Is PVC right for me?
Short Answer, NO.
When it comes to compressed air systems, choosing the wrong piping material can create a serious safety hazard. Standard above-ground PVC pipe is not considered safe for compressed air because it can shatter under pressure, sending sharp fragments flying if it fails. OSHA addresses this risk under the General Duty Clause, making it a critical issue that every business owner and facility manager should understand before installing or upgrading an air system.
What OSHA says:
OSHA prohibits using standard above-ground PVC pipe for compressed air systems under the OSHA General Duty Clause, Section 5(a)(1), because pressurized PVC can shatter violently into dangerous shrapnel. Enforcement and safety guidance are further detailed in specific hazard bulletins and interpretations. (General Duty Clause (Section 5(a)(1)): Requires employers to provide a workplace free from recognized hazards causing death or serious physical harm, which applies to using unrated or shatter-prone plastics for compressed air.)
Real Incidents That Led to OSHA Action:
OSHA first issued its Hazard Information Bulletin in 1988 following several serious PVC failures. The agency later clarified its enforcement position through Standard Interpretations issued in 1990 and 1991, making it clear that exposed above-ground PVC compressed air systems violate the General Duty Clause because the material lacks adequate shatter resistance. The following are a few of those instances:
A section of PVC pipe being used for compressed air exploded 27 feet above a warehouse floor, a fragment of the pipe flew 60 feet and embedded itself in a roll of paper. Fortunately, nobody was in the area at the time.
An employee in Texas was injured by a rupture in a PVC compressed air line. Plastic projectiles from the point of rupture caused lacerations of the employee's hand.
A PVC pipe explosion in a new plant in Selah broke an employee's nose and cut his face.
PVC piping buried 3 feet underground at a Yakima manufacturing plant exploded, opening up a crater approximately 4 feet deep by 3 feet across.
“When a PVC pipe or fitting fails when under stress from compressed gas it literally explodes like a bomb, sending shards of plastic flying several feet in all directions.” Jack Roach- ESLON THERMOPLASTICS, INC.
This memorandum was released again in, 1988. But it didn’t become clarified until 1990-1991.
In 1990–1991: OSHA clarified policy via Standard Interpretations stating that exposed, above-ground PVC use violates the General Duty Clause because PVC lacks shatter resistance.
Why PVC Becomes More Dangerous Over Time:
From the moment compressed air leaves the compressor, pressure, heat, and lubricant aerosols begin traveling through the piping system. Over time, these factors—combined with UV exposure and ambient heat—can cause standard PVC to become brittle, significantly reducing its pressure tolerance and increasing the risk of catastrophic failure. For these reasons, we strongly recommend using piping materials specifically designed for compressed air systems.
What The Compressor Guy Recommends:
Unfortunately, we still see the use of PVC on-site as this pipe is still being utilized nationwide by hundreds of unsuspecting operators. At The Compressor Guy, LLC, safety always comes first. If we discover standard PVC being used for a compressed air system, we follow established lockout/tagout procedures before working on the equipment. We then explain the hazard to our customer and discuss safer piping alternatives before any work continues. While buried PVC or properly contained systems may be permitted in certain applications under applicable codes and manufacturer recommendations, standard exposed above-ground PVC should not be used for compressed air because of its shatter hazard.
There are far safer and more reliable options than standard PVC for compressed air systems. Approved piping materials such as aluminum, copper, galvanized steel, black iron, HDPE-aluminum (flexible system) are designed to withstand the demands of compressed air while providing years of dependable service. In our opinion the choice air system medium is best determined by air system design, cost of material, cost of installation, and malleability.
Helping businesses keep their world running starts with keeping the people behind that work safe.
If you walk away from this article remembering one thing, let it be this: don't use standard PVC for compressed air. There are safer materials available that are designed for the job and help protect your equipment, your employees, and your business. If you're not sure what type of piping your system has, give The Compressor Guy, LLC a call. We'd be happy to take a look and point you in the right direction.