COMPRESSION LIMITERS

π x ( Ø22 - Ø12 )
AP=
4

ØB

ØA
ØC
 THE FUNCTION OF A
COMPRESSION LIMITER

The primary function of a Compression Limiter is to provide and maintain joint

integrity of a plastic assembly. Compression Limiters are designed to protect the
plastic components of an assembly from the compressive loads generated by the
tightening of bolts, thereby assuring continued integrity of the bolted connection.

In practice, the Compression Limiter should be slightly shorter than the thickness of the plastic
host. As the bolt is tightened the plastic compresses and the stress in the plastic increases until
the head of the bolt, or washer if one is used, comes into contact with the Compression Limiter.
Thereafter, the Compression Limiter and plastic will compress together at a rate controlled by the
limiter. The Compression Limiter will absorb additional clamping loads without further significant
compression or increased stress in the plastic material.

A properly designed bolted joint must meet the following criteria:

• The head of the bolt, or washer if one is used, should always seat against both the
plastic host and the Compression Limiter under load. This will prevent deterioration of
the bolted joint resulting from diminished clamping load due to plastic creep.

• The rated proof load of the Compression Limiter should be equal to or greater than
the proof load of the bolt to assure that the Compression Limiter will not yield prior to
the bolt under excessive clamping loads.

• The mating component that the Compression Limiter seats against should be strong
enough to withstand the localized compressive stresses generated by the clamping
force.

• The clearance between the maximum bolt diameter and the minimum installed inside
diameter of the Compression Limiter should be sufficient to compensate for expected
assembly tolerances.

Standard SPIROL® COMPRESSION LIMITERS meet these criteria.

Application Engineering Support

It is imperative that the proper Compression Limiter be designed into each application based on the
specific requirements for that assembly, and that the plastic host be designed appropriately to ensure
that bolted joint integrity is maintained throughout the life of the assembly.

Each application has unique considerations such as:

• The specific plastic type in which the • Mating materials

Compression Limiter will be used • Corrosion resistance requirements
• Minimum and maximum thickness of plastic host • Temperature requirements
• Fastener size, strength and tightening torque • Installation method

This catalog provides useful information regarding design guidelines and specifications for assemblies
that use Compression Limiters. In addition, SPIROL’s Application Engineers will partner with your
design team to determine the most appropriate Compression Limiter for your specific application.

Contact SPIROL for design assistance:

www.spirol.com/s/cmpldesign/
 SPIROL’S
COMPRESSION LIMITERS
SPIROL offers a range of both formed and machined Compression Limiters including split seam, molded in, oval
and solid wall designs. All formed Compression Limiters, except the Series CL220, are zinc plated and have a
supplementary coating of trivalent passivation and an organic sealant for corrosion resistance. This finish provides
144 hours to white corrosion, and 384 hours to red corrosion when salt spray tested in accordance with ASTM
B117. SPIROL’s Series CL220 Compression Limiters are coated with ArmorGalv®, a zinc alloy thermal diffusion
coating complimented with two sealers that provides a minimum of 1000 hours corrosion resistance to red rust.
Machined Limiters are manufactured from aluminum and brass, both of which have inherent corrosion resistant
properties and thus do not require supplementary finishing. Each series of Compression Limiter is designed to
meet specific proof loads and accommodate a variety of installation methods.

The clearance between the bolt and the inside diameter of the installed Compression Limiter is typically
adequate to meet normal misalignment. The Compression Limiter’s length should be designed to ensure it will
bottom out against the surface under the bolt’s head and mating component. The appropriate length and length
tolerance is application dependent. While the standard tolerance is sufficient to meet most needs, verification is
recommended. SPIROL‘s Applications Engineers are available to assist in this process. If it is determined that a
special Compression Limiter is required, then a documented recommendation will be provided.

The following details the unique features for each standard series:

• Series CL220 Split Seam: The Series CL220 Compression Limiter is produced from
high carbon steel and intended for post-mold installation. The spring force generated
during installation provides self-retention in the assembly. The flexible diameter
accommodates wide hole tolerances, and the gap is designed such that the parts will
not interlock in the free state. Once installed, the CL220 provides a minimum clearance
of 1mm around the bolt diameter to compensate for misalignment. The CL220 is the
only standard Compression Limiter finished with a protective coating of ArmorGalv®, a
zinc alloy thermal diffusion coating complimented with two sealers that provides 1000+
hours of salt spray protection for highly corrosive applications such as automotive,
marine, mining and industrial manufacturing. Additional benefits of ArmorGalv® include
no insignificant surfaces as the entire inner diameter (ID) of the Limiter receives full
coating and protection. The CL220 is rated for use up to ISO Class 8.8 bolts. The CL220
offers the widest range of standard diameter and length combinations to accommodate
a variety of application requirements.

• Series CL200 Split Seam - Slim Profile: Similar to the Series CL220, the CL200 Slim
Profile Compression Limiter has a smaller inner diameter (ID) after insertion and a
reduced overall profile with less clearance around the bolt. Once installed, the CL200
provides a minimum clearance of 0.5mm as compared to the larger minimum clearance
of 1mm provided by the CL220. The CL200 is rated for use up to ISO Class 8.8 bolts.

• Series CL350 Split Seam - Heavy Wall: The CL350 was designed with a thicker wall
for increased bearing surface when clamped against soft mating materials. Generous
bolt clearance also aids in positional alignment when multiple Compression Limiters are
used in an assembly. The CL350 is rated for use up to ISO Class 10.9 bolts.

• Series CL400 Split Seam - Oval: Produced from high carbon steel, the oval Series
CL400 accommodates 2.25mm extra clearance on one axis, providing additional
flexibility over round Compression Limiters for centerline and stack-up tolerancing. This
split-seam oval Limiter is formed, and it is spring tension that provides positive retention
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in the hole. The forming manufacturing method yields substantial cost savings over
machined and powdered metal products with similar features and characteristics. The
CL400 is rated for use up to ISO Class 8.8 bolts.

1
 SPIROL’S
COMPRESSION LIMITERS

• Series CL460 Molded-In - Oval: The CL460 Series is similar to the oval Series
CL400, but produced with a butted-seam so as to prevent plastic from entering the
inner diameter during the molding process, and a radial groove to ensure positive
retention within the hole. This series also accommodates 2.25mm extra clearance
on one axis. The CL460 is rated for use up to ISO Class 8.8 bolts.

• Series CL500 Molded-In: The Series CL500 is produced from low carbon steel with
a butted seam to prevent plastic from entering the inner diameter of the Compression
Limiter during the molding process. This also provides an anti-rotation feature once
in the assembly. The radial grooves provide axial retention. The CL500 is rated for
use up to ISO Class 8.8/Grade 5 bolts.

• Series CL6000 Precision Machined - Aluminum: The Series CL6000 is machined

from 2024 aluminum as this grade provides the best combination of strength,
corrosion resistance, machinability and cost. Additional advantages of aluminum are
that it is lightweight (1/3 the weight of brass), it is 40% stronger than brass, and it
is lead free. These Limiters can be molded in or pressed into the assembly. The
precision machined ID tolerance allows proper seating on the core pin when molding
into the assembly. When pressed into the assembly, they are designed with a pilot
that allows the part to stand freely in the hole prior to completing the installation.
Once installed, the knurl provides retention within the hole. The CL6000 is rated for
use up to ISO Class 10.9/Grade 8 bolts.

• Series CL6100 Precision Machined - Headed Aluminum: The CL6100 headed

aluminum Compression Limiter is the same as the CL6000, with the addition of a
head. The head provides extra bearing surface on the mating component when a
flanged bolt or a washer is not used.

• Series CL8000 Precision Machined - Brass: The Series CL8000 is machined from
360 brass. Similar to the CL6000, the CL8000 can be molded in or pressed into an
assembly. The applications for SPIROL’s brass and aluminum Compression Limiters
are very similar, however to accommodate the same class/grade bolt, the brass
Limiters have a larger wall thickness due to the material’s lower yield strength. While
this increases the size and weight of the Limiter as compared to the CL6000, the
thicker wall does provide more bearing surface for the mating component. The most
common reason a designer may choose the CL8000 is for those applications that
require a shift away from aluminum on the galvanic series chart to make the Limiter
more noble. The CL8000 is rated for use up to ISO Class 10.9/Grade 8 bolts.

• Series CL8100 Precision Machined - Headed Brass: The CL8100 headed brass
Compression Limiters are the same as the CL8000 with the addition of a head.
Similar to the CL6100, the head provides extra bearing surface on the mating
component when a flanged bolt or a washer is not used.

• Series CL620 General Purpose - Aluminum: The CL620 is designed for use in
non-critical applications and industries with forgiving assembly requirements. Similar
to the CL6000, the CL620 is manufactured from lightweight, lead-free aluminum,
offered in a narrower size range with generous tolerances that enable highly efficient
manufacturing. For applications that are highly automated with stringent tolerance
requirements, or if a headed configuration is required, consider the standard CL6000/
CL6100 lines.

2
 STANDARD OFFERING BREAKDOWN
& MATERIALS

DIA. INSTALL MATERIAL BOLT RATING RETENTION FEATURE /

SERIES
RANGE METHOD TYPE GRADE CLASS GRADE ATTRIBUTES

CL220 M4 - M12 Press-In 8.8 5 Radial Tension / ArmorGalv®

Radial Tension /
CL200 M4 - M8 Press-In 8.8 5
Reduced Profile
B - High UNS G10700 / G10740
CL350 M6 - M8 Press-In 10.9 8 Radial Tension / Heavy Wall
Carbon Steel CS67S (1.1231) / CS75S (1.1248)
CL400 M6 - M8 Press-In 8.8 5 Radial Tension / Oval

CL460 M6 - M8 Mold-In 8.8 5 Radial Groove / Oval

CL500 M6 - M8 / F- Low UNS G10060 / G10100

Mold-In 8.8 5 Radial Groove / Round
#10 - 5/16 Carbon Steel EN10139 DC04 (1.0338) / DC01 (1.0330)
Knurled / Solid Wall /
CL6000
ASTM B211 2024 Lightweight / Lead Free
A - Aluminum
ISO AlCu4Mg1
CL6100 CL6000 w/ Head
M3 - M10 Either
Press-In or 10.9 8 Knurled / Solid Wall /
CL8000
Mold-In UNS C36000 Cathodic Alt. to Aluminum
E - Brass
EN 12164 CW603N CuZn36Pb3
CL8100 CL8000 w/ Head
ASTM B211 2024 Knurled / Solid Wall /
CL620 M3 - M8 A - Aluminum
ISO AlCu4Mg1 Lightweight / Lead Free

Other diameters available upon request.

COMPRESSION LIMITER INSTALLATION TECHNOLOGY

Install one or multiple Compression Limiters simultaneously into various polymers, thermoplastics and/or thermosets.
Options such as vision sensing for part presence, automatic fixture identification, customized rotary or linear fixture
motion, password protection of HMI screens, keyed reset, status/indicator lights, audible fault alarm, and part marking
can be added for enhanced productivity, heightened process control and error-proofing.

Model CL
Model CM Semi-Automatic Multi-Tip
Manual Driver Highly flexible platen-style machine with
Extremely versatile and easily 228mm x 279mm (9" x 11") working area. Rotary
adjustable to accommodate a indexer shortens assembly time. Full insertion
myriad of applications. sensing ensures quality. Interchangeable
tooling facilitates changeover in minutes.

Model CP Pneumatic Model CLX

Installation Machine Semi-Automatic Multi-Tip
An accurate and consistent For larger assemblies and components
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method to install one or more outside the standard footprint of the

Compression Limiters into plastic Model CL. Equipped with a powered
assemblies. Quick-change tooling fixture slide. Working area is customized
adapts the platform to a variety to specific application requirements.
of products within seconds.

3
 DESIGN CONSIDERATIONS

Recommended Loading Determination of Compression Limiter Length

The integrity of a bolted joint requires that all of the Proper length specifications of both the Compression
components in the load path be capable of sustaining for Limiter and the plastic component are crucial to the
indefinite periods, under all environmental conditions, the proper performance of the bolted joint. The recommended
fastening load initially applied. To do this, all components maximum length of the Compression Limiter is the minimum
must be designed for a specific stress, and the fastener thickness of the plastic component. This assures that when
being used must be tightened to an appropriate level so the proper load is applied to the bolt two critical conditions
as not to exceed the yield point (elastic limit) of any of will be met:
the components. The reason that metal Compression • The bolt will be in contact with the Compression Limiter,
Limiters are required is because plastic always exhibits eliminating the possibility of creep.
stress and strain relaxation under even modest loads.
When determining bolted joint characteristics, the following • The plastic host will always have a small amount of
considerations should be evaluated: compression applied.
• What type of load is really required? For example, does The amount of compression on the plastic host will be at
a given plastic flange really need a Class 12.9 cap most the combined thickness and length tolerances of the
screw to hold it in place? two components and the amount of compressive deflection
on the Compression Limiter. In reality, with good SPC and
• What are the strengths of the components in the joint? production controls, the actual compression will be much
• What will the Compression Limiter be seated against? less.
If it is aluminum or plastic, then that may be the limiting
feature. Load Rating
SPIROL rates our Compression Limiters by matching the load
• Is the bolt being threaded into an Insert? If so, is there
required to compress the Limiter 2.5% of its nominal length to the
adequate thread strength and contact area on the Insert clamp load of the nominal sized fastener. See Standard Offering
to fully support the Compression Limiter? Breakdown & Materials.
• What torque should the bolt be tightened to? SPIROL
recommends that the bolt load be 25% to 75% of proof Compression Limiters are rated by the load required to
load. Less than 25% and you risk not generating enough compress the Limiter to a defined, safe distance that meets
frictional retention within the threads. More than 75% the requirements of:
and there is a chance, due to assembly variations, that • Maintaining integrity of the Limiter, preventing rupturing
the proof load of the bolt may be exceeded. or excessive swelling.
• How does torque relate to bolt load? Torque and actual • Maintaining the integrity of the plastic host by keeping
clamping load are very dependant on materials and any localized compressive strains within generally
conditions. The theoretical formula provided on page 5 accepted, safe limits.
is only for reference. Actual torque applied must be
• Maintaining the load of the fastener by preventing stress
determined by the end user and is dependant on a
relaxation, thereby assuring the continued integrity of
variety of factors such as materials and coatings of all
the bolted connection.
the components in the joint as well as the method of
applying the torque. For all engineered thermoplastic materials used in durable
manufactured products, allowing 3%-5% maximum
Recommended Tightening Torque compression has been determined to be a safe, conservative
The integrity of the bolted joint requires that none of the limit. Most plastics are perfectly safe being compressed 5%-
components, including the bolt, be stressed beyond the 7%; many even further. Plastics have the characteristic that
elastic limit. SPIROL recommends a clamping load not to they will very quickly exhibit stress relaxation in the areas
exceed 75% of the proof load of the bolt. The recommended of high compression eliminating the potential of stress
torque values to produce this clamping load are provided cracking and allowing the Compression Limiter to take the
on page 5. fastener load.

4
 BOLT SPECIFICATIONS

Typical tightening torque values to achieve recommended Where:

Clamping Loads are based on the following formula: D = nominal bolt diameter T = torque
T K = torque-friction coefficient KDry = 0.2
P=
DxK P = bolt clamping load KLube= 0.15

COMMON METRIC BOLTS PER ISO 898

CLASS 5.8 CLASS 8.8 CLASS 10.9 CLASS 12.9
THREADS LOADS TORQUE LOADS TORQUE LOADS TORQUE LOADS TORQUE
PROOF CLAMP DRY LUBE PROOF CLAMP DRY LUBE PROOF CLAMP DRY LUBE PROOF CLAMP DRY LUBE
M3 X 0.5 1,910 1,430 0.9 0.6 2,920 2,190 1.3 1.0 4,180 3,140 1.9 1.4 4,880 3,660 2.2 1.6
M3.5 X 0.6 2,580 1,940 1.4 1.0 3,940 2,960 2.1 1.6 5,630 4,220 3.0 2.2 6,580 4,940 3.5 2.6
M4 X0.7 3,340 2,500 2.0 1.5 5,100 3,850 3.1 2.3 7,290 5,450 4.4 3.3 8,520 6,400 5.1 3.8
M5 X 0.8 5,400 4,050 4.0 3.0 8,230 6,150 6.2 4.6 11,800 8,850 8.8 6.6 13,800 10,350 10.3 7.8
M6 X 1 7,640 5,750 6.9 5.2 11,600 8,700 10.4 7.8 16,700 12,550 15.1 11.3 19,500 14,650 17.6 13.2
M8 X 1 14,900 11,200 17.9 13.4 22,700 17,000 27.2 20.4 32,500 24,400 39.0 29.3 38,000 28,500 45.6 34.2
M8 X 1.25 13,900 10,400 16.6 12.5 21,200 15,900 25.4 19.1 30,400 22,800 36.5 27.4 35,500 26,600 42.6 31.9
M10 X 1 24,500 18,400 36.8 27.6 37,400 28,100 56.2 42.1 53,500 40,100 80.2 60.2 62,700 47,000 94.0 70.5
M10 X 1.25 23,300 17,500 35.0 26.3 35,500 26,600 53.2 39.9 50,800 38,100 76.2 57.2 59,400 44,600 89.2 66.9
M10 X 1.5 22,000 16,500 33.0 24.8 33,700 25,300 50.6 38.0 48,100 36,100 72.2 54.2 56,300 42,200 84.4 63.3
M12 X 1.25 35,000 26,300 63.1 47.3 53,400 40,100 96.2 72.2 76,400 57,300 137.5 103.1 89,300 67,000 160.8 120.6
M12 X 1.5 33,500 25,100 60.2 45.2 51,100 38,300 91.9 68.9 73,100 54,800 131.5 98.6 85,500 64,100 153.8 115.4
M12 X 1.75 32,000 24,000 57.6 43.2 48,900 36,700 88.1 66.1 70,000 52,500 126.0 94.5 81,800 61,400 147.4 110.5

COMMON INCH BOLTS PER SAE J429 STANDARD FASTENER

RATING: STRESS UNDER
GRADE 2 GRADE 5 GRADE 8
THREADS PROOF LOAD
LOADS TORQUE LOADS TORQUE LOADS TORQUE ISO Class 5.8 380 MPa
COARSE PROOF CLAMP DRY LUBE PROOF CLAMP DRY LUBE PROOF CLAMP DRY LUBE ISO Class 8.8 580 MPa
#4-40 * 330 250 5.6 4.2 510 380 8.5 6.4 720 540 12.1 9.1 ISO Class 10.9 830 MPa
#6-32 * 500 375 10.4 7.8 770 580 16.0 12.0 1,090 820 22.6 17.0 ISO Class 12.9 970 MPa
#8-32 * 770 575 18.9 14.1 1,190 895 29.4 22.0 1,680 1,260 41.3 31.0 SAE Grade 2 55,000 psi
#10-24 * 960 720 27.4 20.5 1,480 1,110 42.2 31.6 2,100 1,575 60.0 45.0 SAE Grade 5 85,000 psi
1/4-20 1,750 1,310 65.5 49.0 2,700 2,025 101.0 76.0 3,800 2,850 143.0 107.0 SAE Grade 8 120,000 psi
5/16-18 2,900 2,200 138.0 103.0 4,450 3,340 209.0 157.0 6,300 4,725 295.0 221.0
3/8-16 4,250 3,200 240.0 180.0 6,600 4,950 371.0 278.0 9,300 7,000 525.0 394.0
FINE PROOF CLAMP DRY LUBE PROOF CLAMP DRY LUBE PROOF CLAMP DRY LUBE
#4-48 * 360 270 6.0 4.5 560 420 9.4 7.1 790 600 13.4 10.1
#6-40 * 550 410 11.3 8.5 860 645 17.8 13.4 1,210 910 25.1 18.8
#8-36 * 800 600 19.7 14.8 1,250 940 30.8 23.1 1,760 1,320 43.3 32.5
#10-32 * 1,100 825 31.4 23.5 1,700 1,275 48.5 36.3 2,400 1,800 68.5 51.5
1/4-28 2,000 1,500 75.0 56.5 3,100 2,325 116.0 87.0 4,350 3,260 163.0 122.0
5/16-24 3,200 2,400 150.0 113.0 4,900 3,675 230.0 172.0 6,950 5,210 326.0 244.0
3/8-24 4,800 3,600 270.0 202.0 7,450 5,600 420.0 315.0 10,500 7,900 593.0 444.0

Notes:
* Inch sizes are not directly covered by SAE J429, but are calculated appropriately.
• Calculations are based on using bolt proof loads per SAE J429 and ISO 898 respectively.
SPIROL.com

• Clamp load in calculation is based on approximately 75% of the proof load for each bolt. SPIROL strongly
recommends not to exceed 75% of proof load. If the bolt is torqued all the way to proof, the bolt will fail.
• Metric thread torque is N•m and load is N.
• Inch thread torque is in•lbs and load is lbs.
• Torque values shown are for clamp load.
• Actual loads developed by a specified torque value can vary by ±25%.

5
 DESIGN CONSIDERATIONS

Plastic Host Design Mating Component Material

Although the Split Seam Compression Limiters have a The clamping load of the bolt is transferred to the mating
broken edge, this is kept to a minimum in order to maintain component through the Compression Limiter. It must be
the maximum bearing surface area. Accordingly, it is evaluated whether the material of the mating component
recommended that a radius be molded as a lead-in to the is strong enough to withstand the clamping force of the
hole in the plastic component to facilitate insertion. This bolt. The stress imparted onto the mating component can
radius is not necessary for Solid Wall Compression Limiters be calculated by dividing the clamping load applied to
as the pilot is smaller than the hole. The hole should taper the Compression Limiter by the cross sectional area of
within the recommended hole size for the length of the the Compression Limiter. If this stress exceeds the yield
Compression Limiter. Hosts for Split Seam Compression strength of the mating component material, localized
Limiters must be within the hole tolerance for more than permanent deformation may occur, resulting in a loss in
60% of the plastic thickness with at least 4mm (.156”) clamping load.
of engagement. The hole size should not fall below the
minimum recommended diameter in order to prevent the Cost-Effective Fastener Selection
seam of the Limiter from completely closing upon insertion. Designers should be prudent about not choosing a bolt
Hosts for Solid Wall Limiters must be entirely within the class that is too strong for the application and ensuring
recommended hole diameter. (See (A) in Diagram 1) that the proper tightening torque is applied during the
assembly process. A higher bolt class requires a stronger
Compression Limiter and potentially stronger mating
material. Each adds to the total cost of the assembly.
When increased bearing surface at the mating junction
is required, Designers should consider selecting either a
flange head bolt or including a washer rather than investing
in a headed Compression Limiter. In this situation, there is
Hole Diameter a trade-off between cost and ease of assembly. Flanged
(A) bolts and washers cost much less than the added expense
of a headed Compression Limiter. In addition, non-headed
Compression Limiters are easier to feed.
Plastic
(C)
Thickness Selecting the Most Cost-Effective
Compression Limiter
Each standard series of Compression Limiters will affect
Boss Diameter
the overall cost of the assembly in different ways. SPIROL
(B)
Engineering will assist in the determination of which type of
Diagram 1 Compression Limiter is best suited to meet the performance
See Page 7 for Host Thickness Design Guidelines and installation requirements that results in the lowest total
cost of the assembly.
Generally the boss diameter is two (2) times the Compression
Limiter diameter. The wall thickness has to be enough to
avoid bulging or cracking when pressed-in cold, and for
boss diameters to be strong enough for plastic compression
when assembling the bolt. Poor knit lines will cause cracking
failures.

Some Compression Limiters may require larger boss

diameters and/or wall thickness to withstand the greater
stresses induced during installation. For Solid Wall
Compression Limiters, installing while the plastic is still warm
from the molding process generally reduces this need.

6
 DESIGN GUIDELINES

Allowable Compression of the Plastic Force to Seat the Bolt on the Compression
Component Limiter
For most commonly used molded plastics, it is difficult to It is important to always assure that the bolt is seated securely
determine a specific maximum amount that they can be against the Compression Limiter. While proportionally
compressed in a short period of time. There are too many plastic is much more compressible than the Compression
variables involved to make a specific calculation. Such Limiter, in the initial assembled state the plastic will be
features as the specific plastic, filler, mold design, wall nominally thicker than the length of the Compression Limiter.
thickness, and stress concentrations all impact the durability With the use of flanged bolts or large washers, significant
of the plastic. As a general guideline, 3%-5% compression of surface area of the plastic can be put under compression,
thermoplastic materials is reasonable. Over a short period of generating high loads. Therefore, it is necessary to calculate
time the plastic will usually exhibit stress relaxation, thereby the capability of the bolt to compress the plastic and seat
alleviating the compressive load on the plastic and allowing against the Compression Limiter in the worst case scenario.
the Compression Limiter to maintain joint integrity. Stated Formula (3) shows how to calculate the force required to
in formula (1) below: seat the bolt.

(1) dP = Tmax - Lmin + dC ( Tmax - Lmin ) x EP x AP

(3) FB =
Where dP should typically be less than 5% of Tmax Tmax
Where: π x ( Ø22 - Ø12 )
dP = Required deflection of the plastic component, in Where AP =
units of length. 4
Tmax = Maximum thickness of the plastic component, in
units of length. Where:
Lmin = Minimum length of the Compression Limiter, in FB = Compressive force generated by the bolt or
units of length. fastener, in units of force.
dC = Deflection of the Compression Limiter under load, Tmax = Maximum thickness of the plastic component, in
in units of length. units of length.
Lmin = Minimum length of the Compression Limiter, in
units of length.
Deflection of the Compression Limiter EP = Modulus of Elasticity (Young’s Modulus) of the
Deflection of the Compression Limiter under bolt load can plastic component, in units of force per area.
be calculated using formula (2) below: AP = Area of the plastic component being placed in
compression by the bolt, in units of area.
F xL Ø1 = Minimum hole diameter of the plastic component,
(2) dC = AB x EC in units of length.
C C
Ø2 = Maximum diameter of the portion of the bolt or
Where:
washer that will be in contact with the plastic,
dC = Deflection of the Compression Limiter under load,
in units of length.
in units of length.
FB = Compressive force generated by the bolt or
fastener, in units of force. The resultant FB should be in the range of 75% or less of
LC = Nominal length of the Compression Limiter, in the proof load of the selected bolt, thereby assuring that
units of length. sufficient compression is applied to the Compression Limiter
AC = Cross sectional area of the Compression Limiter, after the plastic stress has relaxed.
in units of area.
EC = Modulus of Elasticity (Young’s Modulus) of the
material of the Compression Limiter, in units
of force per area. See Table 2.

Note: Compressive strain is an estimated value. Factors such as the rigidity of

Material psi MPa
the plastic host, material, length to diameter ratio of the Compression Limiter, wall
Carbon Steel 30,000,000 206,000
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thickness, material type, and level of work hardening all affect the actual strain in
Aluminium 10,000,000 69,000 the Limiter under actual compressive loads in the application. For assistance on
determining the most appropriate Compression Limiter for your assembly, please
Brass 14,100,000 97,000
contact SPIROL for complimentary Application Engineering support.
Table 2 - Modulus of Elasticity for Common Materials

7
 DESIGN GUIDELINES

Ideal Bolted Joint

Bolt is tightened to 75% of its proof load. Plastic compression ~ 3% - 5%.

Bolt head applies a clamp load on the
Limiter is compressed between bolt’s
plastic and bottoms out on the Limiter.
head and mating component.
Host thickness is greater than or equal to the
length of the Limiter, and able to absorb the Correct hole size ensures
clamp load. retention of the Limiter.
The installed Limiter is aligned with the Insert The mating component can withstand
(when used) to prevent a jack-out condition. compression force generated by bolt.

The following design guidelines should be considered when Galvanic compatibility of the materials within the assembly
a Compression Limiter is used to ensure its effectiveness should be considered when an electrolyte is present.
in the plastic assembly: Theoretically, galvanic corrosion can be prevented by
use of similar metals on the anodic scale and separating
• The length of the Compression Limiter should be equal dissimilar metals by use of electrical insulators. In reality,
to or slightly less than the host thickness such that there protection is difficult to achieve as it is difficult to always
is a small amount of plastic compression after the bolt is use similar metals or provide complete protection from
torqued. If the plastic is not compressed, the host may the elements. It is important to consider other measures
move about the Limiter. to minimize the effect of galvanic corrosion. The following
factors should be considered:
• The bearing surface beneath the bolt’s head or washer
must extend over the Compression Limiter to contact • Protect the metallic parts from the environment. Without
the plastic component to avoid plastic creep and ensure an electrolyte, galvanic corrosion cannot occur.
bolted joint integrity over the life of the assembly. Methods
that can be used to achieve this include the use of a • Avoid combinations of dissimilar metals that are far
flanged bolt, washer or headed Compression Limiter. A apart on the anodic index. For harsh environments such
washer may be preferred in lower volume and or/non- as outdoor use, materials should be within 0.15V, and in
serviced applications. In higher volume, automated and/ warehouses and other uncontrolled indoor environments
or serviceable applications, a non-headed Compression materials should be within 0.25V. In temperature and
Limiter with a flanged bolt is the easiest to assemble and humidity controlled environments, materials can be as
provides the lowest total cost. far apart as 0.50V.

• The amount of material compressed under the bolt’s • Avoid small anodes and large cathodes as this increases
head varies depending on the application’s loading the corrosion rate of the anode.
and plastic properties. This area of compression must
be large enough to withstand forces attempting to pull Anode
the assembly apart, yet small enough to allow sufficient (Sacrificed) 1.75V Magnesium
plastic compression so that the Compression Limiter
contacts both the bolt and the mating component.
1.25V Zinc Die Cast, Plate / ArmorGalv®
• For any given bolt size and class/grade, the
recommended clamp load is 25%-75% of the proof load. 0.90V 6000 Series Aluminum
(Reference page 5) 0.85V Carbon Steel

0.75V 2024 Aluminum

• It is imperative that the component mating against the
Compression Limiter can withstand the compression 0.60V 420 Stainless Steel (Active)
force generated by the bolt.
0.50V 302 Stainless Steel (Active)
• When using an Insert in the mating component, it is 0.45V 360 Brass
essential for the Compression Limiter to be in contact
with the face of the Insert to avoid pulling the Insert out
of the plastic assembly (jack-out). The Insert must also
be able to withstand the load generated by the bolt. Cathode
(Protected) 0.00V Gold

8
 SPLIT SEAM – COMPRESSION LIMITERS

Series CL220
L+0
-LTol

ØOD

BROKEN EDGE T NOM

MATERIAL FINISH
B High Carbon Steel H ArmorGalv®

DIMENSIONAL DATA
NOMINAL BOLT SIZE  M4 M5 M6 M8 M10 M12
Min. ØID Installed 5.0 6.0 7.0 9.0 11.0 13.0
Wall Thickness “T” 0.85 1.00 1.10 1.50 1.85 2.25
Length Tolerance “LTol” 0.15 0.15 0.15 0.20 0.25 0.25
Outer Diameter ØOD 7.17/7.34 8.47/8.64 9.67/9.89 12.52/12.79 15.27/15.59 18.07/18.44
Recommended Ø Hole Size 7.00/7.10 8.30/8.40 9.50/9.60 12.35/12.45 15.10/15.20 17.90/18.00
6
8
10
LENGTH

12
15
20
25
30

• CL220 rated for use up to ISO Class 8.8 bolts.

• Special lengths and sizes available upon request.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Split Seam Compression Limiters

can be installed with SPIROL Installation Equipment or simply pressed in.

To Order: CMPL, Nominal Bolt Diameter, Length, Material, Finish, Series

Example: CMPL 6 X 6 BH CL220

What is ArmorGalv®?
COMPLETE I.D. COATING
ArmorGalv® is a zinc alloy thermal diffusion coating covered by ASTM
A1059M-08(2013). ArmorGalv® provides uniform deposition of coating
on all surfaces of the part. There are no insignificant surfaces and the
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entire inner diameter receives full coating and protection. ArmorGalv® and ArmorGalv® Coated
two complimentary sealers offers a minimum of 1,000 hours corrosion
resistance to red rust, and is an ideal coating for some of the most INCOMPLETE I.D. COATING
aggressive environments such as marine, automotive, mining, agriculture
and industrial manufacturing.
SPIROL is a licensee of ArmorGalv®, a registered trademark of Distek N.A LLC Electroplated Zinc
9
 SPLIT SEAM – SLIM PROFILE
COMPRESSION LIMITERS

Series CL200

L+0
-LTol

ØOD

BROKEN EDGE T NOM

MATERIAL FINISH
B High Carbon Steel T Trivalent Zinc Plated

DIMENSIONAL DATA
NOMINAL BOLT SIZE  M4 M6 M8

Min. ØID Installed 4.5 6.5 8.5

Wall Thickness “T” 0.85 1.10 1.50
Length Tolerance “LTol” 0.15 0.15 0.20
Outer Diameter ØOD 6.65/6.75 9.15/9.33 11.90/12.20
Recommended Ø Hole Size 6.50/6.60 9.00/9.10 11.75/11.85
8
10
LENGTH

12
15
20
25

• All dimensions apply prior to plating. Thicker finishes, such as ArmorGalv® and dip coatings, may
require adjusted dimensions to ensure form, fit and function. Please consult SPIROL Engineering
if considering these types of finishes for the CL200.
• CL200 rated for use up to ISO Class 8.8 bolts.
• Heat treated versions available to order for use up to ISO Class 12.9/Grade 8 bolts.
• Special lengths and sizes available upon request.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Split Seam Compression Limiters

can be installed with SPIROL Installation Equipment or simply pressed in.

To Order: CMPL, Nominal Bolt Diameter, Length, Material, Finish, Series

Example: CMPL 10 X 12 BT CL200

10
 SPLIT SEAM – HEAVY WALL
COMPRESSION LIMITERS

Series CL350

L+0
-LTol

ØOD

BROKEN EDGE T NOM

MATERIAL FINISH
B High Carbon Steel T Trivalent Zinc Plated

DIMENSIONAL DATA - METRIC

NOMINAL BOLT SIZE  M6 M8

Min. ØID Installed 6.8 8.8

Wall Thickness “T” 1.50 2.00
Length Tolerance “LTol” 0.15 0.20
Outer Diameter ØOD 10.08/10.28 13.25/13.52
Recommended Ø Hole Size 9.95/10.05 13.05/13.20
10
12
LENGTH

15
20
25

• All dimensions apply prior to plating.

• CL350 rated for use up to ISO Class 10.9 bolts.
• Special lengths and inch sizes available upon request.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Split Seam Compression Limiters

can be installed with SPIROL Installation Equipment or simply pressed in.
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To Order: CMPL, Nominal Bolt Diameter, Length, Material, Finish, Series

Example: CMPL 6 X 15 BT CL350

11
 SPLIT SEAM – OVAL
COMPRESSION LIMITERS

Series CL400

L+0 ØOD
-LTol MINOR

ØOD
MAJOR

BROKEN EDGE
T NOM

MATERIAL FINISH
B High Carbon Steel T Trivalent Zinc Plated

DIMENSIONAL DATA - METRIC HOLE SPECIFICATIONS

NOMINAL BOLT SIZE  M6 M8 ØH
MINOR
Min. ØID 6.8 8.8
Wall Thickness “T” 1.10 1.50
Length Tolerance “LTol” 0.15 0.20
Outer Diameter ØOD Major 11.45/11.70 14.30/14.60 ØH
MAJOR
Outer Diameter ØOD Minor 9.40/9.60 12.25/12.50
Recommended Ø Hole H Major 11.55/11.70 14.45/14.60
Size H Minor 9.20/9.30 12.05/12.15
FULL RADIUS
8 2 PLACES
10
LENGTH

12
15
20

• All dimensions apply prior to plating.

• CL400 rated for use up to ISO Class 8.8 bolts.
• Special lengths and inch sizes available upon request.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Oval Split Seam Compression Limiters

can be installed with SPIROL Installation Equipment or simply pressed in.

To Order: CMPL, Nominal Bolt Diameter, Length, Material, Finish, Series

Example: CMPL 6 X 12 BT CL400

12
 MOLDED-IN – OVAL
COMPRESSION LIMITERS

Series CL460

L+0
-LTol MAX ØOD
MINOR

E Ref.
MAX
ØOD
MAJOR

T NOM MIN ØID

MATERIAL FINISH
B High Carbon Steel T Trivalent Zinc Plated

DIMENSIONAL DATA - METRIC

NOMINAL BOLT SIZE  M6 M8

Min. ØID 6.8 8.8

Wall Thickness “T” 1.10 1.50
Elongation “E” 2.25 2.25
Length Tolerance “LTol” 0.15 0.20
Max. Outer Diameter ØOD Major 11.65 14.50
Max. Outer Diameter ØOD Minor 9.40 12.25
6
8
LENGTH

10
12
15

• All dimensions apply prior to plating.

• CL460 rated for use up to ISO Class 8.8 bolts.
• Special lengths and inch sizes available upon request.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Oval Molded-In Compression Limiters

can be molded in using industry standard core pins.
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To Order: CMPL, Nominal Bolt Diameter, Length, Material, Finish, Series

Example: CMPL 8 X 10 BT CL460

13
 MOLDED-IN
COMPRESSION LIMITERS

Series CL500

L+0
-LTol
ØOD
MAX.

T NOM MIN ØID

Parts less than 20mm (.750”) long will have a single groove.

MATERIAL FINISH
F Low Carbon Steel T Trivalent Zinc Plated

DIMENSIONAL DATA - METRIC DIMENSIONAL DATA - INCH

NOMINAL BOLT SIZE  M6 M8 NOMINAL BOLT SIZE  #10 1/4 5/16

Min. ØID 6.8 8.8 Min. ØID .221 .281 .344

Wall Thickness “T” 1.50 2.00 Wall Thickness T .043 .059 .078
Length Tolerance “LTol” 0.15 0.20 Length Tolerance “LTol” .006 .006 .008
Outer Diameter ØOD Max. 10.25 13.25 Outer Diameter ØOD Max. .323 .417 .518
10 .312
12 .375
LENGTH

LENGTH

15 .500
20 .625
25 .750
1.000

• All dimensions apply prior to plating.

• CL500 rated for use up to ISO Class 8.8/Grade 5 bolts.
• Special lengths and sizes available upon request.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Molded-In Compression Limiters

can be molded in using industry standard core pins.

Plastic removed to show

Compression Limiter.

To Order: CMPL, Nominal Bolt Size x Length, Material, Finish, Series

Example: CMPL 6 X 20 FT CL500

14
 PRECISION MACHINED – ALUMINUM
COMPRESSION LIMITERS

Series CL6000 Series CL6100

Knurled Headed
L+0
-0.15 -0.15 =L+T
OAL +0
+0
L -0.15

øB 0.1 X
øC øB 0.1 X
øC
øH

Y 0.1 Y Z 0.1 X
Y T
øA 0.1 M Y Z 0.1 Y Z

X øA 0.1 M Y Z

X
MATERIAL FINISH
A Aluminum K Plain

DIMENSIONAL DATA
NOMINAL BOLT SIZE  M3 M4 M5 M6 M8 M10

Inner Diameter ØA 4.05/4.15 5.05/5.15 6.05/6.15 7.05/7.15 9.05/9.15 11.05/11.15

Body Diameter ØB 5.42/5.58 6.95/7.11 8.47/8.63 10.00/10.16 13.36/13.52 16.72/16.88
Knurl Diameter ØC Nom. 5.83 7.38 8.88 10.43 13.78 17.13
Head Diameter ØH 7.35/7.60 8.95/9.20 10.55/10.80 12.15/12.40 15.35/15.60 18.95/19.20
Head Thickness “T” Ref. 1.00 1.00 1.00 1.25 1.25 1.25
Recommended Ø Hole Size 5.61/5.69 7.14/7.22 8.64/8.72 10.19/10.27 13.54/13.62 16.89/16.97
3
4
LENGTH

5
6
8

• CL6000 / CL6100 rated for use up to ISO Class 10.9 bolts.

• The knurl will always be larger than the maximum hole.
• Additional diameters and special lengths available upon request.
• Available in inch sizes - made to order.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Knurled CL6000 and CL6100 Compression Limiters

are perfect for press-in and molded-in applications - including highly
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automated assembly processes.

To Order: CMPL, Nominal Bolt Size x Length, Material, Finish, Series

Example: CMPL 6 X 8 AK CL6100

15
 PRECISION MACHINED – BRASS
COMPRESSION LIMITERS

Series CL8000 Series CL8100

Knurled Headed
L+0
-0.15 -0.15 =L+T
OAL +0
+0
L -0.15

øB 0.1 X
øC øB 0.1 X
øC
øH

Y 0.1 Y Z 0.1 X
Y T
øA 0.1 M Y Z 0.1 Y Z

X øA 0.1 M Y Z

X
MATERIAL FINISH
E Brass K Plain
DIMENSIONAL DATA
NOMINAL BOLT SIZE  M3 M4 M5 M6 M8 M10

Inner Diameter ØA 4.05/4.15 5.05/5.15 6.05/6.15 7.05/7.15 9.05/9.15 11.05/11.15

Body Diameter ØB 6.03/6.19 7.56/7.72 9.09/9.25 10.92/11.08 14.58/14.74 17.95/18.11
Knurl Diameter ØC Nom. 6.45 7.97 9.50 11.34 15.01 18.36
Head Diameter ØH 7.75/8.00 9.35/9.60 10.95/11.20 13.35/13.60 17.35/17.60 20.45/20.70
Head Thickness “T” Ref. 1.00 1.00 1.00 1.25 1.25 1.25
Recommended Ø Hole Size 6.22/6.30 7.73/7.81 9.26/9.34 11.10/11.18 14.77/14.85 18.12/18.20
3
4
LENGTH

5
6
8

• CL8000 / CL8100 rated for use up to ISO Class 10.9 bolts.

• The knurl will always be larger than the maximum hole.
• Additional diameters and special lengths available upon request.
• Available in inch sizes - made to order.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Knurled CL8000 and CL8100 Compression Limiters

are perfect for press-in and molded-in applications - including highly
automated assembly processes.

To Order: CMPL, Nominal Bolt Size x Length, Material, Finish, Series

Example: CMPL 5 X 6 EK CL8000

16
 GENERAL PURPOSE – ALUMINUM
COMPRESSION LIMITERS

Series CL620
Knurled

L +0
-0.20

øB øC

øA

MATERIAL FINISH
A Aluminum K Plain
DIMENSIONAL DATA
NOMINAL BOLT SIZE  M3 M4 M5 M6 M8

Inner Diameter ØA 4.05/4.15 5.05/5.15 6.05/6.15 7.05/7.15 9.05/9.15

Body Diameter ØB 5.42/5.58 6.95/7.11 8.47/8.63 10.00/10.16 13.36/13.52
Knurl Diameter ØC Nom. 5.78 7.32 8.82 10.38 13.72
Recommended Ø Hole Size 5.60/5.68 7.13/7.21 8.64/8.72 10.18/10.26 13.53/13.61
3
4
LENGTH

5
6
8

• CL620 rated for use up to ISO Class 10.9 bolts.

• The knurl will always be larger than the maximum hole.
• Additional diameters and special lengths available upon request.
• Brass alternative available - made to order with alternate dimensions.
• Please reference pages 6-8 for design considerations and guidelines.

SPIROL® Knurled CL620 Compression Limiters

can be either pressed-in or overmolded into the assembly.
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To Order: CMPL, Nominal Bolt Size x Length, Material, Finish, Series

Example: CMPL 6 X 8 AK CL620

17
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