BIRKOSIT High-Temperature Sealing Compound for Extreme Industrial Conditions

Why Industrial Sealing is a Critical Engineering Challenge

Industrial machines like steam turbines, gas turbines, compressors, pumps, and pressure vessels operate under:

• Extreme temperature (200°C to 900°C)

• Extreme pressure (50 to 550 bar or more)

• Vibration and cyclic thermal expansion

• Aggressive media (steam, oil, gas, chemicals)

The Fundamental Engineering Problem

No metallic surface is perfectly flat. Even machined metal surfaces contain:

• Microscopic scratches

• Surface waviness

• Thermal distortion

• Assembly misalignment

These micro-gaps become leak paths for steam, gas, or fluids.

LIMITATIONS OF TRADITIONAL SEALING CONCEPTS

Gaskets as Mechanical Barriers

Traditional sealing relies on gaskets (metal, graphite, rubber, PTFE). They work by compressing material between two surfaces.

BUT GASKETS HAVE INHERENT FAILURE MODES:

• Creep: Material compresses over time and loses sealing pressure

• Thermal degradation: High heat destroys gasket materials

• Relaxation: Bolts lose tension due to thermal cycles

• Vibration loosening: Causes micro-leak paths

• Surface damage sensitivity: Scratches cause leakage

Metal-to-Metal Butt Joints (Machined Seals)

High-end turbines use machined butt joints instead of gaskets. But even precision machining cannot achieve absolute zero roughness. So metal-to-metal contact still leaks microscopically.

Micro-Sealing Layer Engineering

BIRKOSIT is NOT a glue, gasket, or adhesive. It is a plastic sealing compound designed to create a controlled micro-sealing layer.

CORE ENGINEERING PRINCIPLE

BIRKOSIT works by:

• Filling micro scratches, pores, and waviness

• Forming a thin elastic layer (0.2–0.3 mm)

• Remaining permanently plastic (does NOT harden)

• Compensating for thermal expansion and vibration

WHY BIRKOSIT DOES NOT HARDEN

Most sealants harden (silicone, epoxy, RTV).

Hardening causes:

• Cracking under vibration

• Loss of elasticity

• Seal failure during thermal cycles

BIRKOSIT remains permanently elastic.

• It follows metal expansion

• It absorbs vibration

• It does not crack or shrink

• It self-adjusts under load

HIGH TEMPERATURE SEALING

Temperature Challenge At 900°C:

• Rubber burns

• Graphite oxidizes

• PTFE decomposes

• Metals expand significantly

BIRKOSIT is formulated to resist thermal decomposition and maintain plasticity.

HIGH PRESSURE SEALING CONCEPT

Pressure tries to push fluid through any micro-gap. Even a 1 micron gap becomes a leak path at 500 bar.

• Fills these micro gaps

• Maintains sealing under bolt relaxation

• Prevents micro-blowouts

WHY USED IN TURBINES

Steam turbines rotate at:

• 3,000 to 15,000 RPM

• Subject to thermal cycles daily

• Must be leak-free for efficiency

Leakage causes:

• Energy loss

• Efficiency drop

• Corrosion

• Safety hazards

THE CONCEPT OF LONG SERVICE LIFE

Traditional seals fail due to:

• Compression set

• Aging

• Chemical degradation

BIRKOSIT:

• Does not compress permanently

• Does not cure

• Does not crack

• Is chemically stable

DAMAGE COMPENSATION

Machined surfaces can be damaged during:

• Assembly

• Maintenance

• Handling

Instead of re-machining expensive turbine casings, BIRKOSIT:

• Compensates scratches and dents up to 0.2 mm

• Saves expensive machining costs

• Reduces downtime

IMMEDIATE LOAD BEARING

BIRKOSIT:

• Requires no curing

• Equipment can be pressurized immediately

This is critical for:

• Shutdown windows

• Emergency repairs

• Commissioning schedules

BIRKOSIT AS A SYSTEM ENGINEERING SOLUTION

Reliability Engineering

Prevents leak-induced failures

Maintenance Engineering

Reduces overhaul frequency

Safety Engineering

Prevents steam/gas leak hazards

Cost Engineering

Avoids re-machining and gasket replacement

Efficiency Engineering

Maintains pressure integrity

Industrial Sealing Challenges in High-Temperature & High-Pressure Systems

Modern power plants, oil & gas facilities, and heavy industrial equipment operate under extreme heat, pressure, vibration, and aggressive media exposure. Conventional gaskets and sealants often fail, leading to:

Steam and gas leaks

Pressure loss and efficiency reduction

Equipment downtime and safety risks

Costly maintenance shutdowns

BIRKOSIT Dichtungskitt® is engineered to solve these critical sealing challenges.

ABOUT BIRKOSIT

What is BIRKOSIT Dichtungskitt®?

BIRKOSIT Dichtungskitt® is a single-component industrial sealing compound designed for metallic butt joints and smooth sealing surfaces where extreme temperature and pressure demand the highest sealing reliability.

It is widely used in steam turbines, gas turbines, compressors, generators, pumps, and flange joints in critical industrial applications.

WHY INDUSTRIAL SEALING IS A CRITICAL SAFETY & RELIABILITY ISSUE

Industrial sealing is not just about leakage prevention—it directly impacts:

Operational efficiency

Equipment lifespan

Personnel safety

Regulatory compliance

Maintenance cost optimization

Traditional gasket materials degrade under extreme conditions. BIRKOSIT provides a long-term sealing solution without curing or hardening, maintaining flexibility even under dynamic loads.

BIRKOSIT AS THE ULTIMATE SOLUTION

Extreme Temperature Resistance

BIRKOSIT withstands hot steam, air, water, oils, crude oil, and natural gas at temperatures up to 900°C.

High Pressure Sealing Performance

Up to 250 bar guaranteed sealing

Up to 450 bar for flanges without sealing rings

Up to 550 bar for screw joints

Long Service Life

With proper application and maintenance, BIRKOSIT provides a service life of up to 10 years on machined sealing surfaces.

KEY TECHNICAL FEATURES

Single-component paste sealing compound

Immediate load-bearing (no curing time required)

Flexible and elastic over time

Suitable for smooth metallic butt joints

Compensates sealing surface damage up to 0.2 mm

Can be applied with brush or putty knife

Stable storage life up to 5 years in sealed containers

APPLICATION INDUSTRIES

Power Generation

Steam turbines

Gas turbines

Generators

Oil & Gas

Compressors

Pumps

Flange joints

Gas pipelines

Heavy Industry

Process equipment

High-pressure machinery

Heat exchangers

HOW BIRKOSIT WORKS

BIRKOSIT creates a micro-sealing layer between metallic surfaces, filling microscopic imperfections and preventing leak paths under thermal expansion and vibration.

Unlike conventional gaskets, it:

Does not harden or crack

Maintains elasticity

Allows precision machining of butt joints

Performs under cyclic thermal loads

INSTALLATION & APPLICATION PROCESS

Clean and dry sealing surfaces

Apply BIRKOSIT on both sealing faces

Recommended layer thickness: 0.2–0.3 mm

Assemble joint immediately (no curing time required)

Equipment can be loaded instantly

BENEFITS FOR INDUSTRIAL OPERATORS

✔ Prevents steam and gas leaks

✔ Reduces unplanned shutdowns

✔ Extends turbine and equipment lifespan

✔ Eliminates gasket failure risks

✔ Improves plant efficiency

✔ Reduces maintenance costs

✔ Enhances operational safety

CONTACT US

📞 +91 9603166448
📧 sales@pschandsafety.com

🌐 pschandsafetyindia.com