Intelligent Bolts

Real-time monitoring of critical bolted connections

Bolted joints are used throughout safety-critical industries where reliability, performance and structural integrity are essential. However, changes in preload can occur due to vibration, dynamic loading, temperature variations and changing operating conditions.

Monitoring bolt preload and temperature provides engineers with valuable insight into the condition and performance of critical connections, helping identify changes before they develop into larger maintenance concerns.

Staytite’s cloud-connected Intelligent Bolt technology enables engineers to measure bolt preload and temperature both onsite and remotely. Real-time data helps maintenance teams verify installed conditions, monitor joint performance and support a more proactive approach to asset reliability and condition-based maintenance.

Intelligent Bolt Technology

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. This supports data-driven maintenance decisions and provides greater visibility compared with traditional inspection methods alone.

Onsite Monitoring

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.

Remote Monitoring

Remote monitoring enables engineers to track changes in bolt load over time, providing valuable information about the condition of critical assets.

By collecting real-time data from bolted connections, maintenance teams can make informed decisions, prioritise inspections and support condition-based maintenance strategies.

This approach is particularly valuable for applications where regular physical access is challenging or where asset reliability is critical. 

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

By combining bolt load sensing with remote monitoring capability, Staytite helps engineers improve visibility of critical connections and make better-informed maintenance decisions.

Discuss Your Intelligent Bolt Application

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.

For applications specific to rail you can visit our Staytite Rail website here.