ITH Bolting Technology on the Zugspitze

Efficient maintenance of bolt connections in steel construction

As part of the regular maintenance of the steel construction of the mountain station on the Zugspitze – Germany’s highest workplace at 2,943.75 meters above sea level – ITH Bolting Technology supported the inspection of the bolt connections with expert technical advice, fast service and flexible bolting tools.

Industry

Steel construction

Technology

Maintenance with hydraulic strain gages

Year

2021

Expert technical advice and provision of tools

ITH Bolting Technology provided comprehensive support for the maintenance work at the mountain station on the Zugspitze – Germany’s highest peak. Specially selected hydraulic torque wrenches and modern hydraulic equipment were used for this demanding high-altitude construction site.

ITH already supported the project with technical expertise during the preparation phase:

  1. Technical advice on the pre-selection of the hydraulic torque wrenches and hydraulic equipment used.
  2. Provision of tools and proper instruction of technicians on site.
  3. Qualified assembling during the inspection of bolt connections in compliance with all safety standards.

Safe assembling at extreme heights

During maintenance, all bolt connections were professionally checked and installed – naturally in compliance with all safety standards. The specially trained team set their sights on efficient and safe bolting technology solutions from ITH.

“It was something special for us to work at this height and under these conditions. Although we are familiar with operations on construction sites with height safety, the Zugspitze is an exception for us – you definitely can’t be afraid of heights,” says ITH Sales Manager Jens Borggrebe. “It was impressive how the technicians on site dealt with the height and the view. The enormous experience makes everything look much more natural. Our bolting tools proved their worth and were a relief in these circumstances – especially our battery-powered hydraulic power unit.”
Thanks to cordless technology, it was possible to work flexibly and save time – without the need for time-consuming laying of power cables. This mobility contributed significantly to the efficiency of the operations.

The technicians on site drew a positive balance: “We were able to shorten the overall maintenance of the bolt connections by about a day.”

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More Information

Various bolt connections in the steel construction require flexibility

Bolt connections with different nominal dimensions are installed in the supporting structure of the mountain station. These range from M36-SW55 to M64-SW95; the torques to be applied are between 2,800 Nm and 14,762 Nm.

A total of six different configurations were checked. These were realized with two powerful ITH hydraulic torque wrenches (DMS) and the mobile high-pressure hydraulic unit ITH Hydro-DAX V18 Battery:

  1. DMS type D-Flex 5 for torques up to a maximum of 5,000 Nm, double-acting hydraulic cylinder, two-hose system.

  2. DMS type DKS 250 for torques up to a maximum of 25,000 Nm, simple-acting hydraulic cylinder, single-hose system.

  3. Battery-powered ITH Hydro-DAX V18 Battery high-pressure hydraulic power unit with an operating pressure of 850 bar, 82 V Li-ion battery, low-wear, brushless 1.5 kW electric motor.

The use of the battery-powered ITH Hydro-DAX V18 Battery high-pressure hydraulic power unit made the time-consuming installation of power supplies unnecessary. This significantly accelerated the inspection process. Thanks to the electric motor’s intelligent load-sense technology, the rotational speed adapts dynamically to the required load. This not only increases energy efficiency, but also extends battery life – a clear advantage for operations at extreme altitudes such as on the Zugspitze.

ITH Bolting Technology – Your partner for secure bolt connections in steel construction

Whether for the maintenance of cable car stations, steel bridges or other demanding steel construction projects – ITH Bolting Technology offers tailor-made solutions for every bolt connection. With a comprehensive portfolio of bolting tools and fasteners as well as sound technical advice, ITH stands for quality and reliability in steel construction.

Hydraulic torque wrench
Type D-Flex 5
0

for torques up to a maximum of 5,000 Nm, double-acting hydraulic cylinder, two-hose system.

Hydraulic torque wrench
Type DKS 250
0

for torques up to a maximum of 25,000 Nm, simple-acting hydraulic cylinder, single-hose system.

Hydraulic power unit with battery
Hydro-DAX V18 Battery
0

Operating pressure 850 bar, 82 V Li-ion battery, low-wear, brushless 1.5 kW electric motor.

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