Hydrajaws 2000 User manual

Operating Instructions
HYDR AJAWS
LIMITED
2000 Model Tester

2000 Model Tester
Model 2000 Parts
1. Gauge - Analogue with
QR Hydraulic Coupler
2. Gauge - Digital with
QR Hydraulic Coupler
(optional)
3. Quick release
 couplingwhentted
or gauge (1 & 2)
4. Tester body with
50mm/scale indicator
5. Load jaw
6. Turning handle with
integrated nut
7. Grab Handle
8. Displacement sensor
(Bluetooth option)
9. Level bubble
10. Threaded Legs
11. 75mm Hexagonal
Extension Legs
(optional)
12. 100mm Hexagonal
Extension Legs
(optional)
13. Tester bridge
1
2
4
78
9
3
6
10
11 12
5
2
TECHNICAL SPECIFICATIONS
• Pull-out load range 0-25kN/lb/f
• Weight
Tester only 2.2kg
Packaged weight 8kg (will vary)
• Stroke scale 0-50mm
• Effective stroke 50mm
• Loadgauge xedorInterchangeable
• Casing Aluminium
• Loading jaw Pivotable through
360° with Spring
return
• Operating handle Standard size with
integrated 22mm
operating nut for
  connedspaces
Load Gauges
• Ranges available: Digital: 0-30kN
Analogue: 0-5, 0-10, 0-15, 0-20
and 0-25kN/lb/f (5600lbf).
• Accuracy: Analogue to +/-2.5% fsd
Digital to +/-0.5% fsd
• Indicationofpull-outload
• Calibrated in kN
• TraceableUKAScalibrationcerticate
supplied with each gauge
• Protective rubber cover (analogue only)
• Impactresistantglass
• Protection against sudden load relief
 (i.e.suddenfailureofxing)
• Analogue and Digital: peak hold memory
• Working Temperature:
Analogue: -20°C to +60°C
Digital: -30°C to +85°C
13
See section 8 on tting
Hex Extension legs.

3
SAFETY RULES
•Modicationofthetester,ortampering
with its parts is not permissible.
• Observe the information printed in the
operating instructions applicable to
operation care and maintenance.
• The tester and its accessories may
present hazards when used incorrectly
by untrained personnel or not as
directed.
• Use only the genuine Hydrajaws
accessories or ancillary equipment
listed in the operating instructions.
The model 2000 pull-out tester is
a purpose made system for testing
xings, fasteners and anchors. It
consists of a mechanical screw
arrangement acting through a
hydraulic load cell, which measures
the load applied to the xing directly.
The resulting load value is then
indicated on the dial type analogue
gauge or optional digital gauge.
The tester has a built in movement
indicatorscale50mmtoshow“rst
movement”onthexingpriortothe
test load being applied. The tester and
bridge are supplied as an integral part
of all the 2000 tester kit ranges.
A comprehensive range of accessories
is also available, further increasing the
scope of possible testing applications.
USE OF THE TESTER AS DIRECTED
The tester is intended for use by skilled
personnel with the appropriate training
and knowledge of the applicable safety
precautions.
GENERAL DESCRIPTION
It is essential that the
operating instructions
are read before the tester is
operated for the rst time.
Always keep these operating
instructions together with
the tester.
Ensure that the operating
instructions are with the
tester when it is given to
other persons.
CONTENTS
Page
Model 2000 Parts 2
TechnicalSpecications 2
General description 3
Kit contents 4
1. GENERAL TESTING
PROCEDURE 5
2. PULLING ADAPTORS 8
2.1 The bolt test adaptor
Slotted button adaptors
Threaded button adaptors
2.2 Threaded stud adaptors 9
2.3 The insulation adaptor
2.4 Threaded rod adaptors 10
2.5 The clevis adaptor
3. SCAFFOLD TESTER KIT 11
4. SAFETY HARNESS EYEBOLT
TESTER KIT 14
5. WALL TIE TESTER KIT 16
6. MATERIAL BOND TESTER KIT 18
7. OPTIONAL LOAD
SPREADING BRIDGES 21
8. FITTING HEX EXTENSION LEGS 21
9. CARE OF TESTER
9.1 Lubrication 22
 9.2 Oilrellinginstructions 23
9.3 Calibration

4
FULL KIT CONTENT RANGE:
1. Model 2000 tester attached to
150 load spreading bridge
2. Oil bottle (Detachable gauge only)
3. Analogue load gauge(s)
4. Digital load gauge(s)
5. Button adaptors slotted set.
4.5, 5.5, 6.5, 8.5, 10.5 & 12.5mm
6. Button adaptors metric set.
M4, M5, M6, M8, M10 & M12
7. Hex socket wrench set 2.5mm
and spare screws
8. M12 ringbolt adaptor clevis
9. M5 threaded rod adaptor
10. M6 threaded rod adaptor
11. M8 threaded rod adaptor
12. M10 threaded rod adaptor
13. M10 threaded stud adaptor
14. M12 threaded stud adaptor
15. M16 threaded stud adaptor
16. M20 threaded stud adaptor
17.Insulationadaptor
18. Bolt tester adaptor
19. 50mm hexagon extension legs
20. 75mm hexagon extension legs
21. 100mm hexagon extension legs
22. 3mm Ball driver
23. 10mm single wrench
24. 22m ratchet spanner
25. M12 locking adaptor (inside tester)
26. Piston key
27.Carryingcasewithfoamller
28.OperatingInstructions
29.CerticateofCalibration
Optional Accessories:
For illustration purposes, this tester kit features
many optional accessories.
TESTER AND ACCESSORIES
1
24
22
19
16
12
14
15
2
11
8
18
7
4
17
9
13
3
21
20
29
10
Operating Instructions
HYD R AJ A W S
LIMITED
2000 Model Tester
28
27
5 6 25
23
26

5
1. GENERAL TESTING PROCEDURE
SETTING UP THE TESTER
1 Fit the appropriate adaptor to the tester.
Example shown is a bolt tester adaptor.
(Forttingofotheradaptorspleasesee
individual instructions in this manual).
2. The tester is supplied with a locking
adaptorttedintothetesterbody.
This locking adaptor can be removed
forttingofdifferentadaptorsbyusing
the 3mm Ball Driver. When replacing
back in ensure it is fully engaged into
the tester body before tightening
(g 1). Thread the bolt tester adaptor
into this, until it is fully engaged, using
a quarter turn for position (g 2).
3.Makenaladjustmentssothatthebolt
testeradaptor,testerandxingare
aligned (g 3).
4. Position the tester so that the gauge
can be easily read.
5. Adjust the length of the threaded legs
so that all three are in contact with the
base material and the load spreading
bridge is aligned and level by referring
to the bubble levels on each face.
Fig 3
Fig 2
Fig 1

6
Inconnedspacestheintegratednutcan
be used with a 22mm ratchet spanner for
betteraccessinconnedspacesandfor
easier operation (g 5).
Remove the handles by unscrewing from
the base using the 10mm wrench (g 6).
Ensure when re-attaching handles that
they are tight on and secure.
TESTING PROCEDURE
6. Set the red pointer on the gauge to zero
- hold the tester by the grip handle and
proceed to load the fastener by turning
the operating handle clockwise (g 4).
7.Increasetheloaduntiltherequired
test load is attained. Hold this load and
observe any falling back of the readings
which would indicate movement and
possible failure of the fastener. Record
the satisfactory result.
8. Release the load on the fastener
by turning the operating handle
anti-clockwise and allowing the test
jaw to return to the original position.
9. Remove the tester and bolt tester
adaptor.
Fig 5
CAUTION!
Hold the fastener securely by the grip
handle as long as the fastener is under
load. When the load increases, note
the reading on the displacement scale
onthetester.Indicationoffailureofthe
fastener may be obtained by comparing
the current reading with the original
reading.
Fig 4
Fig 6
Using the integrated nut
in conned spaces
1. GENERAL TESTING PROCEDURE continued..

7
It is recommended
when testing on ceilings
(inverted) and/or vertically,
that a safety line is
attached around the tester body to
a suitable solid xing point. This will
stop the tester falling and prevent
injury to personnel and/or damage
to test unit.
If no suitable xing point is available
then attach to safety harness on
personnel.
Adjusting the handle position (g 7)
Fig 7
The top part of the unit can be rotated if the handle or gauge becoming obstructed by the
unit legs or other objects.
This is achieved by loosening the three grub screws (a) on the body using the allen key
provided. Rotate the top until the handle and gauge are clear of obstacles and re-tighten
the screws.
a
a

8
2. PULLING ADAPTORS
2.1 THE BOLT TEST ADAPTOR
Using the bolt test adaptor directly
Using the bolt test adaptor with the slotted button adaptor
Using the bolt test adaptor with
the threaded button adaptor
For M16 nuts, (g 8) the bolt tester
adaptor (a) directly engages the nut (b) in
the pulling jaw.
Mount the locking adaptor into the tester
(see Section 1 General testing procedure).
Then thread the bolt tester adaptor into the
tester body (g 9).
Fig 8
Fortestingxingswhereaconnectionis
madeunderneaththeheadofthexingor
anchor the slotted button adaptor is used.
Mount the locking adaptor into the tester
(see Section 1 General testing procedure).
Then thread the bolt tester adaptor into the
tester body (g 9).
The slotted button adaptor (a) slots into
the bolt tester adaptor (b) and engages the
xing(c) (g 10).
Fortestingthreadedxingsthethreaded
button adaptor is used.
Mount the locking adaptor into the tester
(see Section 1 General testing procedure).
Then thread the bolt tester adaptor into the
tester body (g 9).
The threaded button adaptor (a) threads
ontothexing(c) and then slots into the
bolt tester adaptor (b) (g 11). Ensure the
button adaptor has at least 2 complete
threadturnsonthexingandissecure.
Fig 10
Fig 11
Fig 9
b
ca
b
c
a
a
b

9
Remove the insulation around the fastener.
Mount the locking adaptor into the tester (see
Section 1 General testing procedure). Thread
the insulation adaptor into the locking adaptor
fully then back off until horizontal.
By holding the tester, slide the head of the
insulation fastener (a) between the two plates
withthestemofthexingrestingintheslotin
the lower plate (b) and adjust the legs on the
load spreading bridge to suit the base material.
Ensure that the pull-out force acts along the
axisofthexingbeingtested(g 15).
Hexagonal leg extensions may be required to
reach an insulation fastener that is raised.
2.3 THE INSULATION ADAPTOR
2.2 M10, M12, M16 AND M20 THREADED STUD ADAPTORS
Fig 12
Suitable for testing sleeve and stud anchors.
(g 12) After the anchor has been set
in accordance with the manufacturers
recommendations, a suitable threaded
rod (a) is screwed into the anchor and the
adaptor (b)thentted.Thelengthofthe
threaded rod to be screwed into the anchor
must be at least equal to the diameter of the
anchor.
Removethelockingadaptoriftted(see
Section 1 General testing procedure).When
theadaptorissecurelyttedtotheanchor
thread position, place the tester over the
adaptor, passing the head through the hole
in the bridge and engage it in the pulling
jaw of the tester (g 13). Level the load
spreading bridge with the adjustable legs
before commencing the application of
the load.
Fig 13
b
a
1 2 3
Fig 15
b
a
Note: (g 14) To use
the optional M30 HD
Threaded stud adaptor,
rstattach45mmM20
thread piece (c) into
adaptor (e) and attach to
thexing.Thenthread
the M20 Adaptor (d)
and proceed as above.
Hexagonal leg extensions
may be required.
d
c
e
Fig 14

10
For testing ringbolts the Clevis adaptor is used.
Mount the locking adaptor into the tester (see Section 1 General testing procedure). Then
thread the clevis adaptor into the tester body until it is fully engaged, using a quarter turn
for positioning (g 18).
Remove crosspin from the clevis adaptor and offer the tester and bridge to engage eye of
the anchor in the clevis. Some adjustment will be required on the swivel feet, so that this
tisachieved.Pushclevispinthroughtheclevisandeyebolt,ensuringthattheballonthe
pin clicks into place, having passed through the second fork (g 19).Oncettedsecurely
commence testing (see Section 1 General testing procedure).
Fig 19
Fig 18
2.5 THE CLEVIS ADAPTOR
2.4 M5, M6, M8 AND M10 THREADED ROD ADAPTORS
Fig 16
The M5 and M6 threaded rod adaptors are
equipped with an external M12 thread for
use in conjunction with the M12 threaded
button adaptor. They are used primarily
for testing remedial wall ties. The M8 and
M10 threaded rod adaptors are equipped
with an M16 external thread and the M16
nutttedwithconnectstothepullingslot
in the tester or bolt tester adaptor.
Connect the threaded rod adaptor
complete with the M12 button adaptor to
thethreadonthexing(g 16).
Removethelockingadaptoriftted(see
Section 1 General testing procedure).
Adjust the length of the bridge legs and
the height of the button adaptor/nut so that
the adaptor can pass through the hole in
the bridge and engage it in the pulling jaw
of the tester (g 17).
Level the load spreading bridge with the
adjustable legs before commencing the
application of the load.
Fig 17
b
a
1 2 3 4

11
3. SCAFFOLD TESTER KIT
The Hydrajaws Test meter is part of a
purposemadesystemfortestingxings
and measures the load supplied. The
Scaffold Tester Kit has accessories
designed to test Scaffold Anchors and
Ringbolts to the requirements of the
guidance note TG4-04 issued by National
Access and Scaffolding Confederation
(NASC) and the Construction Fixings
Association (CFA).
The Tester is factory assembled with the
bolt tester adaptor screwed into the M12
locking adaptor located in the Tester jaw,
and the three 100mm hexagon legs with
swivelfeetxedtothe150loadspreading
bridge. Further adjustment available in the
foot (20mm).
KIT CONTENTS:
• 2000 model Medium Duty Tester
withxedGaugeto20kN*
• 150mm Load Spreading Bridge
• 100mm Hex Extension legs (3)
• Turning handle with integrated
22mm operating nut
• M16 Hex Setscrew
• Bolt Tester Adaptor
• M12 Ringbolt Adaptor Clevis
• M12 Locking Adaptor
•CalibrationCerticate
• Padded Carrying Case
* Some models have removable gauge and
coupler system
TESTING OF M16 DROP IN SCAFFOLD TIE ANCHORS
Fit the M16 hexagon setscrew to the anchor, ensuring at least two complete turns for
ample thread engagement. Offer Tester with bridge to the hexagon head of the setscrew
and engage head in bolt tester adaptor jaw. Make adjustment on each swivel foot by
unscrewing from the hexagon extension legs so that each foot is resting on the material
around the anchor and the bridge is square and level.
Check that the black gauge pointer is resting on zero and set the red maximum indicator
pointer to zero by turning the knob on the gauge glass anti-clockwise.
Commence the test by turning the operating handle on the Tester clockwise and observe
the gauge as the load on the anchor is increasing. Continue applying the load until the
proof test load is reach (kN) with the black gauge pointer. Stop applying the load and
observe if the black pointer falls back, leaving the red pointer at the maximum load
achieved.Ifthefallbackontheblackpointerisminimal,applytheloadagainuntilboth
pointers are at the test load required and leave the test load in place for approximately
10 seconds.
Should the black pointer not reach the maximum test load requirement, or the
operating handle has to be turned to maintain the load, it is certain that the anchor will
have failed the test.

12
TESTING OF EYE TYPE ANCHORS
Unscrew the bolt tester adaptor from the M12 locking adaptor in the Tester jaw and
replace it with the ringbolt adaptor clevis. Ensure that at least 2 complete clockwise turns
are made to safely engage the threads. Remove crosspin from the clevis and offer the
Tester and bridge to engage eye of the anchor in the clevis. Some adjustment will be
requiredontheswivelfeet,sothatthistisachieved,pushclevispinthroughtheclevis
and eyebolt, ensuring that the ball on the pin clicks into place, having passed through the
second fork. Commence the test as described for drop in anchors.
Note: Longer Scaffold Eyebolts used in timber frame construction can be tested. But
extra long extension legs are required – not supplied in standard kit.
ThenewNASC/CFAGuidanceNoteTG4:04*“AnchorageSystemsforScaffolding”sets
outrequirementsforPRELIMINARYTESTSofscaffoldanchors(tocheckthesuitability
and allowable loads of an anchor type in a particular base material) and PROOF TESTS
(sample tests to check that anchors have been installed correctly – to be carried out on
all jobs).
The new Proof Load testing requirement is for a tensile test of 1.5 x the design load.
The Hydrajaws Scaffold Tester Kit will test all of these types to a maximum tensile load
of 20kN. TG4:04 also describes six types of anchor most commonly used for anchoring
scaffold ties. The Hydrajaws Scaffold Tester Kit will test all of these types to a maximum
tensile load of 20kN.
* TG4:11 can be downloaded free of charge from the CFA website at www.xingscfa.co.uk
Fig 20 Test rig arrangements for:
Hex headed bolts, including
self tapping concrete screws
Socket anchors using slave
bolts. e.g. for ringbolt
Threaded
stud adaptor
SCAFFOLD TESTER KIT continued..

13
Fig 21 Test rig arrangements for:
Drop-in anchors (concrete only)
Standard ringbolt
20kN gauge
Scaffold ringbolt

14
4. SAFETY HARNESS EYEBOLT TESTER KIT
TESTING A SAFETY HARNESS EYEBOLT (g 22)
TESTING A LADDER RESTRAINT HOOK (g 23)
For testing Safety Harness Eyebolts to the
requirements of BS5845 and BS EN795
Protection Against Falling From A Height,
Anchor Devices - Requirement for Testing
and BS 7883: 2005 BS 788: 2005 code of
practiceforDesign,Selection,Installation,
Use and Maintenance of Anchor Devices
conforming to BS En 795. The kit may
also be used for testing Ladder Restraint
Hooks and most Ringbolts in concrete or
masonry.
The Tester is factory assembled with the
ringbolt adaptor screwed into the M12
locking adaptor located in the Tester jaw
and the 150 load spreading bridge with the
three 75mm hexagon legs with swivel feet
with25mmofneadjustment.
KIT CONTENTS:
• 2000 model Medium Duty Tester with
xedGaugeto15kN*
• 150mm Load Spreading Bridge
• 75mm Hex Extension Legs (3)
• M12 Ringbolt Adaptor with
Locking Adaptor
• Turning handle with integrated
operating 22mm nut
•CalibrationCerticate
• Padded Carrying Case
* Some models have removable gauge and
coupler system
Placethebridgeovertheeyebolttobetested.Locatetheclevisontheeyeboltandtthe
cross pin through the clevis and eyebolt, ensuring that the ball on the pin clicks into place,
having passed through the second fork (see section 2.5 The Clevis Adaptor).
Adjust the swivel feet by unscrewing from the hexagon leg, so that each foot is resting on
the material around the eyebolt and the bridge is square and level. Fit a protection plate
betweenwallandbridgefeetifnecessary,toprotectsoftdecorativenishes.
Check that the black gauge pointer is resting on zero and set the red maximum indicator
pointer to zero, by turning the knob on the gauge window anticlockwise.
Commence the test by turning the operating handle on the tester clockwise and observe
the gauge as the load on the eyebolt is increasing. Continue applying the load until the
proof test load of 6kN is reached with the black gauge pointer. Stop applying the load and
observe if the black pointer falls back, leaving only the red pointer at the maximum load
achieved.
Ifthefallbackisminimal,applytheloadagainuntilbothpointersareattheprooftestload
and the structural anchorage should then sustain the force for a minimum of 15 seconds.
Follow the same setting up procedure as for Safety Harness Eyebolt test, and apply the
load gradually until the required proof load of 2.5kN is reached or failure occurs. Observe
if the hook withdraws from the structure or the test load cannot be achieved. This would be
considered a failure and must be taken out of service

15
In brickwork reaction
loads are directed
away from the brick
under test
Eyebolt
15kN
gauge
Cross pin
150 load
spreading bridge
75mm hex legs
Clevis
Swivel foot
Reaction loads away
from brick under test
Clevis
Ladder restraint
hook under test
150 load spreading
bridge with 75mm
hex legs
In brickwork reaction
loads are directed
away from the brick
under test
Eyebolt
15kN
gauge
Cross pin
150 load
spreading bridge
75mm hex legs
Clevis
Swivel foot
Reaction loads away
from brick under test
Clevis
Ladder restraint
hook under test
150 load spreading
bridge with 75mm
hex legs
Fig 22
Fig 23

16
5. WALL TIE TESTER KIT
KIT CONTENTS:
• 2000 model Medium Duty Tester with
xedGaugeto5kN*
• Wall Tie Spacer Bridge
• M5 & M6 Wall Tie Adaptors
•CalibrationCerticate
• Padded Carrying Case
* Some models have removable gauge and
coupler system
SITE TESTING OF
WALL TIES
The purpose of carrying out site tests on
wall ties is either as part of a site survey to
investigate the suitability of the base
material for the use of a particular tie or
during the installation of the ties to verify
the quality of the installation.
Fig 24
InaccordancewiththeBBArecommendationonRemedialwalltiesitisrequiredthat
therst3tiesinabuildingshouldbetestedfollowedby1tieinevery20installed.BRE
Digest401‘Replacingwallties’speciesthattheinnerendoftherst20tiesinstalledon
a contract should be all proof tested and that a reducing rate of testing is required for the
remaining ties, for 21 to 250 ties 10% should be tested, for 251 to 1000 ties 5% should be
tested and for more than 1000 ties 2.5% should be tested.
LOAD PROCEDURE
Generally the loading procedure for
testing wall ties is the same for both ends
of wall ties regardless of whether they are
mechanicalandchemicalxings,sothe
loading procedures which follow. Connect
the wall tie adaptor complete with the M12
threaded button adaptor to the end of the
wall tie, taking care not to tighten the outer
leaf expansion nut (g 24).
With the test meter securely attached to
the Bridge, adjusting the length of the legs
on the loading bridge and the position of
the button adaptor if necessary, pass the
adaptors through the keyhole slot in
the loading bridge and ensure that the
button adaptor is centred in the test
meter (g 25).
Use the levelling screws on the bridge
to take up the slack in the system and to
ensure that the test meter is axially
aligned with the wall tie under test.
DO NOT LOAD THE
TIE WITH THE
LEVELLING SCREWS.
a
b
a
b
1
2
3
For inset wall ties - ensure width of hole (a)
is wide enough to accommodate the wall
tie adaptor and is set deep enough (b).

17
Position the test meter so that the
gauge is in the most convenient
place to read it. Set the red pointer
at zero. Whilst holding onto the
handle on the test meter body,
turn the loading handle clockwise
to increase the load on the anchor.
Note: Do not let go of the tester
before the load has been removed.
When the load starts to increase
note the scale reading on the
displacement scale behind the
gauge on the test meter body.
Keep increasing the load until the
required load is achieved (for test
OPTIONAL ADAPTORS
Optional adaptors are available for non-threaded ties.
Forexample,theHelixwalltie(picturedonright)hasa
special adaptor to enable testing.
Please contact us for information on our range of
special adaptors.
Fig 25
a
b
Note: A sample of the tie may be required to conrm the right adaptor is supplied.
load please consult manufacturers recommendation). Some indication of the displacement
of the Tie can be obtained by comparing the reading form the displacement scaled while
thexingisunderloadwiththerstreadingnoted.Toreleasetheloadrotatethehandle
anti-clockwise and push down until the original position is resumed. Lift the test meter off
the stud adaptor and unscrew the adaptor and studding.
PROCEDURE, INNER LEAF
Installthetieintotheinnerleafinaccordancewiththemethodstatementappropriate
tothewalltiebeingused.Ifappropriateleavetheresinmortartocureforatleastthe
recommended curing time. Load the tie in accordance with the procedure given above.
Ifthedisplacementofthetieisjudgedtobeexcessivethenthequalityofthexintothe
base material is suspect. Remove the testing assembly and complete the installation
of the tie in accordance with the appropriate method statement.
PROCEDURE, OUTER LEAF, MECHANICAL CONNECTIONS
Itisnotpossibletotesttheouterleafinisolationonanormallyinstalledtie.
NOW AVAILABLE: WALL TIE TESTER KIT MK 2
The Hydrajaws Wall Tie Tester Kit Mk2 is used for testing all types
ofremedialwalltietomeettherequirementsofDD140.Itisused
with appropriate adaptor and mounts direct to tester.
The Mk2 Kit comes with M5 and M6 threaded rod adaptors and a
selection of adaptors are available to suit a wide range of wall ties.

18
6. MATERIAL BOND TESTER KIT
Procedure for preparing samples for pull-off testing:
1. Clean the steel dollies (degrease and grit blast unless
otherwise stated). This will help to prevent interfacial
failures at the dolly interface.
2. For concrete substrates drill through the repair system
with diamond core drill at (90±)º to the surface into the
test surface by ~5mm or more.
This ensures a consistent bond area and will therefore
help reduce variations in the test results.
3. Clean the substrate test surface as recommended by
the manufacturer.
4. Mix the adhesive as recommended by the adhesive
supplier and add 1% by weight of ballotini (usually
0.5mm unless stated otherwise).
Adding ballotini will reduce alignment errors and
therefore help reduce variations in the test results.
5. Apply adhesive to steel dolly.
• 2000 model Medium Duty Tester with
xedGaugeto25kN*
• Bond test stool with adjustable legs
• 10x50mm & 10x 75mm steel bond
discs
• Bond test plug
•CalibrationCerticate
• Padded Carrying Case
(Can accommodate 20x50 & 20x75 discs)
ON SITE PULL-OFF METHOD
Equipment that may be required in
addition to the standard kit contents:
• Adhesive • Spatula
• Bondline spacers -
i.e.ballotini (glass spheres)
• Diamond-coated core drill
The bonding strengths of a wide and
varied range of materials including
concrete, screeds, repair mortars, epoxy
resin coatings, laminates, plastics,
paints and enamels may be accurately
determined using the Hydrajaws Material
Bond Tester.
Adequate direct tensile strength or
bonding strength between two layers is
important if repairs to concrete structures
or additional overlays and screeding on
existing concrete is to be structurally
sound.
The pull-off test as a means of projecting
the compressive strength of concrete
and other materials involves bonding
a circular steel disc to the surface by
means of an epoxy resin adhesive.
KIT CONTENTS:
A controlled tensile force is then applied to the disc, and as the strength of the bond is
greater than that of the material under stress it will eventually fail in tension. From the
area of the disc and the force applied at failure it is possible to calculate a nominal tensile
strength for the material.
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY DOLLY
TEST SURFACE
Excess adhesive
extruded
TEST SURFACE
DOLLY
TEST SURFACE
LOAD
Loading
bolt
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
DOLLY
TEST SURFACE
Excess adhesive
extruded
TEST SURFACE
DOLLY
TEST SURFACE
LOAD
Loading
bolt
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY DOLLY
TEST SURFACE
Excess adhesive
extruded
TEST SURFACE
DOLLY
TEST SURFACE
LOAD
Loading
bolt
a
b
c
Fig 26
* Some models have removable gauge
and coupler system.

19
Fig 27
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY DOLLY
TEST SURFACE
Excess adhesive
extruded
TEST SURFACE
DOLLY
TEST SURFACE
LOAD
Loading
bolt
Fig 29
Interfacialfailure
to dolly.
Cohesive failure of
the adhesive.
Interfacialfailure
to substrate.
Substrate failure.
6. Apply adhesive to substrate test surface (g 26a). This ensures the adhesive wets out
both surfaces and helps prevent interfacial failures.
7. Pressthesteeldollyintothesubstratetestsurfacewitharmpressure(g 26b)
DONOT‘seat’thedollybytwistingitintoposition.Ifthedollyistwistedintopositionit
will increase the likelihood of interfacial failures.
8. Remove excess adhesive from around the edge of the dolly without disturbing its
position (g 26c). This ensures a consistent bond area and will therefore help reduce
variationsinthetestresults.Ifworkingonaverticaloroverheadsurface,ensurethe
dolliesareheldrmlyinpositionuntiltheadhesivehascured.
9. Connect centering plug to disc using the 8mm thread and hand tighten until bottom is
ushwithtopdisc(g 27a).
10. Lower load stool centre hole over centering plug and adjust the 3 screws until top of
plugisushandlevelwithtopofstool.Itisessentialthatthislevellingiscarriedout
carefully to ensure a square and smooth pull through the stool. The load applied to the
centre of the dolly should be at an angle of 90º±1 (g 27b).
11.SlideTesteroveradaptorontopofplugandt22mmsocketandratchettothe
operating nut (g 28). Secure equipment so that it does not move during testing.
This will cause excess misalignment which will reduce pull-off strengths.
12. Operate ratchet in a clockwise direction until required loading is obtained or bonding
breaks. Record test temperature, failure load and failure mode (g 29) (Record mixed
failure modes in percentages of bond area, i.e. 90% substrate failure, 10% cohesive
failure). Maximum loading achieved will be shown by red indicator pointer. Use this
reading to calculate the bond strength Mpa from the chart on page 20.
ab
TEST SURFACE
DOLLY
TEST SURFACE
LOAD
Loading
bolt
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
LOAD
Loading
bolt
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
DOLLY
TEST SURFACE
DOLLY
TEST SURFACE
LOAD
Loading
bolt
TEST SURFACE
DOLLY
TEST SURFACE
DOLLY
DOLLY
Fig 28

20
ACTUAL PULL FORCE READ DIRECT FROM GAUGE
50mm dia Disc Area 1964mm2 Actual Pull Force 75mm dia Disc Area 4418mm2
Bond Strength kN Bond Strength
MPA Mpa
0.51 1.00 0.23
1.01 2.00 0.45
1.53 3.00 0.68
2.03 4.00 0.90
2.55 5.00 1.13
3.05 6.00 1.36
3.56 7.00 1.59
4.07 8.00 1.81
4.58 9.00 2.04
5.09 10.00 2.26
5.06 11.00 2.49
6.11 12.00 2.72
6.62 13.00 2.94
7.13 14.00 3.16
7.63 15.00 3.40
8.15 16.00 3.62
8.66 17.00 3.85
9.16 18.00 4.07
9.67 19.00 4.30
10.20 20.00 4.52
10.70 21.00 4.98
11.71 23.00 5.20
12.22 24.00 5.43
12.73 25.00 5.65
Mpa (Mega Pascales) = N/mm squared
Mpa = Actual Pull Force divided by Area of Disc x 1000
MATERIAL BOND TESTER KIT continued..
IMPORTANT! A low reading will be obtained if:
• The pull-off tester is misaligned and not perpendicular to the specimen
• The specimen is misaligned and not perpendicular to the pull-off tester
• The bondline is not of uniform thickness (0.5mm)
• A sudden or erratic loading is applied.
Note: This information is for guidance only. Please also refer to adhesive manufacturer’s
data and safety sheets.
Replacement discs available in both sizes from stock.