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Multi-bolt tensioning for large-diameter pipelines — DN325 to DN2000
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Aluminium Test Plugs (0,2 - 2,5 bar)
Lightweight aluminium mechanical plugs for temporary sealing and low-pressure testing — easy to carry, position and install by hand.
- Size range40 — 900 mm
- Back pressure0,2 – 2,5 bar
- MaterialAluminium (NR/SBR, CR, EPDM seal)
- BypassWith bypass (1/2" – 2")
- Working temp.−20 to +80 °C
Description & features
Lightweight aluminium mechanical plugs for the temporary sealing and low-pressure testing of pipelines. Available from DN40 to DN900 with back pressure ratings up to 2,5 bar (36,26 psi), each plug features an integrated bypass for filling, draining, or air release. Their low weight makes them easy to carry, position, and install by hand — the ideal choice for frequent use, larger diameters, and low-pressure leak testing.
Key Features
- Lightweight aluminium body: easy to carry, position and install by hand.
- Wide size range: DN40 — DN900, back pressure up to 2,5 bar.
- Integrated bypass: 1/2" up to 2" connection for filling, draining or air release.
- Seal material choice: NR/SBR, CR or EPDM, operating from −20 to +80 °C.
- Customizable: modified upon customer needs and application requirements.
Application Areas
- Frequent-use jobs: repeated installation and removal across sites.
- Larger diameters: low weight pays off where steel becomes hard to handle.
- Low-pressure leak testing: air and water tests on sewers, drainage and pipelines.
- Temporary sealing: controlled filling, draining and air release through the bypass.
Recommended installation procedure
Plugline mechanical test plugs seal by compressing a rubber element against the pipe wall. Follow the procedure below for safe installation and removal.
Check the plug body, rubber seal and bolts for damage. Confirm the reference matches the inner diameter of the pipe to be sealed.
Clean the pipe end and insert the plug so the sealing element sits fully inside the bore, square to the pipe axis.
Tighten the bolts evenly in a crosswise pattern. The rubber seal compresses and expands against the pipe wall until firmly seated.
Apply test pressure per EN 1610 or local code, staying within the back-pressure rating. Use the bypass for filling, venting or drainage.
Relieve pressure through the bypass, loosen the bolts and withdraw the plug. Clean and inspect before storage — reusable across many cycles.
Datasheets & catalogues
Download the technical catalogue for the Mechanical Pipe Plug range — full size tables, back pressures, bypass options and materials.
Find your model
Enter the measured inner diameter of the pipe to be tested or sealed — every model whose sealing range covers it is shown below.
Available models
40 active references.
| Quantity | Product Code | Nominal size (mm) | Min. inner dia. | Max. inner dia. | Product diameter | SCH STD pipe inner dia. | Back pressure | Bypass diameter | Length | Weight | Configure |
|---|---|---|---|---|---|---|---|---|---|---|---|
0 | ATP40 | DN40 | 39mm/1,54" | 53mm/2,09" | 38mm/1,5" | 40,94mm/1,61" | 2,5bar/36,26psi | 12,70mm/ 1/2" | 85mm/3,35" | 0,17kg/0,37lbs | |
0 | ATP50 | DN50 | 51mm/2,01" | 66mm/2,6" | 50mm/1,97" | 52,48mm/2,07" | 2,5bar/36,26psi | 12,70mm/ 1/2" | 85mm/3,35" | 0,22kg/0,48lbs | |
0 | ATP65 | DN65 | 61mm/2,4" | 79mm/3,11" | 60mm/2,36" | 62,68mm/2,47" | 2,5bar/36,26psi | 12,70mm/ 1/2" | 85mm/3,35" | 0,27kg/0,6lbs | |
0 | ATP80 | DN80 | 76mm/2,99" | 89mm/3,5" | 75mm/2,95" | 77,92mm/3,07" | 1,5bar/21,76psi | 12,70mm/ 1/2" | 85mm/3,35" | 0,4kg/0,88lbs | |
0 | ATP90 | DN90 | 85mm/3,35" | 103mm/4,06" | 84mm/3,31" | 90,12mm/3,55" | 1bar/14,5psi | 12,70mm/ 1/2" | 85mm/3,35" | 0,5kg/1,1lbs | |
0 | ATP100 | DN100 | 99mm/3,9" | 112mm/4,41" | 98mm/3,86" | 102,26mm/4,03" | 0,7bar/10,15psi | 12,70mm/ 1/2" | 85mm/3,35" | 0,8kg/1,76lbs | |
0 | ATP115 | DN115 | 110mm/4,33" | 128mm/5,04" | 109mm/4,29" | 117mm/4,61" | 0,7bar/10,15psi | 12,70mm/ 1/2" | 85mm/3,35" | 1,2kg/2,64lbs | |
0 | ATP125 | DN125 | 126mm/4,96" | 139mm/5,47" | 125mm/4,92" | 128,2mm/5,05" | 0,7bar/10,15psi | 12,70mm/ 1/2" | 85mm/3,35" | 1,3kg/2,87lbs | |
0 | ATP140 | DN140 | 135mm/5,31" | 152mm/5,98" | 134mm/5,28" | 141mm/5,55" | 0,7bar/10,15psi | 12,70mm/ 1/2" | 85mm/3,35" | 1,5kg/3,31lbs | |
0 | ATP150 | DN150 | 149mm/5,87" | 164mm/6,46" | 148mm/5,83" | 154,08mm/6,07" | 0,5bar/7,25psi | 12,70mm/ 1/2" | 85mm/3,35" | 1,5kg/3,31lbs | |
0 | ATP175 | DN175 | 171mm/6,73" | 196mm/7,72" | 170mm/6,69" | 178mm/7,01" | 0,5bar/7,25psi | 25,40mm/ 1" | 139mm/5,47" | 2,2kg/4,85lbs | |
0 | ATP200 | DN200 | 195mm/7,68" | 218mm/8,58" | 194mm/7,64" | 202,64mm/7,98" | 0,5bar/7,25psi | 25,40mm/ 1" | 134,5mm/5,3" | 2,6kg/5,73lbs | |
0 | ATP225 | DN225 | 219mm/8,62" | 245mm/9,65" | 218mm/8,58" | 227mm/8,94" | 0,5bar/7,25psi | 25,40mm/ 1" | 134,5mm/5,3" | 3,2kg/7,05lbs | |
0 | ATP250 | DN250 | 246mm/9,69" | 290mm/11,42" | 244mm/9,61" | 254,46mm/10,02" | 0,5bar/7,25psi | 25,40mm/ 1" | 176mm/6,93" | 3,6kg/7,93lbs | |
0 | ATP275 | DN275 | 272mm/10,71" | 305mm/12,01" | 270mm/10,63" | 279mm/10,98" | 0,5bar/7,25psi | 25,40mm/ 1" | 200,75mm/7,9" | 4kg/8,82lbs | |
0 | ATP300 | DN300 | 297mm/11,69" | 335mm/13,19" | 295mm/11,61" | 304,84mm/12" | 0,5bar/7,25psi | 25,40mm/ 1" | 208,75mm/8,22" | 4,5kg/9,92lbs | |
0 | ATP325 | DN325 | 315mm/12,4" | 355mm/13,98" | 310mm/12,2" | — | 0,5bar/7,25psi | 25,40mm/ 1" | 130mm/5,12" | 5kg/11,02lbs | |
0 | ATP350 | DN350 | 337mm/13,27" | 380mm/14,96" | 335mm/13,19" | 336,54mm/13,25" | 0,5bar/7,25psi | 25,40mm/ 1" | 130mm/5,12" | 5,5kg/12,12lbs | |
0 | ATP375 | DN375 | 365mm/14,37" | 405mm/15,94" | 360mm/14,17" | — | 0,3bar/4,35psi | 25,40mm/ 1" | 130mm/5,12" | 6kg/13,22lbs | |
0 | ATP400 | DN400 | 387mm/15,24" | 430mm/16,93" | 385mm/15,16" | 387,34mm/15,25" | 0,3bar/4,35psi | 25,40mm/ 1" | 130mm/5,12" | 6,6kg/14,55lbs | |
0 | ATP425 | DN425 | 415mm/16,34" | 455mm/17,91" | 410mm/16,14" | — | 0,3bar/4,35psi | 25,40mm/ 1" | 130mm/5,12" | 7,5kg/16,53lbs | |
0 | ATP450 | DN450 | 438mm/17,24" | 480mm/18,9" | 435mm/17,13" | 437,94mm/17,24" | 0,3bar/4,35psi | 25,40mm/ 1" | 130mm/5,12" | 8,2kg/18,07lbs | |
0 | ATP475 | DN475 | 465mm/18,31" | 505mm/19,88" | 460mm/18,11" | — | 0,3bar/4,35psi | 25,40mm/ 1" | 130mm/5,12" | 10kg/22,04lbs | |
0 | ATP500 | DN500 | 489mm/19,25" | 530mm/20,87" | 485mm/19,09" | 488,94mm/19,25" | 0,3bar/4,35psi | 50,80mm/ 2" | 130mm/5,12" | 11,8kg/26,01lbs | |
0 | ATP525 | DN525 | 515mm/20,28" | 555mm/21,85" | 510mm/20,08" | — | 0,3bar/4,35psi | 50,80mm/ 2" | 130mm/5,12" | 12,5kg/27,55lbs | |
0 | ATP550 | DN550 | 540mm/21,26" | 580mm/22,83" | 535mm/21,06" | 539,94mm/21,26" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 13,1kg/28,87lbs | |
0 | ATP575 | DN575 | 565mm/22,24" | 605mm/23,82" | 560mm/22,05" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 15kg/33,06lbs | |
0 | ATP600 | DN600 | 590mm/23,23" | 630mm/24,8" | 585mm/23,03" | 590,94mm/23,27" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 16,6kg/36,59lbs | |
0 | ATP625 | DN625 | 615mm/24,21" | 655mm/25,79" | 610mm/24,02" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 19kg/41,88lbs | |
0 | ATP650 | DN650 | 640mm/25,2" | 680mm/26,77" | 635mm/25" | 640,94mm/25,23" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 21kg/46,28lbs | |
0 | ATP675 | DN675 | 665mm/26,18" | 705mm/27,76" | 660mm/25,98" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 25kg/55,1lbs | |
0 | ATP700 | DN700 | 690mm/27,17" | 730mm/28,74" | 685mm/26,97" | 691,94mm/27,24" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 29kg/63,92lbs | |
0 | ATP725 | DN725 | 715mm/28,15" | 755mm/29,72" | 710mm/27,95" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 30,5kg/67,22lbs | |
0 | ATP750 | DN750 | 740mm/29,13" | 780mm/30,71" | 735mm/28,94" | 742,94mm/29,25" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 32kg/70,53lbs | |
0 | ATP775 | DN775 | 765mm/30,12" | 805mm/31,69" | 760mm/29,92" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 33,5kg/73,83lbs | |
0 | ATP800 | DN800 | 790mm/31,1" | 830mm/32,68" | 785mm/30,91" | 793,94mm/31,26" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 35kg/77,14lbs | |
0 | ATP825 | DN825 | 815mm/32,09" | 855mm/33,66" | 810mm/31,89" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 36,5kg/80,45lbs | |
0 | ATP850 | DN850 | 840mm/33,07" | 880mm/34,65" | 835mm/32,87" | 844,94mm/33,27" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 38kg/83,75lbs | |
0 | ATP875 | DN875 | 865mm/34,06" | 905mm/35,63" | 860mm/33,86" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 39,5kg/87,06lbs | |
0 | ATP900 | DN900 | 890mm/35,04" | 930mm/36,61" | 885mm/34,84" | 894,94mm/35,23" | 0,2bar/2,9psi | 50,80mm/ 2" | 130mm/5,12" | 40,6kg/89,48lbs | |
Send the spec. We send the datasheet.
DN, material, air connection, quantity. We come back inside 24 hours with the right reference, the test report on file, and stock confirmation from Istanbul.
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