What Causes a Gasket Blowout and How Can You Reduce the Risk?

Gaskets play an important role in helping equipment and systems maintain a reliable seal. By sealing two mating surfaces, they can help prevent liquids, gases, and other substances from escaping during operation.

When a gasketed joint loses its ability to maintain that seal, the consequences can extend beyond a simple leak. Depending on the application, gasket failure can contribute to equipment damage, unplanned downtime, product loss, or potentially hazardous conditions. One particularly serious type of failure is a gasket blowout.

What Is a Gasket Blowout?

A gasket blowout occurs when a gasketed joint can no longer contain the system's internal pressure and the gasket is displaced or fails, allowing the contained media to escape. Blowout risk can be influenced by several factors, including internal pressure, gasket compression, material properties, joint conditions, temperature, vibration, chemical exposure, and installation. While no single method can eliminate the possibility of a gasket blowout, understanding these factors can help reduce the risk of failure.

What Can Help Reduce the Risk of a Gasket Blowout?

Maintain Appropriate Gasket Compression

A gasket must receive enough compressive load to seat properly and maintain a seal during operation. Too little compression can increase the potential for leakage and reduce the gasket’s resistance to internal pressure. At the same time, excessive compression can damage some gasket materials or change their ability to perform as intended. Uneven loading can also create areas within the joint that are more vulnerable to leakage or failure. Appropriate compression depends on the gasket material, joint configuration, fasteners, equipment requirements, and installation specifications.

Choose an Appropriate Gasket Thickness

Gasket thickness can influence sealing performance and joint stability. Thicker gaskets may better accommodate certain surface irregularities, but they can also be more susceptible to creep relaxation. Creep relaxation occurs when a gasket gradually deforms under a sustained load, which can reduce clamping force over time. Thinner gaskets may provide greater stability when the mating surfaces and joint conditions are suitable. The appropriate thickness depends on the gasket material, flange condition, joint design, application requirements, and joint configuration.

Consider Vibration and Movement

Repeated vibration or mechanical movement can affect the integrity of a gasketed joint over time. Vibration may contribute to bolt relaxation, uneven loading, shifting components, or other changes that affect sealing performance. When vibration or movement is present, it should be considered as part of the overall gasket and joint requirements.

Evaluate the Full Operating Temperature Range

Temperature can affect both gasket materials and the overall gasketed joint. A material that performs well at one temperature may behave differently when exposed to elevated temperatures, low temperatures, or repeated temperature cycling. Temperature changes can affect material properties, compression, and joint loading. For that reason, material selection should account for the full range of operating conditions the gasket may experience.

Confirm Chemical Compatibility

The gasket material should be compatible with the liquids, gases, chemicals, or other media it may contact during operation. Incompatible media can change material properties, cause swelling, hardening, softening, or other forms of degradation, and reduce sealing performance. External environmental exposure should also be considered when it may affect the gasket material.

Consider Joint and Installation Conditions

The condition and assembly of the gasketed joint can also influence performance. Factors such as mating-surface condition, alignment, surface finish, fastener loading, and installation practices can affect how evenly the gasket is compressed. Even an appropriate gasket material may not perform as intended if the joint does not provide adequate and consistent compression.

Finding the Right Gasket for Your Application

Reducing gasket blowout risk involves more than selecting a material based on pressure alone. Gasket thickness, compression, temperature, chemical exposure, vibration, joint conditions, and other application requirements can all influence material and manufacturing decisions. PGC manufactures custom gaskets from flexible materials based on customer drawings, specifications, material requirements, and application information. Providing complete project details helps PGC evaluate material and manufacturing options for the component and determine whether the project aligns with its converting capabilities.

Have an Active Gasket Project?

Submit your drawing, material requirements when available, operating conditions, and estimated quantity to help PGC evaluate manufacturing fit and prepare an accurate quotation.