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Ultrasonic bolt tension testing is a highly accurate method of determining what bolt tension tightening methods are really achieving. Torque figures are at best an estimate and don’t provide any data. Ultrasonic Bolt Tension Testing also detects any defects in used or new bolts.

Grinding mills, for instance, are massive capital-cost equipment that require proper maintenance to ensure their performance and operation. However, once they halt performing for whatever reason, this leads to significant loss in revenue. The length of time required to get it back on operation can take several hours, days, or even weeks, depending on the severity of damage.

Over time, bolts in many industrial applications loosen because of certain factors such as load and constant vibration. Some companies rely on torque wrenches and bolt tensioners to tighten these bolts and ensure their joint integrity. However, these do not always provide adequate accuracy, nor do they allow for on-going re-monitoring and targeted adjustments.

Boltstress Ultrasonics worked with a large mining company situated in Port Hedland, in Western Australia to ensure the integrity of machines used in heavy-duty tasks. This includes a highly-automated, out-loading circuit, responsible for processing iron ores that are ready for transportation.

Unscheduled downtimes spell out major problems in the mining industry.

With customers expecting to get their deliveries on time, a major shutdown - and an unexpected one, at that - means trouble. It does not only impact their customers but also the company's bottom line.

Shut downs result in time blow outs, productivity losses, and a sharp reduction in profit.

The mining industry is a critical work environment.

Hazards are lurking behind, which can lead to serious consequences if not prevented.

Read on to learn why your mining industry can greatly benefit from ultrasonic testing today.

How can ultrasonic tension measurement technology help improve the lifespan of bolts, as well as enhance the tensioning accuracy?

For industries that rely on a highly automated out-loading circuit, for instance, one key component is the bucket wheel reclaimer. In fact, a Port Hedland-based major mining company has seen the importance of keeping this piece of equipment well-maintained to ensure proper operations.

Time is money in any industry.

When your machinery fails to undergo periodic tests and checks, unexpected downtimes are inevitable.

Such is the case with liner bolts that have accumulated a number of failures in the past.

The question is, how does it happen, why does it occur, and what can be done to prevent it from causing problems in the future?

Boltstress Ultrasonics got to the bottom of this situation and conducted a thorough ultrasonic bolting measurement and analysis of the Mills in question. This task led to numerous revelations, which is presented in this post.

For the last ten years, our liner bolt specialists have worked with clients in need of diagnostics and solutions for problems with their mill liner bolts. One particular mine experienced an alarming one-a-week liner lifter bolt failure.

Fast forward to today, Boltstress prides itself as being a dependable company with a highly competent maintenance crew that carries out ANY bolt-related works.

In any business, time is money. This is why downtime caused by equipment failure and breakdown can result in hundreds and thousands of profit loss. Mining companies, for instance, rely on heavy machinery and equipment to keep their operations going. But what if machinery breaks down? How much is lost and what can be done to prevent this issue?

These images show the G6 in action on a Sizer (used widely in Coal & Iron Ore mines) and what happens when a low strength washer is used.

The required torque had to be increased by 83% to get the correct tension. The indentation is above 1mm deep.

If you are in the mining or any similar industry relying on large equipment for your business, you need to keep the machinery bolts in check.

Why do heat exchanger gaskets leaks so frequently? View our video to find out, or read on!

Standard bolts maintained using Ultrasonic Technology (UT) from Boltstress has proven a reliable and economical choice when compared to SmartBolt and Aligner Bolt. Read on to find out why.

Sophisticated preventative measures to fix problems with bolt tension and integrity
Many Mills experience liner and liner bolt failures, these are costly and can effect the viability of some operations. Boltstress Ultrasonics has eliminated these at several mine sites.
The failure rates heat exchanger (HX) and pressure vessel (PV) flanges is the worst/highest of all joints in the Oil, Gas and Petrochemical industries. Our aim is to eliminate these and provide faster bolt tightening tooling & methods.
After more than 25 years in the industry TCS and Boltstress Ultrasonics created a new force in bolting technology in January 2014.

The combined expertise, technology and service provide an un-paralleled offering to many industries but in particular to the wind energy sector.

Avoid using the wrong socket. Download our free Bolt to Nut comparison chart.