GripSafe® XL Large Bore Isolation & Test Plug, 36" to 48"
Hydrostatic and pneumatic testing for 36", 42", and 48" pipe without welded end caps. Holds pressure up to the pipe’s yield point. Patented self-energizing wedges grip harder as pressure rises, one plug covers a range of wall thicknesses, and a crew of two can install it in about 15 minutes. Available to rent or buy. See specifications ›
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- GripSafe® XL plug
- Pipe size and wall thickness
- Test type (hydrostatic or pneumatic) and pressure
- Quantity needed
- Rental or purchase
- Date needed
| Specification | Details |
|---|---|
| Sizes | 36" • 42" • 48" (larger and custom on request) |
| Wall Thickness | .375" – 2.250" (four ranges per size) |
| Pressure Capability | Up to the pipe’s yield point (hydrostatic and pneumatic) |
| Back Pressure Rating | 3,000 psi (36") • 2,500 psi (42") • 2,000 psi (48") |
| Test Types | Hydrostatic • Pneumatic |
| Torque Range | 250 – 600 ft-lbs |
| Ports | Fill port 2" MNPT • Back pressure vent 1" MNPT |
| Length | 38.50" overall • 31.63" energized body |
| Approx. Weight | 2,700 – 5,450 lbs |
| Installation | About 15 minutes (typical, crew of 1 to 2) |
| Availability | Rent • Purchase |
What Is the GripSafe® XL?
Large diameter pipe concentrates enormous force. At just 500 psi, a 36" pipe generates over 500,000 lbs of force on its end, and a 48" pipe exceeds 900,000 lbs. That has traditionally meant welded end caps.
The GripSafe® XL isolation and test plug is built to hold pressure up to the pipe’s yield point. Its patented wedges spread the force across the pipe wall and grip harder as pressure rises, while Tri-Ply® seals and Gritlock® wedges protect the pipe.
Testing 36" and smaller? See the GSST ORB.
Test Only the Section You Need
Pressurizing an entire large bore system stores a huge amount of energy, and a failure at a welded cap, blind flange, or temporary test head releases it all at once. GripSafe® XL isolates just the section under test.
Where the GripSafe® XL Is Used
Key Features
GripSafe® XL vs. Welded End Caps
GripSafe® XL Specifications
All dimensions in inches. Torque range 250 to 600 ft-lbs, compression hex nut socket 1-7/8", fill port 2" MNPT, back pressure vent 1" MNPT, overall length 38.50", energized body length 31.63" on every size.
| NPS | Wall Thickness | Part Number | Tool Dia. | Pipe ID Range* | Approx. Wt. (lbs) | Back Pressure Rating |
|---|---|---|---|---|---|---|
| 36" | .375 – .750 | GSSTXL-I-S-3600-0750WT | 34.125 | 34.5 – 35.25 | 3,250 | 3,000 psi |
| .875 – 1.250 | GSSTXL-I-S-3600-1250WT | 33.125 | 33.5 – 34.25 | 3,150 | ||
| 1.375 – 1.750 | GSSTXL-I-S-3600-1750WT | 32.125 | 32.5 – 33.25 | 2,800 | ||
| 1.875 – 2.250 | GSSTXL-I-S-3600-2250WT | 31.125 | 31.5 – 32.25 | 2,700 | ||
| 42" | .375 – .750 | GSSTXL-I-S-4200-0750WT | 40.125 | 40.5 – 41.25 | 4,400 | 2,500 psi |
| .875 – 1.250 | GSSTXL-I-S-4200-1250WT | 39.125 | 39.5 – 40.25 | 4,300 | ||
| 1.375 – 1.750 | GSSTXL-I-S-4200-1750WT | 38.125 | 38.5 – 39.25 | 3,950 | ||
| 1.875 – 2.250 | GSSTXL-I-S-4200-2250WT | 37.125 | 37.5 – 38.25 | 3,850 | ||
| 48" | .375 – .750 | GSSTXL-I-S-4800-0750WT | 46.125 | 46.5 – 47.25 | 5,450 | 2,000 psi |
| .875 – 1.250 | GSSTXL-I-S-4800-1250WT | 45.125 | 45.5 – 46.25 | 5,350 | ||
| 1.375 – 1.750 | GSSTXL-I-S-4800-1750WT | 44.125 | 44.5 – 45.25 | 5,200 | ||
| 1.875 – 2.250 | GSSTXL-I-S-4800-2250WT | 43.125 | 43.5 – 44.25 | 5,000 |
* Larger sizes and custom configurations available on request. A PRD is strongly recommended for all Schedule 10/10S and thinner walled pipe. Never exceed the maximum rated pressure of the lowest rated component in the system. Data is subject to change; download the spec sheet (PDF) for the latest release.
Rent GripSafe® XL for Your Next Project
Large bore plugs are a big investment. Rent them for the job instead of buying and storing them, with our team on call 24/7/365.
GripSafe® XL FAQ
What pipe sizes does the GripSafe XL fit?
36", 42", and 48" pipe, with wall thicknesses from .375" to 2.250". Larger sizes and custom configurations are available on request. For 36" and smaller, see the GSST ORB.
How much pressure can it hold?
The GripSafe® XL holds pressure up to the pipe’s yield point during hydrostatic and pneumatic testing. Back pressure ratings are 3,000 psi on 36", 2,500 psi on 42", and 2,000 psi on 48". Never exceed the rating of the lowest rated component in the system.
Can it be used for pneumatic testing?
Yes. The GripSafe® XL is used for both hydrostatic and pneumatic testing, including projects where hydrotesting is restricted and moisture-sensitive piping.
Does one plug fit more than one pipe schedule?
Yes. Each plug covers a wall thickness range, so one plug fits multiple schedules. That means fewer plugs to rent and no size-specific inventory.
How long does installation take?
About 15 minutes per location, typically with a crew of one or two. Removal is just loosening the nuts and extracting the plug.
Do I need a Pipe Reinforcement Device?
A PRD is strongly recommended for all Schedule 10/10S and thinner walled pipe. Call our engineering team to confirm for your application.
Can I rent the GripSafe XL?
Yes, rent or purchase. See rentals.
Downloads & Resources
Patents & Trademarks
Designed, manufactured, and supplied exclusively by USA Industries, an ISO 9001:2015 certified company.
Other US and foreign patents pending. Full details are in the technical documentation.
Why Choose USA Industries
From pipe blinds to heat exchanger tools, we deliver custom-engineered products with the fastest turnaround times in the industry.
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Custom solutions designed to your exact specifications.
ISO Certified Quality
A quality driven ISO 9001:2015 certified manufacturer ensures consistent excellence.
BBB A+ Rated
The highest grade awarded, signifying USAI operates with high integrity and a strong commitment to resolving customer issues.