As should be clear, care must be taken during the installation of each and every O-ring in order to avoid damaging the seal and limiting its effectiveness. All of the care taken in selecting the most effective O-ring material or designing the most efficient seal can be negated by careless installation practices.

Admittedly, however, some environments are more inherently hostile to O-rings than others. Situations most conducive to installation damage include either static or dynamic seals in which the squeeze is between the O-ring’s inside diameter (I.D.) and outside diameter (O.D.), as well as seals in which the O-ring must fit over tube ends or threads.

Installation damage can be seen in the form of surface “skiving,” clean cuts made by metal components. Damage may also involve twisting or puncturing the seal. Figure 135 is an example of O-ring failure due to installation damage.

Though it sounds simplistic, consistently careful use of correctly-sized and adequately-lubricated O-rings can eliminate many installation errors. Beyond that, all sharp gland edges should be radiused prior to installation. Threads should be covered with tape or other buffer elements during installation. A 15° to 20° lead-in chamfer is also advisable. Cleanliness of the installation area will reduce the chances of particulate damage. Proper use of any necessary installation tool(s) will save both time and money.