DIRECT

TENSION
INDICATOR

INSTRUCTION MANUAL

Keep For Your Records

Direct Tension Indicators meaure clamping force

The Director Tension Indicator (DTI) is a specially hardened

Figure 2

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 BOLT TIGHTENING USING DTIs
METHOD #1 (Preferred Method) - PLAIN FINISH DTIs

DTI Under the Stationary Nut - Turn the Opposite Nut to Tighten

This method should be used whenever possible. Other methods are acceptable, but
should only be used when this one cannot be.

ASSEMBLY
Put the DTI under the stationary nut with the bumps facing the underside of the nut
(see figure below).

Stationary Nut

Gap

Opposite Nut

TIGHTENING
PART 1: Turning the nut opposite the stationary nut, apply torque to all bolts in the
pattern using a criss-cross sequence. When turning the opposite nut, prevent the
stationary nut from turning with a hand wrench. Turning can wear down the bumps.
This criss-cross sequence should be performed using a series of passes at a torque
value that is a fraction of the target torque and increases for each pass. For exam-
ple: if the target torque is 300 ft-lbs, the first pass might be 30% of the target torque,
which would be 90 ft-lbs, the second pass might be 70% or 210 ft-lbs, and so on.
The number of passes performed in this manner will be dictated by the application.
A final criss-cross sequence will be performed using the following procedure.
PART 2: Tighten bolt number 1 by slowly applying torque until the desired gap is
achieved in half or more of the entry spaces (SEE INSPECTION). Repeat this
process for bolts 2 through 4. As each of the first four bolts is brought up to the
desired load, record the amount of torque required for each bolt and compute an
average torque value. Use the average torque value to tighten the remaining bolts
in the flange using the criss-cross sequence. Make a final circular pass using the
average torque value. Continue the circular pass until the nut on the next bolt
refuses to turn when torque is applied. Next, check the gap for each bolt in the cir-
cular pattern using the procedure described in the INSPECTION section of this
manual. If the No-Go gauge is not refused in half or more of the entry spaces,
apply a greater amount of torque to the nut until the No-Go gauge is refused in half
or more of the entry spaces. In the rare instance that the No-Go gauge is refused
and the Go gauge is also refused, the target bolt load has been exceeded and the
DTI must be replaced.

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Remove the bolt and reinstall it with a new DTI. Retighten the bolt while monitor-
ing the gap between the DTI and the nut to ensure that the target load is not
exceeded again.

METHOD #2 (Alternate Method) - PLAIN FINISH DTIs

DTI Under the Nut to be Turned - Turn the Same Nut to Tighten

This method should be used only when the preferred method cannot be used. It is
usually limited to an installation where the bolt must be installed in such a way that
the device for applying torque can only be placed on the same end as the DTI and
the DTI cannot be inspected from the other end.

Turning Nut
Hardened Steel Washer

Gap

Stationary Nut

ASSEMBLY
Place the DTI under the nut to be turned with the bumps facing the underside of
the nut. Place a hardened 1/4” thick flat washer between the DTI and the nut.

TIGHTENING
Follow instructions in Parts 1 & 2 of TIGHTENING in METHOD #1 applying torque
to the nut on the same end of the bolt as the DTI.

INSPECTION
Each DTI is marked with a lot number. A test certificate is provided with the DTIs,
which relates bolt load to the gap obtained for each size and lot number tested.
Refer to the test certificate to determine the appropriate size feeler gauge to use.
For example, the test certificate for DTIs used with a 5/8” diameter, B7 stud from
lot number 58BAI indicates a mean gap of .033” when the bolt load is at 50% of
minimum yield strength of the stud. When a feeler gauge (No-Go gauge) of .033”
is refused by a majority of the entry spaces (2 out of 3 in this particular case), the
bolt load is a 50% of minimum yield strength. To determine whether or not the bolt
is within acceptable upper limits, select a feeler gauge (Go gauge), which is .003”
THINNER than the No-Go gauge (in this case, a .030” feeler gauge). The feeler
gauge should be a majority of the entry spaces. Using this process will ensure the
upper and lower limits.

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PROBLEMS COMMONLY ENCOUNTERED WHEN TIGHTENING BOLTS

Dry or Rusty Threads: Usually caused by poor storage conditions, dry or rusty
bolts and nuts should not be permitted. Ideally - nuts, bolts, washers and DTIs
should be kept in dry storage and their containers not opened until immediately
before use. Rust significantly increases the amount of torque required to tension a
bolt. When assembling bolts, always use a lubricant. A molybdenum disulfide
based lubricant with approximately 70% solids is recommended for most applica-
tions. Such lubricants are available at Fastorq Bolting Systems. When applying
lubricant, make sure to lubricate the underside of the nut that will be turning as well
as the washer surface upon which the nut will be turning. Do not lubricate either
surface of the DTI or the side of the washer making contact with the DTI.

Damaged Threads: Usually caused by forcing the bolt through misaligned holes -
this will cause the nut to freeze.

Trapped Bolts: Usually caused by slippage in the joint as a result of flanges slip-
ping out of alignment after the bolts have been installed. Trapped bolts cannot
develop tension along their entire length. Securing the flanges by partially loading
four or more bolts after careful alignment should prevent this problem.

Hardened Washers Under the Turned Element: The use of hardened washers
under the turned element significantly reduces the torque required to tension a bolt
and is recommended by FASTORQ when using DTIs.

Hardened Washers Under the DTI: When the surface of the flange making con-
tact with the DTI is rough or uneven, place a hardened 1/4” thick washer under the
DTI. This will ensure accurate measurement of the gap between the DTI and the
nut.

4 Rev 0/2013