Check that each bolt to be tensioned is visually free from obvious thread defects. Make sure all Nuts and Thread Inserts are free to rotate on the bolts. Try a Thread Insert on a bolt and make sure they are correct mating threads.

Ensure there is sufficient stud protruding from the top of the nuts. A minimum of 1 x stud diameter is essential and also a minimum of 2 x D from top of the bolt to the base of the nut.

Also make sure full thread engagement is available through the hexagon nut on the opposite end of the studs being tensioned.

Check that all calculations pertaining to the tensioning procedure, including pressures, bolt loads, etc are available and have been reviewed by a qualified engineer with bolting experience.

Ensure that personnel are fully trained in bolt tensioning procedures and have thoroughly read this guide and safety notes.

Ensure the pump reservoir is filled and an adequate oil volume is available.

Ensure the correct and preferred grade of oil is used in the pump. Refer to the applicable pump product information document. If the incorrect grade of oil is used, the life and performance of the system will deteriorate.

Be sure all personnel are aware of the maximum working pressure and maximum piston stroke of the tensioners. These details are hard stamped on the tensioner bodies

Fit the nut socket over the hexagon nut.

Fit the tensioner over the stud until it sits flat on the bolted joint. Ensure the bridge access window faces radially out with easy accessibility to the tommy holes in the nut socket. Ensure the hydraulic connections are also facing radially outwards.

Place the thread insert into the tensioner bore until contact is made with the top face of the bolt. Using the tommy bar rotate the thread insert downwards until the thread insert head makes contact with the top face of the tensioner piston.

Ensure the pump pressure release valve is fully open and the pump is off. Connect the link hoses to the installed tensioners. See also configuration instructions for different tensioning procedure configurations and illustrations.

Ensure the two halves of the bolted joint are full aligned.

Fit the tensioners to all of the bolts See also Tensioner System Configuration or illustrations of tensioner set up and Tensioner Installation for installation instructions.

Using link hoses connect the tensioners together and to a suitable pump unit. See also Tensioner System Configuration for configuration illustrations and for link hose connection instructions. Before connecting a link hose to the pump unit make sure the pump is turned off and the pressure release valve is in the open position.

Ensure the tensioning team is aware of the target working pressure. Only qualified engineers who have been appropriately trained or have suitable experience in bolting technology should perform bolting calculations.

For pump operation refer to the supplied pump instruction document. Operate the pump unit and pressurize the system to 1000psi (70 bar) and check that the pressure is holding steady. If the pressure drops investigate the problem looking for leaks.

Once the pressure is holding steady, continue to pressurize the system up to the target calculated working pressure. Continually monitor for piston over stroke, should any piston over stroke indicator become visible immediately stop the pump to hold the pressure, go to step 8 then 9 then 10. Then recommence the tensioning procedure from step 5.

Once the target working pressure is reached, stop the pump to hold pressure. Monitor the pump pressure gauge to ensure the pressure is neither falling nor rising.

Once the pressures is holding steady approach the tensioners and by using a tommy bar inserted into the nut socket holes rotate the nuts firmly against the joint face. Repeat until all of the nuts have been firmly seated against the bolted joint.

Slowly open the pressure relief valve, the pressure will drop to zero.

(OPTIONAL) If the pistons are close to their fully extended position, use a tommy bar inserted into the thread inserts and wind down the inserts to close the pistons to their zero stroke position.

Repeat steps 5 through 10 for a second time.

Repeat steps 5 through 10 for a third time.

Using a tommy bar inserted into the holes in the thread insert head, rotate the thread insert to close the tensioner piston to zero. Repeat until the pistons are fully closed.

Dis-connect all hydraulic hoses and remove all tensioners from the bolted joint. The tensioning procedure is considered complete.

Fit the Tensioners to the bolts and connect the link hoses. See also Tensioner System Configuration for configuration guide and see Tensioner Installation for an installation guide.

Before commencing pressurization, back off all of the thread inserts by 5mm (0.2”). Ensure there is still enough thread engagement between the thread inserts and the bolt thread protrusions.

For pump operation refer to the supplied pump instruction document. Operate the pump unit and pressurise the system to 1000psi (70 bar) and check that the pressure is holding steady. If the pressure drops investigate the problem looking for leaks.

Once the pressure is holding steady, continue to slowly increase the pressure, continually monitor a single joint nut (tensioner end) for rotation. Use a tommy bar inserted into the nut socket. Once the break loose pressure (BLP) is found, stop the pump to hold the pressure and make a note of the pressure. Once the pressure is holding steady, continue to slowly increase the pressure, continually monitor a single joint nut (tensioner end) for rotation. Use a tommy bar inserted into the nut socket. Once the break loose pressure (BLP) is found, stop the pump to hold the pressure and make a note of the pressure.

Break Loose Pressure (BLP) is the pressure at which the user can rotate one of the joint nuts (tensioner end) by hand.

Make sure the pressure is holding steady and using a tommy bar inserted in the nut socket, back off every joint nut (tensioner end) by 3mm (1/8”). Do not back off the nut to a greater value than the distance that you backed off the thread insert in step 2.

If the nuts are difficult to rotate at this break loose pressure, slightly increase the pressure until the nuts become loose. Never exceed the maximum working pressure of the tensioner. Make sure that the bolt material and joint material can withstand the load you are applying.

Slowly release the pressure to zero.

Using a tommy bar, tighten down the thread inserts to fully close the pistons. Repeat until all of the pistons are fully closed.

Disconnect all hoses and remove all tensioners from the joint.

The de-tensioning procedure is complete.

Fit tensioners to every other bolts and connect the link hoses. See also Tensioner System Configuration for configuration guide and see Tensioner Installation for an installation guide.

Before commencing pressurization, back off all of the thread inserts by 5mm (0.2”). Ensure there is still enough thread engagement between the thread inserts and the bolt thread protrusions.

For pump operation refer to the supplied pump instruction document. Operate the pump unit and pressurize the system to 1000psi (70 bar) and check that the pressure is holding steady. If the pressure drops investigate the problem looking for leaks.

Break Loose Pressure (BLP) is the pressure at which the user can rotate one of the joint nuts (tensioner end) by hand.

Once the pressure is holding steady, continue to slowly increase the pressure, continually monitor a single joint nut (tensioner end) for rotation. Use a tommy bar inserted into the nut socket. Once the break loose pressure (BLP) is found, stop the pump to hold the pressure and make a note of the pressure.

Make sure the pressure is holding steady and using a tommy bar inserted in the nut socket, back off every joint nut (tensioner end) by 3mm (1/8”). Do not back off the nut to a greater value than the distance that you backed off the thread insert in step 2.

If the nuts are difficult to rotate at this break loose pressure, slightly increase the pressure until the nuts become loose. Never exceed the maximum working pressure of the tensioner. Make sure that the bolt material and joint material can withstand the load applied.

Slowly release the pressure to zero.

Using a tommy bar, tighten down the thread inserts to fully close the pistons. Repeat until all of the pistons are fully closed.

Reposition the tensioners and link hoses to the remaining 50% of bolts.

Repeat steps 2 through to 7 on the remaining 50% of bolts.

Disconnect all hoses and remove all tensioners from the joint.

The de-tensioning procedure is complete.

Ensure the two halves of the bolted joint are fully aligned. Number each bolt alternatively “1” and “2”.

Fit the tensioners to all the bolts marked “1”, see also Tensioner Installation for installation instructions.

Using link hoses connect the tensioners together and to a suitable pump unit. See also Tensioner System Configuration for configuration illustrations and for link hose connection instructions. Before connecting a link hose to the pump unit make sure the pump is turned off and the pressure release valve is in the open position.

Ensure the tensioning team is aware of the target “A” pressure (1st pass working pressures) and “B” pressure (2nd pass working pressure). “A” pressures are generally higher than “B” pressures to compensate for load loss. Bolting calculations should only be carried out by trained and qualified engineers who have been appropriately trained or have suitable experience in bolting technology.

For pump operation, refer to the supplied pump instruction document. Operate the pump unit and pressurize the system to 1000psi (70 bar) and check that the pressure is holding steady. If the pressure drops investigate the problem looking for leaks.

Once the pressure is holding steady, continue to pressurize the system up to the target calculated working pressure. Continually monitor for piston over stroke, should any piston over stroke indicator become visible immediately stop the pump to hold the pressure, go to step 9 then 10 then 11. Then recommence the tensioning procedure from step 5.

Once the target “A” (1st pass pressure) is reached, stop the pump to hold pressure. Monitor the pump pressure gauge to ensure the pressure is neither falling nor rising.

Once the pressures is holding steady approach the tensioners and by using a tommy bar inserted into the nut socket holes rotate the nuts firmly against the joint face. Repeat until all of the nuts have been firmly seated against the bolted joint.

Slowly open the pressure relief valve, the pressure will drop to zero.

(OPTIONAL) If the pistons are close to their fully extended position, use a tommy bar inserted into the thread insert and wind down the inserts to close the pistons to their zero stroke position.

Repeat steps 5 through 10 for a second time.

Repeat steps 5 through 10 for a third time.

Second pass procedure

Reposition the tensioners on to the remaining 50% of bolts, bolts marked “2” .

Ensure the tensioning team are aware of the target “B” pressure (2nd pass pressure). “B” pressures are generally lower than “A” pressures. Bolting calculations should only be carried out by trained and qualified engineers who have been appropriately trained or have suitable experience in bolting technology.

For pump operation refer to the supplied pump instruction document. Operate the pump unit and pressurize the system to 1000psi (70 bar) and check that the pressure is holding steady. If the pressure drops investigate the problem looking for leaks.

Once the pressure is holding steady, continue to pressurize the system up to the target “B” pressure (2nd pass pressure). Continually monitor for piston over stroke. If the piston over stroke indicator becomes visible on any of the tensioners, immediately stop the pump to hold the pressure. Go to step 18, 19, 20. Then recommence the tensioning procedure from step 15.

Once the target working pressure is reached, stop the pump to hold pressure. Monitor the pump pressure gauge to ensure the pressure is neither fall or rising.

Once the pressures is holding steady approach the tensioners and by using a tommy bar inserted into the nut socket holes rotate the nuts firmly against the joint face. Repeat until all of the nuts have been firmly seated against the bolted joint.

Slowly open the pressure relief valve, the pressure will drop to zero.

(OPTIONAL) If the pistons are close to their fully extended position. Using a tommy bar inserted into the holes in the thread insert head, rotate the thread insert to close the tensioner piston to zero. Repeat until the pistons are fully closed.

Repeat steps 15 through 19 for a second time, to pressure “B”.

Repeat steps 15 through 19 for a third time, to pressure “B”.

Using a tommy bar inserted into the holes in the thread insert head, rotate the thread insert to close the tensioner piston to zero. Repeat until the pistons are fully closed.

Disconnect all hydraulic hoses and remove all tensioners from the bolted joint. The tensioning procedure is considered complete.

Install two tensioners on two 1st 50% bolts (marked “1”), diametrically opposite each other.

Connect the hydraulic link hoses.

Pressurize the system to “B” pressure, hold the pressure.

Using a tommy bar inserted into the nut sockets try to tighten down the nuts further by hand:

This section details the replacement of “Clip - In” type high pressure seals.

Insert the inner seal into the seal housing; the seal clip fits into the seal clip housing.

Using a blunt nose tool push the seal fully into the seal clip housing, work around the periphery of the seal until the seal is completely inserted into the clip housing.

Insert the outer seal into the seal housing; the seal clip fits into the seal clip housing.

Using a blunt nose tool push the seal fully into the seal clip housing, work around the periphery of the seal until the seal is completely inserted into the clip housing.