What percentage of clamping force drop-off may occur when reusing bolts on spade terminals?

Reusing bolts on spade terminals can lead to a significant reduction in clamping force due to various factors such as wear, fatigue, and potential deformation of the bolt threads. An approximate 30 percent drop-off in clamping force is often cited as a conservative estimate in the industry for reused bolts.

This percentage reflects that, over time and with repeated use, bolts may not provide the same level of tension or securing capability as they did when they were first installed. This reduction can compromise the integrity of the connection, leading to potential electrical issues or mechanical failure due to loosening over time. Therefore, it is generally recommended to use new bolts when making connections in critical applications to ensure optimal performance and safety.