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JOININGTHE SPACE RACE
the orion project
A CAREERDEDICATEDTO BOLTS
bill eccles
KEEPING ITALL TOGETHER
skandinaviska glassystem
RELIABILITY STARTSWITH THE RIGHT SOLUTIONS
ABB uses combi bolts
A MAGAZINE ABOUT OPTIMISING BOLT SECURING # 1 201
A PERFECT MATCHSUPERBOLTJOINS THE NORD-LOCK FAMILY
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Nord-Lock Groupwww.nrd-lc.cm [email protected]
The Nrd-Lc cmbi blt is a blt with an integrated
pair f wedge-lcing washers. With the Nrd-Lccmbi blt, yu will be able t increase the efciency,
accuracy and safety f yur assembly, while at the same
time eeping inventry at a minimum. Yur parts will
nt nly be safely secured, but als crrectly assembled.
The Nrd-Lc cmbi blt is an easy-t-use prduct in
eld peratins, as well as in cnned spaces r areas
where access is difcult.
For demanding environments
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08 15
CONTENTS
Same Blted, but nw witheven wider scpe and depthJOININGTHE SPACE RACE
the orion project
A CAREERDEDICATEDTO BOLTS
bill eccles
KEEPING ITALL TOGETHER
skandinaviska glassystem
RELIABILITY STARTSWITH THE RIGHT SOLUTIONS
ABB uses combi bolts
A MAGAZINE ABOUT OPTIMISING BOLT SECURING # 1 2012
A PERFECT MATCHSUPERBOLTJOINSTHE NORD-LOCKFAMILY
08 Introducing SuperboltSuperblt ffers fast, safe and accurate blt securing.
Find out more about Nord-Locs latest acquisition
and the eciting pssibilities.
12 It all starts with the boltsEven the biggest, mst pwerful machines can quickly
becme undne by blt lsening, which is why ABBis s impressed with Nrd-Lcs cmbi blt.
16 A ceiling that wont breakStatin Triangelns glass rf in Malm, Sweden, is nt
nly winning architectural awards, but is s strng itcan survive an attac frm ftball hligans.
You hold in your hand the sixth issue
of Bolted. If youve read previous issues, I
should warn you right now that this issue
might not feel the same. Superbolt products
and the team behind them have joined Nord-
Lock and things will never be the same again!
After close to thirty years of deep commitment
to wedge-locking, we are now ready, together,
to take on whatever bolting challenges the
world might think of. And you can read all
about it in one place Bolted magazine!With our wide-ranging expertise and
the broad range of services currently on of-
fer, there is so much happening and so many
things to share with you that we almost dont
know where to begin! It is fortunate that we
have Bolted magazine to keep you up to date
with an even wider range of interesting ap-
plications, and the latest news. Bolted is the
place to tune in and learn about developments
and innovations that are at the forefront of the
bolt optimisation. I hope you know by now
that you can email your contact info and full
address to [email protected], and we will
send you Bolted free of charge, twice per year
in the language of your choice. (So far, you
may choose from English, German, Japanese,
French, Chinese, Swedish or Finnish).
We, of course, provide a lot of information
and insight into Superbolt in this issue, in-
cluding a theme on multi-jackbolt tensioners
(page 8). If you have any requests for future
themes, dont forget to let us know. We are
also proud to present a customer case with
ABB, using our Nord-Lock combi
bolts (page 12) and an interviewwith world-renowned bolt se-
curity expert Bill Eccles (page
15). Last but not least, we look
back at the founding of the
Nord-Lock Group and its
development over three
decades (page 18). In
2012, the Nord-Lock
Group celebrates its
30th anniversary!
Blted magaine is published by Nrd-Lcand strives t increase nwledge abut
blt assemblies. Nrd-Lc Grup is a wrldleader in blt securing systems and ffers
a wide prduct prtfli, including wedge-lcing technlgy and Superblt tensiners.These unique slutins withstand vibratinand dynamic lads. Fr further infrmatin
visit www.nord-lock.com
Blted is published twice a year in English,German, Japanese, French, Chinese,
Swedish & Finnish. It is free t custmersf Nrd-Lc wrldwide. Published by
Tidningsmpaniet in Gthenburg, Sweden,www.tidningsmpaniet.se
EDITOR-IN-CHIEF:
Carin [email protected]
CO-EDITORS:
Jasn [email protected]
EDITORIAL MANAGER:
Susanne [email protected]
TRANSLATIONS:
Sprblaget www.sprablaget.se
PREPRESS:
Tidningsmpaniet
COVER PHOTO:
Christer Ehrling
Please nte that unslicited manuscripts arent accepted. Material in this publicatinmay nly be reprduced with permissin.
Requests fr permissin shuld be submittedt the Editrial Manager
[email protected] material and pinins epressed inBlted d nt necessarily reect the views f
Nrd-Lc r the publisher.
Feel free t cntact us with any cmments:[email protected]
Printed in Sweden by VTT Grasa. Printedn UPM Finesse Glss 100 gram and
Maiglss 200 gram.
Blted is issued fr infrmatinal purpses.The infrmatin prvided is f a general
nature and shuld nt be treated as advicer be relied upn fr maing decisins rfr use in a specic matter. Any use f the
infrmatin prvided is at the users sle risand Nrd-Lc shall nt be liable fr any
direct, indirect, incidental r cnsequentialdamage arising ut f the use f theinfrmatin made available in Blted.
04 SECURED BY THE NORD-LOCK GROUP07
THE EXPERTS
17 BOLTING NEWS18
30 YEARS OF THE NORD-LOCK GROUP
15 Meet Mr Bolt ScienceBill Eccles travels the wrld prviding training and ex-
pertise n blted jints. He believes many prblemsare due t a lac f nwledge.
12
CARIN ESBERG
GLoBAL MARkETING MANAGER
3BOLTED# 1 2012
bolted# 1 2012Abut ptimising blt securing a custmer magaine frm Nrd-Lc
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WORDS:DAVID WILES
RESILIENTSuperbolt is compactand light, but can stillwithstand powerful shocks.
MANKINDS NEXT GIANTleap in space eplratin will taeus t destinatins thrughut ur slar system never befreeplred by humans.The spacecraft that will tae us there, theorin Multi-Purpse Crew Vehicle, is currently under cnstruc-
tin in New orleans, Luisiana at NASAs Michud AssemblyFacility. It will underg an uncrewed rbital test ight in 2014
CUSTOMER:
LOCKHEED MARTIN SPACE SYSTEMS ORION SPACECRAFT
CREW:
4
BOLTING INTO SPACE
TOTAL MASS TO ORBIT:
18,732 KG
COMPONENTS:
CREW MODULE, LAUNCH ABORT SYSTEM, SERVICE MODULE,
SPACECRAFT ADAPTERCARRIER ROCKET:
SPACE LAUNCH SYSTEMINTEGRATED LAUNCH DATE:
2017
DIAMETER:
5 METERS
and will y crew atp NASAs new Space Launch System snthereafter.
Safety and survivability are the abslute pririties fr theorin prject and, as in all aerspace applicatins, sie andweight are ey factrs. S it is n surprise that orins manu-facturer, Lcheed Martin Space Systems, has chsen Super-
bolt products for critical locations on the spacecraft, suchas the separatin pints between the crew mdule and theservice module, which are forced apart by controlled pyro-
technic charges.The cmpact sie, lightness and prelad prducing capa-
bilities f Superblt were well suited fr orins needs, as was
Superblts ability t withstand pwerful shcs, as prvenby U.S. Navy tests abard submarines.
Superblt is n stranger t the Final Frntier: its prductshave been used previusly n the Space Shuttle, and can befund n satellites. Yu culd call the orin prject ne smallstep fr Superblt.
WORDS:DAVID WILES, NIC ToWNSEND & LINDA kARLSSoN ELDH
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CUSTOMER:
BIFFA WASTE SERVICES LTDWASTE COLLECTED:
30 MILLION TONNES EVERY YEAR
OH WHAT A WASTE!
MODEL:
FITTED TO ALL MERCEDES REFUSE COLLECTION TRUCKSNUMBER OF TRUCKS IN THE FLEET:
+2,000NUMBER OF WHEEL NUTS IN FLEET:
20,000
ONCE WE THROWsmething away in the bin, mst f us have
the luury f nt having t give it anther thught. But this isnly because cmpanies lie Biffa have becme s efcient atcllecting, dispsing and recycling everyne elses waste.
over the past 90 years, Biffa has grwn frm a family busi-ness that cllected ash frm cal-red pwer statins in Ln-don, into the leading nationwide integrated waste manage-
ment business, prviding cllectin, treatment, recycling andtechnologically-driven energy generation services. Helping to
transprt all this waste, Biffa has ver 2,000 trucs, transprt-ing in ecess f 30 millin tnnes f waste every year. Earlierthis year, after etensive trials, Biffa decided t t Nrd-Lcwheel nuts t all its Mercedes trucs. Nw Biffa intends t tNrd-Lc t all its vehicles, acrss all mdels.
Previously, Biffas trucs used another brand on their hub
caps. However, these were buly and did not t all vehicles.Nrd-Lc wheel nuts, n the ther hand, are the same sie asstandard wheel nuts, and signicantly mre secure. They alst all types f vehicles.
The switch was driven by Biffas ey focus on health and
safety and its belief that all accidents can be avoided when
the apprpriate plans and cntrls are in place. As an addedbenet, Nrd-Lck wheel nuts are als cheaper than disk lcks,
thus delivering signicant savings t the business.
SAFE WASTE
All Biffa Mercedes Trucksare now fitted with Nord-
Lock wheel nuts.
PHOTO:BIFFAWASTE
SERVICESLTD
PHOTO:LoCkHEED MARTIN SPACE SYSTEMS
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secured by NORD-LOCK
THE GUITAR AMPLIFIERis a fairly invisible device on the
cncert stage, but it is just as imprtant fr the sund f theelectric guitar as the bw is fr the vilin. The amp increasesthe pwer f the incming electrical signal frm the guitar,but its mst imprtant task is t bring ut that specic sund
in the guitar players head.Anacon Technology in Gothenburg, Sweden, is a com-
pany that specialises in manufacturing high-end custmisedguitar amps. These amps are built using electrn tubes thatrequire high vltage fr their peratin. As this vltage canbe lethal, bolting is a big issue. Extreme vibrations during
turing, with lng-distance transprt n trucs and planes,can lsen the blts that attach the amps tw electric trans-
frmers t the chassis. In the wrst case scenari, the whledevice culd release a deadly charge f 500 vlts.
Since 2006, Anacon Technology has been using Nord-
Loc washers to secure the bolts in the amps. Their reli -
ability has been proven during thorough vibration tests in
accrdance with electrical safety standards. The amp mightbe damaged r brea dwn, but it will never give an electricshc t the guitar player r anyne else wh tuches it.
CUSTOMER:
ANACON TECHNOLOGY
NORD-LOCK GOES ROCKNROLL
LATEST AMPLIFIER MODEL:TUBEWONDER
WEIGHT:19 KGINPUT POWER:
MAX 160 VAMAXIMUM SOUND PRESSURE LEVEL:
118 DBPRICE RANGE:
FROM APPROX. USD 4,500OUTPUT POWER:
55 W
CUSTOMER:
SCOMI ENGINEERING
A COMMUTE TO SAVOUR
TOP SPEED:
80 KM/HAVERAGE SPEED:
65 KM/HELECTRIFICATION:
750V DC
TRAIN LENGTH:
4 CARRIAGES
LINES (PROPOSED):
8
DAILY RIDERSHIP (ESTIMATED):
125,000
HEAVY METAL
Anacons amp transformers are secured withfour pairs of Nord-Lock washers each. Thanksto these, guitar players can be sure that lethalvoltage stays inside the amp.
SAFE TRAVELS
Nord-Lock washers are usedto secure crucial joints on thebogies and train bodies.
WITH ITS POPULATION f 20.5
million and legendary trafc
congestion, the Indian city of
Mumbai presents challenges
to a commuter. But some re-
lief is in sight, in the form of
a USD 3.9 bn prject that willprvide Indias cmmercial cap-
ital city with the wrlds secnd
longest monorail corridor. Al-
thugh the cmmuters enjy-
ing the silky-smth ride f the
Mumbai Mnrail wnt ntice
it, vibratin is a key cncern fr
Scomi Engineering, which is
building 15 sets f 4-car trainsfor the networ at its kuala
Lumpur factry.Scomi had previously used
other bolt securing solutions
such as glue and lcing wire
at crucial jints n the bgies
and the train bdies, but withunsatisfactory results. Scomi
turned to Nord-Loc and has
been delighted with the out-
cme in an applicatin wheresafety is paramunt.
Scheduled to enter opera-
tin in May 2012, these slee,fast, air-cnditined cars culdyet mae cmmuting in Mum-
bai a pleasure.
secured by the NORD-LOCK group
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ASKTHEEXPERTS
Do you have a question aboutbolt securing? Put the Nord-Lockexperts to the test.
Why do Superbolt multi-jackbolt
tensioners prevent loss of preload?
Material fatigueexplained
SEMS overview
Q: What is the fatigue phenom-ena in bolted connections?A:
Material fatigue occurs when a
component is subjected to cyclic
loading. If the cyclic loads applied
are too high, microscopic cracks
will form, and when they reach a
critical size the part will fracture.Material fatigue occurs at a stress
level below the yield strength of a
material.
When designing a bolted joint
it is crucial to minimise the cyclic
loads applied to the bolt to avoid
fracture and subsequent failure of
the connection. The basic princi-
ple for achieving this is to use an
elastic bolt to clamp stiff members
and to tighten the fasteners to a
high preload.
A bolts elasticity may be im-
proved by using a long bolt, forexample, or by reducing the shank
diameter. Generally, it is prefera-
ble to use several thin bolts rather
than one large one if the large bolt
cannot be preloaded properly or
the clamping length cannot be
increased suitably. The clamped
members can be kept stiff by
avoiding the use of steel in prefer-
ence to soft materials such as cast
iron, light metal alloys, polymers
and similar.
A possible cause of fatigue fail-
ure is the over-dimensioning ofbolts which are too stiff. Also, the
most common failure position is in
the first engaged thread. UW
Q:What are SEMS?A:SEMS are a bolt combina-tion with a permanently attached
washer or set of washers. It is also
referred to as captivated wash-
ers, screw/bolt-washer assemblies
or combi bolts. The word SEMS
originates from The Illinois Tool
Q:Superbolts have been usedin numerous demanding bolt-ing applications with extremeworking loads and high vibra-tions. What mechanical princi-ple of Superbolts prevent lossof preload?A:Preventing loss of preload iscertainly a major advantage of
a Superbolt. However, it stems
from Superbolts ability to at-
tain the proper preload in the
first place. This is because, for aproperly designed bolted joint,
achieving the proper preload
(clamping load) over the work-
ing load (separating force) is
what keeps fasteners tight.
However, in the majority of
cases, achieving proper preload
is extremely difficult, espe-
cially when tightening conven-
tional hex nuts. This is because
as the bolt diameter increases,
the torque required to reach a
certain bolt stress increases by
a power of three. Therefore itis very difficult to easily tighten
hex nuts that are over one inch.
The torque required to
tighten Superbolt tensioners, Thread Diameter (mm)
Trque (Nm)
140,000
70,000
30 60 90 120 150 180
Torque Curve for 310 MPa Bolt Stress
Torque RequiredFor Standard Nut
Torque RequiredFor Superboltmulti-jackbolt
tensioner
Works Inc., who made machines
that produced pre-asSEMbled
washers and screws. In spite of
the original patents and trade-
marks, the word SEMS is gener-
ally recognised as a generic term
applicable to screw and washer
assemblies. The washers are in-
stalled on the bolt blank before
thread rolling. Since the outer
diameter of the threads becomes
larger than the inner diameter of
the washers, the washers are pre-
vented from prising loose from
the bolt. It is normally possible for
the washer/washers to slide on the
non-threaded part of the bolt.
SEMS offers several benefits in
terms of faster or easier assem-
bly and handling. The Nord-Lock
combi bolts, which are relatively
new within our product range,
combine the convenience of a bolt
with a pre-assembled Nord-Lock
washer pair for superior locking
capacity.
on the other hand, are kept low
since the large preload is spread
over many smaller bolts known
as jackbolts, which need only
to be torqued with simple hand
tools. Also, with controlled lu-
brication and minimal frictional
losses, Superbolt reaches high
preloads with superb accuracy
and repeatability. Integral to the
design, Superbolt adds desir-
able elasticity to the bolted joint,
which helps maintain preload,
especially in thermal or dynamic
applications. Testing shows that
Superbolt tensioners maintain
the preload even when subjected
to a million cycles of high dy-
namic load at a level of 98% of
the applied preload. Many other
tests, including fatigue and
vibration tests, have been per-
formed. For further details, test
reports are available. SB
The Nord-Lock combi bolt offers
the following:
Ensures faster product assem-
bly, thanks to pre-assembled
and pre-lubricated parts.
Decreases failures relating to
improper mounting or failing toattach washers.
Facilitates product assembly in
the case of extremely small di-
mensions.
Makes service and repair in
rough surroundings or hard-to-
reach areas easier and safer.
Facilitates inventory and logis-
tics, thanks to having fewer item
numbers.
Makes disassembly faster and
easier, as loose washers can be
hard to remove, especially from
tapped holes. FC
Nord-Lock combi bolts offerseveral benefits in terms offaster or easier assembly andhandling.
FRIDA CULLINMATERIALExPERT
ULF WENDTAPPLICATIoNENGINEER
THE EXPERTSEmail yur questins abut blt securing t [email protected]
STEVE BUSALACCHIENGINEERINGMANAGER
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R
OLF STEINBOCKS EUREKAmo-
ment, which came in 1974 while
on a service call to one of his
scrap choppers in a US steel
mill, solved at a stroke two basic
problems with big bolts. One is
that they take a massive amount
of torque to tighten. The second
is that they have a nasty habit of
working loose. When told that
the bolts on the gearbox of theotherwise perfectly-functioning
scrap chopper required tightening a couple of
times a day, Steinbock had a flash of inspiration
which he hastily scribbled down on the prover-
bial napkin. His solution worked perfectly, and
the bolts never came loose again.
Steinbocks solution, to split one big torque
into a number of smaller torques, was commer-
cialised as Superbolt. He was actually surprised
that nobody had thought of it before, says his
son, Allan Steinbock, who is the companys Vice-
President. Word spread to customers beyond the
steel industry and, today, Superbolts multi-jack-
bolt tensioners can be found in a wide range
WORDS:DAVID WILES
PHOTO:CHRISTER EHRLING, SUPERBoLT & CERN
With Superbltyu can tighteneven the largest blts with hand
tls. Lie the Nrd-Lc prductrange, the result is safer, faster andmre accurate blting, maingthem a perfect match. Blted taesa clser l at Nrd-Lcs latestacquisitin.
Like the Nord-Lockwedge-locking products,Superbolts offer a simplebut ingenious design thatsignificantly increasesbolt security while saving
time and labour.
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Superbolts distinctive cir-cle of jackbolts help obtainproper holding power andbolt tensioning, ensuringbolts do not come loose,
even in high-vibrationsituations.
of applications, from satellites to submarines
to the Large Hadron Collider at CERN.
The problem Steinbock tackled is the fact that
for bolt diameters bigger than about M24, it is
very difficult to create enough torque to tighten
or loosen a bolt. Simple physics shows that the
torque needed to properly pre-stress a bolt in-
creases by the third power of the bolt diameter.
Therefore as the bolt diameter increases, the
torque requirement for tightening it soars.
Traditionally this has required some heavy-
handed methods, but all have their drawbacks.
The sledgehammer gives little control, is incon-
sistent and often causes injuries. Thermal tight-ening, crane wrenching, hydraulic wrenching
and hydraulic tensioning can be expensive, in-
accurate, time consuming and unsafe.
However, Superbolt tensioners, which are de-
signed as direct replacements for standard nuts
and bolts, allow for the tightening of large bolts
with simple hand tools, making bolting more ac-
curate, faster and safer. The primary benefit of
Superbolt is the reduction of torque required,
says Steinbock. You only need a handheld
torque wrench or air tool.
SUPERBOLT TENSIONERS UTILISE a ring of hard-
ened jackbolts threaded into a nut body. The Su-
perbolt tensioner is first threaded by hand onto
a new or existing bolt or stud. Once positioned,
As a bolts diameter increases, the torque required for tightening soars, but Superbolt tensionersreduce the torque required by splitting one big torque into a number of smaller torques.
bolt tensioning is accomplished by tightening the
circle of jackbolts. A number of different product
lines are based on the same basic concept.
Because we are able to generate the proper
preload, we achieve the proper holding power
and we dont have bolts or nuts coming loose,
even in high-vibration situations, says Steve
Busalacchi, Engineering Manager. This reduc-
es expensive downtime: both downtime required
for maintenance to retighten loose bolts, but also
downtime caused by studs breaking due to insuf-
ficient holding power.
Because Superbolt can be installed with hand
tools, there are also time savings. We install
quicker and we remove quicker, says Busalac-
chi. Peoples first impression is that it will take
longer because they have several bolts to tighten
instead of one. But once they see that you spin
it on by hand and perform a quick tightening
pattern similar to mounting a wheel on your car
with hand-held tools, then they are impressed by
the time savings we provide.The safety benefits of the Superbolt solution
are highly appreciated at a time when many in-
dustries have implemented safety programmes.
Safety is a huge factor for us, says Steinbock.
Alternative methods require equipment which
can create extremely dangerous conditions. Our
products are safe to use, and this is a huge benefit
to our customers.
FACTS:
BENEFITS OF SUPERBOLT
Only hand tools are required
Time and labour-saving
Maximum holding power
Increased workplace safety
Accurate preload
Ideal for restricted areas
Flexing adds elasticity to the joint
Tightens in pure tension
Economical and reusable
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The forces are so immense that they
require large bolts and the only way to
tighten large bolts without heavy tools
is the Superbolt principle.NORBERT SCHNEIDER, HEAD oF ENGINEERING AT NoRD-LoCk AG
Cheaper and fasterLARGE AMMONIA REACTORSoften require
the use f large and epensive hydraulic ten-sioners, and tightening or untightening can
tae several days, wring arund the clc,and using cranes. At ne such reactr, nt nly
was the initial cst f the Superblt tensin-ers nly a fractin f the cst f the hydraulictensioners they replaced, but the installation
t tw laburers nly 5 hurs.
Gold award from CERNSUPERBOLT SUPPLIED MORE than 1,500
high-strength mechanical tensioners, expan-
sin blts and multi-jacblt tensiners t the
CERN Large Hadron Collider in Switzerland.Multi-jacblt tensiners were used fr an ap-plicatin requiring a very high clamping frce,but with limited space fr tightening the blts.
Since nly hand tls were required, the needt create anchr pints fr heavier tighteningequipment was eliminated. Superblt wn the
CMS gold award for its contribution to the
prject.
Ideal mine solutionTHE SEVERE ENVIRONMENT of an under-
grund cal mine takes a brutal tll n crusher
drum bits. It is a vilent applicatin with high
RPMs and cnstant punding as the bits cutint cal and rc and ften brea ff, requir-ing repair undergrund, where accessibility islimited. With Superblt, space restrictins aref little cncern because nly small hand tlsare required, maing the process easier and
faster.
WHILE SUPERBOLT PRODUCTS are available off-
the-shelf, about half its sales are for special non-
standard items in sizes all the way from M16 to
over M1450. What makes Superbolt unique is
our ability to adapt to different situations, wheth-
er this is reviewing temperatures and changing
materials, or customising designs to fit customer
requirements. We are very adaptable and want
to make sure that the customer receives the right
solution and is satisified, says Busalacchi.
Users of Superbolt products including Gen-
eral Electric, Siemens and Rolls-Royce appreci-ate the fact that that they can receive finite ele-
ment analysis (FEA) carried out by independent
organisations. These organisations can provide
an independent assessment of what we are tell-
ing our customers about our calculations, says
Norbert Schneider, Head of Engineering at
Nord-Lock AG. It boils down to safety and cus-
tomers peace of mind.
A CURRENT INSTALLATION of Superbolts shows
just how extreme an environment they can han-
dle. About 2,000 tensioners made from exotic
nickel-based alloys have been installed at the
Max Planck Institute for Plasma Physics inGreifswald, Germany, where research will be
carried out into the principles of a fusion power
plant, which, in the future, could provide safe,
green energy from the same process that takes
place inside the sun.
The Max Planck Institute has chosen Su-
perbolt because the ambient conditions under
which the research is to be carried out are quite
horrendous - we are talking about -270C, radia-
tion and an absolute vacuum, as well as extreme-
ly high loads, says Schneider. Basically, we are
dealing with outer space conditions found close
to the sun. And highly compact machines mean
that there is no access for heavy tools. The forc-es are so immense that they require large bolts
and the only way to tighten large bolts without
heavy tools is the Superbolt principle, says Sch-
neider.
Such characteristics and performance mean
that once customers have tried Superbolt, they
rarely return to the troublesome methods of the
past.
The hardest part, as with any product, is to
get people to try it, says Steinbock. But once
people have tried it, our repeat order rate is phe-
nomenal. Customers now count on us to provide
a quality product and we receive tremendous loy-
alty from them in return.
Superbolts in use
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The ABB DC drivesare designed formost industries,including metals,mining, wire manu-facturing, oil rigsand cranes.
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POWERINGTHE INDUSTRY
WORDS:LINDA kARLSSoN ELDH
PHOTO:kLAUS HECkE & ABB
MOTORS Electric mtrs are ften called the wrhrsesf the industry, running all inds f machinery rangingfrm escalatrs and si lifts t huge prt cranes. Heavymechanical mvements require a reliable drive that ensuresthe best trque, speed, and mtr efciency. This reliabilityften starts with the right blt securing system.
D
IRECT CURRENT (DC) MOTORS
have been around for almost
100 years. Efficient speed regu-
lation, a compact design and low
maintenance make them a great
option for almost any industrial
application. As the electronics
in heavy machinery has to cope
with high levels of thermal stressand vibrations, the right bolt se-
curing system is vital to ensure
the DC drives reliability.
ABB is the worlds largest drives manufac-
turer, operating in around 100 countries and
employing more than 130,000 people. The
companys DC Drives production operation is
headquartered in Ladenburg, Germany. The
drives are designed for most industries, includ-
ing metals, cement, mining, pulp and paper,
printing, food and beverage, wire manufactur-
ing, oil rigs and cranes.
The DC drive converts AC power to DC volt-
age in order to vary the speed and torque of the
motor. Bolting is an important issue because
heavy machinery, such as port cranes, often need
to double or even triple the load on the motor,
which heats up the power bus bar and can cause
the bolts to loosen.
SINCE THE BEGINNING of the year, ABB in Lad-
enburg has been testing a Nord-Lock combi bolt
wich is a bolt with integrated Nord-Lock wash-ers. The bolt is a M10x20 to be used for fitting
copper bars with thyristor modules. This bolt
connection is the core component of the bolt
structure in the D4 and F4 power units in two
of the companys most important series the
DCS550 standard drives and the DCS800 in-
dustrial drives.
We were used to conventional bolts loosen-
ing by 10 to 20 per cent after being tightened,
says Holger Krhler, head of DC Drives Qual-
ity Management and Development Design. But
after testing the Nord-Lock combi bolt in more
than 1,000 devices, there hasnt been a single sit-
uation where the bolts loosened.
Nord-Lock combi bolts being mounted onto a moduleat the ABB DC Drives production facilities in Ladenburg,Germany.
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Last year, the team delivered 13,000 DC drives. Process optimisation is important inorder to keep pace with the growing demand.
The combi bolt is being tested on the newest member of ABBs DC drive family: the DCS550 series. Holger Krhler ishappy to note that, so far, not one single bolt has loosened.
To stay number one, you alwayshave to optimise the process.Thats what we are doing rightnow, testing the combi bolt from
Nord-Lock.HOLGER KRHLER, HEAD oF DC DRIVES QUALITY MANAGEMENTAND DEVELoPMENT DESIGN AT ABB LADENBURG
Business argumentsTHIS IS HOWABB benets from the Nord-
Lc cmbi blt:TIME-SAVING with just ne cmpnent
instead f three, the blts are faster tinstall.
EASE OF USE fewer cmpnents, fewererrrs.
SAFETY blts dnt lsen.SPACE SAVING small diameter blt de-
sign enables blts t be placed clse teach ther in the device.
WHAT IT DOES:
POWER AND AUTOMATION TECHNOLOGIES
FACTS:
ABB GERMANY
PART OF:
ABB GROUP, ONE OF THE LARGEST ENGINEERINGCOMPANIES IN THE WORLD, WITH HEADQUARTERS INZRICH, SWITZERLAND.
BOLT SECURING:
NORD-LOCK
HISTORY:
ABB WAS FOUNDED IN 1988 IN A MERGER OF THESWEDISH COMPANY ALLMNNA SVENSKA ELEKTRISKAAKTIEBOLAGET (ASEA) AND SWISS BROWN, BOVERI &CIE (BBC).
ANNUAL SALES 2010:
EUR 3.03 BILLIONNUMBER OF EMPLOYEES:
AROUND 10,000
Each power unit contains eight bolts.
Previously, ABB used two plain washers to se-
cure a bolt. The Nord-Lock washers have a
much smaller diameter, which makes it possi-
ble to place them nearer to each other in the
device. A compact design is crucial for applica-
tions where space is at a premium. ABBs DC
drive portfolio, which ranges from 9 to 18,000
kW, provides the highest power-to-size ratio onthe market. For Holger Krhler, this is one of
the main advantages of ABB drives compared
to the competition.
This is due to the fact that ABB complete-
ly separates the manufacturing of AC and DC
drives, he explains. Other companies use the
same electronics for both AC and DC. They are
therefore much more constrained by restrictions
than we are.
FORTY TO FIFTY per cent of ABBs DC drives are
used to revamp ageing electric components in
older plants, making them a simple and cost-ef-
fective solution to reduce operational costs and
increase capacity. There is a booming demand
for this kind of modernisation. The production
volume in Ladenburg has increased steadily
by 10 per cent per year since 2008. Last year,
13,000 DC drives were supplied by the produc-
tion facilities and the company expects growth to
continue. Holger Krhler is proud to state that
ABB has managed the increased demand with-
out having to hire new employees.We put a lot of effort into process optimi-
sation, he says. Weve installed modern equip-
ment and improved handling practices. The new
combi bolt from Nord-Lock is another step in
this direction.
FOREWOMAN JUTTA ZEHNBAUER has worked at
ABB for 26 years and cant even begin to guess
how many bolts she has handled over the years.
With the Nord-Lock combi bolt, we only
have one part to work with, instead of three,
she says. That makes the work a lot quicker and
easier. Our production people are really happy
working with it.
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WORDS:CHRISTINA MACkENzIE
PHOTO:DAN DUNkLEY
ADVISER When Bill Eccles was adesign engineer, he nted that
peple generally agreed n manydifferent things. Hwever, as faras nuts and blts were cncerned,everyne had different infrma-tin. S he paid clser attentint this sectr, even earning himselfa PhD n why nuts cme lse.Tday, his epertise is called upnby cmpanies and regulatryauthrities wrldwide.Regulatory authorities?
Yes, I ften act as an epertwitness. Fr eample, in 2011, Itestied during the inquest int
the Grayrigg accident when miss-ing blts cntributed t the Febru-ary 2007 derailment f a train innrthern England in which nepersn was illed.What kinds of companies doyou work with?
oh, all srts! I didnt real-ise when I was yunger that theindustries which rely n nuts andblts range frm electric tth-brush manufacturers t thse f iland gas pipelines, fr eample.Cant in-house engineers handle
bolting problems?Nt always. They graduate
frm university, ften with ntheretical nwledge n analys-ing blted jints. Many jint failureprblems are due t the jint ntbeing designed crrectly. There isa signicant lac f nwledgeut there. If yu design the jintprperly frm the utset and thefasteners are tightened crrectly,yu dnt need smething t stpit frm cming lse.What sort of problems do you
solve?Very specic nes related t
blted jint failure such as nutscming undne, blt fatigueprblems, thread stripping issuesetc. I have als cvered tighteningprblems bth with fastener tlcmpanies and end users wringn such issues as what the appr-priate tightening trque shuld beand what tightening methds andprcedures t use t reduce bltprelad scatter.What do you think your added-
value is?
It is prviding epertise in slv-ing prblems with state-f-the-artnwledge and, nt nly slvingthe prblem, but slving it ec-nmically. I eep myself up-t-dateby reading research papers pub-lished n the subject tgether withwring with a lcal university.Are there many?
Quite a lt f wr has been
dne since the 1960s but unfr-
tunately research is nt gettingbradcast. Fr eample, the factthat helical spring washers d nt
wr was rst shwn in a 1969research paper and has subse-quently been prved by therstudies. Hwever, they are stillbeing used and failures are ccur-ring as a result, sme f which arecatastrphic in nature.You also provide training?
Yes, I typically train the designengineers, nt the peple actu-ally tightening the blt. I basi-cally shw them hw t preventblted jints failing and hw tptimise the fastener sie, i.e. t
decide what sie and strength f
blt shuld be used, and whatthe tightening trque shuld bes that the structural integrity f
the jint can be assured. I wr inNrth America, Eurpe and the FarEast and fr cmpanies rangingfrm defence cmpanies, lts fnuts and blts n armured vehi-cles and warships!, t car and ma-chinery manufacturers and s n.Has the economic downturn in-fluenced your business?
N. There was a signicantdrp-ff when the crisis rst hitin 2008 but things piced up andIm nw as busy as ever. Perhapsmany engineering rms have es-
caped the wrst?
Knowledge prevents bolt failure
FACTS:
BILL ECCLESAGE:58ROLE: Amongst other qualifica-tions, Bill has a PhD on aspectsof why nuts and bolts self-loos-en. After working as a designengineer and engineering man-ager for a number of compa-nies, Bill founded his consul-tancy company Bolt Science in1992 and now travels the world
giving advice on various aspectsof bolted joints.
Bill Eccles solves problems related to boltedjoint failure such as nuts coming undone, boltfatigue problems, thread stripping issues andmore.
IN THE SPOTLIGHT
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Safe travellingWORDS:LINDA kARLSSoN ELDH
PHOTO:SkANDINAVISkA GLASSYSTEM
THE CHALLENGE The City Tunnel is arail lin between Malm and the resundBridge in Sweden, with a si ilmetrerailway running under Malm city centre.The glasswr cmpany SandinavisaGlassystem, was assigned the tas fcnstructing the rf f the new Triangelnrailway statin situated in central Malm.This required a bearing frame in highstrength stainless steel cvered in 1,200square metres f glass cmprising 1,600different sectins. The steel cnstructinsarms meet in ndes, which are epsed tvibratins frm utside, as well as frm the
trains belw grund. After the glass hasbeen put in psitin, it is impssible tchec if a blt inside a nde is cminglse r nt. Fr this reasn, the team hadt nd a blting slutin guaranteed tstay in place.
ACCESS DENIEDBolts need to be secure because, oncethe glass sheets have been installed,it is impossible to inspect them.
THE SOLUTION Sandinavisa Glassys-tem started t evaluate different slutinsand sn discvered Nrd-Lc washers.
These washers were the nly nes thatculd ffer this ind f wedge-lcing ef-fect, thans t the cams n the inside fthe washers, says Stefan Abrahamssn,Prject and Mareting Manager at Sandi-navisa Glassystem. We were abslutelysure that the blts wuldnt cme lse,but we needed t cnvince the custmerthat Nrd-Lc washers were better thanany f the blt lcing systems apprved inthe Swedish Regulatins fr Steel Struc-
tures.Nrd-Lc therefre perfrmed etend-
ed tests f the washers ability t secureblts safely in this ind f glass and steelcnstructin. These tests were successfuland mre than 5,000 Nrd-Lc washers
were used t secure the blts in the ndesf the Triangeln steel cnstructin. Differ-ent washers were used fr blt sies rang-ing frm M12 t M24, depending n thepressure r pulling effect f the steel arms.
THE RESULT The City Tunnel wasinaugurated by the ing f Sweden at theend f last year and the Triangeln is nwthe third largest railway statin in Sweden.Every day, 37,000 travellers pass under theglass rf that is s safe that it has evenbeen fcially branded hligan prf,which means that it culd cpe with fur
ftball hligans, each weighing 100 il,simultaneusly jumping up and dwn nevery single square metre f the rf. InNvember 2011, the Triangeln wn thekasper Salin prie, which is the mstprestigius architecture prie in Sweden.
THE SOLUTION
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BOLT SECURING COMPANIES, Su-perblt Inc. and P&S Vrspannsys-teme AG in Switerland (tdayNrd-Lc AG), bth acquired byNrd-Lc in August, have receivedcerticatins by Det Nrse Veritas(DNV) fr several series f Super-
blt multi-jacblt tensiners.
Nord-Lock gets type approval by ABS
THE ABS TYPE APPROVALis a vluntary pr-
gramme whereby ABS certies manufacturersarund the wrld, wh are capable f cnsist-ently prducing a prduct in cmpliance withprduct specicatins. The applicatin invlvesa lt f paperwr, thrugh prduct testingand an etensive factry audit. Hwever, frNrd-Lc, it was wrth the tw years f wrt btain an ABS Type Apprval fr all f itswashers.
It was a strategic decisin t apply fr theABS Type Apprval, says Csaba Madru, respn-sible fr Glbal Develpment Perfrmance Ser-vices at Nrd-Lc Internatinal AB. oil & Gasis ne f ur mst imprtant target grups and
ABS is the mst imprtant certicatin in theUSA and Asia. This will further pen up thesemarets fr us.
OIL AND GAS rigs are cnsidered t be amngthe mst dangerus places in the wrld twr: lng shifts, highly cmbustible materials,strms and the ris f natural disasters. Safetyrequirements are etremely stringent, since evensmall mistaes can lead t disasters. Fr manycmpanies in the eld f ffshre and shipbuild-ing, ABS Type Apprvals are a must.
T them, its a guarantee that an independ-ent, neutral authrity has stated that ur prd-
ucts wr in this special envirnment, addsCsaba Madru.
N certicatins in the marine-relat-ed wrld are as imprtant as thsegiven by the tw giant classicatinrganisatins, the American Bureauf Shipping (ABS) and Det NrseVeritas (DNV). Having ne f thesecerticatins is a feat. With its re-cent ABS type apprval certicatin,Nrd-Lc nw has bth.
Nrd-Lc is the nly lcing cmpnentused t prevent r minimise the dynamic, vi-bratin, shc r impact-induced lsening fthreaded fasteners, which is certied with anABS Type Apprval. Nrd-Lc passed all tests,as well as the factry audit.
often, ABS requires fllw-up frm amanufacturer befre a prduct can receive atype apprval, Csaba Madru eplains. In urcase, n cmplementary tests were needed,which is great prf f the high quality andfunctinality f ur prducts.
Since Nrd-Lc cntinues t develp new
prducts, a clse cperatin with ABS will bemaintained ver the net few years. Each andevery new prduct has t be checed and ap-
prved. T the cmpanys custmers, this is aguarantee that new prducts wr and ldprducts maintain cnsistent quality levels. ABScntrls the apprved prductin n a regularbasis and every ve years the type apprval hast be renewed.
SOME CUSTOMERS ARE very surprised t learnthat we have bth f the tw principal certica-tins, DNV and ABS, Csaba Madru says. Butfr us, this is a way t shw ur custmers thatwe dnt just tal abut quality, technlgy, e-pertise and safety. We implement it. We dnt
tell them that were ne f the best. Instead, weprve t them that were number ne.
LINDA KARLSSON ELDH
Superbolt tensioners meet DNV standardsThese certicates lend cred-
ibility t ur technlgy, saysAllan Steinbc, Vice President atSuperblt.
DNV is an independent funda-tin aimed at safeguarding life,prperty and the envirnment, at
sea and nshre. DNV prvides ser-
vice specicatins, standards andrecmmended practices. Superbltstensiners are used fr ffshre ap-plicatins such as munting cranest the drilling rig and securing thedrawwrs. A DNV apprval certi-cate number is ften crucial.
DNV certicatin is prf that
ur prducts are trustwrthy andsafe t use in this eld, AllanSteinbc eplains. In the case fur custmer, Drec Energy Ser-vices Ltd. (Div f NoV), an ffshreapplicatin was even put n hlduntil we had gained DNV certica-
tin.
For us, this is a way toshow our customers thatwe dont just talk aboutquality, technology,expertise and safety.
We implement it.CSABA MADRU, RESPoNSIBLE FoR GLoBALDEVELoPMENT PERFoRMANCE SERVICESAT NoRD-LoCk INTERNATIoNAL AB
bolting NEWSNews frm the wrld f the Nrd-Lc Grup and blt security
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1985 1990
Nord-Lock Group partof French NuclearIndustry AssociationGIIN REPRESENTS the Frenchmanufacturers and service cm-
panies invlved in the nuclearIndustry. Cuntries frm all verthe wrld cnsult the asscia-tin abut safety issues in nu-clear plants. This is where Nrd-Lc cmes in.
Nrd-Lcs slutins cn-tribute t the safety in every nu-clear plant in France, says Den-is Mullenbach, Glbal IndustryManager Energy at Nrd-LcGrup. As a member f GIIN,we advise nuclear energy cm-panies nt nly in France, but at
an internatinal level t.
Nord-Lock grantedmembershipto AFNORIN SEPTEMBER, the French na-tinal rganisatin fr stand-ardisatin, AFNoR, appintedNrd-Lc as a member f thecmmissin fr fasteners. Nrd-Lc will wr side by side withthe main players in the Frenchfastening systems industry. onef the mst imprtant tassis t review ld standards andbring them up-t-date.
Damien Thmas, Field Appli-catins Engineer at Nrd-Lc,is prud f the appintment.
Develping standards isa great way t wr in the in-terests f ur end-users, hesays. our custmers are verypleased.
FROM HUMBLE BEGINNINGS in a re-mte barn set amng the frests andlaes f central Sweden, Nrd-Lc hasgrwn during 30 years t becme atruly glbal slutins prvider.
The lcing washer cncept wasne-tuned and perfected during thseearly years, thans t hard wr,dedicatin and the desire t develp
the best pssible system fr securingblted jints. We saw its ptentialfrm the start, but we never imaginedwe wuld achieve the ind f successthat we see tday, says c-funderkurt Perssn.
His clleague, Anders keife, trav-elled the wrld with his Juners ma-chine, demnstrating t impressed en-gineers just hw effective the slutinwas. I had n prblem cnvincingthem that this wrs, says keife.
Nrd-Lc established a glbal net-wr f distributrs and grew frm
being a manufacturer f washers t aprvider f engineering cmpetencebased n its respected epertise.
Prductin remains in central Swe-den but the cmpany nw has glbalreach. Tday Nrd-Lc has 350 em-plyees, 17 subsidiaries and technicalcentres f ecellence in Nrth America,Eurpe and Asia. Last years acquisitinf Superblt Inc. and P&S (tday Nrd-Lc AG) mared a majr step twardsthe cmpanys visin f becming theundisputed leader in blt securing.
Mid 70s:First use fSuperblt technlgy byRlf Steinbc fr scrap-
chpper applicatin.
1984:Patent frmulti-jacblt technlgyissued and Superblt, Inc.
is funded.
1982:Nrd-Lc isfunded and prduc-tin starts in Mattmar,Sweden.
1990:First annualmeeting brings tgetherdistributrs frm 14cuntries.
1994:Investment ABLatur acquires Nrd-Lock.
1987:Gert Ple &Rlf Steinbc start a jintventure in Eurpe (P&S
Vrspannsysteme AG).
1989:Previusly de-pendent upn the Steelindustry, Superblt be-
gins t diversify.
NORD-LOCK TIMELINE
NORD-LOCK:
SUPERBOLT TIMELINE
Saint-Laurent Nuclear Power Stationis one of the nuclear plants in Francewhere Nord-Locks solutions contrib-ute to the safety.
30 yearsf respectedepertise
The success of Nord-Locks locking washer concept has surpassed even the expec-tations of those who developed it.
18 BOLTED# 1 2012
bolting NEWSNews frm the wrld f the Nrd-Lc Grup and blt security
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2000 2005 2010
THE SUPERBOLT SOLUTIONgrew utf funder Rlf Steinbcs eperiencewith large blts in the US steel indus-try in the 1970s. He new rst-handthat large diameter blts were prnet cming lse and were difcult andften dangerus t tighten. His idea fsplitting ne big trque up int severalsmaller nes slved bth prblems.
Starting ut in a rented wrshpwith tw emplyees, having duble-mrtgaged his huse t fund theventure, Superblt grew rapidly ascustmers in the steel industry becameaware f his simple but ingeniusidea. Steinbcs sns entered thebusiness and Superblt began t di-versify int ther marets. The family-run cmpany went n t establish ajint venture in Eurpe thrugh P&SVrspannsysteme.
A culture f innvatin led t newprduct lines based n the riginal
multi-jacblt tensiner design, andSuperblt cntinued t epand its Car-negie, Pennsylvania site in what wasthe heart f the US steel industry.
Rlf Steinbc died in 2001, but ithad always been part f his plan frthe cmpany t becme part f a big-ger entity t help it reach its glbalptential. Jining frces with Nrd-Lc creates sme great synergies andis the start f an eciting new peridin ur histry, says Vice-President Al-lan Steinbc.
1998:The rst sub-sidiary, Nrd-Lc Inc, isfrmed in the US.
2001:Test lab is es-tablished and sales stafftaen n in Malm,Sweden.
2008:Nord-Lock
Germany, Nrd-LcBenelu and Nrd-LcJapan are acquired.
2010:Nord-Lock
wheel nuts arelaunched.
2011:Nord-Lock
Grup acquires Sigma3 inItaly, Superblt in the USand P&S in Switerland.
Mid-1990s:Day tday running f the cm-pany is handed ver t
sns Rbert and Allan.
2004 2010:Super-blt cntinues t grw,sales mre than duble
during this perid.
2011:Superbltis acquired by theNrd-Lc Grup.
2000s:Cntinued innvatinwith new patents issued, includ-ing Split-Nut Thrust Cllar and
Tapered Threaded Jacblts.
SUPERBOLT:
A simple ideawith glbalptential
Superbolt started life as a bolting solution for the steel industry but soon spread to other sectors. Top and above left:com-pany founder Rolf Steinbock during testing of a steel mill roll grinder he designed and built in Carnegie, Pennsylvania.
Above right:the first promotional photo of a Supernut tensioner, representing a tie rod application on a hydraulic press.
2012:30 yearanniversary f theNrd-Lc Grup.
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Your trustedglobal partnerin bolt optimization
Tw f the mst innvative and trusted blt securing technlgies have jined frces. The cmbinatin
f Nrd-Lc and Superblt is unique in the blt securing industry. Tgether we are able t serve glbalcustmers with an impressive line-up f innvative blting slutins. our missin is t safeguard human
lives and custmer investments by securing the wrlds mst demanding applicatins.