When facilities are planning or upgrading a compressed air system, the pipework material rarely gets the attention it deserves. Most of the focus goes on the compressor, the air treatment, the pressure requirements, and the layout. But the air piping itself has a significant impact on performance, running costs, and how much of a headache the installation turns out to be.
The two materials that dominate most discussions are aluminium and galvanised steel piping. Both have been used in industrial compressed air piping for years, but they're not equal in practice, and the gap between them has widened as aluminium systems have matured.
Galvanised steel piping has been used in compressed air systems for well over a century. It handles high pressures reliably, it's physically robust, and in environments where pipework might take the occasional knock, that toughness does count for something.
The problems start with installation. Steel is heavy, threaded connections require specialised tooling and skilled trades, and in a larger facility, that labour time adds up fast. There's also a corrosion issue that's easy to underestimate. The zinc coating gives some initial protection, but moisture in the compressed air supply causes the interior of the pipe to degrade over time.
The rust and scale that forms doesn't just stay put; it travels downstream, contaminating tools, damaging equipment, and compromising air quality. For industries where clean air matters (food production, spray finishing, pharmaceuticals), that's a serious problem.
Ageing steel piping also develops leaks at threaded joints, and modifying or extending the compressed air piping layout is a disruptive job. None of this makes it unusable, but it does make it expensive to own over the long term.
Aluminium compressed air piping addresses most of the shortcomings above, which is why it's now the default specification for the majority of new industrial installations.
The main advantages of aluminium air piping over steel:
That said, the piping is only one part of the system, and having a well-matched compressor behind it matters just as much. Our Air Compressor Selector walks you through the process in a few steps and points you toward the right unit for your application.
This is where some hesitation around aluminium comes from. Quality aluminium air piping is rated for pressures well above what most industrial applications require, typically 16 bar or higher. Niche high-pressure applications warrant careful specification, but for the vast majority of facilities, aluminium handles the demands without any compromise.
Whether you're working with aluminium or steel, getting the pipe sizing right before installation is where the real efficiency gains are made. Running a pipe flow calculator or CFM calculator during the planning stage lets you model pressure drop across your layout and size the pipework to avoid bottlenecks. A system that's undersized for the actual demand, or laid out inefficiently, will cost you in pressure losses at every point of use.
Galvanised steel piping often looks cheaper upfront on a per-metre basis. The full picture over 10 to 20 years is different.
Installation takes longer and requires more skilled labour. Ongoing maintenance is more frequent. Corrosion-related damage to downstream equipment is expensive to address, and if the facility layout needs to change, reworking steel compressed air piping is a significant undertaking.
Aluminium costs more per metre in many cases, but the lower installation cost, reduced maintenance, longer service life, and clean air quality typically make it a better investment over time.
For most new installations or system upgrades, aluminium air piping is the practical choice. It installs faster, stays cleaner, requires less maintenance, and adapts well as your facility evolves. Galvanised steel still has a place in certain applications, but those cases are the exception.
IAS supplies the Alu Air reticulation piping range from Pneutech, a high-performance aluminium compressed air piping system built for industrial use and available across New Zealand. Download the free brochure to learn more about our full range.