Tag: fasteners

Broken Bolts on New York’s USD 4 Billion Mario Cuomo Bridge

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Tsamouris, the Fastener Specialists©

New York’s USD 3.9 billion (EUR 3.6 billion) Mario Cuomo Bridge has been mired in controversy since its
opening in 2017, with allegations of faulty bolts and a potential cover-up by the construction consortium,
Tappan Zee Constructors (TZC). Despite assurances from TZC and the New York Thruway Authority that the
bridge is safe, concerns persist about the structural integrity of the span.

In 2018, a whistleblower claimed that engineers secretly replaced failing bolts to hide the faults from
inspectors. The New York attorney general’s office launched an investigation into the alleged 60 failed bolts
out of the more than one million used in the bridge’s construction.

TZC maintains that all bolt testing indicates no issues and that the bridge is completely safe for the traveling
public. The company spent over USD 1 million (EUR 921,000) on expert assessments and testing,
concluding that a small percentage of bolts had manufacturing defects that led to breakage during
tightening.

In 2021, a federal review by the Federal Highway Administration found “no safety concerns” with the bridge,
according to the Thruway Authority. However, an outside bridge expert cited in a report by The Albany Times
Union called the volume of bolt failures “unprecedented and highly alarming.”

Despite the controversy, TZC stresses that the bridge was built with numerous redundancies to prevent a
collapse, even if some bolts were to fail. The most recent inspection found only one failed bolt out of
hundreds of thousands.

Jesus Nut

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The “Jesus nut,” a term coined by American soldiers during the Vietnam War, refers to the main rotor
retaining nut that holds the main rotor to the mast of some helicopters. This single component is so critical
that if it were to fail mid-flight, the consequences would be catastrophic, with the rotor detaching from the
helicopter.

The origin of the term is a grim reminder of the importance of this fastener. Soldiers believed that if the Jesus
nut failed, the only thing left to do would be to pray to Jesus, as a crash would be inevitable. The term has
since been applied more broadly to any single component, such as a bolt, whose failure would lead to the
complete breakdown of a system.

Despite the rarity of actual Jesus nut failures, the component must be rigorously checked before each flight.
In one tragic incident in 2000, a Bell 206B helicopter crashed within ten minutes of takeoff, after the mast nut
was removed for repainting and not properly restored and checked prior to the test flight.

Weak Bolts Troubled Brooklyn’s Barclays Center

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Tsamouris, the Fastener Specialists©

Just a month before the Barclays Center’s grand opening in New York in September 2013, engineers
discovered a potentially serious issue: nearly a quarter of the bolts anchoring the arena’s distinctive steel
panels were weaker than specified. The discovery raised concerns about the structure’s integrity and
sparked a race to replace the subpar fasteners before the inaugural event.

The Barclays Center, with its weathered steel facade and striking canopy, was designed to make a bold
statement about Brooklyn’s resurgence. However, the project faced numerous challenges, including the
abrupt shutdown of the panel fabricator midway through the job and occasional instances of rusty orange
drips staining the sidewalks.

Engineers determined that only 8% of the 23,351 bolts needed replacement, but the issue raised questions
about communication between the arena’s developer, Forest City Ratner, and city regulators. The Buildings
Department claimed it had not been notified of the bolt problem, while Forest City maintained it had
submitted a letter outlining the issue and the planned fix.

Despite the last-minute bolt replacement, the Barclays Center opened on time and withstood Hurricane
Sandy’s winds just a month later. The project’s executive vice president for construction downplayed the
issue, asserting that such problems are not uncommon in highly customized architectural projects.

At Tsamouris, we supply the largest construction companies in Greece with the highest quality screws,
ensuring that problems are avoided and the strictest building standards are maintained.

300-Million-Year-Old Alien Screw?

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A mysterious object resembling a screw embedded in a rock has sparked intense speculation since its
discovery in the 1990s in Russia’s Kaluga region. While some believe the “screw” could be evidence of
advanced ancient civilizations or even alien technology, experts suggest a more down-to-earth explanation.
The “screw,” measuring approximately an inch long (2,54 centimeters), was found by a UFO and paranormal
research team called the Kosmopoisk Group. They claim the stone is between 300 and 320 million years old
and contains another hidden “screw” inside, as revealed by X-rays.

However, without detailed information or the opportunity for conventional scientists to examine the object
firsthand, speculation has been based on grainy online photos. The leading hypothesis is that the “screw” is
actually the fossilized remains of an ancient sea creature called a crinoid, with the rock forming around the
gradually dissolving creature, creating a screw-like impression.

Crinoids, now largely extinct, were abundant millions of years ago, and their fossils often resemble screws.
Some argue that the size and markings of the “screw” don’t match typical crinoid stalks, leading to more farfetched
theories involving ancient advanced technology or alien visitors.

Fasteners Broke off Wing during Southwest Airlines Flight

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Passengers on a Southwest Airlines flight from Austin to Harlingen, Texas, in December 2015 experienced a
harrowing ordeal when a piece of the wing allegedly “fell off” during the journey. The Boeing 737, carrying
109 passengers and five crew members, was forced to make an emergency landing at San Antonio Airport.

Passenger Lorenzo Hernandez Jr. described the incident as a “near death experience,” recounting how
fasteners on the left side of the plane’s wing broke or came off, causing a panel to hang loose. He reported
that some passengers screamed to the aircrew as the plane experienced severe turbulence, with many
praying in the cabin.

Despite the frightening situation, Hernandez praised the staff and pilots for keeping calm and stabilizing the
plane. A Southwest spokesperson confirmed that the captain decided to divert the flight due to a flap track
canoe fairing appearing at an irregular angle. The aircraft landed safely without incident, and no injuries
were reported.

Another passenger, Hayden Ellis, recalled the pilot announcing over the tannoy that something had fallen off
the wing, while Clarissa Ellis mentioned that a flight attendant was alerted to the issue by a concerned
passenger.

Missing Bolts Contributed to Brooklyn F Train Derailment

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Tsamouris, the Fastener Specialists©

Four missing high-strength Grade 8 bolts are at the center of the MTA’s investigation into the January 10,
2024, derailment of an F train in Coney Island, Brooklyn. The bolts, which were meant to secure a critical
component called the “radius arm” to the train’s undercarriage, were discovered missing from the derailed
car.

Radius arms play a crucial role in keeping a subway car’s wheels and axles properly aligned during
movement. Experts warn that a fallen or broken radius arm can lead to a derailment.

While the cause of the derailment is still under investigation, with track issues and other factors not yet ruled
out, the MTA believes the missing bolts may have contributed to the incident. It remains unclear whether the
bolts broke before disappearing or were improperly installed.

In response to the derailment, the MTA has inspected approximately 50,000 radius arm bolts across its
subway fleet, focusing on R160 cars and similar designs. No systemic issues were found during these
inspections, and officials believe riders are not currently at risk.

At Tsamouris, we recognize the critical role that high-quality fasteners play in ensuring the safety and
reliability of transportation systems.

Pagani Huayra Bolts Cost as Much as a Porsche 911

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Tsamouris, the Fastener Specialists©

Pagani’s flagship hypercar, the Huayra, is a true marvel of engineering, boasting a powerful AMG-sourced
V12 engine and stunning design. But it’s the car’s 1,400 unique titanium bolts that truly showcase the
brand’s obsessive attention to detail.

Each bolt, made from grade 7 Titanium with added palladium for enhanced corrosion resistance, is
individually engraved with the Pagani logo. This level of craftsmanship comes at a price: a single bolt costs
around USD 95 (EUR 88), meaning the Huayra’s bolts alone are worth a staggering USD 133,000 (EUR
123,000) – enough to buy a brand new Porsche 911.

Pagani’s choice of high-quality, lightweight materials like Titanium ensures the Huayra can withstand the
rigors of high-performance driving while maintaining its impeccable aesthetics. The engraved bolts serve as
a subtle yet powerful reminder of the brand’s uncompromising commitment to excellence.

At Tsamouris, we share Pagani’s dedication to providing customers with fasteners that meet the highest
standards of strength, durability, and reliability. Discover our range of top-quality fasteners, the go-to choice
for Greece’s leading construction and industrial groups.

Bolt Problems at London’s US Embassy

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In 2015, thousands of bolts on the new US embassy in Vauxhall, London, needed replacement after some of
them were found faulty.

The GBP 800 million (USD 1 billion or EUR 940 million) cube-shaped embassy, America’s largest in the
Western world, was shrouded in secrecy due to its highly sensitive nature. While details remained scarce, it
was understood that the issues involved bolts on the building’s upper floors.

The steel company tasked with replacing the bolts was the same contractor that had to spend over 6 million
GBP (7.6 million USD or 7.5 million EUR) in 2014, when two of its bolts, each the size of a human arm, broke
on the 738 feet tall (225 meters) “Cheesegrater” skyscraper.

The steel company tasked with replacing the bolts at the embassy was the same one that had to spend over
6 million GBP (7.6 million USD or 7.5 million EUR) in 2014. At that time, three of the bolts it had installed in
the 738-foot (225-meter) “Cheesegrater” skyscraper in London, each the size of a human arm, broke, forcing
the contractor to replace all 3,000 bolts in the skyscraper. Thankfully, no one was injured.

An investigation into the “Cheesegrater” bolt failures revealed that they had fractured due to hydrogen
embrittlement, a process in which hydrogen atoms diffuse into a substance, combine, and create internal
pressure, causing the metal to weaken.

In an era where the complexity and scale of architectural projects continue to grow, the need for fastening
solutions that can withstand the test of time and the elements has never been more crucial.

Subsea Oil-Well Bolts Are Failing

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Tsamouris, the Fastener Specialists©

In 2013, the U.S. Department of the Interior (DOI) launched an investigation into the failure of massive bolts
that secure subsea oil equipment in the Gulf of Mexico. The inquiry was triggered by a worldwide recall of
defective bolts by General Electric Co.’s oil-exploration equipment business, which reported incidents of
corrosion and snapping. These failures have led to costly shutdowns and raised serious concerns about the
safety of subsea wells.

The potential consequences of bolt failures in subsea oil equipment are severe, as they could lead to major
oil leaks with devastating environmental impacts. The 2010 BP oil spill in the Gulf of Mexico, for example,
was linked to a record spike in marine animal deaths, particularly among bottlenose dolphins. The spill,
which occurred after the BP-owned Deepwater Horizon oil rig exploded, released more than four million
barrels of unprocessed oil before being sealed five months later, highlighting the difficulty and expense of
cleaning up such disasters.

The DOI’s investigation, along with two additional bolt failure incidents, has led industry officials and safety
regulators to believe that the problem extends beyond GE and its blowout preventers, which are critical
devices used to seal, monitor, and control oil and gas wells. Flaws have also been discovered in bolts
manufactured by GE’s competitors for similar equipment.

Manufacturers and regulators have identified several potential factors contributing to the bolt failures,
including the adequacy of the alloys used in the heavy steel bolts, the appropriateness of the coatings
applied to the bolts, and the practice of “over-torquing” by subcontractors, which can weaken the fasteners.
GE has acknowledged that over-torquing may have played a role in its bolt failures.

The bolt failures have been traced decades back, and while they have not yet resulted in any oil leaks,
regulators consider the issue to be of critical importance. The problem may affect more than 2,400 platforms
and oil rigs in the Gulf of Mexico, 23 off the coast of California, and an active rig on the outer continental
shelf in Alaska.

As an officer of the Bureau of Safety and Environmental Enforcement stated: ”If your smallest component
fails, you can’t expect a sophisticated many-million-dollar piece of equipment to prevent a leak.”

Paris 2024 Olympics — 2.5 Million Rivets Holding an Icon

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As the 2024 Paris Olympics unfold, besides the athletes, all eyes are on the Eiffel Tower. Held together by an
astounding 2.5 million rivets, this marvel of engineering shines even brighter during the Games, as it
receives a special golden paint job to commemorate the occasion.

The construction of the Eiffel Tower relied on a riveting technique that has become the monument’s
trademark. The process involved a team of four skilled riveters working in perfect harmony. One heated the
rivet, another held it in place, a third formed the head, and the final member of the team locked it in place
with a sledgehammer. This efficient method allowed for the tower to be assembled in a record-breaking time
of just two years, two months, and five days.

Many of the tower’s components were pre-assembled at a workshop in Levallois-Perret before being
transported to the site for final assembly. This approach not only streamlined the construction process but
also ensured the highest level of precision and quality control.

In total, the Eiffel Tower comprises 18,000 metal parts, held securely by 13,000 bolts and the aforementioned
2.5 million rivets. Despite the tower’s original design life of just 20 years, the use of high-quality materials
and the dedication to regular maintenance and replacement of various pieces have allowed it to stand tall for
over a century.

Here are 17 mind-blowing facts and figures about the Eiffel Tower

1⃣ Gustave Eiffel built the tower because he won a competition.

2⃣ Eiffel had to pay for much of the build himself.

3⃣ Eiffel didn’t work alone; a team of engineers, architects, and workers contributed.

4⃣ The Eiffel Tower was once the tallest structure in the world.

5⃣ It changes height due to temperature fluctuations.

6⃣ It gets a regular lick of paint, using a special “Eiffel Tower Brown” color.

7⃣ It has over 1,700 steps.

8⃣ The first guided climbing tours launched in 2017.

9⃣ The elevators travel 2.5 times around the Earth every year.

🔟 You can see beyond Paris from the top on a clear day.

1⃣1⃣ In 1909, the tower was going to be demolished but was saved by Gustave Eiffel.

1⃣2⃣ It has 7 million visitors a year.

1⃣3⃣ It was sold by a con artist in 1925.

1⃣4⃣ It “got married” to a woman named Erica in 2007.

1⃣5⃣ The tower has 20,000 lights and sparkles for five minutes every hour after dark.

1⃣6⃣ It’s eco-friendly, producing its own electricity via hidden wind turbines.

1⃣7⃣ It was almost destroyed in WWII but was saved by a general who disobeyed orders.