The British Constructional Steelwork Association Ltd

BCSA CRAFT CERTIFICATE

Competence
Route of
Attainment in a
Fabrication
Trade

Module 21 – Bolting Inspector

This module includes information that can be used to provide a basic
understanding of a specific constructional steelwork topic

BCSA CRAFT Certificate Module 21 – Bolting Inspector

Evidence Module

Introduction
This module can be used to support the employer in the process of developing and
confirming the competency of apprentices or trainees. The module includes information that
can be used to provide a basic understanding of the topic; however the candidate should also
source information from other relevant providers.

Competence
Competence is the ability to do a job to a good standard of quality, to do it safely and in a
reasonable time frame.

Validation
Validation is the process of obtaining evidence and making a judgement about the evidence.
Evidence is needed to prove competence, the company validator for this training module will
be the Bolting Coordinator and will discuss with you the most appropriate ways for you to
demonstrate and then record the evidence to be included in your module. The process will
often identify training needs and these should be discussed with the validator to ensure the
appropriate topics are covered before repeating any practical tests.

Coaches
Coaches will be nominated by the employer to help you learn the process by passing on their
experience and knowledge to you. The coach will also allow you the time to practice what
you have been taught until you are able to demonstrate that you can complete the task to an
acceptable standard, in a reasonable time and safely.

Evidence
The module is a convenient way for your evidence to be recorded and presented to the
validator. Any supporting paperwork can be referenced and kept in a folder or document
case. The evidence should be selected carefully so as not to become unmanageable. The
module should be well organised so it can easily be read and understood. One piece of
evidence can be used to meet several requirements; therefore multiple copies of the same
evidence will not be needed for different sections of the module.

As a guide evidence can include:

 Description of the role/job

 Work sheets
 Written reports on performance
 Practical demonstrations of a task
 Certificates of training
 Witness testimonies

Authenticating the evidence

Wherever possible the evidence you produce should be witnessed, this will be by your
validator, the supervisor or a nominated witness can also contribute by confirming it is
original work that is presented to the validator. This is to ensure the work offered as evidence
was carried out by the candidate.

BCSA CRAFT Certificate Module 21 – Bolting Inspector

Trainee Details
Your validator may need to refer to this page while reading your pack.

Information for registration purposes

Your surname
Your first name
Any other name
Date you started this module

Information for contacting you if necessary

Your validator’s name
Your organisation
Your work contact telephone number

Information for Certification purposes

Date you completed this module

How this training module works

This module enables learning to take place in the workplace and will help you develop the
skills and knowledge to enable you to carry out the tasks required by the employer’s
standards. If you feel you need additional training in this area, please speak to your validator
before you begin this process.

This module will help you in three ways. It will:

 Tell you what you need to do or show to prove you are competent
 Give you guidance on how much evidence you need to provide
 Provide the basic records to help your validator judge your competency

For this section to be achieved, you will need to prove to your validator that you can:

 demonstrate good working practices to reduce exposure to any hazards;

 carry out the work safely; and
 on completion of the task leave the workplace in a safe and tidy condition

This module will guide you through your process of evidence collection and provide useful
evidence that you are competent and have performed the task to the employer’s standards.
When finished, this module and the other documents you provide will be the evidence your
validator needs to determine your competence.

BCSA CRAFT Certificate Module 21 – Bolting Inspector

Bolting
Two types of structural bolts are generally used in construction. These are non-preloadable
bolts (sometimes called Ordinary bolts) and preloadable bolts (sometimes called High
Strength Friction Grip Bolts (HSFG)).

Non-Preloadable Bolts

The most frequently used structural bolt are non-preloadable bolts (ordinary bolts) of
property grade 8.8 for main connections and property grade 4.6 for secondary connections
(eg purlins and sheeting rails).

Recognising the benefits of standardising bolt types and lengths the steel sector has adopted
fully threaded bolts (technically called screws within the standard). It is estimated that fully
threaded bolts, 60mm long and 20mm diameter in property grade 8.8 are suitable for about
90% of the connections in a typical multi-storey building.

The standard for non-preloadable bolts is BS EN 15048.

Non-preloadable bolts are used in ‘simple connections’ where the main loads applied to the
bolts are in bearing and shear. The bolts are required to bring the structural members into
contact with each other and maintain stability of the structure. Tightening of the bolt
assembly is required to ensure that loosing of the joint does not occur. It is generally accepted
that tightening with a ‘podger’ spanner will develop the level of tension required.

In the tightened condition there should be at least one full thread and the point protruding
beyond the nut face. In addition a minimum of one thread and the thread run-out should be
between the loaded nut face and the full shank diameter.

Preloadable bolts

These bolts are used in preloaded connections where the bolts are tightened to develop a
minimum of 70% of their nominal tensile strength so that the steel members are held tightly
together and ‘slip’ relative to the steel members is prevented. These bolts can be used in
normal clearance holes (usually 2mm) and reaming is not required, but it is necessary to use a
hardened steel washer under head or nut, depending on the turned part, to distribute the load
and protect the softer steel of the structural members. A number of different types of
preloadable bolt are available and the specification for each is set out in the various parts of
BS EN 14399.

Below is a complete list of the BS EN 14399 standards and is given in the company
specification for the purchase of structural assemblies and holding down bolts:

BS EN 14399-1 – General requirements

This is the harmonised or CE Marking standards for the bolting assemblies included in the
other parts of BS EN 14399.

BS EN 14399-2 – Suitability test for preloading

This standard describes the suitability test which all preloadable bolting assemblies must
satisfy. The test is untended to ensure that bolt assemblies do not fail prematurely during

BCSA CRAFT Certificate Module 21 – Bolting Inspector

tightening and have sufficient ductility so the nut can rotate by a further rotation after the
minimum preload has been achieved.

BS EN 14399-3 System HR – Hexagon bolt and nut assemblies

The bolts and nuts given in this standard are similar to the British Standard BS 4395. The
mechanical properties for property class 8.8 are higher than those given in BS 4395 for bolt
diameters greater than 24mm. Similarly the mechanical properties for property grade 10.9 are
higher for all bolt diameters. The nut thickness is also larger that those given in BS 4395 and
this together with the increased mechanical properties means that the failure mode if over
tightened is by breaking of the bolt in the thread. These assemblies are generally used in the
UK in preference to those in BS EN 14399-4.

BS EN 14399-4 System HV – Hexagon bolt and nut assemblies

The bolts and nuts given in this standard are dimensionally similar to the German Standard
DIN 6914/6915 but with higher mechanical properties. The nuts are the weaker part of the
assembly and consequently if over tightened the mode of failure is by thread stripping of the
nut. These assemblies are not generally used in the UK.

BS EN 14399-5 Plain washers

These washers should only be used under the nut.

BS EN 14399-6 Plain chamfered washers

These washers can be used under both the bolt head and the nut.

BS EN 14399-7 System HR – Countersunk head bolt and nut assemblies

This is a countersunk bolting assembly based on a UK design with a larger series head that is
thicker than the bolt heads specified in BS 4933. These bolts can be safety preloaded to 70%
of their nominal tensile strength.

BS EN 14399-8 System HV – Hexagon fit bolts and nut assemblies

This is a German preloadable close tolerance bolt (or fit bolt) which is not used in the UK.

BS EN 14399-9 System HR or HV – Direct tension indicators for bolt and nut assemblies
Direct tension indicators (DTIs) were formally known as Load Indicating Washers. DTIs are
placed under either the head of the bolt or the nut and as the torque is applied to the assembly
the dimples on the DTIs are squashed. When the dimples have been squashed to a specified
gap full preload has been achieved.

BS EN 14399-10 System HRC – Bolt and nut assemblies with calibrated preload
This is a European standard for Tension Controlled Bolting (TCB) assemblies.

The most important aspect of preloadable bolts is the method used to obtain the correct
tension in the bolt. The European fabrication standard, BS EN 1090-2, identifies four main
methods of tightening preloaded bolts. Each of these methods is associated with the
lubrication requirements of the assembly which is defined in terms of the K-factor. The four
tightening methods and the K-factor associated with each are:
 Torque control – K2
 Combined method – K2 or K1
 Tension Control Bolt method – K0 with HRD nut only or K2
 Direct tension indicator (DTI) method – K2, K1 or K0

BCSA CRAFT Certificate Module 21 – Bolting Inspector

The K-factor defines the consistency with which the lubrication ensures that the different
methods achieve the required preload. The K-factors are defined as follows:

K0 – the lubrication is only required to ensure that the preload can be achieved with no
attempt to control the preload developed by the torque
K1 – the majority of the preload is developed by torque consequently control of the
lubrication is important
K2 – the entire preload is developed by torque and consequently control of lubrication is
critical

The types of bolt assemblies used in the UK and the ways in which they are assembled are
shown in Table 2 below.

Matching Preloaded Assemblies

Bolt/nut/washer assembly – Bolt/nut/washer
System HR assembly System
HRC
General requirements BS EN 14399-1
Bolt/nut assembly BS EN 14399-3 BS EN 14399-7 BS EN 14399-10
Hexagon Bolt Countersunk Tension Control
Bolt Bolt
Bolt marking HR HR HRC
Nut marking HR HR HR or HRD
Property class 8.8/8 or 8.8/10 8.8/8 or 8.8/10 10.9/10
10.9/10 10.9/10
Washers BS EN 14399-5 or BS EN 14399-6
Washer marking H
Direct tension indicator, BS EN 14399-9
nut face washers and At user’s
bolt face washers discretion
Direct tension indicator H8 or H10
marking
Nut face washer marking HN
Bolt face washer marking HB Not applicable
Suitability test for BS EN 14399-2 and any additional testing specified in
preloading the product standard
Bolt lengths shall be selected to ensure that a minimum of four full threads (in
addition to the thread run-out) remain clear between the bearing surface of the nut and
the unthreaded part of the shank.

Table 2 - Matching Preloaded Assemblies

General Information

 The methods described in this module are limited to Carbon Steel

 Only matching bolt, nut and washer assemblies must be used
 Preloaded assemblies do not need additional locking devices (note: thin gauge material
subject to vibration may need locking devices)
 Bolts and nuts must not be welded (unless specified)

BCSA CRAFT Certificate Module 21 – Bolting Inspector

 Structural bolts must be at least M12
 Bolt length
o Length of protrusion must be at least one thread pitch measured from the outer face of
the nut to end of the bolt.
o At least four full threads (in addition to the thread run out) must remain clear between
the bearing surface of the nut and the unthreaded part of the bolt shank
 Nuts must run freely on the bolt
 Check by hand assembly before installation
 Any nut that does not run freely must be discarded
 Nuts must be assembled so that their designation markings are visible for inspection after
assembly
 Washers are to be placed under the nut or the bolt head whichever is rotated
 Washers used under the bolt head shall be chamfered and positioned with the chamfer
towards the bolt head
 Washers according to BS EN 14399-5 shall only be used under nuts
 Plain or hardened taper washers shall be used as follows:
o For 8.8 bolts a washer shall be used under either the nut or the bolt head whichever is
rotating
o For 10.9 bolts washer shall be used under both the bolt head and the nut
 Plate washers to be use for connections with long slotted and oversized holes
 Up to three plate washers with a max thickness of 12 mm may be used to adjust grip
length
 Plate washers must be placed under the side that is not turned
 Plate washers must be at least 4 mm thick
 Tapered washes shall be used where the surface of the ply is at an angle to the bolt
o 1/20 (3˚) for bolts with d ≤ 20 mm
o 1/30 (2˚) for bolts with d > 20 mm

Precautions to be taken prior to assembly

 Contact surfaces shall be free from oil, dirt, paint etc

 Burrs that prevent solid seating of the connected parts shall be removed
 Uncoated surfaces shall be free of rust and other loose material
 Care should be taken not to damage or smooth the roughened surface
 Untreated areas around the perimeter of the tightened connections shall be left untreated
until any inspection of the connections has been completed
Any surface treatment may be assumed to provide the necessary slip factor (friction)

Torque Control

Using this method the bolt assembly is tightened using a calibrated torque wrench correctly
set to the specified torque value. Two stages are involved in the tightening process:

 Stage 1 - the bolts are tightened to 75% of the bolt preload starting with the bolts in the
most rigid part of the connection and moving to the bolts in the least rigid part, and
 Stage 2 - the bolts are tightened to 110% of the bolt preload again working from the bolts
in the most rigid part to those in the least rigid part of the connection.

BCSA CRAFT Certificate Module 21 – Bolting Inspector

 As-delivered calibration is valid for tightening by rotation of the nut
 If tightening is done by the bolt head additional calibration is required in accordance with
the company procedure.
 Before preloading the connected components shall be fitted together and the bolts
tightened as follows with a residual gap limited to 2 mm:
o The tightening procedure shall be carried out from bolt to bolt in the group starting
from the most rigid part of the connection and moving to the least rigid part
o Each bolt assembly shall be brought to the snug-tight position
o More than one cycle may be necessary
 Torque wrenches shall have an accuracy of ± 4%
 Torque wrenches should be checked at least weekly
 Pneumatic wrenches checked every time the hose length is changed
 Torque wrenches used in the first tightening step to have an accuracy of ± 10% and
checked yearly
 Further checks to be carried out after any incident that may affect the wrench
 Other equipment shall be calibrated to manufacturers recommendations (e.g. axial
preloading by hydraulic devices or tensioning with ultrasonic control)
 If a bolt assembly is tightened to its minimum pre-load and then un-tightened it must be
removed and the whole assembly (bolt, nut and washer) discarded
 Bolt assemblies used for achieving fit up do not generally need to be tightened to their
minimum pre-load or un-tightened and can therefore still be used.
 If the tightening process is delayed under uncontrolled exposure conditions the
performance of the lubrication may be altered and should be checked.
 Hand or power tools may be used
 Impact wrenches may be used for the first step of tightening
 Tightening shall be continuous and smooth
 Tightening shall be applied in the following steps:
o Step 1 – the wrench shall be set to a torque value of 0.75 Mr.i with Mr,i = Mr,2 or Mr,test.
The first step shall be completed for all bolts in one connection prior to starting Step 2
o Step 2 – the wrench shall be set to a torque of 1.10 Mr,i with Mr,i = Mr,2 or Mr,test

Combined method requires two steps

Step 1 - set the wrench to a torque value of about 0.75 Mr,i with Mr,i = Mr,2 or Mr,test. The first
step shall be completed for all bolts in one connection prior to starting Step 2 commencing.
Step 2 - apply a specified part turn
 The position of the nut relative to the bolt threads shall be marked
 A rotation relative to the marked position shall be applied

Total thickness ‘t’ of parts to be

Further rotation to be applied during the 2nd step of
connected
tightening
(including all packs and washers)
Degree Part turn
d = bolt diamenter
t < 2d 60 1/6
2d ≤ t < 6d 90 1/4
6d ≤ t ≤ 10d 120 1/3
Note: Where the surface under the bolt head or nut (allowing for the taper washers, if used)
is not perpendicular to the bolt axis, the required angle of rotation should be determined
by testing.

BCSA CRAFT Certificate Module 21 – Bolting Inspector

Tension Control Bolts (TCB)

A number of proprietary bolts are now available having either annular grooves cut in their
threaded portions adjacent to the faces of their nuts or a similar means of effecting a
predetermined reduction in the area of the shank. This reduction in area in conjunction with
the use of a special tool applying a torque reaction at the point of reduced area, shears the
shank of the bolt when the correct torque is reached.

 TCB bolts shall be tightened using a specific shear wrench equipment with two co-axial
sockets which react by torque one against the other.
 The specified pre-load is controlled by the TCB bolt itself
 The equipment does not need calibrating
 Two Steps are normally required to preload the assemblies
o Step1 - tighten the assembly until the outer socket stops turning. Complete Step 1 for
all bolts in the connection before proceeding to Step 2. (e.g. sound of shear wrench
changing)
o Step 2 - full preload is achieved when the spline shears off

Direct Tension Indicators (DTI)

In this method a washer with a set number and size of protrusions is placed under either the
nut or the head of the bolt. Each bolt is tightened with an ordinary spanner or wrench until the
protrusions just begin to deform. Once this is achieved each bolt is tightened again until the
protrusions are compressed to a certain limit.

The DTIs must be assembled as follows:

 DTIs should be fitted under the bolt head

 The assembly is tightened using the nut
 If access is limited there are a number of alternative configurations (as shown):

BCSA CRAFT Certificate Module 21 – Bolting Inspector

BCSA CRAFT Certificate Module 21 – Bolting Inspector
The tightening method is as follows:

 Step 1 - ‘Snug-tight’ – tighten the assembly until the protrusions just begin to deform.
This first step should be applied to all the bolts in the connection before commencing the
second step
 Step 2 - Each assembly shall be tighter until the protrusions are compressed and the feeler
gauge does not meet certain requirements (see below)

Indicator Position Thickness of feeler gauge (mm)

Under bolt head, when nut is rotated 0.40
Under nut when bolt is rotated 0.40
Under nut when nut is rotated 0.25
Under bolt head when bolt is rotated 0.25
This table applies to both H8 and H10 DTI’s

BCSA CRAFT Certificate Module 21 – Bolting Inspector

 Number of indicator protrusions Minimum number of feeler gauge refusals
4 3
5 3
6 4
7 4
8 5
9 5
No more than 10% of the indicators in a connection bolt group shall exhibit full
compression of the indicator

 This method is additional to the methods given in BS EN 1090-2

 It is a modified form of the combined method but does not require the use of K1 and K1
class bolts
 It is traditional known in the UK as the ‘Part Turn’ method

Combined method

A simple method which has proved satisfactory in practice is known as the ‘Combined
method’ or ‘Part Turn method’. With this method a specified bedding torque is applied to the
group of bolts using a calibrated torque wrench. At this point the relative position of the end
of the bolt and the nut is marked (usually with a centre-punch on each) and the nut is then
further rotated by a specified amount. The additional rotation for property grade 8.8 and 10.9
bolts is given in below:

Total nominal thickness ‘t’ of parts to be Additional rotation to be applied during

connected (including all packs and the second step of tightening
washers) Degrees Part turn
d = diameter of bolt
t < 2d 60 1/6
2d ≤ t < 6d 90 1/4
6d ≤ t ≤ 10d 120 1/3
Note: Where the surface under the bolt head or nut (allowing for taper washers,
if used) is not perpendicular to the bolt axis, the required angle of rotation should
be determined by testing.

Tightening of the part-turn method comprises the following two steps:

 Step 1 - Using a torque wrench, with the torque set to the values given below, tighten all
bolts. This step must be completed for all bolts in a connection before starting Step 2.
 Step 2 - Apply a specified part turn.
o The position of the nut relative to the bolt threads shall be marked
o A rotation relative to the marked position shall be applied

Nominal Diameter Bedding torque of bolt ± 10% Nm

24 270 Nm
30 460 Nm
Total thickness ‘t’ of parts to be connected Further angle of rotation to be applied
(including all packs and washers) during the second step of tightening
Degrees Part turn
T < 160 mm 180 1/2

BCSA CRAFT Certificate Module 21 – Bolting Inspector

BOLTING – PRACTICAL TEST AND VALIDATION EVIDENCE SHEET

Bolting Practitioner’s Name: ................................................................................................

The validator (Bolt Coordinator) must use the questions below as a checklist to ensure the
bolting practitioner candidate understands the various types of fasteners in common use.

Non-Preloadable Bolts:
(a) What property grade should be used for main connections?
(b) What property grade should be used for secondary connections?
(c) What size bolt is accepted for typical use in multi-storey buildings?
(d) What is the standard for non-preloadable bolts?
(e) What type of spanner is used to tighten a non-preloadable bolt?
(f) When tightened what minimum amount of thread should be protruding beyond the nut?
Preloadable Bolts:
(a) What are preloadable bolts designed to prevent?
(b) Are the holes required to be reamed for these bolts?
(c) Is a hardened steel washer required under the head or nut?
(d) Describe the four tightening methods?
(e) Where should the start point be for bolt tightening in a connection?
Combined Method (Part turn method)
(a) What type of wrench is used to ‘bed’ the nut and bolt?
(b) How is the nut and bolt to have their position marked?
(c) What further rotation of the nut should take place after ‘bedding’?

Tension Control Bolts (TCB)

(a) Ability to describe how the torque is reached using a TCB :

Direct Tension Indicators (DTI)

Ability to describe how a DTI is used to confirm tension has been achieved?

The validator (Bolt Coordinator) should only sign this record of evidence for the task if the
work was carried out with efficiency, to an acceptable standard and safely according to the
method statement/company procedure, and is able to demonstrate the following:
 Able to prepare for assembly
 Assemble preloaded bolted connections
 Tighten/tension bolt assemblies using the appropriate equipment
 Demonstrate safe working practices

Validator (Bolt Coordinator) endorsement:

Signature ______________________________________ Date _______________________

On Behalf of (company name): ...............................................................................................

BCSA CRAFT Certificate Module 21 – Bolting Inspector

Endorsement Page

The Trainee candidate has demonstrated that he/she has consistently worked within the
legislative and regulatory framework that applies to them. The managers or other persons
signing this endorsement can discuss with the Validator, Coach and Trainee to satisfy
themselves that the Trainee consistently complies with rules in force in the performance of
the tasks described in this training module.

Trainee Name (Print)

Module Completed

The evidence produced by the above named trainee is in accordance with the training module
and to the required company procedures and standards.

Signed ...................................................................

Date ..........................................

Validator’s Endorsement

The evidence produced by the above named trainee has been produced in accordance with the
training module and to the required company procedures and standards.

Signed ................................................................

Date .........................................

Manager's/Company Representative's Endorsement

The candidate has consistently acted within in accordance with the training module and to the
required company procedures and standards.

Signed ........................................................ Position ..................................................

Date ..............................................

BCSA CRAFT Certificate Module 21 – Bolting Inspector

 Certificate of Bolting Inspector

This certificate is awarded to:

(Delegate’s Name)

of

(insert Compamy Name)

Has been trained and validated to meet the requirements

of the BCSA Bolting Standard

Bolting Coordinator

Name (Print): ............................................ Signature: ..............................

Date: ..................................... Certificate valid to: ...................................

BCSA CRAFT Certificate Module 21 – Bolting Inspector