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A technical paper
presented by
James Walker Australia Pty Ltd

Abstract:

A technical guide for gaskets to suit PE pipe connections

Disclaimer:

This information is based on our general experience, but because of factors which are outside our
knowledge and control, no warranty is given or is to be implied with respect to such information. If any
doubt exists, please seek advice from James Walker.

Gaskets for PE pipe connections

Table of Contents
1.0

REFERENCES AND STANDARDS ................................................................................................ 2

2.0

PURPOSE ....................................................................................................................................... 3

3.0

INTRODUCTION ............................................................................................................................. 3

4.0

SCOPE ............................................................................................................................................ 3

5.0

PE PIPE CLASSIFICATIONS ......................................................................................................... 4

6.0

PE FLANGE CONNECTIONS ......................................................................................................... 4

7.0

METAL BACKING RINGS ............................................................................................................... 5

8.0

GASKET TYPES, STYLES ............................................................................................................. 7

9.0

GASKET MATERIAL SELECTION ................................................................................................. 8

10.0

GASKET DIMENSIONS .................................................................................................................. 9

11.0

10.1 Gasket inside diameter ..................................................................................................... 10

10.2 Gasket thickness .............................................................................................................. 11
BOLT LOAD/TORQUE VALUES................................................................................................... 11

12.0

HOW TO ORDER GASKETS ........................................................................................................ 13

Index of Figures
Figure 1- PE stub flange to PE stub flange ............................................................................................................. 4
Figure 2- PE stub flange to Metal flange ................................................................................................................. 5
Figure 3-PE stub flange to metal flange (flat or raised face) ................................................................................... 5

Technical report Gaskets for PE pipe connections

v3(Released)

Document Control
Rev

Revision
date

Summary of Changes

Changes
marked

0.1

14-AUG-14

Initial draft

0.2

18-AUG-14

Updated after internal review by JWA

1.0

01-SEP-14

Released following general technical review. References to ePTFE

material removed. Material selection for potable water updated

2.0

10-FEB-15

Revised per comments received from PL&PS review team.

3.0

03-MAR-15

Added notes to disadvantages for drop-in gaskets (Fig 5 and Table 6)

Glossary

A list of terms, abbreviations and acronyms used within the document.

Abbreviation

Definition

ESA

European Sealing Association

FSA

Fluid Sealing Association

HDPE

High density Polyethylene

PE

Polyethylene

1.0

References and Standards

The following related documents and standards are referenced in this document.
Reference document

Title

Issue Date(3)

POP007(1)

METAL BACKING FLANGES FOR USE WITH

POLYETHYLENE (PE) PIPE FLANGE ADAPTORS

01-MAR-2006

TN-38(2)

Bolt Torque For Polyethylene Flanged Joints

JULY-2011

AS/NZS 4130

Polyethylene (PE) pipes for pressure applications

2009

AS ISO 9624

Polyethylene (PE) pipe for fluids under pressure mating

dimensions of flange adaptors and loose backing flanges

2008

ASME B16.5

Pipe Flanges and Flanged Fittings: NPS 1/2 through NPS

24 Metric/Inch Standard
Non-metallic flat gaskets for pipe flanges

2013

ASME B16.21
ASME PCC-1

2011

Guidelines for Pressure Boundary Bolted Flange Joint

Assembly
Flanges for pipes, valves and fittings

2013

AS/NZS 4331
(ISO 7005)

Metallic flanges steel flanges

1995

AS/NZS 4087

Metallic flanges for waterworks purposes

2011

AS/NZS 4020

Testing of products in contact with drinking water

2005

AS/NZS 4623

Jointing compounds and materials for use in gas pipe

joints
Dimensions of gaskets for use with flanges to ISO 7005

2008

AS/NZS 2129

ISO 7483

James Walker TR14-08 v3(Released)

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2000

1991

Updated: 03-MAR-2015

Technical report Gaskets for PE pipe connections

v3(Released)

Notes:
1. Available from Plastic Industry Pipe Association of Australia (PIPA) www.pipa.com.au
2. Available from Plastic Pipe Institute (PPI) www.ppi.org
3. Current issue at August 2014

2.0

Purpose

The purpose of this document is to review the various gasket solutions which are now available to suit
Polyethylene (PE) pipe connections.
These are not mandatory requirements but are presented as best practice recommendations when designing
gasket solutions for PE pipe connections.

3.0

Introduction

PE pipe and associated connections are now rated for use in a variety of demanding services, operating
pressures and temperatures; these include water, waste water, potable water, gas and fuel.
It is important to make careful and appropriate gasket decisions to suit the specific requirements for each of
these applications for the same reasons which apply when selecting gaskets for metal flange connections.
Whilst gasket-less connections are possible with these connections it is still common-practice to employ gaskets
between (1) PE to PE stub flange connections, and (2) PE stub flange to metal flange connections. This
document does not discuss gasket-less connections in any detail.
Since these stub flange connections generally employ metallic backing rings which are dimensioned to standard
metallic flange dimensions such as ASME B16.5 one would be forgiven for assuming that the selection of the
companion gasket standard such as ASME B16.21 would also be logical to apply. Unfortunately there are some
key differences in these applications which make these standard gasket dimensions less than optimal in many
PE connections.
It may also be shown that the inside diameter of gaskets has to be considered in relation to various gasket
materials as well as pipe class in some cases.

4.0

Scope

In this document we consider gaskets to suit the two main connection arrangements in use:
1) PE stub flange to PE stub flange (Fig-1) and,
2) PE stub flange to metal flange (flat or raised face) Fig-2
Pipe classifications AS4130 Class PE80 and PE100 across the available range of pipe SDR ratings are
covered.
Various gasket styles such as ring, full face, and drop-in are also discussed here.
Various elastomeric compounds and compressed non-asbestos fibre (CNAF) material options are reviewed in
detail.

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Technical report Gaskets for PE pipe connections

5.0

v3(Released)

PE Pipe classifications

HDPE piping is available in various pressure categories and wall thickness.

The most common standard in use in Australia is AS/NZS 4130:2009 Polyethylene (PE) pipes for pressure
applications. There are two basic categories of pipe in this standard; PE80 and PE100. These are actually
different compounds.
The pipe is classified by an SDR rating. This is the Standard Dimension Ratio of pipe DN to pipe wall
thickness. The relationship between the dimensions of the pipes, the PE material classification and the working
pressure rating are shown in table 1. For simplicity, the dimensions of the pipe have been referred to in terms of
the Standard Dimension Ratio (SDR) where: SDR = (Outside Diameter) / (Wall Thickness).

Table 1-Comparison of SDR and Pressure ratings (PN)

SDR

41

33

26

21

17

13.6

11

7.4

PE80

PN 3.2

PN 4

PN 6.3

PN 8

PN 10

PN 12.5

PN 16

PN 20

PE100

PN 4

PN 6.3

PN 8

PN 10

PN 12.5

PN 16

PN 20

PN 25

6.0

PE Flange connections

There are two common connection methods in use. These are shown in Fig-1 and Fig-2 below and are
discussed in more detail.
Figure 1- PE stub flange to PE stub flange
Fig-1 shows a typical PE stub flange to PE stub
flange arrangement where the two stub flanges are
held together using a pair of metallic backing rings.
Note the relationship of the gasket ID (right) which is
scaled as per ASME B16.21.

The gasket with a reduced ID and thus increased

stress area is recommended where low stress
gasket materials such as elastomeric are used.

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Figure 2- PE stub flange to Metal flange

Fig-2 shows a typical PE stub flange to Metal flange
arrangement where the stub flange is secured with a
metallic backing ring having the same standard
dimensions as the metal flange.
Note the difference between the pipe bore of the
metal and PE pipe. This needs to be considered
when selecting gaskets for this style of connection.
The ASME B16.21 dimensioned gasket and similar
would be appropriate when high compressive
strength materials such as CNAF are used for
gaskets.

Whilst Fig-1 and Fig-2 specifically reference ASME B16.21 for a gasket comparison the same relationship and
scale will also apply to other flange standards which may or may not have companion gasket standards.

7.0

Metal backing rings

Metallic backing rings are discussed in detail in POP007. That document provides details of dimensions and
requirements for backing rings according to flange standards listed in table 2 below.
Table 2 - Metallic backing ring flange standards covered in POP007
Standard

Flange Classification

ASME B16.5

Class 150

Companion gasket
standard
ASME B16.21

AS/NZS 2129

Table D

None

AS/NZS 2129

Table E

None

ISO 7005-1 (AS/NZS 4331-1)

Table 10 or PN10

ISO 7483

ISO 7005-1 (AS/NZS 4331-1)

Table 11 or PN16

ISO 7483

AS/NZS 4087

Fig B7 and PN16

AS/NZS 1646
material only

AS/NZS 4087

Fig-B8 and PN21

AS/NZS 1646
material only

In terms of gasket selection the metallic backing ring selection is significant in that the gasket nominal size (DN
or NPS) is actually based on this backing ring DN or NPS and NOT on the pipe nominal size (DN) directly.
Table 3 shows the relationship between pipe DN and metallic backing ring as well as metal flange DN or NPS
for backing rings covered in POP007.

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mm

mm

AS/NZS 4087

Backing
ring/flange NPS
(Gasket NPS)

ISO 7005

Backing ring or
flange DN
(Gasket DN)

AS/NSZ 2129

Pipe DN
(Nom pipe
OD)

ASME B16.5

Table 3- Pipe DN to Backing ring/Flange/gasket DN per POP007

inch

20

15

25

20

32

25

40

32

50

40

63

50

75

65

90

80

110

100

125

100

125

125

140

125

160

150

180

150

200

200

225

200

225

225

250

250

10

280

250

10

315

300

12

355

350

14

400

400

16

450

450

18

450

500

500

500

560

550

560

600

630

600

710
800

20

24

700

800

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mm

mm

AS/NZS 4087

Backing
ring/flange NPS
(Gasket NPS)

ISO 7005

Backing ring or
flange DN
(Gasket DN)

AS/NSZ 2129

Pipe DN
(Nom pipe
OD)

v3(Released)

ASME B16.5

Technical report Gaskets for PE pipe connections

inch

900

900

1000

1000

8.0

Gasket types, styles

There are three basic styles of gasket to consider for these connections. The following is a discussion of the
advantages and disadvantages of each style. The final selection preference is left up to end users.
Other gasket styles may also exist but are generally of proprietary design and are not discussed here.

Fig -3 Ring gasket style

End users should carefully consider if this gasket style will be suitable for their
purposes and consider potential difficulty during fitting. Installers must juggle metal
backing rings, studbolts as well as the gasket whilst trying to fit it centrally.
There is a high risk of misalignment with ring style gaskets without careful attention
during installation.

Table 4 - Ring gasket summary

Advantages

Disadvantages

Very economical

Risk of misalignment is high

The same gasket may fit multiple

connection classes since the OD and bolt
holes do not need to be matched.

Fitting process can be more difficult

Fig -4 Full face gasket style

This is the most common gasket style employed and is recommended for all
applications.

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Table 5-Full face gasket summary

Advantages

Disadvantages

Easy to fit

More expensive than ring style

Self-centrering

Not interchangeable between different

backing ring standards.

Fig -5 Drop-in gasket style

This is not in common use but is available as an alternative to full face
gaskets.
Not generally recommended.

Table 6-Drop-in gasket summary

Advantages

Disadvantages

Easy to fit only need to align two

studbolts.

More expensive than ring style

Self-centrering

Not interchangeable between different

backing ring standards.
Bolt loads may not be evenly distributed.

9.0

Gasket material selection

There is of course a wide variety of gasket materials to choose from. The following guide provides some general
information but gasket manufacturers should be consulted for best advice regarding materials for specific
applications.
Table 7 provides a summary of commonly used gasket materials and their properties.
When selecting elastomeric gaskets ensure the elastomer is suitable for all intended media and specify good
quality elastomers between 60-70 Shore A durometer hardness. Poor quality elastomers have poor
compression set characteristics and contain a higher percentage of non-reinforcing fillers. Such elastomers will
compromise the gasket performance and may not be able to support the stated pressure limits listed.
There are many other material options and proprietary gasket designs also available. Unfortunately it is not
possible to review all materials here.

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Table 7 - Gasket material selections

Elastomers (1)
Nitrile
Neoprene

Details
Material type

Units

Max operating pressure (4)

bar
(MPa)

8 (0.8)

8 (0.8)

8 (0.8)

100 (10)

100 (10)

Max operating temp

Deg C

100

110

120

400

350

EPDM

CNAF
Sentinel

INCA

Minimum gasket operating

stress

MPa

15

15

Maximum gasket initial stress

MPa

10

10

10

50

50

Suitable for Gas

Suitable for water, waste water

Recommended for Potable

water (3)

(2)

(3)

(3)

(3)

1) AppliestoreinforcedandnonreinforcedgoodqualityelastomericsheetmaterialbutNOTspecialised
gasketswithmetalinsertsorotheruniquedesigns.Thesedesignsmaywellbesuitableforhigherpressures
anddifferentoperatingstresses.
2) SentinelhasAGAGasapprovaltoAS/NZS4623Class3upto2,000kPa
3) PotablewaterapplicationsmayrequirespecialgradesofEPDMandmayrequireapprovaltoAS/NZS4020
requirementsinAustralia.Detailsareavailableonrequest.BothSentinelandINCAalsohaveWRASUK
approvalforhot/coldwaterupto85degC.
4) OperatingpressuresforCNAFcanvarybythickness.Maxvaluesshownforinfoonlyandsubstantially
exceedPEpiperatingsanyway.

Gasket material selection may also affect gasket dimensions, in particular the gasket ID. See further details
below regarding gasket ID vs material discussion.

10.0

Gasket dimensions

Unlike metal flange connections where it is quite common to use elastomeric gaskets on flat-face flanges, all PE
stub flange connections need to be considered the same as raised face (RF) flange applications. This is
because the PE stub flange effectively results in gasket contact areas quite similar to raised face applications.
This is so even when a flat face metal flange is used on one side of the connection.

When determining optimum gasket dimensions the following requirements need to be considered:
1) Gasket stress area vs. studbolt stress area ratio
2) Maximum stress requirements for each different gasket material
3) Intrusion into pipe bore in case of PE stub flange to metal flange connections.
Table 8 below provides methods to use when determining gasket dimensions.

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Table 8 - How to determine dimensional properties of gaskets

Feature
Gasket OD

Gasket style
Ring style

Criteria for dimensions

Calculate Backing ring PCD minus 1 Bolt
hole diameter

Notes

Full face,
drop-in

Use OD of backing ring as per standard of

metal backing ring selected

Same as backing
ring OD

No of holes

Full face,
drop-in

Refer to flange standard applicable to

backing ring

Same as backing
ring

Hole dia.

Full face,
drop-in

Refer to flange standard applicable to

backing ring

Same as backing
ring

Gasket ID

ALL styles

Refer to guidelines shown at para 10.1 and

table 9 below

Gasket
thickness

ALL styles

Refer to guidelines under heading Gasket

thickness

10.1 Gasket inside diameter

This is a key requirement which needs to be considered along with the material selection.
In general, for elastomeric gasket materials, make the gasket ID closer to the pipe bore to maximise the stress
area available. Conversely with high compressive strength materials such as CNAF it is important to ensure the
stress area is not too high. Gasket IDs in line with ASME B16.21 are recommended for such materials.
We could attempt to establish a series of complex tables to list every gasket ID after considering each
pipe/flange SDR, DN, stub flange OD and various gasket materials etc. Instead, we will present a set of
relatively simple rules from which may be derived the suggested gasket ID.
Virtually all existing National and International gasket standards establish the gaskets ID based on the nominal
metal pipe OD. This is indeed the basis for ASME B16.21 etc.

Table 9 provides recommended practices when determining the gasket inside diameter.
Table 9-How to determine correct gasket ID
Gasket material
Elastomeric (1)

Max operating
pressure bar
(MPa)
8 (0.8)

PE to PE
connection

PE to metal flange
connection

Use Rule #1

Do not use

100 (10) (2)

Use Rule #2

Use Rule #2

CNAF materials
1.
2.
3.

Asshownintable7,appliestogoodquality,standardreinforcedornonreinforcedsheetmaterialonly.
ThesevaluesexceedmaximumratingofPEpipeandareshownforinformationonly.

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10.1.1 Rule #1 definition

Define gasket ID based on mean pipe diameter for stated pipe DN and SDR rating per AS 4130.
Recommended for elastomeric materials. This approach maximises the available gasket stress area so that
reasonable bolt loads may be achieved.
Not recommended for high compressive strength materials such as CNAF materials because the available
flange bolt loads may be far too low to deliver the required minimum gasket operating stress with resultant joint
failure or leakage, especially when factoring in the reduced maximum permissible flange stresses and
recommended bolt loads for PE flanges. This is a typical cause of poor joint integrity and is often incorrectly
attributed to the gasket.
It may also be possible and practical to define a common gasket ID to suit a range of pipe/flange SDR ratings
per pipe DN thus reducing the overall variety of gasket sizes needed to be established. In such cases the
calculated ID should consider the worst case pipe bore within the range required.

10.1.2 Rule #2 definition

Define gasket ID based on equivalent metal pipe OD relative to metal backing ring flange standard DN, Class.
i.e.) Use ASME B16.21 dimensions or applicable gasket standard.
Recommended for CNAF materials. For these materials ASME B16.21 or applicable companion gasket
standard dimensions should be used. Reducing the gasket ID to the mean pipe diameter is NOT best practice
for these materials.
Not recommended for elastomeric materials. If gasket IDs equal to those listed for standard metal flanges are
used the maximum initial stress of the elastomeric material may be reached at relatively low bolt stress values.
See Fig-1 and Fig-2 above for relative scales.

10.2 Gasket thickness

THICKER gaskets DO NOT make better gaskets; this is the common creed of most gasket manufacturers and
indeed the FSA and ESA which often goes unheeded. There are numerous valid technical reasons for this but
the full discussion of these is outside the scope of this document. The following is a reference to an article
covering this topic in detail which was published by FSA (Fluid Sealing Association) in 2005:
What gasket thickness should I use in my pump system?
Sealing Sense Article Fluid Sealing Association www.fluidsealing.com/sealingsense/Oct05.pdf
The most common gasket thickness used for elastomeric gaskets is 3mm (1/8). However, these normally only
support relatively low operating pressures and this thickness is generally the most common sheet material
available in a wide variety of compounds.

When selecting non-elastomeric gasket materials you should consider the thinnest practical gasket material to
suit the flange conditions. In general, we suggest 1.5mm thick gaskets for non-elastomeric materials up to
DN600. However, it must also be recognised and considered for existing installations the potential for a
cumulative error in flange face separation over long pipe runs.

11.0

Bolt load/torque values

PPI document TN-38 discusses bolt load/torque requirements for PE stub flanges in detail. This document is
recommended as a guide to determine the bolt load and torque for these applications.
Be aware that TN-38 primarily focuses on gasket-less solutions but also reviews the use of elastomeric gaskets
and is still valid in determining the required bolt loads and stresses when gaskets are used.

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v3(Released)

Where the gasket material, pipe, flange DN or specific application is outside the scope of TN-38 both PE flange
and gasket manufacturers should be consulted to determine a suitable bolt load solution.
ASME PCC-1 also provides detailed guidelines applicable to installation and gasket stress calculations if
required.
Table 10 shows typical gasket and bolt load/stress values based on using elastomeric gaskets. The loads are
based on targeting the maximum initial gasket stress of 10 MPa (table 7). Note the relatively low bolt stress
values.
Table 11 shows the same data based on using CNAF materials but targeting a nominal gasket operating stress
of 15 MPa also per table 7.

Table 10- Sample gasket stress vs bolt stress data (Elastomeric materials)
Detail
Pipe DN

Units
mm

Pipe Class (per AS4130)

Pipe SDR
Operating pressure

Bar
(MPa)

Pipe connection type

Flange/backing ring DN

mm

Backing ring flange standard

Backing ring flange Class
Gasket style
Gasket Rule applied
(per table 9)

Example 1
160

Example 2
160

PE100

PE100

17

17

8 (0.8)

8 (0.8)

PE to PE

PE to PE

150

150

ASME B16.5

ASME B16.5

Class 150

Class 150

Full face

Full face

#1

#2

Gasket ID

mm

140.7

168.3

Gasket OD (effective) (1)

mm

212

212

Gasket contact stress area

mm2

19,751

13,053

ea

Size of studbolts

inch

PE stub flange OD

mm

212

212

Bolt stress area (total)

mm2

1745

1745

Bolt stress

MPa

112

76

Gasket stress (Initial)

MPa

10

10

Gasket stress (Operational)

MPa

9.3

8.9

No of studbolts

Note:
1)

Effective gasket OD is equal to PE stub flange OD for PE-PE connections.

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Table 11- Sample gasket stress vs bolt stress data (CNAF materials)
Detail
Pipe DN

Units

Example 3
160

Example 4
160

PE100

PE100

17

17

16 (1.6)

16 (1.6)

PE to PE

PE to PE

150

150

ASME B16.5

ASME B16.5

Class 150

Class 150

Full face

Full face

#1

#2

mm

140.7

168.3

mm

212

212

mm2

19,751

13,053

ea

Size of studbolts

inch

PE stub flange OD

mm

212

212

Bolt stress area (total)

mm2

1745

1745

Bolt stress

MPa

184

135

Gasket stress (Initial)

MPa

16.3

18

Gasket stress (Operational)

MPa

15

15

mm

Pipe Class (per AS4130)

Pipe SDR
Bar
(MPa)

Operating pressure
Pipe connection type
Flange/backing ring DN

mm

Backing ring flange standard

Backing ring flange Class
Gasket style
Gasket Rule applied
(per table 9)
Gasket ID
Gasket OD (effective)

(1)

Gasket contact stress area

No of studbolts

Note:
1) Effective gasket OD is equal to PE stub flange OD for PE-PE connections.

12.0

How to order gaskets

As may be seen in table 3 above there are multiple examples where the same flange backing ring DN fits
different pipe DN sizes. Therefore, in order to select the correct gasket for each application, the following
minimum information should be supplied when ordering/specifying gaskets:
Essential data
1.
2.
3.
4.
5.

Nominal PE pipe DN
Pipe classification from AS 4130 or pipe standard. I.e.) PE80 or PE100 only
SDR rating of pipe and PE stub flange (these are the same)
Nominal backing ring DN or NPS
Backing ring flange standard selected. Eg) ASME B16.5 Class 150, AS 2129 etc

6. Connection type
a. PE stub flange to PE stub flange (assumed unless stated otherwise)
b. PE stub flange to metal flange (raised face or flat face)
7. Required gasket style. I.e.) Full face ++
8. Required gasket material ++
9. Required gasket thickness ++

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Application data (optional)

++ Instead of these values, if preferred you could supply the gasket manufacturer with the following details, in
addition to the information stated above, and they will suggest a suitable gasket for you:
1. Operating media details eg) LNG, Water etc
2. Operating temp (max)
3. Operating pressure (max)
This information is based on our general experience, but because of factors which are outside our knowledge and control, no warranty is given or is to be
implied with respect to such information. If any doubt exists, please seek advice from James Walker.

James Walker TR14-08 v3(Released)

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