How to Choose the Right Piping System for Your Facility

Choosing the right piping system for a commercial or industrial facility is a critical decision with long-term consequences for performance, safety, and maintenance costs. Whether you're designing a new system or upgrading an existing one, proper material selection, pressure rating compliance, and adherence to local building and safety codes are essential. This guide outlines the key technical factors facility managers should consider to ensure a reliable, compliant, and cost-effective piping solution.

Start with System Requirements and Application

Before selecting materials or calculating pressure ratings, you need to understand the purpose of the system. Different applications demand different piping characteristics. Consider:

• Type of media: Will the pipes carry water, steam, gas, compressed air, chemicals, or corrosive fluids?

• Temperature range: What are the operating and potential peak temperatures?

• Pressure range: What is the working pressure and surge potential?

• Environment: Will the pipes be underground, outdoors, in corrosive or high-traffic areas?

Knowing the answers to these questions will narrow down your material options and ensure your system is both safe and efficient.

Choose the Right Piping Material

Each piping material has unique properties that make it suitable—or unsuitable—for certain environments. Here’s a comparison of common piping materials used in industrial and commercial settings:

Carbon Steel

• Pros: High strength, cost-effective, suitable for high-pressure systems.

• Cons: Susceptible to corrosion unless treated or coated.

• Common uses: Steam, gas, and oil lines.

Stainless Steel

• Pros: Excellent corrosion resistance, good for high temperature and sanitary systems.

• Cons: Higher material and installation costs.

• Common uses: Food processing, chemical plants, potable water.

Copper

• Pros: Corrosion-resistant, easy to install, good thermal conductivity.

• Cons: Expensive, not ideal for high-pressure applications.

• Common uses: HVAC, potable water, compressed air.

PVC / CPVC (Polyvinyl Chloride / Chlorinated Polyvinyl Chloride)

• Pros: Lightweight, corrosion-resistant, low cost.

• Cons: Limited temperature and pressure range; CPVC is better for hot water.

• Common uses: Drainage, wastewater, low-pressure chemical transport.

HDPE (High-Density Polyethylene)

• Pros: Flexible, chemical-resistant, good for trenchless installations.

• Cons: Not suitable for high temperatures.

• Common uses: Underground piping, water mains, and chemical waste.

PEX (Cross-Linked Polyethylene)

• Pros: Flexible, corrosion-resistant, and easy installation.

• Cons: Lower pressure and temperature resistance compared to metals.

• Common uses: Hydronic systems, potable water in commercial buildings.

Understand Pressure Ratings and Safety Margins

Pressure rating is the maximum pressure a piping system can safely handle. Choosing a pipe rated too low for your application can lead to leaks, bursts, or even catastrophic failure.

When selecting pipes, consider:

• Working pressure: The expected constant pressure under normal conditions.

• Burst pressure: The maximum pressure the pipe can withstand.

• Surge pressure: Temporary pressure spikes during system start-up or shutdown.

Always apply a safety factor—typically 1.5 to 4 times the working pressure—depending on the application and regulatory requirements. Manufacturers usually publish pressure ratings based on specific temperature ranges, so be sure to account for temperature-pressure derating factors.

Check Compatibility with Fittings and Valves

Even the best piping material can fail if the fittings, flanges, and valves are not compatible. Ensure that:

• Material types are chemically and mechanically compatible.

• Fittings are pressure-rated to match or exceed the piping.

• Installation methods (e.g., welding, threading, gluing) suit your system's operational demands.

Ensure Compliance with Local Codes and Industry Standards

Your piping system must comply with local building codes and national industry standards to ensure safety and avoid legal or insurance issues. Key regulatory and industry organizations include:

• ASME (American Society of Mechanical Engineers) – Boiler and Pressure Vessel Code (BPVC), B31 Piping Codes.

• ASTM (American Society for Testing and Materials) – Material standards.

• NFPA (National Fire Protection Association) – Fire suppression system standards.

• UPC/IPC (Uniform/International Plumbing Code) – Plumbing requirements.

• Local Authority Having Jurisdiction (AHJ) – May impose stricter codes.

Work with engineers or contractors familiar with your jurisdiction’s specific requirements to avoid costly rework or penalties.

Factor in Maintenance and Lifecycle Costs

Beyond upfront material and installation costs, consider:

• Durability and corrosion resistance – Will it last 10 years or 50?

• Ease of inspection and access – Can maintenance teams easily service the system?

• Repair costs – Are spare parts readily available? Is special equipment needed?

• System downtime – What’s the impact of failures or repairs on operations?

In some cases, a slightly higher upfront investment in premium materials like stainless steel or HDPE can pay off through reduced maintenance and longer service life.

Choosing the right piping system for your facility is not a one-size-fits-all decision. It requires a thorough understanding of your application, environment, and operational needs—along with attention to pressure ratings, material compatibility, and code compliance. Facility managers who take the time to evaluate these factors will end up with a system that performs reliably, meets regulatory requirements, and minimizes long-term costs. For best results, collaborate with experienced contractors who can tailor the system design to your specific facility and industry.

Installing a new piping system? Contact us at Brody’s Welding to learn how we can help!