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Functionality & Uses of The Step Wedge Flange Spreader

The Evolution of the Flange Spreader

Tools Designed for Enhanced Safety, Simplified Tasks, & Greater Efficiency


In the realm of tool design, the pursuit of enhanced safety, simplified tasks, and greater efficiency stands paramount. This approach focuses on creating innovative tools that prioritize user safety, streamline complex processes, and boost productivity. By integrating advanced materials, ergonomic designs, and intelligent technology, these tools are engineered to reduce risks and facilitate ease of use. The goal is to empower users across various industries to achieve their objectives with precision and ease, fostering a safer and  more efficient working environment. 

Customer Testimonial Published in BIC Magazine

Step Wedge Flange Spreaders vs. Traditional Flange Spraders

Understanding the evolution of flange spreader technology is crucial to appreciating the benefits of modern advancements. Flange spreading, a frequent necessity in servicing equipment or replacing gaskets, has historically posed significant risks to service personnel. The challenges faced by operators are manifold, especially considering the potential for shifted forces or increased intensity over time, which have led to numerous injuries and fatalities.

The Comparative Analysis

Traditional Methods and Their Drawbacks


  • The Striking Wedge (Images Above): This method, despite its simplicity, carries inherent dangers. The use of a wooden or metal wedge, combined with a pry bar, can lead to serious injuries. The wedge can be forcefully ejected, and the pry bar can recoil, striking the worker.   Moreover, metal wedges can create sparks, posing an explosion risk in the presence of gas.

Banana Wedge

  • The Banana Wedge (Image Above): An advancement over the hammer-wedge, the Banana Wedge offered slight improvements but essentially presented the same geometrical force distribution and associated risks. 

   The shift from conventional flange spreaders to the innovative Step Wedge Flange Spreaders signifies a substantial technological advancement, with a strong emphasis on enhancing operator safety and increasing operational efficiency. 

The Prying Tool, depicted in the image above and the middle illustration, remains popular due to its simplicity and affordability. However, its reliance on a slender metal tongue is a design flaw that makes it highly susceptible to breakage and ejection, given the directional forces at play during flange spreading. 


The step wedge flange spreader is ingeniously designed to ensure safety and efficiency. Instead of exerting forces in opposing directions (north to south), it pushes the jaws from east to west. This clever arrangement eliminates the risk of incidents arising from conflicting forces.



Step Wedge Flange Spreader

  Hydraulic Flange Spreader with built in pump.

  The introduction of Step Wedge Flange Spreaders, a brainchild of the now-defunct Equalizer International from the 1990s, has addressed nearly all the prevalent issues associated with flange spreading tasks. This technology is now widely recognized as the safest and most effective method for spreading flanges of any size and is gradually being adopted by new market players.

 Perhaps the most revolutionary development was the bolt-hole spreading technology, also an Equalizer International innovation. This cutting-edge approach negates the need to insert any tools between the flange faces. Instead, it employs a set of collets within the bolt holes to latch onto the flanges, which are then separated using a clever lever or hydraulic cylinder mechanism.

Flange spreader and Flange Alignment tool on a flange.

(Secure Grip Flange Spreader) 

 The journey to achieving safe and efficient flange spreading has been extensive. It is rooted in a deep understanding of the physics governing the forces and energy involved. It reflects a sensitivity to the safety concerns of workers who must complete their tasks safely before returning home. It is a testament to the engineering prowess that has gone into designing and rigorously testing these devices until they reached perfection.

 The advancement of flange spreader technology has been a lifesaver, revolutionizing the service industry like never before. Firms dedicated to the safety of their workforce are on a constant quest for superior technologies and reliable partners. At ESI, we stand firm in our commitment to safety, refusing to endorse tools that compromise worker security. Let’s discuss how we can enhance the safety and efficiency of your team with our trusted solutions.


Continue: Flange Tools: A Brief History