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Industrial Flange

Stainless Steel and Non-Metallic (PLASTIC) Flange Protection Covers

The Step-Ko Products flange protector covers are used in the protection of flange faces (Raised face or ring joint type), stud bolts, and gaskets from the elements of corrosion. These flange protection covers are available in 316SS stainless steel as well as Non-Metallic (plastic). Both materials come with the closed-cell rubber liner for sealing protection. The Step-Ko protector covers are currently manufactured in sizes for ½” to 144” diameter in ANSI, API, and AWWA flanged connections. The Step-Ko flange cover systems coupled with the STOPAQ® ER200/EZ400 flange fillers have been used in the protection of flanged connections for many years with much success in harsh conditions, delivering reliable flange corrosion protection in demanding environments.

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Flange Cover Construction

316 Stainless Steel Band - OR - Non-Metallic Band
316 SS Injection Fittings
316 SS Worm Gear Clamps
Closed Cell Neoprene Liner (temp. -30°F to 180°F)
ECH Rubber Liner (Temp. – up to 300°F)
A safety relief valve is available that bleeds at 5 psi

Step-Ko Flange Cover Protection Advantages

Ease of installation
No special tools required
Easy access to inspect the connection
Durable (Not easily damaged)
UV stable Non-Metallic material
Re-usable
Designed to support long-term stainless steel flange protection in corrosive conditions

Flange Filler System

For Temperatures up to 176°F

General

Flange Filler is a unique approach to solving corrosion problems in the long run.

Flange Filler is a coating based on synthetic s-polar polymers. The paste form makes it easy to apply with little preparation. The visco-elastic formulation allows the material to flow into gaps and voids, creating an excellent seal against corrosion.

Flange Filler saves time and money because of the ease of use, giving long-term protection.

The Properties

Excellent bonding to steel, FBE, PU, PE
High specific dielectric resistance
Weather/salt resistant
Temperatures range from -60° to 176°F
Fills the complete space
Removable/Re-usable
No heavy surface preparation to the flange connection is required prior to application.
Ease of injection using the manual or pneumatic guns with the flexible nozzle. This gives assurance that the annulus is completely filled prior to sealing with the CZ system.

For Temperatures up to 250°F

E-2400/E2000 High Temperature Flange Filler

The Step-Ko E2400/E2000 high-temperature corrosion preventative flange filler is designed to protect flange connections from corrosion in high temperatures up to 300 degrees Fahrenheit. The E2400/E2000 is a non-electrolytic approach in the form of a gel to corrosion protection of steel flanges, bolts, pipes, and structures, supporting long-term steel flange protection in demanding environments.

The nut/bolt assembly was tested to the ASTM-B1117 salt spray test for 2000 hours. The area that was protected with the E2000/2400 could still be turned by hand. The E2400/E2000, when properly installed, helps protect flange connections from corrosion for easy corrosion prevention.

Nut/Bolt Protection Covers

Step-Ko Products offers polyethylene nut covers to protect the exposed bolt and nut portion of the flange connection from the elements that cause corrosion. These covers are designed to fit tightly against the nut, therefore protecting from costly repairs or replacements from having to cut stud bolts off. These flange protection caps have been used from the protection of bridge and tunnel bolting, to the harsh environments of offshore platforms and refinery/chemical plant applications. By choosing to protect steel stud bolts and nuts early, the nut protector will help in costly bolt replacements in the future. This is preventative maintenance at its best.

Engineered Reliability with Advanced flange protection covers

Industrial flange connections are constantly exposed to moisture, chemicals, UV radiation, and airborne contaminants. Properly designed flange protection covers create a sealed barrier around the connection, shielding critical components from corrosive elements. These systems protect flange faces, bolts, and gaskets while preserving accessibility for inspection. In many environments, durable flange protection caps are used to safeguard exposed stud bolts and nuts from premature degradation.

Complete System Integrity Through Strategic flange protection

Effective flange protection begins with understanding where corrosion initiates and how environmental exposure accelerates deterioration. Protective systems must resist impact, UV exposure, temperature variation, and chemical attack while maintaining a secure fit. High-performance materials are engineered to remain stable without cracking or warping under stress. These solutions create a physical barrier that blocks moisture intrusion and salt accumulation.

Proven Performance in Harsh Environments with flange corrosion protection

Reliable flange corrosion protection is essential in offshore platforms, refineries, pipelines, and industrial plants where exposure risks are high. Protective systems are designed to encapsulate the flange assembly and prevent the buildup of corrosive agents.

Shields flange faces from moisture, salt spray, and contaminants
Protects exposed stud bolts and fastening hardware
Minimizes corrosion-related maintenance interventions
Reduces the risk of gasket deterioration due to environmental exposure
Supports long-term asset preservation in aggressive conditions

By implementing protective systems early, operators strengthen operational continuity and structural integrity.

Long-Term Asset Value Through Effective Flange Corrosion Prevention

Sustainable flange corrosion prevention strategies focus on eliminating the root causes of degradation before they escalate. Protective covers and fillers help isolate metal surfaces from oxygen, water, and chemical exposure. This barrier approach prevents surface pitting, rust formation, and structural weakening. Designed for durability and reusability, these systems allow inspection without dismantling the entire assembly.

Engineering Solutions Dedicated to preventing flange face corrosion damage

Focused on preventing flange face corrosion damage, protective systems must address both exposed surfaces and concealed crevices. Moisture trapped between flange faces can initiate rapid corrosion if not properly controlled.

Seals around the flange perimeter to block moisture intrusion
Encapsulates bolt heads and nuts to prevent rust formation
Reduces crevice corrosion at gasket interfaces
Allows inspection access without removing the entire system
Maintains structural integrity in severe weather conditions

This proactive approach protects connection surfaces while preserving operational efficiency.

Precision Materials for stainless steel flange protection

High-grade materials are essential when it comes to stainless steel flange protection in corrosive environments. Step-Ko Products designs protective systems that combine strength, flexibility, and chemical resistance to withstand demanding industrial applications. Each component is engineered to maintain fit and durability under environmental stress. By integrating advanced materials with precise manufacturing standards, reliable long-term performance is achieved.

FAQs

1. Why is it important to shield flange assemblies from environmental exposure?

Exposure to moisture, chemicals, and salt can accelerate rust and material degradation. Protective systems help extend service life and reduce repair frequency.