Hydraulic Tensioning
Bolt Tensioners
ToughTorq hydraulic bolt tensioners apply axial load directly to the stud for controlled preload on critical bolted joints. The range includes spring-return systems, load-return systems with modular adaptor kits, and compact multistage tensioners for high-capacity applications with restricted radial clearance.
Controlled Preload
Apply hydraulic load directly to the stud
Hydraulic bolt tensioning stretches the stud axially so the nut can be positioned while the bolt is under controlled load. This reduces dependence on torque-friction relationships and supports repeatable loading on critical joints.
Direct hydraulic bolt preload
Spring-return, load-return, and multistage configurations
Simultaneous multi-bolt tensioning capability
Quick-connect hydraulic interfaces
Wide tooling coverage for multiple bolt and stud sizes
Ultra-high-pressure hydraulic operation
Application-specific adaptors and bridges
Custom configurations available for joint requirements
Spring-Return Series
Automatic spring-return tensioners
Spring-return models cover a broad thread range and are designed for fast repeated operation, quick hydraulic connection, and simultaneous multiple-tool tensioning.
| Model | Thread Range | Max Tension Force | Effective Area | Max Stroke | Return |
|---|---|---|---|---|---|
| TT-ST1 | M24–M27 | 63,396 lbf | 2.92 in² | 0.31 in | Automatic spring return |
| TT-ST2 | M24–M36 | 101,614 lbf | 4.67 in² | 0.39 in | Automatic spring return |
| TT-ST3 | M39–M48 | 150,847 lbf | 6.94 in² | 0.39 in | Automatic spring return |
| TT-ST4 | M39–M48 | 226,832 lbf | 10.43 in² | 0.39 in | Automatic spring return |
| TT-ST5 | M52–M68 | 345,756 lbf | 15.89 in² | 0.39 in | Automatic spring return |
| TT-ST6 | M72–M90 | 571,914 lbf | 26.3 in² | 0.47 in | Automatic spring return |
| TT-ST7 | M90–M100 | 722,986 lbf | 33.23 in² | 0.47 in | Automatic spring return |
Load-Return Series
Modular load-return tensioners
Load-return models use modular adaptor kits, detachable rotational bridges, twin hydraulic ports, and a piston stroke indicator for demanding threaded connections and multi-tool operation.
| Model | Thread Range | Max Load | Working Pressure | Effective Area | Stroke | Weight |
|---|---|---|---|---|---|---|
| TTGT1-LCB | M16-M30 | 50,425 lbf | 21,756 psi | 2.32 in² | 0.39 in | 6.6 lb |
| TTGT2-LCB | M30-M39 | 90,261 lbf | 21,756 psi | 4.15 in² | 0.39 in | 9 lb |
| TTGT3-LCB | M39-M52 | 172,856 lbf | 21,756 psi | 7.95 in² | 0.39 in | 15.4 lb |
| TTGT4-LCB | M52-M68 | 329,772 lbf | 21,756 psi | 15.16 in² | 0.39 in | 26.9 lb |
| TTGT5-LCB | M68-M80 | 508,383 lbf | 21,756 psi | 23.37 in² | 0.39 in | 41.2 lb |
| TTGT6-LCB | M80-M95 | 639,604 lbf | 21,756 psi | 29.41 in² | 0.39 in | 61.3 lb |
Multistage Series
Compact high-capacity tensioning
TTE multistage tensioners operate at up to 21,756 psi and combine a compact outside diameter with high pulling capacity for applications where radial clearance is restricted.
| Model | Bolt | Max Pulling Capacity | Working Pressure | Stroke | Effective Area | Outside Diameter | Weight |
|---|---|---|---|---|---|---|---|
| TTE-24 | M24 | 69,016 lbf | 21,756 psi | 0.28 in | 3.52 in² | 2.32 in | 11 lb |
| TTE-30 | M30 | 103,637 lbf | 21,756 psi | 0.28 in | 5.3 in² | 2.83 in | 14.6 lb |
| TTE-33 | M33 | 133,761 lbf | 21,756 psi | 0.28 in | 6.83 in² | 3.11 in | 17.6 lb |
| TTE-36 | M36 | 152,870 lbf | 21,756 psi | 0.39 in | 7.81 in² | 3.33 in | 23.6 lb |
| TTE-39 | M39 | 179,847 lbf | 21,756 psi | 0.39 in | 9.19 in² | 3.6 in | 28.2 lb |
| TTE-42 | M42 | 207,274 lbf | 21,756 psi | 0.39 in | 10.59 in² | 3.88 in | 35.3 lb |
| TTE-45 | M45 | 244,143 lbf | 21,756 psi | 0.39 in | 12.47 in² | 4.21 in | 46.3 lb |
| TTE-48 | M48 | 291,352 lbf | 21,756 psi | 0.39 in | 14.89 in² | 4.57 in | 48.5 lb |
| TTE-56 | M56 | 373,183 lbf | 21,756 psi | 0.39 in | 19.06 in² | 5.16 in | 52.9 lb |
| TTE-64 | M64 | 528,301 lbf | 21,756 psi | 0.39 in | 29.14 in² | 5.82 in | 103.6 lb |
System Selection
Size the tensioner to the joint
Tensioner selection depends on the bolt and thread specification, required preload, available stud projection, nut dimensions, radial clearance, working pressure, joint geometry, and whether tools will be operated individually or simultaneously.
Bolt diameter
Thread pitch
Required bolt load
Stud projection
Nut size
Radial clearance
Working pressure
Joint geometry
Complete System
Match all ultra-high-pressure components
Applications
Critical bolted joints
Flange joints
Power generation
Wind turbine bolting
Oil and gas equipment
Pressure vessels
Heavy structural connections
Large rotating equipment
Shutdown and turnaround work
Distribution
Find a ToughTorq distributor
Connect with the ToughTorq distribution network for tensioner sizing, hydraulic-system selection, and technical support.
Find a DistributorPurchase, Rental & Service
Commercial support through JAM Torque
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