Failure Files

An assembly line mix-up at Ford's Kansas City plant resulted in the installation of incorrect lower steering shaft fasteners, creating a severe risk of steering detachment at high speed. Learn the engineering lessons behind steering shaft pinch bolts and proper fastener selection.

On February 12, 2002, bow truss 13 fell during construction of Pittsburgh’s David L. Lawrence Convention Center, killing ironworker Paul Corsi Jr. Investigators and the fastener supplier traced a critical error: thinner silver locking nuts were used as the primary load path instead of the thick black heat-treated anchor nuts the joint required.

Ohio DOT pulled aluminum overhead sign trusses after cracks started at every stainless bolt hole. University labs confirmed galvanic corrosion: stainless bolts and washers made the aluminum the anode. The lesson is fastener selection, not just inspection.

On December 18, 2012, all 36 H4 connector bolts on a Gulf of Mexico lower marine riser package failed by hydrogen-induced stress corrosion cracking. BSEE’s QC-FIT report traced a major cause to zinc electroplating done to an outdated ASTM standard without the required post-bake. Here’s what that coating choice still teaches about matching fasteners to the environment.

In July 2006, 26 tons of concrete ceiling panels collapsed inside Boston's I-90 Connector Tunnel, killing one and injuring another. The NTSB investigation confirmed the cause: the wrong type of epoxy was used to anchor the hanger bolts. Fast-set epoxy creeps under sustained deadweight load. The right anchor would have held for decades.

In October 2020, corroded valve bonnet bolts at BASF's Geismar, Louisiana chemical plant catastrophically failed, releasing 554 pounds of toxic chlorine gas. The U.S. Chemical Safety Board confirmed the cause: the wrong fastener material in a chemical service environment. Here's what the right bolt choice looks like.

In May 2026, GM recalled 2,464 full-size SUVs — Escalades, Tahoes, Suburbans, and Yukons — because dealers had been installing the wrong wheel hub bolts on vehicles with 24-inch wheels. The NHTSA filing confirmed the root cause: the parts catalog didn't distinguish between wheel sizes. Here's what the physics of a bigger wheel have to do with bolt selection.

In 1985, a concrete ceiling collapsed onto a swimming pool in Uster, Switzerland, killing 12 people. The confirmed cause: the wrong grade of stainless steel — V2A (Type 304) without molybdenum — was used for load-bearing suspension rods in a chloride-rich pool environment, leading to silent, catastrophic stress corrosion cracking.