Direct Tension Indicators/DTIs

DTI's are individual bolt load cells, which

measure pretension developed during
tightening, regardless of torque
resistance of the bolt. By far the simplest
method, a DTI is put on one end of a bolt
and tightened until the bumps are
compressed enough so that a feeler gage
cannot be inserted all around, or when
the Squirter® DTI has deployed silicone
properly. DTI's are completely
independent of torque resistance of the
bolt assembly, and because the
compression of the DTI bumps can be visually observed, bolt installers tend NOT to leave the bolts with
insufficiently compressed DTI's.
When Using Squirter® DTIs, Installers don't miss any bolts. Inspection by using a feeler gage (on a sample
of the bolts only) can be done by anyone at any time. If the DTI is put on the nut end of the bolt,
tightening can be done by one person because it is not necessary to hold the bolt roll.

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 bolts 1, applying additional lubricant may

1
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”

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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
applying a torque value to compress a DTI or use a torque value as an inspection technique. Doing so
combines elements of Calibrated Wrench and DTIs.

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.”
With only hand tight as the inspection criteria, Snug-tight may begin with a pretension that is negligible
or zero.

Conversely, snug-tightening may result in a pretension near or greater than the minimum required and
may strip or break the bolt. This is especially true of bolt diameters ¾” and below. Also, if the bolt
survives, a DTI will prematurely flatten and must be replaced before pretensioning begins.

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 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 pretensioning 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 7.1:

“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.

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.”

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 Tension Calibrator Steps
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 105% of the minimum
required bolt pretension as listed in AISC/RCSC Table 5.2 or AISC 360 table J3.1M, as
appropriate.
4. Insert the appropriate feeler gauge into 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 at 105% of the minimum value listed in
AISC/RCSC table 5.2 or AISC 360 table J3.1M.
6. The number of entries/refusals defines the unique assembly’s test gap3 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% at 105% of the value in in
AISC/RCSC table 5.2 or AISC 360 table J3.1M, consult the advisory section 4 of Applied Bolting
Technology’s website and apply the recommendation described therein.

Bolting Methodology, non-squirting DTI

1. Snug the steel plies, in as many steps as necessary, to bring the steel into firm contact as
required by AISC/RCSC section 8.1, without compressing the DTI below the Job Inspection Gap.
If the DTI is compressed below the Job inspection Gap, during the snugging operation, remove
and replace the DTI.
2. After snugging, apply enough torque to compress the DTI until the residual gap is less than the
Job Inspection Gap.

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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.
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https://www.appliedbolting.com/advisories.php. Additional assistance is available by directly contacting Applied
Bolting Technology via email at [email protected] or calling 800 552-1999 or 802 460-3100.

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 Bolting Methodology, Squirter® DTI
1. Snug the steel plies, in as many steps as necessary, to bring the steel into firm contact as
required by AISC/RCSC section 8.1, without compressing the DTI below the Job Inspection Gap.
If the DTI is compressed below the Job inspection Gap, during the snugging operation, remove
and replace the DTI.
2. After snugging, apply enough torque to compress the DTI until the orange Squirt™ indication
media is expelled from every available location and the residual gap is less than the Job
Inspection Gap.
When inspecting non-squirting & Squirter® DTIs the inspector MUST:
1. Verify Pre-Installation Verification has been performed.
2. Verify the joint has been snug-tightened.
3. Verify the DTI bumps have not been compressed beyond the job inspection gap during the
snugging operation.
4. Verify DTI bumps have been compressed below the job inspection gap after pretensioning.
5. Accept any fastener with a pretension greater than the minimum required. 5

When inspecting non-squirting & Squirter® DTIs the inspector MUST NOT:
1. Inspect DTI assemblies with a torque wrench.
2. Compare the amount of turn between the nut and bolt with Turn-Of-Nut table 8.1.
3. Reject DTIs that have been completely flattened during pretensioning.

Minimum Bolt Pretension Per AISC/RCSC Table 5.2

Bolt diameter, in. A325 bolts A490 bolts
1� 12 15
2
5� 19 24
8
3� 28 35
4
7� 39 49
8
51 64
1
64 80
1 1�8
81 102
1 1�4
97 121
1 3�8
118 148
1 1�2

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.

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AISC/RCSC 9.2.4 “A pretension that is greater than that specified in Table 5.2 or feeler gage refusal in all locations shall not be
cause for rejection.”

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Minimum Bolt Pretension Per AISC 360, Table J3.1M
Bolt diameter, mm A325M bolts A490M bolts

M16 91 114

M20 142 179

M22 176 221

M24 205 257

M27 267 334

M30 326 408

M36 475 595

Equal to 0.70 times the minimum tensile strength of bolts, as specified in ASTM F3125/F3125M
for grades A325M and A490M bolts, with MC threads, rounded to the nearest kN.

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 Pre-Installation Verification Test Teport
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: