A failed gasket means leaks, downtime and sometimes safety risks. Most failures can be traced to a handful of avoidable causes.
1. Wrong material for the media
A gasket that is not compatible with the fluid will swell, soften or crack. Always match the compound to the media — for example EPDM for water and steam, NBR for oils.
2. Over-compression
Over-tightening bolts crushes the gasket, pushing material out of the joint and destroying its ability to spring back. Follow the recommended bolt torque and tighten in a cross pattern.
3. Under-compression
Too little load leaves gaps for leaks. Uneven bolt tightening and warped flanges are common culprits.
4. Poor surface finish
Deep scratches, rust or old gasket residue on the flange create leak paths. Clean and inspect both faces before fitting a new gasket.
5. Temperature beyond the compound's limit
Heat ages rubber quickly. If the joint runs hot, consider a higher-temperature compound such as Silicone or Viton.
Never reuse an old gasket. Once compressed and aged, it will not seal as well as a new one.
Prevention checklist
- Select the right compound and thickness
- Clean flange faces thoroughly
- Tighten bolts evenly in a cross pattern
- Replace gaskets during maintenance instead of reusing them
