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Sealant Stars Among Chemical Raw Materials: Key Choices to Meet Diverse Needs
DATE:2025-01-02
 

When working with chemicals, picking the wrong coating can cause big problems with how things work. System leaks and lost output can happen, leading to unplanned downtime and repairs that need to be done right away.

These failures not only make upkeep more often and cost more, but they also expose chemicals that could be dangerous. Also, closing solutions that aren't good enough can cause problems with following the rules, especially in places where dangerous materials are handled.

Here are five types of seals that are often used in places that process chemicals. There are different chemical makeups, performance traits, and best use situations for each type.

 

1. Silicone-Based Sealants

Chemical Processing Applications

Primary Process Equipment

Reactor vessel connections, heat exchanger assemblies, distillation column seals

Storage Applications

Tank rim seals, expansion joint seals in storage vessels

Utility Systems

Steam line connections, hot oil system seals, heat tracing enclosures

External Applications

Weather-exposed equipment housings, outdoor pipeline connections, ventilation duct seals

Performance Properties

Temperature Performance

  • Operating Range: -60°C to 200°C
  • Temperature Cycling: Stable across full range
  • Heat Aging Resistance: Excellent up to 180°C continuous exposure
  • Cold Temperature Flexibility: Maintains elasticity down to -55°C
  • Temperature Shock Resistance: Superior
Property Value
Movement Capability ±25%
Tensile Strength 2.4-3.1 MPa at 23°C
Elongation at Break 400-600%
Shore A Hardness 25-35

Chemical Resistance

  • Acids Good resistance to mild acids (pH>4)
  • Bases Compatible up to pH 10
  • Solvents Limited resistance
  • Cleaning Agents Common industrial cleaners
  • UV and Ozone Excellent resistance

Environmental Conditions

  • Ambient Temperature 5°C to 40°C
  • Substrate Temperature 3°C above dew point
  • Relative Humidity 30-90%
  • Storage Conditions 10-25°C, dry location

Application Guidelines

  • Surface must be clean, dry, and free of oils and contaminants
  • Priming is required for most metal and concrete surfaces
  • Application temperature should be maintained between 5°C to 40°C
  • Joint design should follow 2:1 width to depth ratio recommendation
  • Working time is approximately 30-45 minutes at 23°C
Important Note: Full cure time requires 24-72 hours. Protect from rain for first 24 hours. Regular inspection and maintenance recommended for optimal performance.

Usage Limitations

  • Not recommended for continuous solvent exposure
  • Avoid use in concentrated acid environments
  • Requires careful surface preparation for optimal adhesion
  • Paint adhesion may be poor without special primers
  • Not suitable for submerged applications
  • Avoid contact with certain organic rubbers

Quality Control Measures

 

Adhesion Testing

Conduct pull test after 7 days of cure time

 

Visual Inspection

Check for bubbles, voids, and proper fill

 

Dimension Control

Verify joint dimensions meet specifications

 

Documentation

Record batch numbers and application conditions

Important Quality Control Note

Regular monitoring and documentation of quality control measures are essential for ensuring long-term performance. Maintain detailed records of all tests and inspections for regulatory compliance and troubleshooting purposes.

 

2 Polyurethane Sealants

Chemical Processing Applications

 

1
Secondary Containment

Containment walls, chemical storage dikes, spill barrier joints

 

2
Process Areas

Equipment foundations, pump bases, process floor joints

 

3
Loading Areas

Tank truck loading zones, loading dock seals

 

4
Maintenance Areas

Equipment mounting pads, pipe supports

Temperature Performance

  • Operating Range -40°C to 80°C
  • Temperature Cycling Good within range
  • Heat Resistance Up to 75°C
  • Cold Flexibility Down to -35°C

Chemical Resistance

  • Aliphatic Hydrocarbons Excellent
  • Mild Acids and Bases Good
  • Oils and Fuels Moderate
  • UV Resistance Fair

Key Mechanical Properties

  • Movement Capability ±25-35%
  • Tensile Strength 3.4-4.1 MPa
  • Shore A Hardness 35-45
  • Service Life 3-4 years in chemical exposure

Application Guidelines and Environmental Requirements

Proper application and environmental control are critical for optimal polyurethane sealant performance. Follow these guidelines to ensure successful installation and long-term durability.

Installation Requirements
  • Mechanical cleaning and degreasing required
  • Essential priming for concrete surfaces
  • Application temperature: 10°C to 35°C
  • Cure time: 24-48 hours depending on conditions
  • Joint design per manufacturer guidelines
  • Surface must be clean and dry
Environmental Controls

Temperature Control

Maintain 10°C to 35°C during application

Substrate Temperature

Must remain above dew point

Humidity Control

Monitor and control during application

Weather Protection

No moisture exposure during cure

Quality Control Checkpoints

  • Verify adhesion after initial cure
  • Check surface preparation quality
  • Confirm joint dimensions
  • Monitor cure progress
  • Document application conditions

Critical Application Note

Strict moisture control is essential during application and initial cure. Any exposure to moisture before proper cure can significantly impact adhesion and long-term performance. Regular maintenance inspection is required for optimal results.

3 Polysulfide Sealants

Chemical Processing Applications

1

Primary Containment

Chemical storage tanks, process vessels, acid tanks

2

Hazardous Materials

Solvent storage systems, corrosive material containment

3

Process Equipment

Flanged connections, manway seals, pipeline joints

4

Safety Systems

Emergency containment areas, spill control zones

Temperature Performance
  • Operating Range -50°C to 120°C
  • Temperature Stability Very good
  • Heat Resistance Up to 110°C
  • Cold Flexibility Down to -45°C
Chemical Resistance
  • Oils and Fuels Superior
  • Acids and Oxidizers Excellent
  • Industrial Solvents High
  • UV and Weathering High

Superior Performance in Aggressive Chemical Environments

Movement Capability: ±25-30%
Tensile Strength: 2.8-3.5 MPa
Shore A Hardness: 30-40
Service Life: 5-7 years in aggressive environments

Critical Installation Notice

Proper installation is crucial for chemical containment. Failure to follow these guidelines may result in seal failure and chemical leakage.

Installation Process
  • Thorough cleaning and profiling required
  • Mandatory priming for all substrates
  • Application temperature range: 5°C to 35°C
  • Initial cure: 24-48 hours
  • Full chemical resistance: 5-7 days
  • Joint design according to exposure level
Environmental Controls

Temperature Range

5°C to 35°C during application

Substrate Condition

Above dew point temperature

Ventilation

Essential during curing phase

Protection

No chemical exposure during cure

Quality Control Measures

Chemical Resistance Testing After Full Cure
Adhesion Verification on Actual Substrates
Joint Inspection for Dimensions and Fill
Cure Monitoring Through Hardness Tests

Safety and Handling Considerations

  • Higher material cost compared to alternatives - proper planning required
  • Extended cure time necessary before chemical exposure
  • Requires skilled application personnel with proper training
  • Specific storage and handling requirements must be followed
  • Temperature limitations during application must be strictly observed

4 Acrylic-Based Sealants

Laboratory Equipment
  • 1
    Analytical instrument seals
  • 2
    Calibration equipment mounts
  • 3
    Laboratory bench joints
Quality Control Areas
  • 1
    Testing chamber seals
  • 2
    Inspection equipment mountings
  • 3
    Vibration isolation joints

Performance Properties

Temperature Performance
  • Operating Range -20°C to 70°C
  • Heat Resistance Up to 60°C
  • Cold Flexibility Down to -15°C
Chemical Resistance
  • Acids (pH>5) Good
  • Bases (pH≤9) Good
  • Lab Cleaning Agents Standard

Usage Considerations

Indoor Use

Recommended for controlled environment applications

Movement Capacity

Limited to joints with ±12-15% movement

Chemical Exposure

Not suitable for continuous chemical immersion

Maintenance

Regular inspection and maintenance required

Application Guidelines for Controlled Environments

Precise application procedures ensure optimal performance in laboratory and clean room settings.

Surface Preparation
  • Clean surface thoroughly, free from dust and grease
  • Ensure substrate temperature is 3°C above dew point
  • Use appropriate cleaning solvents for surface type
  • Allow surface to dry completely before application
Application Parameters
  • Temperature Range 10°C to 35°C
  • Relative Humidity Maximum 80%
  • Working Time 20-30 minutes
  • Initial Set Time 4 hours

Application Best Practices

Joint Design

Width to depth ratio 2:1 for optimal performance

Tool Selection

Use standard caulking gun and smoothing tools

Ventilation

Adequate ventilation required during curing

Protection

Keep dry for first 4 hours after application

Quality Control Measures

Adhesion Testing
Visual Inspection
Dimension Control
Documentation

Usage Limitations

  • Not suitable for continuous chemical immersion
  • Avoid application in areas exposed to strong chemicals
  • Not suitable for expansion joints exceeding 15% movement
  • Indoor use recommended
  • Regular inspection and maintenance needed

5 Butyl Rubber Sealants

Quick-Fix Solution for Temporary Applications

Ideal for emergency repairs and temporary sealing needs in industrial settings.

Emergency Repairs
  • ! Leak sealing in process equipment
  • ! Temporary pipe joint repairs
Maintenance Operations
  • ! Quick fixes during scheduled maintenance
  • ! Temporary vessel sealing

Performance Characteristics

Temperature Performance
  • Operating Range -30°C to 80°C
  • Heat Resistance Up to 70°C
  • Cold Flexibility Down to -25°C
Chemical Resistance
  • Water Resistance Excellent
  • Weathering Good
  • Gas Permeability Excellent

Important Usage Notes

Temporary Only

Not suitable for permanent chemical containment

Movement Limits

Limited to ±5-10% movement capability

Regular Checks

Requires weekly monitoring and inspection

Replacement

Plan for permanent solution within 1-2 years

Emergency Application Guide

Quick implementation procedures for temporary sealing solutions

Immediate Response Protocol
1 Basic Surface Preparation
  • Basic cleaning and degreasing
  • Remove loose debris
  • Dry surface if possible
2 Rapid Application
  • Direct application or preformed strips
  • Temperature range: 5°C to 40°C
  • Minimum 3mm thickness

Immediate Monitoring Requirements

Visual Inspection

Check for continuous contact and coverage

Bond Verification

Test immediate adhesion strength

Thickness Control

Verify minimum required thickness

Regular Checks

Weekly inspection schedule

Critical Usage Alerts

Temporary Only

Not for permanent sealing solutions

Limited Duration

1-2 year maximum service life

Movement Restriction

Minimal joint movement only

Chemical Exposure

Limited chemical resistance

Permanent Solution Planning

Assessment

Evaluate failure cause

Selection

Choose permanent sealant

Scheduling

Plan replacement timing

Implementation

Execute permanent fix

Select the Right Sealant for Your Project Success!

Make informed decisions based on your specific requirements and operating conditions.

Key Selection Criteria
  • Operating temperature range
  • Chemical exposure conditions
  • Movement requirements
  • Safety and compliance needs
  • Long-term performance expectations
Implementation Considerations
  • Installation requirements
  • Maintenance needs
  • Cost considerations
  • Application environment
  • Required service life
Sealant Type Best For Key Advantage Main Limitation
Silicone High-temperature applications Excellent temperature resistance Limited solvent resistance
Polyurethane Structural applications Strong adhesion properties UV sensitivity
Polysulfide Chemical containment Chemical resistance Higher cost
Acrylic Controlled environments Easy application Limited movement capability
Butyl Emergency repairs Quick implementation Temporary solution only

High Temperature Areas

Choose silicone-based sealants for excellent heat resistance and stability.

Chemical Exposure

Select polysulfide sealants for superior chemical resistance.

Structural Integrity

Opt for polyurethane sealants in load-bearing applications.

Emergency Situations

Use butyl rubber sealants for quick, temporary repairs.

Final Selection Checklist

Verify temperature requirements
Assess chemical exposure risks
Consider movement needs
Check safety compliance
Review installation conditions
Plan maintenance schedule
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