A Complete Guide to Jointing Sheet With Wire: Specifications, Types, and Applications

Types of Jointing Sheets with Wire

A jointing sheet with wire is a specialized sealing gasket used in industrial applications to ensure leak-proof connections between flanges in piping systems, heat exchangers, reactors, and other high-pressure or high-temperature equipment. These sheets are engineered to withstand extreme operating conditions, including fluctuating pressures, thermal cycling, and exposure to aggressive chemicals.

They are differentiated based on their construction materials, temperature and pressure resistance, chemical compatibility, and specific application requirements. The inclusion of wire reinforcement enhances structural integrity and prevents blowout under pressure. Below is a detailed breakdown of the most common types of jointing sheets with wire.

Spiral Wound Jointing Sheets

One of the most widely used gasket types in industrial settings, spiral wound jointing sheets feature a unique alternating spiral of metal and filler material, providing excellent resilience under dynamic conditions.

Advantages

• Highly flexible and conformable to flange irregularities
• Excellent performance under thermal cycling and pressure fluctuations
• Reusable in many applications with proper inspection
• Available with inner and outer guiding rings for alignment and stability

Limitations

• Requires proper bolt torque for optimal sealing
• Can be damaged during improper handling or installation
• Filler material (e.g., graphite) may degrade in oxidizing environments at high temps

Best for: Oil & gas pipelines, chemical processing, steam systems, refineries

Jacketed Jointing Sheets

These composite gaskets consist of a spiral wound core enclosed within a metallic jacket, combining the flexibility of spiral wound designs with the added protection and strength of a full metal outer layer.

Advantages

• Superior resistance to high and low-temperature extremes
• Excellent protection against media corrosion due to sealed core
• High compressive strength and blowout resistance
• Ideal for vacuum and high-pressure applications

Limitations

• Higher cost due to complex manufacturing
• Less conformability than bare spiral wound types
• Requires precision flange finishing for optimal seal

Best for: Cryogenic systems, high-pressure reactors, vacuum chambers, pharmaceutical processing

Corrugated Jointing Sheets

Designed for high-load environments, these gaskets feature a corrugated metal core sandwiched between two flat metal facings, enhancing compressive strength and sealing performance under extreme pressure.

Advantages

• Exceptional compressive strength and load distribution
• Improved sealing due to increased surface contact area
• Resistant to creep and relaxation at elevated temperatures
• Effective in applications with vibration or thermal cycling

Limitations

• Less flexible than spiral wound types
• Requires higher bolt loading for proper sealing
• May not perform well on rough or damaged flanges

Best for: Heat exchangers, reactors, turbine housings, power generation systems

PTFE Jointing Sheets

Made from expanded polytetrafluoroethylene (ePTFE), these non-metallic gaskets offer unmatched chemical resistance and are often reinforced with wire or embedded in metal for added strength.

Advantages

• Outstanding resistance to virtually all chemicals and solvents
• Non-conductive and non-contaminating
• Excellent for high-purity applications (e.g., food, pharma)
• Operates effectively across a wide temperature range (-200°C to +260°C)

Limitations

• Lower compressive strength compared to metal-reinforced types
• Prone to cold flow under constant load
• Requires careful installation to avoid damage

Best for: Chemical processing, semiconductor manufacturing, food & beverage, pharmaceuticals

Customized Jointing Sheets

Tailored to meet unique operational demands, customized jointing sheets are engineered with specific materials, dimensions, reinforcement patterns (including wire configuration), and performance characteristics based on client requirements.

Advantages

• Perfect fit for non-standard or proprietary flange systems
• Optimized for unusual media, pressures, or temperatures
• Can integrate hybrid materials (e.g., PTFE + metal core)
• Supports compliance with industry-specific standards (ASME, API, etc.)

Limitations

• Longer lead times due to design and manufacturing process
• Higher cost compared to off-the-shelf options
• Requires detailed technical specifications from the user

Best for: Unique industrial processes, R&D facilities, legacy equipment, extreme environments

Type	Temperature Range	Pressure Resistance	Chemical Resistance	Typical Applications
Spiral Wound	-200°C to +1000°C	High	Good (depends on filler)	Oil & gas, chemical plants, refineries
Jacketed	-270°C to +650°C	Very High	Excellent (sealed core)	Cryogenics, high-pressure reactors
Corrugated	-196°C to +600°C	Very High	Good (metal-dependent)	Heat exchangers, turbines
PTFE-Based	-200°C to +260°C	Moderate to High	Exceptional	Pharma, food, semiconductor
Customized	Custom	Custom	Custom	Specialized industrial systems

Expert Tip: When selecting a jointing sheet with wire, always consider the flange type, surface finish, bolt load, and potential for thermal cycling. For critical applications, consult engineering standards such as ASME PCC-1 or EN 1591 for proper gasket selection and installation procedures.

Specific Features of Jointing Sheet with Wire

Jointing sheets with wire reinforcement represent a significant advancement in industrial sealing technology. Designed to perform under extreme mechanical, thermal, and chemical conditions, these gaskets combine the compressibility and conformability of traditional jointing materials with the structural stability provided by embedded metal wires. This hybrid construction makes them ideal for critical applications where both durability and leak-tight performance are essential.

Internal Wire Reinforcement

The defining characteristic of wire-reinforced jointing sheets is the integration of high-tensile wires within the gasket matrix. These wires—typically embedded in a crisscross or parallel grid pattern—are strategically placed to resist stretching, distortion, and blowout under high internal pressure.

This internal skeleton significantly enhances the mechanical strength of the gasket, reducing the risk of creep relaxation and extrusion in flanged joints. By maintaining structural integrity during thermal cycling and vibration, wire reinforcement ensures long-term reliability and minimizes the need for frequent re-torquing or maintenance.

Enhanced Sealing Performance

Unlike standard non-reinforced jointing sheets that may deform permanently under load, wire-reinforced variants maintain dimensional stability even after prolonged exposure to extreme temperatures and pressures.

The embedded wires act as a stabilizing framework, allowing the sealing material to compress uniformly without excessive cold flow. This results in consistent contact stress across the flange surface, which is crucial for preventing leaks in dynamic systems. Additionally, the resilience of the wire core enables the gasket to recover its shape after pressure cycles, preserving sealing integrity over time.

Material Composition

Wire-reinforced jointing sheets are engineered using a dual-component approach: a flexible sealing matrix (such as graphite, PTFE, rubber, or compressed fiber) combined with a metallic reinforcement core.

The wires are most commonly made from **austenitic stainless steel (e.g., 304 or 316)** due to their excellent tensile strength, corrosion resistance, and compatibility with a wide range of chemicals and temperatures. The base sheet material is selected based on media compatibility—graphite for high-temperature steam systems, PTFE for aggressive chemicals, and elastomers for low-pressure dynamic seals.

Applications Across Industries

Thanks to their robust performance, wire-reinforced jointing sheets are widely used in demanding industrial environments. Key applications include:

• Oil & Gas: Flange seals in pipelines, valves, and pressure vessels exposed to high-pressure hydrocarbons.
• Chemical Processing: Reactors and storage tanks handling corrosive fluids at elevated temperatures.
• Power Generation: Steam turbines, boilers, and heat exchangers where thermal cycling is frequent.
• Aerospace & Automotive: Engine components and exhaust systems requiring vibration-resistant seals.
• Pharmaceutical & Food Processing: Sanitary fittings when compliant materials like PTFE and 316L stainless steel are used.

Customization Options

Manufacturers offer extensive customization to meet specific engineering requirements. These include:

• Varying wire gauge and spacing (pitch) to balance flexibility and strength.
• Choice of wire material (stainless steel, Inconel, carbon steel) depending on temperature and corrosion needs.
• Selection of sealing matrix (flexible graphite, PTFE, non-asbestos fiber) based on chemical compatibility.
• Tailored thickness and density for specific flange types (raised face, flat face, etc.).
• Custom shapes and sizes, including spiral-wound or stamped gaskets for complex geometries.

This level of customization allows engineers to optimize sealing solutions for unique operating conditions, ensuring maximum efficiency and safety.

Performance Comparison

Feature	Standard Jointing Sheet	Wire-Reinforced Jointing Sheet
Tensile Strength	Moderate	High (due to metal core)
Creep Resistance	Low to Moderate	High
Pressure Rating	Up to 15 bar (typical)	Up to 40+ bar (depending on design)
Temperature Range	Limited by base material	Extended (e.g., -200°C to +650°C with graphite)
Reusability	Poor (prone to permanent deformation)	Good (shape recovery due to wire core)

Important: When selecting wire-reinforced jointing sheets, always verify compatibility with the process media, operating pressure, and temperature. Improper material selection can lead to premature failure, leaks, or safety hazards. Consult technical data sheets and consider professional engineering advice for critical applications. Proper installation—including correct bolt torque and flange alignment—is equally vital to ensure optimal sealing performance.

How to Choose Jointing Sheet with Wire

Selecting the right jointing sheet with wire reinforcement is a critical decision in ensuring leak-free, durable, and safe sealing in industrial applications. These gaskets are widely used in piping systems, heat exchangers, pressure vessels, and chemical processing equipment, where they must withstand extreme conditions. Making an informed choice involves evaluating multiple technical and operational factors to ensure optimal performance, longevity, and system integrity.

Operating Temperature and Pressure

Temperature and pressure are the most critical parameters when selecting a jointing sheet with wire. The gasket must maintain its structural integrity and sealing capability across the full range of expected operating conditions.

• High-temperature environments (e.g., steam systems, exhaust lines) require materials like graphite or PTFE with high thermal stability
• Extreme pressure fluctuations can cause creep or blowout in inadequately reinforced gaskets—wire reinforcement helps resist such failures
• Thermal cycling can lead to compression set or relaxation; choose materials with low creep and high recovery characteristics
• Always verify that the jointing sheet’s maximum rated temperature and pressure exceed the system’s peak operating values by a safe margin

Key consideration: Account for transient spikes in temperature or pressure during startup, shutdown, or process upsets.

Chemical Compatibility

The jointing material must be chemically resistant to the media it will be exposed to—whether it's acids, solvents, oils, or gases. Incompatible materials can swell, degrade, or disintegrate, leading to leaks or contamination.

• PTFE-based sheets offer excellent resistance to most chemicals, including strong acids and bases
• Graphite is ideal for high-temperature and corrosive environments but may not be suitable for strong oxidizing agents
• Elastomer-impregnated sheets (e.g., nitrile or EPDM) are cost-effective but limited in chemical resistance
• Consult chemical resistance charts and manufacturer guidelines before finalizing material selection

Pro tip: In mixed-media environments, test the gasket material against the worst-case chemical exposure scenario.

Wire Reinforcement Design

The embedded wire mesh provides mechanical strength, prevents blowout, and improves dimensional stability under pressure. The design of the wire reinforcement significantly impacts performance.

• Tightly spaced wires offer higher tensile strength and are ideal for high-pressure applications
• Wider spacing allows greater conformability to flange irregularities, improving sealability on uneven surfaces
• Wire diameter influences strength—thicker wires enhance durability but may reduce flexibility
• Stainless steel (304/316) is commonly used for corrosion resistance and high-temperature performance
• Some advanced designs feature multiple wire layers or crimped patterns for enhanced resilience

Critical factor: Match wire design to flange type (e.g., raised face, flat face) and bolt load distribution.

Temperature/Pressure Ratings

Manufacturers provide standardized temperature and pressure ratings (often per ASME, DIN, or EN standards) that define the safe operating envelope for each gasket type.

• Ratings are typically given as maximum temperature at a specific pressure (and vice versa)
• Higher-rated gaskets may use advanced materials like flexible graphite or reinforced PTFE
• Always refer to the manufacturer’s performance charts and derating curves for elevated temperatures
• Never assume interchangeability between products—even with similar appearances

Smart choice: Select a gasket with a safety margin of at least 20% above expected operating conditions.

Thickness and Size

Proper fitment is essential for effective sealing. The jointing sheet must match the flange dimensions and accommodate the required compression.

• Standard thicknesses range from 1.5mm to 3.0mm; thinner gaskets suit smooth, high-load flanges, while thicker ones accommodate surface imperfections
• Excessive thickness can lead to instability or extrusion under pressure
• Custom die-cutting ensures precise outer diameter (OD), inner diameter (ID), and bolt hole alignment
• Follow ASME B16.21 or equivalent standards for dimensional tolerances

Technical note: Over-compression can damage the wire mesh or cause material extrusion, leading to premature failure.

Customization Options

Many manufacturers offer tailored solutions to meet unique application demands, especially in specialized industries like petrochemical, pharmaceutical, or power generation.

• Custom wire patterns (e.g., crimped, welded, or expanded metal) for specific load requirements
• Hybrid materials combining PTFE, graphite, and elastomers for multi-environment resistance
• Non-standard sizes, shapes, or multi-hole configurations for complex flanges
• Special coatings or treatments for enhanced anti-stick or anti-corrosion properties
• Traceability options (e.g., lot numbering, material certifications) for regulated industries

Time-saving tip: Work with suppliers who offer CAD-based design support and rapid prototyping services.

Professional Recommendation: For critical applications, prioritize gaskets from reputable manufacturers that provide full technical documentation, including material test reports (MTRs), compliance certifications (e.g., FDA, PED, ATEX), and detailed installation guidelines. When in doubt, consult with an engineering specialist to validate the selection based on your system’s P&ID, flange class, and service conditions.

Application Type	Recommended Material	Wire Reinforcement	Max Temp (°C)	Max Pressure (bar)
Steam Lines	Flexible Graphite	SS316, High Density	550	100
Chemical Processing	PTFE with EPDM Core	SS304, Medium Spacing	260	70
Oil & Gas Pipelines	Graphite-PTFE Hybrid	SS316, Double Layer	300	150
Pharmaceutical Systems	Pure PTFE	Optional (Low Pressure)	200	40

Additional Considerations

• Flange Surface Finish: Rougher finishes may require thicker or more compressible gaskets to achieve a seal
• Bolt Load Uniformity: Proper torque sequencing ensures even compression and prevents gasket damage
• Reusability: Most jointing sheets with wire are single-use; reuse can compromise sealing integrity
• Regulatory Compliance: Ensure materials meet industry-specific standards (e.g., FDA for food, NORSOK for offshore)
• Environmental Conditions: Outdoor or marine installations may require enhanced corrosion protection on the wire

Scenarios for Jointing Sheet with Wire: Critical Applications Across Industries

Jointing sheets reinforced with wire are engineered sealing solutions designed to perform under extreme conditions where standard gaskets would fail. The integration of metal wire mesh or perforated metal cores within compressible sealing materials provides enhanced structural integrity, resistance to blowout, and stability under high pressure, temperature fluctuations, and chemical exposure. These composite gaskets are essential in industries where system integrity, safety, and operational efficiency are paramount. Below are key applications demonstrating the versatility and necessity of wire-reinforced jointing sheets.

Safety Note: In all high-pressure and high-temperature applications, proper installation and torque procedures are critical. Always follow manufacturer specifications for compression, bolt tightening sequences, and material compatibility to ensure long-term seal reliability.

High-Temperature Sealing in Power Plants

In electric power generation facilities, jointing sheets with embedded wire reinforcement are extensively used to seal critical components such as boilers, steam turbines, and high-pressure piping systems. These environments often exceed 500°C (932°F) and operate under pressures of 100+ bar, creating extreme thermal and mechanical stress on gaskets. The wire core prevents extrusion and creep, maintaining a consistent seal even during thermal cycling. Without these reinforced sheets, steam or gas leaks would compromise energy efficiency, increase maintenance costs, and pose serious safety hazards. Their role in ensuring uninterrupted, efficient power generation makes them indispensable in modern power infrastructure.

Chemical Processing

The chemical manufacturing industry relies on wire-reinforced jointing sheets to contain aggressive substances such as acids, solvents, and reactive gases. These materials can degrade conventional elastomeric or non-reinforced gaskets, leading to catastrophic failures. The metal wire reinforcement provides mechanical strength and dimensional stability, allowing the gasket to withstand internal pressure surges and maintain integrity during chemical reactions. Additionally, the composite structure resists permeation and swelling, reducing the risk of hazardous leaks that could endanger personnel, damage equipment, or result in environmental contamination. As such, these gaskets are a cornerstone of process safety and regulatory compliance in chemical plants.

Oil and Gas Refineries

In oil and gas refining operations, jointing sheets with wire reinforcement are deployed in pipelines, distillation columns, reactors, and flare systems—environments characterized by high pressures, fluctuating temperatures, and exposure to flammable hydrocarbons. The wire matrix within the gasket prevents extrusion under pressure and resists degradation from crude oil fractions and byproducts. This is particularly crucial in preventing leaks of volatile organic compounds (VOCs) and toxic gases like hydrogen sulfide (H₂S), which pose explosion risks and health hazards. By ensuring reliable sealing in these harsh conditions, wire-reinforced jointing sheets enhance both operational safety and environmental protection, directly supporting process uptime and regulatory adherence.

Heat Exchangers in Industrial Facilities

Heat exchangers are vital for energy recovery and temperature control in industrial processes, but their flanged connections are prone to leakage due to repeated thermal expansion and contraction. Jointing sheets with wire reinforcement are specifically designed to handle these dynamic stresses. The wire core provides tensile strength and limits compression set, allowing the gasket to recover and maintain sealing force over multiple thermal cycles. This prevents cross-contamination between process fluids (e.g., cooling water mixing with oil or chemicals) and minimizes energy loss. In sectors such as petrochemicals, food processing, and HVAC, the use of reinforced gaskets significantly improves system efficiency, reduces downtime, and extends equipment life.

Aerospace Engineering

In aerospace applications, jointing sheets with wire are used in propulsion systems, fuel lines, and environmental control systems where components are exposed to extreme temperature gradients—from cryogenic conditions in fuel tanks to intense heat in engine compartments—and rapid pressure changes during flight. The wire reinforcement ensures the gasket maintains structural integrity and sealing performance in vacuum or high-altitude conditions. Any failure in these seals could compromise mission-critical systems, endanger crew safety, or lead to vehicle malfunction. As such, these high-performance gaskets undergo rigorous testing and certification, making them a vital component in both commercial aviation and space exploration technologies.

Industry	Operating Conditions	Key Benefits of Wire-Reinforced Sheets	Common Materials Used
Power Generation	High temperature (up to 600°C), high pressure, thermal cycling	Prevents blowout, resists creep, maintains seal integrity	Graphite with stainless steel core, ceramic fiber composites
Chemical Processing	Corrosive chemicals, variable pressure/temperature	Chemical resistance, mechanical strength, low permeability	PTFE with metal reinforcement, elastomer-metal laminates
Oil & Gas	High pressure, flammable media, outdoor exposure	Explosion resistance, durability, leak prevention	Flexible graphite with alloy 400 or 316L stainless steel
Industrial Heat Exchangers	Thermal cycling, fluid-to-fluid separation	Recovery after compression, dimensional stability	Non-asbestos fiber with perforated steel core
Aerospace	Extreme temperature shifts, vacuum, vibration	Reliability under stress, lightweight strength, sealing consistency	High-temp elastomers with titanium or Inconel mesh

Expert Tip: When selecting wire-reinforced jointing sheets, always verify compatibility with the specific media, temperature, and pressure of your application. Consider factors such as flange type, surface finish, and bolt load to ensure optimal performance and longevity.

Additional Considerations

• Regular inspection of gasketed joints is recommended to detect early signs of wear, compression failure, or leakage.
• Follow proper bolt-tightening procedures (e.g., cross-pattern torquing) to ensure even compression and prevent gasket damage.
• Store jointing sheets in a dry, cool environment away from direct sunlight to preserve material properties.
• Use only certified gaskets that meet industry standards (e.g., ASME, API, DIN) for critical applications.
• Consult with gasket manufacturers or engineering specialists when designing seals for new or modified systems.

Wire-reinforced jointing sheets represent a critical advancement in sealing technology, enabling safe and efficient operations across some of the most demanding industrial environments. Their ability to combine flexibility with strength makes them a preferred solution where failure is not an option. As industrial processes continue to push the limits of temperature, pressure, and chemical exposure, the importance of high-performance gasketing solutions will only grow.

Frequently Asked Questions About Wire-Reinforced Jointing Sheets

Q1: How does wire reinforcement improve the sealing ability of jointing sheets?

Wire reinforcement significantly enhances the structural integrity of jointing sheets, enabling them to withstand extreme operational stresses. By embedding a metal wire mesh—typically in the center layer—the jointing sheet maintains its shape and resists deformation under high pressure and fluctuating temperatures. This dimensional stability ensures consistent compression and contact between mating surfaces, which is critical for maintaining a reliable seal.

Additionally, the reinforcement prevents blowout or extrusion of the gasket material into the flange joint, especially in dynamic systems where vibrations or thermal cycling occur. As a result, wire-reinforced jointing sheets offer superior leak prevention compared to non-reinforced alternatives, making them ideal for demanding industrial applications.

Q2: What materials are commonly used for wire reinforcement in jointing sheets?

The choice of reinforcement material is crucial to ensure long-term performance under specific service conditions. The most widely used material is stainless steel, particularly grades 304 and 316, due to their excellent combination of:

• Corrosion resistance in humid or chemically aggressive environments
• High tensile strength to resist stretching or breaking
• Thermal stability across a broad temperature range
• Flexibility for conformability during installation

However, depending on the application, alternative materials may be selected:

• Brass: Used in low-pressure systems where moderate corrosion resistance and non-magnetic properties are required.
• Inconel (Nickel-Chromium Alloys): Ideal for high-temperature and highly corrosive environments such as those found in chemical processing or aerospace.
• Monel or Galvanized Steel: Employed in marine or acidic environments where enhanced protection against rust and chemical attack is necessary.

Manufacturers often coat the wires or select alloys based on the expected exposure to chemicals, temperature extremes, and mechanical stress.

Q3: Are jointing sheets with wire suitable for highly corrosive environments?

Yes, wire-reinforced jointing sheets can be specifically engineered for use in highly corrosive environments. The key lies in selecting compatible materials for both the reinforcing wire and the sealing matrix (typically elastomers, graphite, or PTFE-based compounds).

To maximize corrosion resistance:

• Wires are made from inherently resistant alloys like Monel, Inconel, or 316L stainless steel.
• Surface treatments such as passivation or galvanization further enhance protection.
• The surrounding gasket material acts as a barrier, shielding the metal reinforcement from direct contact with corrosive media.

For example, in chemical plants handling sulfuric acid or chlorine gas, a graphite-based jointing sheet with Inconel reinforcement provides both thermal resilience and chemical inertness. Proper material selection ensures longevity and safety, preventing leaks that could lead to equipment damage or hazardous spills.

Q4: What industries commonly use jointing sheets with wire?

Wire-reinforced jointing sheets are essential components in industries where system integrity under extreme conditions is non-negotiable. Key sectors include:

Industry	Application Examples	Why Wire Reinforcement Is Critical
Oil & Gas	Pipelines, refineries, offshore platforms	Resists high pressure, vibration, and hydrocarbon exposure
Chemical Processing	Reactors, pumps, storage tanks	Prevents leaks in corrosive and high-temperature environments
Power Generation	Steam turbines, boilers, heat exchangers	Maintains seal integrity under thermal cycling and pressure surges
Aerospace	Engine components, fuel systems	Ensures reliability in lightweight, high-stress applications
Marine & Shipbuilding	Seawater systems, exhaust manifolds	Withstands saltwater corrosion and constant vibration

These industries rely on wire-reinforced jointing sheets not only for performance but also to meet strict regulatory and safety standards.

Q5: How can one determine the appropriate type of jointing sheet for a particular application?

Selecting the right wire-reinforced jointing sheet involves a comprehensive evaluation of the operating environment and mechanical requirements. Consider the following factors:

• Temperature Range: Ensure the gasket material (e.g., graphite, rubber, PTFE) can endure minimum and maximum temperatures without degrading.
• Pressure Levels: High-pressure systems require stronger reinforcement and denser filler materials to prevent creep or extrusion.
• Chemical Exposure: Verify compatibility between the gasket’s sealing layer and the fluids or gases present using chemical resistance charts.
• Flange Type and Surface Finish: Smooth vs. serrated flanges may require different gasket thicknesses or compressibility levels.
• Cyclic Loading: Applications with frequent thermal or pressure cycling benefit from resilient, fatigue-resistant designs.

Best practices include:

1. Consulting technical data sheets from reputable manufacturers.
2. Engaging with gasket suppliers or engineers who can perform application-specific assessments.
3. Following industry standards such as ASME, API, or ISO guidelines for gasket selection and installation.

Proper selection ensures optimal sealing performance, reduces maintenance downtime, and enhances overall system safety and efficiency.