Mar 17, 2025
Gasket failure is one of the most common causes of unplanned downtime in industrial systems. When gaskets fail, they create leaks that compromise system integrity, reduce operational efficiency, and pose safety risks. Understanding the causes of gasket failure and implementing prevention strategies can help maintenance teams avoid costly repairs and extend equipment lifespan.
Gaskets seal flange joints, valves, pipelines, and other critical equipment, withstanding extreme pressures, high temperatures, and chemical exposures. A properly installed gasket prevents leaks and maintains system reliability. However, factors like improper installation, material degradation, inadequate bolt load, and environmental stressors can lead to premature failure.
This guide outlines the primary causes of gasket failure, common failure scenarios, and proven prevention methods. By following these best practices, engineers and maintenance teams can reduce the risk of gasket damage and improve system performance.
What Causes Gasket Failure?
Gasket failure typically results from one or more of the following factors:- Low Gasket Load: Insufficient compressive force prevents the gasket from forming a proper seal, leading to leakage.
- Low Bolt Strength: Weak or undersized bolts cannot maintain the necessary clamping force over time.
- Bolt Relaxation: Approximately 10% of the initial torque is lost within the first 24 hours due to material settling and stress redistribution.
- Torque Loss: Vibrations, thermal expansion, and improper installation gradually reduce clamping force.
- Gasket Creep: Some materials experience compression set over time, which reduces sealing effectiveness.
- System Vibrations: Continuous vibrations loosen bolts and compromise the seal.
- Pressure Surges (Water Hammer): Sudden pressure fluctuations can displace or damage gaskets.
- Uneven Flange Loading: Non-uniform compression creates weak points in the seal where leaks can occur.
- Improper Installation: Misalignment, incorrect torque application, or skipped steps during assembly shorten gasket lifespan.
Identifying these causes during troubleshooting gasket failure helps maintenance teams address the root problem rather than treating symptoms.
Common Gasket Failure Scenarios
Three failure modes account for the majority of gasket issues:Over-Compression and Material Damage
Excessive bolt load crushes the gasket, reducing its contact area and allowing fluid to bypass the seal. In softer gasket materials, excessive compression can lead to material extrusion, while metallic and semi-metallic gaskets are more likely to fail through loss of load or deformation rather than extrusion.Torque Loss and Bolt Relaxation
When internal system pressure exceeds the remaining clamping force, leaks or complete blowouts occur. Torque loss is accelerated by bolt relaxation, thermal expansion, and system vibration. Without periodic re-torquing, even correctly installed gaskets can fail.Chemical Incompatibility
If the gasket material is not compatible with the sealed media, chemical attack can degrade, crack, or soften the material. This failure mode is often identified by uneven discoloration, surface cracking, or loss of structural integrity. Selecting the correct gasket material for the application is critical to preventing chemical-related gasket failure. For high-pressure or high-temperature applications, metallic gaskets may be required.How to Prevent Gasket Damage
Preventing common gasket issues requires proper material selection, correct installation procedures, and adherence to safety protocols. Follow these steps to reduce the risk of gasket damage:- Follow Lock-Out and Tag-Out Procedures: Always adhere to plant safety protocols before disassembling or reassembling flanged joints.
- Lubricate Bolts and Fasteners: Apply appropriate lubrication to bolts, washers, and nut facings to reduce friction, minimize torque loss, and improve load distribution.
- Align Flanges Gradually: Bring flanges together slowly and evenly to ensure uniform gasket compression and avoid distortion.
- Use the Correct Tightening Pattern: Apply torque in a cross-pattern (star pattern) to distribute the load evenly across the gasket and prevent misalignment.
- Use Calibrated Torque Tools: Always use calibrated torque wrenches and follow manufacturer-recommended torque values to avoid over- or under-tightening.
- Ensure Adequate Gasket Stress: Gaskets require sufficient compressive force to maintain a secure seal. Verify that the bolt load meets or exceeds the gasket manufacturer’s specifications.
- Perform Periodic Re-Torquing: Re-torque bolts after installation and during initial operational cycles to compensate for bolt relaxation and gasket creep.
Implementing these gasket damage prevention practices improves seal reliability and reduces maintenance costs.
Extending Gasket Lifespan Through Proper Maintenance
Gasket lifespan depends on material composition, installation quality, operating conditions, and maintenance practices. Even high-performance gaskets require routine inspections and torque verification to maintain their sealing effectivenessEstablish a maintenance schedule that includes:
- Routine visual inspections for signs of leakage, discoloration, or surface damage.
- Torque checks at scheduled intervals, especially after thermal cycling or pressure fluctuations.
- Operator training to ensure installation personnel understand proper techniques and safety protocols.
Durlon offers Gasket Fundamentals and Installation Training, with options for beginner and advanced levels. Our flange assembly demonstration unit (FADU) provides hands-on experience that replicates real-world installation conditions. Proper training reduces installation errors and extends gasket service life.