A Complete Guide to Pipe Plug Materials and Their Chemical Compatibility

Pipe plugs are essential tools for isolating, testing, or maintaining pipelines. They create a tight, reliable seal inside a pipe to prevent the flow of liquids or gases during maintenance or pressure testing. One of the most important factors in choosing the right plug is material compatibility . The wrong material can lead to swelling, cracking, or chemical degradation, reducing performance and safety.

This guide explains the most common pipe plug materials, their chemical resistance, and how to select the best option for your application.

Why Material Selection Matters for Pipe Plugs?

Pipe plug performance depends on how well the material resists the fluid or gas inside the line. Each application has unique requirements based on:

• The type of media (water, oil, gas, chemical, or air)
• Temperature and pressure conditions
• Duration of use (temporary or long-term)
• Environmental exposure such as ozone, sunlight, or saltwater

Selecting the right material ensures that the plug maintains a proper seal, resists degradation, and performs safely under pressure.

Common Pipe Plug Materials and Their Characteristics

Natural Rubber

Natural rubber plugs are flexible, durable, and provide an excellent seal for air and water applications.

• Best for: General-purpose testing and isolation
• Resists: Water and mild chemicals
• Avoid with: Oils, solvents, and high-temperature media

These pipe plugs are often used for standard water and low-pressure air applications where chemical resistance is not a major concern.

Nitrile (Buna-N) Rubber

Nitrile is widely used for its strong resistance to oils and fuels.

• Best for: Hydrocarbon pipelines and refinery operations
• Resists: Petroleum-based fluids and hydraulic oils
• Avoid with: Strong oxidizers and some solvents

It provides a good balance of strength, flexibility, and resistance to abrasion in oil or fuel environments.

Neoprene Rubber

Neoprene offers a mix of oil resistance and excellent weathering properties.

• Best for: Marine and wastewater systems
• Resists: Water, air, and moderate oils
• Avoid with: Strong acids and aromatic hydrocarbons

This material performs well outdoors or in systems exposed to ozone and sunlight.

EPDM Rubber

EPDM is known for outstanding resistance to water, steam, and many chemicals.

• Best for: Water treatment, chemical processing, and steam applications
• Resists: Water, steam, alcohols, and weak acids or alkalis
• Avoid with: Oils, fuels, and hydrocarbons

EPDM is a reliable choice when exposure to heat, sunlight, or oxidizing chemicals is expected.

Viton® (Fluoroelastomer)

Viton® offers high chemical and heat resistance, making it suitable for demanding applications.

• Best for: Chemical plants, refineries, and power generation
• Resists: Strong acids, solvents, and oxidizers
• Avoid with: Very low temperatures

Although more expensive, Viton® provides superior performance when sealing aggressive chemicals or high-temperature media.

Silicone Rubber

Silicone remains flexible across a wide temperature range and is non-reactive.

• Best for: Food, pharmaceutical, and laboratory use
• Resists: Air, water, and mild chemicals
• Avoid with: Oils and fuels

Its clean, non-contaminating properties make it suitable for sanitary and precision applications.

Chemical Compatibility Overview

Selecting the Right Material for Your Application

To ensure reliable sealing and safety, follow these steps when selecting a pipe plug:

1. Identify the type of media or chemical exposure.
2. Check the temperature and pressure rating of the system.
3. Determine if the plug will be used temporarily or long-term.
4. Match the plug material to the compatible chemical group.
5. Confirm that the plug meets the required safety and pressure standards.

Petersen Products manufactures inflatable and mechanical pipe plugs designed for most size, pressure, chemical, and temperature requirements . Selecting the correct material helps maintain performance and reduces the risk of downtime or damage.

Custom Material Options for Specialized Applications

For specialized needs, custom elastomers and coatings can be engineered to handle specific conditions. Examples include:

• Oil-resistant inflatable plugs for refineries or fuel transfer lines
• Steam-compatible EPDM plugs for high-temperature utilities
• Chemically inert seals for laboratory or pharmaceutical systems

Our team designs and fabricates custom inflatable seals and plugs to meet exact application requirements, ensuring performance even in extreme environments.

Conclusion

Choosing the right pipe plug material is essential for safe and reliable operation. Each rubber compound has unique strengths that make it suitable for specific chemical and environmental conditions.

For help selecting a plug compatible with your media and pressure needs, contact Petersen Products at sales@petersenproducts.com or 262-692-3100 .

Media

Taxonomy

• Plumbing
• Plumbing
• Pipe Plugs