SEALING PLUG
Efficient sealing of holes
SEALING PLUG – High performance, low cost
Simply sealed! – SEALING PLUG permanently seals holes.
The SEALING PLUG is a two-part all-metal component which works according to the
push/pull expansion principle. It is used to permanently close and seal holes in pneu-
matic and hydraulic components and systems. Simply insert the SEALING PLUG into
the drilled hole, expand the plug and seal the hole. This highly efficient method means
there is no need for tapping or reaming of holes. Furthermore, additional sealants are
not required.
The SEALING PLUG can be used to regulate and control all types of flow as it can
withstand operating pressures of up to 500 bar.
Method / principle
The SEALING PLUG with ball works according to the push-expansion principle. The
ball is pushed into the sleeve, causing it to expand.
The SEALING PLUG with mandrel and the PULLPLUG™ work according to the pull-
expansion principle. The mandrel / pin is pulled into the sleeve, causing it to expand.
All versions of the SEALING PLUG feature serrations on the outside of the sleeve,
which anchor the SEALING PLUG into the housing material as it expands. This addi-
tionally increases the performance of the SEALING PLUG.
Application areas
SEALING PLUGS can be used to control and regulate all kinds of flow. Typical applica-
tions include, for example, motors, power and drive trains, chassis and brake systems,
steering and injection components as well as various hydraulic applications.
Advantages at a glance:
n Permanent closure and sealing of holes
n Up to 500 bar operating pressure
n Easy installation
n No tapping or reaming of holes required
n Use of additional sealants not required
n Process reliable and reproducible
2
SEALING PLUG with ball – Series 1 1
Available in diameters D1 D2
x
from 3 mm to 22 mm.
L2 118°
n Push-expansion principle L1 L3
n Up to 350 bar operating pressure
Version: D3
Sleeve: Ball:
1 Case Hardening Steel, 1 Bearing Steel,
Zinc-Plated (CrVI-free) Black Oxide Finished
Conversion table
D2 D3 L3 x Böllhoff KVT Farmington
D1 L1 L2 +0.1 / -0.0 max. min. +/-0.2 Article no. Article no. Article no.
3.0 3.6 4.6 3.0 2.2 3.4 0.4 ET11030 MB850-030 CVMS0031110A
4.0 4.0 5.2 4.0 3.3 3.8 0.2 ET11040 MB850-040 CVMS0041110A
5.0 5.5 7.1 5.0 4.3 5.3 0.4 ET11050 MB850-050 CVMS0051110A
6.0 6.5 8.7 6.0 5.3 6.3 0.4 ET11060 MB850-060 CVMS0061110A
7.0 7.5 10.2 7.0 6.4 7.3 0.4 ET11070 MB850-070 CVMS0071110A
8.0 8.5 11.6 8.0 7.4 8.3 0.3 ET11080 MB850-080 CVMS0081110A
9.0 10.0 13.6 9.0 8.4 9.8 0.4 ET11090 MB850-090 CVMS0091110A
10.0 11.0 15.2 10.0 9.4 10.8 0.4 ET11100 MB850-100 CVMS0101110A
12.0 13.0 17.9 12.0 10.6 12.8 0.4 ET11120 MB850-120 CVMS0121110A
14.0 15.0 20.6 14.0 12.7 14.5 0.4 ET11140 MB850-140 CVMS0141110A
16.0 17.0 23.4 16.0 14.7 16.5 0.6 ET11160 MB850-160 CVMS0161110A
18.0 19.0 26.4 18.0 16.7 18.5 0.6 ET11180 MB850-180 CVMS0181110A
20.0 22.0 30.1 20.0 18.7 21.5 0.8 ET11200 MB850-200 CVMS0201110A
22.0 25.0 34.0 22.0 20.7 24.5 0.8 ET11220 MB850-220 CVMS0221110A
Appropriate tools on request.
Installation materials
SAE 1144 SAE 10L15 ASTM A48 ASTM A356 2024-T4 EN 6061-T6 356-T6
ETG100 C15Pb GG-25 GGG-50 AlCuMg2 AlMg1SiCu* G-AlSi7Mg
Ø 3 — 10 mm
Test pressure 16.000 psi / 1.100 bar 14.500 psi / 1.000 bar
Maximum operating
5.000 psi / 350 bar 4.500 psi / 320 bar
pressure
Ø 12 — 22 mm
Test pressure 13.000 psi / 900 bar 11.500 psi / 800 bar
Maximum operating
4.000 psi / 280 bar 3.500 psi / 250 bar
pressure
* Material composition similar to AlMgSiPb / EN 6005 / EN 6012
All dimensions specified in mm.
3
SEALING PLUG with ball – Series 3 1
Available in diameters D1 D2
x
from 3 mm to 22 mm.
L2 118°
n Push-expansion principle L1 L3
n Up to 450 bar operating pressure
Version: D3
Sleeve: Ball:
3 Stainless Steel, 1 Bearing Steel,
AISI 300 Black Oxide Finish
Conversion table
D2 D3 L3 x Böllhoff KVT Farmington
D1 L1 L2 +0.1 / -0.0 max. min. +/-0.2 Article no. Article no. Article no.
3.0 3.6 4.6 3.0 2.2 3.4 0.4 ET31030 MB700-030 CVMS0033110A
4.0 4.0 5.2 4.0 3.3 3.8 0.2 ET31040 MB700-040 CVMS0043110A
5.0 5.5 7.1 5.0 4.3 5.3 0.4 ET31050 MB700-050 CVMS0053110A
6.0 6.5 8.7 6.0 5.3 6.3 0.4 ET31060 MB700-060 CVMS0063110A
7.0 7.5 10.2 7.0 6.4 7.3 0.4 ET31070 MB700-070 CVMS0073110A
8.0 8.5 11.6 8.0 7.4 8.3 0.3 ET31080 MB700-080 CVMS0083110A
9.0 10.0 13.6 9.0 8.4 9.8 0.4 ET31090 MB700-090 CVMS0093110A
10.0 11.0 15.2 10.0 9.4 10.8 0.4 ET31100 MB700-100 CVMS0103110A
12.0 13.0 17.9 12.0 10.6 12.8 0.4 ET31120 MB700-120 CVMS0123110A
14.0 15.0 20.6 14.0 12.7 14.5 0.4 ET31140 MB700-140 CVMS0143110A
16.0 17.0 23.4 16.0 14.7 16.5 0.6 ET31160 MB700-160 CVMS0163110A
18.0 19.0 26.4 18.0 16.7 18.5 0.6 ET31180 MB700-180 CVMS0183110A
20.0 22.0 30.1 20.0 18.7 21.5 0.8 ET31200 MB700-200 CVMS0203110A
22.0 25.0 34.0 22.0 20.7 24.5 0.8 ET31220 MB700-220 CVMS0223110A
Appropriate tools on request.
Installation materials
SAE 1144 SAE 10L15 ASTM A48 ASTM A356 2024-T4 EN 6061-T6 356-T6
ETG100 C15Pb GG-25 GGG-50 AlCuMg2 AlMg1SiCu* G-AlSi7Mg
Ø 3 — 10 mm
Test pressure 20.000 psi / 1.400 bar 17.500 psi / 1.200 bar
Maximum operating
6.500 psi / 450 bar 5.500 psi / 380 bar
pressure
Ø 12 — 22 mm
Test pressure 16.500 psi / 1.150 bar 13.000 psi / 900 bar
Maximum operating
5.000 psi / 350 bar 4.000 psi / 280 bar
pressure
* Material composition similar to AlMgSiPb / EN 6005 / EN 6012
All dimensions specified in mm.
4
SEALING PLUG with ball – Series 3 3
Available in diameters D1 D2
x
from 3 mm to 22 mm.
L2 118°
n Push-expansion principle L1 L3
n Up to 450 bar operating pressure
Version: D3
Sleeve: Ball:
3 Stainless steel, 3 Stainless steel,
AISI 300 AISI 300
Conversion table
D2 D3 L3 x Böllhoff KVT Farmington
D1 L1 L2 +0.1 / -0.0 max. min. +/-0.2 Article no. Article no. Article no.
3.0 3.6 4.6 3.0 2.2 3.4 0.4 ET33030 MB600-030 CVMS0033130A
4.0 4.0 5.2 4.0 3.3 3.8 0.2 ET33040 MB600-040 CVMS0043130A
5.0 5.5 7.1 5.0 4.3 5.3 0.4 ET33050 MB600-050 CVMS0053130A
6.0 6.5 8.7 6.0 5.3 6.3 0.4 ET33060 MB600-060 CVMS0063130A
7.0 7.5 10.2 7.0 6.4 7.3 0.4 ET33070 MB600-070 CVMS0073130A
8.0 8.5 11.6 8.0 7.4 8.3 0.3 ET33080 MB600-080 CVMS0083130A
9.0 10.0 13.6 9.0 8.4 9.8 0.4 ET33090 MB600-090 CVMS0093130A
10.0 11.0 15.2 10.0 9.4 10.8 0.4 ET33100 MB600-100 CVMS0103130A
12.0 13.0 17.9 12.0 10.6 12.8 0.4 ET33120 MB600-120 CVMS0123130A
14.0 15.0 20.6 14.0 12.7 14.5 0.4 ET33140 MB600-140 CVMS0143130A
16.0 17.0 23.4 16.0 14.7 16.5 0.6 ET33160 MB600-160 CVMS0163130A
18.0 19.0 26.4 18.0 16.7 18.5 0.6 ET33180 MB600-180 CVMS0183130A
20.0 22.0 30.1 20.0 18.7 21.5 0.8 ET33200 MB600-200 CVMS0203130A
22.0 25.0 34.0 22.0 20.7 24.5 0.8 ET33220 MB600-220 CVMS0223130A
Appropriate tools on request.
Installation materials
SAE 1144 SAE 10L15 ASTM A48 ASTM A356 2024-T4 EN 6061-T6 356-T6
ETG100 C15Pb GG-25 GGG-50 AlCuMg2 AlMg1SiCu* G-AlSi7Mg
Ø 3 — 10 mm
Test pressure 20.000 psi / 1.400 bar 17.500 psi / 1.200 bar
Maximum operating
6.500 psi / 450 bar 5.500 psi / 380 bar
pressure
Ø 12 — 22 mm
Test pressure 16.500 psi / 1.150 bar 13.000 psi / 900 bar
Maximum operating
5.000 psi / 350 bar 4.000 psi / 280 bar
pressure
* Material composition similar to AlMgSiPb / EN 6005 / EN 6012
All dimensions specified in mm.
5
SEALING PLUG with mandrel – RS series
Available in diameters L4
from 4 mm to 9 mm.
D3
n Pull-expansion principle
n Up to 500 bar operating pressure
L2
L3
Version: L1
Sleeve: Case Hardened Steel, Black Oxide Finish
D1 D2
Pin: Heat Treatable Steel, Black Oxide Finish
With either standard (RS) or long mandrel (RSL).
Standard mandrel length (RS)
Conversion table
L3 L4 D3 Böllhoff KVT
D1 L1 D2 L2 max. max. +0.12 / -0.0 Article no. Article no.
4.0 4.5 2.50 39.0 9.0 6.5 4.0 ETRS040 SK550-040
5.0 5.5 3.00 41.0 10.0 7.5 5.0 ETRS050 SK550-050
6.0 6.5 3.40 43.0 12.0 8.0 6.0 ETRS060 SK550-060
7.0 7.5 4.10 38.0 14.0 9.0 7.0 ETRS070 SK550-070
8.0 8.5 4.20 40.0 15.0 10.5 8.0 ETRS080 SK550-080
9.0 9.5 4.50 43.0 17.0 11.0 9.0 ETRS090 SK550-090
Appropriate tools on request. Special materials on request.
Installation materials
SAE 1144 SAE 10L15 ASTM A48 ASTM A356 2024-T4 EN 6061-T6 356-T6
ETG100 C15Pb GG-25 GGG-50 AlCuMg2 AlMg1SiCu* G-AlSi7Mg
Ø 4 — 10 mm
Test pressure 23.000 psi / 1.600 bar 20.000 psi / 1.400 bar
Maximum operating
7.000 psi / 500 bar 6.500 psi / 450 bar
pressure
* Material composition similar to AlMgSiPb / EN 6005 / EN 6012
All dimensions specified in mm.
6
PULLPLUG™ – RST series
Available in diameters L3 L1
from 6 mm to 22 mm. L2
n Pull-expansion principle D2 D1 t
n Up to 500 bar operating pressure
Version:
Sleeve: Case Hardening Steel, Black Oxide Finish
Pin: Heat Treatable Steel, Black Oxide Finish
D2 Böllhoff
D1 L1 +0.1 / -0.0 L2 L3 t Article no.
6.0 11.0 6.0 6.5 7.0 M3 ETRST060
7.0 13.0 7.0 7.5 8.0 M 3.5 ETRST070
8.0 14.0 8.0 8.5 9.0 M4 ETRST080
9.0 16.0 9.0 9.5 10.0 M4 ETRST090
10.0 18.0 10.0 10.5 11.0 M5 ETRST100
12.0 21.0 12.0 12.5 13.0 M5 ETRST120
14.0 25.0 14.0 14.5 15.0 M6 ETRST140
16.0 28.0 16.0 16.5 17.0 M8 ETRST160
18.0 31.5 18.0 18.5 19.0 M8 ETRST180
20.0 35.0 20.0 20.5 21.0 M 10 ETRST200
22.0 38.5 22.0 22.5 23.0 M 10 ETRST220
Appropriate tools on request. Special materials on request.
Advantages of PULLPLUG™ compared
to SEALING PLUG with mandrel
n Less material = lower price
n No noise when mandrel breaks off
n No disposal of broken mandrel required
n No raw material after mandrel breaks off
n Higher process reliability as controlled by stroke and not by
nominal breaking force
n Therefore, particularly suited to harder installation materials
n Creates a usable internal thread
All dimensions specified in mm.
7
SEALING PLUG – Installation guidelines
Installation guidelines for:
SEALING PLUG series 1 1 (ET11)
SEALING PLUG series 3 1 (ET31)
SEALING PLUG series 3 3 (ET33)
Drill holes
n Use the relevant catalogue sheet or drawing to determine the correct dimensions
and tolerances.
n The roundness tolerances of the hole must be held within t = 0.05 mm.
n The surface roughness of the hole must be RZ = 10 – 30 μm.
n Longitudinal and spiral grooves may affect the performance and must be avoided.
n The holes must be free from burrs, oil and grease.
How to install
n Insert the SEALING PLUG with the ball facing outwards into the counterbored hole.
n The top of the sleeve must be below the contour of the workpiece.
n This can be ensured by complying with the hole dimensions and tolerances in the
catalogue sheet.
n Push the ball into the sleeve so that the top of the ball is slightly below the top
F
of the sleeve. The table below contains guideline values for the stroke s and the
dimension x (position of ball).
n Please make sure that you use the correct installation tool for each size.
Position of top of ball
Stroke relative to top of sleeve
D1 s x
3.0 1.2 0.4
4.0 1.5 0.2
5.0 2.0 0.4
6.0 2.5 0.4
7.0 3.0 0.4
8.0 3.5 0.3
9.0 4.0 0.4 x s
10.0 4.5 0.4
12.0 5.5 0.4
14.0 6.4 0.4 D1
16.0 7.0 0.6
18.0 8.0 0.6
20.0 9.0 0.8
22.0 10.0 0.8
All dimensions specified in mm.
8
Installation guidelines for:
SEALING PLUG RS series (ETRS – Rivet Style)
Drill holes
n Use the relevant catalogue sheet or drawing to determine the correct dimensions
and tolerances.
n The roundness tolerances of the hole must be held within t = 0.05 mm.
n The surface roughness of the hole must be RZ = 10 – 30 μm.
n Longitudinal and spiral grooves may affect the performance and must be avoided.
n The holes must be free from burrs, oil and grease.
How to install
n Insert mandrel side into tool.
n Insert sleeve side into hole to be sealed.
n By triggering the setting process, the pin is pulled until the nominal breaking force
is reached and the mandrel breaks off. The pin is pulled into the sleeve, causing
the sleeve to expand, and anchors itself in the installation material.
9
PULLPLUG™ – Installation guidelines
Installation guidelines for:
PULLPLUG™ RST series (ETRST)
Drill holes
n Use the relevant catalogue sheet or drawing to determine the correct dimensions
and tolerances.
n The roundness tolerances of the hole must lie within t = 0.05 mm.
n The surface roughness of the hole must be RZ = 10 – 30 μm.
n Longitudinal and spiral grooves may affect the performance and must be avoided.
n The holes must be free from burrs, oil and grease.
How to install
n Position tool and PULLPLUG™.
n Push PULLPLUG™ onto thread of tool. The PULLPLUG™ will automatically
screw / thread itself on.
n Insert into hole to be sealed.
n By triggering the setting process, the pin is pulled along the preset stroke and then
automatically unthreads itself. The pin is pulled into the sleeve, causing the sleeve
to expand, and anchors itself in the installation material.
10
SEALING PLUG – Design guidelines for wall thicknesses and edge distances
Through semi-plastic radial expansion, the SEALING PLUG / PULLPLUG™ is anchored in the installation material.
In order to optimise the anchoring and withstand the hydraulic pressures and thermal stresses that exist in the
application, it is important to comply with minimal wall thicknesses/edge distances
Distance to external Distance to external Distance between holes
contour (straight) contour (round)
D1 D1 D1
Wmin. Wmin. Wmin.
The guideline values for the minimum wall thicknesses and edge distances (Wmin) are set out below.
If you comply with these guideline values, only slight deformations (≤ 20 μm) may occur on the external contours
of the installation material. This will not affect the performance of the SEALING PLUG / PULLPLUG™.
If the wall thicknesses and edge distances are below the Wmin guideline values, the function of the
SEALING PLUG / PULLPLUG™ cannot be guaranteed. If this is the case, please contact us and we will be
happy to advise you. Together we can find a solution for your application.
Guideline value Wmin. for wall thicknesses and edge distances
D1 ≥ 4 mm: Wmin. = fmin. x D1
D1 < 4 mm: Wmin. = fmin. x D1 + 0,5 mm
Installation materials
SAE 1144 SAE 10L15 ASTM A48 ASTM A356 2024-T4 EN 6061-T6 356-T6
ETG100 C15Pb GG-25 GGG-50 AlCuMg2 AlMg1SiCu* G-AlSi7Mg
Article Factor fmin.
SEALING PLUG series 1 1 0.5 0.6 1.0 0.6 0.6 1.0 1.0
SEALING PLUG series 3 1 0.6 0.8 1.0 0.8 0.8 1.0 1.0
SEALING PLUG series 3 3 0.6 0.8 1.0 0.8 0.8 1.0 1.0
SEALING PLUG RS series 0.5 0.6 1.0 0.6 0.6 1.0 1.0
PULLPLUG™ RST series 0.5 0.6 1.0 0.6 0.6 1.0 1.0
* Material composition similar to AlMgSiPb / EN 6005 / EN 6012 All dimensions specified in mm.
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On the internet: On the internet:
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11
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8050/20-V1-EN (WBH)
Subject to technical change.
Reprinting, even in extract form, only permitted with express consent.
Observe protective note according to ISO 16016.
