Air Compressor Pipework Installation
Compressed air is the "fourth utility" for UK industry. Unlike water or electricity, you generate it yourself, and your pipework decides how efficiently it is delivered.
A poor distribution network wastes energy, drops pressure, and ruins air quality. Even the most efficient compressor cannot fix a bad pipe system.
At Control Gear, we design and install compliant systems that keep pressure stable and bills low. Correct sizing and layout maintain steady pressure at every tool. For every 1 bar of pressure drop, your compressor uses about 7% more energy. We help you avoid that waste.
How Does Pipe Selection Affect Performance?
Your choice of pipework material affects pressure drop, air quality, and installation time. We help you choose the right material based on your specific needs, such as hygiene standards or factory temperature.
Aluminium (AIRnet)
Aluminium is the modern standard for industry. Systems like Atlas Copco’s AIRnet have a smooth internal bore. This keeps friction low and airflow high.
- Pressure Ratings: Standard up to 16 bar (high-pressure versions available up to 70 bar).
- Temperature Range: Works from -20°C to +80°C.
- Fittings: Push-fit (20–50 mm) and clamp fittings (63–158 mm) mean no threading or welding.
- Modularity: We can use Quick-Drop brackets to add new drops to a live ring main.
- Multi-Gas: Suitable for compressed air, nitrogen, and vacuum.
- Warranty: Comes with a 10-year material warranty.
- Hybrid Capability: We can easily connect aluminium to old steel headers for phased upgrades.
Stainless Steel
You need stainless steel (304L or 316L) for Food & Beverage, Pharmaceutical, and Medical sites. It withstands chemical wash-downs and keeps air sterile. These systems are essential for Class 0 oil-free air applications.
Galvanised Steel
Old galvanised steel systems rust from the inside. This rust roughens the pipe and slows down the air.
- Operational Risk: Rust flakes break off and block your valves or tools.
- Leakage: Threaded joints loosen over time due to vibration.
Replacing these systems is often the quickest way to recover energy costs.
Rigid Plastic (PVC/ABS)
Warning: Never use rigid plastic (PVC or ABS) for compressed air. Under pressure, these materials can shatter rather than split, creating dangerous shards. Compressor oils also attack PVC chemically. We only use engineered polyamide for short flexible hose drops.
You can compare material options in detail in our Guide to Choosing the Right Compressed Air Piping System.
What Is the Best System Layout?
Your pipework layout has a major impact on pressure stability and energy use.
Ring Main (Closed Loop)
Most facilities benefit from a ring main. The pipe loops around the production area, so air reaches tools from two directions.
- Cuts Energy Loss: Splitting the flow halves the air velocity. This reduces pressure drop by a factor of four.
- Easier Maintenance: We can isolate specific sections without shutting down the whole plant.
Straight Line (Spur)
A single line with a dead end causes pressure to drop as it travels. Tools at the end get the lowest pressure. This often forces you to turn up the compressor, which wastes energy. This layout is only suitable for small, narrow workshops.
Sizing and Velocity Control
We size pipes based on airflow (CFM) and distance, not just the compressor outlet size.
- Main Line Velocity: We aim for 6–10 m/s to keep pressure drop minimal.
- Drop Leg Velocity: Up to 15 m/s is fine for short drops.
- Future Proofing: We design with spare ports so you can expand later.
We recommend upgrading to Modern Modular Aluminium Piping to ensure your system is sized correctly.
Critical Design Elements
- Vibration Isolation: We install a heavy-duty flexible hose (whip hose) between the compressor and pipework. This stops vibration from cracking the pipes.
- Earth Bonding: Aluminium conducts electricity, but plastic fittings can insulate sections. We add earth bonding straps where needed for safety.
How Do We Manage Water and Dirt?
Even with dryers, your pipe design must handle moisture and debris.
- Goose Neck Drops: Drop legs must come from the top or side of the main ring. This stops water or rust on the bottom of the pipe from draining into your tools.
- Drainage: We install automatic drain valves at low points.
- COSHH Compliance: Condensate is hazardous waste. Drains must run to an oil-water separator before entering the sewer.
- Air Treatment: Dryers and filters go before the distribution network.
- Point of Use: We install Filter-Regulator-Lubricator (FRL) units at tool connections for final protection.
What Are the UK Safety Requirements?
Compressed air systems must meet strict UK regulations. Control Gear ensures full compliance.
- Pressure Systems Safety Regulations 2000 (PSSR 2000): Under UK law, your pipework counts as part of the pressure system. If the system is large enough (>250 bar-litres), you legally need a Written Scheme of Examination (WSE).
- PUWER 1998: These regulations require your equipment to be safe for use and properly maintained.
- BS EN 13480: This is the standard for metallic industrial piping design and installation.
- BCAS Best Practice: We follow British Compressed Air Society (BCAS) guidelines, specifically BPG 101 (Installation) and BPG 103 (Testing).
How We Commission Your System
Commissioning proves your system is safe and leak-free before you use it.
RAMS and Site Safety
Our teams work under strict safety protocols (RAMS):
- Working at Height: Our engineers are IPAF-certified for access lifts.
- Asbestos: We check the Asbestos Register before drilling in older buildings.
- LOTO: We lock out and tag out live systems before connecting new pipes.
Testing Protocol
- Pneumatic Testing: We test with air in safe, small steps (following BCAS BPG 103). We avoid hydraulic (water) testing on air systems to prevent rust.
- Leak Verification: We monitor the pressure for 24 hours to ensure it holds.
- Purging: We blast high-velocity air through the system to clear out any installation dust.
- Handover Pack: You get your Pressure Test Certificate, Material Certificates, CAD Drawings, and WSE.
Energy and Cost Benefits
Poor pipework wastes money every minute the compressor runs.
- Stop Leaks: A 3mm hole in a 7 bar system costs about £4,500 a year. Old steel systems often lose 20–30% of their air to leaks.
- Reduce Friction: Aluminium pipes let air flow freely. Reducing generation pressure by just 1 bar saves ~7% in energy.
- Recover Heat: We can duct waste heat from the compressor to heat your warehouse or water, recovering up to 94% of input energy.
We verify these savings during our regular Compressed Air Leak Detection audits.
Why Choose Control Gear?
Control Gear has been serving industry since 1973. With over 50 years of experience, we support clients across South Wales and the West, including Cardiff, Newport, Swansea, Bristol, Stroud, and Swindon.
- Atlas Copco Premier Distributor: We are experts in AIRnet and Atlas Copco systems.
- Accredited Quality: We hold ISO 9001, ISO 14001, and ISO 45001 certifications.
- Turnkey Service: We handle everything, design, installation, testing, and PSSR paperwork.
- Guardian Service Plans: We offer fixed-cost maintenance that includes annual leak audits and air quality testing.
Start Your Pipework Upgrade
Poor pipework wastes energy and causes pressure problems across your site. Contact Control Gear to schedule a site survey or discuss a system design that works for you.
Why Work With Us?
