What tools should be used for high torque applications?

In industries where the precise tightening and loosening of bolted joints requires the application of significant forces, specialized tools designed to handle high torques play a crucial role. This article presents professional technical solutions used in power hydraulics that enable the controlled transmission of high torques.

Torque wrenches—essential tools for precise tightening

Torque wrenches are essential tools in applications that require precise and repeatable tightening of bolted joints. Made of high-strength aluminum alloys, they ensure controlled tightening and loosening of fasteners. They are available in various power options:

Hydraulic wrenches—offer the highest torque, making them particularly useful for tight tolerances and repetitive bolting applications.

Pneumatic wrenches—powered by compressed air—deliver an impressive torque range from 70 Nm to as much as 15,000 Nm. Their power comes from the steady flow of compressed air supplying the tool.

Electric wrenches—offer high precision and repeatability, making them ideal for industrial applications.

Torque amplifiers

In situations where standard tools do not provide sufficient force, torque amplifiers are used. These devices convert low input torque into high output torque. They come in two main types:

Reaction rod amplifiers—recommended for applications with limited space, where multiple reaction points are available, or where mobility is required. They can generate torque up to 4,300 Nm.

Reaction plate torque multipliers—used for torques exceeding 4,300 Nm, particularly on flanges and in applications where adjacent fasteners can counterbalance extreme reaction forces.

Power hydraulics systems for generating high torques

Power hydraulics form the foundation for tools that operate at high torque levels. It utilizes the principle of pressurized fluid to transmit significant forces. The key components of a hydraulic system are:

Hydraulic pumps—both gear and piston types—generate power by forcibly expanding and compressing fluid. They can achieve a displacement of up to 220 cm³/rev at high pressures.

Hydraulic cylinders—convert the potential energy of hydraulic fluid into the kinetic energy of piston motion, generating linear force or torque.

Control valves—enable precise control of flow direction, fluid volume, and system pressure, which is essential for accurate torque control.

Choosing the right tools

When selecting tools for working with high torques, the following should be taken into account:

• Required torque range (from 30 Nm to over 34,000 Nm for specialized wrenches)
• Availability of power sources (hydraulic, pneumatic, electric)
• Space constraints in the workplace
• The need for precise torque control
• Repeatability of operations

Professional tools from RAD Torque Systems and Enerpac offer high precision, safety, and ergonomic design—all of which are essential for operations requiring high torque.

In the case of corroded or rusted bolted joints, it may be necessary to apply twice the normal torque to loosen them, which further underscores the need for specialized hydraulic tools.