Compressed air systems are essential in many industries. They provide a reliable source of energy for a great number of critical tasks, from operating assembly lines and controlling automation systems to powering pneumatic tools.
But did you know that the type of piping you choose can make a world of difference in your compressed air system’s performance, efficiency and maintenance needs?
While that may seem like a daunting fact as you embark on building your system, don’t worry! In this guide, we’ll explore everything you need to know – from the best types of piping materials for different jobs, to important considerations and risks to watch out for.
By the end of this guide, we’re confident you’ll have a strong understanding about what pipe to use for your compressed air system.
Best types of piping materials for compressed air systems
Compressed air systems are energy-efficient, resistant to wear, safer than their electrical counterparts, and highly adaptable, allowing for easy integration into existing infrastructure.
While the benefits are seemingly endless, these systems come in a variety of materials, so how do you know which material is most ideal for your project? Let’s break it all down:
1. Aluminium
Aluminium piping was introduced into the compressed air industry in the late 1980s. What made it a popular choice then, and still to this day, is its corrosion-resistance. Aluminium has a natural oxide layer that protects it from corrosion. This makes it an excellent material in environments where moisture may be present.
For example, in the food and beverage industry, moisture is frequently present as a result of cleaning processes, steam and condensation. Aluminium piping’s high resistance to corrosion makes sure that the air delivered is clean and free from contaminants – crucial for maintaining stringent hygiene standards in food and beverage production.
Drawbacks to consider
Choosing aluminium piping for your compressed air systems can be beneficial, but it comes with some drawbacks. For instance, although aluminium has a resistance to corrosion, it’s not as strong or durable as stainless steel, which can cause issues in industrial applications where pressure and external impacts are more likely.
Once you’ve installed aluminium piping, it can be extremely difficult to modify or extend compared to stainless steel systems. This is because aluminium is more prone to deformation under stress than stainless steel. For this reason, if you wanted to modify an aluminium system, you may run the risk of damaging the existing pipes.
Additionally, aluminum’s susceptibility to deformation under stress can pose challenges during modifications or extensions of the piping system. This characteristic increases the risk of damaging existing pipes during such activities. In contrast, SS316 stainless steel offers greater strength and durability, making it more accommodating to modifications and less prone to corrosion and damage under stress.
2. Copper
Copper is extremely strong and durable, so it can be an excellent piping choice if your compressed system is going to be regularly exposed to high pressure and temperature variations.
Because it’s exceptionally strong, manufacturing companies can use copper piping to supply compressed air for pneumatic tools and equipment. Tools in manufacturing operate under high pressure, which demands a robust piping system. Copper’s durability ensures that the compressed air supply remains consistent.
Copper’s thermal conductivity is another reason industries may choose copper piping. In compressed air systems, heat can build up due to compression processes or friction within the pipes. Copper has the ability to transfer heat away from the air within the pipes, helping maintain optimal temperatures. This can both improve system efficiency and prolong the life of the piping and connected equipment.
Drawbacks to consider
While choosing copper piping for compressed air has its merits, it has a few drawbacks that are important to know.
Firstly, copper can be expensive, both in terms of the material itself and installation costs – which can greatly impact your budget if you’re planning large installations. If you’re searching for a premium material, stainless steel can provide you with better value in the long run because of its superior durability and lower maintenance costs.
Secondly, copper piping requires specialised skills and equipment for soldering or brazing connections. This can complicate your installation process, which may also require additional training or staff.
For a much more straightforward installation, ibex’s stainless steel piping is your best choice, as it uses innovative press-fit technology. This eliminates the need for welding and threading, both significantly reducing installation time and workplace safety concerns.
3. Black steel
Black iron is known for its incredible strength and ability to withstand rough conditions. Compared to more traditional materials like copper and plastic, black iron pipes are less prone to damage from impacts or external forces, reducing the likelihood of damage or leaks over time.
This can be highly advantageous in metal fabrication plants, as they usually require high-pressure air for their pneumatic tools and equipment. Black iron’s strength and high-pressure tolerance can provide reliable air delivery over long distances without compromising air pressure, which is crucial for maintaining consistent power in industrial tools.
Drawbacks to consider
Before settling on black iron as your choice for compressed air piping, it’s important to consider some of its drawbacks. One of the major disadvantages of black iron pipes is their susceptibility to corrosion and rust. Black iron pipes are also significantly heavier than other pipes like aluminium and copper, which can make your installation process more labour-intensive and time-consuming.
Additionally, because black iron pipes are typically threaded at the joints, there is an increased risk of leaks at their connection points. This contrasts with newer piping systems, such as Ibex’s stainless steel press fittings, which provide more secure, leak-proof connections.
4. Stainless steel
Stainless steel, particularly 316L stainless steel, is a superior material choice for compressed air systems. It provides superior strength compared to alternatives like copper or aluminium, making it reliable for long-term performance in high-pressure environments like automotive manufacturing or oil and gas facilities.
For example, In the automotive industry, assembly lines typically run for long hours, requiring compressed air systems that can withstand constant, high-pressure use. 316L stainless steel offers the strength and durability to maintain high-performance levels without the risk of pipe failure.
In contrast to black iron or other materials that may degrade over time or introduce contaminants, Ibex Australia’s stainless steel range provides not only clean air delivery, but also a robust and resilient compressed air system that stands the test of time.
For example, in the pharmaceutical industry, cleanliness is crucial. Using Ibex’s stainless steel piping ensures that no rust, corrosion, or particulate matter contaminates the compressed air supply.
5. Polyethylene – Blutube
Blutube® is a high-performance polyethylene (PE100) piping system specifically designed for compressed air applications. Unlike metal pipes, Blutube® is completely corrosion-free, ensuring that air quality and flow rates remain consistent over time. With a high-strength design and greater wall thickness, it offers excellent pressure and temperature capabilities, making it a reliable long-term solution.
The system is lightweight and easy to install, featuring multiple connection options that reduce installation time and complexity. Additionally, Blutube® has extensive chemical resistance, making it ideal for environments where exposure to corrosive substances is a concern.
Drawbacks to consider
While Blutube® provides significant benefits, it does come with some limitations. Its temperature resistance, while suitable for most compressed air applications, is limited to a continuous operating range of -20°C to +60°C, with short-term resistance up to 95°C. This may not be sufficient for high-temperature applications that require sustained exposure to extreme heat. Additionally, its pressure capacity is rated up to 16 bar for compressed air, which, although suitable for many industries, may not meet the requirements of high-pressure applications that demand greater tolerance.
Moreover, installations using Blutube® might require additional support structures to ensure stability, especially in settings where environmental factors play a significant role. Greater consideration for thermal expansion is also necessary, as the material’s dimensions can vary with temperature fluctuations, potentially affecting its performance over time.
Important things to consider when choosing piping materials
When it comes to choosing the right piping materials for your system, there are a number of factors to consider. Let’s take a look at some of these factors to help make sure you’re ahead of the game when building your compressed air system:
1. Air quality
Maintaining air quality in compressed air systems is critical. Contaminants like moisture and dirt can damage components within your system. In terms of preventing contamination, stainless steel stands out as your most effective solution. Unlike black iron and galvanised steel, which can rust and flake over time, stainless steel maintains a smooth, corrosion-resistant surface that minimises the risk of particulates entering your system’s air stream.
2. Installation costs and time
While aluminium piping is known for its lightweight nature and ease of installation – which can result in lower immediate labour costs – it’s essential to consider long-term expenses as well.
Stainless steel piping, though it may have a higher upfront cost, offers significant savings over time because of its exceptional durability and corrosion resistance. This means fewer repairs and less frequent replacements, ultimately reducing maintenance costs and system downtime.
3. Durability
You want a compressed air system that stands the test of time, so it’s important to consider durability when selecting piping materials. Although there are many durable materials available, stainless steel can provide you with an excellent balance of strength and longevity.
Unlike copper, which can degrade over time due to corrosion and exposure to moisture, stainless steel remains resilient under various environmental conditions.
For example, in a manufacturing environment, copper pipes may be exposed to moisture and chemicals which, over time, can lead to corrosion and cause leaks. In contrast, the inherent corrosion resistance of stainless steel piping allows it to maintain integrity and performance, even when exposed to moisture, oil and other substances found in manufacturing.
4. System pressure
When building a compressed air system, it’s crucial to consider system pressure, as this impacts operational performance, equipment compatibility and energy costs. Stainless steel is a standout in terms of system pressure because of its exceptional ability to handle high-pressure environments and perform effectively under varying temperatures.
In industries such as oil and gas, chemical processing, and manufacturing, the ability to withstand high pressures is both a matter of performance and safety. For example, if a failure in the piping system occurred, this could lead to hazardous situations like explosions and toxic leaks. This is why considering system pressure is vital. Stainless steel’s robust nature provides industries like these with peace of mind, as they ensure the system can handle the pressures involved without compromising safety.
What are the risks of choosing the wrong piping system?
So far we’ve discussed a lot about the ideal pipe materials to choose for different industry needs, which is fantastic to know, but what happens when the wrong piping system is chosen?
Choosing the wrong piping system can lead to several risks that can adversely affect your operational efficiency and safety. Let’s take a closer look at these potential consequences:
1. Pressure loss
Choosing the wrong material or pipe diameter in a compressed air system can lead to significant pressure drops, which can cause major issues for your tools and machinery. Without the right air pressure, equipment might not perform as expected, slowing down operations and reducing efficiency.
On top of that, inconsistent pressure can make air-driven tools behave unpredictably, leading to operational delays and even increasing wear and tear over time. Simply put, the right materials and sizing are crucial for keeping your system running smoothly and avoiding unnecessary headaches.
2. Increased energy usage
If your piping system isn’t designed properly, your compressors might have to work overtime to maintain pressure, which means higher energy consumption and bigger utility bills. This extra strain can also lead to more frequent maintenance or even early equipment replacement.
In the long run, those added energy costs can eat into your return on investment (ROI), wiping out any savings you might have gained from choosing cheaper materials upfront.
To make this risk clearer, imagine a large automotive assembly plant that installs a compressed air system using PVC piping to save on upfront costs. While initially cheaper and easier to install, over time the PVC begins to expand because of the high pressures required for the plant’s air tools, which gradually leads to tiny leaks throughout the system.
These leaks cause the compressor to work harder to maintain the required pressure levels, resulting in increased energy usage and spikes in the plant’s utility bills.
Now, had the plant invested in stainless steel piping, such as Ibex’s 316L stainless steel, their compressed air system would’ve been better suited for high-pressure environments. With stainless steel, the plant’s system would’ve been much more efficient, significantly reducing energy consumption and maintenance costs.
3. Corrosion from clogged pipes
Using the wrong materials for your piping can seriously shorten its lifespan, especially if there’s moisture or contaminants in the air supply. This is because corrosion can build up inside the pipes, causing clogs that restrict airflow and put extra strain on your system. As these clogs worsen, you’ll likely face frequent breakdowns, which will need constant maintenance, quickly adding up in terms of money, time and labour.
So what piping materials are susceptible to this risk? Typically galvanised steel and iron pipes are your biggest culprits, as these materials are prone to rust and corrosion, especially in the presence of moisture, which is commonly found in air systems.
To combat this risk, consider using stainless steel piping. Stainless steel is highly resistant to both corrosion and moisture, providing you with a cleaner and more efficient system. Additionally, stainless steel’s resilience not only extends the lifespan of the piping but also reduces the need for frequent maintenance, making it a more cost-effective choice in the long run.
4. Safety risks
If your piping system isn’t built to handle the right pressure, it can cause serious problems like ruptures or leaks, which can lead to equipment failure and pose safety risks for anyone working nearby.
For example, a sudden burst can not only damage machinery and bring production to a halt, but it might also cause debris to go flying across a workspace, putting workers at serious risk of injury.
5. Troubleshooting issues
A poorly designed compressed air system can make troubleshooting a nightmare. For instance, figuring out the source of pressure drops, leaks or other failures can take a lot of time and effort, pulling you and your team away from more productive tasks.
Plus, if the piping system isn’t documented well or if changes are made without proper planning, it can get really tricky to track what’s been modified, or to understand the current layout. This lack of clarity can lead to mistakes during maintenance or upgrades, making everything even more complicated.
In short, investing in a well-designed piping system and keeping good records can save you a lot of frustration down the line.
Partner with Ibex for a superior compressed air system
When it comes to building a compressed air system, choosing Ibex’s stainless steel piping stands out as your smartest, most cost-effective choice.
Our stainless steel piping is not only highly durable and resistant to corrosion, making it ideal for withstanding high pressures and harsh environments, but its exceptional resilience also means you’ll benefit from lower maintenance costs and fewer repairs. This sets your system up for long-term success and reliability.
Don’t put your compressed air system at risk of failure. Get the best materials for the job at Ibex Australia. To explore our full range of products and services, and to get expert advice for your system, contact our friendly support team today.
