Slip factor test of HEMPEL’S GALVOSIL 15700

Requested by: Niels Lund Jensen

Reported by: FORCE Technology, Gunnar Sørensen
Reviewed by: FORCE Technology, Thomas Jensen
Your ref.: Niels Lund Jensen
Our ref.: 115-22734

21 July 2015

Structural Design and Stress Analysis

Reviewed by: Reported by:

Thomas Jensen Gunnar Sørensen

Specialist Specialist
Table of Contents
Scope of work .......................................................................................................... 2
Hempel’s coating procedure....................................................................................... 2
Test specimens ........................................................................................................ 2
Bolt preload tightening .............................................................................................. 2
Test procedure......................................................................................................... 3
Slip factor test ......................................................................................................... 3
Delayed slip test....................................................................................................... 4
Extended creep test.................................................................................................. 5
Conclusion............................................................................................................... 6

OVERVIEW OF APPENDICES
Annex A: Protocol on testing of friction coefficient of Hempel’s Galvosil 15700
Annex B: Customer report for the relevant application details
Annex C: Bolt preload tightening
Annex D: Photos test setup
Annex E: Slip factor test
Annex F: Delayed slip test
Annex G: Extended creep test

1
Scope of work

FORCE Technology has performed test to determine the slip factor of Hempel’s Galvosil
15700 zinc silicate paint on steel plates to be used in slip resistance bolted connections.

The slip test is made in accordance with the procedure in EN 1090-2:2008 “Execution of
steel structures” Annex G “Test to determine slip factor”.
The testing includes slip factor test, delayed slip test and extended creep test according to
EN 1090-2:2008 Clause G.4 and G.5.

The requirements to the design slip factor is 0.40 for friction surface Class B according to
EN 1090-2:2008 Table 18, and the actual structural design life is 120 years.

Hempel’s coating procedure

The protocol for the testing and preparation of test panels is described in Annex A
“Protocol on testing of friction coefficient of Hempel’s Galvosil 15700”.

Test specimens

Standard steel grade S355 J2+N test specimens are prepared by FORCE Technology
according to BS 1090-2:2008 Figure G.1 a), and HEMPEL has blast cleaned and coated the
sample surfaces according to the Customer report in Annex B.

M20 bolts grade 10.9, nuts grade 10 and washers hardness 300 HV to 370 HV EN 14399
are used for tightening the test specimens.

Bolt preload tightening

Prior to the slip test the bolts are lubricated with molycote and tightened to the specified
bolt preload force corresponding to 70% of the bolt ultimate strength.

The tightening torque is calibrated with bolt strain gauge type BTM-6C on one bolt, and
the tightening procedure is applied to the following bolts.
All of the bolts are tightened and released 3 times, until the preload force is stable during
the test period within the required deviation of ± 5% as required in EN 1090-2 Clause G.3.

As shown in Annex C the calibrated bolt preload force of 171.9 kN is stable within 1.1%
15 minutes after tightening for the applied tightening torque of 400 Nm.

2
Test procedure

The slip factor test specimens are tested on a AMSLER W Testor test machine at a load
speed of 0.01 mm/sec until final slip failure occurs.
The delayed slip test and the extended creep test specimens are tested at a constant
specified load at three hours for the delayed slip and up to 70 hours for the creep test.

The slip is measured as the relative displacement between the inner plate and the cover
plates with clip gauges type TML UB-5A. During the tests the slip displacement and the
friction load are recorded by BHM Catman 4.5 program at a sample speed of 5 Hz.

For each test specimens two load – displacement curves are recorded resulting in two slip
factor values for one test sample.
Photos of test specimens and the test setup are shown in Annex D.

Slip factor test

According to EN 1090-2 the slip load Fs is defined at the mean slip displacement point of
0.15 mm between the main plate and the cover plates.
The recorded “load–displacement” curves and read out slip loads are given in Annex E,
and the calculated clip factor values according to Clause G.6 are shown in Table 1 below.

Table 1. Slip factor test results

Test to determine slip factor EN 1090-2:2008 Annex G File 115-22734
Client Hempel Test bolt preload Fp (kN) 171.9
Test no. Test slip load Test slip factor
Fs1 (kN) Fs2 (kN) �1 �2
1 364.2 342.8 0.530 0.499
2 340.5 381.1 0.495 0.554
3 354.1 343.7 0.515 0.500
4 339.7 365.9 0.494 0.532
5 333.6 355.5 0.485 0.517
Mean slip factor value 0.512
Standard deviation 0.022
Coefficient of variation 4.2%
Required number of tests 1
Number of tests 5
5% fractile constant 2.05
Characteristic 5% fractile value 0.468

The tested mean slip factor value is 0.51 and the characteristic 5% fractile value is 0.46.
It is noted that the characteristic slip factor is higher than the design slip factor of 0.40,
and the coefficient of variation of 4.2% is lower than EN 1090-2 acceptable limit of 7.8%
for ten valid test results.

3
Delayed slip test

According to EN 1090-2:2008 Clause G.4 specimen no. 5 shall be delayed slip tested for
three hours at load equal to 90% of the mean slip load of the first four specimens.
After the delayed slip test the fifth specimen is loaded to final slip similar to the first four
test specimens.
The acceptable delayed slip measured between five minutes and three hours after
applying the load is 0.002 mm.
As shown in Table 2 the 90% mean slip value of the first four specimens is 318.6 kN
corresponding to a slip factor of 0.46, which is higher than the design slip factor 0.40.

Table 2. EN 1090-2 delayed slip load calculation

Test to determine slip factor EN 1090-2:2008 Annex G File 115-22734

Client Hempel Test bolt preload Fp (kN) 171.9
Test no. Test slip load Test slip factor
Fs1 (kN) Fs2 (kN) �1 �2
1 364.2 342.8 0.530 0.499
2 340.5 381.1 0.495 0.554
3 354.1 343.7 0.515 0.500
4 339.7 365.9 0.494 0.532
90% mean value Test 1 - 4 318.6 0.463

To our experience the delayed slip limit of 0.002 mm is very stringent, and it is agreed to
carry out the delayed slip test at a slip load of 275 kN corresponding to the design slip
factor value 0.40. This slip load is similar to the proposed extended creep test load given in
EN 1090-2 Clause G.5.

The delayed slip “load–displacement” curve are plotted in Annex F.

One of slip surfaces has failed the delayed slip limit of 0.002 mm, with a measured slip of
0.018 mm, while the delayed slip of the other slip surface is only 0.0002 mm or ten times
lower the required slip limit.

If the delayed slip test is not complying with the slip limit of 0.002 mm, an extended creep
test according to EN 1090-2 Clause G.5 shall be performed.

4
Extended creep test

The slip load applied to the extended creep test is 275 kN corresponding to the design slip
factor of 0.40, which is in accordance with EN 1090-2 recommendations.
Three specimens shall extended creep tested, and the extrapolated design life creep shall
not exceed 0.30 mm.

There is no specific requirements to the extended creep test duration, but the slip value at
the design life shall be determined with sufficient accuracy by tangential extrapolation of
the “slip - log time” test curve.
At all three specimens are tested between 16.5 and 70 hours, and the “slip - log time”
curves are extrapolated linearly to the design life of 120 years in order to estimate the
design life creep slip.
The “slip-log time” test curve are plotted in Annex G, and the extrapolated 120 years slip
values are shown in Table 3 below.

Table 3. Extended creep test results

Extended creep test EN 1090-2 Annex G.5 File 115-22734
Specimen Test time Gauge 120 years
no. (hours) no. slip (mm)
1 0.11
6 16.5
2 0.13
1 0.15
8 67
2 0.19
1 0.09
9 70
2 0.04

All of the extrapolated slip values are below the acceptable slip limit of 0.30 mm for the
design life according to EN 1090-2 Clause G5.

It shall be noted that the linear regression of the “slip-log time” curve is performed with a
high R2 = 0.99 coefficient of regression.

5
Conclusion

The test mean slip factor value is 0.51, and the characteristic 5% fractile value is 0.46.
The slip factor is tested with a small test deviation of 4.2%, which indicates a uniform friction
surface characteristic.

One of slip surfaces has failed the stringent delayed slip limit of 0.002 mm, but the other
surface has shown a ten times lower slip value than the required limit of 0.002 mm.

All of the extended creep slips are significant lower than the 120 years design life creep limit
of 0.30 mm.

The characteristic Hempel’s Galvosil 15700 slip factor of 0.46 is 15% higher than the
required design slip factor of 0.40 for friction Class B, and Hempel’s Galvosil 15700 comply
with the 120 years design life creep requirements.

6
ANNEX A Protocol on testing of friction coefficient
of Hempel’s Galvosil 15700
(4 pages including this page)

7
8
9
10
ANNEX B Customer report for the relevant
application details
(6 pages including this page)

11
12
13
14
15
16
Annex C Bolt preload tightening
(2 pages including this page)

17
 Test to determine slip factor EN 1090-2:2008 Annex G File115-22734
Client HEMPEL M20 10.9 Bolt tightening measurement
Bolt stress area (mm^2) 245
Bolt ultimate stregth fub (MPa) 1000
Bolt preload force Fp (kN) 171.5
Bolt shaft diameter (mm) 19.8
Gauge hole diameter (mm) 2.0
Strain gauge area Ap (mm ^2) 304.8
T orque Strain Stress Preload
Bolt preload
Mr (Nm) � p (�S) �p (MPa) Fp (kN)
0 238 0.0 0.0
150 1323 227.9 69.4
T ightening 200 1728 312.9 95.4
300 2354 444.4 135.4
400 2945 568.5 173.3
Delay 1 min 400 2933 566.0 172.5
Delay 5 min 400 2926 564.5 172.0
Delay 10 min 400 2920 563.2 171.7
Delay 15 min 400 2916 562.4 171.4
Max. Preload settlement 1.1%
Test bolt preload F p (kN) 171.9

200

150
Preload Fp (kN)

100

50

0
0 100 200 300 400 500
Torque Mr (Nm)

18
Annex D Test setup
(2 pages including this page)

19
20
ANNEX E Slip factor test
(6 pages including this page)

21
 Slip Test no. 1
400

350

300 Clip gauge 1

Slip load (kN)

250 Clip gauge 2

200

150

100

50

0
0.00 0.50 1.00 1.50 2.00
Slip (mm)

Slip Test no. 1

400

350

300 Fs1 = 364.2 kN

Slip load (kN)

250 Fs2 = 342.8 kN

200

150

100

50

0
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Slip (mm)

22
 Slip Test no. 2
400

350

300
Clip gauge 1
Slip load (kN)

250
Clip gauge 2
200

150

100

50

0
0.00 0.50 1.00 1.50 2.00
Slip (mm)

Slip Test no. 2

400

350

300 Fs1 = 340.5 kN

Slip load (kN)

250 Fs2 = 381.1 kN

200

150

100

50

0
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Slip (mm)

23
 Slip Test no. 3
400

350

300
Clip gauge 1
Slip load (kN)

250
Clip gauge 2
200

150

100

50

0
0.00 0.50 1.00 1.50 2.00
Slip (mm)

Slip Test no. 3

400

350

300 Fs1 = 354.1 kN

Slip load (kN)

250 Fs2 = 343.7 kN

200

150

100

50

0
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Slip (mm)

24
 Slip Test no. 4
400

350

300
Clip gauge 1
Slip load (kN)

250
Clip gauge 2

200

150

100

50

0
0.00 0.50 1.00 1.50 2.00
Slip (mm)

Slip Test no. 4

400

350

300 Fs1 = 339.7 kN

Slip load (kN)

250 Fs2 = 365.9 kN

200

150

100

50

0
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Slip (mm)

25
 Slip Test no. 5
400

350

300
Clip gauge 1
Slip load (kN)

250
Clip gauge 2
200

150

100

50

0
0.00 0.50 1.00 1.50 2.00
Slip (mm)

Slip Test no. 5

400

350

300
Fs1 = 333.6 kN
Slip load (kN)

250
Fs2 = 355.5 kN
200

150

100

50

0
0.00 0.05 0.10 0.15 0.20 0.25 0.30
Slip (mm)

26
ANNEX F Delayed slip test
(2 pages including this page)

27
 Delayed Slip Test no. 5
400

350

300

250
Slip load (kN)

200

150

100

50

0
0 60 120 180 240
Time (min)

Delayed Slip Test no. 5

0.250
Clip gauge 1 Creep 1 = 0,018 mm
Clip gauge 2 Creep 2 = 0,0002 mm
0.200

0.150
Slip (mm)

0.100

0.050

0.000
0 60 120 180 240
Time (min)

28
ANNEX G Extended creep test
(4 pages including this page)

29
 Extended creep test no. 6
0.250

Clip gauge 1
0.200
Clip gauge 2

0.150
Slip (mm)

0.100

0.050

0.000
0 2 4 6 8 10 12 14 16 18
Time (hours)

Extended creep test no. 6

0.300

Clip gauge 1 y = 0.009ln(x) + 0.1855

0.250
Clip gauge 2 R² = 0.999

0.200
Slip (mm)

0.150

y = 0.0095ln(x) + 0.1713
0.100 R² = 0.9989

0.050

0.000
1.00E-04 1.00E-03 1.00E-02 1.00E-01 1.00E+00 1.00E+01 1.00E+02
Time (years)

30
 Extended creep test no. 8
0.250

Clip gauge 1
0.200
Clip gauge 2

0.150
Slip (mm)

0.100

0.050

0.000
0 12 24 36 48 60 72
Time (hours)

Extended creep test no. 8

0.300

Clip gauge 1 y = 0.0078ln(x) + 0.1518

0.250
Clip gauge 2 R² = 0.9986

0.200
Slip (mm)

0.150

0.100
y = 0.0062ln(x) + 0.1222
R² = 0.9974
0.050

0.000
1.00E-04 1.00E-03 1.00E-02 1.00E-01 1.00E+00 1.00E+01 1.00E+02
Time (years)

31
 Extended creep test no. 9
0.250

Clip gauge 1
0.200
Clip gauge 2

0.150
Slip (mm)

0.100

0.050

0.000
0 12 24 36 48 60 72
Time (hours)

Extended creep test no. 9

0.300

Clip gauge 1 y = 0.0013ln(x) + 0.0375

0.250
Clip gauge 2 R² = 0.8818

y = 0.0047ln(x) + 0.0692
0.200 R² = 0.9885
Slip (mm)

0.150

0.100

0.050

0.000
1.00E-04 1.00E-03 1.00E-02 1.00E-01 1.00E+00 1.00E+01 1.00E+02
Time (years)

32
33