TANZANIA ELECTRIC SUPPLY COMPANY LIMITED

“We light up your life”

SPECIFICATION S35

BOLTS, NUTS AND WASHERS

JULY, 2011.

TANZANIA ELECTRIC SUPPLY COMPANY LIMITED

Umeme Park, Morogoro Road, Ubungo

P.O. Box 9024, Dar es Salaam, Tanzania.

Telephone: +255-22-2451130/41; 2451149; 2451133

Facsimile: +255-22-2451149; 2451133

 TABLE OF CONTENTS

PART 1: GENERAL

1. SCOPE............................................................................................... S35-1

2. STANDARDS................................................................................... S35-1

3. SERVICE CONDITIONS................................................................. S35-3

4. SYSTEM CONDITIONS.................................................................. S35-4

5. INSPECTION, TESTING AND QUALITY ASSURANCE............ S35-4

5.1 Inspection........................................................................................... S35-4

5.2 Testing ............................................................................................... S35-4
5.3 Quality Assurance.............................................................................. S35-6

6. PACKING AND SHIPPING............................................................. S35-6

6.1 Packing .............................................................................................. S35-6

6.2 Shipping............................................................................................. S35-7
6.3 Hazardous Substances ....................................................................... S35-7

7. SUBMITTALS .................................................................................. S35-8

7.1 Submittals required with the Bid........................................................ S35-8

7.2 Submittals required by TANESCO before material is dispatched...... S35-9

PART 2: TECHNICAL

8. GENERAL ...................................................................................... S35-10

9. PERMISSIBLE LOADS ................................................................. S35-10

10. BOLTS AND NUTS ....................................................................... S35-11

11. RAG BOLTS................................................................................... S35-13

12. J BOLTS.......................................................................................... S35-13

13. EYE BOLTS AND NUTS .............................................................. S35-13

14. TIE RODS ....................................................................................... S35-14

15. WASHERS...................................................................................... S35-14

16. SCREWS......................................................................................... S35-16

17. GALVANISING.............................................................................. S35-16

17.1 General............................................................................................. S35-16

17.2 Hot Dip Galvanising Bath................................................................ S35-17
17.3 Coating Finished Appearance .......................................................... S35-17
17.4 Coating Thickness............................................................................ S35-17
17.5 Coating Uniformity .......................................................................... S35-18
17.6 Coating Mass ................................................................................... S35-18
17.7 Testing Procedure ............................................................................ S35-18
17.8 Sampling .......................................................................................... S35-19
17.9 Visual Inspection ............................................................................. S35-19
17.10 Magnetic Measurements.................................................................. S35-20
17.11 Measurement of Coating Thickness................................................. S35-20
17.12 Measurement of Coating Uniformity ............................................... S35-20
17.13 Measurement of Coating Mass ........................................................ S35-20
17.4 Rejection.......................................................................................... S35-21

18. SCHEDULES.................................................................................. S35-22

18.1 Technical Data Schedule.................................................................. S35-22

18.2 Non Compliance Schedule............................................................... S35-23
18.3 Test Certificates Schedule................................................................ S35-24

PART 3: INSTALLATION

19. INSTALLATION ............................................................................ S35-25

FIGURES

Figure 1: Bolt, Nut and Washer................................................. S35-26

Figure 2: Eye Bolt and Nut ........................................................ S35-27
Figure 3: Tie Rod and Nut ........................................................ S35-28
Figure 4: Round Washer (Flat) ................................................... S35-29
Figure 5: Square Washer (Curved)........................................... S35-30
Figure 6: Square Washer (Flat).................................................. S35-31
Figure 7: Square Washer (Curved, Tapered) ..................... S35-32
Figure 7: Staples U-Type ………………………………....S35-33

TABLES

Table 1: Bolts Safe Working Loads.......................................... S35-33

Table 2: Bolt Threaded Length................................................. S35-11
Table 3: Safe Working Loads of M20 Eye Bolts and Eye Nuts S35-15
Table 4: Round Flat Washer Dimensions ................................. S35-16
Table 5: Galvanizing Zinc Mass and Coating Thickness.......... S35-19
 Specification S35 - Bolts, Nuts and Washers

PART 1: GENERAL

1. SCOPE

This specification covers the design, manufacture, testing, supply, and

delivery and performance requirements of steel bolts, nuts and washers for
use in the networks of the Tanzania Electric Supply Company Limited.

Any departure from the provisions of this specification shall be disclosed at

the time of tendering in the Non compliance schedule, in part 2 of this
document.

2. STANDARDS

The equipment shall comply with the latest editions of, and amendments to,
the international standards listed below. Where any provision of this
specification differs from those of the standards listed below, the provisions of
this specification shall apply:

BSI British Standards Institution:

 BS 729: Specification for hot dip galvanised coatings on iron and steel
articles.

 BS 1494: Specification for fixing accessories for building purposes.

 BS 1494-1: Specification for fixing accessories for building purposes:

Part 1: Fixings for sheet, roof and wall coverings.

 BS 3410: Specification for metal washers for general engineering

purposes.

 BS 3643: ISO metric screw threads.

 BS 4190: Specification for ISO metric black hexagon bolts, screws and
nuts.

 BS 4320: Specification for metal washers for general engineering

purposes. Metric series.

S35-1
 Specification S35 - Bolts, Nuts and Washers

European Union Commission:

 SI 426: European Communities (dangerous substances) (classification,

packaging, labelling and notification) regulation, 1992.

ISO International Organization for Standardization:

 ISO 752: Zinc ingots.

 ISO 1460: Metallic coatings - Hot dip galvanised coatings on ferrous

materials. Gravimetric determination of the mass per unit area.

 ISO 2178: Non magnetic coatings on magnetic substrates -

Measurement of coating thickness - Magnetic method.

 ISO 9000: Quality management and quality assurance standards -

Guidelines for selection and use.

The bidder may propose alternative standards, provided it is demonstrated

that they give a degree of quality and performance equivalent to that of the
referenced standards. Acceptability of any alternative standard is at the
discretion of the TANESCO.

3. SERVICE CONDITIONS

The service conditions shall be as follows:

 Altitude (above sea level) 1,600m

 Maximum outdoor temperature 40C
 Minimum outdoor temperature 10C
 Maximum monthly mean temperature 35C
 Annual mean temperature 22C
 Maximum relative humidity 60% to 96%
 Isokeraunic level tropical
 Maximum wind velocity 58km/h

S35-2
 Specification S35 - Bolts, Nuts and Washers

 Prevailing wind direction SE and NW

 Type of atmosphere coastal

Environmentally, the region where the work will take place is a coastal area,
subject to an overall medium relative humidity, which can give rise to
condensation. Onshore winds are frequently salt laden. On occasions, the
combination of salt and condensation may create pollution conditions for
outdoor insulators.

Therefore, outdoor material and equipment shall be designed and protected

for use in an exposed, polluted, salty, corrosive and humid coastal
atmosphere.

Indoor material and equipment shall be designed and protected for use in
buildings, which occasionally may be wet and damp.

4. SYSTEM CONDITIONS

The equipment shall be suitable for installation in supply systems of the

following characteristics:

 Frequency 50Hz
 Nominal system voltages 33kV
11kV
400/230V

 Maximum system voltages: 33kV 36kV

11kV 12kV

 Maximum LV voltage 440/253V

 Minimum LV voltage 374/215V

 Nominal short circuit levels: 33kV 16.5kA

11kV 25kA

 Insulation levels:
1.2/50s impulse
(positive and negative polarity): 33kV 170kV
11kV 75kV

S35-3
 Specification S35 - Bolts, Nuts and Washers

power frequency
(one minute withstand, wet): 33kV 70kV
11kV 28kV
LV 3kV

 Neutral earthing arrangements:

33kV effectively earthed
11kV effectively earthed
LV effectively earthed

 Creepage distance 30mm/kV

(of maximum system voltage)

5. INSPECTION, TESTING AND QUALITY ASSURANCE

5.1 Inspection

The contractor shall submit a detailed programme covering the design,

manufacture and testing of the equipment within one month of receipt of the
tender award.

Reports shall subsequently be submitted at intervals, outlining progress and, if

necessary, explaining deviations from the programme.

TANESCO’s representative shall have free entry at all times, while work on
the contract is being performed, to all parts of the manufacturer's works which
concern the processing of the equipment ordered. The manufacturer shall
afford the TANESCO’s representative, without charge, all reasonable
facilities to satisfy himself or herself that the equipment being furnished is in
accordance with this specification.

5.2 Testing

The equipment shall successfully pass all the type tests and routine tests listed
in the most recent edition of the standards given in clause 2 of this
specification.

Each separate consignment of material shall be accepted or rejected by the

TANESCO’s representative on the basis of the results of the tests carried out
on 10% of each of the individual items of the consignments. The
TANESCO’s representative reserves the right to reject an item of equipment

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 Specification S35 - Bolts, Nuts and Washers

if the test results do not comply with the values specified or with the data
given in the technical data schedule.

Type tests shall be carried out at an independent testing laboratory or be

witnessed by a representative of such laboratory or some other representative
acceptable to TANESCO. Routine tests shall be carried out at the
manufacturer's works.

Type tests may be dispensed with at the TANESCO's discretion if the

contractor furnishes evidence to TANESCO satisfaction that the relevant tests
have already been performed on identical equipment. In this case test
certificates shall be submitted with the bid for evaluation.

TANESCO shall have the tests witnessed by a representative if desired. In

order to facilitate this, the contractor shall give TANESCO minimum of four
weeks notice that the material is ready for testing. If TANESCO does not
indicate her intention to participate in the testing, the manufacturer shall carry
out the tests and the contractor shall furnish the results thereof to the
TANESCO before dispatch of the materials.

Full details of the proposed methods of testing shall be submitted to

TANESCO by the contractor for approval, at least one month before testing.

All costs in connection with the testing shall be borne by the contractor who
shall provide the TANESCO’s representative with all the test facilities which
the latter may require, free of charge. The TANESCO’s representative shall
have the right to select the samples if he or she so desires and shall also have
the right to satisfy himself or herself that the testing apparatus is correct.

The contractor shall submit to the TANESCO’s representative two signed

copies of the test certificates, giving the results of the tests as required. No
materials shall be dispatched until the test certificates have been received by
the TANESCO’s representative.

The test certificates must show the actual values obtained from the tests, in
the units used in this specification, and not merely confirm that the
requirements have been met.

TANESCO shall have the equipment inspected after reception and

TANESCO representatives shall have the right to select the samples, if
desired. The contractor shall provide the TANESCO’s representatives, free of
charge, all the facilities which the latter may require. TANESCO shall inform

S35-5
 Specification S35 - Bolts, Nuts and Washers

the contractor on the outcome of the inspection in writing immediately after

inspection.

In the case of components for which specific type tests or routine tests are not
called for in the quoted standards in clause 2 of this specification, the supplier
shall include a list of all tests he or she proposes the manufacturer to carry out.

5.3 Quality Assurance

The supplier shall provide current certification showing the manufacturer's

compliance with ISO 9000 or equivalent national standard.

6. PACKING AND SHIPPING

6.1 Packing

All equipment shall be packed and securely clamped against movement in

robust, wooden, non returnable packing cases to ensure safe transit from the
manufacturer's works to the TANESCO Central Store.

The packing shall provide suitable protection against all climatic conditions
prevailing during transport and on site.

Equipment or material liable to deterioration by sea water, moisture, or

ingress of foreign matter shall be totally sealed in strong polythene bags.

Each packing case shall be indelibly marked, in two adjacent sides and on the
top, with the following:

 Client's name, that is Tanzania Electric Supply Company Limited;

 Contract number;
 Name and address of supplier's agent in Tanzania; if any
 Manufacturer's name;
 Description of contents;
 Country of origin;
 Case measurements;
 Gross and net weights in kilogrammes; and
 All necessary slinging and stacking instructions.

S35-6
 Specification S35 - Bolts, Nuts and Washers

Each case shall contain a fully detailed packing list in a sealed waterproof
envelope.

6.2 Shipping

The contractor shall be responsible for the shipping of all plant and equipment
supplied from abroad to the ports of entry (for CIF price). If required in the
general conditions the contractor may be responsible also for the transport of
all goods to TANESCO Central Store in Dar Es Salaam; and for all the costs
and expenses resulting from it, including customs clearance, offloading,
warehousing and insurance.

All transport accessories, such as riding lugs, jacking pads, blanking off
plates, etc. shall become the property of TANESCO

All items of equipment shall be securely clamped against movement to ensure

safe transit from the manufacturer's facilities to the work sites. The equipment
shall be fully protected during transport and handling operations and while in
storage.

The contractor shall advise, if required, the storage requirements for any
plant and equipment that may be delivered to the TANESCO's stores. The
contractor shall be required to accept responsibility for the advice given, in so
far as these arrangements may have a bearing on the behaviour of the
equipment in subsequent service.

6.3 Hazardous substances

The contractor shall submit safety data sheets for all substances used with the
equipment. These substances shall be classified in accordance with the
European Union SI 426: European Communities (dangerous substances)
(classification, packaging, labelling and notification) regulation, 1992, or any
subsequent amendment.

The contractor shall give an assurance that there are no other substances
classified as hazardous in the equipment supplied. The contractor shall accept
responsibility for the disposal of such hazardous substances, should any be
found.

The contractor shall also be responsible for any injury resulting from
hazardous substances.

S35-7
 Specification S35 - Bolts, Nuts and Washers

7. SUBMITTALS

Some technical documentation is required as set out in clauses 7.1 and 7.2
below:
7.1 Submittals required with the Bid

The following shall be required:

 Completed technical data schedule;

 General description of the equipment, original brochures including

brochures;

 Outline dimension drawing for each major component;

 Detailed specification of the steel used;

 Statement setting out the anticorrosion protection method to be used,

and field experience;

 Overview of the manufacturing process;

 Safety data sheets for all substances used with the equipment;

 Type test certificates, where available, and sample routine test reports;

 Detailed reference list of customers already using equipment offered

with particular emphasis on bolts, nuts and washers of similar type and
size;

 International or national certificate of manufacturer's quality assurance;

and
 Deviations from this specification. Only deviations approved in writing
before award of contract shall be accepted.
 Some production samples of the bolts, nuts and washers offered.

7.2 Submittals required by TANESCO before material is dispatched:

The following shall be required:

S35-8
 Specification S35 - Bolts, Nuts and Washers

 One bound folders with records of the technical particulars relating to

the equipment. The folder shall contain the following information:

 Descriptive literature giving full technical details of equipment

offered;
 Technical data schedule, with approved revisions;
 Detailed dimension drawing for all components;
 Inspection and test reports of tests carried out in the
manufacturer's works;
 Detailed installation and commissioning instructions, including
maximum permissible torque; and
 Maintenance instructions, if any.

S35-9
 Specification S35 - Bolts, Nuts and Washers

PART 2: TECHNICAL

8. GENERAL

This specification covers the design, manufacture, testing, supply, delivery

and performance requirements of galvanized steel bolts, nuts and washers,
required for use in the 33 kV, 11 kV and LV networks of the Tanzania
Electric Supply Company Limited (TANESCO).

The bolts and nuts shall comply with BS 4190 and the washers shall conform
with BS 4320. All this hardware shall be galvanized to BS 729.
The dimensions and characteristics given in this specification are intended to
describe typical ISO metric bolts, nuts and washers, such as are commonly
used in the construction of distribution lines and other distribution plant and
equipment. However, the bidder is free to propose alternative hardware.

Furthermore, it shall be the bidder's responsibility to ensure that the bolts,

screws, nuts, washers, clips, fasteners of any description and any other
hardware, are capable of supporting the loads acting on them, as per the
bidder's design, by wind, vibration and short circuit forces, for all permitted
line and plant duties.

9. PERMISSIBLE LOADS

The safe working shear stress of bolts is 118N/sq mm, with the area of the
bolt measured at the root of the thread. Table 1 shows the ultimate tensile
strength and the tensile stress areas, as per BS 4190 and the safe working
tensile and safe working shear loads for the bolts covered by this
specification. The ultimate shear strength has been assumed to be 75% of the
ultimate tensile load and a factor of 2.5 has been applied:

Bolt Ulitmate Tensile Ultimate Safe Safe

Size Tensile Stress Stress Area Tensile Working Working
(N/sq.mm) (sq.mm) Strength Tensile Shear
(dia.)
(kN) Load (kN) Load (kN)
M12 392 84.3 33.05 13.22 9.91
M16 392 157.0 61.54 24.62 18.46
M20 392 245.0 96.04 38.42 28.81

Table 1: Bolts safe working loads

S35-10
 Specification S35 - Bolts, Nuts and Washers

10. BOLTS AND NUTS

The ISO metric galvanised black hexagon bolts listed in table 2 and shown in
figure 1 shall be used either as pole bolts, namely, where the bolt is required
to pass through the centre of the pole, or as assembly bolts. The bolts shall
comply with BS 4190, strength grade designation 4.6 and shall also conform
with the dimensions given in table 2. Nuts shall be in accordance with BS
4190, strength grade designation 4.

Unless otherwise specified, each bolt shall be supplied with one full nut.
Individual nuts may also be used for special purposes, such as lock nuts.
These nuts shall also conform with BS 4190, strength grade designation 4.

Screw threads shall be parallel throughout their length. They shall be so

formed that, after galvanising, the nut can be easily screwed by hand over the
whole threaded length, without excessive play. Before dispatch from the
works one washer shall be fitted to each bolt and a nut shall be screwed on
the whole threaded length and left in this position.

S35-11
 Specification S35 - Bolts, Nuts and Washers

Diameter Length Threaded Length (mm)

(mm)
(mm)

M12 80 30
110 38
140 70
200 70
220 70
230 70
260 80
M16 40 Fully Threaded
45 Fully Threaded
70 30
110 38
130 70
150 70
180 70
200 70
220 70
230 70
260 80
280 80
300 90
M20 40 Fully Threaded
50 Fully Threaded
65 30
220 70
260 80
280 80
300 90
330 90
360 100
380 100
400 120
480 140
M22 40 Fully Threaded

Table 2: Bolt threaded length

S35-12
 Specification S35 - Bolts, Nuts and Washers

11. RAG BOLTS

Rag bolts shall conform with BS 1494, except that the bolts shall be 100mm
long and they shall be supplied with M12 or M16 threads to BS 3643, coarse
pitch, free fit, class 7H/8g. Each bolt shall be supplied with one full nut.

12. J BOLTS

J bolts shall be in agreement with figure 2 and shall be supplied with one full
nut and round washer. The material of the bolts shall be steel to BS 4190,
strength grade designation 4.6 and shall meet the requirements for mechanical
properties detailed in BS 4190, table 14. Associated nuts shall conform to BS
4190, strength grade designation 4.

13. EYE BOLTS AND NUTS

M20 eye bolts shall preferably be of drop forged manufacture, dimensionally

in accordance with figure 3 and shall be supplied complete with one full nut.

Eye bolts shall be manufactured from steel to BS 4190, strength designation

4.6 and shall meet the requirements for mechanical properties detailed in BS
4190, table 14.

Where a welding process is used in the manufacture, each eye bolt shall be
individually proof tested by the manufacturer in accordance with BS 4190 to
125% of its safe working tensile load, that is, to 48kN. The safe working
tensile load shall be the ultimate axial tensile strength divided by the factor of
safety, or 2.5.

The eye shall be permanently and legibly stamped with the letter METRIC in
letters not less than 3mm high.

The safe working load of any eye bolt is that load which may be safely carried
in an axial direction. If loaded in any other direction the safe working load is
reduced and reference shall be made to table 3 for safe working loads:

S35-13
 Specification S35 - Bolts, Nuts and Washers

Angle between Direction of Load Safe Working Load (kN)

and Axis of Bolt
0 38.42
5 30.55
10 25.52
15 22.05
20 19.54
25 17.67
30 16.24
35 15.13
40 14.26
45 13.58
50 13.06
55 12.68
60 12.40
65 12.23
70 12.15
75 12.17
80 12.28
85 12.49
90 12.81

Table 3: Safe working loads of M20 eye bolts and eye nuts

14. TIE RODS

Tie rods shall be in accordance with figure 4 and shall be supplied with four
full nuts. The material of the rods shall be steel to BS 4190, strength grade
designation 4.6 and shall meet the requirements for mechanical properties
detailed in BS 4190, table 14. Associated nuts shall comply with BS 4190,
strength grade designation 4.

15. WASHERS

Washers shall be of the following different types:

 Round, flat, mild steel washers, as shown in figure 5 and having the
dimensions shown in table 4.

S35-14
 Specification S35 - Bolts, Nuts and Washers

Type Internal External Thickness

Diameter (mm) Diameter (mm) (mm)
M12 14 28 2.5
M16 18 34 3.0
M20 22 39 3.0
M22 24 44 3.0
Table 4: Round flat washer dimensions

These washers shall comply with BS 4320;

 Square (curved) mild steel washers as shown in figures 6;

 Square, flat, mild steel washers, in accordance with BS 3410, table 11

and with the dimensions shown in figure 7.

The imperial British standard BS 3410 is quoted here because its metric
version BS 4320 does not yet include this type of washer. The washers
chosen from table 11 are those whose whole sizes will provide sufficient
clearance over the metric bolt size to allow for galvanising of the bolt and
washer. The metric dimensions shown in figure 7 are equivalent to the
dimensions of the preferred washer sizes when metricated with a 2mm hole
diameter clearance and not the equivalent dimensions of the chosen imperial
washers;

 Tapered, D shaped, malleable iron washers, in accordance with BS

3410, table 12 and with the dimensions shown in figure 8.

The imperial British standard BS 3410 is quoted here because its metric
version BS 4320 does not yet include these type of washer. The washers
chosen from table 12 are those whose whole sizes will provide sufficient
clearance over the metric bolt size to allow for galvanizing of the bolt and
washer. The metric dimensions shown in figure 8 are equivalent to the
dimensions of the preferred washer sizes when metricated with a 2mm hole
diameter clearance and not the equivalent dimensions of the chosen imperial
washers; and

 Tapered, squared (curved) malleable iron washers as shown in figure 9.

S35-15
 Specification S35 - Bolts, Nuts and Washers

16. SCREWS

Screws may be:

 Coach screws of galvanised mild steel, gimlet pointed, in accordance

with BS 1494. The screws shall be 10mm in diameter and supplied in
lengths of 38mm, 76mm and 152mm; or

 Roundhead drive screws of galvanised mild steel, 63mm long and with
6.3mm diameter and in accordance with BS 1494-1.

 38mm length x 12 gauge cup headed galvanized mild steel

17. GALVANISING

17.1 General

Hot dip galvanizing is the application of a zinc coating by dipping cleaned,

prepared, metal articles in molten zinc, by which process alloy layers may be
formed between the basic metal and the outer pure zinc layer. Under some
circumstances, the whole coating may consist of alloy layers and, in such
cases, the appearance may be a dull grey.

Mild steel, low alloy steel and cast iron are metals particularly suitable for hot
dip galvanizing, but other ferrous metals may also be hot dip galvanized. The
fabricator shall ensure that the items to be galvanized consist of metal suitable
for galvanizing.

The fabricator shall also ensure that internal stresses in the material are
relieved as necessary before submission for hot dip galvanizing. These
stresses could lead to em-brittlement or inter-crystalline cracking after
galvanizing.

Surface contaminants which cannot be removed by pickling, such as for

example, oil, fat, tar, paint, welding slag and similar impurities, shall be
removed prior to pickling.

Articles shall not be galvanized if their design and shapes are such that the
pickling solution cannot be removed with certainty or if adequate venting or
drainage is not possible to ensure a safe and effective galvanizing dip. If it is

S35-16
 Specification S35 - Bolts, Nuts and Washers

necessary to bore drainage or vent holes in articles, the supplier shall obtain
the consent of the TAANESCO.

In addition to the stipulations of BS 729 all galvanizing shall also meet the
conditions set out below.

17.2 Hot dip galvanizing bath

The zinc of the hot dip galvanizing bath shall contain not less than 98.5% of
zinc (by mass) according to ISO 752. No zinc impurities or additives which
could have a deleterious effect on the durability of the zinc coating shall be
acceptable.

17.3 Coating finished appearance

The galvanizing coating shall be smooth, continuous, uniform and free from
anything that is detrimental to the stated use of the coated article. It shall be
free from acid spots and flux stains and shall not scale or blister. The coating
shall not be removable by normal handling or packing.

Shiny, dull gray or spangled surface appearance shall be generally acceptable.

Extensive wet storage stain (white rust) shall be unacceptable.

17.4 Coating thickness

The thickness of the galvanising coating shall comply with the minimum
average values given in table 5, below, when tested in accordance with the
requirements set out below:

S35-17
 Specification S35 - Bolts, Nuts and Washers

Item Description Minimum Zinc Mass Minimum Average

Deposited Coating Thickness
(g/sq.mm) (mm)
Steel Items, 5mm thick 610 85
and over

Steel Items between 460 65

2mm and 5mm thick

Steel Items under 2mm 335 47

thick

Threaded Steel Items 305 43

Iron Castings 610 85

Table 5: Galvanizing zinc mass and coating thickness

* The minimum average thickness figures given in this table can be

defined as the lowest of the individual average values for the number of
samples under test.

17.5 Coating Uniformity

The uniformity of the galvanizing coating shall be such that the minimum
individual thickness measurement on any test sample shall be not more than
7m below the minimum average figure specified for that article in table 5.

17.6 Coating Mass

The mass of the galvanizing coating per square meter of the surface area shall
comply with the minimum values given in table 5 when tested in accordance
with the requirements set out below.

17.7 Testing Procedure

The tests detailed below, shall be carried out by the galvanizer on the first
consignment of articles under each new procurement contract and the results
shall be recorded on the test certificate.

S35-18
 Specification S35 - Bolts, Nuts and Washers

The following tests shall be carried out on each of the selected samples :

 Visual inspection;
 Thickness of coat; and
 Uniformity of coat.

In the event of disagreement or dispute over the results of the above tests a
coating mass test shall be carried out, as set out below. The result of this test
shall be definite and binding.

17.8 Sampling

The number of samples to be selected for the tests shall be determined by the
following formula :

s = 4 + 1.5n
1000

where s = number of samples

n = quantity of items in consignment

s shall be adjusted to be not more than 15 and not less than 4.

17.9 Visual Inspection

The inspection shall include the following aspects:

 Smoothness: there shall be no exposed spots, spikes or anything

detrimental to the stated use of the articles or to personnel handling
them;

 Stains: there shall be no acid spots, flux or dross stains;

 Adhesion: there shall be no blisters, peeling or flaking. Normal

handling shall not give rise to deterioration:

 Wet storage: storage and stacking conditions shall be appropriate.

Excessive white rust will cause the consignment to be rejected; and

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 Specification S35 - Bolts, Nuts and Washers

 Threaded items: oiled nuts with uncoated female threads, cut

oversize to allow for the galvanising coating on the standard bolt
threads, shall have free travel.

17.10 Magnetic Measurement

Thickness measurements shall be determined by a magnetic instrument

method as set down in ISO 2178.

The instrument used shall have the necessary degree of accuracy, range of
probes and probe adapters to enable reliable readings to be obtained
consistently. Otherwise, the TANESCO representative shall nominate a
suitable instrument for the purpose of obtaining the measurements.

Before taking measurements, the instrument shall be calibrated, preferably on

an un-galvanized sample of the articles under test. The steel surface used for
the calibration shall be cleaned, if possible, by machine process or abrasive.

17.11 Measurement of Coating Thickness

Between five and ten measurements shall be taken per sample, depending on
size, shape, etc. The average thickness shall be taken to be the average of all
the readings for that sample. The minimum average coating thickness shall be
defined as the lowest of the individual average thickness values for the
number of samples under test.

17.12 Measurement of Coating Uniformity

The minimum individual value of the readings taken on each sample, in

accordance with the sampling clause above, shall be used to determine the
coating uniformity, in conformity with the requirements of the coating
uniformity clause.

17.13 Measurement of Coating Mass

The coating mass shall be determined by a coat stripping procedure as set

down in ISO 1460.

This test, when required, shall normally be carried out on two samples. The
two samples chosen shall be the ones that have given the lowest readings
when tested by the magnetic measurement method.

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 Specification S35 - Bolts, Nuts and Washers

17.14 Rejection

If any sample fails to meet the galvanizing requirements of this specification,

twice the original number of samples shall then be tested. If any of these
samples fails to conform, the whole consignment of items represented by
these samples shall be rejected.

A consignment that has been rejected may be re-galvanized and again offered
for test, provided that it is according to specification in all other respects.

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 Specification S35 - Bolts, Nuts and Washers

18. SCHEDULES

18.1 Technical Data Schedule

Description Unit TANESCO Bid

Item & Type
Manufacturer
Catalogue Number
International Standard it complies with
Material
Grade
Ultimate Tensile Strength N/sq.mm
Galvanizer
Galvanizing International Standard BS 729
Dimensions - Length mm
- Diameter mm
- Width mm
Length of Thread mm

NB: please fill one schedule for bolts, one for nuts, washers, staples
etc.

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 Specification S35 - Bolts, Nuts and Washers

18.2 Non Compliance Schedule

On this schedule the bidder shall provide a list of non compliances with this
specification, documenting the effects that such non compliance is likely to
have on the equipment's life and operating characteristics. Each non
compliance shall be referred to the relevant specification clause.

Clause No. Non-compliance

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 Specification S35 - Bolts, Nuts and Washers

18.3 Test Certificates Schedule

On this schedule a list of the test certificates included with the bid shall be
provided. This list shall include type test certificates and samples of routine
test reports. Each certificate listed shall be referred to the relevant
specification clause.

Clause No. Type Test Certificate or

Routine Test Report

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 Specification S35 - Bolts, Nuts and Washers

PART 3: INSTALLATION

19. INSTALLATION

TANESCO’s employees shall do the physical work of installing the bolts,

nuts & washers unless otherwise stated. General guidelines for installation
work is given in specifications S01: General technical requirements of 33kV,
11kV and LV networks and S02: General technical requirements of 33/11kV
primary substations.

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Specification S35 - Bolts, Nuts and Washers

Figure 2: Eye Bolt and Nut

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Specification S35 - Bolts, Nuts and Washers

Figure 3: Tie Rod and Nut

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 Specification S35 - Bolts, Nuts and Washers

Figure 4: Round Washer (Flat)

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Specification S35 - Bolts, Nuts and Washers

Figure 5: Square Washer (Curved)

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Specification S35 - Bolts, Nuts and Washers

Figure 6: Square Washer (flat)

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 Specification S35 - Bolts, Nuts and Washers

Figure 7: Square Washer (Curved, Tapered)

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 Specification S35 - Bolts, Nuts and Washers

NOTES

Material: Hot Dip Galvanised Mild Steel (GMS) ASTM A36 or BS Equivalent

Galvanisation: To BS 729 or equivalent

Dimensions up to and including 35mm………..± 0.7 mm

Dimensions greater than 35mm…………………..± 2%

Figure 8: Staples U-Type

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