Specification                  Item code: 11175682 

                                                            Index: 002     
     

SITE PORTAL FLANGE JOINT ASSEMBLY BOLTING PROCEDURE

Site inspection of flange joint mating surfaces

Manufacture Requirements For Flanges

In order for satisfactory flange friction grip coefficient values outlined by the design
requirements, (0.55 friction coefficient requirements as per FEM table T.A 3.2.2.2.2.3.1)
then the flange joints must be shot blasted to Sa 2 1/2 requirements ISO 8501-1. This
gives rise to a peak to valley roughness of 60-80μm typically. Flange squareness with
bolt hole must be maintained. Prior to leaving LCC all friction grip flange joint are
painted with International paints Interzinc 22 paint, this paint system provides a dual
function:
 Protects the flange joint mating surfaces from corrosion during transport,
 while promoting good friction coefficient for the flange mating surface.

If site personnel find a situation where the flange protection cover Interzinc 22 has been
removed due to transport accidents, etc, then it is necessary to rough sand or wire bush
and clean the affected areas before assembling the joint. Note, the joint must be
assembled within five hours of sanding and all debris cleaned from the flange
mating surfaces. Site personnel should photograph the affected area before and after
dressing to maintain records for PA files.

Bolt Joining Procedures

Before & during the joint assembly the site supervisor must ensure:

 Correct bolts, washers, nuts and lock nuts are being used for the assembly.
 Bolts threads are adequately lubricated with Liebherr Special Screw Paste and the
nut face that mates with washer has the Liebherr Special Screw Paste sparingly
applied.
 A LCC copy of the required torque values plus the assembly diagram/Binding BOM
for the bolted joint assembly must be available. The appropriate sequence to tighten
a joint should be used i.e.,
o All bolts tightened to 80% of final torque value before final torque sequence is
carried out.
 A valid certified torque wrench is available. A copy of the certificate should be
obtained for LCC records – PA file.

LCC
Date Work Prepared Checked Approved

No copying or duplication of this document without the permission of Liebherr.

This document has been issued electronically and is valid without signature.
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 Specification                  Item code: 11175682 
                                                            Index: 002     
     
 A valid certified power pack and pressure gauge is available. A copy of the
certificate should be obtained for LCC records – PA file.
 A data sheet outlining the correct pressure settings for the power pack being used is
required in order to achieve the correct torque settings. A copy of this data sheet
should be obtained for LCC records and state what pressure settings were used –
PA File.
 Ensure hydraulic pressure line fittings are correctly secured, as partially secured
fittings will give rise to incorrect torque results (lower torque valves).
 Ensure when pressure setting is set that the pressure setting relief valve is locked in
position using the lock nut, if the relief valve is not locked then the valve may change
position as a result of vibration thus causing incorrect pressure settings. Check at
regular intervals to see if the pressure setting is maintained.
 Observe work methods when torqueing the bolts. Ensure that the torque wrench is
perpendicular to the flange and there are no kinks present on the pressure lines.
 Once joint is fully torqued, caulk joint seam with appropriate sealant and paint as per
standard LCC painting policies.
 Degrease each bolt assembly and apply primer & paint as carried out by our
standard LCC painting policies.

Figure 1 Pre-stressed High-tensile Bolt Connections Greasing

 
LCC
Date Work Prepared Checked Approved

No copying or duplication of this document without the permission of Liebherr.

This document has been issued electronically and is valid without signature.
2 
 Specification                  Item code: 11175682 
                                                            Index: 002     
     
 

Figure 2 Pre-stressed High-tensile Bolt Connections

LCC
Date Work Prepared Checked Approved

No copying or duplication of this document without the permission of Liebherr.

This document has been issued electronically and is valid without signature.
3 
 Specification                  Item code: 11175682 
                                                            Index: 002     
     
Table 1. Pre-stressed High-tensile Bolt Connections Torque Values

                                        Torque Wrench Assembly 
   Property Class 8.8                          Property Class 10.9   Property Class 12.9 

ISO 4014   ISO 4014 
ISO 4014  ISO 4017  ISO 4017 
ISO 4017  ISO 7412  ISO 4762  ISO 4762 
DIN 931  DIN 6914  DIN 931  DIN 931 
DIN 933  DIN 933  DIN 933 
DIN 912  DIN 912 
  
   kp.m  N.m  lb/ft  kp.m  N.m  lb/ft kp.m  N.m  lb/ft  kp.m  N.m  lb/ft 
M12  5.2  51  37  9.8  96  70  7.4  73  53          
M14  8.4  82  61           13  127  94          
M16  14  137  101  24.7  242  178  19.1  187  138          
M18  18  177  130           26  255  188          
M20  25.9  254  187  48.3  474  350  37  363  267          
M22  35.8  351  258  66  647  477  51.1  501  370          
M24  44.8  439  323  83  814  600  64  628  462          
M27  70  686  506  123  1206 890  100  981  723          
M30  95.8  939  692           136.8 1342 990          
M33  130.9  1284  946           187  1834 1352 230.8  2264 1669
M36  167.3  1641  1209           239  2344 1728 296.1  2904 2141
M39  217.3  2131  1570           310.4 3044 2244 383.6  3762 2773
M42  268.4  2632  1940           383.4 3760 2772 476.3  4670 3444
M45  335.4  3289  2424           479.1 4693 3463 594.8  5833 4300
M48  403.6  3958  2918           576.6 5655 4168 717.8  7039 5190

LCC
Date Work Prepared Checked Approved

No copying or duplication of this document without the permission of Liebherr.

This document has been issued electronically and is valid without signature.
4