How to Remove a Broken Bolt?
Broken bolts are a common challenge in routine mechanical repairs and maintenance. Whether it’s on aging equipment, or due to over-tightening, corrosion, or improper installation conditions, bolts can break.
In such cases, knowing how to effectively remove a broken bolt can greatly improve repair efficiency and prevent unnecessary time wastage. In this article, we will introduce several common methods on how to remove a broken bolt to make the process easier for you.
Table of Contents
Part 1. Why Do Bolts Break?
Before we go further to get a bolt out that broken off, let’s first understand the reasons behind its breakage. This helps us not only remove broken bolts more effectively but also avoid similar issues in the future. Here are some common causes of bolt breakage:
Over-tightening: If a bolt is tightened beyond its design capacity during installation, it can damage the bolt’s structure, making it more prone to breakage. Over-tightening can cause thread slippage or stress concentration, making the bolt vulnerable to failure during use.
Corrosion: Bolts exposed to humid, saline, or corrosive environments for extended periods can suffer from oxidation and rusting. Corrosion weakens the strength of the bolt and reduces its tensile strength.
When corrosion becomes severe, the bolt’s structure becomes brittle and prone to breaking. This is especially true for bolts used in marine environments, chemical plants, or other harsh conditions.
Fatigue: Bolts that are subjected to prolonged vibration, pressure, or cyclic loads can experience metal fatigue. Even if each load is below the bolt’s maximum load-bearing capacity, repeated stress can cause microscopic cracks, which will eventually expand and cause the bolt to break.
Bolts in cars, aviation, and industrial equipment are particularly susceptible to fatigue breakage due to constant vibration.
Improper installation: Using incorrect tools or improper bolt installation methods is another common cause of bolt breakage. If the torque is not properly controlled during installation or if inappropriate bolt materials are used, the risk of breakage increases.
Additionally, improper installation due to unclean threads or mismatched bolts can lead to hidden issues, making the bolt prone to breaking during use.
Material defects: Sometimes, the cause of bolt breakage lies not in external factors but in defects in the bolt material itself. During production, there can be inconsistencies in the metal or tiny internal cracks, which can lead to breakage over time.
Overloading: When a bolt is subjected to loads beyond its design capacity, it is likely to break. Overloading typically occurs when the estimated load in design or use is underestimated or when equipment is run beyond its capacity, causing the bolt to fail under excessive pressure.
Part 2. How to Remove a Broken Bolt?
Here we list 5 different ways to remove broken bolts, let’s check it out.
Way 1. Using a Bolt Extractor
Bolt extractor is a tool specifically designed to remove broken bolts. It is typically made of hardened steel and has a special reverse thread design that allows it to grip the head of the broken bolt.
To use, simply attach the extractor to a power tool, align it with the broken bolt, and slowly rotate. The threads of the extractor will embed into the bolt head and gradually loosen it.
Advantages: Bolt extractors are highly efficient at gripping and loosening bolt heads, making them suitable for most types of broken bolts. They are a common tool used by mechanics.
Way 2. Drilling Broken Bolt Out
If you don’t have a bolt extractor, you can use a drill to remove a broken bolt. This method is ideal for more stubborn or larger broken bolts. Start by drilling a small hole in the center of the bolt and gradually increase the drill bit size until the bolt is fully removed. Caution is needed to avoid damaging surrounding materials.
Advantages: This method can handle almost all types of broken bolts, especially when the bolt is very strong or made of hard material. It requires skill and careful handling, but it’s a versatile solution.
Way 3. Heating the Bolt
Heating the bolt is an effective method for removing a broken bolt, especially when it is stuck due to rust or prolonged fixation. Heat can cause the bolt to expand and loosen, making it easier to remove.
A welding torch, flame gun, or other heat sources can be used to heat the bolt. Once heated, use the appropriate tool to turn and remove the bolt.
Advantages: Heating the bolt helps loosen it, especially in cases of corrosion or long-term fixation. It is a practical method for bolts exposed to extreme environments, such as in marine or chemical equipment.
Way 4. Using a Rust Remover
If the broken bolt is stuck due to rust, you can use a chemical rust remover to help loosen it. The rust remover can penetrate between the bolt and the surrounding material, dissolving the rust and reducing friction, making the bolt easier to remove.
Simply spray the rust remover on the bolt, wait for a specified time, and then use the appropriate tool to loosen it.
Advantages: This method is especially effective for heavily corroded bolts and is easy to use. It’s an economical solution for bolts that are difficult to remove due to rust.
Way 5. Using a Reverse Drill Bit
A reverse drill bit is a specially designed drill bit that creates reverse force while rotating, helping to pull out the broken bolt. By drilling with a reverse drill bit, you can generate enough torque to rotate the bolt and remove it.
This method is especially effective for broken bolts that no longer have a noticeable thread.
Advantages: The reverse drill bit method is effective for bolts that cannot be removed using traditional drills or extractors, especially those without visible threads.
Part 3. How to Prevent Broken Bolts in the Future?
Bolt breakage is often caused by improper installation, corrosion, or other factors. Preventing breakage not only extends the life of equipment but also saves on repair costs. Here are some effective ways to prevent bolt breakage:
1. Correct Torque
Always use the proper tools and follow the recommended torque when tightening bolts. Over-tightening can damage the bolt, while under-tightening may cause loosening. A torque wrench ensures the correct tightening force, preventing both breakage and instability.
2. Regular Inspections
Regularly inspect bolts for looseness, corrosion, or damage, especially in equipment exposed to vibration or heavy loads. Early detection of problems allows for tightening or replacing bolts before issues escalate, reducing repair costs.
3. Rust Prevention
Apply rust inhibitors or use stainless steel bolts in humid or corrosive environments to prevent corrosion. Regularly check bolts for rust, and use coated or galvanized bolts in harsh conditions to protect against breakage.
4. Use High-Quality Bolts
Choosing the right bolt material is an important factor in preventing breakage. The quality of the bolt directly affects its durability and tensile strength. Using high-strength alloy bolts, especially in applications that bear heavy loads or high temperatures, can effectively reduce the risk of breakage.
Ensure that the bolts meet industry standards and are suitable for the specific working conditions, avoiding the use of low-quality or non-compliant bolts. If you are looking for high quality bolts, KENENG, as a professional bolt manufacturer, can provide reliable bolts for you.
Summary
Removing a broken bolt can be tricky, but with the right tools and methods, it can be easily resolved. Whether you’re using a bolt extractor, drilling tool, heat treatment, or a rust remover, each method has its unique advantages.
At the same time, you should know prevention is always more effective than repair. By regularly checking and using the correct tools, you can avoid most bolt breakage issues and keep your equipment running at its best.
