Thermal, hydrodynamics, structural and environmental requisites determine gasketed plate heat exchangers (GPHE) characteristics and material in a given industrial application. Heat transfer rates as well as static pressure and pressure drop levels determine plate main dimensions and corrugation features. The choice of thin plates can also yield higher thermal exchange efficiency; however, it can also promote mechanical strength issues, including GPHE failure as a result from excessive plate deformation. This study systematically evaluates the role of GPHE plate characteristics on its mechanical behavior. The GPHE plate behavior was evaluated during the equipment assembly and in working conditions. Deformation was measured by strain gauges at several plate sites. Stress values were calculated for a broad variety of GPHE plates, including different plate material (316 L Stainless Steel and Titanium Grade 1), thickness (0.5 and 0.7 mm), chevron angles (L- and H-plates), and several tightening distances. Experiments indicated that stresses promoted by the assembly procedure are essential to determine GPHE useful life. Plate areas where the highest mechanical stresses occur are subjected to plastic deformation, and coincide with failure regions described in literature. There is evidence that typical GPHE failures are related to its frequency of maintenance and assembly. Stress reduction at the diagonal gasket groove and the porthole edge locations after second and third assemblies are possibly explained by the combined effect of localized hardening and the Mullins effect. Increasing plate thickness contributes directly to stress reduction during the assembly. Stress levels increase with increasing static pressure and decreasing thickness in working conditions where GPHE pressurization occurs in a single branch or simultaneously in two branches. They are considerably higher in single condition. Stresses increase with decreasing chevron angles, mainly with plate thickness of 0.7 mm. Once the heat exchanger is properly set with ideal tightening distance, only the flow distribution area is significantly deformed and stressed.”