When to Choose an Inflatable Pipe Plug over a Mechanical Pipe Plug

08 Sep.,2025

 

When to Choose an Inflatable Pipe Plug over a Mechanical Pipe Plug

The Advantages of Inflatable Pipe Plugs

When handling a line stop operation, you have two primary pipe plug variations to choose from: inflatable and mechanical. Both types can be effective at getting a workable seal, but there are certain conditions and situations when it makes the most sense to use an inflatable plug. In this article, we’ll cover what inflatable plugs are and when it makes the most sense to use them. 

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What Is An Inflatable Pipe Plug? 

Inflatable plugs are inserted into a pipe and filled with gas, liquid or grout. They are designed to fit snugly into the interior of any line and can be inflated to the required size, providing a tight seal. Inflatable plugs are an essential tool for maintenance activities, because they can fit through small openings and are effective even when a pipe has an odd shape or uneven surface. 

The question is, when should you use an inflatable plug over a different type of pipe plug? 

Top 9 Reasons To Use An Inflatable Line Stop Over Mechanical Plug

1. Cost effectiveness

Unlike mechanical plugs or other pipe maintenance solutions, inflatable plugs are typically less expensive, require minimal equipment to implement, and can be reused, making them much more cost effective than alternative methods.

2. Flexibility to conform to almost any shape

Rigid mechanical plugs cannot create an effective seal when there are weld beads, corrosion, deposits, an out of round pipe shape, or other imperfections. An inflatable pipe plug is designed to fit all the contours of a pipe line and create a seal despite bumps, dips, or other obstructions. 

3. Fast installation and removal

If your job requires speed, or if you are frequently installing and removing the pipe plug, then we recommend using inflatable plugs, because they can be added and taken out much more rapidly than a conventional mechanical plug. 

4. Easier to store and transport

By deflating an inflatable plug when it’s not in use, even a very large one can take up less space during storage and transport than a smaller mechanical plug. 

5. Heavy equipment not required

One of the benefits of using an inflatable pipe plug is that they don’t require any heavy equipment to install or use (for most sizes).

6. Tap Near Or at pipe bends

Because they are flexible and can conform to essentially whatever shape you place them in, inflatable plugs are the best solution when you are tapping the pipe and blocking the flow near or at a pipe bend.

7. Fit through small holes

With a narrow deflated diameter, an inflatable pipe plug can fit through a much smaller tap hole than mechanical plugs thus providing greater pipeline integrity.

8. Lower environmental risk

Inflatable plugs are an environmentally friendlier alternative, because they minimize the need for excavation or other disruptive activities that can damage the environment.

9. Limited Space Work Environment

Because inflatable plugs don’t require heavy equipment to install or use, they can accommodate almost any limited work space environment.

For more information, please visit Inflatable Sewer Pipe Plugs.

If you have any questions about choosing the right pipe plug for your application, please reach out to the Petersen team today! 

Disclaimer: The information may be used but with no warranty or liability. This information is believed to be correct but should always be double checked with alternative sources. Strictly adhere to and follow all applicable national and local regulations and practices.

Regardless of these comments, it is always necessary to read and understand manufactures instructions and local regulations prior to using any item.   

Choosing the Right Pipe Plug for Your Needs: Types and Applications

Selecting a pipe plug depends upon the following: material of pipe, diameter, pressure conditions, and the specific application requirement. The following are the various types of pipe plugs:

1. Mechanical Pipe Plugs

Mechanical pipe plugs use mechanical means, located at the ends, for instance, an expanding seal or a threaded plug to prevent liquid flow with a large seal inside the pipeline. Most often they serve for:

  • Blocking: Temporary stoppage of a pipeline section for maintenance, inspections, or repairs.
  • Bypassing: Changing the natural flow through another route while a section is being worked on.

Mechanical pipe plugs come in small sizes to very large, commonly from 0.39-18 inch in diameter, while failing to use any inflation. Most of its applications just need hand tightening for a good seal. 

2. Pneumatic (Inflatable) Pipe Plugs

Pneumatic pipe plugs, also known as inflatable underwater pipe plugs, are made from materials like rubber and are inflated to form a seal within the pipe. Their applications include:

  • Testing: Testing line integrity by closing sections of a pipeline and monitoring for leaks.
  • Maintenance: Closing sections for cleaning or repairs without interrupting the entire system.

They are manufactured in sizes varying from 1 inch to 96 inches for blocking, bypassing, or conducting line acceptance or leak-location tests using air.

3. High-Pressure Pipe Plugs

The high-pressure pipe plugs are designed for a certain application of withstanding extreme back pressure. Their applications include:

  • High-Pressure Systems: Sealing pipelines operating under high pressures like water mains or industrial lines.
  • Some plugs are usually made of very high-grade, durable materials, if they withstand high pressure.

Safety testing has to do with testing the pipeline somehow so that it will not leak under the pressure required to do its function. 

4. Multi-Size Pipe Plugs

Multi-size pipe plugs can accommodate the sealing of pipes having all different diameters. They are particularly useful when:

  • Uncertain Pipe Dimensions: The pipe sizes are not accurately known, or they differ within a system.
  • Economical: Reducing not only storage space but also the initial investment required to stock various sizes to cover all applications.

These plugs fit more pipe sizes, thus making them convenient to use in different situations. 

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