tools and accessories -...

24 www.precision-hayes.com

Tools and Accessories

Only Precision-Hayes International provides a

complete line of tools and equipment to help you get

your installation done quickly and safely.

The Jack and Pump Systems provide a matched

set guaranteeing correct performance. This includes

a high quality stressing jack, an industry standard pump,

hoses, gauge and fi ttings. The complete system is easy

to order and ensures jack and pump compatibility.

Customers can choose to shear the tendons with or

without fl ame, in or out of the pocket. Precision-Hayes

International off ers both a hydraulic and a battery

powered PocketShear®, still the only in-pocket fl ameless

cutting solutions. The Utility Shear and PLASMA Cutting

Systems are also available.

▼ Full line of installation, maintenance, and troubleshooting tools and accessories are available to keep you up and running

25

▼

H007111

H007112

H006928

PTJ5S

PTJ6S

PTJ5P

PTJ6P

5DA1

5DA1-AL

5DA1-ALS

6DA1

6DAH-306

6DAH-308

6DAH-3012

SCJ

PTJ5S

PTJ6S

PTJ5P

PTJ6P

5DA1

5DA1-AL

6DA1

H007731H007736H007733H007738H007749H007758H010000H007978H008052H008055H008057H008008H007755H007779H007729H007751H007727H007759H007980

H007924H007927H007925H007928H007930H007935H007933H007988

***

H008007****

H007931*

H007989

ItemNumber

ItemNumber

* Available upon request

115-1-50/60

220-1-50/60

Jack and Pump Systems

1. PumpVoltage

(volts-ph-Hz)

Jack and Pump Systems

2. Jack 3. Pump

ZU4 PE55

▼ SELECTION CHART

Typical mono-strand system set-up

Pump Types:

ZU4 and PE55Jack Types:

PTJ, DA, DAH, SCJVolts:

115 and 220 v.a.c.

A Complete System to Get Your Work Done Fast

Please follow the steps below to select your jack andpump system:

• Step 1: PUMP VOLTAGE SELECTION Our pumps work at either 115 v.a.c. or 220 v.a.c.

Please select based on your need.

Ex. Select "115" under "1. Pump Voltage" column

• Step 2: JACK SELECTION Please refer to page 18 and 19 to learn the wide

selection of stressing jacks we off er.

Ex. Select "SCJ" under "2. Jack" column

• Step 3: PUMP SELECTION We provide both ZU4 and PE55 Stressing Pumps.

Please select based on preference.

Ex. Select "ZU4" under "3. Pump" column

• Step 4: ORDER YOUR SYSTEM Based on your previous selections, please fi nd

the item number of the Jack and Pump System in the grey boxes of the Selection Chart. Use that item number to place your order. Note: Every Jack and Pump System comes with a hose, gauge and fi tting.

Ex. The system number is "H008008"

0.375" x 10' x 0.375"

0.25" x 10' x 0.375"

4" 0-10,000 psi fluid-filled gauge

DescriptionPart ItemNumber

Hose H9310

Hose H9210S

Gauge


B

C

A

A

CBDAH Series

DA Series

PTJ Series

SCJ Series

PTJ5

PTJ6

5DA1

6DA1

SCJ-204

SCJ-2010

6DAH306

6DAH308

6DAH3012

H007114

H007050

ZU4

PE55

Dimensions (in)

• Durable, field proven designs, with “soft-grip” ergonomic handles reduce operator fatigue

• Single-acting PTJ models, available with spring seating or power seating, are ideal for slab-on-grab applications

• Double-acting DA models have an 8.5" stroke and are machined from a steel billet; feature standard power-seating and “gun-drilled” internal hydraulic passages

• 5DA1 jacks come standard with 4" noses. PTJ and DAH jacks come standard with 3" noses. Other nose sizes are available upon request

• A full line of grippers are available to stress common strand diameters

• Complete offering of repair parts and soft kits allow quick and easy service

A B CModel No.

All advance and retract hydraulic ports are 0.375" NPTF.

Stressing JacksField Proven Tools forMono-Strand Stressing

Optional and Replacement

Accessories Available

• Noses and wedge seaters

are available in 3''- 8''.

Other sizes available

upon request

• Gripper Set Diameter from

0.38''-0.62'' and 4 mm-7 mm

For your system,

please refer to the

chart below and use

only the recommended

hydraulic oil in your jack

and pump systems.

DescriptionItemNumber

Pump

1 Gallon

2.5 Gallons

6.50

7.0

6.50

6.50

4.80

4.80

—

—

8.50

21.0

22.0

18.50

18.50

12.0

19.0

16.20

18.10

22.30

9.0

10.20

7.50

8.50

8.30

8.30

7.10

7.10

—

27

1

2

3

H007730

H007732

H007735

H007737

H007747

H007781

H007785

H007941

H008051

H008054

H008056

H008009

H008006

PTJ5S

PTJ5P

PTJ6S

PTJ6P

5DA1

5DA1-AL

5DA1-ALS

6DA1

6DAH-306

6DAH-308

6DAH-3012

SCJ-204

SCJ-2010

S/A

S/A

S/A

S/A

D/A

D/A

D/A

D/A

D/A

D/A

D/A

S/A

S/A

5DA1

6DA1

H007922

H007974

Weight

(lbs)

OilCapacity

(in3)

SeaterType

ItemNumber

Model Number

ToolOperation

Strand Diameter

Range

(in)

Stroke

(in)

ToolCapacity

(tons)

Tool Effective

Area

(in2)

Spring

Power

Spring

Power

Power

Power

Power

Power

Spring

Spring

Spring

Spring

Spring

▼ TOOL SELECTION CHART

Max Pressure

(psi)

① Nose

② Wedge Seater

③ Gripper

Installation Pulling Tendon

Mono-Strand Stressing Tool Operational Sequence

The sequence of operation of the double-acting 5DA1 tool is illustrated. Single-acting, spring seat models are similar.

Seating Wedge Retraction

Stressing Jacks

Capacity:

20 to 30 tonsStroke:

8.5 to 10 inchesStrand Sizes:

0.375 to 0.60 inch

PTJ, DA, DAH, SCJ Series

Maximum Operating Pressure:

6,500 to 10,000 psi

Used with Jack

Jack Feet

Two required per jack. Used

in place of a nose to react on

either side of wedge pocket.

PTJ Single-Acting Twin-Line Stressing Jacks

DA Double-Acting Twin-Line Stressing Jacks

6DAH Double-Acting Hollow Stressing Jacks

SCJ Short Cable Twin Ram Stressing Jack

Item Number

0.50 - 0.52

0.50 - 0.52

0.60 - 0.62

0.60 - 0.62

0.50 - 0.52

0.50 - 0.52

0.50 - 0.52

0.60 - 0.62

0.60

0.60

0.60

0.25 - 0.50

0.25 - 0.50

10.0

10.0

10.0

10.0

8.50

8.50

8.50

8.50

6

8

12

4

10

55

55

76

76

42

35

42

52

44

48

61

25

40

4.48

4.48

6.28

6.28

6.28

6.28

6.28

7.95

5.47

5.47

5.47

4.48

4.48

20

20

30

30

20

20

20

26

30

30

30

20

20

10,000

10,000

10,000

10,000

6,500

6,500

6,500

6,500

10,000

10,000

10,000

10,000

10,000

45.30

45.30

62.80

62.80

53

53

53

67.60

32.80

43.70

65.60

18.46

45.30


H006769H006770 H006771 H006773

ZU4 Classic SS-115

ZU4 Classic SS-220

ZU4 Classic PS-115

ZU4 Classic PS-220

VM43M

VM43M

VM43-LPS

VM43-LPS

• Classic Series pumps feature traditional electro-mechanical components

• High-effi ciency pump element delivers high-performance while drawing less electrical power

• Multiple valve options to meet your application requirement

The High-Performance Option

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

▼

UsableOil

Capacity

(gal)

Weight

(lbs)

Used withTool

ItemNumber

DescriptionValveType

Output Flow Rate (in3/min) Relief Valve Adjustment

Range

(psi)

Motor Electrical Specification

(volts-ph-Hz)

Motor Size

(hp)

Sound Level

(dBA) 100 700 5,000 10,000 psi psi psi psi

▼ SELECTION CHART

① User Adjustable Relief Valve② Oil Fill Port SAE #10③ Oil Level Sight Gauge

④ Oil Drain 0.50" NPTF⑤ M8 x 12 LG⑥ VM43M Valve (shown)

Factory Installed Features and Options

⑦ Skid Bar (shown; optional)

Spring Seat

PowerSeat

ZU4 Stressing Pumps

Flow at Rated Pressure:

60 in^3/minMotor Size:

1.7 hpMaximum Operating Pressure:

10,000 psi

ZU4 Stressing Pumps

Note: all dimensions are in inches

700 535 76 60 2 1,000-10,000

115-1-50/60

220-1-50/60

115-1-50/60

220-1-50/60

1.667 85-90 71

9.0

11.00

16.29

19.00

.50

5.6

0

3.75

8.1

9.46

10.50

17.0

0

3/8"-18NPTF

29

H006789H006790 H006786 H006787

PE55 SS-115

PE55 SS-220

PE55 PS-115

PE55 PS-220

• Axial piston pump element is fi eld proven and easy to service

• Universal electric motor is durable and easy to service

• True unloading valve achieves greater pump effi ciency, allowing higher fl ows at maximum pressure

The Industry Standard

The PE55 is lightweight and portable.▼

UsableOil

Capacity

(gal)

Weight

(lbs)

Used withTool

ItemNumber

DescriptionValveType

Output Flow Rate (in3/min) Relief Valve Adjustment

Range

(psi)

Motor Electrical Specification

(volts-ph-Hz)

Motor Size

(hp)

Sound Level

(dBA) 100 700 5,000 10,000 psi psi psi psi

▼ SELECTION CHART

Spring Seat

PowerSeat

PE55 Stressing Pumps

Flow at Rated Pressure:

60 in^3/minMotor Size:

1.125 hpMaximum Operating Pressure:

10,000 psi

PE55 Stressing Pumps

9500

9500

9628

9628

700 380 70 55 2 1,000-10,000

115-1-50/60

220-1-50/60

115-1-50/60

220-1-50/60

1.125 86-92

66

69

14.0

10.0

11.50

18.25

9.50

8.0

7.0

4 Mounting Holes 0.50"– 20

Note: All dimensions are in inches


PSBF-05H

PSBF-06H

PSBR-05H

PSBR-06H

PSBF-05B

PSBF-06B

PSBR-05B

PSBR-06B

H008124

H008144

H008072

H008142

H008079

H008162

H008078

H008163

• Available in battery and hydraulic versions and sizes to cut 0.50 inch or 0.60 inch strand sizes

• Reversible, hardened blades extend life (only the fi xed blades are reversible)

• Shear tendons inside the pocket, providing controlled tendon length without applying heat to the anchorage

• Battery models include two industrial 28 VDC battery packs and fast charger

• Battery models shipped in durable product case for protection and easy transport

• Eliminates the need for Hot Work Permits on the job when cutting tendon tails

• Provides quick and effortless tendon cutting with no risk of abrasive saw kick-back

PocketShear®

Additional Protection

After shearing the tendon,

the PocketCap® is the

perfect way to seal the

pocket and reduce the

chance for corrosion in

the anchorage zone.

Replacement Blades

Order the correct blades to

match your Shear from the

table shown below.

Fixed

Fixed

Rotating

Rotating

Fixed

Fixed

Rotating

Rotating

0.50

0.60

0.50

0.60

0.50

0.60

0.50

0.60

For PocketShear® Blade

Power

Type

Blade

TypeStrand

Size

(in)

Model

Number

Item

Number

Battery

Hydraulic

Cut PT Tendons in the Pocketwith Hydraulic or Battery Power

▼ The hydraulic PocketShear® makes quick and easy work of shearing tails on this elevated slab.

PocketShear® Pump

To power the hydraulic

PocketShear®,

the PocketShear

Pump H007684 is

the perfect choice.

31

✓

H008101

H008137

H008088

H008089

PSH05-O

PSH06-O

PSB05-TH

PSB06-TH

A

B

E

D

C

Hydraulic Version

B

D E

C

A

Battery Version

Only the PocketShear® can guarantee adequate

concrete cover, no heating of the tendon or

wedge set, and a clean cut end.

Cut-off saws cannot cut the tendon inside the

pocket, leaving the tendon end exposed to

moisture, creating the chance for corrosion.

Oxyacetylene torches heat the tendon and the

wedge when cut deep inside the pocket.

Even if the tendon is cut at the correct depth, the

tendon is still heated and the end is left jagged,

preventing re-gripping for possible future lift-off.

Without controls, there is little chance for

correct coverage of the tendon, leading to

future corrosion.

Throat

Style*

Operating

Pressure

(psi)

Length

A

(in)

Depth

B

(in)

Height

C

(in)

Nose

Depth

D

(in)

Clamp

Depth

E

(in)

Strand

Size

(in)

ItemNumber

ModelNumber

Power

Type

Weight

(lbs)

*May be special ordered with other throat styles.

Hydraulic

Hydraulic

Battery

Battery

Open

Open

Through

Through

▼ SELECTION CHART

PocketShear®

Strand Sizes:

0.50 and 0.60 inchPowered:

Hydraulic and BatteryMaximum Operating Pressure:

3,000 psi

PocketShear®

Open Throat Design

The Hydraulic PocketShear®

features an Open-Throat

design that allows easy

insertion of the strand into

the tool. This makes the

Shear easier to position and operate

on elevated applications.

3000

3000

n/a

n/a

22.60

28.60

4.25

5.75

9.80

10.70

17.99

18.10

8.80

10.20

12.12

13.50

2.51

3.02

4.03

4.13

3.50

3.50

2.17

2.13

27

35

29.1

37.7

0.50

0.60

0.50

0.60


H010318*

H010319*

H010306

H010307

H010309

H010308

H010310

H010311

H010312

H010313

H010314

H010315

H010316

H010317

Strand Capacity:

0.50 to 0.60 inchVoltage:

200 to 480 v.a.c.Current Draw:

52 to 22 amps

FlushCut™ Tip and

Wedge-Guard

The wedge-

guard protects

the encapsulated

components, including

the wedge, during the cutting process.

FlushCut™ PLASMA

torch tip fi ts into

compact, symetrical,

oval shaped

pocket formers.

• For applications or preferences that will not accept a PocketShear® or acetylene/oxygen torch

• Standard system requires external air and electrical supply

• Available with 25' or 50' cable packages

• Cut tendons quickly and eff ortlessly

• FlushCut™ tip cuts tendon near 90° and easily provides coverage for the grease cap and required concrete coverage

• System includes wedge-guard tool for 0.50" strand

Fast Tendon Cutting In or Out of the Pocket

PLASMA Cutting System

▼ SELECTION CHART – Consumables

Strand

Size

(in)

▼ SELECTION CHART – Component

DescriptionItemNumber

Tool TypeItemNumber

Power Type Electrical Specifications

Voltage Current

(v.a.c.) (amps)

Weight

(lbs)

Torch Tip

Cap, FlushCut™ 65

Swirl Ring; FlushCut™ 65

Electrode; PLC65

Electrode Bulk Pack

Nozzle Assembly

Retaining Ring

*Includes Power Unit, FlushCut™ Torch, Work-Lead and Starter Kit; **The pack is in a bulk of 25; FlushCut™ is a registered trade mark of Hypertherm® Inc.

PLASMA System 25'

PLASMA System 50'

Power Unit

FlushCut™** Head - 25'

FlushCut™ Head - 50'

Work Lead - 25'

Work Lead - 50'

Starter Kit

FlushCut™

FlushCut™

n/a

FlushCut™

FlushCut™

n/a

n/a

n/a

Electric

Electric

Electric

n/a

n/a

n/a

n/a

n/a

0.50

0.50

0.50

0.50

0.50

n/a

n/a

n/a

200-480

200-480

200-480

n/a

n/a

n/a

n/a

n/a

52-22

52-22

52-22

n/a

n/a

n/a

n/a

n/a

64

70

57

7

13

3

6

1

33

Utility Shear

H007714

H010318

H010319

BA

C

1.2

36-39 Pages:

Maximum Strand Capacity:

0.70 inchVoltage:

115 v.a.c.Current Draw:

11 amps

• Cut strand in the shop or in the fi eld easily and safely

• Do not cut any material other than strand (max of .70 PC strand)

• Low current draw will operate from 15 amp circuit

• Lightweight and portable; easy-load, open-throat for quick and eff ortless strand insertion

• One size cuts multiple strand sizes for increased fl exibility

• Simple operation: trigger switch to cut; lever to release

• Transparent guard protects against fl ying debris and allows easy monitoring of the cut

Cut Tendon Safely in the Shop or on your Site

Plant Production

Equipment

We provide a wide

array of fabrication,

extrusion and cut-off

lines for all of your PT

production requirements.

Strand Shearing Systems

PT strand is a very strong and

resilient material. This same

strength makes it very diffi cult to

cut safely with most portable cutting tools.

Cutting the tendon tails in the shop or on

a job site can be done quickly and safely

using a Utility Shear.

▼ SELECTION CHART

Replacement BladesItemNumber

Fixed Blade

Moveable Blade

Throat

Style

Operating

Pressure

(psi)

Length

A

(in)

Depth

B

(in)

Height

C

(in)

Maximum

Strand Size*

(in)

ItemNumber

Power

Type

Electrical Specifications

Voltage Current

(v.a.c.) (amps)

Weight

(lbs)

*Do not cut any material other than strand.

OpenElect/Hyd 8,4000.74 18.7 6.7 10.0 115 11.0 35


Installation Tools and Accessories

8

20-23

6-7

Keeping You Up and Running

▲ The SRT - Sheath Removal Tool is easy and eff ective at removing sheathing inside the pocket.

SURE-LOCK® Anchors

The industry standard

SURE-LOCK® and

SURE-LOCK® II anchors

are eff ective, proven

cast anchors.

Pre-Stress Products

High quality, durable strand

chucks, splice chucks,

and anchor chucks are

available for the precast/

pre-stressed concrete industry.

Certifi cations and other

product information are

available online:

www.precision-hayes.com

SURE-LOCK®

Chucks and Wedges

Trusted and recognized,

SURE-LOCK® chucks

and wedges are available

for one time use applications.

Installation• Hand Wedge Setter provides a quick way to

pre-seat wedges for retention in anchor

• SRT - Sheath Removal Tool, cuts the sheathing from the strand in the anchor cavity so it can be removed, allowing wedges to seat properly in the anchor cavity after stressing

• Tendon Tail Gauge: visual tool to ensure proper fi nished tendon length to prevent grease cap damage

• Short Cable Tubes and Short Cable Noses are used with Pre-Tension Splice Chucks to facilitate stressing of short cables

• 12" and 18" Chairs are used with Pre-Tension Splice Chucks to facilitate stressing of short cables

• 45° Stress Spacers are used to allow a jack to make full contact with the anchor when 45° pocket formers are used

Maintenance & Inspection• Grease Cones are used with the Lubrication Fixture

to eff ectively release lubricants

• Lubrication Fixtures are used with reusable chuck bodies to properly lubricate for release

• Jaw and chuck body brushes make cleaning and inspection fast and eff ective

• Anchor Cleaning Tools remove residual concrete slag and debris from seating area, for improved seating performance

Trouble Shooting• Trouble Shoot Anchors are used to help free a jack

that will not release from a tensioned cable

Page:

Pages:

Pages:

35

Installation Tools and Accessories

It is critical that Chucks and Wedges are clean before use.

Build up from contaminants can result in hazards to users and potential damage to structures. Build up can also make it diffi cult to properly inspect chucks and wedges for damage, which can result in dangerous situations.

To assist in properly maintaining chucks and wedges, we off er a number of products for cleaning and lubrication including chuck and wedge brushes, pictured to the left.

Item DescriptionItemNumber

Short Cable Tube H007788

Short Cable Nose H007789

Trouble Shoot anchor H007791

45° Stress Spacer H007793

12" Chair H007795

18" Chair H007797

Hand Wedge Setter H007799

Anchor Cleaning Tool H007923

SRT - Sheath Removal Tool H009929

Tendon-Tail Gauge H005003

Item DescriptionItemNumber

F7562 0.5625"- 0.60"

Wedge brushH007373

F7500 0.50" Wedge brush H007372

F7437 0.4375"- 0.46875"

Wedge brushH007371

F7375 0.375" Wedge brush H007370

F7250 0.25"- 0.3125"

Wedge brushH007369

F8562 0.5625"- 0.60"

Body brushH007368

F8500 0.375"- 0.50"

Body brushH007367

F8250 0.25"- 0.3125"

Body brushH007366

F10000 Lubrication fi xture H008617

F10003 Grease cone for

F1B bodyH008596


F2B bodyH008597


F3B bodyH008598

▼ SELECTION CHART – Post-Tension Accessories

▼ SELECTION CHART – Reusable Accessories

Installation Tools & Accessories

Tool Types:

Installation, Maintenance and Troubleshooting

Strand Sizes:

0.25 to 0.60 inch

ChuckBody

Wedge Brush

ChuckBrush Wedge

Bench mounted

drive motor with

correct cleaning

brush attached

tools and accessories -...

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