In demanding industrial environments—like power plants, refineries, chemical facilities, and high-temperature equipment—leak prevention is not a luxury; it’s a necessity. Enter the metal jacketed gasket, a hybrid sealing solution engineered to withstand extreme pressure and temperature fluctuations.
While spiral wound and ring-type gaskets are popular choices, metal jacketed gaskets offer a unique balance between metallic strength and non-metallic flexibility, making them indispensable in critical applications. This comprehensive guide explores everything business professionals and technical engineers need to know about metal jacketed gaskets—from their construction and advantages to their types, applications, and selection criteria.
What Is a Metal Jacketed Gasket?
A metal jacketed gasket is a composite gasket that features a soft filler material encased in a thin metal cover (jacket). This design allows the gasket to provide a tight seal under harsh operating conditions, including high pressure, temperature, and chemical exposure.
The metal jacket serves as a protective barrier and structural element, while the soft filler ensures adaptability to surface irregularities and provides effective sealing.
Construction and Materials
Basic Construction
- Outer Layer (Jacket): A thin metal sheet shaped to form a cover around the filler.
- Inner Layer (Filler): Usually a compressible material like graphite, ceramic fiber, or PTFE.
This composite structure allows for high compressive strength and effective sealing capability.
Common Filler Materials
| Filler Material | Temperature Range | Benefits |
|---|---|---|
| Graphite | Up to 500°C | Excellent thermal resistance, chemical compatibility |
| Ceramic Fiber | Up to 1000°C | Ideal for high-temp sealing |
| PTFE | Up to 260°C | Great for chemical resistance, non-stick |
Common Jacket Materials
| Jacket Material | Properties |
|---|---|
| Stainless Steel (304, 316) | Corrosion resistance, high strength |
| Inconel | Suitable for extremely high temperatures |
| Copper or Monel | Malleable, corrosion-resistant, used in heat exchangers |
Key Features and Advantages
Metal jacketed gaskets combine metallic robustness with non-metallic flexibility. Their main benefits include:
High-Temperature Resistance
Can operate in environments exceeding 500°C to 1000°C, depending on the material.
Withstands High Pressure
Ideal for flange joints under significant internal pressure.
Excellent Chemical Compatibility
Customizable jacket materials offer compatibility with acids, alkalis, and hydrocarbon media.
Long Service Life
Durability in harsh environments leads to lower replacement frequency.
Custom Fabrication
They can be manufactured in non-standard shapes and dimensions as per customer specifications.
Common Types of Metal Jacketed Gaskets
Each type of metal jacketed gasket is designed for specific flange configurations and sealing requirements.
Types of Metal Jacketed Gaskets
While the basic principle remains the same, metal jacketed gaskets come in several variations to suit different needs:
- Single Jacketed, Flat Metal: The simplest form, with the filler enclosed on one side and the inner diameter. Suitable for lower pressure and temperature applications.
- Single Jacketed, Overlap: Similar to Style 1 but with an overlapping jacket on the outer diameter, providing slightly better protection.
- Double Jacketed, Fully Enclosed: The filler is completely encapsulated by the metal jacket, offering superior protection against corrosion and blowouts. This is the most common and versatile type.
- Double Jacketed, Corrugated: Combines the benefits of double jacketing with a corrugated profile, enhancing resilience and sealing even with minor flange separation or thermal cycling.
- Double Jacketed, Welded: Used in extremely high-pressure and temperature applications where a fully sealed and robust gasket is critical. The jacket seams are welded for maximum integrity.
- Heat Exchanger Gaskets: Often designed with multiple bars to seal individual passes within a heat exchanger. These are highly customized based on the heat exchanger’s design.
Industries and Applications
Metal jacketed gaskets are trusted across numerous industries for their reliability under extreme conditions.
| Industry | Applications |
|---|---|
| Oil & Gas | Flanges, heat exchangers, valve covers |
| Power Generation | Boilers, turbines, high-pressure vessels |
| Chemical Processing | Reactors, pipeline systems |
| Pharmaceutical | Equipment sterilization seals |
| Marine | Engine covers, exhaust systems |
| Petrochemicals | Fractionation columns, distillation units |
Their ability to operate under cyclic loading, high pressures, and aggressive media makes them a go-to option for mission-critical sealing.
Metal Jacketed Gasket vs. Other Gasket Types
Here’s how metal jacketed gaskets compare with other commonly used gasket types:
| Feature | Metal Jacketed | Spiral Wound | Ring Type | Soft Gasket |
|---|---|---|---|---|
| Temperature Tolerance | High | Very High | High | Low |
| Pressure Handling | High | High | Very High | Moderate |
| Reusability | No | Sometimes | No | No |
| Surface Finish Compatibility | Requires good flange surface | Can adapt | Needs matching flange | High adaptability |
| Cost | Medium to High | High | High | Low |
Conclusion: Metal jacketed gaskets fill the gap between soft gaskets and high-performance metallic gaskets, providing excellent value for specific applications.
How to Select the Right Metal Jacketed Gasket ?
Selecting the right gasket requires understanding your operating environment and system design. Here’s a quick checklist:
✔ Temperature & Pressure
Choose filler and jacket materials based on thermal and pressure exposure.
✔ Media Compatibility
Corrosive or chemically aggressive environments require special alloys like Inconel or Monel.
✔ Flange Condition
Ensure flange faces are clean, flat, and within tolerance. Metal jacketed gaskets require better surface finish than soft gaskets.
✔ Size & Shape
Accurate dimensions are critical. Provide inner and outer diameters, thickness, and bolt circle details.
✔ Application Type
Special gaskets may be needed for heat exchangers, manways, or oval flanges.
Consult with your gasket manufacturer for customizations.
Installation Best Practices
Even the best gasket can fail if not installed correctly. Follow these practices for maximum efficiency:
✅ Surface Preparation
Ensure flanges are clean, dry, and free of debris or old gasket material.
✅ Proper Centering
Misalignment can cause uneven pressure and lead to leaks.
✅ Use Recommended Torque
Over or under-tightening can damage the gasket or fail to achieve a seal. Use a calibrated torque wrench.
✅ Avoid Reuse
Metal jacketed gaskets are not designed to be reused. Always replace with a new one after disassembly.
✅ Store Properly
Keep gaskets flat in a dry, cool place away from sunlight or corrosive materials.
Common Failure Modes and Maintenance Tips
Even durable gaskets can fail if not monitored or installed properly.
❌ Overcompression
Too much bolt load crushes the filler and deforms the jacket, leading to leakage.
❌ Improper Material Selection
Wrong filler or jacket material can degrade due to chemical attack or temperature.
❌ Flange Irregularities
Uneven or warped flanges won’t provide uniform pressure distribution.
🔧 Maintenance Tips
- Perform periodic flange checks.
- Monitor joint temperature and vibration.
- Replace gaskets during scheduled shutdowns.
- Use anti-stick coatings to simplify future removal.
Final Thoughts
A metal jacketed gasket may not be the most widely used sealing solution, but it plays a vital role in industries where reliability under stress is non-negotiable. Combining metallic protection with a resilient filler core, these gaskets provide excellent sealing performance under extreme conditions.
They are particularly valuable in high-temperature, high-pressure, and chemically aggressive environments—where conventional gaskets would fail or deteriorate rapidly.
If you’re in the process industry, power sector, or any business where operational downtime equals lost revenue, investing in the right gasket solution is a small step that can prevent big losses.
Optimize Your Sealing Performance with the Right Partner
At Asian Sealing Products, we specialize in custom-designed metal jacketed gaskets for all industrial applications. With decades of experience and a commitment to quality, we help our customers achieve leak-proof performance and long-term reliability.
- Precision Manufacturing
- Material Expertise
- Industry Certifications (ISO, ASME)
- Global Delivery
Frequently Asked Questions
What is a metal jacketed gasket?
A metal jacketed gasket is a composite sealing device consisting of a soft filler material (like graphite, non-asbestos fiber, or PTFE) completely or partially enclosed within a metallic outer jacket (made from materials like stainless steel, carbon steel, or Monel).
Why use a metal jacketed gasket instead of a soft gasket?
Metal jacketed gaskets are preferred for applications involving high temperatures, high pressures, and aggressive chemicals where soft gaskets would typically fail. The metal jacket provides superior strength, blowout resistance, and durability.
What are the main components of a metal jacketed gasket?
The two main components are the metallic jacket (outer shell) and the filler material (inner core).
What metals are commonly used for the jacket?
Common jacket materials include Stainless Steel (304, 316, 321, 347), Carbon Steel/Soft Iron, Monel, Inconel, Nickel, Copper, and Aluminum. The choice depends on temperature, pressure, and chemical compatibility.
What’s the difference between single and double jacketed gaskets?
A single jacketed gasket has the filler enclosed on one face and the inner diameter, leaving the outer diameter exposed. A double jacketed gasket fully encapsulates the filler material, offering better protection, resilience, and blowout resistance. Double jacketed is generally preferred for more demanding applications.
What does “corrugated” mean in a corrugated jacketed gasket?
A corrugated jacket means the metal has a wavy or rippled profile. This corrugation increases the gasket’s resilience and ability to compensate for minor flange imperfections or thermal cycling, improving sealing performance.
What are the typical temperature and pressure limits for these gaskets?
Limits vary widely depending on the specific jacket and filler materials. Generally, they can handle temperatures from cryogenic up to 1000°C (1832°F) or more, and pressures well over 200 bar (3000 psi). Always consult material datasheets for specific ratings.
Where are metal jacketed gaskets commonly used?
They are extensively used in the petrochemical, oil & gas, power generation, chemical processing, and heat exchanger industries due to their ability to withstand harsh conditions.
Can they seal against aggressive chemicals?
Yes, by selecting appropriate corrosion-resistant jacket materials (e.g., stainless steel, Monel) and chemically inert filler materials (e.g., PTFE, graphite), they can effectively seal many aggressive chemicals.
What are the common reasons for metal jacketed gasket failure?
Common causes include:
- Incorrect material selection for the application.
- Improper installation (uneven torquing, dirty flanges).
- Flange misalignment or damage.
- Exceeding temperature or pressure limits.
- Chemical attack on the gasket materials.
