When a rubber gasket or seal fails earlier than expected, it is rarely down to a single cause — usually several factors combine. Even with the right material selected, improper installation, over-compression, or chemical incompatibility can cut a part’s service life dramatically short. This article covers the most common causes of gasket and seal failure and how each one can be prevented.
Chemical Incompatibility and Swelling
Not every elastomer is compatible with every chemical. A poorly chosen material can absorb the oil, solvent, or chemical it contacts and swell or soften — or, in the opposite case, harden and crack. This type of failure usually shows up as a visible dimensional change and a tacky or rough surface.
Over-Compression and Compression Set
If a seal is compressed too much, or kept under high compression for a long time, the material may not spring back to its original thickness — this is known as compression set. The result is a loss of sealing force and leakage.
- Over-torquing flange bolts during installation.
- Incorrectly designed gland or groove depth.
- Using a lower-quality compound or the wrong Shore hardness for the application.
Temperature Excursions
Every elastomer has a safe operating temperature range. Above that range, the material hardens, cracks, and loses elasticity; below it, the material can become stiff and brittle. Repeated temperature cycling often fatigues a seal faster than a constant high or low temperature would on its own.
Improper Installation and Material Selection
A significant share of failures come not from the material itself but from how it was applied:
- Nicking, twisting, or misplacing the seal during installation.
- Dry-fitting without lubrication, which accelerates wear in dynamic applications such as O-rings.
- Using a seal designed for a static application in a dynamic one, or vice versa.
- Not sharing the application’s pressure, temperature, and media conditions with the manufacturer up front.
At Alpin Rubber & Plastic Technologies, we work closely with customers to review the full application conditions before finalizing material and design, which helps prevent these types of seal failures before they happen.