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How a Bolt is Made – Portland Bolt & Manufacturing

How a Bolt is Made – Portland Bolt & Manufacturing


Hello! My name is Al Fogel. I’ve been the Operations Manager
here at Portland Bolt since 1987. This is an inch and a quarter
diameter by 48 inch long, galvanized F1554 grade 36 hex head anchor bolt. We just completed 356 of
these anchor bolts for the Caney River Substation project in Howard, Kansas. We’ve been manufacturing bolts
like these by hand since 1912 and we would like to
take you through our shop to show you how a bolt
like this is manufactured. The first step in the
manufacturing of any bolt is to cut the round bar to length. Our Peddinghaus shears
function much like a guillotine and chop the steel, rather than using
a saw blade to cut through it We are capable of shearing round
bar up to 2 inches in diameter and up to 100″ in length. Bolts that are larger in diameter or
longer in length are cut using a band saw. Next, A hex head is hot-forged
onto one end of the steel rod An induction heating coil
heats the end of the rod to approximately 2000 degrees Fahrenheit. A National Upsetter is used to
forge the heated end of the rod into a hex shaped head. Gripper blocks clamp the round
bar securely in place while a plunger or die compresses
the heated end of the rod reshaping it into the
hex head configuration. A second position in the gripper
block is used to stamp the head with the manufacturer’s logo
and grade symbol as required. The hex head of this anchor bolt
will be embedded in concrete and is intended to provide
pull-out resistance. High speed cutting blades
apply a chamfer to the ends of the bolts
prior to threading. This beveled end will help
facilitate easy assembly of the nut once the bolts
have been threaded and galvanized. Landis threaders are used
to cut 8″ of thread onto the end of these anchor bolts. Rotating heads contain chasers
which cut away steel from the round bar to produce the threads. A constant stream of cutting oil
is applied to reduce friction and prevent overheating. Threads are gauged
by the threading operators to ensure conformance
to dimensional tolerances. The bolts must be pickled
prior to galvanizing. This process cleans the
bolts and prepares the surface of the steel
to accept the zinc. Parts are first submerged
in caustic soda which removes cutting oil
and other organic materials that accumulate
during the manufacturing process. The bolts are then rinsed
and submerged in sulfuric acid, which removes any scale from the bolts
and etches the surface of the steel. The bolts are rinsed again
and then submerged in flux which is a chemical that assists
in the bonding of the zinc to the steel. After pickling, bolts
are placed in racks and lowered into our 12 foot long
by 4 foot wide by 7 foot deep tank
of 840 degree molten zinc. The bolts remain in the zinc
for between 2 to 4 minutes. When the bolts are
removed from the zinc, they are spun in a high speed centrifuge to remove excess zinc
from the threads. Due to the proprietary nature
of this process, we have not included it in the video. Finally, the bolts are cooled
in quench tanks so they can be inspected and packaged as soon as they are removed
from the galvanizing tank. Blue paint is applied
to the threaded end of each F1554 grade 36 anchor bolt
to identify the grade, as is required by the specification. In preparation for shipping, bolts are banded to pallets,
shrink wrapped, and clearly labeled. The morning after
your order leaves our facility you will receive an email
that contains shipment tracking information in addition to a copy
of full mill test reports. Portland Bolt provides
complete certification documents free of charge with every order. Portland Bolt products
ship nationwide and internationally. Refer to this page of our website to learn about the geographical
distribution of the bolts we manufacture.

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100 thoughts on “How a Bolt is Made – Portland Bolt & Manufacturing

  1. I'm proud to say that I'm STILL wearing one or other of my Portland Bolt baseball caps and beanie.
    Thank, Mike.
    tac in UK

  2. Sorry but this video was not useful or educational at all. They showed only one bolt that 95% of builders, mechanics or designers will never see or use.

  3. Love that NATIONAL header. We used to make the heading tools that went into those machines for 50 years.

  4. They should shotpeen them before threading to stress relieve them / the blank , and the zink would also look better to / more uniform ! Pretty quick and dirty if you ask me .

  5. Whats sad is that when you go to the hardware store to buy bolts most are made in china or some other god forsaken country and you can not be sure of the quality even if it is a grade 8. I try to buy American when I can, but man is it hard since so much of the every day items we use come from overseas.

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  7. Great to see old-fashioned high quality Made In USA manufacturing. Sad to think the Chinese have stolen these processes, use totally inferior materials with practically no quality control, then sell it back to America and the West at cheaper prices by paying slave labor wages to their workers.

  8. I am a retired Engineer.When I was an Apprentice one of the jobs I had was using a roller box, making studs from !/4" to 3/4". This was one of the many skills I learned. I eventually became a Development Engineer, Developing projects for some major companies.

  9. Worked in a pile driver boat (USCGC Hatchet construction tender) used bolt similar to these….to hold the platform where later the channel light was placed….on the previously punched pylon into the floor of the channel.

  10. Thank you for posting this great video and showing us how you mfr bolts! I hope in the years since posting, that you have somewhat updated your processes to make them more efficient. I hate to be the one to say it, but the labor involved seems in excess of what could be used. There's a lot of hand-handling that could be streamlined. I'm not even saying to use robots, but just by redesigning your jigs, introducing new jigs and other devices, you could make your labor more efficient. I'm not sure what your economic challenges are; whether you are protected somewhat through domestic procurement requirements, but you could protect yourself with greater efficiency. I'm not intending to just be critical, but to encourage actions that will keep more jobs here in the country. Thank you!

  11. The only reason this company still exists is probably because the bolts they make are specialty and not many are manufactured. Money is the name of the game. Anything shown here could be done automatically. Patriotism is NOT the name of the game. Here is a company in China that makes large bolts automatically. https://www.youtube.com/watch?v=Yhml2XiMFPA

  12. EXCELLENT Video, My father and I started Advance Electric Motors in 1976 using antiquated equipment, and STILL have " OLD ORIGINAL " Rewinding Machines to make our coils. The dinosaur stuff was much better than the modern equipment( That also cost a small fortune) We have both, but rely on the machines that were made by Gabe Pascuzzi of Milwaukee Machinery from the 40's. I retired (6) years ago, and after seeing your video, wish I had repaired some of your electric motors. My partner is still successfully running the business, and if your looking for a Very Good Rewind Shop ADVANCE ELECTRIC (503) 238-3944 is the place. Notice my plug!!! Hahahahaha. I'm still selling. Thanks. Paul M.

  13. Why aren't the Portland SJW types protesting to shut down the "toxic" masculine, CIS gendred, inherently racist, oppressive capitalistic work environment at a manufacturing plant???! 😂😃😄

  14. I used to make bolts for Bethlehem Steel I made cold formed bolts from 1/4 inch in dia. To 1-1/4 in dia any length ordered –And had to run two machines at one time —usually a 1/4 inch mach. and a 5/8th mach.. I also ran at the time the largest cold forming bolt machine in the USA. Our machines cut the wire –formed the upset–formed the head and trimmed the upset to a hex then pushed the blank bolt up a hollow tub to a pointer then up a track to the roller dies, all in one stroke once all the stations were full.

  15. I couldnt believe the head is forged onto the shaft..is it as strong as a one piece item,i can see the cost savings with waste etc but how does it compare to say a fully turned down shaft..at 2000 degrees does the bolt head become one with the shaft?

  16. I love watching how items are made. So often we take for granted common items, or the parts of a complex piece of machinery. Very interesting.

  17. I applaud of this American plant of not outsourcing so as to secure a supply of engineering logistics for America BY MANUFACTURING EVERYTHING LOCALLY but I must be truthful. They should use stainless steel micro-ball sand blasting that uses minute size stainless steel alloy balls that has the proper balance of hardness and toughness, stiffness and rigidity, abrasion-resistance and wear-resistance, DUCTILITY AND MALLEABILITY, and corrosion risistance to sand blast clean the bolts from the top, bottom, left, and right and at an angle so as to sand blast clean the surface ends on both sides of the bolts without damaging or harming them (in the 1980s, plastic pellets that are made from recycled plastics are used in sand blasting were used to remove paint from military aircrafts without harming the aluminum and titanium skin) while simultaneously applying the peening effect to strenghten the bolts as if they are being forged 3 dimensionally. Then using dry ice sand blasting to remove any last remaining vestiges of contaminants and unavoidable but extremely rare metal particles from the minute stainless ball sand blasting-peening-strenghtening effect-process. Then using the multi-phase array EDDY CURRENT TESTING AND ULTRASONIC TESTING and X-Ray inspection process. And then using the iron and steel anodizing process that uses potassium permaganate to protect against rust and then using powerful omni-directional ultrasonic beams to rinse it clean of any chemical residues. Then using a very powerful precision electrostatic ultrafine molten metal spray, spraying a zinc-silicon-tin alloy so that the screw threads and bolts and washers still fits. And then start using again the multi-phase array EDDY CURRENT TESTING AND ULTRASONIC TESTING and X-Ray inspection process for quality control and using an electrostatic cathod ray tube open air styled conductive ink applicator printer which is an old 1970s invention by the British to print the code number of each bolt, date-time-place of manufacture, and quality control standard qualification inspections-tests-checks CERTFICATION and then they are finally and carefully packaged for storage and eventually shipment.

  18. If I am an American and I am buying a 100% made-in-America product that costs 2 to 5 times more but will last and last and last and will last for many, many, many years THEN I'D RATHER BUY LOCALLY MADE AMERICAN PRODUCTS for it will save me money in the long run in terms of replacements AND INFLATION. I can still remember that in 1933 a very big can of pork and beans just costs cents and now a small can of pork and beans costs $2.00 to $3.00 plus! The same goes for manufactured products, we now have the technology to make incandescent light bulbs to last indefinitely but not anymore because of planned obsolescence but if it costs 4 times to 5 times more I'd rather buy it than a cheap version of it that will last only for a couple of years and I'll beat inflation and replacement costs in the long run. Besides LED can cause eye damage which was detected by Spanish researchers https://www.upi.com/LED-lights-ruin-retinas-researchers-say/52041368287606/

  19. Before the invention of the wire nail machine, they used to shear wedge-shaped blanks out of iron plate, and a heading technique put the rose-head on a lot like the hex machine here.  A type of upset-forging.  Some thread technique on heavy bolts involves starting with a rod of a diameter between the root diameter and the external outermost thread diameter of what would be the finished product.  The threads are hot-rolled (I think) onto the rod. There is no metal removed, and the strength of the actual diameter of the unfinished rod is not compromised by metal reduction.  The threads do stand taller than the diameter of the rod though, due to the flowing upward of the displaced metal to the finished diameter of the outer edge of the thread.

  20. I use to work  for a packaging company. the one thing that would drive us bonkers is the misuse of shrink wrap and stretch wrap. Shrink wrap is a sheet of plastic that is put over something then HEAT is applied causing the film to shrink. Stretch wrap is film that is put over some thing when it stretched, like saran wrap.

  21. Next we'll show you a 123,49,3092,487,11894,3887620,3876,38,91,4817,8476,28456582,827452,HSPTUYBNDR3672917, 38209274PLIN.

  22. Really nice video. Thanks!
    I met some of your competition: a farmer up Highway 8, north of Hamilton, Ontario, has a $500,000 four-axis machine out in the barn, spends a few hours a day carving bolts out of raw stock, custom-made for customers like Hydro-Quebec.
    "Gotta have something to do while the cows are in the field."

  23. Hi sir i am from pakistan plz establish a factory of nuts and bolts in pakistan here in pakistan very big market but no such good quality manufacture in this market this the time to invest in profitable business and new gov is very honest and clean minded for doing eas of bussines

  24. Hello

    I am manufacturing foundation bolts which are used in setting up an industrial structures. I would like to export this product in your country. Foundation bolts have different diameters and we are manufacturing every types of foundation bolts.
    If you are interested please let me know. We will discuss about this in more detail

    Thanks nd regards
    Karan

  25. Great work Portland. Always force your government to help. Keep your US business running! Consumers- keep your government and infrastructure and other contractors honest alwsys buying US because even if more expensive, that money circulates locally and indirectly keeps them in business. These big companies do hot exist without the smaller ones who employ the most people and generate the largest govt revenue. SMEs should be doted on like a long awaited child.
    My father used to work for a very well established bolt company Ajax Bolts & Fasteners Australia in management. They built a factory closer to the CEOs house and sold their old 70+ year site for real estate in the neighbourhood which had become gentrified (Richmond, Victoria, Australia). Shortly after, the crooked bstrds at the top sold the whole shop and machinery to China. Ajax was the largest single suppliers to the now defunct Australian auto industry- Toyota (CKU assembly and some manufacturing), Ford Geelong (now shuttered), Holden GMH (now shuttered) employing at Ajax over 400 skilled workers, machinists and operators. Dad quit when they moved first moved having heard of plans. He tried to warn many employees, but many were over 40, had mortgages, and some very bad English (they were Greeks, Italians, Cypriots, Yugos etc told Australia was the land of dreams with streets paved w gold). The bastrds were thwarted in tens of millions on their plans to cash-in big time because the idiots had no realization the old Richmond plant had severe soil contamination and pollution due old nanufacturing methods, and long before environmental legislation.
    Never let the crooks in government or the top level in management ever sell you out. Former CEO without any tears said "Fck off and die" to 400 loyal workers the majority worked for Ajax most of their career, auto industry had major problems finding new fastening contractors which may have been a minor influence in Australian auto industry, sick of useless government treating them like a tax farm to say "Fugg it, the Chinese, the Thai and the Malaysians have all offered us new facilities close to ports with 20+ year tax holiday- all you Aust Gov does is tax us dry and demonise us".

  26. I worked for 16 years for big bolt corp. in chicago and also made those bolt and up to 3"x 8' and then sent them to heat thread and the quality control department made them the test of stretching their head to know how much it was the resistance they endured to know if he passed the test

  27. Fascinating inside look at one of the products (production processes too) which built this country and literally help hold it together.

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