When people hear "aluminium pipe", strength isn't always the first thing that comes to mind.
But aluminium piping systems can be designed for demanding industrial applications, including high-pressure systems.
Unipipe demonstrates this through pressure-to-burst testing, with testing that recorded pipe failure at pressures far beyond those typically encountered in standard industrial compressed air systems.
One high-pressure tube split at 535 bar without visible leakage or fitting failure.
So what does that actually tell us about Unipipe?
What Is Pressure-to-Burst Testing?
A burst test deliberately increases pressure within a pipe or component until it fails.
The purpose isn't to establish the normal operating pressure of the system.
Instead, burst testing helps demonstrate how the pipe and fittings behave under extreme pressure conditions and where failure occurs.
For Unipipe, testing has been carried out under different temperature conditions to assess performance beyond normal operating environments.
Unipipe Tube Tested to 535 Bar
One of the most notable Unipipe test results involved a high-pressure tube that split at 535 bar.
Importantly, the tube split without visible leakage or fitting failure.
That's a significant result when considering the relationship between the aluminium pipe and the fitting.
The pipe ultimately became the point of failure rather than the fitting connection.
535 bar in perspective
Most industrial compressed air systems operate at pressures considerably below this level.
For example, many standard compressed air systems operate around 7–8 bar.
That means the 535 bar burst-test result represents an extreme test condition rather than a normal operating pressure.
It demonstrates the substantial pressure capability observed during testing, but it should not be interpreted as a recommended operating pressure.
What Happened at High Temperature?
Pressure isn't the only variable that can affect pipe performance.
Temperature can also influence material behaviour and pressure capability.
Unipipe was tested at 100°C, where the standard pipe recorded a burst pressure of 202.9 bar.
The fitting did not fail during the test.
This provides an indication of how the pipe and fitting behaved under a combination of elevated temperature and high pressure.
Again, a burst result should not be confused with a working pressure rating. The permitted operating conditions depend on the exact product and application.
What About Low Temperatures?
Unipipe was also tested at -30°C.
During this test, the recorded burst pressure was 243.2 bar, with no fitting failure reported.
This is relevant for industrial environments where piping may be exposed to significant temperature variation.
The test demonstrates that the system was subjected to extreme conditions well beyond those found in many conventional indoor compressed air installations.
Unipipe Pressure Testing at a Glance
| Test condition | Recorded result |
|---|---|
| High-pressure tube | Split at 535 bar |
| High-pressure tube result | No visible leakage or fitting failure |
| Standard pipe at 100°C | Burst at 202.9 bar |
| Standard pipe at -30°C | Burst at 243.2 bar |
| High-pressure Unipipe operating range | Up to 70 bar, depending on configuration |
These figures describe specific test results and product configurations. They are not a substitute for the manufacturer's published operating limits.
How Does This Compare With Normal Compressed Air?
The difference between burst pressure and normal operating pressure is important.
A typical industrial compressed air system may operate at approximately 7–8 bar.
Unipipe's high-pressure range is designed for applications up to 70 bar, subject to the exact configuration and operating conditions.
The pressure-to-burst testing therefore provides an additional perspective on the system's pressure performance.
It demonstrates that the pipe and fittings were subjected to pressures substantially above typical operating conditions during testing.
Why Test the Fitting as Well as the Pipe?
A piping system isn't just a length of tube.
Every connection creates another potential point of failure.
That's why the performance of the fitting is important when assessing an industrial piping system.
In the 535 bar test, the tube split without visible leakage or fitting failure.
The result demonstrates the strength of the connection under that specific test condition.
This is particularly relevant to Unipipe's fitting design, which uses a unique internal nut engineered to provide increased resistance to pressure and fitting blow-off.
Does Higher Burst Pressure Mean You Can Operate at Higher Pressure?
No.
This is an important distinction.
Burst pressure and operating pressure are not the same thing.
Burst testing deliberately takes a component beyond normal operating conditions to determine how and when it fails.
The maximum permitted operating pressure must be determined from the manufacturer's specifications for the exact pipe, fitting, temperature and application.
For Unipipe, different configurations are available for different applications, including standard compressed air, high pressure, oil and vacuum.
Why Aluminium Is Used for Industrial Piping
Aluminium offers several practical advantages for industrial piping systems.
It's lightweight, making pipe easier to handle and position. It also works well with modular mechanical fitting systems.
For facilities that regularly change production layouts, this modularity can be just as important as the pipe material itself.
New outlets can be added, sections can be extended and parts of the system can be reconfigured as requirements change.
Where Can High-Pressure Unipipe Be Used?
The Unipipe range includes configurations for applications such as:
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High-pressure air
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Industrial compressed air
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Oil applications
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Vacuum systems
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Manufacturing
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Production facilities
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Industrial workshops
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Pneumatic equipment
The exact product configuration should always be selected based on the operating pressure, temperature and medium.
The Takeaway: Look at the Complete System
When evaluating an industrial aluminium piping system, don't look at the pipe alone.
Consider the complete system:
Pipe + fittings + connection design + pressure rating + temperature + application
Unipipe has been designed as a complete modular aluminium piping system, with fittings engineered to work with the pipe and testing demonstrating substantial pressure performance.
The 535 bar burst test, along with testing at 100°C and -30°C, provides useful evidence of how the system behaved under extreme test conditions.
For normal applications, however, the correct operating limits always come from the manufacturer's specifications.
Need Help Selecting an Aluminium Pipe System?
Air Energy supplies Unipipe aluminium piping systems for industrial applications across Australia.
If you're comparing aluminium pipe systems or need to select a system for compressed air or a higher-pressure application, talk to the Air Energy team.