Operating air springs at high pressures demands a high level of engineering awareness and procedural care. At Tevema, we prioritize precision and durability, but also emphasize the safety protocols essential for ensuring reliable performance in demanding environments. In this article, we’ll discuss our most important best practices when using high-pressure air springs, especially those configured with multiple convolutions or specialized rubber-metal assemblies. These systems operate at working pressures ranging from 8 to 12 bar depending on their construction. The natural frequency range of Tevema air bellows starts as low as 1.2 Hz, which ensures excellent vibration isolation. Our designs support axial strokes from 20 mm to over 400 mm. Load capacities vary, reaching up to 450 kN in reinforced units. These figures make technical validation more concrete. Proper specification, use, and maintenance of each unit are key to safe performance. Let’s examine each critical factor in detail.
Know your operating pressure limits
All air springs have designated maximum pressure ratings that must not be exceeded. Standard units typically tolerate up to 8 bar, but four-ply constructions can handle up to 12 bar. It’s crucial to respect these limits during system commissioning and maintenance. Over-pressurization leads to material fatigue, unexpected deformation, and ultimately, rupture risks. We advise integrating pressure regulators and overpressure relief valves in all designs. This minimizes the likelihood of system failure and supports long-term use. For reference, a single-convolution bellow at 7 bar can exert up to 75 kN of force, depending on its size. Always review the rated stroke and height specifications. Operating outside those values dramatically shortens lifespan. Cracking, delamination, and performance loss occur rapidly under improper loading. Consistent, correct pressure guarantees longer cycles and safer conditions. Monitoring pressure during operation is critical. Digital gauges and inline transducers should be used where possible. Do not allow pressure spikes from compressors to pass through unregulated.
Select suitable elastomer compounds
The rubber compound used in the bellows dramatically affects durability under pressure. At Tevema, we utilize a wide range of compounds, including natural rubber, chlorobutyl, nitrile, EPDM, and chloroprene. Each provides unique chemical resistance, temperature tolerance, and aging characteristics. When working at high internal pressures, compounds like chlorobutyl and EPDM offer greater resilience, especially in environments exposed to ozone or heat cycles. Temperature ranges vary from -40°C to +115°C depending on the material. Use nitrile for contact with oils or fuels and EPDM for outdoor or thermal loads. The wrong compound leads to early swelling or hardening. Each compound’s dynamic modulus affects how the bellows respond under cyclical loads. Reinforced elastomers have higher burst thresholds and maintain flexibility over more cycles. Always consult a compatibility chart before selecting material. Ensure internal fabric plies and outer coatings are aligned with pressure and media demands. These decisions improve operational lifespan and prevent accidents.
Verify compatibility with working media
Although designed for compressed air, Tevema’s industrial air springs also operate with nitrogen, water, and oily air. However, for non-air media like water or hydraulic oil, stainless steel components are essential to avoid corrosion. Operating with incompatible media can lead to internal degradation and premature system failure. Before introducing alternative gases or liquids into the bellows, consult with our engineering department to determine media compatibility. Our bellows can include sealing systems designed for BSP or NPT air inlets and support pressures up to 12 bar. In water or chemically aggressive media, use AISI-304 or AISI-316L for metal parts. This protects structural integrity and prevents bead ring corrosion. Water-based systems without appropriate materials corrode within weeks. In nitrogen-based isolation systems, verify internal volume and fill rates to prevent over-pressurization. Oil mist in compressed air can accelerate elastomer decay. Filter air supply and monitor for residue build-up. Proper preparation ensures safety and avoids costly damage.
Use appropriate metallic parts
High-pressure applications necessitate strong, corrosion-resistant metals. Tevema offers metallic components in electro-galvanized steel, AISI-304, and AISI-316L stainless steel. These materials resist abrasion, chemicals, and high-cycle loading. For processes involving cleaning agents, acids, or exposure to wet environments, stainless variants should be prioritized. Improper selection can compromise sealing surfaces and create structural weaknesses, particularly when under elevated stress levels. Electro-galvanized parts are acceptable for indoor, dry systems with neutral media. For systems exposed to chloride vapors or aggressive solvents, use AISI-316L. Our end closures include blind nuts and threaded holes (M8 or M10) for secure fixation. Crimped versions ensure permanent closures, while bead ring designs allow disassembly. Every component must match its expected pressure load and vibration cycle. Torque values for assembly should be followed precisely. Excess torque warps plates; too little causes leaks. Always inspect threads for wear during installation. Material choice affects both safety and performance stability.
Account for height and stroke limits
Each bellow type has a minimum and maximum design height. Compressing or extending beyond these limits causes internal tension loss, wrinkling, and delamination of the inner layers. When operating at high pressures, height control becomes even more critical due to the force exerted. We recommend installing mechanical height stops and pressure-controlled regulators to maintain axial balance and avoid overextension. Consistent monitoring helps avoid mechanical lockout scenarios. For example, a triple convolution unit may offer a stroke of 250 mm, but extending beyond that risks separation. At full compression, some bellows can handle up to 75 kN, but only within rated height. Exceeding design parameters stresses internal plies and vulcanized joints. Axial movement should be centered to prevent skewed loading. Shock absorbers can be added in dynamic systems. Always verify design height in drawings. Never rely solely on visual judgment. Use mechanical guides to maintain vertical motion within safe parameters.
Install vibration isolators properly
Air spring vibration isolators offer more than 99% vibration reduction, but require precise mounting. Misalignment under high pressure introduces lateral stress, increasing the chance of early fatigue. Use adjustable plates and leveling systems to accommodate floor irregularities. Ensure bolt threads and mounting holes match the bellows’ specifications to avoid localized deformation or mechanical play. Adequate alignment also prevents torsional loads from affecting structural stability. Our bellows offer natural frequencies from 1.2 to 4 Hz depending on design. Incorrect orientation compromises this isolation ability. A standard 10-inch diameter bellow at 6 bar can support over 25 kN but only when mounted correctly. Slotted mounting plates should align with stud patterns. Use anti-vibration washers to prevent loosening. Preload all mounts during assembly and recheck after first inflation. Avoid weld seams near critical areas. If mounting to frames, use vibration-insulated anchor bolts. This ensures vibration damping and structural integrity remain uncompromised.
Monitor ambient operating conditions
High-pressure environments often come with variable ambient conditions. Temperature fluctuations, ozone exposure, and humidity can degrade rubber materials. Bellows should be placed away from direct sunlight, heat sources, and ozone-emitting equipment. For environments beyond standard thresholds, materials like nitrile or chlorobutyl are ideal. Controlled environments significantly extend product lifespan and help maintain consistent axial stiffness under load. Ambient temperature should remain between -25°C and +70°C depending on compound. In high-humidity areas, condensation can form on metallic parts, accelerating corrosion. Use protective coatings or stainless steel where necessary. Ozone, often emitted by electrical devices, attacks rubber molecules and causes cracking. Install shielding if ozone generators are nearby. UV rays degrade natural rubber quickly. Store bellows in dark, dry, and cool places when unused. Monitor room temperature with calibrated sensors. If operating outdoors, use weatherproof enclosures. Thermal cycling reduces flexibility and increases internal stress. Proper environment keeps bellows safe, responsive, and durable under pressure.
Avoid side loading and misalignment
Even though air springs tolerate tilt angles up to 25° and lateral offsets to 30 mm, prolonged side loading at high pressure weakens the internal ply structure. This is especially risky in multi-convolution bellows. Avoid installing units at an angle unless absolutely necessary. For systems with known movement paths, include lateral guides or slide rails to restrict motion. Such planning minimizes torsional fatigue and enhances system efficiency. Load misalignment alters axial force distribution. For example, a 300 mm stroke under 7 bar may shift, causing bellow skewing. Torsion resistance in bellows is limited. Uneven movement degrades convolution geometry. Guide rails must be parallel and have low friction. Consider flexible couplings in case of unavoidable misalignment. Mount bellows with flat, parallel surfaces. Inclined or tilted surfaces cause non-uniform wear. Regularly inspect for twist marks or bellow asymmetry. These indicate excessive misalignment. Early correction prevents structural breakdown and avoids unplanned outages.
Use precision clamping and closures
Tevema air springs come in dismountable, bead ring, and crimped designs. Each has a defined clamping strategy. When operating at elevated pressures, ensure all bead rings or crimped closures are torqued precisely. Use certified torque wrenches and follow the manufacturer’s specifications for each closure type. Incomplete clamping results in air leaks, while over-tightening can deform the bead edge, compromising the pressure seal and increasing system vulnerability. Typical torque for M8 studs is 25 Nm; for M10, up to 50 Nm. Plate deformation may begin above those values. Dismountable versions include dual ring clamps which require symmetrical tightening. Crimped assemblies are not adjustable and must be inspected visually after inflation. Bead ring closures support fast maintenance but demand clean thread interfaces. Lubricate threads before assembly to ensure even tension. Never reuse deformed plates or rings. Always check for cracking near bolt holes. Precision during assembly ensures sustained, safe pressure operation.
Respect maintenance and inspection intervals
Although air springs are largely maintenance-free, high-pressure use requires scheduled inspections. Look for surface cracks, bulging, and deformation near the bead plates. Ensure air ports are clean and pressure readings stable. In multi-shift operations, consider using pressure loggers to detect gradual loss of performance. Replace units at the first signs of compound breakdown, particularly under continuous load conditions. Preventive maintenance prevents catastrophic failure and reduces downtime. Typical inspection intervals range from 3 to 6 months in static systems and monthly in dynamic setups. Use a flashlight and magnifier to check fabric exposure or cracking. Inflate system slowly to observe behavior. If deformation appears near convolution rings, retire the unit. Check stud torque values and bead plate alignment. Test for leaks with soap solution. Document all inspection outcomes. A proactive approach reduces safety risks and operating costs.
Safety first in every installation
Every high-pressure air spring setup must begin with a risk assessment. Identify worst-case failure modes and plan for emergency pressure release. Protect surrounding equipment and personnel by installing containment shields or protective cages. Use warning labels, pressure monitoring devices, and clear SOPs for staff handling the system. Tevema supports customers with training, technical documents, and custom engineering solutions that uphold the highest levels of industrial safety. Identify maximum stroke, tilt, and load per location before commissioning. Use quick-connect fittings rated for the full system pressure. Ensure electric grounding to avoid electrostatic charge buildup. Label shut-off valves clearly. All personnel should wear PPE during pressurization. Include emergency shut-off diagrams near control panels. Isolation valves should be easily accessible. Safety is planned, not improvised. Tevema provides data sheets and 3D files for all standard designs. Use these in simulations and safety modeling before activation. Careful preparation saves lives and assets.
Key takeaways for operational safety
We cannot stress enough the importance of systematic care when operating air springs at high pressures. From selecting resilient compounds and corrosion-proof hardware to maintaining precise height control and enforcing inspection routines, safety is the sum of attention to every detail. At Tevema, we deliver solutions that endure, perform, and protect. Use our design tables to match each unit’s stroke, pressure, and mounting interface to your application. Never exceed the convolution count’s axial motion rating. Check system pressure daily during startup. Record monthly operating data for trend analysis. Replace aging bellows before signs of deterioration appear. Evaluate all new applications with updated spec sheets. Involve certified installers for pressurized setups. Safety grows from routine discipline and accurate selection. We invite engineers to consult us during every design phase. Our commitment is delivering performance with protection built-in.