Why Piping Selection Matters? the capacity of their piping system.

They need more air, so they

Restrictions in airflow (rust, build-up, etc.) create air turbulence
that results in pressure drop as the air flows down the line. The
degree to which this occurs depends in part on the materials
you’ve chosen. Consider copper or aluminum piping. They do
not rust or trap contaminants, providing many years of smooth
flow, stable system pressure, and better air quality than galva-
nized or black iron pipe.
Pipe size also impacts system performance. Pressure drop
changes exponentially with pipe diameter. Bigger is better. We
see many compressed air users who have quickly outgrown
buy more compressors. Unfortunately, the piping can’t handle
the increased flow, and the end users don’t get more air.
A small step up in pipe diameter – as little as 1/4 inch – may
make a large difference in the capacity of the system. There are
standard charts published that provide guidelines. Check with
a compressed air specialist or contact the Compressed Air and
Gas Institute (www.cagi.org).
For example, the pressure drop of 40 cfm (from a 10-hp com-
pressor) through 500 feet of 3/4-inch straight pipe would be

Material Advantages Disadvantages

Black Iron • Moderate materials costs • Labor intensive installation
• Readily available in multiple sizes • May rust and leak
• Rough inside promotes contaminant build-up and creates pressure drop

Galvanized Iron • Moderate materials cost • Often exterior is coated

• Readily available in multiple sizes • Labor intensive installation
• Some rust protection • Rough inside promotes contaminant build-up and creates pressure drop
• May rust at joints and leak

PVC • Lightweight • Lower safety

• Inexpensive • In certain areas, not compliant with certain codes
• Readily available in multiple sizes • Carries static charge
• Subject to bursting
• Adhesives not compatible with compressor oils

Copper • No rust, good air quality • Requires quality brazing to prevent leaks
• Smooth interior—low pressure drop • Susceptible to thermal cycling
• Installation requires open flame

Aluminum • Corrosion resistant • Materials costs

• Lightweight
• Easy to install
• Lower cost of ownership
• Smooth interior—low pressure drop
about 8 psi. If the shop added another 10-hp
compressor, the total flow would be about 80
cfm and the pressure drop would increase to
32 psi. An increase to 1-inch diameter pipe
would change these numbers to 2 psi and 9 psi,
respectively. Pressure drop also increases with
the number of turns in the system and with rough
interior surfaces.

Weighing Your Options

When setting up your compressed air system,
you can choose from several piping materials.
The most common piping materials includes black
iron, galvanized, copper, and PVC. Aluminum compressed air
piping is a relative newcomer but is on the rise.

What you choose has a large impact on both air quality and flow.
Tips for installing
Copper offers an excellent combination of performance, material your air compressor
system piping:
and installation costs.

Plastics aren’t recommended. PVC is commonly used since it

is inexpensive, lightweight, and easy to find at local building
supply stores. It is not a material that is recommend to use
 Plan for future growth and install the
because of the safety concerns associated with installing it.
Also, it is not code compliant in many areas.
largest pipe diameter feasible

When selecting piping for your compressed air system, consider  Minimize the use of pipe “T”s and right
the following:
angles
Air quality: Can your shop tolerate contamination from rust
or other build-up flaking off from the pipe? (Black iron and
 Install a flexible hose between the
galvanized iron are notorious for this).
compressor/or tank and the piping to
Installation: Will you need to outsource? Also, do you antic- eliminate stress on joints caused by
ipate growth or making changes to your piping? (Aluminum compressor vibration.
pipe can be disassembled easily and adding in drops to
accommodate growth is fast. Copper is not as quick to install  Provide adequate bracing/support when
as aluminum, but it is still faster than threaded pipe).
hanging pipe from ceilings or walls.
Material cost: Will you need to purchase special tools to
install or maintain the pipe?  Use only full flow ball valves to minimize
pressure drop. Always open and close
Maintenance: Do you have the time and manpower to con-
tinually monitor and fix leaks that can occur with materials
valves slowly.
that are more susceptible to rusting at joints and leaking?
(A concern for black iron and galvanized iron. Also, the  Pipe the system in a complete loop
brazing on copper should be inspected regularly). distribution to balance pressure and flows
at all points of use.
Look at more than the cost of the material and installation.
Think about how your shop is set up and the flow of the work.
Look ahead when planning your system and allow for business  Use overhead takeoffs and drip-legs at
growth. It’s time consuming and expensive to install a larger points of use to reduce moisture carry-
distribution system later. Think about your system needs today over.
and long term. 
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