for 20 mm dia HSFG bolt, the hole shall be 21.5 mm in diameter. If the HSFG bolts are being
used in existing structures, the oversize holes may be permitted subject to maximum of 1.25 d
or d + 4 mm, whichever is less.
4. Deduction for holes: The deduction for holes and for asymmetric connections to get the
effective area of the members shall be done in a manner similar to the one adopted for the
holes for rivets and other bolts, i.e. the gross area may be considered in compression and net
area in tension as per provisions of clause 4.3 of IRS Steel Bridge Code32.
5. Property class to be chosen: Property class 8.8 bolts are better as these are ductile and have
good reserve strength. However, if the joints are to be made smaller and/or for better detailing,
we can go for property class 10.9.
6. Slip factor to be adopted: Following values of slip factor shall be used in design:33
S No Surface Preparation of the interface between plies in a HSFG Slip factor
bolted joint
1 Surface blast cleaned and spray metallized with aluminium 0.40
(thickness> 100 m), with no overcoating
2 Surfaces cleaned by wire brushing or flame cleaning, with 0.25
loose rust and paint layers removed (Only isolated patches of
coatings/ rust can remain)
3 Any other surface preparation34 To be established as per
procedure given in
Annexure B of IS 4000.

30
Clause 5.5.1 of IS 4000
31
Clause 6.1 of IS 4000.
32
Fatigue for joints with HSFG bolts shall be taken on gross area as per detail (4) in table 9.1 of revised Appendix G
in IRS Steel Bridge Code.
33
As per clause 7.12.6.4 of IRS Steel Bridge Code.
34
Painting with alkali- zinc salicylate paint 50 to 80 is a very good option which can give good slip factor (refer
table 18 (Clause 8.4) of EN 1090-2).
BS-111 (Revision 5) Page 26/39

Note: If it is not possible to make proper surface preparations as given in 1 and 2 above, the slip
factor shall be established as per 3 above and the same shall be used for design. Otherwise, the
rivets shall be replaced by other modes such as by appropriate close tolerance turned bolts as
per IS 1364 and para 28.6 and 28.7 of IRS B1.
The preparation of surface by removal of paint is not allowed for new construction. If interface
has been painted inadvertently, the same shall be sand/grit blast cleaned and metallising shall
be done, even if the surface was already metallised.
7. Design of joints subject to shear: Most of the bolts in girders such as those that connect the
bracing, cross frames, flange angles with web etc are subject to pure shear loading only. The
design of HSFG bolts for such applications shall be such as to ensure that the shear force applied
does not exceed35:

The minimum bolt tension is as specified in table 3 of IS 4000 and factor of safety shall be 1.4
under normal loads. Where the effect of wind load has to be considered on the structure, this
factor of safety may be reduced to 1.2, provided the connections are adequate when (i) wind
forces are not considered, and (ii) wind load is not the primary loading for the purpose of
design.36
In other words, the factor of safety shall be adopted as 1.4 or 1.2 as per load case in
case of Railway girders, Road Over bridges and turn tables etc where wind load is not a primary
load.
For Foot Over Bridges, where wind load is a primary load, the same may be taken as 1.4.
8. Design of joints subject to shear as well as tension: Some joints such as the connection of the
bracket sideways on a column are of the nature of partial fixity. The bolts might be subject to
some axial loads along with shear in such a case. Due to externally applied tension, the
effective clamping action of a bolt is reduced. To account for this, bolt shall be proportioned to
satisfy the expression:

( )

The value of factor F shall be taken as 2.0 if external force is repetitive and 1.7 if non repetitive.
A question might arise here in the mind of designers that the tension in bolt ought to be
reduced to allow for the tension which is coming from the load. However, it has been found that
the actual tension change in the bolt due to the applied load is very less and the full tension may
be applied, provided the tensile load is not too much large as compared with the shear load.
9. Limitation of Shear Transmitted to Plies: The bearing force transmitted between any bolt and
any ply shall not exceed 1.2 fy x d x t where fy is yield stress of the ply, d is nominal dia. of HSFG
bolt and t is the thickness of ply. In addition, the component of force acting on the edge of a bolt

35
Clause 5.4.2 of IS 4000.
36
Clause 5.4.2 of IS 4000.
BS-111 (Revision 5) Page 27/39

in the direction of the minimum distance toward the edge of a ply shall not exceed exfy x t/
1.4.37(wheree is edge distance of bolt plus half the bolt diameter, in mm). These provisions are
meant to prevent failure of the steel members joined together by the HSFG bolts.
10. Design of joints subject to pure tension: Normally the bolts in railway application are not
subject to pure tension. However, if such joints are to be designed, the tension in the bolts shall
be limited to the values given in table 2 of IS 4000. (Which are equal to 0.6 times the minimum
bolt tension specified in table 3 of IS 4000).38 In case the bolts are subject to tension in fatigue
conditions, the minimum tensile force in the bolt shall not exceed 50% of the minimum bolt
tension values specified in table 3 of IS 4000.39 Table 2 of IS 4000 is reproduced at Annexure II.
11. Tension to be given in Bolts: All HSFG bolts shall be tightened by procedure given in para 10 to
impart the minimum tension specified in table 3 of IS: 4000 given in para10.I.b). The torque
corresponding to the bolt tension indicated shall be as specified by the manufacturer of torque
wrench.
12. Fatigue design: The HSFG bolts are pre-tensioned and the level of this tension does not change
much even when subjected to repetitive loads, so these need not be designed separately for
fatigue.40 The structural steel plies which are connected by the HSFG bolts shall be designed for
fatigue, if these are subjected to fluctuating loads as given in IRS Steel Bridge code. The fatigue
category of the steel members shall be as given in IRS Steel Bridge Code. It is worth mentioning
here that the fatigue category of members connected by HSFG bolts is higher than that for the
members connected by rivets. This is because the shank and hole edges, where stress
concentration is there in case of rivets, do not come into action in case of HSFG bolts, resulting
in better fatigue performance of members.
13. Detailing: The detailing of joints shall be done carefully ensuring that for all the bolts, access for
fixing of torque wrench head (approximately 100 mm) is available on one side while the other
side can be held with normal spanner. The detailing of the joints with HSFG bolts shall be done
as per IRS Steel Bridge Code rather than IS 800 mentioned in clause 1.3 of IS 4000.41In other
provisions also, where IS codes are referred and IRS code provisions are also available, IRS codes
shall take precedence. Where both IRS and IS codes are silent, Euro codes shall be referred.
Some provisions of the IRS Steel Bridge Code are enumerated for information below:
Provision Reference
Edge distance (Minimum) 1.75 d for sheared or hand Clause 7.5.1 of IRS Steel
flame cut edges Bridge Code
1.5 d for rolled, machine flame
cut, sawn or planed edge
Edge distance (Maximum) 4 t + 40 mm from nearest edge. Clause 7.5.2 of IRS Steel
Bridge Code
c/c spacing (Minimum) 2.5 d Clause 7.3 of IRS Steel

37
Clause 5.3.4 of IS 4000.
38
Clause 5.2 of IS 4000.
39
Clause 5.2.1 of IS 4000.
40
Clause 5.4.2 of IS 4000, subject to provisions of Clauses 5.2.1 and 5.4.3.
41
As per clause 7.12.8 of IRS Steel Bridge Code.
BS-111 (Revision 5) Page 28/39

Provision Reference
Bridge Code
c/c spacing (Maximum) Adjacent 32 t or 300 mm whichever is Clause 7.4.1 of IRS Steel
rivets in tension/ compression lesser Bridge Code
c/c spacing (Maximum) 16 t or 200 mm whichever is Clause 7.4.2 of IRS Steel
Bolts lying in direction of stress lesser Bridge Code
tension/ compression
c/c spacing (Maximum) 12 t or 200 mm whichever is Clause 7.4.2 of IRS Steel
Bolts lying in direction of stress lesser Bridge Code
compression If load is transferred by butting
in compression members, for a
length equal to 1.5 times width,
the spacing shall not exceed 4.5
d.
c/c spacing (Maximum) Staggered, 50 % more than the values Clause 7.4.3 of IRS Steel
gauge not exceeding 75 mm given in clause 7.4.2 and 7.4.3 Bridge Code
Maximum Length of Bolt The grip including the plies, Proposed correction slip to
packings and packing washers IRS Steel bridge Code.
shall not exceed 10 times the
nominal bolt diameter.
Where d is diameter of hole
t is thickness of thinner outside plate
d is the nominal diameter of the bolt/ rivet
BS-111 (Revision 5) Page 29/39

Annexure I
Annexure D of IS 4000 (Reproduced)
BS-111 (Revision 5) Page 30/39

Annexure II
Table2 of IS: 4000 (Reproduced)
BS-111 (Revision 5) Page 31/39

Annexure III
FREQUENTLY ASKED QUESTIONS
RDSO is being contacted by field/ design engineers with their queries ever since this new subject
has been introduced. Some of the most common questions are given below:
Is there an RDSO approved vendors list for HSFG bolts?
This most popular query is causing considerable distress to the bolt manufacturer and bolt users
alike. The concerns of the engineers with regards to quality of HSFG bolts are genuine as the age-old
rivets are being replaced by a new product. The matter of vendor list to be prepared by RDSO is being
discussed regularly in various fora. The latest orders with RDSO are to circulate a list of known suppliers
to facilitate the field engineers to contact the manufacturers. However, there is no approved list and
even the list of known manufacturers, if circulated by RDSO, will also be advisory in nature and any bolt
manufacturer can supply the HSFG bolts provided the bolts are as per relevant codal provisions for
which inspection may be done by zonal railways themselves or entrusted to some third party.
Which is better class 10.9 bolt or class 8.8 bolt?
HSFG bolts of class 10.9 are stronger than those of class 8.8. It is clear that for the same loads, the
number of bolts of class 10.9 will be lower than those of class 8.8. The class 10.9 bolts will, therefore, be
cheaper than class 8.8 bolts on overall basis. There are certain issues, however, which need to be
considered before we conclude the matter. The class 10.9 bolt is tightened beyond 90% of the Ultimate
Tensile Strength of the bolt. While this is efficient use of the material, it creates some problems during
tightening operations. If the torque wrenches are faulty, or due to other reasons, overload is applied to
the bolts, the margin available before the bolt breaks is quite less. This margin is 20% in case of class 8.8
bolts. Therefore, it can be concluded that the tolerance for material/ procedure inaccuracies is slightly
higher for class 8.8 bolts. But there is no denying the fact that class 10.9 bolts are ultimately cheaper
and if proper quality control is exercised, their performance is as good as that of class 8.8 bolts.
Bolts are breaking during tightening OR the bolts are unusually heating up during tightening?
What shall be done?
The problem of excessive bolt heating or bolt breaking during tightening has been reported in few
cases. Mostly it is the 10.9 class bolts where this problem has been reported but such problems can
occur in class 8.8 bolts also. Some heating of bolts is natural as lots of work is done on the bolts during
tightening procedure. More load is applied on class 10.9 bolts, so naturally these heat up more than
class 8.8 bolts. If the torque wrench is not set properly or if the threads of bolts are rusted, then even
higher work is required to be done on the bolts. This can lead to unusual heating up of the bolts. In
some cases, the bolts can get snapped also. The class 10.9 bolts which have lesser margin between the
lower yield stress and the Ultimate Tensile Strength and if there is either some manufacturing error or
over-tightening, the bolt can break also. In fact, the unusual occurrences like overheating and/or
breaking of bolts is good indicator of quality of manufacturing of the bolts. Isolated occurrences of
such nature may not be important but if larger proportion of bolts is exhibiting this problem, the
matter shall be further investigated.
Can I use class 10.9 bolts in place of class 8.8 bolts given in design? Can I only change the nut?
This is quite frequent query, especially if the class 8.8 bolts are not available. For replacing bolt
with higher category bolts, design office shall check the edge distance and check for stresses in plates
BS-111 (Revision 5) Page 32/39

connected. Mostly this is not a problem but for very thin plates or where marginal edge distance has
been provided, there can be some problem. If class 10.9 bolt is used, the tightening shall be done for
the load specified for class 10.9 bolt, otherwise the joint will not work as friction grip type and there
can be problems. If only nuts are required to be changed to a higher category, there is no problem as
nuts of higher category are stronger than those of lower category. This change can be done without
design checks and the tightening shall be done for the loads specified for class 8.8 bolts only.
Can we take supply of galvanized HSFG bolts and nuts?
The HSFG bolts/nuts prescribed for Indian Railways shall have phosphate coating as per IS 1367
(Part XII), as specified in clause 28.9.4 (v) and 28.9.5 (vi) of IRS B1. Supply of galvanized bolts/ nuts shall
not be taken as the bolts are susceptible to Liquid Metal Assisted Cracking during the hot dip galvanizing
procedure. Since the bolts are to be painted with the girders, the same corrosion protection measures
adopted for the complete girder shall be sufficient for the bolts also.
Are HSFG bolts mandatory to be used for Foot Over Bridges and cover shelters etc?
A major advantage of HSFG bolts is that the connection is much better in fatigue and there is good
amount of saving in steel due to this higher fatigue category. For structures not subjected to fatigue
loading, like Foot Over Bridges and Platform cover shelters etc, where fatigue design is not done, HSFG
bolts may not be required. For such structures, welding and load bearing bolts may provide better
options. It is definitely not mandatory to provide HSFG bolts for such structures.
Is it important to calibrate the DTI washers?
DTI washers are specially engineered load indicators. These are very important for ensuring
visually that adequate tension has been imparted to the bolt. Hence the quality of these is very
important. These shall conform to EN 14399 Part-9. It is, however, mandatory to physically prove that
these washers are performing in actual site conditions. Hence the calibration as per clause 28.9.6 (iii) of
IRS B1 shall be done.
How important is the training in HSFG bolts? Who shall check the training?
HSFG bolts being a new area, knowledge of the field engineers and personnel engaged in various
procedures linked with HSFG bolts is likely to be imperfect. Since the performance of the HSFG bolts
depends on the surface preparation and tightening methodology, it is quite important that training be
imparted on each work to the people directly linked with the HSFG bolts execution. This will serve as a
refresher for people already aware of the procedures and will help in removing any ambiguities in the
minds of people on the methodology to be followed. Special focus must be given to the Dos and
Donts during the training. The training shall be checked by an officer not below the rank of ADEN who
shall also issue competency certificates to all personnel, which shall be valid for six months as per clause
28.10.4 of IRS B1.
-0-0-0-0-0-
BS-111 (Revision 5) Page 33/39

Annexure IV
DOs AND DONTs FOR CONSTRUCTION ENGINEERS
DOs:
Do ensure that all bolts, washers and nuts are accompanied by manufacturer test
certificates and appropriate markings indicating that these bolts are as per relevant codes.
Do metallise the surface which is to be connected by the HSFG bolts, but without painting.
Do ensure that all bolts, nuts and washers are coated with zinc phosphate, sealed with suitable
oil of rust-prevention type(Only DTIs may have other surface coatings as approved by the
manufacturer).
Do make sure that there is proper storage arrangement for the bolts, nuts and washers away
from moisture, rain, dust, dirt and sunlight.
Do clean and lubricate the bolt and nut threads if these are dirty.
Do ensure that the nut moves freely on the bolt threads.
Do use only calibrated torque wrench (Calibrated within last 1 year).
Do properly check the bolts after initial tightening and after second stage tightening.
Do ensure that protrusions of the DTI are towards the bolt head or towards the nut depending
on whether the DTI is provided under the head or nut of HSFG bolt.
Do use tapered washers wherever required.
Do check the tightening procedure if bolt breaks during tightening operation. It obviously means
that the bolts are being over-tightened.
Do tighten the bolts starting from the stiffest part (middle of the joint) to the free edges.
Do provide small welding tack after final tightening and inspection to damage the threads to
prevent the bolt from being opened where threat of sabotage/ theft is apprehended.

DONTs:
Dont paint the interface which has been metallised.
Dont reuse a bolt which has been fully tightened once.
Dont use rusted and dirty bolts.
Dont hammer the bolts to damage the threads.
Dont overheat the bolt while making welding tack as the bolt might get damaged.
Dont use Direct Tension Indicators which have not been calibrated.

*********************
ANNEXURE V: QAP FOR HSFG BOLTS,NUTS AND WASHERS FOR INDIAN RAILWAYS Page 34/39

REVIEWEDBY
APPLICABLE

PERFORMED

WITNESSED
SAMPLE SIZE/

FOR
S.N.

BY

BY
ACCEPTANCE/ Independent
PARAMETER METHOD INSTRUMENT EXTENT OF LOCATION REMARK
REF. DOC Testing
CHECK

Minimum 1 IS:1367-6 for At NABL/ If Spectro-test


Analytical
B, N, No/ Nominal B and N. govern- is decisive
Chemical Spectroscopy/ instruments/ To be done
1 W, diameter or IS:6649 for W, S - Rly ment then wet
composition @ Wet Analysis/ Spectro- independently
DTI Min 1 per relevant code approved analysis not
scope required
10000 nos. for DTI lab.

@ For DTI washers, codes like ASTM F959 and EN 14399-9 are available. DTI washers are required to undergo additional testing to verify that manufacturer
claims about efficacy. Before accepting any type of DTI washer of a diameter, 3 nos. DTI washers shall be checked as per procedure given in para 28.9.6 (iii)of
IRS B1. Only those DTI washers that satisfy the acceptance testing shall be further tested and brought to site if found satisfactory.

2 Dimensions

Across flat,
Across corner,
Hex. Height,
washer dia,
Rly
washer For balance
Minimum 1 (10%
thickness, total Vernier 90%
No/Nominal
2.1 length under B Measurement Callipers/ IS:3757 S - At works - samples, IC
diameter or 1 sam-
head, thread Screw gauge to be
per 100 nos. ples )
length, Shank verified
length, shank
diameter, Mid
chamfer & end
chamfer etc

Legend: B: Bolt, N: Nut, W: Plain Washer, DTI: Direct Tension Indicator Washer;
S: SUPPLIER; Rly: Zonal Railway; IC: Inspection certificate; TC: Test certificate.
Wherever works dont have facility for any test(s), the inspecting official may allow testing to be done in any other laboratory
ANNEXURE V: QAP FOR HSFG BOLTS,NUTS AND WASHERS FOR INDIAN RAILWAYS Page 35/39

REVIEWEDBY
APPLICABLE

PERFORMED

WITNESSED
SAMPLE SIZE/

FOR
S.N.

BY

BY
ACCEPTANCE/ Independent
PARAMETER METHOD INSTRUMENT EXTENT OF LOCATION REMARK
REF. DOC Testing
CHECK

Minimum 1
Thread RING No/Nominal IS:4218 or IC to be
2.2 Threads B Thread fitment S - Rly At works -
gauge diameter or 1 ISO-965 reviewed
per 100 nos.

IS:4218 or
Minimum 1
ISO-965 for
Microscope/ No/ Nominal
Thread form, Microscopic testing and IC to be
2.3 B Profile diameter or 1 S - Rly At works -
laps etc examination IS:1367-9 sec- reviewed
projector per 10000
2 for
nos,
acceptance

Across flat, Rly


IC to be
across corner, Minimum 1 (10%
Vernier reviewed for
hex height, No/Nominal
2.4 N Measurement Callipers/ IS:6623 S - At works - balance
bearing dia, diameter or 1 sam-
Screw gauge 90%
chamfer depth per 100 nos. ples )
samples
etc

Minimum 1
Thread plug No/Nominal IS:4218 or IC to be
2.5 Threads N Thread fitment S - Rly. At works -
gauge diameter or 1 ISO 965 reviewed
per 100 nos.

Rly
Dia- IC to be
Minimum 1 (10%
Inner/Outer, Vernier IS:6649 for W, reviewed for
No/Nominal
2.6 thickness, W, DTI Measurement Callipers/ relevant code S - At works - balance
diameter or 1 sam-
protrusion Screw gauge for DTI 90%
per 100 nos. ples )
dimensions etc samples

Legend: B: Bolt, N: Nut, W: Plain Washer, DTI: Direct Tension Indicator Washer;
S: SUPPLIER; Rly: Zonal Railway; IC: Inspection certificate; TC: Test certificate.
Wherever works dont have facility for any test(s), the inspecting official may allow testing to be done in any other laboratory
ANNEXURE V: QAP FOR HSFG BOLTS,NUTS AND WASHERS FOR INDIAN RAILWAYS Page 36/39

REVIEWEDBY
APPLICABLE

PERFORMED

WITNESSED
SAMPLE SIZE/

FOR
S.N.

BY

BY
ACCEPTANCE/ Independent
PARAMETER METHOD INSTRUMENT EXTENT OF LOCATION REMARK
REF. DOC Testing
CHECK

3 Mechanical Properties

Testing as per
Minimum 1
IS:1586/
per 10000
Minimum 1 IS:1500/
Rly nos to be
No/Nominal IS:1501. TC to be
(10% got
diameter or 1 Acceptance as reviewed for
B,N,W, Hardness independ-
3.1 Hardness @ Hardness Test per 1000 nos. per IS:1367- 3 S - At works balance
DTI Tester sam- ently done
or 10 nos./ for B, IS:6623 90%
ples ) at NABL/
heat treatment for N, IS:6649 samples
government
batch for W and
approved
relevant code
Lab
for DTI.

Minimum 1
Tensile stress, per 10000
Minimum 1
Yield stress, % nos to be
No/Nominal
Elongation, % Universal/ got
diameter or 1
Reduction in tensile IS:1608, independ- TC to be
3.2 B Tensile test per 1000 nos./ S - Rly At works
area. (Where testing IS:1367-3 ently done reviewed
1 no. per heat
the part size Machine at NABL/
treatment
(nominal dia. & government
batch.
length) permits approved
Lab

Legend: B: Bolt, N: Nut, W: Plain Washer, DTI: Direct Tension Indicator Washer;
S: SUPPLIER; Rly: Zonal Railway; IC: Inspection certificate; TC: Test certificate.
Wherever works dont have facility for any test(s), the inspecting official may allow testing to be done in any other laboratory
ANNEXURE V: QAP FOR HSFG BOLTS,NUTS AND WASHERS FOR INDIAN RAILWAYS Page 37/39

REVIEWEDBY
APPLICABLE

PERFORMED

WITNESSED
SAMPLE SIZE/

FOR
S.N.

BY

BY
ACCEPTANCE/ Independent
PARAMETER METHOD INSTRUMENT EXTENT OF LOCATION REMARK
REF. DOC Testing
CHECK

Minimum 1
Wedge load per 10000
Minimum 1
test & Proof nos to be
No/Nominal
load test Universal/ got
diameter or 1 IS:1367-3 for
(Where the tensile independ- TC to be
3.3 B, N Tensile test per 1000 nos./ B, IS:6623 for S - Rly At works
product size testing ently done reviewed
1 no. per heat N.
does not Machine at NABL/
treatment
permit the government
batch
tensile test) approved
Lab

Minimum 3
No/Nominal
diameter (1
1 per 10000
Set) or 9 Nos
nos to be
per 1000 nos,
got
(3 sets)
Impact independ-
Impact whichever is TC to be
3.5 B Impact test testing IS:1367-3 S - Rly At works ently done
strength higher. Or 1 reviewed
machine at NABL/
set of 3 nos.
government
per heat
approved
treatment
Lab
batch.

Legend: B: Bolt, N: Nut, W: Plain Washer, DTI: Direct Tension Indicator Washer;
S: SUPPLIER; Rly: Zonal Railway; IC: Inspection certificate; TC: Test certificate.
Wherever works dont have facility for any test(s), the inspecting official may allow testing to be done in any other laboratory
ANNEXURE V: QAP FOR HSFG BOLTS,NUTS AND WASHERS FOR INDIAN RAILWAYS Page 38/39

REVIEWEDBY
APPLICABLE

PERFORMED

WITNESSED
SAMPLE SIZE/

FOR
S.N.

BY

BY
ACCEPTANCE/ Independent
PARAMETER METHOD INSTRUMENT EXTENT OF LOCATION REMARK
REF. DOC Testing
CHECK

4 Metallurgical tests

Minimum 1
Measurement Rly
No/Nominal IC to be
of (10%
diameter or 1 reviewed for
Decarburiz- Decarburizatio Microscopic
4.1 B per 1000 nos, IS:1367-3 S - At works - balance
ation n, examination sam-
or 1 no. per 90%
partial/complet ples )
heat treatment samples
e
batch

1 per 10000
Minimum 1 No nos to be
Rly
per Nominal got IC to be
Hardness (10%
diameter or 1 independ- reviewed for
Re tempering testing and
4.2 B Hardness Test per 1000 nos, IS:1367-3 S - At works ently done balance
test^ tempering sam-
or 1 no. per at NABL/ 90%
furnace ples )
heat treatment government samples
batch approved
Lab

^ Surface hardness of the bolts is one of the most important parameters which may affect their performance. In addition to the value of surface hardness,
depth of bolt material affected during the tempering process is also important. For verifying this, the record of temperature during the tempering process
shall also be reviewed. Continuous record of temperature during entire process of tempering shall be made available for the same. If there are doubts
about the process, bolt shall be cut and microstructure of the cross-section shall be verified.

Legend: B: Bolt, N: Nut, W: Plain Washer, DTI: Direct Tension Indicator Washer;
S: SUPPLIER; Rly: Zonal Railway; IC: Inspection certificate; TC: Test certificate.
Wherever works dont have facility for any test(s), the inspecting official may allow testing to be done in any other laboratory
ANNEXURE V: QAP FOR HSFG BOLTS,NUTS AND WASHERS FOR INDIAN RAILWAYS Page 39/39

REVIEWEDBY
APPLICABLE

PERFORMED

WITNESSED
SAMPLE SIZE/

FOR
S.N.

BY

BY
ACCEPTANCE/ Independent
PARAMETER METHOD INSTRUMENT EXTENT OF LOCATION REMARK
REF. DOC Testing
CHECK

Minimum 1 No IS:1367-9 sec Rly


IC to be
per Nominal 1 & 2 for B, (10%
reviewed for
Surface B, N, Surface diameter or 10 IS:1367-10 for
4.3 MPI test S - At works - balance
Integrity W, DTI defect per 500 nos. N, IS:6649 for sam-
90%
whichever is W, relevant ples )
samples
higher code for DTI

IS:1367-9 sec Rly


Minimum 10 IC to be
1 & 2 for B, (10%
Identification Nos or 5% of reviewed for
B, N, IS:1367-10 for
5 Visual of, any visual Visual the batch qty S - At works - balance
W, DTI N, IS:6649 for sam-
defect whichever is 90%
W, relevant ples )
higher samples
code for DTI

Mass of
coating (Zinc
Phosphate to B, N, Quality of Min. 1 per TC to be
6 # IS:1367 12 S - Rly At works -
be 2.3-4.5 W coating 10000 nos. reviewed
g/m of treated
surface)

#
DTI washers shall have coating as recommended by manufacturer and these shall be checked as per above frequency as per relevant applicable
code

Thread fitment shall be checked by thread plug gauge and assembly shall be checked for fitment during use in field. If any problems are
seen, the matter shall be referred to the manufacturer who shall be responsible for these aspects. The manufacturer shall replace bolts
and/or nuts which are not having proper threads, if problems are encountered.

-0-0-0-0-0-
Legend: B: Bolt, N: Nut, W: Plain Washer, DTI: Direct Tension Indicator Washer;
S: SUPPLIER; Rly: Zonal Railway; IC: Inspection certificate; TC: Test certificate.
Wherever works dont have facility for any test(s), the inspecting official may allow testing to be done in any other laboratory

You might also like