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ITH Hydraulic Bolt tensioning system

ITH Hydraulic Bolt tensioning system
  • Most accurate bolt tensioning system with control on dial
  • Easy simultaneous application of multiple cylinders
  • Enormous time savings compared to heat or torsion treatment
  • Tightening and loosening of bolts even under the most difficult situations such as heat (up to 650°), corrosion etc.

ITH Single-stage bolt tensioning cylinders, type ES, for bolt qualities 10.9
For use in areas where access is free in the radial direction but restricted in the axial direction

Photo
Type / Model No.

pre-tensioning
force kN

Bolt size
M

Bolt nut
SW

Dia.
Ø mm

Height
mm

ITH ES Detail
ES 20
200
M20x2.5
3/4"
30
1 1/4"
65
94
ES 24
290
M24x3
7/8"
36
1 7/16"
78
102
ES 27
380
M27x3
1"
41
1 5/8"
86
108
ES 30
460
M30x3.5
1 1/8"
46
1 13/16
97
106
ES 33
570
M33x3.5
1 1/4"
50
2 "
107
114
ES 36
670
M36x4
1 3/8"
55
2 3/16"
117
118
ES 39
800
M39 4
1 1/2"
60
2 3/8"
127
125
ES 42 920 M42x4.5 1 5/8" 65 2 9/16" 137 134
ES 45 1080 M45x4.5 1 3/4" 70 2 3/4" 148 135
ES 48 1220 M48x5 1 7/8" 75 2 5/16" 158 140
ES 52 1450 M52x5 2" 80 3 1/8" 169 151
ES 56 1680 M56x5.5   85   179 158
ES 60 2010 M60x5.5 2 1/4" 90 3 1/2" 199 167
ES 64 2210 M64x6 2 1/2" 95 3 7/8" 211 172
ES 68 2600 M68x6   100 4" 228 180
ES 72 2880 M72x6 2 3/4" 105 4 1/2" 238 186
ES 80 3610 M80x6 3" 115 4 5/8" 267 202
ES 90 4650 M90x6 3 1/2" 130 5 3/8" 300 220
ES 100 5830 M100x6 4" 145 6 1/8" 340 240

Equipment:

  1. Handle, can be turned and folded over, enabling the bolt tensioning cylinder to be transported safely and conveniently.
  2. Safety cover, ensures that the socket remains in the cylinder on excessive loading.
  3. Piston spring loaded, when the pressure is released, the piston is returned automatically into its end position.
  4. Pinion gear, enables the nut to be applied simply and exactly from outside without using an additional pin.
  5. Inspection groove, for inspecting the exact position of the nut when adjusting it against the flange.
  6. Patented fracture safety device.
ITH bolt tension details
click on picture to enlarge
Design:

One unit allows the tensioning or loosening of various bolt sizes. To change over to a different size the changeable bush as well as the rotating sleeve has to be changed.
  1. Changeable bush: joining part between bolt stud and bolt tensioning cylinder
  2. Rotating sleeve: joining part between bolt nut and the external gear drive
Ith Bolt tensioning system

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ITH Multiple-stage bolt-tensioning cylinders, type MS
For use in areas where access is free in the axial direction but restricted in the radial direction

Photo
Type / Model No.

pre-tensioning
force kN

Bolt size
M

Bolt nut
SW

Dia.
Ø mm

Height
mm

Ith MS details
MS 20
200
M20 x 2.5
3/4"
30
1 1/4"
51
156
MS 24
290
M24 x 3
7/8"
36
1 7/16"
59
192
MS 27
380
M27 x 3
1"
41
1 5/8"
65
188
MS 30
460
M30 x 3.5
1 1/8"
46
1 13/16
73
182
MS 33
570
M33 x 3.5
1 1/4"
50
2 "
79
198
MS 36
670
M36 x 4
1 3/8"
55
2 3/16"
84
240
MS 39
800
M39 x 4
1 1/2"
60
2 3/8"
90
248
MS 42 920 M 42 x 4.5 1 5/8" 65 2 9/16" 98 253
MS 45 1080 M45 x 4.5 1 3/4" 70 2 3/4" 107 256
MS 48 1220 M48 x 5 1 7/8" 75 2 5/16" 112 260
MS 52 1450 M52 x 5 2" 80 3 1/8" 123 268
MS 56 1680 M56 x 5.5   85   129 288
MS 60 2010 M60x5.5 2 1/4" 90 3 1/2" 136 328
MS 64 2210 M64x6 2 1/2" 95 3 7/8" 146 330
MS 68 2600 M68x6   100 4" 155 346
MS 72 2880 M72x6 2 3/4" 105 4 1/2" 164 358
MS 80 3610 M80x6 3" 115 4 5/8" 183 385
MS 90 4650 M90x6 3 1/2" 130 5 3/8" 203 414
MS 100 5830 M100x6 4" 145 6 1/8" 232 446

Equipment:

  1. Handle, can be turned and folded over, enabling the bolt tensioning cylinder to be transported safely and conveniently.
  2. Safety cover, ensures that the socket remains in the cylinder on excessive loading.
  3. Piston spring loaded, when the pressure is released, the piston is returned automatically into its end position.
  4. Pinion gear, enables the nut to be applied simply and exactly from outside without using an additional pin.
  5. Inspection groove, for inspecting the exact position of the nut when adjusting it against the flange.
  6. Patented fracture safety device.
Bolt tensionsing detail
click on picture to enlarge
Design:

One unit allows the tensioning or loosening of various bolt sizes. To change over to a different size the changeable bush as well as the rotating sleeve has to be changed.
  1. Changeable bush: joining part between bolt stud and bolt tensioning cylinder
  2. Rotating sleeve: joining part between bolt nut and the external gear drive
ITH MS Details
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ITH Hydraulic Pumps
Photo
Type / Model No.

Motor

Power Oil capacity

Dimension
mm

Weight
kg
ITH Electric pump
EA1
380 / 415V 50Hz IP54
1.1 kW 6 l
550x310x250
29.5

ITH Pneumatic Pumps
Photo
Type / Model No.

Motor

Max. air pressure Oil capacity Oil
pressure

Oil
volume

Dimension
mm
Weight
kg
ITH Air pump
PA 1
Air
4 bar 6 l 1600-2750 bar
3.5 - 6.0 litre
590x250x300 25.0

ITH Hand operated hydraulic pump
Photo
Type / Model No.

Stages

Oil
volume

Dimension
mm
Weight
kg
ITH Hand Pump
HA 1
single
2.5 litre
800x230x310 10.5
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ITH Hydraulic accessories
Photo Description
ITH Coupling High pressure 90° angle coupling, Part-No. 34.0060
ITH Adaptor High pressure multiple couplings, to couple up to 8 individual hydraulic hoses for simultaneous use of hydraulic bolt tensioners
ITH Hydraulic hose High pressure hydraulic hoses, standard lengths 3m, 4m, 5m, 8m, available also in any other length
ITH Coupling hydraulique High pressure hydraulic couplings and adapters available on request
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Principles of bolt tensioning
Bolts are the most commonly used type of machine element for detachable constructions. Using bolts different parts are connected using the pretension of a bolt. To achieve this tension there are various methods available today:

Torsion-Method

The most commonly used method is the turning of the bolt nut on the thread against the bearing surface. The bolt shaft is stretched through the lead of the thread.
Advantage: simple, cost effective, universal applications
Disadvantage: tightening bolt using this method produces inconsistent pretension results due to varying friction coefficients from µ-0.07-0.2. The tolerances can be as much as 100%!

Out of the total torque applied in tightening, roughly 10% is used for bolt tension, while the remaining 90% is used in overcoming the friction (50% friction loss under head, 40% friction loss in thread)
If 85% to 90% of your torque is consumed by friction, then this only leaves 15% to 10% for actual bolt tension. 10% is 33% less than 15%. So the 5% difference in friction gives you a 33% variation in bolt tension. And if you use a much better lubricant, then maybe only 80% to 87% of the torque is consumed by friction. This leaves 20% to 13% for actual bolt tension. 13% is 35% less than 20% (20-13=7. Then 7/20 = 35%). So the 7% difference gives you a 35% variation in tension. But, this reduction in torque - needed to get the same bolt tension - leads to a 25% reduction in the required torque, but the variation in friction still leaves you with a 35% variation in bolt tension. So the friction variation is usually the same or worse, when you use lubricants.

Stretch-Method

Two different stretch-methods are common:

Temperature Stretch Method Hydraulic Stretch Method
the lengthening of the stretch bolt is achieved by heating up the bolt with heating bars until the desired length is reached
Using the ITH hydraulic stretch method, the bolt stud is stretched to the desired length using ITH hydraulic bolt tensioning cylinders and the bolt nut is turned onto the bearing surface by hand. This is by far the most accurate way of tightening a bolt in critical applications. By creating a straight pulling tension the bolt stud can be stretched up to the stretch limit.
Advantage:
Advantage:
no need for additional space for bolt tensioning tools
very high accuracy and repeatability, pure pulling tension on the diagonal stretch surface, compact construction, low in emissions, ideally suited for the simultaneous tightening of multiple bolts on one construction, fast and cost-effective process respective to the quality, unlimited applications, tightening and loosening of various sized bolts possible with one hydraulic bolt tensioning cylinder
Disadvantage:
Disadvantage:
time consuming, limited applications, requires the use of special bolts with bores in axial direction (equivalent to the thermal element), the entire construction is being heated up
bolt thread has to be long enough to stand out at least 0.6 - 1 times the size of the diameter of the bolt above the bolt nut.
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last updated 18.8.15
 

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