Corus Tubes library publication

The contents of this publication are current, when republished it will be in the new Corus housestyle.

SHS Jointing Flowdrill & Hollo-Bolt

Flowdrill&Hollo-Bolt

Flowdrill & Hollo-Bolt Jointing

for Hollow Sections
Flowdrill and Hollo-Bolt give a choice of two methods to produce bolted joints in Hollow Sections. Both systems offer the following benefits: q They produce bolted joints of structural capacity in Hot Finished Rectangular Hollow Sections (HFRHS). q They minimise the change in the fabrication process by using connection details which are standard in the construction industry. q They reduce fabrication by removing the need to weld plates or other fittings onto the outside surface of the RHS. q They simplify erection by using fully threaded bolts -an increasing practice in the construction industry. q They maintain aesthetics by producing a flush face on the RHS after fabrication.

Design Guidance
The design guidance produced in this publication is for Flowdrill and Hollo-Bolt systems with grade 8.8 bolts in conjunction with Tubes and Pipes hot finished structural hollow sections. The design guidance, for joints in simple construction, result from Tubes & Pipes initial research work undertaken in connection with CIDECT (Ref. 1). The guidance complements the information published by the BCSA/SCI and is presented in a form compatible with their publication Joints in Simple Construction (Ref. 2). Further test work is being undertaken to establish design guidance for semi-rigid joints. Procedural checks are given for bearing, shear and local bolt pull out of the RHS wall and for the combined effect of the column axial load and the structural integrity tensile load of BS 5950 : Part 1. The combined check for the column axial load and the structural integrity tensile load recognises that the flexibility of the RHS face caused by the tensile load can, in the presence of the column axial load, reduce the overall joint capacity.

Fabrication and Construction

General detailing recommendations for beam column connections, given in this publication, are in accordance with the BCSA/SCI publication -Joints in Simple Construction (Ref. 2). Both Flowdrill and Hollo-Bolt use fully threaded bolts which allows standardisation of bolt lengths throughout the construction. Where beams are connected to adjacent faces of an RHS column a check must be made with the chosen bolt length to ensure that assembly is possible (see Fig. 3 and 6) and the bolts do not touch. Both Flowdrill and Hollo-Bolt are suitable for use with the two standard grades of Tubes & Pipes SHS to BS EN10210-1 of S275J2H and S355J2H (formerly BS4360 Gr43D and 50D respectively). At present, application of the Flowdrill process is limited to RHS thicknesses up to and including 12.5mm. For thicknesses of 16mm and over, conventional drill and tap methods are recommended, although due to the RHS material strength being lower than that of the grade 8.8 bolts, pull out strengths may be below the bolt tension capacity.

Flowdrill
Reference 1. Comit International pour le Dveloppment et ltude de la Construction Tubulaire UK Member British Steel plc Tubes & Pipes PO Box 101 Corby Northants NN17 5UA 2. Joints in Simple Construction Volume 1 : Design methods Volume 2 : Practical applications Published jointly by: BCSA SCI 4 Whitehall Court Silwood Park Westminster Ascot London Berks SL5 7QN SW1A 2ES

Hollo-Bolt

Flowdrill

Flowdrilling is basically a thermal drilling process which makes a hole through the wall of a structural hollow section without the removal of metal normally associated with a drilling process. The formed hole is then threaded by the use of a roll thread forming tool, leaving a threaded hole which will accept a standard fully threaded bolt.

The Tools

Flowdrill
The Process

The initial hole is made by a Flowdrill tool consisting of a tungsten carbide bit held in a Flowdrill Morsetaper collet adaptor (Fig. 1). The tool can be used in a conventional drilling machine or CNC machine as found in fabricators works, provided it has adequate horsepower and spindle speed.

1st stage
The tungsten carbide bit is brought into contact with the RHS wall where it generates sufficient heat to soften the steel. The bit is then advanced through the wall and in so doing the metal is redistributed (or flows) to form an internal bush. As well as drilling the initial hole, the tool is fitted with the means of removing any surplus material which may arise on the outside of the RHS section. The cycle time for Flowdrilling is similar to that for conventional drilling. However, if done on CNC machines the feed rate can be slow at the beginning, rapidly increasing as the material softens to improve efficiency.

Fig. 1

Tool holder

Collet Flowdrill bit

2nd stage
The 2nd and final stage is to tap the Flowdrill bush. This is done by roll threading the bush with a Coldform Flowtap. The complete cycle is shown in Figure 2.

Fig. 2

1st Stage

2nd Stage

Flowdrill data : The Flowdrill system was developed by Flowdrill BV in Holland, and is available in the UK from their agent - Robert Speck Ltd,. Little Ridge, Whittlebury Road, Silverstone, Northants NN12 8UD. Tel: 01327 857307 Contact Mr Mike Carpenter.

Drilling machine parameters : Table 1 gives a guide to required machine parameters for producing Flowdrill holes for M12 to M24 bolts: Note: The Flowdrill process is not suitable for hand held or magnetic clamp type drilling equipment when used in the sizes shown.

Thread size Flowdrill size M/c spindle speed rpm M/c feed rate Motor power KW Min Tapping speed rpm

M12 10.9

M16 14.8

M20 18.7

M24 22.5

1000-1500 700-1100

600-1000

500-800

0.1/0.15mm (0.004/0.006 inches) per rev 2 2.5 3.5 5

250

200 Table 1

150

100

Flowdrill Length Max material thickness (mm) 3 5 6 8 10 12 16 Thread Size M12 Short Long Long Long M16 Short Short Long Long Long Table 2 M20 Short Short Short Long Long Long M24 Short Short Short Long Long Long -

Drill length: The recommended length of Flowdrill bits varies with the thread size and thickness of material as given in Table 2. Drill care: Flowdrills are made from tungsten carbide. They are extremely hard but cannot withstand shock loads. After drilling each hole, FD KS paste should be applied to the Flowdrill whilst it is still hot, so minimising oxidation and preventing build up on the surface. Flat surface: the raised rim on the outer surface of the RHS material caused during Flowdrilling should be removed using Flowdrills with cutting edges provided on the collar. One rotation of the cutter is all that is required to remove the rim.

Flowdrill detailing requirements. See Fig. 3 and Table 3. Note: q Flowdrilled joints used at locations exposed to the weather should not be considered as water tight. q Flowdrilling is not suitable for use with pre-galvanised materials.
tc

Width Fig. 3

Min bolt centres

E1

tp Lb A1 D1 B1 C1 E1

Dimensions (mm) A1 B1 C1 D1 E1 Minimum

Thread size/Bolt diameter M12 7 13 18 M16 10 17 20 M20 12 22 26 M24 15 25 29

Varies with overall bolt length (Lb) specified C1/2 + tc (for connection made to a single face or opposite faces) B1/2 + A1 + D1 + tc (for connection made to adlacent faces)

Min Bolt Centres

30

40

50

60

Table 3 (See Fig. 3 for nomenclature)

Hollo-Bolt HOLLO-BOLT is a pre-assembled

three part fitting consisting of body, cone and bolt.

Hollo-Bolt

The pre-assembled unit (Fig. 4) is inserted through normal tolerance holes in both the attatchment plate and the RHS. As the bolt is tightened the cone is drawn into the body, spreading the legs, and forming a secure fixing. Once installed only the Hollo-Bolt head and collar are visible (Fig. 5).

Fig. 4

The Hollo-Bolt

Hexagon Head

Location Flats

Collar

Fixture

RHS Body Cone

Legs Cone Knurling Central Bolt

Fig. 5

Further information on Hollo-Bolt is available from

Lindapter International A Division of Victaulic plc., Lindsay House, Brackenbeck Road, Bradford, West Yorkshire, Tel: 01274 521444 England, BD7 2NF Fax: 01274 521130

Drilling requirements: Hollo-Bolt uses a plain drilled hole which can be made on site or in the fabrication shop using all normal drilling equipment. The finished hole should have a tolerance of -0.2mm to +1.0mm from the nominal given in the data table (Table 4).

Bolt size

Bolt Fixing Bolt Internal Edge Bolt length thickness centres min. edge distance hole (V) (W) (X) distance (E1) dia. Min Max Min (Y) Min (Dh) mm mm mm mm mm mm 45 49 53 57 80 3 3 3 3 3 22 22 25 28 34 35 40 50 55 70 13 15 18 20 25 50-tp 55-tp 60-tp 65-tp 90-tp 14 18 20 26 33

Across Tightening flats torque main body mm Nm 19 24 30 36 46 21 40 78 190 300

M8 M10 M12 M16 M20

Width

Table 4 (See Fig. 6 for nomenclature)

Fig. 6 tp V E1

tc W

Material Options Standard product is manufactured from mild steel and is electro-zinc plated with the addition of JS500 1000 hour saltspray corrosion protection. The central fastener is a grade 8.8 bolt. For special applications, the Hollo-Bolt is available manufactured from 316 stainless steel, with a grade A4-80 central bolt. This will not be a stocked item, and would be manufactured to order. Installation The only tools required to fit Hollo-Bolt are two spanners - an open ended spanner to hold the collar and a torque wrench to tighten the central bolt. Alternatively a power operated electric hand tool is in development. Should the steelwork need to be adjusted, the fixing can simply be removed and the hole reused with another Hollo-Bolt. Sealing Options In certain applications, it may be necessary to seal the Hollo-Bolt to prevent ingress of water or other corrosive agents. For details of sealing options available, please contact Lindapter. Special Options (manufactured to order) q Stainless steel q Button head setscrew q Socket head capscrew q Countersunk setscrew/body q Special body lengths

Fig. 7

Design of Joints in Simple Construction

Simple connections between Universal beams and RHS columns can be made using double angle web cleats or flexible end plates. The following procedural checks are compatible with the BCSA/SCI rules for Joints in Simple Construction (Ref. 2).

Double Angle Cleats

End projection t1, approx 10mm Length of cleat I 0.6D Face of column

Flexible End Plates

Length of plate I 0.6D Face of column

Cleat thickness, tp tp= 8mm or 10mm g Bolt diameter, d

Plate thickness, tp tp= 8mm or 10mm g

Bolt diameter, d

Flowdrill hole diameter, Dh Dh = d+2mm for d 24mm Dh = d+3mm for d > 24mm For Hollo-Bolt Dh see Table 4.

Notes q The cleats or end plates are generally positioned as close to the top flange of the beam as possible to provide adequate positional restraint and a plate length of at least 0.6D is usually adopted to give adequate torsional restraint (BS 5950: Part 1, Table 9). q Bolt gauge g: 90mm g 140mm, but g 0.3 x RHS face width B. q Although it may be possible to satisfy the design requirements with tp< 8mm, it is not recommended in practice because of the likelihood of weld distortion during fabrication and damage during transportation. q The plate thickness and gauge limitations apply equally to partial depth and to full depth end plates. If necessary, to comply with structural integrity requirements for a 75 kN tie force, the connection must have at least 2 no. M20, Grade 8.8 bolts in tension with / 140mm, t 8mm and g 140mm.

Local shear and bearing capacity of the RHS column wall and bolts. Basic Requirement For Shear Q Pv _ 2 Pv = = Av Avnet n p d = = = = = local shear capacity of RHS column wall smaller of 0.6pyc Av and 0.5 Usc Avnet [g/2 + (n -1) p = et] tc with [et 5 d] Av - n d tc number of rows of bolts bolt pitch nominal bolt diameter (or hole diameter in RHS columns for Hollo-Bolt) bolt gauge width RHS column wall thickness design strength of RHS colunm wall (S275 = 275 N/mm2 : S355 = 355 N/mm2) ultimate tensile strength of RHS column wall
et p n rows of bolts g p p

Critical sections

tc

Q/2 Q

Q/2

g tc pyc

= = =

Usc

For bearing Q _ 2 Pbsc pbsc = = Pbsc bearing capacity of the RHS column wall per bolt = d tc pbsc bearing strength of the RHS column wall (S275 = 460 N/mm2 : S355 = 550 N/mm2)

Flowdrill Bolt diameter M12 M16 M20 M24 kN 31.6 58.9 91.9 132

Flowdrill Bolt diameter M8 M10 M12 M16 M20 kN 12 25 38 75 100 -

Bolt Check (Table 5) The single shear capacity for Flowdrill and Hollo-Bolt can be taken as follows:-

Structural integrity-local bolt pull-out of RHS colmn wall. Note: This check is only needed if it is necessary to comply with structural integrity requirements. Basic Requirement Tie force Local bolts pull-out resistances Local bolt pull-out resistances = 2 n Pp(si) The local bolt pull-out design resistance in kN of a grade 8.8 bolt in a flowdrilled hole or a Hollo-Bolt should be taken from the following tables which are based on test results:
Flowdrill normal design strength (Pp(n)kN Bolt diameter mm 5 M16 M20 M24 46 70 80 RHS column wall thickness tc mm Grade S275 (Grade 43) 6.3 60 85 101 95 122 8 10 70 97 134 110 159 12.5 Grade S355 (Grade 50) 5 59 102 103 130 6.3 8-12.5 70 110 159
n rows of bolts (critical bolts are those in the column) Tie force

Note: 1. The tension capacity of Grade 8.8 bolts for normal design and for structural integrity design is shown in the shaded areas. 2. The pull-out resistances for structural integrity Pp(si) are less than those for normal design because the design method presented here for structural integrity leads to thinner cleats or end plates than for normal design methods, based on BS 5950: Part 1, and, as a result, will lead to higher prying forces. This has been taken into account in the quoted resistances.

Table 6

Flowdrill structural integrity design strength (Pp(si)kN Bolt diameter mm 5 M16 M20 M24 30 46 53 RHS column wall thickness tc mm Grade S275 (Grade 43) 6.3 40 56 67 63 81 8 10 46 65 89 73 106 12.5 Grade S355 (Grade 50) 5 39 68 68 86 6.3 8-12.5 46 73 106

Table 7 Hollo-Bolt design strengths

Bolt diameter mm M8 M10 M12 M16 M20

Normal design strength (Pp(n)) kN 16 26 38 70 110

Table 8

Structural integrity design strength (Pp(si)) kN 10 17 25 46 73

Structural integrity - tie force capacity of RHS column wall in the presence of axial compression in the column. Note: This check is only needed if it is necessary to comply with structural integrity requirements.
Bolt holes deducted B

Basic Requirement Tie force Tying capacity of RHS column wall Tying capacity of RHS column wall 8 mu = ( 1+ 1.5 (1 - 1)0.5 (1 (1 - 1) Mu = = pyc tc
1

tc p (n-1)p g 1.5 tc

0.5 1) ) Tie force (applied at bolt positions)

moment capacity of RHS column wall per unit length pyctc2 4

Yield lines

= = =

design strength of the RHS column (S275 = 275 N/mm2 : S355 = 355 N/mm2) thickness of RHS column wall n (n - 1)p - d 2 (B - 3tc) g (B - 3tc) d (B - 3tc) overall width of RHS column wall to which the connection is made. bolt diameter (or hole diameter in RHS column for Hollo-Bolt) bolt gauge width number of rows of bolts bolt pitch

= = =

d g n p

= = = =

British Steel Tubes & Pipes PO Box 101, Weldon Road, Corby, Northants, NN17 5UA Tel: 01536 402121 Fax: 01536 404111

British Steel plc Registered Office: 9 Albert Embankment, London, SE1 7SN Reg. in England No: 2280000

TD 384.12E.95