Page 1 of 3 - Indian Railway · Page 1 of 31 Effective from September 2012 Specification No. TI/SPC/OHE/ FASTENERS/0120 GOVERNMENT OF INDIA MINISTRY OF RAILWAYS ... Stainless Steel

Page 1 of 31 Effective fromSeptember 2012

Specification No. TI/SPC/OHE/ FASTENERS/0120

GOVERNMENT OF INDIAMINISTRY OF RAILWAYS

RESEARCH DESIGNS AND STANDARDS ORGANISATIONMANAK NAGAR, LUCKNOW-226011

Specification for Steel Fasterners & Stainless Steel Fasterners for25 kV A.C. Traction Overhead Equipment

1. SCOPE

1.1 This Specification covers the requirements of Steel Fasterners andStainless Steel Special Head/Hexagon straight Bolts and Screws, FlatCountersunk Nib Bolts and Screw, U-Bolts, J-Bolts, Hexagon Nutsand Lock Nuts and Plain and Spring Washers used on 25 kV A.C.Traction Overhead Equipment. The term Fasteners shall includeBolts, Nuts, Lock Nuts and washer. The term nut shall include lockNuts. The term Bolt shall include Screws, Special head Bolts/Screws.

1.2 This Specification supersedes RDSO Specification No.ETI/OHE/18(4/84) with A&C Slip No. 1 to 5.

2. GOVERNING SPECIFICATIONS

2.1 The fasteners shall generally conform to the respective IndianStandards unless specified otherwise herein. The provisions of thegoverning Specifications shall be applied in the manneraltered/amended or supplemented by this Specification.

2.2 In preparation of this Specification reference has been made to thefollowing Specifications.

Sl.No. Specification No. Specification Title.

i) IS: 1363-2002 Black hexagon bolts nuts and locknuts (Dia 6 to 39) & black hexagonscrews (Dia 6 to 24 mm).

ii) IS: 1367 (Pt.2, 3, 5, 6, 7,9, 10, 13, 18).

Technical supply conditions forthreaded Steel fasteners

iii) IS: 1570 (Pt. 5) – 1985 Schedule for wrought steels(Stainless & heat resisting steels)

iv) IS: 2016- 1967 Plain washersv ) IS: 3063 – 1994 Spring washer for bolts, nuts &

screws.vi ) BS: 2061 – 1953 Phosphor bronze spring washer for

General engineering purposes.



Sl.No. Specification No. Specification Title.

vii) IS: 549 – 1974 Split pines.viii) IS: 9549 – 1980 Dimension for split pin holes, wire

holes and head slots for bolts.ix) IS: 9519 – 2005 Dimensions for width across flats

for hexagon head bolts & nuts.x ) IS: 8353 – 1977 Flat countersunk nib bolts.xi ) IS: 730 – 1978 Hook bolts for corrugated sheet

roofing.xii) IS: 1368 – 1987 Dimensions for ends of bolts and

screws.xiii) IS: 4172 – 1987 Dimension for radii under the head

of bolts and screws.xiv) IS: 5369 – 1975 General requirements for plain

washers and lock washers.xv ) IS: 4206 – 1987 Dimensions for nominal lengths

and thread lengths for bolts screwsand studs.

xvi ) IS: 4213 – I, II, III, IV, V ISO metric screws threads.xvii) IS: 2334 – 2001 Gauging practice for ISO metric

screw threads.xviii) IS: 1369 – 1995 Dimensions for screw thread run

out sand undercuts.xix) IS: 2614 – 1969 Methods for sampling of fastenersxx ) IS: 2629 – 1985 Recommended practice for hot dip

galvanising of iron and steel.xxi ) IS: 4211 – 1993 Thread pitch gauges for ISO metric

screws threads ( Pitch range0.25 to 6.0 mm ).

xxii) IS: 6745 – 1972 Methods for determination of massof zinc coating on zinc coatediron & steel articles.

xxiii) IS: 2633 – 1986 Method for testing uniformity ofcoating on zinc coated articles.

xxiv) IS: 9141 – 1979 Code of practice for packing offasteners

xxv) IS: 3203 - 1982 Methods of testing local thicknessof electroplated coatings.



3. DEVIATION FROM SPECIFICATION

3.1 Any deviation from this Specification calculated to improve theperformance, efficiency and utility of fasteners proposed by thetenderer will be given due consideration provided full particulars withjustification thereof are furnished.

4. SERVICE CONDITIONS

4.1 The fasteners are used in conjunction with variousfittings/components of Traction Overhead Equipment including thosecarrying current.

4.2 Weather Conditions

The fasteners are used very widely under the severe Weatherconditions. The limiting conditions which have to be withstood inservice are indicated below :

Maximum temperature of Air in shade - 45° C

Minimum temperature of Air in shade - 0° C

Maximum temperature attainable by an - 65.5° Cobject exposed to Sun.

Maximum relative Humidity - 100%

Average annual Rainfal - 1750 to 6250 mm

Average number of Dust - 35 days. Max.Storm days per annum

Number of Thunder storm days - 35 days Max.per annum.

No. of Rainy days per annum - 120 days Max

Maximum Wind pressure - 200Kg/Sq. meter.

Altitude - Not exceeding 1000 m.

4.3 The fasteners are also subjected to chemical pollution from theeffluent gases of Chemical Plants, exhaust of Steam/Diesellocomotives and to saline atmosphere in coastal areas.



5. MATERIAL

5.1 Ferrous fastenersSteel Fasteners shall conform to Grade-C Specification inIS:1367 (Part-2) –2002. Bolts/Screws shall comply with mechanicalproperty class 4.6 of IS: 1367 (Part-3) – 2002. Nuts shall complywith the mechanical property class 4.6 of IS:1367(Part 3) -2002.Nuts comply with the mechanical property class 04, 4 or 5 (asapplicable) of IS:1367 shall (Part-6) – 1994.

5.2 Stainless Steel FastenersThe Stainless Steel Bolts, Nuts, Lock Nut & Washers shall conform toAISI 316.

5.3 Plain WashersPlain Washers shall conform to IS: 2016 – 1967. Galvanised SteelPlain Washers (Punched, Type A) shall be used with galvanised SteelBolts, Bronze, Stainless Steel or Copper Washers (punched, Type A)shall be used with Stainless Steel Bolts.

5.4 Spring WashersThe Spring Washers shall conform to IS: 3063 – 1994. GalvanisedSteel Spring Washers with flat ends (type B) shall be used withGalvanised Steel Bolts. Phosphor Bronze Spring Washers,conforming to BS: 2061– 1953, shall be used with Stainless SteelBolts.

6. GENERAL REQUIREMENTS

6.1 WorkmanshipThe Bolts and Nuts shall be clearly finished, sound & free fromdefects which may effect their serviceability, and shall be consistentwith the grade prescribed. The fasteners shall have full surfaces andedges in keeping with the method of manufacturing used. These shallbe free from burrs, although barely perceptible thin burrs whichresults for example, from slotting and trimming operations, may beleft out.

The Black Grade Bolts may have reasonable die – seem on theshank; but in no case the shank diameter with such seams shallexceed the maximum permissible diameter. The Stainless SteelBolts, Nuts, Locknut, Plain Washer, Spring Washer shall be suppliedin natural finish.



The Washers shall be free from cracks, burrs, pits and otherdefects. The holes of Plain Washers shall be reasonably concentricwith the outer periphery. All sharp edges shall be removed.

The surfaces of Washers shall be free from die marks and shallbe finished smooth. The ends shall be so severed as to preventtangling.

6.2 Bolts end Nuts shall be classified by their nominal diameter. Thedimensions of hexagons, chamfers, shank diameter and otherdimensions for different nominal sizes of Bolts and Nuts, whetherferrous or stainless steel shall be in accordance with Table 1.

6.3 Unless otherwise shown in the Purchaser’s drawings, the Nuts shallhave single chamfer, and Lock Nuts shall have double chamfer.

6.4 Bolts shall be drilled for Split Pins wherever shown in the Purchaser’sdrawings. Split Pin holes shall be at right angles to the axis of Bolts.The dimensions for Split pin holes for a particular size of Split pinshall be according to IS: 549 – 1974.

6.4.1 The tolerance in the location of split pin holes shall be according toIS: 9549 – 1980.

7. DIMENSIONS

7.1 The dimensions for hexagon Bolts, Screw and Nuts shall be inaccordance with Table 1 read in conjunction with the relevantPurchaser’s Drawings and IS:9519 – 2005 “Specification for modifieddimensions of width across flats for hexagonal Bolts/ Screws andNuts normal series”.

7.2 The dimensions for special head Bolts and Screws, U–Bolts, J-Boltsshall be as shown in the purchasers drawings.

7.3 Dimensions of flat countersunk nib Bolts/Screws shall conform toIS: 8353 – 1977 and those of J Bolts shall conform to IS:730 – 1978.

7.4 Dimensions of ends of Bolts and Screws shall be as perIS: 1363 – 2002 and the dimensions for radii under the head of Boltsand Screws shall be as per IS: 4172 – 1987. The cone point/turncated cone point ends of Bolts and Screws shall be as shown inpurchaser’s drawings.



7.5 Dimensions of Plain and Spring Washers shall be as shown inIS:2016 -1967 and IS: 3063-1994 respectively. The permissibledeviations from dimensions of plain washers shall be in accordancewith Table 3 and 4 of IS: 5369 -1975.

7.6 The dimensional tolerances for Galvanised Steel and Stainless SteelBolts, Screws and Nuts shall be as per Table 1.

8. LENGTHS AND THREADED LENGTHS

8.1 The lengths and threaded lengths of Bolts/Screws shall be generallyas per IS: 4206 – 1987. However, exact lengths and threadedlengths shall be as shown in Purchaser’s Drawings.

9. THREADS (INTERNAL AND EXTERNAL)

9.1 The threads shall be ISO metric. The internal and external threadprofile shall be in accordance with IS : 4213 (Part I) – 1976.



Table – 1 (Refer Fig.1)INDICATING THE DIMENSIONS AND TOLERANCES ON BOLTS AND NUTS AND THREADS OF BOLTS AND NUTS

Sl.No. SizeDimension

M10 M12 M14 M16 M18 M20 M22 M24 Remarks

(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)1. NOM

d MAX

MIN

1011.24

(10.90)9.79

(9.64)

1213.44

(13.10)11.72

(11.57)

1415.44

(15.10)13.72

(13.57)

1617.44

(17.10)15.72

(15.57)

1819.44

(19.10)17.72

(17.57)

2021.64

(21.30)19.63

(19.48)

2223.64

(23.30)21.63

(21.48)

2425.64

(25.30)23.63

(23.48)2. NOM

s MAX

MIN

1616.34

(16.00)15.72

(15.57)

1818.34

(18.00)17.72

(17.57)

2121.34

(21.00)20.31

(20.16)

2424.34

(24.00)23.31

(23.16)

2727.34

(27.00)26.31

(26.16)

3030.34

(30.00)29.31

(29.16)

3434.34

(34.00)33.15

(33.00)

3636.34

(36.00)35.15

(35.00)3. c MIN 17.76

(17.59)20.02

(19.85)22.95

(22.78)26.34

(26.17)29.73

(29.56)33.12

(32.95)37.46

(37.29)39.72

(39.55)4. NOM

k MAX

MIN

77.79

(7.45)6.70

(6.55)

88.79

(8.45)7.70

(7.55)

99.79

(9.45)8.70

(8.55)

1010.79

(10.45)9.70

(9.55)

1212.89

(12.55)11.60

(11.45)

1313.89

(13.55)12.60

(12.45)

1414.89

(14.55)13.60

(13.45)

1515.89

(15.55)14.60

(14.45)5. da MAX 12.54

(12.2)15.54(15.2)

17.54(17.2)

19.54(19.2)

21.54(21.2)

24.74(24.4)

26.74(26.4)

28.74(28.4)

6. a MAX 5.0 6.0 7.5 7.5 9.0 9.0 9.0 11.0





(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)7 b b1 MIN

b2 MINb3 MIN

2632-

303649

344053

384457

424861

465265

505669

546073

8 NOMm MAX

MIN

88.79

(8.45)7.70

(7.55)

1010.79

(10.45)9.70

(9.55)

1111.89

(11.55)10.60

(10.45)

1313.89

(13.55)12.60

(12.45)

1515.89

(15.55)14.60

(14.45)

1616.89

(16.55)15.60

(16.45)

1818.89

(18.55)17.60

(17.45)

1919.99

(19.65)18.50

(18.35)9 NOM

f MAX

MIN

55.62

(5.38)4.77

(4.62)

77.69

(7.45)6.70

(6.55)

88.69

(8.45)7.70

(7.55)

88.69

(8.45)7.70

(7.55)

99.69

(9.45)8.70

(8.55)

99.69

(9.45)8.70

(8.55)

1010.69

(10.45)9.70

(9.55)

1010.69

(10.45)9.70

(9.55)10 r MIN 0.3

(0.4)0.5

(0.6)0.5

(0.6)0.5

(0.6)0.5

(0.6)0.7

(0.8)0.7

(0.8)0.7

(0.8)11 l ≤ 150

>1501±0.901±1.80

1±0.901±1.80

1±0.901±1.80

1±0.901±1.80

1±0.901±1.80

1±1.051±2.10

1±1.051±2.10

1±1.051±2.10

12 Pitch P 1.5 1.75 2 2 2.5 2.5 2.5 313 Pitch Bolt MAX

Dia MINMeter

Nut MAXMIN

8.9948.7829.2509.026

10.82910.59311.11310.863

12.66312.41312.96612.701

14.66314.41314.96614.701

16.33416.06916.65616.376

18.33418.06918.65618.376

20.33420.06920.65620.376

22.00321.66822.38622.051



Note :-1. Use b1 for l ≤ 130, b2 for 130 < l ≥ 200 and b3 for l > 200.2. Modified dimensions for width across flats (Normal series) for M10, 12, 14 and 22mm as per

IS:9519-1980 shall also be acceptable.3. The tolerances on the last four dimension i.e. Sl.No. 12 to 15 are applicable in black condition for

ferrous nuts and bolts and these for Sl. No. 1 to 11 are applicable after galvanising.4. Figures in brackets wherever shown indicate the dimensions for SS fasteners.



(1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)14 MAJOR Bolt MAX

Dia MINMeter

Nut MAXMIN

9.9689.593

-10.00

11.96611.541

-12.00

13.96213.512

-14.00

15.96215.512

-16.00

17.95817.428

-18.00

19.95819.428

-20.00

21.95821.428

-22.00

23.95223.352

-24.00

15 Minor Bolt MAXDia MINMeter

Nut MAXMIN

8.1287.8088.7518.376

9.8199.45710.53110.106

11.50811.11412.31011.835

13.50813.11414.31013.835

14.89114.44615.85415.294

16.89116.44617.85417.294

18.89118.44619.85419.294

20.27119.74021.38220.752



9.2 The diameter and pitch and combination shall be according to IS:4213(Part II)- 1976. The pitch shall be coarse.

9.3 The basic dimensions for profiles of ISO metric screw threadsshall be as per IS: 4213 (Part III) – 1976.

9.4 The tolerance class for ISO metric screws threads shall be coarseas given in table 5 of IS:4213(Part IV)-1976.

9.5 The deviations from basic dimensions for nut and bolt threads ofthe tolerance class specified in clause 9.4 shall be as tabulated intable – 1. The tolerance class shall be 7H for nuts and 8g for boltthreads. The limits of sizes for tolerance class 7H for nut threadsand 8g for bolt threads are given in table-1. These limits areapplicable to ferrous fasteners in black condition and to stainlesssteel fasteners in finished condition.

9.6 The thread run outs and undercuts shall be as per IS: 1369-1995.

10. GALVANISING OF FERROUS FASTNERS

10.1 Dimensions

10.1.1Fasteners with internal Threads –Prior to galvanising andsubsequent tapping the dimensions of fasteners with internalthreads shall conform to the relevant standards. Internal threadsshall be tapped over-size after galvanising and they shall be oiledfor corrosion protection.

10.1.1.1 The oversize tapping allowance shall be as given in Tablebelow. These allowances are applicable to major, pitch andminor diameters, the amended diameters being subject to thesame manufacturing tolerances of the appropriate grade ofthreads stated in the relevant fastener standard.

TABLE: ALLOWANCES FOR INTERNAL THREADS TOACCOMMODATE GALVANIZED EXTERNAL THREADS.

Nominal Size Internal Diametral AllowancesThreads. mm

Below M16 +0.40M16 to M22 +0.50Over M22 andup to and including M36 +0.65



10.1.2 Fasteners with External Threads – Prior to galvanising, thedimensions of fasteners with external threads shall conform tothe relevant standards including thread sizes.

10.1.2.1The thickness of galvanized coating on external threads shall beso controlled in the galvanising process that galvanisedfasteners with external threads can be assembled by hand withinternally threaded fasteners complying with 10.1.1.

10.1.2.2Galvanised external threads shall not be recut.

10.1.3 Coating Requirements

10.1.3.1Mass of Coating - The mass of coating per square meter ofthe surface shall comply with the minimum average andminimum individual sample coating given in Table below. Themass of coating shall be determined by one the followingmethods:

a) The stripping test described in Append-ix B; or

b) Magnetic or electronic thickness measuring devices ascovered in IS: 3203-1965 ‘Method of testing local thicknessof electroplated coatings’. The mass of coating in g/m2 isfound by multiplying the thickness in micrometers by 7.0.

10.1.3.2 In case of dispute, the stripping test shall be the refereetest.

TABLE: MASS AND EQUZAVALANT THICKNESS OF COATING

Minimum Average Minimum IndividualMass Thickness Mass Thicknessg/m2 µm g/m2 µm

375 54 300 43



10.1.4 Uniformity of Coating – The uniformity of zinc coating shallbe such that the coating shall withstand the copper sulphatetest as given in IS : 2633- 1986. ’Methods of testinguniformity of coating on zinc coated articles (first revisions )‘without showing any adherent red deposit of metalliccopper upon the base metal with the following exceptions.

a) A fine line of copper on the crest of the screw threads or onsharp edges of Bolt/Nut or at or adjacent to any cut ofabrasion present in the original fastener shall not beconsidered a defect to cause rejection, and

b) Any deposit of metallic copper with threads of fastenerswhich have been re-thread rolled after galvanising, isallowable.

10.1.5 Adhesion of Coating - The coating shall withstand the knife testas covered in IS: 2629-1985.

10.2 All ferrous fasteners including washers shall be hot dipgalvanized for electro-galvanised to achieve a uniform adherentcoating of zinc. The minimum thickness of zinc coating shall be of400 g/m2 (55 microns).

11. TESTS

11.1 The manufacturers shall carry out the specified tests, duringproduction on the samples, taken at regular intervals, separatelyfor the different sizes, grade & material, which are beingmanufactured under similar processes of productions to ensureconformity to relevant specifications as also to maintain propercontrol over the process of manufacture. The manufacturer shallat the time of inspection, produce a certificate showing therecords of various inspections/tests which have been exercisedduring manufacture.

11.2 When the purchaser requires additional tests, related to his orderbut not specified hereunder, such tests shall be subject ofagreement between the purchaser and the manufacturer.

11.3 All the tests on the fasteners shall be carried out at manufacturersworks. The manufacturer shall arrange, without making claim orcharge, all the necessary machinery, apparatus, labour,assistance etc. required to get the prescribed tests conducted inthe presence of purchaser’s representative.



11.4 Type Tests

i) Visual examination ( 12.1)ii) Measurement of dimensions (12.2)iii) Gauging of threads ( 12.3)iv) Chemical composition (12.4)v) Mechanical tests (12.5)

a) Tensile test (12.5.1)b) Elongation after fracture (12.5.2)c) Hardness test (12.6)d) Proof load test (12.7)

(for ferrous bolts and nutsand stainless steel nuts).

e) 0.2% permanent strain test (12.8)(For S.S. bolts only)

f) Head soundness test ( 12.9)g) Crushing test on nuts (12.10)

(SS nuts only)h) Bend test on straight bolts (12.11)

(SS bolts only).i) Torsion test on bolts & nuts (12.12)

(for SS bolts & nuts only)vi) Galvanising test on ferrous fasteners (12.13)

vii) Inter-crystalline corrosion bend test (12.14)for SS fasteners, or Micro examination ofSS fasteners (12.15)

viii) Permanent set test on spring washers (12.16)

ix) Twist test on spring washers (12.17)

11.5 Routine tests

Visual examination (12.1)



11.6 Acceptance tests

i) Visual examination ( 12.1)ii) Measurement of dimensions (12.2)iii) Gauging of threads (12.3)iv) Chemical composition (12.4)

(only for stainless steel fasteners)

v) Mechanical tests (12.5)a) Tensile test (12.5.1)b) Percentage elongation after fracture (12.5.2)c) Hardness test (12.6)d) Proof load test (12.7)

(for ferrous bolts & nuts and for stainless steel nuts).e) Stress at 0.2% permanent strain test (12.8)f) Head soundness test for bolts (12.9)g) Crushing test on nuts (12.10)

(SS nuts only)h) Bend test on straight bolts (12.11)

( SS bolt only)i) Torsion test on bolts & nuts (12.12)

(for SS bolts & nuts only)

vi) Galvanising test on ferrous fasteners (12.13)vii) Inter-crystalline corrosion bend test on (12.14)

stainless steel fastners.Or

Micro examination of stainless steel (12.15)Fasteners.

viii) Permanent set test on spring washers (12.16)

ix) Twist test on spring washers(12.17)

11.6.1 Sampling procedure

11.6.1.1 Lot : All the fasteners in a consignment belonging to thesame size, grade, material and manufactured under similarprocess of production and submitted for inspection at oneinstance shall constitute a lot.



11.6.2 Scale of sampling

11.6.2.1 Samples shall be selected at random and examined for eachlot separately for ascertaining their conformity to therequirements of this specification. Only one set of samples asindicated in 11.6.2.2 shall be drawn from a lot for all thecharacteristics.



TABLE 2SCALE OF SAMPLING AND CRITERIA FOR CONFORMITY FOR INSPECTION

( Clause 11.6.1, 11.6.2, 11.6.3 )

Lot size VISUAL CHARACTERISTICS DUDS DIMENSIONAL CHARACTERISTICS STAINLESS STEELFASTERNERS

Sample Samplesize

Cumulative

size

Ac Re Ac Re Sample Samplesize

Cumulative

size

BLACK FASTNERSMajordefect

Majordefect

Majordefects

Minordefects

Ac Re Ac Re Ac Re Ac Re

AQL 4.0 0.65 2.5 4.0 1.5 2.51 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Upto 100First

Second

20

20

20

40

1

4

4

5

0

1

2

2

First

Second

8

8

8

16

0

1

2

2

0

1

2

2

0

1

2

2

0

1

2

2

101”300First

Second

32

32

32

64

2

6

5

7

0

1

2

2

First

Second

13

13

13

26

0

1

2

2

0

3

3

4

0

1

2

2

0

1

2

2

301”500First

Second

50

50

50

100

3

8

7

9

0

1

2

2

First

Second

20

20

20

40

0

3

3

4

1

4

4

5

0

1

2

2

0

3

3

4

501”1000First

Second

80

80

80

160

5

12

9

13

0

3

3

4

First

Second

32

32

32

64

1

4

4

5

2

6

5

7

0

3

3

4

1

4

4

5

1001”3000First

Second

125

125

125

250

7

18

11

19

1

4

4

5

First

Second

50

50

50

100

2

6

5

7

3

8

7

9

1

4

4

5

2

6

5

7



Note:- Classification of major and minor defect is given in Appendix A of IS: 2614 – 1969. [ LEGEND + AQL= Acceptable qualityLevel]

Lot size VISUAL CHARACTERISTICS DUDS DIMENSIONAL CHARACTERISTICS STAINLESS STEELFASTERNERS

Sample Samplesize

CumUlativesize

Ac Re Ac Re Sample Samplesize

CumUlativesize

BLACK FASTNERSMajordefect

Majordefect

Majordefects

Minordefects

Ac Re Ac Re Ac Re Ac Re

AQL 4.0 0.65 2.5 4.0 1.5 2.51 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

3001”10000First

Second

200

200

200

400

11

26

16

27

2

6

5

7

First

Second

80

80

80

160

3

8

7

9

5

12

9

13

2

6

5

7

3

8

7

9

10001”35000First

Second

315

315

315

630

11

26

16

27

3

8

7

9

First

Second

125

125

125

250

5

12

9

13

7

18

11

19

3

8

7

9

5

12

9

13

Over 35000First

Second

500

500

500

1000

11

26

16

27

5

12

9

13

First

Second

200

200

200

400

7

18

11

19

11

26

16

27

5

12

9

13

7

18

11

19



11.6.2.2 Samples shall be drawn from each lot in accordance with Cols. 1,2,3 of table 2 for visual and dimensional verifications and forinspection of physical and other properties.

11.6.3 Criteria for conformity

11.6.3.1 Visual characteristics : All the fasteners drawn in accordancewith clause 11.6.2.2 shall be first examined for visualcharacteristics like type, finish, workmanship, duds, visualsurface discontinuities and identification mark. To ascertain theconformity of the lot to the requirements of all visualcharacteristics, except duds, the procedure given in 11.6.3.1.1shall be followed. For duds, procedure given in 11.6.3.1.2 shallbe followed.

11.6.3.1.1 Visual characteristics ( other then duds) :If in the first samplethe number of defective fasteners with respect to all visualcharacteristics, except duds, is less than or equal to thecorresponding acceptance number (Ac) given in Col.5 of table 2the lot shall be declared as conforming to the requirements forthese characteristics. If the number of defectives is greater thenor equal to the corresponding rejection number (Re) given inCol.6 of table 2 the lot shall be deemed as not meeting therequirements for these characteristics. If the number ofdefectives is greater than the acceptance number but less thanthe rejection number a second sample of the same x number offasteners selected as the first sample shall be taken todetermine the conformity or otherwise of the lot. The number ofdefectives found in the first and second sample shall becombined and if the combined number of defectives is less thanor equal to the corresponding acceptance number the lot shall bedeclared as conforming to the requirements; otherwise not.

11.6.3.1.2 Duds: If the number of defective fasteners in respect of duds isless than or equal to the corresponding acceptance numbergiven in col.7 of table 2, the lot shall be declared as conformingto the requirements for duds. If the number of defectivefasteners is greater than or equal to the rejection number givenin col.8 of table 2, the lot shall be declared as not conforming tothe requirements for duds. If the number of defective fastenersis greater than the acceptance number but less than therejection number, a second sample of the same number offasteners selected as the first sample shall be taken to



determine the conformity or otherwise of the lot. The number ofdefective fasteners found in the first and second samples shallbe combined and if the combined number of defective fastenersis less than or equal to the corresponding acceptance number,the lot shall be declared as conforming to the requirements forduds, otherwise not.

11.6.3.2 Dimensional characteristicsThe lot which has been found satisfactory in respect of visualcharacteristics (See 11.6.3.1) shall be tested for dimensionalcharacteristics like diameter, length etc. except pitch, basicdimensions of threads which will be tested as per clause 12.3after stripping / case of ferrous fasteners. The fasteners for thispurpose shall be taken at random in accordance with col.9 and10 of table 2, from those already drawn for inspection of visualcharacteristics ( see 11.6.3.1) and tested for dimensionalcharacteristics. If the number of fasteners failing to satisfy therequirements for these characteristics is less than or equal to thecorresponding acceptance number given in col. 12,14,16 or 18of table 2, the lot shall be declared as to have not therequirements of the specification in respect of thesecharacteristics. If the number of defectives is greater than orequal to the corresponding rejection numbers given in col.13,15,17 or 19 of table 2 the lot shall be deemed as notconfirming to these characteristics. In case the number ofdefective lies in between the acceptance and rejection number, asecond sample of the same size shall be taken and inspected fordimensional characteristics and inference drawn accordingly.

11.6.3.3 Physical chemical & galvanising requirements

11.6.3.3.1 From the samples taken in accordance with 11.6.2.2 end whichhave been subjected to the visual and dimensional tests,samples in multiples of 5 or 6, as the case may be shall bedrawn at random for mechanical, chemical and galvanising testsin case of bolts and nuts. In case of spring washers, samples inmultiples of 4 shall be selected for twist test and permanent settest.



11.6.3.3.2 Galvanized Fasteners

i) BOLTS : - The samples selected in accordance with clause11.6.3.3.1 shall be divided in 6 equal parts. Each part shallbe subjected to one of the following tests:

a) Tensile / elongation test ( Cl.12.5.1 and 12.5.2 )b) Proof load test (Cl.12.7)c) Head soundness test ( Cl. 12.9)d) Hardness test ( Cl.12.6)e) Galvanising test ( Cl.12.13)f) Gauging of threads ( Cl. 12.3)

and visual examination after stripping ( 12.1)

ii) NUTS : - The samples selected in accordance with clause11.6.3.3.1 shall be divided into 4 equal parts. Each part shallbe subjected to one of the following tests.

a) Proof load test ( 12.7)b) Hardness test (12.6)c) Gauging of threads (12.3)d) Galvanising test and visual examination.

after stripping ( 12.13 & 12.1 )11.6.3.3.3 Stainless steel fasteners

(i) BOLTS : - The samples selected in accordance with clause11.6.3.3.1 shall be divided in 6 equal parts. Each part shall besubjected to the following tests:

a) Tensile strength / Extension ( 12.5.1 & 12.5.2)b) Stress at 0.2% permanent strain ( 12.8)c) Head soundness test (12.9)d) Bend test (12.11)e) Gauging of threads end Torsion test ( 12.3 & 12.12)f) Micro examination, hardness & Chemical.

Composition ( 12.15, 12.6 & 12.4 )

ii) NUTS : - The samples selected in accordance with clause11.6.3.3.1 shall be divided into 4 equal parts. Each part shall besubjected to following tests.a) Proof load test ( 12.7)b) Gauging of threads and Crushing test ( 12.3 and 12.10)c) Micro examination ( 12.15 )d) Chemical composition (12.4)e) Hardness test (12.6)



11.6.3.3.4 Should more than one sample fail in any test(s), the lot shall berejected. If only one sample fails in any test, twice the number ofsamples shall be drawn and the test, twice the number of samplesshall be repeated. The lot shall be accepted if there is no failure inthe re-test.

12. METHOD OF TESTS

12.1 Visual ExaminationAll the bolts & nuts shall be visually examined for finish,workmanship, chamfers and identification mark and for visualsurface discontinuities referred in IS: 1367 (Part 9) – 1993 and IS:1367(Part.10) – 2002. The bolts shall be examined for straightnessof shank and for any eccentricity of shank with respect to head.Nuts & washers shall be examined for eccentricity of the holes,crack, burrs, pits and other defects. Zinc coating on ferrousfasteners shall be examined for defects defined in Appendix A ofIS: 2629 – 1985.

12.2 Measurement of dimensionsThe dimensions of fasteners including lengths and threadedlengths of bolts shall be measured with the help of suitablegauges/devices and shall be within the limits specified in clause 7& 8 of this specification or these specified in purchaser’s drawings.

12.3 Gauging of threadsThese tests shall be done in black condition of galvanised fastenersafter stripping. The thread pitch for particular diametercombination [See Table 1 of IS:4213 (Part –II - 1976)] shall bemeasured with the help of thread pitch gauges conforming toIS:4211-1993. The thread profile shall be checked with the help ofgauges in accordance with IS: 2334-2001. The limits of sizes ofnut and bolt threads for tolerance class7H and 8g respectively arespecified in Table -1.



12.4 Chemical composition

12.4.1Ferrous fasteners: Chemical analysis of the galvanised steel boltsshall be carried out in accordance with IS: 228 -1987 and parts andshall conform to Clause 4 of IS : 1367(Part 3) – 2002 i.e. Carbon shallnot exceed 0.55%, sulphure 0.06% and phosphorus 0.05% for bolts.The chemical composition for ferrous nuts shall be as follows:

Property Class C Mn P S%Max. %Min. %Max. %Min.

4,5 0.50 - 0.110 0.15004 0.53 0.25 0.060 0.150

12.4.2 Stainless steel fasteners shall be analyzed in accordance with IS:228-1987 and parts. The chemical composition shall conform toGrades Mentioned clause 5.2.

12.5 Mechanical Tests12.5.1 Tensile Test for Bolts

12.5.1.1 G.S. Bolts: The tensile test shall be carried out on all sizes of boltsin finished condition where a. free threaded length equal to onediameter of bolt shall also be subjected to tensile load. The fractureshall occur in the shank or thread of bolt and not at the junction ofthe head and the shank. The calculation of the tensile strength isbased on the stress area. The tensile strength shall not be less than400 N/mm2.

12.5.1.2 Stainless Steel Bolts and Studs: The Tensile Test shall be carriedout on all sizes of Bolts and Studs in finished condition where a freethreaded length equal to one diameter of bolt shall also besubjected to tensile load. The fracture shall occur in the shank orthread of bolt and not at the junction of the head and the shank.The calculation of the tensile strength is based on the stress area.The tensile strength shall not be less than 500 N/mm2.

12.5.1.3 Test Rig: For the purpose of tensile test the rig shall be designedaccordingly. The speed of testing shall not exceed 25 mm/min. Thegrips of testing machine should be self aligning to avoid sidethrust on the specimen".



12.5.2 Determination of percentage elongation after fracture

12.5.2.1 G.S. bolts: The elongation test shall be carried out on full sizebolts in finished condition where it is possible to mark the gaugelength equal to 5.65 √So on the shank. Where it is not possible tomark the gauge length on the shank, machined test pieces shall beused for the purpose of determination of percentage elongation afterfracture as per clause 8.1 IS:1367 (Part 3):2002. The load shall beapplied in the manner as in 12.5.1.3. The elongation after fracturein both the cases shall not be less than 22%. The applicability of theelongation test on the full size bolts in finished condition and onmachined test pieces (refer Drg. No. ETI/C/0073 Mod. A) Shall beas under:-

Nominal thread /shank diameter

(mm)

Dimensions for bolts as per Drg. No.ETI/C/0073 Mod. AMachined test pieces In finished condition.

12 60/30 and below 120/36 and above.14 All sizes16 100/38 and below 175/44 and above.18 All sizes20 100/46 and below 200/52 and above.24 All sizes

12.5.2.2 Stainless Steel Bolts and Studs: The extension after fracture ofstainless steel bolts and studs shall be measured during the tensiletest (see sub- clause 12.5.1.2). The extension shall not be less than0.6 d (where d is nominal diameter of bolt).

12.6 Hardness Test :

12.6.1 Hardness test for galvanised steel fasteners shall be carried out afterremoval of zinc coating. On steel bolts, the test shall be carried outin accordance with Clause 8.4 of IS:1367(Part 3)-2002 and on steelnuts in accordance with 8.2 of IS:1367(Part.6)-1994. On stainlesssteel bolts and nuts this test shall be carried out in accordance withIS:1586-2000 or latest version. The values of hardness shall bewithin the ranges given in Table 3 below.



Table 3[Ref : IS:1367 (Part-V)-1994 or Latest]

FastenerProperty

classNominal size Hardness

Minimum MaximumSteel Bolts 4.6 All 120 HV 220 HVSteel Nuts 04 All 188 HV 302 HV

4 Over M16 toM39

117 HV 302 HV

5 M10 – M 16 130 HV 302 HVOver M16 toM39

146 HV 302 HV

Stainless steelBolts & Nuts

- All - 95 HRB

12.7 Proof load test on Bolts and Nuts12.7.1 Proof load test on Bolts and Nuts shall be carried out in accordance

with Clause 8.5 of IS:1367 (Part 3) - 2002 and Clause 8.1 of IS:1367(Part.6)-1994 respectively. The Stainless Steel Bolts shall be capableof being fully loaded upto the proof load, as prescribed in Table 4.Steel and Stainless Steel Nuts shall be capable of being fully loadedupto proof loads indicated in Table 5.

Table 4 - PROOF LOADS FOR STEEL BOLTS ISO METRICCOARSE TIREAD

NominalThread

Pitchof the

NominalStress

PropertyClass

Diameter(mm)

Threads(mm)

Area(mm2 )

4.6 of IS:1367(Part-6)-1994(Proof load N)

6 1 20.1 45207 1 28.9 65008 1.25 36.6 824010 1.5 58.0 1300012 1.75 84.3 1900014 2 115 2590016 2 157 3530018 18 18182.5 192 4320020 2.5 245 5510022 2.5 303 6820024 3 353 7940027 3 459 103000



TABLE 5 – PROOF LOAD VALUES FOR NUTS – ISO METRIC COARSE TIREADS

NominalSize

Pitch ofthe

threadmm

Nominalstressareaof

MandrelMm2

Proof load N

Steel Nuts StainlessSteelNuts,(ProofStress500

N/mm2)

PropertyClass 04

PropertyClass 4

PropertyClass 5

M6 1 20.1 7640 ---- 11700 10000M7 1 28.9 11000 ---- 16800 14500M8 1.25 36.6 13900 ---- 21600 18300M10 1.5 58 22000 ---- 34200 29000M12 1.75 84.3 32000 ---- 51400 42200M14 2 115 43700 ---- 70200 57500M16 2 157 59700 ---- 95800 78500M18 2.5 192 73000 97900 121000 96000M20 2.5 245 93100 125000 154400 122500M22 2.5 303 113100 154500 190900 152000M24 3 353 134100 180000 222400 476500M27 3 459 174400 234100 289200 229500M30 3.5 561 213200 286100 353400 280500M33 3.5 694 263700 353900 437200 347000M36 4 817 310500 416700 514700 408500M39 4 976 370900 497800 614900 488000

12.8 Stress at 0.2% Permanent Strain Test (For Stainless Steel Bolt only)

12.8.1 This test shall be conducted in accordance with IS:1608 – 2005 orlatest version. The stress at 0.2% permanent strain shall not beless than 205 N/mm2.

NominalThread

Pitchof the

NominalStress

PropertyClass

Diameter(mm)

Threads(mm)

Area(mm2 )

4.6 of IS:1367(Part-6)-1994(Proof load N)

30 3.5 561 12600033 3.5 694 15600036 4 817 18400039 4 976 220000



12.9 Head soundness test for Bolts

12.9.1 This test is not applicable to U Bolts, J Bolts and Flat Countersunk NibBolts.

12.9.2 This test shall be carried out as illustrated in figure 2 (enclosed) andin Fig. 4 of IS:1367(Part-3) - 2002.

12.9.3 The Bolt shall be inserted in a special Steel Die of the dimensionsgiven in Table II of IS:1367(Part-3)-2002. The hole in the die shallbe at an angle of 600 to its upper surface.

12.9.4 When struck several blows with a hammer the head of Bolt or Screwshould be bent to an angle (90-60)0 without showing any sign ofcracking at the fillet between Shank and head.

12.9.5 Where Screws are threaded upto the head the test will be regardedas established even if a crack should appear in the first thread,provided that head does not snap off.

12.10 Crushing test on Nuts (Stainless Steel only)

12.10.1 The Nut under test shall be placed edgewise on an anvil andcrushed by hammering till its threads come in contact with a mandrel,the diameter of which shall be 0.9 D1 where D1 is the minor diameterof Nut described in figure 1 of IS:4213(Part.I):1976. After crushing,the Nut shall not exhibit any fracture or crack at any point. The Nutmay then be broken for further chemical analysis and inspection ofstructure.

12.11Bond Test on Straight Bolts (Stainless Steel only)

12.11.1 This test is applicable only to straight Bolts.

12.11.2 The threaded part of the bolt shall be so held in the jaws of a vicethat the threaded part projects for a distance equal to at least half thenominal diameter. The projecting part shall then be bent byhammering so that the axis of free portion is at an angle of 165degree to the axis of the portion held in the vice. On examination, thebend shall not exhibit any crack (see figure-3).

12.12 Torsion test on Bolts and Nuts (For Stainless Steel Bolts & Nuts only)

12.12.1 A torsion test shall be conducted on Stainless Steel Bolts and Nuts.The test shall be conducted as described in 12.12.2 in case of straightBolts and as described in 12.12.3 in case of U Bolts. The ultimatetorsional strength shall be not less than that specified in Table 6.



TABLE – 6

ULTIMATE TORSIONAL MOMENT FORSTAINLESS STEEL BOLTS AND NUTS

Diameter of Boltmm

Ultimate Torsional Strength (Minimum)(kg-m)

10 6.512 1214 16

12.12.2 The head of the Bolt shall be gripped in a Vice and a Steel Plateslipped over the thread, the diameter of the hole drilled in this steelplate being 11 mm in case of 10mm diameter Bolts, 14 mm in case of12 mm diameter Bolts and 16 mm in the case of 14 mm diameterBolts. A Flat Steel Washer is then placed between the Steel Plate andthe Nut (but none between Plate and head of Bolt). The totalthickness of the Steel Plate and the Washer shall be so chosen thatthe position of Nut on the threaded portion of Bolt is the same aswhen the Bolt is in actual use. The test shall be carried out withoutlubrication of the parts in contact with each other. The torque shall beapplied by means of Torque Spanner, the design of which is subject tothe approval of the purchaser. The torque shall be increased in stepsuntil the Bolt fractures. After each increment of torque, the Nut shallbe unscrewed and the threads on both Bolt and Nut examined.

12.12.3 The torsion test on U bolts shall be conducted in a manner similar tothat described in 12.12.2, but the U bolt shall be prevented fromdeforming in the course of the test by seating it on a mandrel, theradius of curvature of which is equal to that of the inner edge of the Ubolt. A Steel Plate with two drilled holes shall be slipped over the twolimbs of the U bolt, the diameter of the holes in the Steel Platebearing the same relationship to the diameter of the Bolt as in thecase of straight Bolts. The steep Plate may be integral with themandrel. A Flat Steel Washer shall then be placed between the SteelPlate and the Nut on each limb(Fig 4). The torsion test shall then becarried out as described in 12.2.2 after gripping the mandrel in aVice. It is sufficient if the test is conducted on one limb of the U-Bolt.

12.12.4 The test shall result in fracture of the Bolt, but not of the Nut. Thevalues of torque at fracture shall be not less then that indicated in



Table-3. Further, on unscrewing the Nut at any value of torque belowthe value specified in Table 3, the threads on Bolt and Nut shall befound to be undamaged and it shall be possible to work the nut alongthe entire threaded length of the Bolt.

12.13 Galvanising testThe zinc coating on galvanised fasteners shall be tested foradherence, uniformity and mass. The mass of zinc coating shall bemeasured on the unthreaded portion by stripping method (IS:6745 -1972) or by previously calibrated Elcometer (magnetic method). Theuniformity shall be checked by Preece Test (IS:2633-1986) on thethreaded portion of Bolts. It shall withstand at least five successivedips in one minutes. Adherence shall be checked on the shank orhead by any one of the methods prescribed in clause 6.4 of IS 2629-1985.

12.14 Inter-Crytallic Corrosion Bend Test (For stainless steel only)

12.14.1 The Bend Test pieces shall not be larger than 12.5 mm (1/2 inch)diameter. The test piece shall be sensitized by heating to atemperature of 6500C for the period stated in the relevant materialspecification, followed by cooling in air. All test pieces shall beimmersed for 72 hours in boiling solution having the followingcomposition:

111 grams Copper Sulphate (CuSo4.5 H2O),98 grams Sulphuric acid [Relative Density (d) = 1.84]made upto 1 litre with distilled water.

Precautions shall be taken during the boiling to prevent concentrationof the solution due to evaporation.

After this preparation each test piece shall be bent through 90°round a radius equal to three times the diameter and thickness of thetest piece, and shall withstand this treatment without cracking on theouter, convex surface.

12.15 Micro examination of Stainless Steel Fasteners(Test for freedom from Carbide precipitation)

12.15.1 Micro examination on transverse section of Stainless Steel Bolts andNuts shall be carried out to ascertain freedom from Carbideprecipitation at grain boundaries. In case any sample shows evidenceof Carbide precipitation, the lot represented by the same may be



reheat treated, and resubmitted as a new lot at the discretion of thepurchaser. Otherwise the lot shall be rejected.

12.16 Permanent Sat Test on Spring Washers

12.16.1The Spring Washers under test shall be compressed flat for3 Minutes duration and released between two Plates having ahardness of 60 HRC, Minimum on release if the pressure, the freeheight (h2 = 2S indicated in IS:3063 1994) of the washer shall not beless then that given in Table 2 A & 2 B of IS:3063-1994. Thiscompression and removal of pressure shall then be repeated 20times in quick succession after which the free height shall not havefurther reduced.

12.17 Twist Test on Spring Washers

12.17.1 A portion of the Washer shall be gripped in Vice jaws and thenequal portion shall be gripped in wrench jaws as shown in Fig. 1 ofIS:3063-1994. Edges of the Wrench jaws shall be sharp and parallelto Vice jaws. The Wrench shall than be rotated in a direction thatincreases the free height of the Spring Washer till the Washer istwisted through on angle of 900. The Washer shall show no sign offracture.

13. MARKING AND MODE OF DELIVERY

13.1 The Bolts shall be delivered assembled with their Nuts and Lock Nutsand Washers (wherever required). The Nuts and Lock Nuts shall befully screwed on by hand.

13.2 Bolts, Screws and Nuts shall be provided with identification markingas laid down in IS: 1367 (Part.18)-1996. The marking of themanufacturers trade mark of name is mandatory for all productscovered by the obligatory marking requirements for property classes.For Stainless Steel Fasteners, AISI 316 should be marked asproperty class.

13.2.1 If the Fasteners are not properly marked by the manufacturersaccording to clause 13.2, then the whole lot shall be rejected.

13.3 The fasteners shall be packed as described in IS:9141-1979.



13.4 Each package shall contain only one grade and dimension offasteners.

13.5 The packages shall be marked clearly and legibly with the followinginformation.

a) The product designation,b) A pictorial representation of the product,c) Total number of pieces in the package,d) Net and gross mass of package,e) Name or identification symbol of the manufacturer,f) Purchase order No. and consignee,g) Date of inspection and inspecting authority andh) Any other information as required by Purchaser.



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