UnipipeHP is a high-pressure aluminium piping system.

This piping system is engineered for industrial air, gas and fluid applications operating between 435 PSI and 1015 PSI. It is manufactured from EN AW 6060 – T5 aluminium and uses mechanically tightened fittings with O-ring sealing and a 360-degree stainless steel clamp ring to maintain leak-free performance under elevated pressure conditions. UnipipeHP is designed for strength, pressure integrity and controlled installation in demanding industrial environments.

For a complete overview of the aluminium system architecture, see What Is Unipipe Aluminium Industrial Piping?.

Operating Pressure Range

• Minimum High-Pressure Range: 435 PSI
• Intermediate Configurations: 580 PSI
• Maximum Rated Configuration: 1015 PSI

System configuration, pipe diameter and fitting selection determine the final allowable working pressure. Always confirm component ratings before commissioning.

435–1015 PSI Design Criteria

1. Correct Pipe Sizing

Pipe diameter must match flow rate and system demand. Undersized pipe increases velocity, pressure drop and mechanical stress at fittings.

2. Fitting Selection

Only approved UnipipeHP high-pressure fittings should be used within this operating range. Standard low-pressure fittings are not suitable.

3. Controlled Tightening Procedure

• Hand tighten first
• Wrench tighten approximately ¼ turn past hand-tight
• For larger fittings (50–63 mm), 75 N.m torque is recommended during re-assembly
• Avoid over-tightening to prevent seal deformation

See the complete installation procedure here: How to Install Unipipe Aluminium Piping.

4. Thermal Considerations

Standard operating temperature range is -22°F to 266°F. O-ring material selection may extend this from -40°F up to 350°F depending on application.

Safety Factors for High-Pressure Installations

High-pressure systems require conservative design margins. Operating near maximum rating without appropriate safety factors increases risk.

Recommended Safety Practices

• Confirm maximum allowable working pressure (MAWP) for each component
• Conduct pressure testing before commissioning
• Use proper anchoring and pipe supports
• Avoid excessive vibration exposure
• Ensure O-ring compatibility with media
• Document torque settings during installation

High-pressure systems should always be designed in accordance with site-specific engineering standards and regulatory requirements.

Material Performance Under Extreme Pressure

UnipipeHP aluminium pipe conforms to EN AW 6060 – T5 and related material standards including EN 755-2 and ASTM B241.

Material Considerations

• Seamless aluminium construction improves structural consistency
• Internal polymer coating prevents corrosion-related weakening
• External polyester coating (≥ 60 µm) protects against environmental exposure
• Anodized nuts (≥ 13 µm) and cataphoresis-treated bodies enhance durability

Under high pressure, surface integrity and uniform wall thickness are critical to maintaining long-term reliability.

Typical High-Pressure Applications

High-Pressure Compressed Air

Industrial processes requiring elevated operating pressures for specialised tooling or automation.

Nitrogen and Gas Delivery

High-pressure inert gas systems used in fabrication, laser cutting and industrial processing.

Hydraulic Support Systems

Controlled air or gas systems supporting hydraulic operations.

Water Jet Cutting and Processing

High-energy systems where pressure stability is critical to performance.

Advantages of UnipipeHP

• Rated up to 1015 PSI
• Lightweight compared to traditional heavy steel systems
• Modular mechanical installation
• Reusable fittings
• Corrosion-resistant internal protection
• Expandable high-pressure network capability

Explore the product range here: UnipipeHP High-Pressure Systems.

Limitations and Design Considerations

• Not interchangeable with lower-pressure product ranges
• Requires strict adherence to torque recommendations
• Must be engineered with appropriate safety margin
• O-ring material must match temperature and media
• Professional design oversight recommended for systems approaching 1015 PSI

Frequently Asked Questions

What is the maximum pressure rating of UnipipeHP?

Depending on configuration, UnipipeHP is rated between 435 PSI and 1015 PSI.

Can standard Unipipe fittings be used in high-pressure systems?

No. Only fittings specifically rated for UnipipeHP should be used within the high-pressure range.

Does UnipipeHP require welding?

No. It uses mechanically tightened fittings with controlled torque specifications.

What material is used for UnipipeHP pipe?

The pipe is manufactured from EN AW 6060 – T5 aluminium and treated internally and externally for corrosion resistance.

How should high-pressure systems be tested?

Pressure testing should be conducted in accordance with site safety standards and documented before commissioning.

Real-World Application Example

Environment: Heavy fabrication facility

Problem: Requirement for stable 580 PSI compressed air supply

Solution: Engineered UnipipeHP installation with reinforced supports and torque-controlled assembly

Result: Reliable high-pressure delivery with modular expandability

Related Technical Guides

Learn more about how Unipipe aluminium systems work: What Is Unipipe Aluminium Industrial Piping?

Explore UnipipeAIR installation details: UnipipeAIR Technical Guide

Review the UnipipeHP High-Pressure System Handbook (435–1015 PSI Design Guide)

Review the UnipipeAIR Technical Guide (232 PS Design Guide)

Why Choose Air Energy

• Technical Expertise Since 1993 – Over 2,000 industrial installations across mining, aquaculture, manufacturing, and remote sites

• Multi-Industry Experience – Experts in compressed air, fuel, water, and process piping systems

• Project Support – Our technical team ensures safe, efficient, and long-lasting installations

With Air Energy, you get a piping solution designed for performance, reliability, and long-term operational efficiency.