DECEMBER 2008
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THE GASKET FABRICATOR www.gasketfab.com
Volume 27 Number 3
DECEMBER 2008
PRESIDENT'S MESSAGE
IN THIS ISSUE President's Message Pages 1-2
Clem Foley
Hang in There!
As you read this, our Canadian elections New Association are just over and the U.S.A. one will be finalized Members as well. In Canada, we have five political parties Page 2 compared to the main two in the States. Our voting can become a little complicated and Meet the New Director confusing so this year, I tried a very simplistic Page 2 approach to voting. I drove around and counted all the lawn signs and voted for the person with Company Profiles the most signs. I guess I was not the only one to Page 3 use that approach as we elected two independent members of parliament. Both were sales people for Remax Reality. Boy, were Future Meeting Schedule they surprised! Page 3 On a more serious note, how about that ever changing economy? As a friend of mine said, “This is worse than a divorce, I lost half my assets and I Press Releases still have my wife.” His words, not mine. Page 5 Frankly, we have had it very good for a long time and our economies needed a retrofit. Over the next little while, most of us will have to learn to live Member Presentation on less, spend less, plan better, perform business tasks we have been putting Summaries aside, and overall, we will rethink a lot of things we do and why we do them. Page 6 This is good for our firms and the economy as well. We are getting back to the basics and not living in a dream world. Hang in there. As an association and Eco-Materials and group of friends, we will help each other out and climb this hill. The end result, Sustainability whenever it may come, will be stronger and healthier companies and employees. Page 7 Change is good when it teaches us lessons and points us in the right direction. For those of you that own your companies, now may be the time to stop Membership Anniversaries and smell the roses. You are more in control of your destiny than an executive Page 7 employed by a supplier firm. Money and growth can be gained or lost in a very short time frame and often through no fault of your own. The prize at the end Fall Meeting Photos of the road becomes minute if you do not have your health or great friends. Pages 8-9 When we attend these GFA meetings, we often travel to locations that are really beautiful and also relaxing, but most plan to just make the meetings General Rubber Compounds and fly home as soon as they can to get back to work so that one day, they can Pages 10-11 afford to take a vacation with their family and mellow out. Please think about this for a second. You are already at a convention Gasket Factors: m, y that more often than not, it takes the better part of a day to get there and you Pages 11 & 13-14 are away from the office. Why not arrive a couple of days early and enjoy the peace and quiet, get acclimatized, and spend time with your spouse or friend. Benchmarking Report You can also stay a couple of days after the meetings to again relax or party, Page 14 Continued on Page 2...
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PRESIDENT'S MESSAGE (Continued from Page 1...)
depending on your makeup, and the cost to you will be four additional nights’ accommodations. It just seems to me that this would add so much more pleasure to your life, give you quality time with your spouse or friend, and it just may show your office that yes, they can actually run your business without you phoning in every half hour. Everybody wins! It was a great meeting at the Loews Ventana Canyon Resort in Tucson, AZ, and I am looking forward to spending some time with you March 31 to April 2 at the Saddlebrook Resort in Tampa, FL. Maybe I should say March 29 to April 4. Remember...... Life is short.
NEW ASSOCIATION MEMBERS Fabricator CGS Technologies, Inc. Phoenix, AZ www.CGSTech.com Leader Global Technologies Deer Park, TX www.leadergt.com Marian, Inc. Indianapolis, IN www.marianinc.com Suppliers Arlon Engineered Coated Products Dallas, TX www.arlon.com/ecp Repuestos Auto-Industriales, SA de CV (RAISAMEX) Monterrey, NL, Mexico www.raisamex.com.mx Virtek Vision International Waterloo, ON, Canada www.virtek.ca
DECEMBER 2008
MEET THE NEW DIRECTOR Pamela Siano Fardelos, National Sales Manager Adchem Corporation Pamela S. Fardelos received her undergraduate degree in International Business & Foreign Languages at Lake Erie College in Painesville, OH, and she attained her MBA from Babson College’s F.W. Olin Graduate School of Business. Pamela has over 20 years of experience in the pressure-sensitive tape industry in various global sales and marketing management positions. She has served as National Sales Manager for the Adchem Corporation for five years, with a focus on high performance, highly engineered bonding applications.
NEWSLETTER The Gasket Fabricator is published by the Gasket Fabricators Association and distributed to all members and prospective members of GFA. President ................................................................Clem Foley Vice President ...................................................Steve Hanson Executive Director....................................... Robert H. Ecker Administrative Director/Newsletter Editor...............Peter Lance Communications Committee Chair.....................Chris Brand Members are encouraged to contribute articles and items of interest to the Gasket Fabricator. All contributions should be addressed to: Executive Director, GFA, 994 Old Eagle School Road, Suite 1019, Wayne, PA 19087-1866, Phone (610) 971-4850, Fax (610) 971-4859, Home Page: www. gasketfab.com, E-mail:
[email protected]. Articles appearing in this publication may not be reproduced without written consent from the Association. Articles appearing in the Gasket Fabricator are the views of the authors and not necessarily those of the Association. © Copyright 2008 Gasket Fabricators Association
DECEMBER 2008
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COMPANY PROFILES K-Flex USA K-Flex USA, with offices and manufacturing operations in Youngsville, NC, is the North American business unit for L’Isolante K-Flex, headquartered in Milan, Italy. L’Isolante K-Flex is the world’s leading manufacturer of elastomeric thermal insulations with worldwide manufacturing operations in China, Poland, India, Turkey, Italy, United States, Iran, and Russia. L’Isolante K-Flex’s mission is to draw upon its global experience to provide elastomeric insulation products that are energy-saving, innovative, fiber free, mold and mildew resistant, environmentally friendly, and easy-to-use. K-Flex USA products are used in residential, commercial, industrial, solar, marine and OEM applications. Our materials are offered in a variety of wall thicknesses and lengths from cut to length pieces to continuous coils. Tube, sheet, and roll forms are available with or without easy-to-use pressure sensitive adhesives. Sheet/Roll products are available up to 60” wide and 2” thick. K-Flex USA products meet exacting industry standards, (945U) national building codes, and are third party certified. Our products carry FM, UL, and GREENGUARD® approvals. The GREENGUARD® Environmental Institute (GEI), a third party listing agency has listed K-Flex® LS, Insul-Tube®, Insul-Sheet® and K-Flex® Gray Duct Liner as mold resistant. These products are also GREENGUARD® certified as low VOC materials, meeting the requirements of the Children and Schools Classification. Our experienced worldwide sales team and dedicated inside sales representatives are available to answer your questions and serve your needs. Please contact us to learn more about K-Flex USA. Visit our website at www.kflexusa.com or call at 800-765-6475.
Visit us online at: www.gasketfab.com
Arlon Engineered Coated Products Arlon Engineered Coated Products (ECP) has been a World Class leader in pressure sensitive adhesive coatings for over 40 years. Arlon ECP manufactures pressure sensitive tape products, including double and single coated foams, papers, films, foils, transfer adhesives and other custom coated specialty products. Providing solvent and aqueous adhesive solutions, Arlon ECP products cover a wide range of performance characteristics. Key applications are gasketing, vibration dampening, mounting, sealing, sound deadening, weather stripping, medical, automotive, appliance and general industrial markets. Arlon ECP offers complete converting for end users and distributors, including custom slitting, corona treating, flame laminating and die cutting. Arlon ECP is headquartered in San Antonio, Texas, and has another manufacturing facility in Dallas, Texas. Both sites are ISO 9001:2001 certified For more information, please contact Dan Morse, Director of Sales and Marketing at 303-841-2378.
GFA FUTURE MEETING SCHEDULE Spring 2009 Semi-Annual Meeting & Celebration of GFA's 30th Anniversary March 31 - April 2, 2009 Saddlebrook Resort Tampa, FL Fall 2009 Semi-Annual Meeting September 22-24, 2009 Arizona Grand Resort Phoenix, AZ
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THE GASKET FABRICATOR
DECEMBER 2008
MANUFACTURES OF
DURAFOAM
TM
CLOSED CELL SPONGE & PLASTIC FOAM
GO GREEN WITH
BONDAFLEX
TM
97% RECYCLED MATERIAL
PHONE: 1.800.375.1960 FAX: 1.800.375.1962
DECEMBER 2008
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PRESS RELEASES Freeman Schwabe Machinery On The Move
Freeman Schwabe Machinery, a Global OEM of Die Cutting Presses, Machines and Systems, has purchased a new headquarters and manufacturing facility in Clermont County, Ohio and completed the move in August 2008. President and CEO Greg DeFisher commented: “This is the right move for Freeman Schwabe, as there is demand for our products throughout the world, and we required space better suited to our manufacturing and assembly needs as well as a showplace to demonstrate our Die Cutting Presses, Machines and Systems to our customers. Clermont County, and in particular, Union Township is a great location for our type of Global Business and has given us great support.” The building plans will allow the facility to eventually grow to 50,000 SF. Freeman Schwabe serves a broad range of industries globally, including automotive interiors, packaging, gaskets, carpet tiles, and envelopes to name a few. Additionally, the magnetic stripe on the Ohio driver's license is applied on a Freeman Schwabe machine. Freeman Schwabe’s new address is: 4064 Clough Woods Drive, Batavia, Ohio 45103 USA (1513-947-2888). More information about Freeman Schwabe is available on the company's website at www. freemanschwabe.com.
Monmouth Achieves ISO 9001:2000
“Monmouth Rubber & Plastics Corp. is proud to announce its ISO 9001: 2000 certification. This milestone brings added value to our customers namely gasket cutters, fabricators and resellers worldwide,” said John M. Bonforte Jr. Sales Manager. “Our ISO 9001: 2000 certification has been made possible through the hard work and a team based atmosphere possessed by the Monmouth Rubber family of dedicated people,” said Bonforte. For over 40 years, Monmouth’s commitment to its customers has been state of the art quality and product performance. The ISO certification reinforces that commitment toward quality management practices. Monmouth manufactures closed cell sponge rubber and plastic foam in Long Branch, NJ. For more information, call (800) 375-1960 or visit www. rubberplastics.com
New GFA Member Service
The GFA, in collaboration with the International Association of Diecutting and Diemaking (IADD), is offering a new service to members. Through the Members Only area of the GFA’s website, you can access TechTeam™, a group of dedicated and experienced industry professionals who stand ready to assist you with your specific technical questions, issues, and problems. When you contact them through the website, their mission is to quickly research and answer your technical gasket fabricating, diecutting, and diemaking questions in an unbiased, confidential, current, and direct manner. It's like having a team of industry experts at your side, at no additional cost to you! GFA Members can access the service by clicking on Members Only on the GFA’s home page (www.gasketfab.com). Members who have forgotten their user name and password should contact the GFA office at 610-971-4850 or
[email protected].
Rich Corr With Venture Tape Presented With Plaque By GFA
Bob Ecker, GFA Executive Director (center) presented Rich Corr with Venture Tape Corporation and his wife Betty Anne with a plaque for Rich’s invaluable service rendered to the GFA while serving on the Board from 2005 - 2008.
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DECEMBER 2008
MEMBER PRESENTATION SUMMARIES
Below are summaries of presentations given by GFA Members at the Fall Meeting in Tucson, AZ.
Armacell, LLC
Armacell accelerated its growth in advanced foams and engineered thermoplastics in 2008, concluding a twopart transaction with Cellect that significantly broadens Armacell’s polyolefin foam product line. Armacell purchased Cellect’s physically blown, non-crosslinked polypropylene business – the PropaCene®, E-Cell® and T-Board® products for numerous applications in key segments like automotive, packaging and construction. PropaCene is a 100% recyclable, patented blend of polypropylene and metallocene polyethylene resin that provides strength, higher temperature resistance and improved stiffness at less thickness and lower density. It has superior moisture, chemical and impact resistance. In specific applications it is a value-added replacement for non-foam films, crosslinked PP and PE foams for automotive water shields, air caps, evaporator trays and fender silencers, bottle cap gaskets and other uses. E-Cell is also a patented blend of PE and metallocene PE for gasket, packaging and construction applications. T-Board is physically blown high density foam of polypropylene-based resins in a flat sheet form. In the second part of the transaction, Armacell and Cellect completed a long term global supply agreement for Armacell to market, sell and distribute Cellect’s I-Cell® irradiated crosslinked PE foams. In North America, Armacell is focused on marketing and distributing I-Cell specifically for automotive, flooring and bottle cap applications.
MACtac
MACtac is a manufacturer of pressure sensitive adhesive tapes, double and single-sided tapes, foams, films and foils, serving a wide range of markets. MACtac was founded in 1959 in Stow, Ohio and we still have our world wide headquarters there. MACtac is a global company with facilities in 12 countries, with our European-Asian headquarters located in SOIGNIES, BELGIUM. MACtac is well staffed and positioned to support your business regionally, and on a global scale employing over 1600 people world wide. MACtac had net sales last year of approximately 630 million, and is part of the Bemis Company located in Neenah, Wisconsin. Our parent company Bemis had net sales last year of approximately 3.6 billion dollars, with
56 plants in 10 different countries, employing over 16,000 people world wide. Some of our sister
companies include, Curwood, Perfecseal, Clysar, Banner Packaging, Dixie Toga, Milprint Incorporated and Bemis Tape. MACtac’s Specialty Division includes MACtac Technical Products, MACtac Medical Products, Transdermal Medical group, and our Specialty Custom Products Group. MACtac has multiple adhesive platforms and can coat solvent rubber and acrylic based adhesives, modified acrylics, hot melt, emulsion, transdermal medical, and phenolic adhesives on a wide variety of substrates including; SCK, PCK, PET Polystyrene, metalized film and papers, foil, FSK, ASJ, tissue, and scrim to name a few. MACtac has the ability to zone coat adhesives, pattern coat adhesives and can coat in a variety of thicknesses up to 50 mil. We have the adhesive solution for you and look forward to working with you. Call us at 800-328-2619.
Rogers Foam Corporation Rogers Foam Corporation is a custom converter of end applications using Specialty Foams, Films, Fabrics, and Adhesive Systems. Our expertise is developing innovative solutions for your custom designed applications. Rogers Foam Corporation is a privately held company and considered one of the largest foam fabricators worldwide. We have multiple locations globally and continue to expand our presence within North America, Europe and Asia through the acquisition of existing businesses and development of new applications and markets for foam-based products. We possess an extensive set of converting capabilities within our various facilities. In addition, we can provide specialty fabrication and assembly work in a cost effective manner. Combined with an in-house Design and Engineering group, we can provide a “cradle to grave” solution for you. RFC’s long history of fabrication expertise and supplier partnerships has enabled us to possess a broad working knowledge in a diversified range of materials that may be used to meet your customer’s performance objectives. Rogers Foam Corporation is a ‘full service’ company that can design and supply a diversified set of solutions for your customer’s needs. We look forward to working together with you on your upcoming projects.
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ECO-MATERIALS AND SUSTAINABILITY By: Demitri Fardelos and Tim Vos, Amorim Cork Composites
Sustainability is on everyone’s mind these days both at home and in the office. Companies large and small are making efforts in conservation working toward the triple bottom line of People, Planet and Profit. What about making sustainability a part of your company’s vision? Create an ongoing process for getting each part of the company to recognize and understand its environmental, economic and social impacts. Each department should be thinking about how they can use that knowledge to innovate through a systematic and integrated approach to all daily tasks. Entering into partnerships with customers and suppliers who share the same ideals with all three aspects of the bottom line in mind can give you a competitive advantage. In every place from the purchasing department to the material specifiers, an impact can be made. Purchasing recycled paper for the office is a simple step. However, a paperless office is a whole new concept and takes a little more effort, but the gains are greater. The same applies to using materials for production purposes. Identifying and specifying an eco-material may be a little more challenging. Educating your customers regarding both new and existing materials with a low environmental impact can be a major differentiator for you in the years to come. Your customers (or their customers) will require “green”, “eco-friendly”, and sustainable benefits in the products they use in the near future. Gasket fabricators are used as a resource for many industries and have direct influence in many circumstances for material choices and design criteria for OEM’s. With the rising cost of petroleum-based materials and the trend toward green manufacturing, support of organic materials is growing due to the lower costs to recycle, recover or reprocess. Low material VOC (volatile organic compound) emissions at both the fabrication and manufacturing levels are also being recognized as a simple contributor to a healthy workplace. As an example, cork and cork rubber materials can contribute in a variety of ways to a “green objective”. Cork has a very low specific gravity and is a lightweight component with enough compressibility in 1 square inch to support 14,000 lbs. of pressure and can recover to at least 90% of its original thickness. Used in rolling stock (auto, truck, bus, etc.) applications, the lightweight factor is a key to improved fuel economy and CO2 emission reduction. The combination of cork
and rubber are naturally excellent for anti-vibration and acoustic control (NVH). The rubber component adds to cork’s inherent ability to resist the penetration of liquids. The organic cellular structure is excellent in friction applications and retains the friction properties even when in contact with oils or water. Benefits of sustainable materials, such as cork, exist all around us and are being refined for a variety of bio-technologies. The bottom line is simple. A proactive approach to new trends and updated requirements can lead you toward dynamic new directions. Eco-based materials are now a real part of a new industrial revolution and recognition can easily be gained by being known as an innovator in your industry. The work involved in being an educated partner to both your customers and suppliers can be rewarding in all aspects of your future initiatives, giving you the competitive advantage in a challenging economic environment.
MEMBERSHIP ANNIVERSARIES
In 2008, the following companies are celebrating anniversaries. We would like to thank them for their ongoing support. 20 Years Amorim Cork Composites, Inc. Reeves-Trelleborg 15 Years CGR Products, Inc. E.G. Gasket & Supply, Inc. Ilene Industries, Inc. Scapa North America 10 Years M&C Specialties Southern Rubber Co., Inc. TB Philly, Inc. Technicon Industries WARCO BILTRITE 5 Years Armacell, LLC Berry Plastics Insul-Fab
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DECEMBER 2008
FALL 2008 MEETING LOEWS VENTANA CANYON RESORT TUCSON, ARIZONA
Clem Foley, GFA President, and Steve Pendergast at the Semi-Annual Dinner
Dr. Jeff Dietrich with the Institute for Trend Research, presenter at the General Session
GFA New Members & First Time Attendees (left to right): Matt Malles with Ecore International, Tom Wiley with CGS Technologies, Inc., Toby Martinez with Syntac Coated Products, Sandra Chastain with MACtac, Phil Pitney with TBP Converting, and Carrie Marotta with Rogers Foam Corp.
Shelby Ricketts with Insul-Fab, presenter at the General Session
Monica Hale with SAIC Energy Solutions Operation, presenter at the General Session
Hotshot Gunslinger Johnny Tuscadero, performer at the Semi-Annual Dinner
DECEMBER 2008
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SUPPLIER EXPO
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GENERAL RUBBER COMPOUNDS By: Jim Ward, BRP Manufacturing
Rubber products are generally composed of four major parts: A) polymers (the ‘rubber” portion) B) processing oils C) carbon blacks and/or fillers D) curing agents In combining these items, you obtain the general rubber products purchased within our industry. Polymer (rubber) selection is usually based upon application and material specifications. The following information may be used to assist you in selecting the right rubber for the application. Please remember that these are suggestions based upon historical uses; for proper consideration and accurate selections, please consult an applications engineer. Natural Rubber (polyisoprene) NR & Synthetic Natural Rubber (polyisoprene) IR: Natural rubber was the “original” rubber product. Its first uses were in footwear, protective coverings, and tubing. It has excellent abrasion and tear resistance with very high tensile strengths. It has very poor heat, ozone, sunlight (UV), oil, and fuel resistance. Its temperature range is -40 to 180° Fahrenheit. Its most common usages are in mining and material conveyance (belting). Cost fluctuations due to availability and market controls of this product make it very price sensitive. Synthetic natural rubber was developed during World War II to provide rubber products to the Allied countries while Japan controlled the Southeast Asian rubber plantations. As a laboratory product, it is generally higher in cost than NR. SBR (styrene butadiene rubber) SBR: SBR was the first synthetic elastomer. It was also developed during WWII to replace the natural rubber used in tires. It has excellent abrasion resistance with good tensile strength. It has moderate heat resistance and may be compounded to offer some ozone resistance. It has very poor oil and fuel resistance. Its temperature range is -40 to 210° Fahrenheit. SBR was used to blend with other polymers to help reduce cost, but skyrocketing market costs and supply problems have minimized its use in today’s market. It is still a key component in tires. Neoprene (polychloroprene) CR: Neoprene was initially a trade name for one of the first synthetic polymers developed by DuPont. It is a good general all purpose elastomer with moderate oil and ozone resistance and good compression set. High content polychloroprene has excellent fungus resistance, flame retardance, and bonding characteristics to metal. It has a very limited fuel
resistance. Its temperature range is -40 to 220° Fahrenheit. A wide range of Neoprene products are offered within the marketplace and used in many general applications including military, automotive and appliance. Neoprene is also used in the construction trade in high load bearing applications. Buna “N” (acrylonitrile butadiene) NBR: Buna “N” (sometimes referred to as nitrile or NBR) is the least expensive polymer associated with fuel (gasoline) resistance. It has excellent fuel and oil resistance including petroleum based lubricating oils and transmission fluids, good compression set, low gas permeation rates, and good low temperature flexibility. It has a very poor ozone resistance. Its temperature range is -40 to 220° Fahrenheit. It is generally used where continuous exposure to gasoline or oil is needed. The development of alcohol blended fuels, flex fuels and biodiesel products may present application issues when considering Buna “N” in those type applications. EPDM (ethylene propylene polymer) EP: EPDM may also be referred to as EPT, EP or some variation in ethylene propylene. EPDM is generally considered to be the most economic polymer with the widest environmental resistance. It has excellent low temperature, heat, coolant, water, steam, ozone, and sunlight (UV) resistance. It has virtually no resistance to oils or fuels. It is generally considered to be nonstaining to painted surfaces. Its temperature range is -60 to 240° Fahrenheit. With a peroxide curing system, the temperature range is raised to 300° Fahrenheit and above. EPDM is commonly used in automotive and building applications, especially rubber roofing. Butyl (isobutylene isoprene) IIR: Butyl rubber is noted for its extremely low air permeability with a good tear resistance; one of its first uses was in the manufacture of tire inner tubes. It is still used today in the patch kits of many cyclists. It has excellent water, steam, ozone, and alkali resistance. It has very poor oil and fuel resistance. Its temperature range is -40 to 240° Fahrenheit. Butyl rubber is also very popular in the rubber roofing industry. HYPALON® (chlorosulfonated polyethylene) CSM: HYPALON® is another DuPont registered trademark rubber. As engine temperatures increased, HYPALON® filled a niche where higher temperature ranges were needed in Neoprene type applications. It has excellent ozone, oxidation, and sunlight (UV) resistance with moderate resistance to alkalis and acids. It has similar oil resistance to Neoprene, but at higher operating temperatures. Its temperature range is -40 to Continued on Page 11...
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GENERAL RUBBER COMPOUNDS
(Continued from Page 10...) 240° Fahrenheit. With oil resistance in a wider temperature range come higher costs than with other oil resistant products. Epichlorohydrin ECO, ECH: Epichlorohydrin is commonly referred to as ECO or ECH, the technical abbreviation assigned by ASTM standards. It has a wide temperature range with excellent resistance to oils and fuels. It also exhibits good ozone and sunlight resistance. Its temperature range is -60 to 240° Fahrenheit. Its high cost has prevented its use in many commercial applications, but it is extremely popular in automotive fuel applications. Fluoroelastomer (fluorocarbon) FKM: The most common trade names in the fluoroelastomer products are VITON®, FLUOREL®, and DYNEON®. The fluorine content of this rubber product makes it almost universally applicable to any rubber application, but its cost dictates otherwise. It has excellent fuel, oil, and high temperature resistance as well as compression set, aging characteristics, and flame retardance. Its major shortcoming is its very poor low temperature characteristics. Its temperature range is 0 to 450° Fahrenheit. It is extremely popular in oil refining and electrical transformers where service costs outweigh the cost of material. Silicone: Silicone rubber products cover a very wide range of chemical compositions; in most cases, temperature values determine the proper chemical composition. Silicone rubber is best noted for its broad temperature range, excellent ozone resistance, and excellent compression set. It has very poor tear strength as well as poor tensile strengths. It has a moderate oil resistance. Its temperature range is -80 to 500° Farenheit. One of the most common usages for silicone is in food processing. The broad range of silicone products contributes to a very wide price range. Other Rubber Products and Trade Names Carboxylated Nitrile (XNBR) Highly Saturated Nitrile (HNBR) Fluorosilicone (FVMQ) Polyacrylate (ACM) Ethylene Acrylate VAMAC® (AEM) Chloropolyethylene (CM) Polysulfide THIOKOL®
Technical articles by GFA members that appeared in past issues can be downloaded on the website at www.gasketfab.com/techinfo.asp.
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GASKET FACTORS: M, Y By: Larry Pyle, LFP Technologies
BACKGROUND: The Boiler and Pressure Vessel Code is the standard by which all such vessels are designed and built. The full code is contained in multiple volumes that is revised and published every two years by the American Society of Mechanical Engineers. Addendums are issued twice yearly. The cost of a copy of the entire code is approximately $13,500. The code establishes rules of safety governing the design, fabrication, and inspection of boilers and pressure vessels, and nuclear power plant components during constructions. The objective of the rules is to provide a margin for deterioration in service. Advancements in design and material and the evidence of experience are constantly being added by Addenda. Originating in 1914, the ASME Boiler and Pressure Vessel Code is now adopted in part or in its entirety by 49 states and numerous municipalities and territories of the United States and all the provinces of Canada. The Boiler and Pressure Committee, a volunteer group of more than 950 engineers, keep the Code current. The Committee meets regularly to consider requests for interpretations, revision, and to develop new rules. GASKET FACTORS: Gaskets for the use with these types of vessels governed by the Code are also carefully controlled. This brings us to the definition and use of the Gasket Factors that are used in the Code. Because the mechanical behavior characteristics of the gasket are complex and specific data are generally unavailable, the design of gasketed joints has been reduced to a series of simplified equations based on experimentally determined “gasket factors”. The basic behavior of the gasket is supposedly defined by the gasket factors, which are tabulated in the Boiler and Pressure Vessel Code. This procedure has been successful and is still widely used. Research in recent years, however, shows that the present Code gasket factors give an overly simplified view of the behavior of a gasket. A far more complete understanding is emerging but that may be the subject of a future article. The y Factor: The y factor is the initial gasket stress or surface required to preload or seat the gasket to prevent leaks in the joint as the system is pressurized The m Factor: When the vessel is pressurized, the contact pressure on the gasket is reduced to some Continued on Page 13...
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www.rogerscorp.com/hpf
DECEMBER 2008
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GASKET FACTORS: M, Y (Continued from Page 11...) residual value, depending on the elastomeric behavior of the gasket and its relationship to the elasticity of the joint. Experiments show that the liquid or gaseous pressure a joint will contain is proportional to the amount of residual contact pressure exerted by the joint surfaces on the gasket and that the contact pressure on the gasket contained pressure is called the m factor and may be different for must be larger than the pressure being contained. The ratio of the contact pressure to the different types of gasket as suggested in the following table of some typical m and y factors. Some typical values for m and y are given in the table below. A complete list can be found in the Code (Section VIII, Division 1, Appendix II, Table 2-5.1). Because a full copy of the table would be too large for this publication, a full copy of the table can be provided to those interested. Type of Gasket
Maintenance factor (m)
Min.seating stress (y), psi
Mineral fiber with suitable binder: 1/8” thick 2.00 1/16” thick 2.75 1/32” thick 3.50
1600 3700 6500
Spiral-wound metal, mineral fiber filled: Carbon 2.50 Stainless/Monel 3.00
10000 10000
Elastomers without fabric or high percentage of mineral fiber: Below 75A Shore durometer 0.50 75A or higher Shore 1.00
have shown that both of these gasket factors are equally important. FLANGED GASKETED JOINT DESIGN, How to use m and y: Two design procedures are allowed by the Code. Outlined below is the simpler of the two. This procedure is covered in Section VIII, Division 1, Appendix II of the Code. The more complex procedure is also described in Section VIII, Division 2, of the Code and allows the designer greater freedom of choice, but requires a detailed design analysis. Those interested in the more complex procedure can consult the Code. The simpler procedure is described below. Refer to the figure below.
0 200
Solid flat metal: Soft Aluminum 4.00 8800 Iron or soft steel 5.50 18000 Note that the y and m factors, respectively, define the amount of assembly stress that must be placed on the gasket, and the amount of residual stress that must be present to prevent a leak after the system has been pressurized. Decades of experience and experiment
1) The designer selects the general size and type of flange to be used. 2) Determines the following design conditions: • Operating temperatures • Operating pressures • Flange, bolt, and gasket materials • Allowable stress levels 3) Computes the loads which will be placed on the joint by the internal pressure. This consists of two components: the hydrostatic end force, HD, exerted on the closed end of the vessel or pipe system, and the pressure force HT which acts directly on the exposed inner face of the flange surface. The end force reaches the flange through the pipe and the hub. 4) Compute two bolt load: that required for the seating of the gasket, WM2 , and that required to prevent leaks when the system is pressured, WM1. In so the experimentally Continued on Page 14...
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GASKET FACTORS: M, Y
BENCHMARKING REPORT
(Continued from Page 13...)
determined and published y and m factors discussed above are used. These calculations require an estimate of the effective width of the gasket, b, using rules given by the Code. Because of such things as flange rotation and nonuniform loading of the gasket, there can be substantial change in the effective width. Note that the loaded gasket exerts a reaction force, HG, on the flange, and that this force is in the same direction as the previously calculated pressure forces, HD and HT. The expression for seating (Wm2) and maintenance (Wm1) bolt loads is: Wm2 = µbGy
Where:
Below are the results from the Benchmarking Survey, which was undertaken to give GFA members a thumbnail sketch of how other members are fairing at this time. We had 36 out of 78 Fabricator responses. 1. Most Recent Quarter Sales Compared to Previous Quarter
Wm1 = (µG2/4) P + 2µGbmP G = diameter of the pressure vessel to the midpoint of the gasket P = contained pressure (psi) b = effective width of the gasket m, y = gasket constants discussed earlier
Wm1 is the minimum required bolt load for the operating conditions. Wm2 is simply the effective contact surface area of the gasket (µbG) times the recommended seating stress (y, in psi). This defines the total clamping force the bolts are expected to exert on the joint upon initial, roomtemperature assembly. There are more steps in the full and complete procedure. What I have tried to provide here is the definition and use of the Gasket Factors m and y. Those interested in the detailed design procedure should consult the full Code. Resource material used: • 2007 Boiler and Pressure Vessel Code, Section VIII, Division 1, Appendix II • An Introduction to the Design and Behavior of Bolted Joints, by John H. Bickford, published by Marcel Dekker, Inc., 1990
If you have technical questions you would like to see answered in future issues, please send them by e-mail to
[email protected].
DECEMBER 2008
UP 16 44%
DOWN 13 36%
SAME 7 19%
2. Current Quarter Sales Projection Compared to Last Quarter
UP 9 25%
DOWN 19 53%
SAME 8 22%
We had 25 out of 63 Supplier responses. 1. Most Recent Quarter Sales Compared to Previous Quarter UP 11 44%
DOWN 7 28%
SAME 7 28%
2. Current Quarter Sales Projection Compared to Last Quarter UP 5 20%
DOWN 16 64%
SAME 4 16%
DECEMBER 2008
THE GASKET FABRICATOR
PAGE 15
ACRYLIC & RUBBER BASED GASKET ATTACHMENT SOLUTIONS
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PAGE 16
THE GASKET FABRICATOR
DECEMBER 2008
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