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New: Tensioner Tottight Plugs
Multi-bolt tensioning for large-diameter pipelines — DN325 to DN2000
Learn More →
Mechanical Pipe Plugs
Tensioner Tottight Steel Test Plugs (0,2 - 1 bar)
General specifications
Multi-bolt tensioning system for secure sealing, blockage and testing of large-diameter pipelines from DN325 to DN2000.
- Size range325 — 2000 mm
- Back pressure0,2 – 1 bar
- MaterialSteel (NR/SBR, CR, EPDM seal)
- Bypass2" connection
- Working temp.−20 to +80 °C
Description & features
Tensioner Tottight Steel Test Plugs are designed for secure sealing, blockage, and testing of large-diameter pipelines. The plug uses a multi-bolt tensioning system around the steel flange. Tightening the bolts compresses the rubber seal between the steel plates, forcing it to expand against the inner pipe wall and create a strong mechanical seal.
The distributed tensioning points provide more even sealing pressure, improved stability, and reliable performance during pipe testing, blockage, maintenance, and repair operations. The bypass connection allows controlled flow, drainage, and pressure release when required.
Key Features
- Multi-bolt tensioning system: distributed tensioning points for even sealing pressure and improved stability.
- Large-diameter coverage: DN325 — DN2000, back pressure 0,2 – 1 bar.
- 2" bypass connection: controlled flow, drainage and pressure 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
- Sanitary systems: air and water testing, temporary sealing, or controlled isolation.
- Sewerage pipelines: maintenance, blockage, testing, or flow management.
- Drainage lines: secure pipe-end sealing during inspection or repair works.
- Industrial pipelines: reliable sealing, low-pressure testing, or temporary blockage.
- Municipal infrastructure: pipe isolation and bypass flow control during repairs or installations.
- Wastewater systems: stable sealing and controlled drainage during maintenance operations.
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.
01
Inspect
Check the plug body, rubber seal and bolts for damage. Confirm the reference matches the inner diameter of the pipe to be sealed.
02
Position
Clean the pipe end and insert the plug so the sealing element sits fully inside the bore, square to the pipe axis.
03
Tighten
Tighten the bolts evenly in a crosswise pattern. The rubber seal compresses and expands against the pipe wall until firmly seated.
04
Test
Apply test pressure per EN 1610 or local code, staying within the back-pressure rating. Use the bypass for filling, venting or drainage.
05
Release
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.
Matching: All 68 models shown
Available models
68 active references.
QUICK GUIDEThe table below is a live RFQ builder — add models, tailor the options and send the list. Nothing is charged.
1FindFilter by pipe inner diameter
2AddUse + / − to set the quantity of each model
3ConfigureSet the options per model in its row
4SendOpen your RFQ list and send it — we reply with a formal quotation
MATERIALNR/SBR + Kevlar standard for water & air · NBR for oils · EPDM for chemicals
Set these per model with the Configure button in each row — defaults are pre-selected, and you can add several variants of the same model.
| 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 | TTSTP325 | DN325 | 315mm/12,4" | 355mm/13,98" | 310mm/12,2" | — | 1bar/14,5psi | 50,80mm/ 2" | 130mm/5,12" | 9kg/20,55lbs | |
0 | TTSTP350 | DN350 | 337mm/13,27" | 380mm/14,96" | 335mm/13,19" | 336,54mm/13,25" | 1bar/14,5psi | 50,80mm/ 2" | 130mm/5,12" | 10kg/22,53lbs | |
0 | TTSTP375 | DN375 | 365mm/14,37" | 405mm/15,94" | 360mm/14,17" | — | 1bar/14,5psi | 50,80mm/ 2" | 130mm/5,12" | 11kg/24,91lbs | |
0 | TTSTP400 | DN400 | 387mm/15,24" | 430mm/16,93" | 385mm/15,16" | 387,34mm/15,25" | 1bar/14,5psi | 50,80mm/ 2" | 130mm/5,12" | 12kg/27,39lbs | |
0 | TTSTP425 | DN425 | 415mm/16,34" | 455mm/17,91" | 410mm/16,14" | — | 1bar/14,5psi | 50,80mm/ 2" | 130mm/5,12" | 14kg/30lbs | |
0 | TTSTP450 | DN450 | 439mm/17,28" | 480mm/18,9" | 435mm/17,13" | 437,94mm/17,24" | 0,6bar/8,7psi | 50,80mm/ 2" | 130mm/5,12" | 15kg/32,71lbs | |
0 | TTSTP475 | DN475 | 465mm/18,31" | 505mm/19,88" | 460mm/18,11" | — | 0,6bar/8,7psi | 50,80mm/ 2" | 130mm/5,12" | 16kg/35,54lbs | |
0 | TTSTP500 | DN500 | 489mm/19,25" | 530mm/20,87" | 485mm/19,09" | 488,94mm/19,25" | 0,6bar/8,7psi | 50,80mm/ 2" | 130mm/5,12" | 17kg/38,47lbs | |
0 | TTSTP525 | DN525 | 515mm/20,28" | 555mm/21,85" | 510mm/20,08" | — | 0,6bar/8,7psi | 50,80mm/ 2" | 130mm/5,12" | 19kg/41,76lbs | |
0 | TTSTP550 | DN550 | 540mm/21,26" | 580mm/22,83" | 535mm/21,06" | 539,94mm/21,26" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 20kg/44,92lbs | |
0 | TTSTP575 | DN575 | 565mm/22,24" | 605mm/23,82" | 560mm/22,05" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 22kg/48,21lbs | |
0 | TTSTP600 | DN600 | 590mm/23,23" | 630mm/24,8" | 585mm/23,03" | 590,94mm/23,27" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 23kg/51,65lbs | |
0 | TTSTP625 | DN625 | 615mm/24,21" | 655mm/25,79" | 610mm/24,02" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 25kg/55,11lbs | |
0 | TTSTP650 | DN650 | 640mm/25,2" | 680mm/26,77" | 635mm/25" | 640,94mm/25,23" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 27kg/58,72lbs | |
0 | TTSTP675 | DN675 | 665mm/26,18" | 705mm/27,76" | 660mm/25,98" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 29kg/62,91lbs | |
0 | TTSTP700 | DN700 | 690mm/27,17" | 730mm/28,74" | 685mm/26,97" | 691,94mm/27,24" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 30kg/66,76lbs | |
0 | TTSTP725 | DN725 | 715mm/28,15" | 755mm/29,72" | 710mm/27,95" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 32kg/70,72lbs | |
0 | TTSTP750 | DN750 | 740mm/29,13" | 780mm/30,71" | 735mm/28,94" | 742,94mm/29,25" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 34kg/74,79lbs | |
0 | TTSTP775 | DN775 | 765mm/30,12" | 805mm/31,69" | 760mm/29,92" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 36kg/78,97lbs | |
0 | TTSTP800 | DN800 | 790mm/31,1" | 830mm/32,68" | 785mm/30,91" | 793,94mm/31,26" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 39kg/85,74lbs | |
0 | TTSTP825 | DN825 | 815mm/32,09" | 855mm/33,66" | 810mm/31,89" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 44kg/95,89lbs | |
0 | TTSTP850 | DN850 | 840mm/33,07" | 880mm/34,65" | 835mm/32,87" | 844,94mm/33,27" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 46kg/100,69lbs | |
0 | TTSTP875 | DN875 | 865mm/34,06" | 905mm/35,63" | 860mm/33,86" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 48kg/105,6lbs | |
0 | TTSTP900 | DN900 | 890mm/35,04" | 930mm/36,61" | 885mm/34,84" | 894,94mm/35,23" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 50kg/110,58lbs | |
0 | TTSTP925 | DN925 | 915mm/36,02" | 955mm/37,6" | 910mm/35,83" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 53kg/115,76lbs | |
0 | TTSTP950 | DN950 | 940mm/37,01" | 980mm/38,58" | 935mm/36,81" | 945,94mm/37,24" | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 55kg/121,18lbs | |
0 | TTSTP975 | DN975 | 965mm/37,99" | 1005mm/39,57" | 960mm/37,8" | — | 0,4bar/5,8psi | 50,80mm/ 2" | 130mm/5,12" | 57kg/126,37lbs | |
0 | TTSTP1000 | DN1000 | 990mm/38,98" | 1030mm/40,55" | 985mm/38,78" | 996,94mm/39,25" | 0,4bar/5,8psi | 50,80mm/ 2" | 150mm/5,91" | 79kg/173,91lbs | |
0 | TTSTP1025 | DN1025 | 1015mm/39,96" | 1055mm/41,54" | 1010mm/39,76" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 82kg/181,12lbs | |
0 | TTSTP1050 | DN1050 | 1040mm/40,94" | 1080mm/42,52" | 1035mm/40,75" | 1047,94mm/41,26" | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 90kg/197,71lbs | |
0 | TTSTP1075 | DN1075 | 1065mm/41,93" | 1105mm/43,5" | 1060mm/41,73" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 93kg/204,73lbs | |
0 | TTSTP1100 | DN1100 | 1090mm/42,91" | 1130mm/44,49" | 1085mm/42,72" | 1098,94mm/43,27" | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 96kg/212,07lbs | |
0 | TTSTP1125 | DN1125 | 1115mm/43,9" | 1155mm/45,47" | 1110mm/43,7" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 100kg/219,95lbs | |
0 | TTSTP1150 | DN1150 | 1140mm/44,88" | 1180mm/46,46" | 1135mm/44,69" | 1148,94mm/45,23" | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 104kg/230,04lbs | |
0 | TTSTP1175 | DN1175 | 1165mm/45,87" | 1205mm/47,44" | 1160mm/45,67" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 108kg/237,71lbs | |
0 | TTSTP1200 | DN1200 | 1190mm/46,85" | 1230mm/48,43" | 1185mm/46,65" | 1199,94mm/47,24" | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 112kg/246,37lbs | |
0 | TTSTP1225 | DN1225 | 1215mm/47,83" | 1255mm/49,41" | 1210mm/47,64" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 115kg/254,28lbs | |
0 | TTSTP1250 | DN1250 | 1240mm/48,82" | 1280mm/50,39" | 1235mm/48,62" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 119kg/262,18lbs | |
0 | TTSTP1275 | DN1275 | 1265mm/49,8" | 1305mm/51,38" | 1260mm/49,61" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 123kg/271,71lbs | |
0 | TTSTP1300 | DN1300 | 1290mm/50,79" | 1330mm/52,36" | 1285mm/50,59" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 127kg/279,23lbs | |
0 | TTSTP1325 | DN1325 | 1315mm/51,77" | 1355mm/53,35" | 1310mm/51,57" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 131kg/289,58lbs | |
0 | TTSTP1350 | DN1350 | 1340mm/52,76" | 1380mm/54,33" | 1335mm/52,56" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 135kg/297,31lbs | |
0 | TTSTP1375 | DN1375 | 1365mm/53,74" | 1405mm/55,31" | 1360mm/53,54" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 139kg/305,39lbs | |
0 | TTSTP1400 | DN1400 | 1390mm/54,72" | 1430mm/56,3" | 1385mm/54,53" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 147kg/323,41lbs | |
0 | TTSTP1425 | DN1425 | 1415mm/55,71" | 1455mm/57,28" | 1410mm/55,51" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 151kg/332,94lbs | |
0 | TTSTP1450 | DN1450 | 1440mm/56,69" | 1480mm/58,27" | 1435mm/56,5" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 155kg/341,62lbs | |
0 | TTSTP1475 | DN1475 | 1465mm/57,68" | 1505mm/59,25" | 1460mm/57,48" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 150mm/5,91" | 159kg/351,21lbs | |
0 | TTSTP1500 | DN1500 | 1490mm/58,66" | 1530mm/60,24" | 1485mm/58,46" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 191kg/420,39lbs | |
0 | TTSTP1525 | DN1525 | 1515mm/59,65" | 1555mm/61,22" | 1510mm/59,45" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 191kg/420,79lbs | |
0 | TTSTP1550 | DN1550 | 1540mm/60,63" | 1580mm/62,2" | 1535mm/60,43" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 201kg/443,93lbs | |
0 | TTSTP1575 | DN1575 | 1565mm/61,61" | 1605mm/63,19" | 1560mm/61,42" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 205kg/452,59lbs | |
0 | TTSTP1600 | DN1600 | 1590mm/62,6" | 1630mm/64,17" | 1585mm/62,4" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 210kg/463,86lbs | |
0 | TTSTP1625 | DN1625 | 1615mm/63,58" | 1655mm/65,16" | 1610mm/63,39" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 216kg/477,06lbs | |
0 | TTSTP1650 | DN1650 | 1640mm/64,57" | 1680mm/66,14" | 1635mm/64,37" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 220kg/485,13lbs | |
0 | TTSTP1675 | DN1675 | 1665mm/65,55" | 1705mm/67,13" | 1660mm/65,35" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 222kg/489,29lbs | |
0 | TTSTP1700 | DN1700 | 1690mm/66,54" | 1730mm/68,11" | 1685mm/66,34" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 224kg/494,39lbs | |
0 | TTSTP1725 | DN1725 | 1715mm/67,52" | 1755mm/69,09" | 1710mm/67,32" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 233kg/513,75lbs | |
0 | TTSTP1750 | DN1750 | 1740mm/68,5" | 1780mm/70,08" | 1735mm/68,31" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 241kg/530,15lbs | |
0 | TTSTP1775 | DN1775 | 1765mm/69,49" | 1805mm/71,06" | 1760mm/69,29" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 195mm/7,68" | 244kg/538,22lbs | |
0 | TTSTP1800 | DN1800 | 1790mm/70,47" | 1830mm/72,05" | 1785mm/70,28" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 300kg/660,58lbs | |
0 | TTSTP1825 | DN1825 | 1815mm/71,46" | 1855mm/73,03" | 1810mm/71,26" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 309kg/680,11lbs | |
0 | TTSTP1850 | DN1850 | 1840mm/72,44" | 1880mm/74,02" | 1835mm/72,24" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 319kg/702lbs | |
0 | TTSTP1875 | DN1875 | 1865mm/73,43" | 1905mm/75" | 1860mm/73,23" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 326kg/719,25lbs | |
0 | TTSTP1900 | DN1900 | 1890mm/74,41" | 1930mm/75,98" | 1885mm/74,21" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 334kg/736,4lbs | |
0 | TTSTP1925 | DN1925 | 1915mm/75,39" | 1955mm/76,97" | 1910mm/75,2" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 337kg/743,72lbs | |
0 | TTSTP1950 | DN1950 | 1940mm/76,38" | 1980mm/77,95" | 1935mm/76,18" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 345kg/759,69lbs | |
0 | TTSTP1975 | DN1975 | 1965mm/77,36" | 2005mm/78,94" | 1960mm/77,17" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 353kg/777,97lbs | |
0 | TTSTP2000 | DN2000 | 1990mm/78,35" | 2030mm/79,92" | 1985mm/78,15" | — | 0,2bar/2,9psi | 50,80mm/ 2" | 215mm/8,46" | 362kg/798,5lbs | |
Specifying for a project
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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