Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
STANDARD SPECIFICATION FOR
NON-FERROUS RODS, BOLTS, TUBES, AND FORGING
1.0
GENERAL
A.
This specification covers the manufacture and testing of high-strength, corrosion
resistant bronze for cold working and hot forging, and copper tubes and bars for
electrified railroad application within the Philadelphia and Reading Districts (unless
otherwise stated separately).
B.
Where an American Society for Testing and Materials (ASTM) specification
designation is given, the latest revision shall apply. All hardware shall meet or exceed
the latest edition of the following specifications: ASTM-B98-03, ASTM-B124, and
ASTM B139.
C.
Definitions, material, testing inspection, shipment, and rejection shall be in accordance
with this specification.
D.
Bolts, Hex Head Cap Screws, and Studs shall be manufactured to meet all the
requirements of ASTM Spec. F468. All nuts shall be manufactured to meet the
requirements of ASTM Spec. F467.
1.1
SUBMISSIONS
A.
Pre-production
B.
1.
Pre-production Samples
Two (2) pre-production prototype samples of each product included in this
order must be submitted for SEPTA evaluation and approval.
2.
SEPTA-approved Unique Vendor Marking
Provide, for SEPTA approval, a description of the unique identification
marking to be stamped on each piece produced for the order. The marking
shall become the vendor's standard identifier for all future orders.
3.
Metallurgical material composition analysis of materials to be used for this
order shall be submitted for SEPTA approval.
Post-production
The following documents and prototype samples must be provided and accompany the
first shipment of each order:
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Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
1.
Certified Mill Test Report of alloy for the stock material of the order.
2.
Validation Report of the method used to provide stress relief after threading.
The previously mentioned reports and prototype samples are to be delivered to:
Director, RR Power Maintenance
Wayne Junction Line Maintenance Building
4500 Germantown Avenue
Philadelphia, PA 19144
2.0
INDUSTRY STANDARDS
All materials ordered under this specification, unless otherwise stated herein, shall
conform to all applicable provisions of the latest standards of the American National
Standards Institute and the American Society for Testing Materials.
3.0
A.
MATERIAL
C65500 High Silicone Bronze ASTM B124 (For Hot Working):
The eye-bolt, (bronze forging) shall be made of C65500 Bronze, with the following
chemical and physical requirements:
1.
Chemical Requirements:
Material
Copper
Silicone
Manganese
Zinc
Iron
Lead
Nickel
Percent Minimum
94.80
2.80
.50
Percent Maximum
3.8
1.3
1.5
.8
0.05
0.6
The sum of all the above elements shall not be less than 99.5 percent.
2.
Physical Requirements (Raw Material Requirements):
Dimensions and markings shall be per SEPTA Drawing E-659
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Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
E-659 (Eye Bolt)
Minimum Tensile Strength:
52,000 psi
Minimum Yield Strength:
18,000 psi
(Stress corresponding to 0.5 percent strain)
Minimum Elongation in 2" Lengths: 45%
B.
C65500 Copper Silicone Alloy ASTM B98-03 (For Cold Working):
U-bolts, J-bolts, hexagonal head bolts, hanger rods, and bronze tubes and bars shall be
made of C65500 Bronze per SEPTA drawings E-733, E-737, ET-146-1, ET-148-1, &
146-3, with the following chemical and physical requirements:
1.
Chemical Requirements:
Material
Percent Minimum
Percent Maximum
Remainder
2.8
----.5
1.5
0.8
0.05
0.6
----3.8
---1.3
1.5
0.8
0.05
0.6
Copper
Silicone
Tin
Manganese
Zinc
Iron
Lead
Nickel
2.
Physical Requirements - Bronze Bolts, Rods, and Bars (Raw Material
Requirements):
Diam. 1/4"
and Below
Diam. 1/4"
and Above
Minimum Tensile Strength
70,000 psi
70,000 psi
Minimum Elongation in 2"
Length
8%
15%
Number of Twists in 10"
Length
8
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8
Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
3.
Physical Requirements - Hanger Rods (Raw Material Requirements):
Diam.
(inches)
5/16
3/8
7/16
0.34
0.42
0.48
4.
0.077
0.110
0.151
0.090
0.138
0.180
Minimum Minimum
Nos. of
Weight
Tensile
Elongat.
Twists
Lbs./Ft.
Str. Psi
% in 10"
10" Length
.298
.428
.585
.341
.523
.682
70,000
70,000
70,000
70,000
70,000
70,000
2.40
2.85
3.25
2.41
2.41
2.41
10
10
10
10
10
10
Physical Requirements - Bronze Tube (Raw Material Requirements):
Nominal
Diam.
(Inches)
3/4"
1-5/8"
2"
C.
Num. Area
Sq. Inch
Outside
Diam.
(Inches)
Wall
Thickness
(Inches)
Weight
Lbs./Ft.
1.050
1.625
2.000
0.113
0.109
0.180
1.25
2.01
3.79
Minimum
Tensile
Minimum
Strength
Elongation
(Psi)
(10" Length)
60,000
60,000
60,000
0.03
0.03
0.03
C54400 and C52100 Phosphor Bronze ASTM B139:
Carriage bolts shall be made with UNS C52100 and nuts shall be made with UNS
C54400 per SEPTA Drawings E-735A and ET 148-3. C65100 silicone bronze material
may be substituted for both bolts and nuts.
1.
Physical Requirements (Raw Material Requirements): Carriage Bolts
Diam. 1/4"
To ½”
Minimum Tensile Strength
85,000 psi
Minimum Elongation in
2" Length
12%
Number of Twists in
10" Length
8
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Diam. 1/2"
To 1” Over 1”
75,000 psi
15%
8
60,000 psi
20%
8
Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
D.
Copper: (Raw Material Requirements)
Tubes and bars made from copper shall have a purity of at least 99.88 percent as
determined by electrolytic assay, silver being counted as copper. Copper tubes and bars
shall have the following physical requirements:
Nominal
Diam.
(Inches)
Outside
Diam.
(Inches)
Wall
Thickness
(Inches)
1-1/8"OD
1-1/4"IPS
1-1/2"OD
4" IPS
1.125
1.660
1.500
4.500
0.109
0.146
0.065
0.250
Minimum
Tensile
Weight
Strength
Lbs./Ft.
(psi)
1.35
2.69
1.14
12.94
Minimum
Elongation
(10" Length)
40,000
40,000
40,000
40,000
4.0
TESTING
A.
Twisting and Bending Tests - (Hanger Rods, Bolts, U-Bolts, and J-Bolts):
0.05
0.05
0.05
0.10
For the purpose of determining and developing defects which may be prejudicial to the
life of the specimen, twisting and bending tests shall be made upon three samples selected
by SEPTA's Representative from each lot of 200 rods. Twist tests shall be made upon
samples ten inches in length between jaws. The twisting machine shall apply a twist not
faster than ten revolutions or turns per minute. All samples shall be twisted to
destruction and shall not reveal under this test any seams, pits, slivers, or surface
imperfections not consistent with the best commercial practice. At the time of fracture,
the sample shall be twisted with reasonable uniformity. Samples of specimen must
withstand at least eight revolutions before breaking. Specimen shall bend through an
angle of 360 degrees about its own diameter without a sign of cracking.
B.
Tensile and Elongation Tests - (Hanger Rods, Bolt Stock, U-Bolts, J-Bolts, Tubes, and
Bars):
1.
Tensile and elongation tests shall be made upon three samples selected by
SEPTA's Representative from a lot of 200 rods or tubes.
2.
The elongation of the specimen shall be determined as the permanent increase in
length due to the breaking of the specimen as result of tension, measured
between gage marks originally placed upon the specimen ten inches apart. The
fracture shall occur between the gage marks and not closer than one inch to either
mark.
3.
The tensile strength shall be the maximum recorded tension in pound per square
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Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
inch applied to the specimen before fracture occurs.
C.
Nick and Break Test - (Bolts, Stock, U-Bolts, and J-Bolts):
The two ends of the bolt stock formed from a bronze billet which is to be made into bolts
covered by this specification shall be given a "nick and break" test to determine that there
are not "pipes" in the stock. By "pipe" is meant a separation of the material within the
bolt stock that may have been caused during the pouring of the billet.
D.
Residual Stress Test - (Tubes and Bars):
Three samples each six inches long, selected from each lot of 200 bronze tubes shall be
tested in accordance with ASTM B154. No cracking shall develop because of the test.
E.
Tube Test:
Three samples of tube from each lot of 200 tubes shall be flattened to the extent that a
micrometer caliper set at three (3) times the wall thickness can be passed over the tube
freely throughout the flattened area except at the points where the change in element of
flattening takes place. The test shall be made without annealing.
5.0
WORKMANSHIP
A.
Bolts shall conform to details shown in this Specification and ASTM Spec. F 468.
B.
The heads of all bolts shall be neatly formed, free from large projecting fins, with no
nicking or reduction of the size of the body of the bolt by dies.
C.
Re-entrant carvers shall have small fillets to prevent high stress concentration.
D.
Bolts and nut threads manufactured shall conform to the standards set up as Free Fit
(Class 2) of the coarse thread series of the "American National Standards Institute".
E.
Bolts and Nuts shall be dipped in paraffin or tallow or other approved lubricant to
facilitate turning during erection.
F.
Nuts shall develop the full strength of the threaded section of the bolt.
G.
Threads of hexagonal head bolts, U-bolts, and J-bolts may be rolled or cut, unless a
specific method is shown on the drawings.
H.
Threads of carriage bolts shall be rolled.
I.
Bolts shall conform in dimensions and tolerances for screw threads as set forth in
standards for screw threads of the "American National Standards Institute".
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Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
J.
All bronze bolts shall be supplied with bronze nuts.
K.
All carriage bolts shall be a made of UNS C52100 Phosphor Bronze.
L.
All carriage bolts shall be stress-relieved at 550
in still air.
M.
All stress-relieved carriage bolts shall have raised letter "T" on heads.
N.
All bronze bolts shall be imprinted in an easily visible place with the identity initials of
the
manufacturer.
O.
Hanger rods shall have standard diameter of different rod lengths to suit each job, a
variation in rod diameter of 0.0015" above or below the specified nominal diameter will
be allowed.
P.
A variation in outside diameter of tubes above or below the nominal size shall be allowed
within one percent. Thickness of wall on thinnest side shall not be less than that specified
on the table.
Q.
Curved hanger rods dimensions must comply with SEPTA Drawing No. E-733.
6.0
MARKING
A.
Head of bolts shall be marked with SEPTA identification.
B.
U-bolts and J-bolts shall be marked on the ends before threading with SEPTA
identification.
C.
Each carton box shall have the following identification prominently marked on at least
two
(2) sides or on the top and one side:
7.0
1.
Project Name and Date
2.
Type of Product
3.
Class and Lot Number
PACKING AND SHIPPING
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Non-Ferrous Rods, Bolts, Tubes, & Forgings (Standard)
Rods, bolts, and pipe shall be packed in such a manner that it may be received in proper
condition for installation by Purchaser. Package size shall be approved following placing
of the individual orders.
8.0
REJECTION
SEPTA expressly reserves the right to reject any product which does not meet all the
requirements of this specification. SEPTA further has the right to reject any product
received in cartons which are obviously damaged or have not been adequately protected
from injury, in the opinion of SEPTA. Upon notice to the manufacturer, any such rejected
material shall be removed promptly from SEPTA's property, and shall be replaced, at no
additional cost to SEPTA, with material which complies fully with each and every
requirement of this specification.
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