Dead Ender Jack Maintenance and Repairs
Dead ender jack maintenance and repairs are important to keep crews working safely and efficiently. Dead ender jacks are responsible for tensioning the dead end of the strand’s anchorage. Once secured in place, the dead end provides the necessary internal stresses for reinforcement. With one half of the anchorage already tensioned, post-tensioning crews in the field can work faster and with greater reliability.
When dead ender jacks break down, it can bring production to an expensive standstill. The surest way to avoid this is to invest in regular dead ender jack maintenance, and the occasional repair when necessary. A hydraulic power expert can provide those critical repairs, ensuring your dead ender jacks remain reliable.
Reliability is a Critical Trait to Have in a Dead Ender Jack
Reliability is an essential characteristic in any hydraulic power system, and this is certainly true of dead ender jacks. During a typical production day, a dead ender jack may be responsible for tensioning hundreds of anchors, with little time to waste on each one.
Inefficiency with your dead ender jacks – a loss of operating pressure, for example – can badly hamper your operator teams and result in more expensive jack problems down the road.
Signs That a Dead Ender Jack Needs Maintenance or Repairs
Hydraulic equipment failures can bring a sudden halt to your operations, but there are normally some signs that failure is imminent. Respond to these signs early enough and you’ll likely be able to avoid worse damage:
- Loss of operating pressure – During operation, if the jack cannot output at its rated operating pressure, this could be due to one of many – or more – causes. Internal leaks, component wear, a failing seal, contamination, a stuck valve, cylinder rod issues – the list goes on. Any one of these problems warrants a closer inspection, so monitor those pressures, preferably with a fluid-filled gauge. Any signs of power loss and the equipment should be removed from operation and scheduled for a breakdown and inspection.
- Inconsistent power application – Loss of power is an obvious concern. So is inconsistent power application. If dead ender jacks cannot maintain loading while tensioning strand, it’s not just an efficiency concern – it’s a safety issue if there’s a sudden loss of tensioning force. If your jacks cannot smoothly come up to pressure or maintain it, an expert inspection is needed.
- Overheating – Overheating is another sign that a dead ender jack is struggling. If excess temperatures are present in a hydraulic system, the problem can often be traced back to the pump, but a faulty valve could also be the culprit. In either case, overheating will threaten the system’s reliability and safety if not addressed promptly.
- Unusual sounds – It doesn’t take long for jack operators to grow accustomed to typical operating noises, so if a particular sound sticks out, that’s normally a concerning sign. Banging or knocking noises are of note, as these sounds are common when air is trapped in the system and potentially causing cavitation. Cavitation can rapidly wear down internal parts and therefore necessitates immediate service.
- Rough handling – If the jack kicks or jerks during operation, this could be a sign that hydraulic fluid is backflowing. It’s often the sign of a worn or stuck valve, so the problem may originate outside of the dead ender itself.
Preventative Maintenance Tips for Dead Ender Jacks
Some equipment failures are unavoidable, but regular preventative maintenance can keep the avoidable failures at bay. To ensure your dead ender jacks remain in excellent operating condition, consider implementing the following preventative maintenance tasks:
- Keep an up-to-date maintenance log for your jacks – The first step in preventing equipment failures is vigilance. Specifically, monitoring your equipment assets and their maintenance schedules. Each dead ender jack’s operation history and condition should be tracked, so maintenance can be scheduled in advance and on time. If there are emerging performance issues with a particular jack, details of such should also be included in your equipment tracking system. If a jack is showing signs of oncoming failure, it can be removed from operation immediately to protect it from further damage (and to protect your workers from a potential safety issue).
- Perform a visual inspection of the equipment after operation – Following every round of duty, your dead ender jacks should undergo a detailed visual inspection. Look for any signs of wear or damage around the nose piece and cylinders.
- Check the seals, hoses, and connections for signs of leaks – During each visual inspection, any signs of leaking should also be noted. Leaks place the system at high risk of contamination and pressure loss, so if fluid is seeping out anywhere, it’s a cause for concern. These leaks tend to appear around connections and couplers, so be sure to check the hoses and cylinders.
Worn seals are another primary cause of leaks, including internal leaks. Hydraulic cylinders are an obvious starting point for seal problems, so occasionally opening the cylinder and inspecting the seals is important. An expert hydraulic technician can assist with this if your operators are unfamiliar with comprehensive equipment breakdowns. - Check the jack’s fluid levels and fluid quality – Hydraulic fluid will degrade in quantity and quality over weeks of operation. So, it’s important for operators to check fluid levels in the dead ender system on a weekly basis. Fluid should also be sampled for its clarity – any signs of sediment or discoloration indicate contamination.
- Take the jack’s temperature occasionally – If excessive heat emerges anywhere in the system, this could indicate issues with flow or a problem with the system’s cooling equipment, such as the heat exchanger. Tracking typical operating temperatures is essential, which you can do with a simple laser thermometer (infrared gun). Take the jack’s temperature at the same time of the day and in the same spots, for accurate comparison’s sake. If temperatures exceed the manufacturer’s guidelines, get the system checked out.
Time for Jack Maintenance or Repair? A Hydraulic Power Expert Can Correct Any Problems
If your dead ender jacks are showing signs of damage or wear, or if it’s just been a while since the equipment was inspected, an expert inspection and round of maintenance may be in order. Hydraulic power experts are familiar with how tensioning jacks function and how they are most likely to fail. As such, they’re the professionals to call when your dead ender jacks need routine maintenance or a full system breakdown and repair.