Ship Deck Seal

Background

A global defense contractor needed a high-performance seal to integrate mating surfaces between a module for large missile canisters and the deck of a Navy ship. The seal would serve as a barrier against harsh environmental conditions, helping to eliminate water below deck and maintain positive interior air pressure within the vessel while operating at sea.

Challenge

The contractor asked PGC to develop a rubber elastomer seal with complex performance properties under tight time and cost constraints. The seal had to:

• Maintain a particular footprint and extend as long as 40 feet.
• Meet demanding tolerances and specifications.
• Be delivered in six weeks.

PGC’s engineers knew the application required a multi-pronged solution: 

• Develop a manufacturable design for the seal.
• Determine the suitable elastomeric material to address form, fit, and function requirements, along with fatigue, temperature, and space constraints.
• Design a mechanical interface that made mounting the part to the ship deck as easy as possible.

Solution

To prototype the extrusion without building a die, PGC developed a basic design profile at a limited length, allowing the contractor to evaluate the concept at significantly reduced development time and cost. While the company finalized designed parameters, PGC presented five highly engineered material options, ranging from a Nitrile/PVC blend to an EPDM formulation to a Viton® fluoroelastomer, which the contractor selected for its balance of performance and cost.

Our engineers then provided concepts and drawings for the drilling fixture that allowed a secondary operation to create thru holes in the elastomer part, used for installation to the deck and module.

PGC played a significant role in designing and managing all process aspects, from extrusion, splicing, and forming tools, to the curing and drilling jig.

Result

Being asked to meet steep requirements for a large-scale project on an extremely tight timeline, PGC delivered, earning the confidence of a demanding customer and even more demanding end-user—the US Navy.