The new structural design introduces several improvements in bolted connections. For friction-type high-strength bolts, slippage can occur when overloaded. However, grease-loaded bolts prevent this kind of momentary slip, allowing them to handle short-term overloads more effectively. Additionally, if the thickness of the plates and the diameter of the bolts are properly proportioned, grease-loaded bolts without pre-tension can offer similar resistance to traditional friction-type high-strength bolts. In situations where space is limited and each bolt needs to provide higher resistance, pre-tensioned grease-filled bolts become a better option. These bolts combine two sources of resistance: friction and the structural support from the resin. This dual mechanism allows them to deliver greater strength under harsher conditions, even with fewer bolts.
High-strength bolts require specific surface treatments to achieve the necessary coefficient of friction, and painted surfaces must also meet these standards for long-term performance. In contrast, grease-loaded bolts without pre-tension do not need such surface preparation, as they are designed to prevent slippage naturally. Moreover, high-strength bolts demand specialized tools for proper pre-tensioning, while pre-tensioned grease-filled bolts eliminate this requirement. Another advantage is that grease-filled bolts are easier to install and maintain. However, their removal can be challenging unless special measures are taken beforehand—such as using a release agent to prevent the resin from bonding with the bolt or the hole walls. In comparison, high-strength bolts are simpler to disassemble.
When it comes to material costs, grease-filled bolts involve several components: the cost of the bolt itself, preparation of nuts and washers (including drilling and fitting), and the preparation and injection of resin. Fortunately, in Europe, there are established products available, and the equipment required for resin injection is relatively simple. Since only a small amount of resin is needed per bolt, the overall material cost remains low. Labor costs depend on factors like the total number of bolts, the number per connection, the precision required, the size and length of the bolts, and potential delays due to environmental conditions—such as ensuring dry holes during installation. On average, installing a single grease-filled bolt takes about 12 minutes. By reducing the number of bolts at each joint, the overall cost decreases, and lower hole accuracy further simplifies the process, lowering labor expenses. Installation is typically done in groups of two—one person injects the grease, while the other checks for resin overflow from the leak hole. With a hand-press injection device, it may take around 30 minutes to install 20 bolts. For longer or larger installations, a pneumatic system would be more efficient and time-saving.
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