Concrete Stressing Products

A complete solution designed for the challenging demands of concrete stressing

Enerpacs Global Leadership In Products and Services Expanded to Markets of Prestressed Concrete, Cable Stay, Mining, Geotechnical, and Barrier Cable
Precision Sure-Lock (Dallas, Texas) and TT Fijnmechanica (Roermond, The Netherlands), two of the largest suppliers of prestressing products, has combined with Enerpacs global presence to provide an unprecedented range of products and services throughout the world. From wedge anchoring products to tensioning jacks to fabrication equipment, Enerpacs three manufacturing locations have over 60 years of experience and knowledge providing products that have PTI, ICC, IBC and ETAG acceptance. Enerpacs SURE-LOCK branded products are the most trusted and recognized names in the industry. We provide over 400 anchorage products, including wedges, chucks, and anchor plates. Enerpacs SURE-LOCK and SURE-LOCK II single strand anchorage systems meet the requirements of the International Code Councils (ICC) Acceptance Criteria 303. All SURE-LOCK strand chucks and wedges are manufactured in-house, using only the highest quality steel. Where appropriate, components are heat-treated and tested to rigorous specications, including 100% magnaux inspection, hardness testing and individual load-testing to ensure reliable performance. Enerpac has built a strong reputation supplying tensioning components for the worlds largest ETAG approved system holders. Wedges of all sizes and anchor heads up to 59 inches (1500 mm) in diameter are produced using state-of-the-art CNC machining centers. 100% inspection of size and laser checking thread tooth proles are just a few ways Enerpac meets and exceeds our customers high expectations for quality, reliability, and delivery. Enerpac has also broadened its line of production equipment and eld-proven installation equipment, such as stressing rams, multistrand jacks, hydraulic pumps, tools and accessories. Around the globe, Enerpac is committed to be the rst choice provider of Pre-stressed/Post-Tensioned concrete products.

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Index

Category

Description

Series

Page

One time use products: Wedges, Anchors, Splice Chucks and Barrel Chucks

4 6 8 9

SURE-LOCK

Multi-Use products: Strand Chucks, Splice Chucks and Wedges Cable Barrier products: GRABB-IT Anchors and Ferrule Loops

Accessories: Anchor Cleaning Tool, Hand Wedge Setter, more

Tensioning Jacks

Mono-strand: Tensioning Jacks, Noses and Gripper sets Multi-strand: Tensioning Jacks Hydraulic Pumps: For use with Mono-strand Tensioning Jacks Hydraulic Pumps: For use with Multi-strand Tensioning Jacks Strand Processing Equipment

DA PTJ SCJ

10 14 16 18 22

Hydraulic Pumps

ZU ZE, ZG PE, EG

One-Time Use Products

Shown left to right: F5PF, F5CA, F5CHR, F500SL2 and F5TCA

Trusted and Recognized Brand

Contact Enerpac @ 972-287-2390 Custom anchors and wedges are available to meet your unique stressing needs.

SURE-LOCK Wedges Custom sizes and congurations Pulling wedges Cable-stay wedges SURE-LOCK Anchors SURE-LOCK Mono-strand castings SURE-LOCKII Mono-strand castings Multi-strand wedge plates SURE-LOCK Chucks Splice chucks safely connect two sections of strand RCB chucks for In-Pocket stressing Chucks include 2-part wedge without ring (available with other wedge types) ICC-ES report ESR-2381 ensures Enerpacs SURE-LOCK and SURE-LOCKII single strand anchorage systems comply with the prevailing building codes
One-time use Wedges, Anchors and Chuck Bodies Strand Size (in)

Tensioning Jacks A complete line of eldproven hydraulic tensioning jacks for both mono-strand and multi-strand applications.

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10

Anchor Heads Machined anchor heads available in customer specied sizes and hole patterns.

2-Part Wedge 2-Part Wedge 3-Part Wedge SURE-LOCK SURE-LOCKII SURE-LOCK Chuck Body RCB Chuck Model Number with Ring with Ring 0.5" Anchor 0.5" Anchor 0.6" Anchor Model Number Body Model Model Number Model Number Model Number Model Number Model Number Number

0.25 0.38 0.43 0.50-0.52 0.50-Jumbo 0.60-0.62

F250SL2 F375SL2 F437SL2 F500SL2 F500SLJ2 F600SL2

F250SL2R F375SL2R F437SL2R F500SL2R F500SLJ2R F600SL2R

F250SL3R F375SL3R F437SL3R F500SL3R F500SLJ3R F600SL3R

F5CA F5CA F5CA F5CA

F5TCA F5TCA F5TCA F5TCA

F6CA F6CA

F8B F8B F8B F8B F13B F13B

RCB RCB RCB RCB

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One-Time Use Products

Unbonded Post-Tensioning Systems rely on critical SURE-LOCK Anchor and Wedge components to transfer compressive and load balancing forces to concrete.

SURELOCK

Strand Sizes:

0.25 to 0.60 inches

Photo: Suncoast Post-Tension

Wedge Type:

2-part, 3-part
Coating Type:

Unplated
Description Weight (oz)

Pocket Former and Chair Strand Size (in) Model Number

0.50 0.50 0.50 0.50 0.60

F5PF F545PF F5CHR F5SPT F6PF

1.5 Inch pocket former 45 degree pocket former 1.5 inch intersectional chair Split pocket former Pocket former

1.0 1.9 0.6 0.3 2.1

Splice Chucks Strand Size (in) Model Number Description Weight (lbs)

0.25 0.38 0.43 0.50 0.60

F6250 F6375 F6437 F6500 F6600

Splice chuck Splice chuck Splice chuck Splice chuck Splice chuck

3.5 3.5 3.5 3.5 3.5

Chucks and Wedges Strand Size (in) Model Number Description Body Wedge Weight (lbs)

0.25 0.38 0.43 0.50 0.50 0.60 0.60

F5250 F5375 F5437 F5500 F5500R3 F5600 F5600R3

Chuck and 2-part wedge without ring Chuck and 2-part wedge without ring Chuck and 2-part wedge without ring Chuck and 2-part wedge without ring Chuck and 3-part wedge with ring Chuck and 2-part wedge without ring Chuck and 3-part wedge with ring

F8B F8B F8B F8B F8B F13B F13B

F250SL2 F375SL2 F437SL2 F500SL2 F500SL3R F600SL2 F600SL3R

1.0 2.0 2.0 2.0 2.0 2.1 2.1

Multi-Use Products
Shown longest to shortest: Splice Chucks, Strand Chucks and Anchor Chucks

High Quality, Durability and Reliability

Multi-Use Strand Chucks N ormally used at the stressing end of a bed. Bayonet cap offer less likelihood of damage to cap during tensioning. Includes cap, spring, wedge and body Easy opening, cleaning and inspection Replacement parts available

Multi-use design offers economical solution for pre-casting and pre-stressing applications Bayonet cap features knurled nish for improved grip and easy opening Chuck and anchor components available separately for economical service and repair Engineered plating reduces corrosion and extends chuck life All wedge assemblies include o-ring retainer to reduce lost pieces and ease assembly

Multi-Use Splice Chucks Two lengths of strand can be connected while maintaining the strength of a continuous length. Safely connects two strand sections Quick and simple assembly Reduces waste

SURE-LOCK multi-use chucks and wedges are used by pre-cast/prestressed concrete plants to produce poles, slabs, walls, segments, T sections, beams and girders used in all types of construction.

Multi-Use Anchor Chucks O ften used on the non-stressing end of a bed, these chucks are very economical with few components. Open chuck Simple and easy to use Most economical

Photo: DYWIDAG-Systems Intl.

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Multi-Use Products
SURELOCK

Multi-Use Strand Chucks Strand Size Model Number Jaw Assembly Retaining Ring Body Cap Spring Weight (lbs)

Strand Sizes:

5 mm to 0.60 inch
Wedge Type:

5 mm 7 mm 0.25" 0.31" 0.34" 0.38" 0.43" 0.50" 0.56" 0.60"

F1197 F1276 F1250 F1312 F1343 F1375 F1437 F1500EL F1562 F1600

F197J F276J F250J F312J F343J F375J F437J F500JEL F562J F600J

F1R F1R F1R F1R F1R F2R F2R F2R F3R F3R

F1B F1B F1B F1B F1B F2B F2B F2B F3B F3B

F1C F1C F1C F1C F1C F2C F2C F2C F3C F3C

F1S F1S F1S F1S F1S F2S F2S F2SEL F3S F3S

1.0 1.0 1.0 1.0 1.0 2.0 2.0 2.0 2.6 2.6

2-part and 3-part

Coating:

Zinc plated
Contact Enerpac @ 972-287-2390! Custom anchors and wedges are available to meet your unique stressing needs.

Multi-Use Splice Chucks Strand Size Model Number Jaw Assembly Coupling Body Back Plate Spring Weight (lbs)

Pre-Tensioning Systems Hydraulic pre-tensioning systems available with custom strokes, capacities and controls.

5 mm 7 mm 0.25" 0.31" 0.34" 0.38" 0.43" 0.50" 0.56" 0.60"

F4197 F4276 F4250 F4312 F4343 F4375 F4437 F4500EL F4562 F4600

F197J F276J F250J F312J F343J F375J F437J F500JEL F562J F600J

F1CP F1CP F1CP F1CP F1CP F2CP F2CP F2CP F3CP F3CP

F9B F9B F9B F9B F9B F10B F10B F10B F11B F11B

F1BP F1BP F1BP F1BP F1BP F2BP F2BP F2BP F3BP F3BP

F1S F1S F1S F1S F1S F2S F2S F7S F3S F3S

2.5 2.5 2.5 2.5 2.5 4.0 4.0 4.0 6.0 6.0

Accessories A complete line of accessory components for wedge and anchor maintainence, such as cleaning brushes and wedge setters.
Page:

SURE-LOCK Multi-Use Anchor Chucks Strand Size Model Number Jaw Assembly Retaining Ring Body

5 mm 7 mm 0.25" 0.31" 0.34" 0.38" 0.43" 0.50" 0.56" 0.60"

F2197 F2276 F2250 F2312 F2343 F2375 F2437 F2500GL F2562 F2600

F197J F276J F250J F312J F343J F375J F437J F500JGL F562J F600J

F1R F1R F1R F1R F1R F2R F2R F2R F3R F3R

F4B F4B F4B F4B F4B F5B F5B F5B F6B F6B

Barrier Cable Products

Clockwise from center: F21000, F18500, F22000, F22500, F500SL2P, F21500, F20500, F8BP, F17500 and FRCBP

Strand Sizes:

0.50 inch
Wedge Type:

2-part and 3-part

Coating:

Zinc Plated

GRABB-IT Simple, Reliable and Cost Effective

Cable anchorage can be assembled prior to installation (with wedges fully seated) Ferrule insert design allows easy installation Neat appearance no chipping or removal of concrete required Easy maintenance and repair of damaged cable A cost-effective method of installing or re-tensioning barrier cable Swivel GRABB-IT makes installation easy and can accomodate 5 ramp inclines
Barrier Cable Products
Strand Size (in) Model Number Description Weight (lbs)

Contact Enerpac @ 972-287-2390! Custom anchors and wedges are available to meet your unique stressing needs.

Barrier Cable provides a safe and economical solution for vehicle and pedestrian protection in this parking structure.

0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5 0.5

F18500 F20500 F21500 F17500 F21000 F500SL2P F500SL2RP F500SL3P F22000 FRCBP F8BP F22500 F18550 F20550

1/2" Male GRABB-IT 1/2" Female GRABB-IT Loop Ferrule Insert GRABB-IT De Bar Chuck Assembly 1/2" GRABB-IT Splice 2-Part Wedge 2-Part Wedge with Ring 3-Part Wedge with Ring 0.5" OTU Chuck Threaded/Zinc 0.5" RCB Chuck Chuck 1-1/4" Galvanized Threaded Cap 1/2" Male Swivel GRABB-IT 1/2" Female Swivel GRABB-IT

2.40 2.20 0.55 1.75 8.00 0.13 0.13 0.13 0.60 0.55 0.55 0.35 2.40 2.20

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Accessories
Shown: F10000, F7562 and F7250

Tools and Accessories for SURE-LOCK Products

Chair Available in various lengths. Jack Feet and Stressing Tubes are also available.

Wedge and chuck body brushes make cleaning and inspection fast and effective Several head sizes for correct lubrication essential for ease of release and proper wear to extend chuck life
Tools and Accessories
Use Model Number Description Weight (lbs)

Anchor Cleaning Tool Removes residual concrete slag and debris from seating area, for improved seating performance.

Trouble Shooting Anchor Used to help free a jack that will not release from a tensioned cable.

400460 400480 400520 400530 400555 400560 400580 402220 F10000 F7562 F7500 F7437 F7375 F7250 F8562 F8500 F8250 F10003 F10004 F10005

Short cable tube Short cable nose Trouble shoot anchor 45 Stress spacer 12" Chair 18" Chair Hand wedge setter Anchor cleaning tool Lubrication fixture 9/16" 0.60" Jaw brush 1/2" Jaw brush 7/16"15/32" Jaw brush 3/8" Jaw brush 1/4" 5/16" Jaw brush 9/16" 0.60" Body brush 3/8" 1/2" Body brush 1/4" 5/16" Body brush Grease cone for F1B body Grease cone for F2B body Grease cone for F3B body

22.85 2.25 2.20 4.05 25.80 34.50 2.45 1.65 21.55 0.55 0.50 0.50 0.50 0.50 0.65 0.60 0.60 0.25 0.25 0.25

POST-TENSION ACCESSORIES

Hand Wedge Setter Provides a quick way to preliminary seat wedges for retention in anchor.

MULTI-USE MAINTENANCE

Mono-Strand Stressing Tools

Shown: PTJ5S and 5DA1

Field-proven Tools for Mono-Strand Tensioning

SCJ Short Cable Jack For pulling applications where the tendons are shortened, the SCJ Jack only requires 4" of exposed cable. Uses standard 10" stroke S/A cylinders, other strokes available upon request.

Durable, field-proven designs, with soft-grip ergonomic handles reduce operator fatigue Single-acting PTJ models, with spring-seating and optional power-seating are equipped with the new Enerpac RC Post-tensioning cylinders with a 10" stroke, ideal for slab-on-grade applications Double-acting DA models have an 8.5" stroke and are machined from a steel billet; feature standard powerseating and gun-drilled internal hydraulic passages All jacks have a standard 3" nose assembly. Longer nose assemblies are available as accessories for all models A full line of grippers is available to tension common strand diameters Complete offering of Enerpac parts and soft kits allow quick and easy service

RC-1010PT and RC-1510PT Cylinders Longer spring life and improved retraction are the benets from these specially designed cylinders.

5DA1-AL Reduced Weight Jack With a 17% weight reduction, this jack increases operator safety by reducing fatigue, while still having all the durability of a SURE-LOCK product.

TOOL SELECTION CHART

Tool Capacity (tons) Seater Type Strand Diameter Standard (in) Model Number Tool Operation Stroke Oil Capacity (in3) Tool Effective Area (in2) Max Pressure (psi) Weight

(in)

(lbs)

20 20 20 20 30 30 26

Spring Power Power Power Spring Power Power

0.50-0.52 0.50-0.52 0.50-0.52 0.50-0.52 0.60-0.62 0.60-0.62 0.60-0.62

PTJ5S PTJ5P 5DA1-AL 5DA1 PTJ6S PTJ6P 6DA1

S/A S/A D/A D/A S/A S/A D/A

10.0 10.0 8.50 8.50 10.0 10.0 8.50

45.3 45.3 53.0 53.0 62.8 62.8 67.6

4.48 4.48 6.28 6.28 6.28 6.28 7.95

10,000 10,000 6,500 6,500 10,000 10,000 6,500

55 55 35 42 76 76 52

10

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Mono-Strand Stressing Tools

Mono-Strand Tensioning Tool Operational Sequence The sequence of operation of the double-acting 5DA1 tool is illustrated. Single-acting, spring-seat models are similar. Installation Pulling Tendon Seating Wedge Retraction

Series
Capacity:

DA, PTJ, SCJ

20-30 tons
Stroke:

8.5-10 inches
Strand Diameters:

.375-.60 inch
Maximum Operating Pressure:

6,500-10,000 psi
Nose Wedge Seater Gripper HC-Series Hoses Durable rubber hoses designed to stand up to the rigors of long-term tensioning applications.
Internal Length Dia. (in) (ft) Hose End (NPT) 1 2 Model Number

Dimensions (in) Model No. A B C B

3/8 1/4

10 10

3/8 3/8

3/8 1/4

H9310 H9210S

PTJ5 PTJ6 5DA1 6DA1

21.0 22.0 18.5 18.5

9.0 10.2 7.5 8.5

6.5 7.0 6.5 6.5

A

Jack Feet Two required per jack. Used in place of a nose to react on either side of wedge pocket.

3/8" NPTF ports; PTJ and DA power seat models include FZ-1055 fitting.

Model Number

Used with Jack

OPTIONAL AND REPLACEMENT ACCESSORIES SELECTION CHART

Nose 3" 6" Wedge Seater 3" 6" 0.38" 0.43" 0.50" 0.62"

402000 403325
Gripper Set Diameter 4 mm 5 mm

5DA1 6DA1

6 mm

7 mm

400740* 400740* 401520* 401520* 400740* 400740* 403180*

401180 401180 401840 401840 401180 401180 403220

305340* 305340* 305360* 305360* 305340* 305340* 403140*

401200 401200 305365 305365 401200 401200 403165

400900 400900 401652 401652 400900 400900 400988

400880 400880 401655 401655 400880 400880 N/A

400850* 400850* 401660* 401660* 400850 400850 400986

N/A N/A N/A N/A 400980* 400980* 400990*

400930 400930 400930 400930

400940 400940 401670 401670 400940 400940

400950 400950 400950 400950

400960 400960 400960 400960

*Shipped with tool.

11

Mono-Strand Jack Pump Sets

Shown: ZU4408PB, PTJ5S, 5DA1

The Quickest and Easiest Way to Start Working Right Away

More information See the Yellow Pages section for precautions to consider during tensioning applications.
Page:

17

4" Face Pressure Gauges Durable and built to hold calibration, this easy to read gauge is glycerin-filled.

Optimum match of individual components Sets include 10 ft. hose(s), gauge and ttings Uses reliable ZU-Series Post Tensioning Pump

Pressure (psi)

Port (in)

Fill

Model Number

0-10,000

1/4

Glycerin

H4049L

Designed to be tough, the ZU4-Series pump with steel reservoirs will take the abuse of todays construction sites. The ZU4 is the ideal pump for post tensioning applications.

1 Jack Selection (See Mono-strand Jack Section of this catalog for full product descriptions)
Page:

Tool Capacity

Seater Type

Nominal Strand Diameter Range (in)

Stroke (in)

Stressing Jack Model Number

10

(ton)

Ideal for slab-on-ground applications. Ideal for slab-on-ground applications with power seating. Ideal for elevated applications. Fast, double-acting with power seating.

20 30 20 30 20 20 26

Spring

0.50-0.52 0.60-0.62

10

PTJ5S PTJ6S

Power

0.50-0.52 0.60-0.62 0.50-0.52

10

PTJ5P PTJ6P 5DA1-AL

Power

0.50-0.52 0.60-0.62

8.5

5DA1 6DA1

12

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Mono-Strand Jack Pump Sets

SET SELECTION: EXAMPLE:

1 Select the jack 2 Select the pump

set model 3 Find the in the blue number field of the matrix

1 5DA1, Double-acting jack for use with 0.50 strand, 8.5" stroke 2 ZU4908PB, 115VAC with Power Seating Valve 3 S5D-ZB, which will include: (2) H9310 hoses
(1) H9210S hose (1) H4049L gauge Fittings to assemble hoses and gauge

Series

Capacity:

20 to 30 tons
Stroke:

8.5-10 inches
Maximum System Operating Pressure:

6,500-10,000 psi
Hydraulic Oil

To protect your system, use only Enerpac hydraulic oil in your jack and pump systems. Oil is available in a number of capacities to match your needs.

Model Number Typical Mono-Strand system set-up. ZU4908PB Electric Pump and the VM43-LPS Manual Valve for power-seating. 5DA1 Stressing Jack, used for power-seat applications of 0.50 inch strand.

Contents

HF-100 HF-101 HF-102

1 Quart 1 Gallon 5 Gallons

2 Pump Selection (See Pump Section of this

catalog for full product descriptions)
ZU4408PB* Page: ZU4908PB* 16 Hose(s)

Accessories Included

Gauge

Swivel Fitting

45 Street Elbow

3 S5S-ZB*
S6S-ZB* -

3 S5J-ZB* S6J-ZB* S5DAL-ZB* S5D-ZB* S6D-ZB*

(1) H9310

(1) FZ1660

(1) H9310 (1) H9210S

(2) FZ1660 H4049L F100095

(2) H9310 (1) H9210S

(3) FZ1660

*115 Volt model shown. To order 208-240-Volt pump, replace B with I (Americas) or E (Europe).

13

Mullti-Strand Stressing Jacks

Shown: Stressing Jack - 680 ton, 150 mm stroke

Multi-Strand
Series
Capacity:

50-1000 tons
Stroke:

6-20 inches
Maximum Operating Pressure:

8,800 psi

Custom sizes available Equipped with hydraulic lock noses or self-tightening Multi-use stressing heads available Plated for corrosion resistance Power seating available on all models For use with 0.50" 0.62" strand

Anchor Heads A number of standard anchor head sizes and patterns are available. They can also be built to customers specic design.

Pumps for Multi-Strand Jacks A complete line of large pumps are available to power any size multi-strand stressing jack. From 3 hp to 20 hp and with any valve requirement, there is an Enerpac pump to t your application.
An example of the versatile, durable multi-strand stressing jacks available.

Contact Enerpac @ 972-287-2390 Contact Enerpac to specify custom jacks and anchor heads.

14

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Stressing Jack System Worksheet

Please complete the following information prior to contacting Enerpac for a stressing jack system proposal.
Company _________________________________________ Contact ______________________________________ Project_______________________________________ _ Phone ___________________________________________ Fax __________________________________________ E-mail _______________________________________

Description of Application (provide drawings if possible): ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________

Tensioning System Tendons Jack Design Bearing Location Number of Strands Strand Size Hole Pattern and Diameter Anchor Head Diameter Anchor Head Height Anchor Head Material Stroke Total Force Needed Hydraulic Seating Device Front or Rear Gripping Tube Bundle Quantity Stressing Wedge Release Number of Hose Connections Special Corrosion Requirement Weldable Cylinder or Non Required Lead Time Spare Part Requirements

Existing Bonded Standard Anchor Head Yes Yes Yes Auto 2 No No

Development Unbonded Custom Bearing Plate No

DRAWING EXAMPLE

Drawing of Anchor Head(s) Available

Manual 3

Environmental Conditions (e.g. ambient temperature, dust, saltwater, etc.) ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ Additional Requirements (e.g. lifting attachments, spare parts) ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________ ________________________________________________________________________________________________________________

155 1

ZU4 Classic Electric Pumps

Shown: ZU4908PB

Your First Choice for a Construction Pump

Electrical Information Basic electrical package includes mechanical contactor, ON/OFF toggle switch, pendant with single electro-mechanical pushbutton, 24V transformer and operator accessible circuit breaker.

VM-22 Valve The VM-22 is a 3-way, 2-position valve with in-line check to hold pressure after pump is turned off. Select by placing a 7 in the fourth digit of the pump model number.

Features Z-Class high-efciency pump design, higher oil ow and bypass pressure, cooler running and requires 18% less current draw than comparable pumps Powerful 1.7 hp universal electric motor provides high power-to-weight ratio and excellent low-voltage operating characteristics High-strength, molded composite shroud protects motor and electric components, while providing an ergonomic, non-conductive handle for easy transport Low-voltage pendant provides additional safety for the operator (remote control units) Metal valve handle provides strength for repetitive actuation and allows operator to select handle positions

Optional Skidbar A n optional skidbar provides greater pump stability on soft or uneven surfaces. To order, add -K to model number or SB2-4.

ZU4 Pump with LCD LCD readout provides diagnostic capabilities and a visual pressure display for operators demanding the most sophisticated portable electric pump. To order, specify model ZU4408KB-T or ZU4908KB-T.
Page:

17

Increased output ow and extended brush life increase productivity for post-tensioning applications.

16

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Classic Electric Pumps

Z-Class A Pump for Every Application Patented Z-Class pump technology provides high by-pass pressures for increased productivity important in applications using long hose runs and high pressure-drop circuits, like heavy lifting or certain doubleacting tools. Choosing the right ZU4 pump for your application is easy: Premium Electric Pump Digital (LCD) display features a built-in hour meter and shows selfdiagnostic, cycle-count and low voltage warning information. Pressure can also be displayed when the pump is equipped with an optional pressure transducer. These premium features are not available on any other pumpanywhere! Standard Electric Pump For applications that do not require digital display features of the Premium Pump. Available in all manual or jog versions. Classic Electric Pump The Classic has traditional electro-mechanical components (transformers, relays and switches) in place of solid-state electronics. The Classic delivers durable, safe and efcient hydraulic power for demanding markets like construction, post-tensioning and foundation repair.

ZU

Series

Reservoir Capacity:

1.0-10.0 gal.
Flow at Rated Pressure:

60 in3/min.
Motor Size:

1.7 hp
Maximum Operating Pressure:

10,000 psi

3/8"-18 NPTF
Flow (in3/min)
700 600 500 400 300 200 100

FLOW CHART
25

17.00

115V

20 15

5.60

230V

10 5 0 10,000

9.00 11.00 16.29 19.00

Dimensions (in) Reservoir Size (gal)

3.75 A 9.46 10.50

Factory Installed Features and Options Skid Bar (shown)

.50

2000

4000

6000

8000

Flow (in3/min) Current (amps)

Pressure (psi)

1 6.0

2 8.1

User Adjustable Relief Valve Oil Fill Port SAE #10 Oil Level Sight Gauge Oil Drain 1/2" NPTF M8 x 12 LG VM43M Valve (shown)

SELECTION CHART
Used with Tool Valve Type1) Model Number 2) 3) 115 VAC Output Flow Rate (in3/min)
100

Usable Relief Valve Oil Cap.4) Adjustment Range (gal) (psi)

Motor Electrical Specication3) (volts-ph-Hz)

Motor Sound Weight Size Level (hp) (dBA) (lbs)

psi

700 psi

5,000 10,000 psi psi

VM22 VM43M S/A & D/A VM43M VM43M VM43-LPS Power VM43-LPS Seat VM43-LPS *

ZU4704PB ZU4404PB ZU4408PB ZU4408KB-T ZU4904PB ZU4908PB ZU4908KB-T

700 700 700 700 700 700 700

535 535 535 535 535 535 535

76 76 76 76 76 76 76

60 60 60 60 60 60 60

1.0 1.0 1.75 1.75 1.0 1.75 1.75

1,00010,000

115-1-50/60

1.7

85-90

61.1 59.4 65.6 67.3 63.5 69.7 72.0

* odel used for single-acting cylinder in foundation repair applications. 1) A VM33M may be substituted when only single-acting tools are used. Replace the 4th digit with number 3. M 2) To order pump with no remote operator control, replace the P with R in the model number. 3) To order pump with 208-240V, 1ph, 50/60 Hz, replace the B with I in the model number. 4) To order pump with larger oil reservoir, replace the 04 (1 gal.) in the model number with 08 (1.75 gal.), 10 (2.5 gal.), 20 (5 gal.) or 40 (10 gal.).

Current (amps)

17

Hydraulic Pumps for Multi-Strand Jacks

Shown from left to right: ZG6440MX-BCFH, ZG5420MX-B

The Right Pump for the Job

Power Options P umps can be powered by electricity or gasoline, with multiple horsepower and reservoir options for greater versatility.

Two-speed pump design, with high by-pass pressure, for rapid cylinder advance Electric pumps available in multiple voltage options Full length reservoir sight tube for monitoring oil level Gasoline pumps utilize 4-cycle Briggs, Honda and Waukesha Engines Electric pumps include TEFC motors with starters

All Z-Class electric pumps are CSA compliant and most are also CE compliant. Contact Enerpac for more information.

4" Face Pressure Gauges Durable and built to hold calibration, this easy to read gauge is glycerin-filled.

Pressure (psi)

Port (in)

Fill

Model Number

0-10,000

1/4

Glycerin

H4049L

Photo: DYWIDAG-Systems Intl.

The San Francisco - Oakland Bay Bridge (far left) is a dramatic example of SURE-LOCK components performing in signature projects. SURE-LOCK Wedges are part of the PT System for the Woodrow Wilson Bridge crossing the Potomac River. Sixty massive precast posttensioned segmental V-Piers connected by posttensioned tie beams are the core of the project which will support over 200,000 vehicles per day.

Photo: Schwager Davis, Inc.

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Hydraulic Pumps for Multi-Strand Jacks

17.5

ZG5, ZE5, ZE6

17.5

ZE, ZG, PE, EG

Series

10.6**

15.7** 17.3 28.0

5.2 15.7** 17.3 28.0 5.2

10.6**

19.9** 22.7** 19.9** 22.7**

Reservoir Capacity:

5-18 gal.
Motor Size:

ZG6

22.5 22.5

Flow at Rated Pressure:

39.3 39.3

0.43 - 4.40 gal/min. 3-18 hp

Maximum Operating Pressure:

36.8

36.8

22.6

10,000 psi
22.6

5.5

5.5

20.0 33.0

47.4

61.0 47.4 61.0

20.0 Dimensions shown in inches. 33.0

User adjustable relief valve on all manual valves, 3/8" NPTF on A and B ports, 1/4" NPTF on auxiliary ports. Roll Bar (optional) Return Line Filter (optional on ZG5, Standard on ZG6)

Oil Level Gauge Oil Drain Collapsible Handles (ZG6 only) Cart (standard on ZG6 only)

Due to the differences in control requirements and size of certain multi-strand jacks, please contact Enerpac for the correct pump and valve conguration for your exact application. The selection chart shown here is for use in determining pump ow, oil capacities and weight of the different pump series.

PE, EGM
Valve Location Relief Valve Fill Port Gauge Shut Off Valve 35.00 22.25 Drain Plug Oil Level and Temperature Gauge Gauge 15,000 psi Motor/Engine Size* Sound Level Weight

46.00 Dimensions shown in inches. Usable Oil Capacity Motor / Engine Type Pump Series (See info box above, right) Pressure Rating (psi) 1st stage 2nd stage Output Flow Rate (gal/min) 1st stage 2nd stage (hp)

(gal)

(dBA)

(lbs)

5,10 5 5,10 10 18 18

Electric Gas - Honda Electric Gas - Briggs Electric Gas - Kohler

ZE5 ZG5 ZE6 ZG6 PE EGM

1,200 1,800 1,200 2,000 3,700 3,700

10,000 10,000 10,000 10,000 10,000 10,000

3.68 3.03 3.90 3.90 4.40 3.40

0.52 0.43 0.87 0.87 2.00 1.50

3.0 5.5 7.5 13.0 12.5 18.0

75 88-93 80 91-95 78-84 94

210 140 250 334 720 890

* Consult Enerpac for available voltages. ** Dimension shown based on 10-gallon reservoir to approximate size. Consult Enerpac for exact specifications on models with 2.5 and 5gallon reservoirs.

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Prestressing Precautions and Definitions

Denitions1)
Anchor:For monostrand tendons, normally a ductile iron casting which houses the wedges and is used to transfer the prestressing force to the concrete. AnchorHeads(WedgePlate):The hardware which holds the wedges of a multi-strand tendon and transfers the tendon force to the bearing plate. BarrelChuck:A cylindrical metal device housing the wedges and normally used with a bearing plate to transfer the prestressing force to the concrete. CalibrationofJackandGauge: Calibration is extremely important. This is the process of using a load cell to validate the load induced by the jack, through its entire stroke, correctly corresponds with the pressure on the gauge. In general, stressing jacks are about 95% efficient, actual efficiency will vary with age and condition of the jack. Chair:Hardware used to hold post-tensioning tendons in their proper position to prevent displacement before and during concrete placement. SpliceChuck:A device, normally spring loaded, for connecting two strand ends together, transferring the prestressing force from one end to end of the tendon. EncapsulatedSystem:A system which provides watertight connections at all stressing, intermediate and fixed-ends, and has the anchor cavity side of the anchorage covered by a water-tight cap filled with a corrosion inhibiting coating material. HandSeatingTool:A small, hand held device used to properly align (seat) the wedges in the anchor prior to attaching the jack to the strand for stressing. Lift-Off:The process of checking the force in a stressed tendon by using a jack and lift-off chair (optional) to load the strand until the wedges begin to move from the wedge plate. Multi-UseSpliceChuck: A coupler which uses a 3-piece wedge and is made of material for repeated use. OTU:One-time use. PocketFormer:A temporary device used at the stressing-end during casting of the concrete to provide an opening in the concrete, allowing the stressing equipment access to the anchor cavity. SOG:Slab-on-ground. Trouble-ShootingAnchor:A special anchor used for structural modification or repair of existing tendons. The anchor consists of a removable segment which allows it to slide onto an existing strand. The segment is then returned and tightened by screw or bolt. Wedge:A conically shaped device which transfers the stressing force from the prestressing steel (strand) into the wedge plate or anchor. The teeth are beveled at the front end to assure gradual development of tendon force over the length of the wedge.
1)

Precautions
1. Only trained and certied personnel are allowed to operate the stressing equipment and observe stressing operations. 2. Follow all instructions in the Post-Tensioning Institute Field Procedures Manual. 3. Dont stress any tendons with concrete slurry inside the anchor cavity. Concrete in the anchor cavity will prevent proper seating of the wedges and can cause property damage or injury. 4. Dont use the jack if it does not seat properly on the face of the anchor. 5. Dont overstress tendons in order to achieve elongation. 6. Dont allow obstructions in the path of the jack extension. 7. Dont use extension cords longer than 100 ft. (30m) or less than 3 wire, 12 gauge. Improper power supply will damage the equipment. 8. Dont continue stressing if you suspect that something is not working properly. 9. Dont de-tension with loose plates, spacing shims or piggy backing. Always use proper tools and training. 10. Dont stand in the immediate vicinity of the jack, any point of the tendon being stressed, or between the jack and the pump during stressing or de-stressing. 11. Dont permit other workers in the immediate area of the jack or pump during stressing operations. 12. Dont hammer or beat on the jack or jack cylinders. 13. Dont do anything if you are not sure contact an expert.

www.enerpac.com Visit our web site to learn more about hydraulics and system set-ups.

From Post Tensioning Institute

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General Capability Sheet

System Component Supply
All information show is for general understanding, contact Enerpac to discuss your specic requirements.

Common Wedges
Strand Type Diameter Range (in) Wedge Material

Single-use Multi-use

0.19-0.62

Carbon and Alloy Steels

Common Anchor Heads

Strand Quantity Diameter Range (in) Diameter (in) Height (in) Anchor Head Material

1 3 6 7 12 19 27 31 37 42 Common Couplers
Strand Quantity

0.50-0.62

1.97 4.33 5.12 5.91 6.69 8.27 10.24 10.24 11.81 12.60

2.17 2.56 2.56 2.56 2.56 2.95 4.33 4.33 4.92 4.92

Carbon and Alloy Steels

Coupler Diameter (in) Height (in) Material

Diameter Range (in)

4 7 12 19 27 31 37 42

0.50-0.62

6.30 7.68 9.06 10.63 13.98 14.37 15.16 17.52

3.35 4.13 4.13 4.13 5.12 5.12 6.10 6.50

Carbon and Alloy Steels

Custom Products
Enerpac/PSL has built a strong reputation supplying tensioning products to our ETAG approved system holders and to other system holders as well. Wedges of all sizes and anchor heads up to 59 inches (1500 mm) in diameter are produced using state-of-the-art CNC machining centers. 100% inspection of size and laser checking thread tooth proles are just a few ways ENERPAC meets and exceeds our customers high expectations for quality, reliability, and delivery.

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Strand Processing Equipment

Unbonded Tendon Fabrication Lines

SURE-LOCK builds machines to suit the needs of the client. We manufacture 2-, 3-, and 4-tub lines depending on the customers preference. SURE-LOCK lines automatically measure and shear the strand, giving accurate length control. Single or dual pay-offs can be provided, making material changes swift and easy. Leveraged hydraulic shears provide clean end cuts of 0.50" and 0.60" PC strand. Easy access to rotate or change shear blades minimizes downtime, and multi-track drive belts reduce expense. Local or remote data input is available. SURE-LOCK delivers quality, durability, and customer support in our complete line of equipment.

Fixed End Seating Equipment

SURE-LOCK builds complete anchor seating systems that include the required hydraulic pump, seating ram, steel work bench, gauge, and hoses with both 0.5" and 0.6" strand capacity. We provide either push or pull systems according to the customers need.

Unbonded Tendon Extrusion Lines

Complete lines are available in several congurations. Single or multiple strand pay-offs, various extruder diameters depending on desired output, cooling trough lengths, chiller capacity, and single or multiple take-ups are all options for the client. SURE-LOCK lines are built with everything the customer needs, including pumps, vacuum loaders, drawer magnets, high capacity chillers, heat exchanging coils, and the most durable take-ups in the industry. Individual components are also available for upgrade of existing lines.

Cable Bolt Fabrication Lines

SURE-LOCK builds automatic cable bolt fabrication equipment for the mine supply industry. These lines include strand pay-off, measuring, and cutting stations, providing accurately cut pieces for further fabrication into roof bolts.

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Strand Processing Equipment

Strand Anchor Fabrication Lines and Assembly Table

G eotechnical strand anchors require specialized production equipment. SURE-LOCK provides equipment built with knowledge of the industry requirements. Precise measurement and cutting along, with either half-pipe or rolling tables, make anchor assembly efficient. SURE-LOCK provides high-quality equipment for coiling and uncoiling anchors that is proven durable and reliable.

Anchor Coilers and Uncoilers

SURE-LOCK manufactures extremely productive coating lines for strand used in the fabrication of geotechnical anchors. The heart of this system is an innovative computer-controlled skip-coating system that provides clean bonded zones and stressing tails while properly unbonding the free length. Touch screen programming of various congurations within coils is easy and intuitive.

Strand Anchor Extrusion Lines and Custom Machinery

SURE-LOCK also has capabilities to manufacture custom equipment. Based on the clients desired function or proprietary design, SURE-LOCK makes machines that work.

Material Handling Equipment

SURE-LOCK manufactures strand reels, fork extensions, racks, coil stackers, and many other types of handling equipment.

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Concrete Stressing Products

The Industrial Tools Line Cylinders General Purpose Pancake Aluminum Lightweight Low Height Heavy-duty Hollow Plunger Industrial Pull Long Stroke Jacks Spread Pumps Manual Electric Driven Compressed Air Driven Petrol Driven System Components Hoses, Couplers, Oil Gauges, Adaptors Manifolds, Fittings Valves 3- and 4-Way Directional Pressure and Flow Control Presses Bench and Workshop Roll Frame Presses Arbor and C-Clamps Pullers Master Pullers Sets Multi Purpose Puller Sets Posi Lock Pullers Tools Maintenance Sets Punches Machine Lifts Load Skates Cutters Pipe Benders Bolting Tools Nut Splitters Flange/Wedge Spreaders Flange Alignment Tools Torque Wrenches Hydraulic Wrench Pumps Twin Safety Hoses Integrated Hydraulic Solutions Synchronous Lifting and Weighing Heavy Lifting (Strand Jacking Systems) Concrete Stressing Products Hydraulic Construction Solutions Permanent Hydraulic Installations

Enerpac Worldwide Locations

ENERPAC PRECISION-SURELOCK 704 W. Simonds Dallas, TX 75159, USA Tel: 1 972 287 2390 + Fax: 1 972 287 4469 +
Australia and New Zealand Actuant Australia Ltd. Block V Unit 3 Regents Park Estate 391 Park Road Regents Park NSW 2143 (P.O. Box 261) Australia T +61 297 438 988 F +61 297 438 648 [email protected] Brazil Power Packer do Brasil Ltda. Rua dos Inocentes, 587 04764-050 - Sao Paulo (SP) T +55 11 5687 2211 F +55 11 5686 5583 Toll Free: 0800 891 5770 [email protected] Canada Actuant Canada Corporation 6615 Ordan Drive, Unit 14-15 Mississauga, Ontario L5T 1X2 T +1 905 564 5749 F +1 905 564 0305 Toll Free: T +1 800 268 4987 F +1 800 461 2456 [email protected] China (Taicang) Actuant Industries Co. Ltd. No. 6 Nanjing Road, Taicang Economic Dep Zone Jiangsu, China T +86 0512 5328 7529 +86 0512 5328 7500 F +86 0512 5335 9690 [email protected] China (Beijing) Actuant China Ltd. 709B Diyang Building Xin No. 2, Dong San Huan North Rd. Beijing City, 100028 China T +86 10 845 36166 F +86 10 845 36220 [email protected] France, Switzerland, North Africa and French speaking African countries ENERPAC Une division dACTUANT France S.A.S. ZA de Courtaboeuf 32, avenue de la Baltique 91140 VILLEBON /YVETTE France T +33 1 60 13 68 68 F +33 1 69 20 37 50 [email protected] Germany and Austria ENERPAC GmbH P.O. Box 300113 D-40401 Dsseldorf Willsttterstrasse 13 D-40549 Dsseldorf, Germany T +49 211 471 490 F +49 211 471 49 28 [email protected] India ENERPAC Hydraulics Pvt. Ltd. No. 1A, Peenya Industrial Area IInd Phase, Bangalore, 560 058, India T +91 80 40 792 777 F +91 80 40 792 792 [email protected] Italy ENERPAC S.p.A. Via Canova 4 20094 Corsico (Milano) T +39 02 4861 111 F +39 02 4860 1288 [email protected] Japan Applied Power Japan LTD KK Besshocho 85-7 Kita-ku, Saitama-shi 331-0821, Japan T +81 48 662 4911 F +81 48 662 4955 [email protected] Middle East, Egypt and Libya ENERPAC Middle East FZE Office 423, LOB 15 P.O. Box 18004, Jebel Ali, Dubai United Arab Emirates T +971 (0)4 8872686 F +971 (0)4 8872687 [email protected] Russia Rep. office Enerpac Russian Federation Admirala Makarova Street 8 125212 Moscow, Russia T +7 495 9809091 F +7 495 9809092 [email protected] Singapore Actuant Asia Pte Ltd. 83 Joo Koon Circle Singapore 629109 T +65 68 63 0611 F +65 64 84 5669 Toll Free: +1800 363 7722 [email protected] South Korea Actuant Korea Ltd. 3Ba 717, Shihwa Industrial Complex Jungwang-Dong, Shihung-Shi, Kyunggi-Do Republic of Korea 429-450 T +82 31 434 4506 F +82 31 434 4507 [email protected] Spain and Portugal ENERPAC SPAIN, S.L. Avda. Los Frailes, 40 Nave C & D Pol. Ind. Los Frailes 28814 Daganzo de Arriba (Madrid) Spain T +34 91 884 86 06 F +34 91 884 86 11 [email protected] Sweden, Denmark, Norway, Finland and Iceland Enerpac Scandinavia AB Fabriksgatan 7 412 50 Gothenburg Sweden T +46 (0) 31 7990281 F +46 (0) 31 7990010 [email protected] The Netherlands, Belgium, Luxembourg, Central and Eastern Europe, Baltic States, Greece, Turkey and CIS countries ENERPAC B.V. Galvanistraat 115 6716 AE Ede P.O. Box 8097 6710 AB Ede The Netherlands T +31 318 535 800 F +31 318 535 848 [email protected] ENERPAC Roermond B.V. Daalakkerweg 24 6041 BL Roermond P.O. Box 49 6040 AA Roermond The Netherlands T +31 475 355 000 F +31 475 331 774 [email protected] South Africa and other English speaking African countries ENERPAC B.V. Galvanistraat 115 6716 AE Ede P.O. Box 8097 6710 AB Ede The Netherlands T +31 318 535 911 F +31 318 525 613 [email protected] United Kingdom and Ireland ENERPAC Ltd., Bentley Road South Darlaston, West Midlands WS10 8LQ England T +44 (0)121 50 50 787 F +44 (0)121 50 50 799 [email protected] USA, Latin America and Caribbean ENERPAC P.O. Box 3241 6100 N. Baker Road Milwaukee WI 53209 USA T +1 262 781 6600 F +1 262 783 9562 User inquiries: +1 800 433 2766 Distributor inquiries/orders: +1 800 558 0530 [email protected]

e -mail: [email protected] Internet: www.precision-surelock.com

03-0301032 609_US_R1 2011 Enerpac - Subject to change without notice.