Intelligent Bolts

Real time monitoring of critical bolted connections

Onsite Monitoring

The wireless, battery operated device enables bolt load to be measured both onsite and remotely.

Remote Monitoring

The Bolts have inbuilt LED indicators on the end cap and wireless connectivity to the Intelligent Bolt App.

Perfect fit, zero downtime

The bolts ensures bolts are tightened accurately onsite and eliminates the need for manual periodic inspection.

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    How do the Intelligent Bolts work?

    Reduce On-Site Inspection

    The Intelligent Bolt is a miniature, high-accuracy bolt load sensor integrated directly into a bolt or stud. The wireless, battery-powered device measures bolt preload and provides engineers with real-time information about the condition of bolted connections.

    By combining sensing technology with digital monitoring, Intelligent Bolts allow engineers to understand how critical joints are performing throughout their service life.

    ‘Removing Boots From Ballast’

    Intelligent Bolt technology enables bolt load measurements to be accessed both onsite and remotely.

    During installation, commissioning or maintenance activities, engineers can quickly check bolt condition using integrated LED indicators and wireless connectivity through the Tablet App.

    For applications where access is difficult, disruptive or costly, remote monitoring provides continuous visibility of critical bolted connections without requiring technicians to be physically present at the asset.

    The Interbolt App

    During installation, commissioning or maintenance activities, engineers can quickly check bolt condition using integrated LED indicators and wireless connectivity through the Tablet App.

    Remote Monitoring

    Available from the Network Rail iStore

    Email Alerts

    Integrated LED indicators

    Data Review and Export

    Reduced Maintanance

    Watch Our Bolt Installation Demo

    Intelligent Bolt technology supports industries where maintaining reliable bolted connections is essential, including rail infrastructure, industrial equipment and other demanding engineering environments.

    (For ROBEL Temporary Clamp installation, follow your work instructions)

    Frequently Asked Questions

    A Staytite Intelligent Bolt works by measuring the change in length of the bolt as clamp force is applied.

    As the bolt is tightened, it behaves much like a spring or stretched string. The bolt elongates under tension, and this change in length is directly related to the preload in the joint.

    The Intelligent Bolt contains a sensor that measures the distance between the sensor and a precision gauge pin positioned within the bolt. By monitoring this distance, the system can detect changes in bolt elongation and calculate the corresponding clamp force.

    The measurement also accounts for thermal expansion and contraction, helping to distinguish changes caused by temperature from changes in bolt preload.

    The result is a continuous, measurable indication of bolt condition and preload, which can be monitored through the InterBolt App. This allows engineers to check bolt performance and identify changes without relying solely on manual inspection or torque checks.

    Staytite Intelligent Bolts are available from the Network Rail iStore or directly from Staytite Rail.

    If you would like to understand how Intelligent Bolt technology could support your application, our engineering team can help.

    Intelligent Bolt data can be accessed remotely through the cloud, allowing engineers to monitor bolt performance without needing to be on site.

    Using the InterBolt system, engineers can view current measurements, review historical data and track changes in bolt preload over time. This provides a clearer picture of how a joint is performing and can help identify changes that may require further investigation.

    Remote access can reduce the need for routine site visits while giving maintenance teams access to the information they need when making decisions about bolt condition and joint performance.

    For applications where onsite checks are required, data can also be accessed locally using the InterBolt App.

    Staytite Intelligent Bolts are available from the Network Rail iStore or from staytite-rail.com

    Whether you are looking to monitor bolt preload, improve maintenance strategies or understand how Intelligent Bolt technology can support your application, Staytite’s engineering team can help.

    Email rail@staytite.com or call 0300 373 9029 to discuss your requirements.

    Staytite Intelligent Bolts can be activated using the magnet supplied with the InterBolt tablet.

    Simply hold the magnet over the LED on the end of the Intelligent Bolt and wave it across the LED. This activates the bolt and allows it to communicate with the InterBolt system.

    Once activated, the bolt is ready to be read and its data accessed through the InterBolt App.

    Staytite Intelligent Bolts transmit data every 30 minutes as standard, providing regular updates on bolt performance.

    The transmission interval is user configurable and can be reduced to as frequently as every 15 minutes, depending on the requirements of the application.

    This allows engineers to choose a monitoring frequency that suits the joint, site conditions and maintenance strategy.

    The battery in a Staytite Intelligent Bolt typically lasts 10 to 15 years, depending on how frequently data is transmitted.

    The battery is also replaceable, so the Intelligent Bolt does not need to be replaced when the battery reaches the end of its service life. Staytite supplies a battery replacement kit, allowing the battery to be changed and the bolt to continue in service.

    Yes. Staytite Intelligent Bolts can be reused, provided they have not been damaged during installation, removal or use.

    The bolts are specially coated with GEOMET 321 for corrosion protection. Care should be taken to ensure that the sensor cap is not damaged, as this could affect the bolt’s functionality.

    Before reuse, the Intelligent Bolt should be checked to ensure it is in suitable condition and that the sensor cap remains intact.

    Staytite Intelligent Bolts can be used with a range of rail clamps, including:

    • ROBEL temporary clamps
    • Short clamps
    • Long clamps

    This allows Intelligent Bolt technology to be used across different temporary clamping and rail joint applications, providing engineers with real-time bolt preload data during use.

    The Intelligent Bolt Gateway has a communication range of up to 1 km to connect with Intelligent Bolts in the surrounding area.

    Once data is collected from the connected bolts, the Gateway uses 4G connectivity to transmit the information securely to the cloud. This allows engineers and maintenance teams to access bolt data remotely, without needing to be physically on site.

    The Gateway can support applications where multiple Intelligent Bolts need to be monitored across a wider area, helping provide a central view of bolt performance and historical data.

    If you are considering Intelligent Bolts for your application and would like to understand Gateway placement, coverage or connectivity requirements, contact Staytite’s engineering team for advice.

    The Intelligent Bolt Gateway can manage a large number of connected Intelligent Bolts, with a capacity well beyond the requirements of most applications. In practice, users are unlikely to come close to the Gateway’s maximum allowance.

    Multiple Gateways can also be deployed within the same application and used together without interference. This can provide additional coverage and redundancy, helping maintain connectivity and data collection across larger or more demanding installations.

    If you are planning an application with a large number of Intelligent Bolts, contact Staytite’s engineering team to discuss the required Gateway configuration and ensure the system is set up to suit your application.

    Intelligent Bolt technology supports industries where maintaining reliable bolted connections is essential, including rail infrastructure, industrial equipment and other demanding engineering environments.

    Whether you are looking to monitor bolt preload, improve maintenance strategies or understand how Intelligent Bolt technology can support your application, Staytite’s engineering team can help.

    Contact Staytite on 0300 373 9029 to discuss your requirements.