AJAX ONESIDE TRAINING MANUAL TRAINING... · As an option ONESIDE ™can be supplied with Direct Tension Indicators “Squirters” (DTI’s). DTI’s are to be placed between the

AJAX ONESIDE TRAINING MANUAL

All information provided in this document is confidential, and CANNOT be copied distributed for any purpose. The document is only for the intended recipient and cannot be altered or provided to a 3rd party. COPYRIGHT © 2016

Confidential & Copyright © April 2016

All information provided in this document is confidential, and CANNOT be copied

distributed for any purpose. The document is only for the intended recipient and cannot

be altered or provided to a 3rd party. COPYRIGHT © 2016

Introduction

AJAX ONESIDE™ provides full structural strength of the bolt, in both shear and in tension. It provides far superior clamping forces. In many instances the clamping forces achieved are 3+ times greater than other competing products. This document is designed to provide information to the installer, so that correct installation and use of the product is achieved. This will ensure the correct tensioning required for the correct bolting connection as designed and stipulated by the engineer. Currently there are a number of different ONESIDE ™ products available in the market as shown. These different products vary in mechanical properties and tightening methods (to be discussed later in this document). But all are installed the same way using the same ONESIDE™ installation tool.





ONESIDE installation tool and components

Depending on which product has been purchased the product can arrive either completely assembled or as individual components. It is essential that the installer has a clear understanding as to the order of components and the correct orientation of each component supplied. The picture above shows the correct order of components to be installed onto the bolt prior to installation. It is essential that the Split washer is positioned under the head with the locating lip facing towards the nut. The solid washer is positioned with the lip facing the bolt head as shown below.

Split step washer with adhesive tape towards the head of the bolt

Solid step washer with locating step towards the head of the bolt

It is essential that both the split and solid stepped washers are assembled as shown

to ensure correct installation. Although product may come assembled, it is always

best to check the correct orientation of these washers.





ONESIDE – with Direct Tension Indicators (DTI’s) As an option ONESIDE ™can be supplied with Direct Tension Indicators “Squirters” (DTI’s). DTI’s are to be placed between the solid face washer and the nut, with a hardened flat washer. As shown, the silicone cavities must be against the solid ONESIDE™ washer. DTI’s squirter Correct Orientation Hardened Washer Information on the use of the DTI’s will be covered in later sections. Also provided in the appendix is a user manual supplied by Applied Bolting USA.

Installation instructions ONESIDE™ Hi-Shear comes pre-assembled as shows below. To see the installation process scan the QR code and watch the video. Engagement / locking to installation tool:

Slide the sleeve back on the tool and insert the tip of the bolt into the socket. To lock the ONESIDE to the tool, slide the sleeve forward. Un-assemble the ONESIDE. Sliding the components back onto the shaft of the tool. Move the split / collapsible washer to the correct seating location on the tool and fold as shown. It is important that the split washer is seated correctly.

Now the ONESIDE is ready for installation.





Installation:

Guide the bolt and the collapsible washer through the pre-drilled hole of the connection, it is advisable to hold the split washer as it enters the pre-drilled hole. Make sure the holes are aligned properly. AJAX recommend the split washer be held (as shown) and guided into the hole. Failure to do so may cause issues with the adhesive washer and may cause installation issues.

Rotate the tool 180° (important), to

ensure the split/collapsible washer opens. It is very important that this is undertaken to ensure correct opening of the washer. The tool is designed and has features built into it to ensure the washer opens correctly. Failure to rotate the tool may cause the washer to remain closed

Pull back the installation tool, rocking the tool side-to-side to locate the split/collapsible washer against the back of the joint. Ensure the lip of the washer is engaged into the pre-drilled hole. Slide forward the other components into the connection.

Shear Sleeve (Hi-Shear only)

Wave Spring (Hi-Shear only)

Solid Outer Face Stepped washer

“Squirter” DTI (optional)

F436 Flat washer (optional)

Structural 2H Nut

Finally finger tighten the nut to a secure condition. Remove the installation tool. The rear of the installation tool can be used to engage the tip and a spanner should be used to SNUG tighten the joint, if the connection needs to be pulled together. (See video for instructions)

For further information please do not hesitate to contact AJAX or local representative. Or watch the video, for more tips.





Important items on the installation to remember

1. Once the ONESIDE product has been connected to the insertion tool, ensure the locking sleeve is moved forward.

2. Installation of the oneside should preferably be at eye-level, so installer can see that both inner and outer holes are aligned. It is still acceptable to install at chest height, provided adequate visibility of the joint may be achieved.

3. Split / Collapsible washer, must be held and guided into the hole. 4. Once split / collapsible washer has passed through the joint, 180°rotation of the

tool must occur – CRITICAL. 5. Tool may remain connected to bolt until the finger tight condition is achieved. 6. Tool locking sleeve must be retracted prior to dis-engaging the bolt from the tool. 7. For SNUG tightening, the rear of the tool handle should be used to secure the bolt,

if spinning has occurred. (method covered in later section in detail) 8. Installation tool must be removed prior to any full tightening, using any mechanical

devise.

Notes:





Tightening Methods / Procedures

AJAX ONESDIE ™ Standard & Hi-Shear versions (With or without DTI’s)

AJAX ONESIDE ™ in either standard or Hi-Shear variations, can be installed with or without Direct Tension Indicators (DTI’s). We will discuss a number of methods of tightening in this section. But the process will ultimately be at the discretion of the customer or the certifying engineer.

Tools required AJAX ONESIDE installation tool

Standard spanner either ring or open ended

Impact wrench min Torque rating (600Nm / 442 ft.lbs)

Non-impact torque controlled wrench, with reaction arm, Minimum torque rating (600Nm / 442 ft.lbs)





Turn-of-nut Method or Part Turn Method. All bolts and nuts in the joint are first tightened to a SNUG tight condition. SNUG tight condition is defined as the tightness attained by the full effort of a man using a standard podger spanner or by a few impact with an impact or non-impact wrench. This assures the complete seating of the joint members. Location marks are then established to mark the relative position of the bolt to the nut (see diagram below). The bolts are then finally tightened by the amount of turn shown on the table below.

Starting position marked 1/3 turn or 120°

ONESIDE bolt length under head to end of

thread Angle of turn

Bolt tension achieved minimum

M16 x 30-64mm 8.8 1/3 turn or 120° 94.1kN / 21.2Kips

M16 x 64-128mm 8.8 1/2 turn or 180° 94.1kN / 21.2Kips

M20 x 30-80mm 8.8 1/3 turn or 120° 147kN / 33.0Kips

M20 x 80-160mm 8.8 1/2 turn or 180° 147kN / 33.0Kips

M20 x 160-250mm 8.8 2/3 turn or 240° 147kN / 33.0Kips Notes

Nut rotation is relative to the bolt, regardless of the component turn

Nut rotations specified are only applicable to connections in which all materials within the grip are steel

Direct Tension Indicators (DTI’s) “Squirters™” Tightening of AJAX ONESIDE when using DTI’s, shall be done in accordance with the DTI manufacturer’s instructions and the following procedure. On assembly all bolts and nuts in the joint are first tightened to the SNUG tight condition. The nut is then tightened in accordance with the requirements of the DTI manufacture. AJAX nominally use Applied Bolting DTI Squirter™. Installation instructions as per Applied Bolting requirements are contained at the rear of this document in full.





SNUG Tighten the Bolt

Always SNUG tighten the array of bolts to bring the steel into firm contact (as described above). Make sure you don’t fully compress the DTI on the first pass. On the final pass, compress the DTIs fully.

Drive it till it Squirts

Tighten the bolt until after the ORANGE silicone appears in volume from most of the DTI’s squirt locations. Each DTI has one squirt location for every bump. The number of squirts should be at least equal to the number of bumps on the DTI less ONE. For example, a five bump DTI should have a minimum of 4 squirting positions.

FOR MORE INFORMATION SEE COMPLETE INSTALLATION INSTRUCTIONS FROM APPLIED BOLTING IN THE APPENDIX, OR WATCH THE VIDEO TRAINING TIPS. SCAN WITH A SMARTPHONE OR GO TO APPLIED BOLTING .COM





Final condition once tightened Having a minimum of 2 threads extended beyond the leading edge of the nut at final tightening will satisfy the requirements of all standards [ASTM (USA), RCSC (USA), AS4100, European and JIS standards]. IMPORTANT: AS SHOWN IN THE PICTURE IT IS ESSENTIAL THAT THIS CONDITION IS MET TO ENSURE COMPLIANT TO MANY RELEVANT STRUCTURAL CODES. If this has not been achieved, the incorrect bolt length has been used.

FAQ’s on tightening of AJAX ONESIDE™ & Important items

1. Bolt is spinning when tightening? What can I do? AJAX ONESIDE™ Bolt come with under head serrations (see photo) to restrict the potential of bolt spinning. However in instances where the inner diameter of the hollow section is small or thread friction is high, there is a possibility of the bolt spinning. This is fixed by using the special socket in the rear of the handle (see below). It is extremely important that the installation tool tip, is not used in this instance, as it will cause the tool to break. Insert the “D” tip of the bolt into the socket. Using a spanner, retighten the nut. Once complete, the tightening procedure can recommence, with the tightening tool. If spinning occurs again, repeat the process.

2. I am having trouble getting the DTI’s to “POP” OR “SQUIRT”, why is this happening? Is it possible to lubricate the nut or bolt further to ensure the DTI’s squirt?

Applied Bolting, USA manufacture the “squirter” DTI’s. They are manufactured to ensure that a minimum tension of 145kN is developed in the connection. But due to manufacturing tolerances the tension required to pop / squirt can be greater. The normal torque required to achieve this tension is approximately 400-450Nm (295-331 ft.lbs). Ensure that the powered wrench has sufficient capacity. If cordless tools are used ensure the wrench is fully charged (partially depleted batteries can have dramatic loss of available torque).





As DTI’s work on the principles of mechanically depressing the bumps to cause the squirt, it is possible to lubricate the bolt threads or nut to reduce the friction and achieve a correct result. The lubrication will not affect the force required to flatten the bumps and achieve the correct tension in the connection.

3. If using the Turn-of-nut or Part turn method, should I go beyond the required angle? Is it possible to lubricate the nut or bolt further to achieve the correct angle?

AJAX ONESIDE™ bolts, are designed to be tightened to the specified turn-of-nut method. It is possible to go slightly beyond the angle to ensure that the correct minimum tension is achieved. It is not necessary to go beyond more than 10° of the angle stipulated in the table provided. Over-tightening can cause potential over stressing of the bolt and connection. As this method uses angle and the geometry of the thread, it is possible to further lubricate the thread, to ensure the minimum correct angle is achieved. But as the AJAX ONESIDE nuts are already pre-lubricated, it should not be necessary.

Notes:





Un-installing AJAX ONESIDE™ AJAX ONESDIE ™ Standard & Hi-Shear versions (With or without DTI’s)

Un-installing of the AJAX ONESIDE Standard and Hi-Shear version, can be done in two steps. Firstly, the tension on the bolt needs to be broken. This can be done two ways

1. The use of an impact wrench in reverse to break the initial tension

2. Or manually, using the “D” socket in the rear of the installation tool and a spanner.

Once all the external components are removed, the bolt and the internal split washer are pushed into the cavity. There is no easy way of removing the bolt and the split washer once installed.





Tightening Methods / Procedures

AJAX ONESDIE ™ TC (Tension Control bolt)

AJAX ONESIDE Hi-Shear TC™ is the latest product to enter the ONESIDE range, and combines the original ONESIDE concept and installation methods. Now it includes the “Tension Control” or “Twist-off” feature, used widely in the structural steel construction market. The product is fully compliant to all US, European and JIS standards. The product is guaranteed to achieve the minimum tension as required for a friction grip connection, as stipulated by the relevant standard. Installation is exactly the same as other ONESIDE products, and uses the same installation tool. Tightening method is the only difference. To tighten the ONESIDE Hi-Shear TC™, a Special Shear Wrench and Sockets MUST be used. AJAX through their engineering department, has designed specific inner and outer sockets to suit ONLY THE AJAX ONESIDE BOLTS. The system is developed using CAD and 3D simulations to ensure correct fitment at all times. It is important to note: this will not interfere with the design of the Makita® shear wrench, and all its features are preserved. The following components are:

Ejector pin spring

Specially designed inner socket

And specially designed HEAVY DUTY outer sockets shown above, are all designed specifically to suit the Makita® 6922NB shear wrench and utilise all the features of the Makita® Shear Wrench system. The AJAX ONESIDE sockets are exact replicas of the Makita® just re-designed to suit the ONESIDE product.





Attachment of the sockets is exactly the same as the originally supplied Makita® silver sockets.

MAKITA® 6922NB ORIGINAL SET-UP MAKITA® 6922NB WITH ONESIDE SET-UP

To make your MAKITA® 6922NB ONESIDE™ COMPLIANT IS VERY EASY. It’s all about BLUE!!

1. Remove the original Makita inner and outer sockets. 2. Remove the ejector pin and spring 3. Replace the ejector spring with the AJAX ONESIDE ejector spring (Blue) 4. Select the correct AJAX ONESIDE (Blue) outer socket for the ONESIDE Hi-Shear TC™

to be installed. 5. Take the AJAX ONESIDE (Blue) inner socket and install, into the selected outer

socket. As per Makita ® Manual 6. Put your Makita® 6922NB back together as shown in the standard Makita® manual. 7. YOU’RE GOOD TO GO!

IMPORTANT: AJAX blue components cannot be used with any other product, they are specifically designed to work ONLY with the AJAX ONESIDE product and will not function PROPERLY with other products.





Notes on operation and socket change over The AJAX ONESDIE TC system, contains all the original functionality and features for the Makita® 6922NB shear wrench. Attachment and operation is as defined in the Makita® 6922NB operational manual. The Following is a direct extract from this Makita manual.





Please consult your Makita® manual for correct operation and safe usage conditions.





Final condition once tightened Having a minimum of 2 threads extended beyond the leading edge of the nut at final tightening will satisfy the requirements of all standards [ASTM (USA), RCSC (USA), AS4100, European and JIS standards]. IMPORTANT: AS SHOWN IN THE PICTURE IT IS ESSENTIAL THAT THIS CONDITION IS MET TO ENSURE COMPLIANT TO MANY RELEVANT STRUCTURAL CODES. If this has not been achieved, the incorrect bolt length has been used. The sheared off section exposes the base metal material to the environment. A zinc rich or corrosion resistant paint should be applied to the end of the bolt, which is exposed to the outside environment. If used for internal applications (away from the elements), this is at the customer’s discretion.

About AJAX ONESIDE TC bolt AJAX ONESIDE TC™, are manufactured to be compliant to all international standards, USA / Europe / Japanese. The product has the correct metric spline for the corresponding metric thread and grade, as specified in the standards

Shear wrenches are “Dumb tools” and do not need calibration. They do require some maintenance and must be handled carefully, to avoid potential damage. (Refer your Makita® manual)

Maintenance of TC Wrench Clean both inner and outer sockets to avoid build-up of foreign matter or debris /

dirt. AJAX recommend regular oiling of inner sockets to ensure locking pins ( Anti-slip mechanism move freely. Before starting any installation ensure the inner socket is in good working condition.

Change the motor’s carbon brushes when necessary, drop in performance is an indicator that the motor brushes have worn. Brushes and spare parts are available direct from and authorised Makita® dealer

Do not carry the shear wrench by the electrical cable. Most good quality shear wrenches are sold with a protective case.

Inspect electrical cable and plug regularly – replace if damaged to avoid electrical shock.

Replace inner and outer sockets when worn.

Maintain the cleanliness of the wrench as would be the case for any other electrical tool.

2 threads minimum

Exposed base metal requiring coating





To maintain the shear wrench in good condition and service, it is advised that the wrench be

maintained every 40,000 bolt or 6 months. Details of care and maintenance are provided in

your Makita® manual.

Handling – Storage - installation

All structural fasteners should be protected from dirt and moisture at the job site. No more than the amount of bolts to be used should be removed from the container. Remaining bolts at the end of the day should be returned to the correct container. Dirty / oily / rusted or bolts that have been lubricated after received from the manufacturer or been exposed to water after supply, bolts should not be used ONESIDE Bolts are certified in the AJAX NATA laboratory, to achieve the minimum tension requirements before shipping. Changes in the condition and the addition of foreign matters or lubricants may alter the performance in the field. TC Bolts should never be lubricated, once supplied from the factory. They must be installed and tightened in a factory supplied condition

TCB’S (Tension Control Bolts) are “FAIL SAFE” BOLTS

It is important to understand the difference between tension control bolts and conventional pre-loaded bolts. With any threaded fastener an occasional failure could occur. This is generally attributed to a problem during installation and can be the results of SEVERAL factors including the following:

o Using a TCB as a slave bolt o Alignment problems o Foreign materials in the threads such as grit, mastic, oil, water, etc o Temperature o Moisture o Coating co-efficient of friction and its variances

If the friction coefficient of the bolt is altered due to the points raised above. One of three things could occur:

The threads will strip in which case the spline will not be removed. The threads will hold and the increased preload will break the bolt

due to torsional tension overload. Spline will twist-off, but the required tension in not achieved.

Example of thread stripping Example of torsional overload

Lowering of the coefficient of friction on TCB’s result in the “dumb” tool continuing to take the least line of resistance (rotate the outer socket).

THESE BOLTS SHOULD BE REMOVED AND REPLACED WITH NEW ONES BOLTS MUST BE INSTALLED AND TIGHTENED IN AN “AS SUPPLIED” CONDITION ONLY





If on inspection it can be seen that the spline has sheared off, then one can be certain that the bolt is installed correctly. It is not possible to properly remove the spline during installation AND the bolt breaks afterwards without additional forces being applied, thus reinforcing the ‘fail-safe’ properties of this type of bolt system.

Tightening of TCB’s

Tension Control Bolts (TCB’s) are a simple and uncomplicated system that completely removes the responsibility of attaining the correct preload in a given connection. The Shear wrench is light in weight, quiet to use and requires minimal effort to achieve the correct tension. For example to tighten a M20 bolt for a friction joint connection requires approximately 375-450Nm. A substantial force if hand tightened and extended time when installed by an impact wrench. Before commencing of preloading, all the connected components shall be fitted together and the bolt in the assembly shall be brought to a finger tight condition. This shall be carried out for all bolts to be installed in the connection starting from the most rigid part of the connection. In order to ensure that the preload in fully installed bolts meet the specified minimum preload, the installation process consists of two tightening stages. The first stage applies a bedding torque to ensure a firm contact between components. This can be accomplished by one of two methods:

1. Using the Shear wrench, but only snugging the bolts and not shearing off the splines.

There is distinct change in sound/tone of the wrench motor, when used this way. It is

indicated that pre-tensioning has commenced and a bedding torque has been

applied. Once bedded, when the power trigger is disengaged the wrench gearing will

backtrack / reverse allowing the tool to be easily removed from the bolt.

2. Using a standard nut runner / impact wrench with a deep socket to pull all the

surfaces into contact without

involving the bolt spline. (As the

shear wrench is required for final

tightening, this is the least preferred

option)

NOTE – If mating surfaces are SIGNIFICANTLY distorted or misaligned “SLAVE” bolts should be used. AJAX ONESIDE TC’s can be used as slave bolts, but they must be identified and replaced with new bolts once all bolts in the connection have been tightened and the mating surfaces are in contact. The second tightening stage can only be achieved using the shear wrench. When the spline end of the bolt shears off at the break neck, full preload has been achieved as discussed previously.





FAQ’s on tightening of AJAX ONESIDE™ & Important items

1. How do we know which is the correct socket to select? As the product range on the ONESIDE Hi-Shear TC™ covers two sizes (M16 & M20), information is supplied separately as to the correct outer socket for the grip range. For M20 x 65/ 95/135/165, there are 2 outer sockets and one internal socket.

2. How can we be assured that the socket system will work correctly?

AJAX has spent a lot of time, using CAD and 3D modelling to ensure the outer and inner sockets perform exactly as required. Ensuring that spline engagement and nut coverage occurs correctly throughout all grip ranges. The AJAX ONESIDE sockets maintain the fail-safe and safety features present and designed into the Makita® 6922NB.

3. With some alternative products there has been issues with stripping of spline and external nut stripping?

As detailed in the about section, the AJAX product is manufactured with the correct metric spline arrangement to suit an M20 bolt in accordance with US / European and Japanese standards, other products ARE NOT. AJAX ONESIDE spline is solid, has correct dimensions to suit the forces required for M20 Bolt design, as compared to other products in the market. From the photos you can see the AJAX spline after shearing (un-damaged) and the other product. Twisting and deforming during the tightening process. TC bolts should never strip the spline as long as the inner socket is in good condition and the correct spline is used. The gun MUST BE set-up with the correct inner socket / outer socket arrangement. The same is true for stripping the outside of the nut. As long as the nut is completely covered inside the socket, and the socket is in good condition, this should not occur.

Torsional Damage to spline due to hollow cavity and incorrect size for forces. Installed with brand new inner socket. Protective coating flaking off .product.

Solid spline and correct size for M20





4. Can bolts be lubricate on site? Definitely Not!!! As per the ASTM standards, no alterations or changes of the product as

supplied is possible. Bolts must be kept dry and free from any dirt or foreign product. Bolts are manufactured and tested prior to packaging to ensure the correct

tension will be obtained when the spline tip breaks off. Adding lubricants to the nut and threads will alter the resulting tension, and when the tip shears off. This is a CRITICAL requirement of ASTM 3125 -16. The addition of any lubricant / water or dirt will affect the co-efficient of friction of the bolt. A lower coefficient of friction, will result in the bolt being over tensioned / stripping of either the bolt thread or nut thread, or in extreme cases completely breaking the bolt. Dirty or rusty parts, will increase the coefficient of friction. Parts will appear to be installed correctly, but may not have reached the correct minimum tension, when the tip being sheared off.

Notes:





Appendix Squirter Installation instructions

Documents

AJAX ONESIDE TRAINING MANUAL TRAINING... · As an option ONESIDE ™can be supplied with Direct Tension Indicators “Squirters” (DTI’s). DTI’s are to be placed between the