Nut Splitter Selection Guide: Size & Tonnage Chart

The Right Nut Splitter: How Do You Choose It?

Choosing a hydraulic nut splitter isn't just a matter of checking a single measurement: wrench opening, bolt diameter, clearance in the work area, and how badly the nut is seized all need to be considered together. This guide covers the HSP series' complete size and tonnage chart and the model selection steps.

When Does a Nut Splitter Come Into Play?

Rusty / corroded nutsConnections that won't turn with a wrench or power tool

Rounded-off nutsNuts with worn corners that a wrench can no longer grip

Areas where sparking is prohibitedPetrochemical plants, refineries, ATEX zones — as an alternative to grinding/cutting discs

Tight or restricted-access pointsConnections with no room for a grinding disc or gas cutting torch

Removal where the stud must be preservedIf the bolt/stud will be reused, removal must not damage the thread

Unplanned breakdown responseFast, safe removal completed by a single operator

HSP Series Size / Tonnage Chart

Model	Nut Range (mm)	Bolt / Stud	Cutting Force	Weight
HSP1319	10 – 19 mm	M6 – M12	49 kN	0.8 kg
HSP1924	19 – 24 mm	M12 – M16	98 kN	2.0 kg
HSP2432	24 – 32 mm	M16 – M22	147 kN	3.0 kg
HSP3241	32 – 41 mm	M22 – M27	196 kN	4.4 kg
HSP4150	41 – 50 mm	M24 – M33	343 kN	8.2 kg
HSP5060	50 – 60 mm	M33 – M39	490 kN	11.8 kg
HSP6075	60 – 75 mm	M39 – M48	882 kN	34.1 kg
HSP7590	75 – 90 mm	M48 – M60	1,153 kN	65 kg
HSP90105	90 – 105 mm	M60 – M75	1,320 kN	100 kg

// All models run on a 700 bar class hydraulic pump. If your measurement falls right at the boundary between two models, or the nut is heavily rusted/seized, choosing the next size up gives you a safety margin.

Find the Right Model in 4 Steps

Measure the wrench opening

Measure the nut's flat-to-flat width (the wrench opening) in millimeters. This is the primary criterion that maps directly to the "Nut Range" column in the chart.

Confirm the bolt / stud diameter

If possible, confirm the connection's M size (e.g., M20, M33). If the wrench opening measurement isn't clear, bolt diameter can serve as a second reference point.

Check clearance in the work area

Make sure there's enough radial clearance from adjacent surfaces, the flange edge, or neighboring bolts so the splitter can approach the nut from the side.

Assess the nut's condition

For lightly rusted/standard nuts, the model that exactly matches your measurement is sufficient. For heavily corroded or seized nuts, choosing the next capacity up improves your odds of finishing in a single cut.

// QUICK CHECKLIST

01 Wrench opening (mm) measured

02 Bolt / stud size (M) confirmed

03 Side-access clearance checked

04 Nut condition (rust / seizure) assessed

Once you have your measurements, send them through the quote form; we'll confirm the right model together.

Versus Grinding or Gas Cutting

The traditional ways of removing a seized nut — grinding discs, gas cutting, or an impact chisel — are both slow and risk damaging adjacent parts, gaskets, and coatings. Spark-producing methods also can't be used in flammable environments. A hydraulic nut splitter uses 700-bar-class hydraulic force to drive a replaceable blade into the nut body, splitting it along its axis without touching the bolt or stud thread. The result is a spark-free removal completed by a single operator in minutes.

Frequently Asked Questions

Does a hydraulic nut splitter damage the bolt or stud?

No. The cutting blade only contacts the nut body, splitting and weakening it along its axis without touching the bolt or stud thread. With the right model and alignment, the stud remains reusable in most cases after removal.

How do I choose the right HSP model?

First measure the wrench opening (the nut's flat-to-flat width) in millimeters, then match that measurement to the nut range in the model selection chart above. You can use the bolt diameter (M size) as a secondary check.

What if my measurement falls right on the boundary between two models?

If the measurement is close to the upper end of the range, or the nut is rusted/seized, we recommend choosing the next capacity up. Extra cutting force provides a safety margin, whereas insufficient force can leave the nut only partially split and require a second attempt.

What pump pressure do HSP series nut splitters require?

All HSP series models are designed to run on a 700 bar class hydraulic pump. Required oil volume increases with model size; for the larger models (HSP7590, HSP90105), a higher-flow pump speeds up the operation.

Is the cutting blade replaceable?

Yes. The blade in the HSP series is replaceable, and once one face wears down it can be flipped over to use the second face, which lowers operating cost.

Not sure about your measurement? Send us the nut size and bolt diameter — Hydro Bard's engineering team will confirm the right HSP model for you at no cost.

Free Assessment →

The Right Nut Splitter: How Do You Choose It?