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Safety when Bolt Tensioning

In this article, we look at the key safety aspects you need to check when using the Bolt Tensioning method

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Learn about safety when Bolt Tensioning

Bolt tensioning is one of the most accurate ways of tightening bolts, but it needs to be completed correctly with proper processes and procedures. 

In this video, Global Product Manager Ashish Malhotra, takes you through all of the key aspects you must consider when bolt tensioning.

Bolt Protrusion

  • Check the bolt protrusion is at least 1x the diameter of the bolt

Diameter and thread

  • Ensure the correct diameter and thread, for both tool and joint.
  • Check marking on the tool along with the specifications.


  • Ensure the rundown of tool does not rotate the bolt. This can lead to a lower thread engagement than the minimum 1x diameter of the bolt.
  • Do not use high torque tools to run down the puller bar, this can damage the thread of the bolt.

Multiple tool connection

  • Always leave a coupler at the end, rather than a nipple.
  • Ensure couplers are locked.
  • Check the hose for cracks.
  • Check couplers: Worn out nipples/couplers sets can get stuck making the release potentially dangerous. 

Operator position

  • Never stand in line of pressurization.
  • Do not hold onto the coupler during pressurization.
  • Do not hold, and try to avoid moving the pressurized swivel.


  • Do not interchange low-pressure couplers for high-pressure ones.
  • Check for MWP (Maximum Working Pressure) of the tool.
  • Never try to remove with a spanner.

Max stroke indicator

  • Check for max stroke indicator for when to stop, as over-stroke will lead to oil leakage and damaged seals.
  • WTB (Wind Tensioner) have over-stroke protection, but never exceed the max stroke indicator.

Click wrench

  • Use correctly and do not push more than set torque.


  • Once mounted, the puller bar or threaded insert needs to be back off by just over a half turn to start. This will compensate the relaxation of the joint, avoiding the tensioner getting stuck.
  • Ensure this is accounted for with bolt protrusion to ensure at least 1x diameter of bolt remains.

Learn more about Bolt Tensioning

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