Flat Jacks

1

FLAT JACKS
Hydra-Capsule low height flat jacks range from 8 to 1000 tons
in capacity. The ultra compact jack is capable of exerting
extremely high thrust forces. They are normally used by the
civil and construction industry for a multitude of applications,
such as heavy lifting of structures, stressing operations,
transferring existing loads to temporary or permanent
supports and permanently pre-loading operations for
buildings, steelworks or bridge bearings.

6000

400
500
600
700
0
bar
1000
100
8000
300
200
psi
All our Hydra-Capsule flat jacks are designed, fully tested

and manufactured in-house within our special facility.
PERMANENT FLAT JACKS

flat jack
Where a permanent force / load is required to a structure,

flat jacks are installed in-situ and inflated using a high
pressure injection system, epoxy resin or cementitious
grout can be precisely injected.
funnel
This process is primarily implemented whist carrying out

works for pre-loading of structural steelworks or part of
other alterations, such as, underpinning or bridge bearing
replacement operations.
flexible
or hard
lines
The benefits of permanent flat jacks are:

Permanently induced force.
Known and precise load induction.
double
acting
pump
flexible
lines
Balanced loading of multiple sets.

Very low crushing forces, 14 N/mm 2
Jacks can be pre-cast into concrete blocks.
injection
cylinder
Hydra-Capsule Ltd provide a full design, in-house

manufacturing for bespoke units and installation
service offered throughout the UK, Ireland and
Europe using our specially trained and qualified
Engineers.
pressure
gauge
flat jacks
TEMPORARY FLAT JACKS

When flat jacks are required for a temporary duration and
subsequently removed, the operation is normally executed by
inflating the jacks with either water or hydraulic oil.
isolation
valves
The benefits of temporary flat jacks are:

manifold
Used as load cells when connected to pressure transducers

with calibrated digital readout displays.
Continuous load monitoring and adjustment possible.
flexible
hoses
pressure
gauge
hand
pump
Uniform loading of multiple sets.

Ability to transfuse jack fluid from temporary to permanent grout.
tel: +44 (0) 1885 490405
www.hydra-capsule.com
email: [email protected]
SELECTION CHART
closed
from 8 to 1000 tons capacity

JACK
CODE
CAPACITY
(tons)
CLOSED
HEIGHT
OUTSIDE
DIAMETER
THRUST
DIAMETER
MAXIMUM
STROKE
MAXIMUM
PRESSURE
FLUID
LITRES
WEIGHT
(KGS)
FJ-12
28
120
75
25
150 bar
0.3
FJ-15
15
29
150
105
25
150 bar
0.5
FJ-17
20
29
170
125
25
150 bar
0.8
FJ-19
25
30
190
145
25
150 bar
1.1
10
FJ-22
40
30
220
175
25
150 bar
1.2
16
FJ-25
50
30
250
205
25
150 bar
1.3
19
FJ-27
60
31
270
225
25
150 bar
1.6
20
FJ-30
80
32
300
254
25
150 bar
1.9
23
FJ-35
100
34
350
304
25
150 bar
2.6
26
FJ-38
130
34
380
334
25
150 bar
3.1
28
FJ-42
160
35
420
373
25
150 bar
3.6
29
FJ-45
180
36
450
403
25
150 bar
4.1
30
FJ-48
210
36
480
433
25
150 bar
4.7
32
FJ-50
235
36
500
453
25
150 bar
5.1
34
FJ-52
265
36
520
473
25
150 bar
5.7
36
FJ-54
280
37
540
493
25
150 bar
5.9
37
FJ-56
300
37
560
512
26
150 bar
6.2
38
FJ-60
345
38
600
553
27
150 bar
7.4
43
FJ-69
480
38
690
640
28
150 bar
10.5
67
FJ-75
600
39
750
700
32
150 bar
12.4
89
FJ-87
760
39
870
820
35
150 bar
16.8
111
FJ-92
870
42
920
895
36
150 bar
18.7
126
FJ-102
1000
55
1020
940
40
150 bar
24.5
172
When selecting a flat jack the ideal working range should be 25% to 75% of the jacks capacity.
open
TYPE A
thrust area
TYPE B
thrust area
TYPICAL APPLICATIONS
Shown below are just a few examples of flat jack applications.

Hydra-Capsule flat jacking systems have been successfully used
on a multitude of major projects worldwide for over 25 years.
Excavation Strut Pre-Loading

Flat jacks are commonly used for pre-loading horizontal struts
for major ground work projects prior to excavation taking place,
ensuring unwanted settlements or excessive deflections do not
occur. The strut is normally supported by angle brackets, one
end is grouted and the flat jack is placed at the opposite end.
The grout filled flat jack is then loaded to 90% of the calculated
imposed force thus providing safe excavation.
Ground Settlement Compensation

Flat jacks are ideal for dealing with unwanted foundation
settlements occurring during constriction works or building
alterations. The jacks are initially inflated with water and
then at a later stage after settlement transfused to grout
to make them permanent.
Lifting Heavy Structures

Flat jacks can be set-up in multiple groups to enable
the lifting of very heavy structures, such as, bridges to
change existing defective elastomeric bearings. The
loads and movements of each group can be precisely
monitored and controlled using our fully synchronised
electronic pumping systems.
Pre-Loading of New Steelworks

Flat jacks are commonly used for pre-loading new
steelworks to enable the formation of openings within
load bearing walls with zero deflection. The stressing
operation is normally carried-out using grout filled units
and electronic movement sensors to determine the exact
lifting point during loading. The arrangement can also be
used for pre-stressing new strengthening beams fitted
below a weak structure.
Pre-Loading of Bridge Bearings

Using grout filled or transfusion flat jacks to pre-load replacement
bridge bearings provides an effective method of loading individual
bearings to a specific load or deflection. Once installed and loaded
the flat jacks are normally encased within the bearings grout plinth.
tel: +44 (0) 1885 490405
www.hydra-capsule.com
email: [email protected]

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1

All our Hydra-Capsule flat jacks are designed, fully tested

PERMANENT FLAT JACKS

Where a permanent force / load is required to a structure,

This process is primarily implemented whist carrying out

The benefits of permanent flat jacks are:

Balanced loading of multiple sets.

Hydra-Capsule Ltd provide a full design, in-house

TEMPORARY FLAT JACKS

The benefits of temporary flat jacks are:

Used as load cells when connected to pressure transducers

Uniform loading of multiple sets.

tel: +44 (0) 1885 490405

from 8 to 1000 tons capacity

Shown below are just a few examples of flat jack applications.

Excavation Strut Pre-Loading

Ground Settlement Compensation

Lifting Heavy Structures

Pre-Loading of New Steelworks

Pre-Loading of Bridge Bearings

tel: +44 (0) 1885 490405

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