It is possible for a Tapcon® concrete screw
to break while being installed into a base material. This breaking or
shearing off of the Tapcon® usually happens when the screw is within
1/4" of full installation/embedment. If the screw is installed properly,
the chances of it breaking are slim. Chances for the breaking or
shearing of a concrete screw are also decreased when using a real, brand-name Tapcon®.
Below are some common reasons why Tapcons may break during the installation process.
#1: Generic Tapcon
because a concrete screw is blue doesn't mean that it is a genuine
Tapcon®. Tapcon® is the brand name for the original concrete screw and
is manufactured in the United States. Many companies sell concrete
screws but they are not Tapcons. In most cases, these screws are simply
imported than painted blue to look like Tapcons.
Get rid of generic concrete screws and purchase Tapcon® brand concrete screws. This should solve this problem.
#2: Wrong Application for Tapcons
work in most applications, but as with all concrete fasteners they may
not work in all applications all the time. If the material is too
abrasive and the lead thread is worn down during installation, the
Tapcon® screw will stop tappingthreads. This continued torqueing of the
screw can shear the Tapcon® in half.
Find another concrete fastener to use such as a hammer drive or split drive concrete anchor.
#3: Drill Being Used for Tapcons
tolerance, shape and consistency is critically important for the proper
installation of Tapcons. A standard rotation drill will not make a
correct hole on a consistent basis and should not be used when drilling
holes in concrete, brick or block. These concretescrews may penetrate
the hole and then get stuck. Adding torque at this point in the
installation process may shear or break the Tapcon®.
Use a hammer drill when drilling holes for
Tapcon® anchors. A hammer drill must be used when drilling holes into
concrete, brick or block. The holes will be correct and the hammer drill
will easily cut through the base material.
#4: Diameter of Hole for Tapcons
diameter is critical for the proper installation of Tapcons. The
tolerance between the concrete screw and the hole size is also critical
for proper installation. Each diameter of Tapcon® has a specific drill
bit diameter that must be used and the bit must meet ANSI standards as
well. Carbide tipped bits can wear down as they are used and this can
decrease the diameter of the hole being drilled, especially in abrasive
material such as brick.
Make sure that the drill bit being used is not
worn out, meets ANSI standards and is being used in a hammer drill.
#5: Depth of Hole for Tapcons
depth of the hole for a Tapcon® should be a minimum of 1/2" deeper into
the base material than the screw will penetrate. This allows space for
the material created during the installation process. Also, this will
ensure that the Tapcons do not bottom out before the head is seated
against the fixture being installed. If the Tapcon® screw bottoms out in
the hole before it is fully inserted and too much torque is applied,
the Tapcon® may break of shear off.
Make sure that the hole is drilled a minimum of
1/2" longer by using the depth gauge on the hammer drill or by putting a
piece of tape on the bit at the proper embedment depth.
#6: Clean Hole for Tapcons
is created during the hole drilling process and must be cleaned out of
the hole before the screw is used to tap threads in the base material.
The dust can build up and create a situation where the screw is unable
to be fully inserted in the hole and if too much torque is applied, the
Tapcon® screw may break of shear off.
The hole must be cleaned of all dust debris by
using a wire brush and a vacuum, compressed air or a blow-out-bulb.
#7: Length of Tapcon®
should be embedded a minimum of 1" and a maximum of 1-3/4" into the
base material. If the screw is embedded into the material deeper than
1-3/4", it may break or shear off. 1-3/4"is the maximum embedment- in
harder, more abrasive base materials, the closer the screw gets to this
maximum, the more likely the screw may break or shear. The lead thread
of one of these screws does all of the cutting of the base material and
may loose its ability to cut if it is installed deeper than the maximum
embedment or close to the maximum embedment in more abrasive materials.
To determine the shortest length of Tapcon® that
can be used, add the thickness of the material being fastened to the
minimum embedment of 1". This will provide the size of the shortest
screw that can be used. To determine the longest Tapcon® that can be
used, add the thickness of the material to be fastened to the maximum
embedment of 1-3/4". These two formulas will give you the minimum and
maximum length of Tapcons to use for any particular application.
The seven reasons
outlined above explain potential causes for Tapcons to break during
installation. Tapcons are strong concrete screws that can be used in
numerous applications. However, they must be used and installed properly
to ensure that they don't break or shear off during your project. By
following the solutions offered above, Tapcon® installations can be a smooth and simple process.
Please remember with all fastening jobs to keep safety in mind. Always follow safety instructions on all tools, and refer to manufacturer's installation instructions when available and always remember to wear safety goggles!
Article written by: Bob Carlisle, President Concrete Fastening Systems, Inc