Mastering Air Lines: A Comprehensive Guide to Installing and Running Air Piping in Your Shop

Compressed air is the lifeblood of many workshops, powering everything from pneumatic tools to spray guns. Having a reliable and efficient air distribution system is crucial for smooth operations and optimal tool performance. While a professional installation is always an option, understanding how to run air lines in your shop yourself can save you money and give you a deeper understanding of your system. This comprehensive guide will walk you through the entire process, from planning your layout to testing the finished system.

Why Bother With DIY Air Lines?

Before we dive into the specifics, let’s explore why you might choose to install your own air lines:

• Cost Savings: Professional installation can be expensive. Doing it yourself significantly reduces labor costs, allowing you to invest in better materials or tools.
• Customization: You have complete control over the layout, ensuring it perfectly fits your shop’s needs and workflow.
• Understanding Your System: The process of installing your own lines will give you an intimate understanding of how your air system works, making troubleshooting and future modifications easier.
• Satisfaction: There’s a certain satisfaction that comes from building something yourself, and a well-functioning air system is a valuable accomplishment.

Planning Your Air Line System: The Foundation for Success

Proper planning is absolutely essential for a successful air line installation. Haphazardly running pipes can lead to inefficiencies, pressure drops, and future headaches. Here’s how to plan effectively:

1. Assess Your Needs

• Air Tool Requirements: Make a list of all your air tools and their CFM (Cubic Feet per Minute) requirements. This information is usually found on the tool itself or in its manual. Add up the CFM requirements of all tools you might use simultaneously. This total will determine the size of your compressor and the diameter of your main distribution lines.
• Future Needs: Consider potential future purchases of air tools and their potential CFM needs. It’s always better to over-engineer your system slightly to accommodate growth.
• Layout of Your Shop: Sketch out the layout of your shop, including the location of your compressor, workbenches, and any other areas where you’ll need air access. This sketch will be the basis for your piping plan.

2. Compressor Selection and Placement

• Compressor Size: Choose a compressor that can comfortably handle the total CFM requirements of your tools. It’s wise to have some extra capacity for future growth or to handle higher intermittent demands.
• Placement: Locate your compressor in a well-ventilated area. Avoid corners or enclosed spaces where heat can build up. It’s ideal to have it located centrally to minimize pressure drops due to long runs of pipe. Consider also the noise level and plan accordingly.
• Drainage: Air compressors generate moisture. Place your compressor in a location where you can easily drain the condensation tank regularly. A good drain valve and potentially an automatic drainer are recommended.

3. Choosing the Right Materials

The materials you choose for your air lines will significantly impact their durability, performance, and ease of installation. Here are the most common options:

• Black Iron Pipe: This is the traditional choice, known for its durability and resistance to high pressure. It is, however, more difficult to install, requiring threading and the use of specialized tools. It’s also susceptible to rust if not properly cared for.
• Copper Pipe: Copper is another durable option and resistant to rust but is expensive and requires soldering or compression fittings to join.
• PEX Tubing: PEX (Cross-Linked Polyethylene) tubing is a flexible, lightweight, and relatively inexpensive option. It’s easy to install using crimp or push-to-connect fittings. It’s resistant to corrosion and can withstand moderate temperatures and pressures. PEX may require supports if running over long distances to prevent sagging.
• Aluminum Air Pipe: Aluminum air pipe is another excellent option and more user-friendly to install as it uses push fit fittings. It’s lightweight and doesn’t corrode. It’s a more expensive option to PEX but provides long-lasting reliability.
• Polyurethane Tubing: Polyurethane tubing is flexible and easy to install but it is typically only for drop lines. It’s not durable enough for the main lines, and it’s susceptible to punctures.

Recommendation: For ease of installation and good performance in a typical shop, PEX or Aluminum air pipe are excellent choices. Black Iron Pipe requires specialized skills and equipment. Polyurethane is only suitable for short drops.

4. Planning Your Piping Layout

The layout of your piping is as important as the materials you choose. Here are some guidelines:

• Main Distribution Line: Run a main distribution line from your compressor to the area where most of your air tools will be used. This line should be of sufficient diameter to handle the maximum CFM demand. If using Black Iron, consider using a larger size (e.g., 3/4″ or 1″) for the main line and reduce to 1/2″ at outlets. For PEX or Aluminum, start with 3/4″ and 1/2″.
• Drop Lines: Install drop lines or outlets at each location where you will be using air tools. These drop lines can be smaller diameter than the main distribution line and can terminate in a quick-connect coupling or an appropriate manifold.
• Slope for Drainage: If using Black Iron or Copper, slope the pipe slightly towards drain points to allow moisture to condense and be drained. PEX or Aluminum may not require this if moisture traps are used properly.
• Avoid Sharp Bends: Use gentle bends (45-degree fittings rather than 90-degree ones) to minimize friction and pressure drops.
• Support the Lines: Use pipe clamps or brackets to securely support the piping. This will prevent sagging and reduce stress on connections.
• Consider a Moisture Separator: Install a moisture separator near the compressor and possibly at various drop lines to remove water from the system. It’s recommended to have the water separator after the compressor, preferably followed by an air regulator.
• Regulators and Lubricators: If using specific tools that need lower or regulated pressure, you will need to include air regulators at the drop lines. If your tools need lubricated air, include an inline lubricator.

Step-by-Step Installation Guide

Now that you have a solid plan, let’s get into the actual installation process. We will focus on using PEX as a material, as it is more commonly installed by DIY enthusiasts, but most of these principles will still apply to Aluminum piping.

Tools and Materials You’ll Need

• PEX tubing (or Aluminum air pipe and fittings)
• PEX crimping tool (or PEX cinch clamp tool) for PEX (or appropriate cutter for Aluminum)
• PEX crimp rings or cinch clamps
• PEX tubing cutter (or pipe cutter)
• Appropriate fittings (tees, elbows, couplings, adapters)
• Air hose quick-connect couplings
• Pipe clamps or brackets
• Drill
• Screws or anchors
• Measuring tape
• Marker
• Safety glasses
• Gloves
• Moisture separator, regulator, lubricator (if required)

Step 1: Marking and Mounting Pipe Supports

1. Use your plan to mark the locations of your main distribution line and drop lines on the walls or ceiling.
2. Measure the distances between support points and mark the locations for pipe clamps. Typically these are every 3-4ft for horizontal runs and closer at changes of direction.
3. Drill pilot holes and mount the clamps securely using screws or anchors.

Step 2: Cutting and Assembling Main Distribution Line

1. Using a PEX tubing cutter, cut the first section of PEX to your desired length, based on your layout. If using Aluminum air pipe, use a pipe cutter.
2. If using PEX, slide a crimp ring or cinch clamp over one end of the PEX tubing.
3. Insert a PEX fitting (e.g., a straight coupling or tee) into the end of the tubing.
4. If using PEX, position the crimp ring or cinch clamp approximately 1/8” from the edge of the fitting.
5. Using your PEX crimping tool, crimp the ring securely. If using a cinch clamp, use the cinch clamp tool to secure it. If using Aluminum piping, push the fitting onto the pipe until it locks.
6. Repeat this process to join multiple sections of pipe and add tees for drop lines.
7. Secure the assembled pipe sections into the mounted clamps.

Step 3: Installing Drop Lines

1. Cut the PEX tubing for each drop line to the desired length.
2. Repeat the crimping process from step 2 to attach PEX fittings (elbows or tees) to your drop lines. If using aluminum push fittings just insert into the main pipe fitting and then fit your drop line push fit fitting.
3. Install air hose quick-connect couplings onto the ends of the drop lines.
4. Secure the drop lines to walls or benches with pipe clamps if necessary.

Step 4: Installing Moisture Separators, Regulators, and Lubricators

1. Install your moisture separator in-line as close to your compressor as possible.
2. If using regulators and lubricators, install them in-line on drop lines, as needed.

Step 5: Testing and Leak Check

1. Before starting the compressor, ensure all connections are properly connected.
2. Turn on the compressor, and allow the system to pressurize.
3. Listen carefully for any air leaks. Pay close attention to all fitting connections.
4. Use a spray bottle with soapy water to check the fittings. If a leak is present, bubbles will form.
5. If you find any leaks, release the pressure, tighten the connection or re-make the crimp/push fit if needed, and repeat the test.

Step 6: Final Touches

1. Once your system is leak-free, secure all piping and clamps.
2. Label drop lines, if needed, for easy identification.
3. Drain the compressor and lines to remove any moisture.

Best Practices and Maintenance

Once your air system is installed, follow these best practices to keep it running smoothly:

• Drain your compressor tank regularly: Moisture build-up can lead to corrosion and reduce compressor efficiency.
• Check and empty moisture separators: Regularly emptying the moisture separator prevents water from reaching your tools.
• Inspect your air lines regularly: Check for any signs of damage, wear, or leaks.
• Apply thread sealant: If using threaded connections, use Teflon tape or a thread sealant to prevent leaks.
• Lubricate tools: Use an inline lubricator to ensure your pneumatic tools are properly lubricated.
• Proper CFM: Choose the right size and type of air tools for your compressed air system.

Safety Precautions

Safety should always be your top priority. Here are some important precautions to take when installing and using your air system:

• Wear safety glasses: Always protect your eyes when cutting, crimping, or testing air lines.
• Use proper tools: Use the right tools for each task to avoid injury and ensure quality connections.
• Do not exceed pressure ratings: Never exceed the pressure ratings of your pipes, fittings, and tools.
• Depressurize the system before working on it: Always release the pressure in the system before making any repairs or modifications.
• Never point an air nozzle at yourself or others: Compressed air can cause serious injury if misused.
• Be aware of noise levels: Use hearing protection if working with a loud air compressor for an extended period.

Troubleshooting Common Issues

Even with careful planning and installation, you may encounter some issues. Here are a few common problems and how to troubleshoot them:

• Low Pressure: Check for leaks in the system, ensure the compressor is running correctly and has enough capacity, and verify that the air regulator (if present) is set correctly.
• Water in the Lines: Ensure moisture separators are working properly, the compressor tank is being drained regularly, and that pipes are sloped appropriately for drainage (if applicable).
• Leaks: Identify and tighten or replace leaky fittings. Re-crimp PEX fittings if necessary. Ensure the pipe is cut square, and the fitting is inserted fully if using a push fit system.
• Tool Malfunction: Ensure tools are clean, properly lubricated, and operating within the pressure range of the system.

Conclusion

Installing your own air lines can seem daunting, but with careful planning and attention to detail, it is a manageable project that can save you money and increase the efficiency of your shop. By following the steps outlined in this guide, you can create a reliable and effective air system tailored to your specific needs. Always prioritize safety, and take the time to plan your system correctly before starting. If you find that the task is beyond your expertise, don’t hesitate to consult with a professional.