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The BoltSafe bolt load cell is a specialized sensor designed to monitor the actual load in bolted joints, ensuring precise bolt tension and enhancing safety and structural integrity. Integrated with a Continuous Monitoring System (CMS), multiple load sensors can be networked for continuous monitoring from a single point. Each sensor contains an ASIC for signal conditioning and digital communication, with a unique serial number for traceability. Available in regular stainless steel or a stronger variant, the load cell also monitors sensor temperature. Additionally, these sensors are used in temporary construction for load monitoring and structural health to prevent collapse.

 

How does the CMS bolt load cell work?


The BoltSafe bolt load cell is a specially designed load cell (load sensor) that monitors the actual bolt load in bolted joints. CMS stands for Continuous Monitoring System, which allows for continuous monitoring of the bolt load from one connection point. Several load sensors can be interconnected within a network. Using a BoltSafe load cell eliminates any uncertainties about the bolt load. This results in enhanced safety, dependable joints and better control over the structure. Besides those safety benefits, the costs during installation and throughout the joint’s service life are reduced.

Each sensor utilizes an ASIC (Application Specific Integrated Circuit), which performs all signal conditioning and digital communication. Because of this, each BoltSafe load sensor has a unique serial number for individual identification and traceability. The digital monitoring system not only measures the bolt load, but can also monitor the sensor temperature. The load cell is available in two kinds of steel: our regular stainless steel, and a stronger version that can withstand 15% more load while keeping the same compact dimensions.

Another application of the load cells is in temporary construction or for Structural Health Monitoring. In this case the sensors are used as washers to check the load in the construction to make sure that the (temporary) construction does not collapse.

How is the CMS bolt load cell used?


The load cell is shaped and used as a regular washer and is available in sizes M12 to M72 and 7/8” to 2-3/4”. The BoltSafe bolt load cell is installed on the non-driven side of a bolted connection, preferably under a nut. While tightening the bolt, force is being applied to the load washer, which will result in minor deformation of the stainless steel washer. The sensor constantly measures changes in electrical resistance caused by these deformations. This data is used to determine the actual bolt load at any given moment.

Because of the rugged design of the load cells, they are able to withstand harsh conditions, such as heavy industrial environments. The load sensors can be used in contact with oil, rain, seawater, ice and temperatures up to 80 degrees Celsius. We do not recommend using the washers in conditions where the temperature is above 80 or below -40 degrees Celsius. 

The calibration of the sensor is done once by BoltSafe. After that, the sensor is plug-and-play and there is no need to recalibrate when different readout methods are used. There is also no need for recalibrating the load cell during its service life, provided that it is used according to its specifications and requirements.
 

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