Bolt Tensioning Guide

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Bolt Tensioning Guide


What is Bolt Tensioning?

Hydraulic Bolt Tensioning is a simple yet effective method that involves the elongating and subsequent tightening of large bolts to accurately meet high levels of preload and tension. The result is a much larger capacity for high loads and more efficiency and accuracy across various environments and industries.

How does Bolt Tensioning Work?

To achieve the levels of tension necessary, Engineers will utilise a variety of different hydraulic-bolt-tension tools. While all devices are different, they typically follow the same pattern:

Firstly, the hydraulic-bolt-tension tool is fitted over the large bolt and locked into place. The tool will then apply a great deal of pressure against the surface while simultaneously pulling against the head of the bolt. This dual pressure will elongate the bolt, allowing the engineer to wound it into a much deeper position. The hydraulic pressure is then released, resulting in a high degree of tension remaining in the head of the bolt against the surface.

When elongating and stretching materials, there are two levels of tensile stress an engineer should know about. The first is what is called the Elastic Region. When a material is put under just enough tensile pressure, it will elongate and return to its original state. However, the second tensile stress level is known as the plastic region. When a material is put under too much stress, it does not go back to its original form once the pressure is released.

To prevent your materials from being stretched to the plastic region, it is crucial to invest in high-quality tensioning tools that are accurate and reputable.

Why use Bolt Tensioning?

Tensioning is a much more reliable and effective strategy for achieving preload when compared to alternatives such as Torquing. Most importantly, Tensioning is aligned with higher levels of safety compliance as it mitigates the number of pinch points, allowing for a much larger capacity for higher load. Tensioning is also more accurate when dealing with large quantities of joints which is vital for achieving structural integrity and preventing problems over time. By using the tensioning method, engineers can also utilise the durability of their tools in a variety of limited and restricted environments and industries.


Bolt Tensioning is not only a more effective, efficient method for workflow. But it can also provide a much safer and more reliable structure that could save lives and prevent problems down the road.


Featured Product

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POWER TEAM® Gauges Digital 9042DG 1500

Product Type: GAUGES
Digital Pressure Gauge 21,750 PSI (1,500 BAR)


  • Digital gauge is easier to read and offers better accuracy(*) than a conventional analog gauge.
  • The laser welded stainless steel sensor & socket and the IP67 weatherproof rating make this product suitable for use in the most demanding of applications.
  • Six pre-programmed engineering units allow technicians to read pressure in the unit of measure most applicable to the process.
  • The gauge also features a bar graph display for enhanced visibility.
  • I ncludes automatic off-battery conservation, pressure tare, minimum pressure memory and maximum pressure.
  • Vibration & shock tested to MIL-STD-202G.
  • Agency Compliance / Approval: RoHS, CE, ASME B40.7, UL, cUL 61010-1.
  • The gauges are calibrated for life at the factory and can be certified in the field if required.

(*) Accuracy is 0.5% Full Scale, including the effects of linearity, hysteresis and repeatability. Comparison made against a 9040 analog gauge – including friction, parallax and other reading errors.

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bolt tensioning

Typical Setup:

1Protective rubber boot52,000 hr. life, (2) AA (LR6) batteries
2Back-light and large 0.48″ (12.2 mm) display easy reading6Typical Cycle Life: 10,000,000
3Displays in multiple engineering units: psi, bar, mPa, inHg, kg/cm279/16-18 UNF-2B (High Pressure 60° cone port.)
4Weatherproof IP67 enclosure

TJI Solutions – Torquing Your Language!!

Scotland: 01224 063 680

England & Wales: 0191 917 0576

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