PRE-INSTALLATION VERIFICATION

Per AISC/RCSC section 7 Pre-Installation verification, fastener assembly testing must be conducted,
onsite, by the installation crew, using actual installation tools. Contrary to popular opinion Pre-
Installation Verification testing DOES NOT pass or fail fastener assemblies. Testing is intended to
discover possible issues between fasteners, tools and installers, before field bolting operations
commence.

The next few sections describe issues that may be highlighted by Pre-Installation testing results.

Fasteners:
Are the fastener assemblies capable of achieving 105%, or more, of minimum required bolt pretension
at all?

Torque must be applied to the fastener assembly until the tension calibrator indicates adequate
pretension or the bolt fails, whichever occurs first. Failure occurs by either the bolt breaking before
minimum pretension, or tensile load climbs and then falls, as indicated by the tension calibrator,
without ever achieving minimum pretension. Except for TC bolt 1, applying additional lubricant may
alleviate failure. However, if additional lubricant solves bolt failure, all fasteners represented by
lubricated test samples, must be similarly lubricated.

Tools:
Do the installation tools have enough output torque to tighten adequately lubricated fastener
assemblies, to at least 105% of minimum required pretension?

If the full effort of an installation tool applied to a fastener assembly, does not result in at least 105% of
required minimum pretension, the tool must be replaced for testing as well as for installation. While not
always true, an adequate installation tool should have a drive chuck at least as large as the fasteners
being tightened. For example, when tightening ¾” bolts, the installation tool should have a square drive
chuck of ¾” or more. Also, a tool’s manual may claim a higher output torque than the tool can produce.
Such claims are usually stated vaguely, such as, claiming the tool’s motor can produce some high
amount of torque. This statement may describe no-load torque output, but once load is applied, the
high torque described will not be realized.

Installation crews:
Do the installers understand how to employ the selected method?

The installers must understand that a snugged tightened condition must be achieved before the
pretensioning method is employed. Once a snug condition exists, the installers must fully understand
the method they employ and not confuse, or combine, fundamentals of individual methods. Such as

1
The Research Council on Structural Connections, Specification for Structural Joints Using High-Strength Bolts:
Section 2.10.4 “matched bolting assemblies shall not be relubricated by anyone other than the Manufacturer”
applying a torque value to rotate the nut to turn angle listed for Turn-Of-Nut or employing a torque
wrench as an inspection technique after the turn is complete. Doing so combines elements of Calibrated
Wrench and Turn-Of-Nut. In the same fashion, inspecting a DTI installation with a torque wrench
combines DTI and Calibrated Wrench methods.

Snug-tightened Joints
Every bolted joint must be snug-tightened before a pretensioning method can be performed. Snug-
tighten is defined as the effort applied to bring the steel plies into firm contact. AISC/RCSC describes the
effort as the full effort of an ironworker or a few impacts of an impact wrench (section 8.1) until the nut
cannot removed by hand. An attempt at manual nut removal is the only requirement for inspection
(section 9.1). There is no pretension requirement for a “snugged” joint. Per AISC’s Specification for
Structural Steel Buildings (AISC 360) Section J3:

“There are no specific minimum or maximum tension requirements for snug-tight bolts.”

The snug-tight condition is critical for the Turn-Of-Nut method since it relies on the snug position as its
starting point. With only hand tight as the inspection criteria, Snug-tight may begin with a pretension
that is negligible or zero. If so, the turn listed in table 8.1 may result in less than minimum required
pretension to comply with AISC/RCSC table 5.2.

Conversely, snug-tightening may result in a pretension near or greater than the minimum required, and
the required turn may strip or break the bolt when employed. This is especially true of bolt diameters ¾”
and below.

Snug-tightening does not affect the success of other methods. Calibrated wrench, DTIs, and TC bolts do
not use a snug position a starting point. If aggressive (high snugging) occurs, these methods will alert
those involved aggressive snugging has occurred. A DTI will flatten, a TC bolt will shear, or a calibrated
wrench will not advance the nut/bolt during the pretensioning operation. If low snugging occurs, the
same three methods will work as designed. The DTI and TC bolt will remain intact, and a Calibrated
Wrench will continue to tighten until the stall torque is reached.

Verification Basics
The following content applies to AISC/RCSC Pre-installation testing only. Individual projects, State DOTs
and Federal Highway specifications may differ substantially and will not be covered here. The following
represents Applied Bolting Technology’s interpretation of AISC/RCSC Pre-installation testing based on
The Research Council on Structural Connections’, Specification for Structural Joints Using High-Strength
Bolts (AISC 348) and the American Institute of Steel Construction’s Specification for Structural Steel
Buildings (AISC 360). Anyone interested in a different interpretation is welcome to read the documents
themselves.

Verification testing can be summarized as snug-tightening, at least three sample fastener assemblies, in
or with, a tension calibrator, applying the selected pretensioning method, and confirming at least 105%
of minimum required pretension has been achieved. While each method accomplishes this with
different tools, fastener components, or tightening techniques, all 4 tensioning methods follow these
basic principles of snug fastener, apply method, and verify conformity to specification. Lastly, all
acceptable methods are expected to permanently deform the fastener into its inelastic region 2.

Sampling
Pre-Installation verification testing begins with sampling. Per AISC/RCSC section 7.2:

“On a sample of not fewer than three complete bolting assemblies of each combination of diameter,
length, grade, and lot to be used in the work; Using bolting assemblies that are representative of the
condition of those that will be pretensioned in the work” (AISC/RCSC 16.2-52)

Regardless of method, it is critical that assembly samples be TRULY REPRESENTATIVE, that is, in similar
condition as fasteners being actively pretensioned. Testing a “new” fastener, removed directly from
sealed shipping receptacles, does not constitute a representative sample, unless only new condition
fasteners are actively being pretensioned.

Fasteners that have been snug-tightened & exposed to the weather, for any amount time, must be
verified as is, if this condition accurately represents the fasteners’ being tightened in the
steelwork. TRULY REPRESENTATIVE samples are especially important for TC bolts and Calibrated
Wrench installation and testing because these methods are negatively affected by weathering and
lubrication degradation.

Turn of Nut
1. Place each unique configuration of sample fastener assembly in a tension calibrator with
washers positioned in accordance with table 6.1, if necessary, and section 6. 2.
2. Snug the fastener in accordance with AISC/RCSC section 8.1 and inspect per section 9.1.
3. Apply the appropriate turn angle based on the ratio of the bolt diameter to its length (table 8.1).
4. Verify the resulting pretension meets or exceeds the value in table 7.1.
5. If the turn angle does not produce adequate pretension per table 7.1, continue turning until the
resulting pretension meets or exceeds the minimum required bolt pretension as listed in table
7.1. Since table 8.1 permits an upper tolerance for each rotation angle/turn, it is allowable to
rotate the nut beyond the value listed in the table. However, if more turn is necessary, the
ACTUAL turn angle/rotation determined must be used for field bolting operations, and not table
8.1’s listed turn.

TC Bolt
1. To be performed with every installation tool and repeated after any changes to the TC bolts
original lubricated condition.

2
AISC/RCSC 16.2-47 "In any of the foregoing installation methods, it can be expected that a portion of the bolt
assembly (the threaded portion of the bolt within the grip length and/or the engaged threads of the nut and bolt)
will reach the inelastic region of behavior. This permanent distortion has no undesirable effect on the subsequent
performance of the bolt."
 2. Place each unique configuration of sample fastener assembly in a tension calibrator with
washers positioned in accordance with table 6.1, if necessary, and section 6.2.
3. Snug the fastener in accordance with AISC/RCSC section 8.1 and inspect per section 9.1.
4. Apply the TC Shear tool to the fastener and operate until the splined end twists off the fastener.
5. Verify the resulting pretension meets or exceeds the minimum required bolt pretension as listed
in table 7.1.
6. If the resulting pretension does not meet the value in table 7.1, the fasteners must be returned
to the manufacturer for rework and the non-compliant lot of TC fasteners must not be
incorporated in the steel work. TC Bolts may not be altered or reworked by anyone but the
manufacturer. It is not permissible to remedy noncompliant TC assemblies. 3

Calibrated Wrench
1. To be performed daily with every installation tool and repeated with any changes to the tool’s
supply (adding additional air lines etc.).
2. Place each unique configuration of sample fastener assembly in a tension calibrator with
washers positioned in accordance with table 6.1, if necessary, and section 6.2.
3. Snug the fastener in accordance with AISC/RCSC section 8.1 and inspect per section 9.1.
4. Apply the assumed torque value to the fastener assembly.
5. Verify the resulting pretension meets or exceeds the minimum required bolt pretension as listed
in table 7.1.
6. If the resulting pretension does not meet or exceed the value in table 7.1, increase the applied
torque or clean and lubricate additional samples and reattempt all steps described here.

DuraSquirt® DTI in accordance with AISC/RCSC 2.12 (no

feeler gauge)
1. Place each unique configuration of DuraSquirt® DTI bolt assembly in a tension calibrator with
washers placed in accordance with table 6.1, if necessary, and a washer against the DTI bumps.
2. Snug the fastener in accordance with AISC/RCSC section 8.1 and inspect per section 9.1.
3. Tighten the fastener assembly until DuraSquirt® indication material appears at every available
Squirt™ location, i.e., a 5 bump DTI has 5 available Squirt™ locations.
4. Verify the resulting pretension meets or exceeds the minimum required bolt pretension as listed
in table 7.1.
5. If the resulting pretension does not meet or exceed the value in table 7.1, consult the advisory
section 4 of Applied Bolting Technology’s website and apply the recommendation described
therein.

3
The Research Council on Structural Connections, Specification for Structural Joints Using High-Strength Bolts:
Section 2.10.4 “matched bolting assemblies [TC bolts] shall not be relubricated by anyone other than the
Manufacturer”
4
https://www.appliedbolting.com/advisories.php. Additional assistance is available by directly contacting Applied
Bolting Technology via email at info@appliedbolting.com or calling 800 552-1999 or 802 460-3100.
Standard (non-squirting) & Squirter DTIs
The following lists the steps for both Standard (non-squirting) and Squirter type ASTM F959 DTIs

1. Place each unique configuration of sample fastener assembly, containing a DTI, in a tension
calibrator with washers placed in accordance with section 6.1, if necessary, and a washer against
the DTI bumps.
2. Snug the fastener in accordance with AISC/RCSC section 8.1 and inspect per section 9.1.
3. Tighten the fastener assembly until the tension calibrator indicates the minimum required bolt
pretension as listed in table 7.1.
4. Insert the appropriate feeler gauge between each available space between the DTI protrusions
until the gauge physically touches the bolt shank. Each instance the feeler gauge fits between
the DTI protrusions, and touches the bolt shank, shall be known as an entry. Each time the feeler
gauge does not touch the bolt shank, shall be known as a refusal.
5. The number of entries may not be zero. Conversely, the number of refusals may not be 100%. In
other words, a DTI must not be completely flattened when the tension calibrator dial reaches
the minimum value listed in table 7.1.
6. The number of entries/refusals defines the unique assembly’s test gap5 and Job Inspection Gap.
7. Record the number of refusals as the baseline for field inspection. The number of refusals
permitted in the steelwork must be more than assembly’s test gap discovered during
verification. For example, if the test gap is defined as 0 refusals, out of a potential of 5, the Job
Inspection Gap shall be at least one additional refusal in the steelwork.
8. If the number of entries equal zero and refusal count is 100% when the tension calibrator dial
reaches the minimum pretension listed on table 7.1, consult the advisory section6 of Applied
Bolting Technology’s website and apply the recommendation described therein.

5
ASTM F959 Appendix X1. "The job inspection gap shall be a gap less than the measured DTI test gap at 1.05× the
minimum required bolt tension."
AISC/RCSC 16.2-xi: Job Inspection Gap. A gap between a direct tension indicator and the hardened surface on
which it bears that is less than the gap measured in a bolt tension measurement device when a tension equal to
1.05 times the minimum required pretension is applied to the bolting assembly.
6
https://www.appliedbolting.com/advisories.php. Additional assistance is available by directly contacting Applied
Bolting Technology via email at info@appliedbolting.com or calling 800 552-1999 or 802 460-3100.
 Inch Bolt Tables
Pretension for Pre-Installation
Minimum Bolt Pretension Per
Verification Testing per AISC/RCSC
AISC/RCSC Table 5.2, inch series.
Table 7.1, inch series.

Bolt Bolt
A325/120 A490/150/144 A325/120 A490/150/144
diameter diameter
bolts bolts bolts bolts
in. in.

1/2 13 16 1/2 12 15
5/8 20 25 5/8 19 24
3/4 29 37 3/4 28 35
7/8 41 51 7/8 39 49
1 54 67 1 51 64
1 1/8 67 84 1 1/8 64 80
1 1/4 85 107 1 1/4 81 102
1 3/8 102 127 1 3/8 97 121
1 1/2 124 155 1 1/2 118 148
Equal to 105% of minimum bolt
pretension, rounded to the nearest kip. Equal to 0.70 times the minimum tensile
strength of bolts as specified in ASTM
F3125/F3125M for grades A325 and
A490 bolts, with UNC threads, rounded
to the nearest kip.
Metric Bolt Tables
Minimum Bolt Pretension for Pre-
Installation Verification Testing, metric Minimum Bolt Pretension, metric series.
series.

Bolt Bolt
A325M/8.8 A490M/10.9 A325M/8.8 A490M/10.9
diameter diameter
bolts bolts bolts bolts
mm mm

M12 51 76 M12 49 72
M16 96 120 M16 91 114
M20 149 188 M20 142 179
M22 185 232 M22 176 221
M24 215 270 M24 205 257
 M27 280 351 M27 267 334
M30 342 428 M30 326 408
M36 499 625 M36 475 595
Equal to 105% of minimum bolt Equal to 0.70 times the minimum tensile
pretension, rounded to the nearest kN. strength of bolts as specified in ASTM
F3125/F3125M for grades A325M and
A490M bolts, with MC threads, rounded
to the nearest kN.
 Pre-Installation Verification Test Report
using Direct Tension Indicators
Date:

Wrench Model:

Skidmore No.: Skidmore Calibration Date:

Bolt Grade: ASTM A325 ASTM A490

Bolt Size: BLACK GALVANIZED DACROMET

Lot No.:

DTI Lot & config.: DTI ON NUT SIDE DTI ON HEAD SIDE

Nut lot number:

F436 FW:

F436 Wide FW:

Required Tension:
(5% over minimum tension)
(7/8" Minimum = 39 kips, 5% over = 41 kips)
ASSEMBLY
ACCEPTABLE
Sample #1 .005" Refusals Yes No
Bolt Tension .015"
ASSEMBLY
ACCEPTABLE
Sample #2 Refusals Yes No
Bolt Tension
ASSEMBLY
ACCEPTABLE
Sample #3 Refusals Yes No
Bolt Tension

Inspector: Date: