Scribd Logo
Upload

Welcome to Scribd!

  • Fastener & Tower Accessories

    Uploaded by

    tejasj2002
    29 views47 pages
    The document discusses various types of fasteners and tower accessories used in construction, including their manufacturing processes, standards, sizes, grades, inspections, and tests. It covers hex bolts and nuts, washers, step bolts, anti-theft nuts, sign plates, earthing products, and more. Key points addressed are material specifications, dimensional checks, mechanical properties testing, chemical composition analysis, and galvanizing treatment assessments.

    Original Description:

    Ppt

    Copyright

    © © All Rights Reserved

    Available Formats

    PPTX, PDF, TXT or read online from Scribd

    Did you find this document useful?

    Is this content inappropriate?

    The document discusses various types of fasteners and tower accessories used in construction, including their manufacturing processes, standards, sizes, grades, inspections, and tests. It covers hex bolts and nuts, washers, step bolts, anti-theft nuts, sign plates, earthing products, and more. Key points addressed are material specifications, dimensional checks, mechanical properties testing, chemical composition analysis, and galvanizing treatment assessments.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    29 views47 pages

    Fastener & Tower Accessories

    Uploaded by

    tejasj2002
    The document discusses various types of fasteners and tower accessories used in construction, including their manufacturing processes, standards, sizes, grades, inspections, and tests. It covers hex bolts and nuts, washers, step bolts, anti-theft nuts, sign plates, earthing products, and more. Key points addressed are material specifications, dimensional checks, mechanical properties testing, chemical composition analysis, and galvanizing treatment assessments.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 47

    Bought-Out Items

    (Fasteners & Tower Accessories)

    By : Sachin Patel
    Fasteners : A fastener is a hardware device that mechanically joins or affixes two or
    more objects together. In general, fasteners are used to create non-permanent joints; that is,
    joints that can be removed or dismantled without damaging the joining components.
     
    Type of Fasteners :
    Hex Bolt & Nut Flat/Pack washer
    Anti theft Bolt & Nut Step bolt
    Spring washer ACD Rod

    Various National & International Standards :


    IS-12427, IS-14394, IS-1367 (P-3 & 6), IS-3063, IS-1572, IS-1367 (P-13), IS-2016 , IS-10238 etc…
    ISO-898 (Part-1 & 2), ISO-4034, ISO-4016, ISO-1461 etc..
    DIN-7990, DIN EN-24024, DIN-127, DIN-267 (P-26), DIN-126, DIN-7989-1 etc…
    ASTM A394, A563, A153, F436, F2329 etc…
    ASME B18.2.1 & 2 etc…
    AS/NZS 1559 etc…

    Various Sizes:- Various Grades:-


    Metric - M12, M16, M20, M24, M27, M30 4.6, 5.6, 6.8, 8.8, 9.8, 10.9
    Inches - 1/2, 5/8, 3/4, 7/8, 1 Type – 0, 1 & 3
    BOLT :
     

    Hex Bolt Anti Theft Bolt

    Manufacturing Process:-

    Steel Wire Rod  Wire Draw  Heading making Trimming  Thread Rolling
     Galvanizing
    Inspection criteria :-
     
    Visual Inspection :-

    Tool Marks Shear Burst

    Forging Burst Voids


     
    Inspection criteria:-
     
    Visual Inspection :-

    Line Marks Forging Crack


    Dimensional Check :-

    s = Across Flat e = Across Corner


    k = Head Thickness d = Shank Diameter
    b = Thread Length l = Total Length

    Chemical Analysis :- (e.g. M16 Grade 5.6 as per ISO 898 (P-1)
    Carbon = 0.13 to 0.55 %
    Phosphorus = 0.050 % max
    Sulfur = 0.060 % max
    Mechanical Tests :- (e.g. M16, Grade 5.6 as per ISO 898 (P-1)
    Wedge Tensile Test : Proof Load Test :
    (Requirement - 500 MPa min.) (Requirement – 44 KN for 15 Sec.)
    Mechanical Tests :- (e.g. M16, Grade 5.6 as per ISO 898 (P-1)
    Shear Test : Hardness Test :
    (Requirement – 310 MPa min.) (Requirement – 79 to 99.5 HRB)
    Mechanical Tests :- (e.g. M16, Grade 5.6 as per ISO 898 (P-1)
    Impact Test :
    (Requirement – 27 J min. @ -20° C (Sample size - 10x10x55)
    Galvanizing Tests :- (e.g. as per ISO 1461)
    Coating Thickness : Adhesion Test :
    (Requirement – 40 micron local & (Requirement – No Flaking/Peeling)
    50 micron Mean)
    Galvanizing Tests :- (e.g. as per ISO 1461)
    Preece Test/Copper Sulfate Test:
    (Requirement – No Red deposit observed)

    Embossing : (Manufacturing Identification Mark & Property class)

    Normal Embossing Embossing with size Sweden Embossing


    NUT :
     

    Hex Nut

    Various Grades:-
    Metric – 5, 6, 8, 9, 10 & 12
    Inches – A & DH

    Manufacturing Process:-

    Steel Wire Rod  Wire Draw  Nut Forging  Tapping


     Galvanizing  Re-Tapping
    Inspection criteria:-

    Visual Check :- Same defects as per Bolt slides


    Dimensional Check :-

    Chemical Analysis :- (e.g. M16 Grade 5 as per ISO 898 (P-2)


    Carbon = 0.58 % max.
    Phosphorus = 0.060 % max
    Sulfur = 0.150 % max
    Mechanical Tests :- (e.g. M16, Grade 5 as per ISO 898 (P-2)
    Proof Load Test : Hardness Test :
    (Requirement – 95.8 KN for 15 Sec.) (Requirement – 71 to 107 HRB)
    Galvanizing Tests :- Same tests as per Bolt slides

    Embossing : (Manufacturing Identification Mark & Property class)


    ANTI THEFT NUT :
     

    Manufacturing Process:-

    Steel Hex Wire Rod Machining  Tapping 


    Galvanizing  Re-Tapping
    Inspection criteria:-

    Visual Check :- Same defects as per Bolt slides


    Dimensional Check :-

    Chemical Analysis :- Same requirement as per Nut slides


    Mechanical Tests :- (e.g. M16, Grade 5 as per ISO 898 (P-2)
    Torque Test
    (Requirement – 10 to 16 N-m)

    Hardness Test : Same requirement as per Nut slides

    Galvanizing Tests :- Same tests as per Bolt slides


    FLAT/PACK WASHER :
     

    Manufacturing Process:-

    Steel wire / Plate  Forging / Punching  Galvanizing


    Inspection criteria:-

    Dimensional Check :-

    Galvanizing Tests :- Same tests as per Bolt slides


    SPRING WASHER :
     

    Manufacturing Process:-

    Steel wire  Wire Draw  Cutting  Heat Treatment


     Galvanizing (Hot Dip OR Electro Plating)
    Inspection criteria:-

    Dimensional Check :-

    d = ID S = Thickness
    d2 = OD h = Free Height
    s = Width

    Chemical Analysis :- (e.g. M16 as per IS 4072 Gr 70C6)


    Carbon = 0.65 to 0.75 % Silicon = 0.10 to 0.35 %
    Phosphorus = 0.050 % max Manganese = 0.50 to 0.80 %
    Sulfur = 0.050 % max
    Mechanical Tests :- (e.g. M16 as per IS 3063 Type-B)
    Permanent Set Test (2 Minute) : Permanent Load Test (48 Hours) :
    (Requirement – 56.3 KN, Free Height to be checked) (Requirement – 56.3 KN, Washer
    should not be Crack/Fracture)
    Mechanical Tests :- (e.g. M16 as per IS 3063 Type-B)
    Twist Test (90°) : Hardness Test :
    (Requirement –No fracture) (Requirement – 43.6 to 51.7 HRC)
    Galvanizing Tests :- (e.g. M16)
    Hot Dip Galvanizing (ASTM A153) : Electro plated (IS 1573 , SC-4) :
    Coating thickness Coating thickness
    (Requirement – 36 micron Individual) (Requirement – 25 micron Individual)
    43 micron Average) 38 micron Average)
    Preece Test
    Adhesion Test
    STEP BOLT (Set of NUT, FW & SW):
     

    Various Sizes:- Various Grades:-


    Metric - M12, M16, M20, M24, M27, M30 4.6, 5.6, 6.8, 8.8, 9.8, 10.9
    Inches - 1/2, 5/8, 3/4, 7/8, 1 Type – 0, 1 & 3

    Manufacturing Process:-
    Cold Forging
    Steel Wire Rod  Wire Draw  Heading making  Thread Rolling  Galvanizing
    Hot Forging
    Steel Wire Rod  Wire Cutting  Heating  Forging  Trimming 
     Thread Rolling  Galvanizing
    Visual Check :- Same defects as per Bolt slides

    Dimensional Check :- (As per Drawing)

    Head Dia Thread Length


    Head Thickness Total Length
    Shank Diameter

    Chemical Analysis :- (e.g. M16 Grade 4.6 as per IS 10238 & IS 1367 (P-3)
    Carbon = 0.55 % max Sulfur = 0.060 % max
    Phosphorus = 0.050 % max Boron = 0.003 % max
    Mechanical Tests :- (e.g. M16 Grade 4.6 as per IS 10238 & IS 1367 (P-3)

    Tensile Test (Requirement - 400 MPa min)


    Hardness Test (Requirement - 67 to 99.5 HRB)
    Cantilever Test (150 kg load for 10 sec. Deflection not greater than 30 micron)

    Embossing :- Same as per Bolt slides


    Galvanizing Tests :- Same tests as per Bolt slides
    Anti Climbing Device ROD
    (Set of Nut, FW & SW):
     

    Manufacturing Process:-
    Steel Wire Rod  Wire Draw  Cutting  Bending
    Thread Rolling  Galvanizing
    Dimensional Check :- (As per Drawing)

    Rod Diameter Thread Length Length between thread and bending angle
    Bending Angle Total Length Cutting Angle

    Chemical Analysis :- (As per required standard/drawing)


    Mechanical Test (Tensile Test) :- (As per required standard/drawing)
    Galvanizing Test :- (As per required standard/drawing)
    FASTENER PACKING
    Bag Packing Box Packing

    Pallet Packing
    Tower Accessories
    BIRD GUARD

    Manufacturing Process:-
    Steel Sheet Cutting, Punching  Galvanizing
    Dimensional Check :- (As per Drawing)

    Chemical Analysis :- (As per required standard/drawing)


    Mechanical Test (Tensile Test) :- (As per required standard/drawing)
    Galvanizing Test :- (As per required standard/drawing)
    ENAMEL COATED PLATES (SIGN PLATES)
    Number plate Circuit plate Phase Plate

    Arial plate Danger plate


    Manufacturing Process:-
    Steel Sheet  Cutting  Punching  Backing  Pickling  Enamel color applying  Backing  Printing  Backing

    Visual Check:-
    Improper Edges Back Side Patches
    Dimensional Check :- (As per Drawing)
    Color Retention Test & its Procedure :-

    On the sample selected from the lot several drops of aged Cupric Sulphate solution placed on
    plate and immediately cover with a clean 25mm-dia watch glass having free polished edges.

    Place the sample with watch glass in position in the test chamber at 27±2°C.
    After 20 hours samples taken out of from test chamber and rinse the samples with water after
    removal of watch glass.

    Darkening not to be observed on tested portion.


    PIPE TYPE EARTHING

    Manufacturing Process:-
    Black Pipe  Cutting  One side angle cutting  One side heating 
    One side Pressing  Punching  Drilling  Galvanizing
    Dimensional Check :- (As per Drawing)
    Chemical Analysis :- (As per IS 1161 Gr NB25)
    C – 0.16 % max S – 0.040 % max
    Mn – 1.20 % max P – 0.040 % max

    Mechanical Test (Tensile & Bend Test) :- (As per IS 1161 Gr NB25)
    Yield strength - 210 N/mm² min.
    Ultimate tensile strength - 330 N/mm² min.
    Elongation - 20% min.
    Bend test – 2t

    Galvanizing Test :- (As per required standard/drawing)


    Adherence test as per IS 2629
    Preece test as per IS 2633
    Thickness of zinc coating and Mass as per IS 4759/IS 6745
    COUNTER POISE EARTHING

    Manufacturing Process:-
    Galvanized Wire  Wire Cutting  Crimping Lugs
    Dimensional Check :-
    Wire Dimension (As per IS 12776)

    Lug Dimension (As per Drawing)


    Chemical Analysis :-

    For Wire:- As per IS 12776 For Lug :- As per IS 2062 E250A


    Carbon = 0.55 % max Carbon = 0.23 % max
    Manganese = 0.40 % to 1.10 % Manganese = 1.50 % max
    Sulfur = 0.050 % max Sulfur = 0.045 % max
    Phosphorus = 0.050 % max Phosphorus = 0.045 % max
    Silicon = 0.15 % to 0.35 % Silicon = 0.40 % max

    Mechanical & Galvanizing Test for Wire :-


    Galvanize Wire Testing Snaps :-
    KPTL Inspection Procedure :-
    Offer given by Supplier/Purchase.
    Send person for Inspection.
    Review BN test certificate, Internal test record and Raw Material Test Certificate.
    Verify material as per provided Packing list.
    Sampling as per QAP/Standard/KPTL procedure.
    Visual, Dimensional check, Mechanical test, Chemical test and Galvanize test perform
    as per QAP/Standard.
    After completion of all tests, witness report to be verified with all documents provided
    by supplier before start inspection.
    If all tests correlated with provided documents based on that dispatch clearance to be
    given to supplier/purchase.
    Inspection detail send to all relevant department.

    In case of waiver due to urgency, Internal tests records is reviewed and dispatch
    clearance is given.
    Once material is received at our plant, we will perform all tests as per QAP/Standards
    as our plant.
    If all tests are satisfied, we will clear the material for further process.
    THANK YOU

    You might also like