Butyl Rubber Gaskets and Seals

Butyl rubber is a synthetic elastomer also known as IIR, or isobutylene isoprene rubber. It is characterised by very low gas permeability together with excellent resistance to moisture, ozone, weathering and ageing.

These properties have made butyl rubber an established sealing material for applications where protection against air, gas or moisture transmission is particularly important.

Butyl rubber combines flexibility and compressibility with extremely low permeability to air and gases. When compressed between mating surfaces, it can provide an effective environmental barrier whilst accommodating small surface variations.

Its resistance to moisture, ozone and weathering also makes it particularly useful for long-term sealing applications and equipment exposed to outdoor or demanding environmental conditions.

Butyl rubber can typically be used across a temperature range of approximately -40°C to +120°C, although the exact operating limits will depend upon the particular compound, thickness, mechanical load and application conditions.

Specialist butyl compounds may have different temperature capabilities, so operating conditions should be considered when selecting material for a particular application.

Yes. Very low gas permeability is one of the principal characteristics of butyl rubber. It provides an effective barrier to air and many gases, making it particularly useful for sealing applications where gas transmission or air leakage needs to be minimised.

The suitability of the material for a specific gas should nevertheless be confirmed where critical containment or specialist process conditions are involved.

Yes. Butyl rubber has excellent resistance to moisture, ozone, oxidation and weathering. This makes it particularly suitable for outdoor applications, equipment housings, environmental seals and assemblies that may be exposed to damp or changing weather conditions.

Its long-term resistance to environmental ageing can also help maintain sealing performance over extended periods.

Butyl rubber offers good resistance to many dilute acids, alkalis, aqueous chemicals and other inorganic substances. It can therefore be suitable for a variety of industrial and chemical-processing applications.

Chemical compatibility varies according to the substance, concentration, temperature and operating conditions, so material suitability should be checked where aggressive chemicals are involved.

Butyl rubber is generally not recommended for prolonged contact with petroleum-based oils, fuels or hydrocarbon solvents.

Where resistance to oils, fuels and greases is a primary requirement, an alternative material such as nitrile rubber may be more appropriate. Material selection should always take account of the fluids and operating conditions involved.

Both butyl rubber and EPDM provide excellent resistance to weathering, ozone and moisture and can be suitable for outdoor and environmental sealing applications.

Butyl rubber is particularly notable for its very low permeability to air and gases, making it advantageous where gas or vapour transmission needs to be minimised. EPDM may be preferred for other applications depending on temperature, chemical exposure and mechanical requirements.

Yes. Bluemay Weston manufactures bespoke butyl rubber gaskets and seals to customer drawings, dimensions, samples and specifications.

Components can be produced in simple circular or rectangular formats as well as complex profiles incorporating apertures, fixing holes, slots and other features using precision punching and water jet cutting techniques.

Bluemay Weston manufactures butyl rubber gaskets and seals from sheet material using precision punching and water jet cutting.

Punching provides an efficient manufacturing method for repeat production quantities, whilst water jet cutting is particularly useful for prototypes, low-volume batches, larger components and complex profiles where dedicated tooling may not be appropriate.

Bluemay Weston can manufacture butyl rubber gaskets and seals in quantities ranging from prototypes and small development batches through to high-volume production runs of many thousands or potentially millions of components, depending on the component design, material specification and customer requirements.