What is your permanent air line garage solution and why?

I am going to be needing to run a fair amount of air line in the near future and have been reviewing my options.

My main tools are standard hand tools, Hypertherm 85 amp plasma, and feed for cnc plasma table.

First up is PVC. The internet is filled with horror stories about it possibly exploding. This seems more like an urban myth than something the actually happens all the regularly. However, it is plastic and I want to do this one time and not have to touch it much for the next 20 years so I am leaning away from this because of longevity.

Next is black iron. Seems almost as cheap as PVC (kind of) and is nice and sturdy. Pressure ratings are fine for my 150 psi max requirements. I have read that corrosion and rust are potential issues but it is possible to run an air filter at the end of the iron before my flexible hose to collect this junk. Pain in the ass to install.

Galvanized. Similar to black iron but more durable. Flaking is a big issue apparently but the filters are a possible fix again. Price is higher than iron. Pain to install.

Copper. I am afraid of pricing it out. Better than others on durability if I get a nice thick wall. Sweating pipes might be easier than getting the threaded pipes not to leak.

Something called modular aluminum. This sounds like Pex with aluminum pipe. It clicks together but sounds like it is going to cost more than my air compressor to buy.

I specifically left out Pex type options (I don't want water pooling) but feel free to try and talk me into it.

I went with black iron. Cheap. Easy DIY. Just pitch and drain the low spots. I suspect it will last as long as I do.

For cost reasons, I'm looking at black iron when I do mine. After pouring over garage journal the past few weeks, a couple of ball valves plugged in to drain water and a decent dessicant/filter combo should make for a very long lasting combo. Pipe dope or Teflon to seal the threads seems fairly common place.

Following along to get more tips from people that have done it though.

I have PVC, which I've used for 30 years now. I'm sure I'll be killed at any moment by it. Anyway, I ran it around the shop and put a water trap (HF filter) in about the middle of it. What the filter at the compressor doesn't catch because it's still vapor, the second filter about 60 ft of line away catches.

I also recently purchased (on sale) the HF 50' air hose reel. I like that thing. No more hose all over the floor. No more welding splatter burning through my air hose.

I did exactly as Dr. Hess with the PVC and spaced out filters in my last shop. I remember the PVC we used had a working pressure of 300 psi and we ran our compressor a 125. Never had an issue with it and that shop saw temps from the teens to high 90's.

Don't know if its the "right" way to do it but that's what we did.

I went around and around on this for years before just putting in a big 50' reel. A whole lot less work and fewer potential leaks.

But when I was still thinking of running air around the shop, I had pretty much decided on Rapidair for ease of installation and safety reasons. I know people that have used PVC and had it for years with no issues, but I was sufficiently scared off by the horror stories.

I have a buddy who sells air compressors, and does air line installations for businesses. He has a product similar to Rapidair with aluminum pipe and plastic fittings that screw together. What I like about his over Rapidair is that his pipe comes in straight 8' sections. It makes for a much cleaner install than the roll of pipe that you have to try and straighten. Cost depends on length and how many drops you want to do. He said he could probably do a home garage for $400.

In reply to D2W:

Interesting. I would be interested in hearing more about that.

That Rapidair stuff is nice! They have the roll type but they also have straight aluminum clad pipe that is around $400 for 100' with fittings and all. I don't know what shipping would be, but I'm bookmarking that for when I get to my air line install.

In reply to dculberson:

I just found that on their site. It is tempting. I am currently pricing out replicating that kit myself as I am not sure that the 100 ft kit will cover my needs.

I used 3/4" galvanized pipe because an electrical contractor had it left over on a project and gave it to me for free. In my previous shop I ran PVC and was unfortunately killed. I got better though.

I used a rubber air hose to a 50 foot hose reel mounted centrally in the ceiling. Cheap, easy, serviceable, and easy enough to replace if ever necessary.

Same here and one of the best things I ever did to clean up garage clutter, putting it up high enough it's completely out of the way but with the end reachable. The other thing was one of those seemingly-lame extension cord winders, but it works great as well.

I'd probably go with black iron (it's actually steel). The failure mode of PVC is not pretty when it has air pressure behind it, people get away with it but that doesn't make it safe.

I'm copper at home, and copper/black iron at the shop. Copper is expensive these days, but every part of my shop serviced by black iron is very restricted. One corner has been blocked for ten years or more. Luckily, that's the corner I don't use much.

PS- I'd look at the aluminum stuff if I was doing something new.

D2W wrote: I have a buddy who sells air compressors, and does air line installations for businesses. He has a product similar to Rapidair with aluminum pipe and plastic fittings that screw together. What I like about his over Rapidair is that his pipe comes in straight 8' sections. It makes for a much cleaner install than the roll of pipe that you have to try and straighten. Cost depends on length and how many drops you want to do. He said he could probably do a home garage for $400.

I bought the $75 Rapidair 90500 kit from Amazon for my garage. It comes with a roll of pipe, so you need to lay it out in the sun to straighten it, but that's really not a big deal. I needed a few extra fittings (right angles and the like), and overall I'm pretty happy with it.

As proven by the number of people who are getting away with using them, PVC airlines aren't a certain death certificate. However, multiple health and safety organizations and governing bodies as well as every manufacturer of PVC piping expressly prohibit it. The problem isn't so much that it's guaranteed to fail it's that if it does fail it will do so in a way that can kill you.

https://www.osha.gov/dts/hib/hib_data/hib19880520.html https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=INTERPRETATIONS&p_id=20202 http://www.usplastic.com/knowledgebase/article.aspx?contentkey=787

If cost were no object I'd go with one of the push to connect aluminum tube systems because they look so nice. In the plant where I work we use copper because it's sort of reasonably priced and it's less susceptible to corrosion than cast iron. In my home shop I still drag air hoses around from the compressor because I haven't had time to install a better system.

The old factory I used to work had 3" PVC lines running from the screw compressor (115psi) to the main ABS manifold. We had 4 or 5 major explosions with it and I was only able to phase it out when it was spotted on an OSHA inspection and we got a big fine.

The problem with it is that it shatters and shoots shrapnel when it goes. I have personally pulled a shard of PVC out of the steel building skin it pierced. Once you have seen the aftermath of a failure you would never run the risk.

My shops are plumbed using 1/2" DOT air brake tubing held to the wall with P clips and push lock compression fittings at the drops with quick disconnects. It is inexpensive and easy to run.

The aluminum tube systems look fantastic and I will be doing that at the next building.

APEowner wrote: As proven by the number of people who are getting away with using them, PVC airlines aren't a certain death certificate. However, multiple health and safety organizations and governing bodies as well as every manufacturer of PVC piping expressly prohibit it. The problem isn't so much that it's guaranteed to fail it's that if it does fail it will do so in a way that can kill you.

The way I see it, why take the chance when there are so many other options that don't have the potential danger?

I'm using the Maxline stuff. It's awesome, the manifolds and fittings it comes with are top notch and I have three convenient outlets scattered about the garage. It's easy to work with and looks good to boot.

+1 rapidair. I used 3/4, and went way overkill with outlets. I figure $150 at Northern would do it again at the next shop, no matter the size. I might have spent 4250 last time. Fittings add up. Super easy to run.

Edit $250. stupid fingers. Stupid brain.

wheelsmithy wrote: I might have spent 4250 last time. Fittings add up.

Holy Moly! $4250, that is nuts!

The rapidair stuff seems like a good solution that isn't any pricier than all but PVC. Thanks for the personal experience Jumper, that is enough to make me write it off as an option.

APEowner wrote: As proven by the number of people who are getting away with using them, PVC airlines aren't a certain death certificate. However, multiple health and safety organizations and governing bodies as well as every manufacturer of PVC piping expressly prohibit it. The problem isn't so much that it's guaranteed to fail it's that if it does fail it will do so in a way that can kill you. https://www.osha.gov/dts/hib/hib_data/hib19880520.html https://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=INTERPRETATIONS&p_id=20202 http://www.usplastic.com/knowledgebase/article.aspx?contentkey=787

I'm a little surprised by the folks defending the use of PVC in compressed air applications. It's clearly the wrong material.

http://www.lascofittings.com/compressed-air-and-pvc

In reply to 1988RedT2:

Cheap and easy is a powerful motivator in virtually all aspects of life.

BrokenYugo wrote: In reply to 1988RedT2: Cheap and easy is a powerful motivator in virtually all aspects of life.

Rapidair is almost as cheap, and actually easier.