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How to Use Air Tools and an Air Compressor in Your Workshop

Updated on January 01, 2017
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Eugene is an avid self taught DIYer, and over 30 years has acquired lots of experience of power/hand tools, plumbing, electrics and woodwork

Air Tools to Compliment the Tools in Your Workshop

Air tools as the name suggests are tools powered by compressed air, unlike conventional power tools which are either powered by a battery or a 120/240 volt mains supply. This article outlines the basics of how they work, what tools are available, and what you need to put together a system for your home workshop.

Source

Glossary

CFM or Cubic Feet / Minute The quantity of compressed air which an air compressor can supply or which an air tool requires

Pressure Air is compressed or "squashed" inside a compressor into a fraction of it's original volume. Air is stored in a tank. The pressure of the air is measured in bar, pounds per square inch (PSI) or kilopascals.
1 bar = 14.5 psi = 100,000 pascals or 100 kPa

Pneumatics This refers to using compressed or pressurized air

BSP Thread British Standard pipe thread. Even in countries which use the metric system, the imperial based BSP standard is used (Except in the U.S.)

NPT Thread National Pipe Thread. An inch based thread used in the U.S.

Gage (Gauge in UK) In the context of air tools, this refers to the size of a fitting or internal diameter of a hose

What Tools are Powered by Air?

Basically the same tools as are available in battery or mains powered versions....and some others. Some examples:

Drills
Sanders
Angle grinders
Saws
Nail guns
Chipping hammers
Spray guns
Tire inflators
Air ratchet
Impact wrench

Other tools which aren't commonly available in electric versions are:

Air gun
Sand blasting gun
Air shears
Pop riveter

What Are the Advantages of Air Tools?

  • They have a high power to weight ratio. In other words, an air tool will be lighter than a cordless or mains powered tool of the same power rating. Air tools have simple air motors or pistons which are lighter than an electric motor. This is important for assembly workers who may be using a tool all day, and obviously a lighter tool will lessen fatigue
  • They are simpler and have less working parts than an electric tool, so there is less to go wrong
  • An air tool can be stalled indefinitely. If you stall an electric tool, the back EMF(Electro Motive Force) drops to zero and current flowing through the motor becomes very large. If the trigger on the tool isn't released immediately, the motor can rapidly burn out
  • Unlike electric tools which have a universal motor (it can run on AC or DC) which produces sparks at the brushes in contact with the commutator, an air tool is spark-less. This can be a distinct advantage in hazardous environments where there may be gas or flammable liquids
  • There is no electrocution risk in damp environments

Do Air Tools Have Any Disadvantages?

Yes they do. However depending on the application or environment, the advantages may outweigh the disadvantages.

Some disadvantages:

  • An air hose is required to supply air to the power the tool. This is usually thicker, heavier and less flexible than the power cord of an electric tool. However coiled air hoses are available which may be more convenient e.g. for low powered bench tools
  • An air compressor is required, adding to the cost of the system
  • Air fed to a tool must be filtered and lubricated to prevent premature wear. If a tool is used infrequently, it can be lubricated with a few drops of oil dropped into the intake port
  • Air tools can be somewhat noisy as air exits the exhaust port on the tool
  • They are usually more expensive than their electric counterparts

So as you can see, there are advantages and disadvantages to using air tools and there is a time and place for using either a cordless battery tool, a mains powered tool or an air tool. It is not a case of "either or"



What is Required to Build an Air System in a Workshop?

  1. An Air Compressor This compresses the air and stores it in a tank. Various types / sizes / capacities are available. The important things to consider when buying are the horse power of the compressor (HP), the delivery rate in cubic feet per minute (cufm) or liters per minute, the gas tank capacity in gallons or liters and whether the compressor is electric or gas powered.

    Wilderness has an article on HubPages which covers all aspects of buying a compressor:
    http://wilderness.hubpages.com/hub/an-air-compressor-buying-guide-for-home-use-air-compressors
    Check it out for further details
  2. A Filter / Regulator / Lubricator A filter removes dust and water from air. Dust can scour and damage the working parts of tools, eventually clogging everything up, but more importantly it will cause wear and badly sealing surfaces. When air is compressed, water can condense out (depending on the humidity). This water may cause corrosion inside tools if it isn't removed by the filter.
    A regulator is like a faucet, controlling the pressure of the air, allowing it to be turned up and down, depending on the maximum requirements of the tool and also the application. A good quality regulator should keep the pressure constant, independent of the air demand of the tool.
    A lubricator creates a mist of tiny oil droplets in the air flow, which lubricate moving surfaces in contact inside the tool. When spray painting, obviously lubrication is not necessary and would spoil a finish. For infrequent, short and occasional use, a lubricator is not necessary and a tool can be lubricated with a few drops of oil dropped into the intake port.
    A regulator, filter and lubricator can be bought as a single unit, or the modules can be plumbed individually together in various combinations. Sometimes the regulator/filter may be provided with and attached to the air compressor.
    You can dispense with all this stuff and just use air straight from the compressor. However water and dust will shorten the life of your tools if you are using them regularly. Tools also have a max pressure rating which can be less than the typical 8 bar / 120 PSI output pressure rating of a compressor. Overpressure could cause damage to a tool, or worse still, rupture. A regulator will drop the pressure to a safe value.

  3. An Air Hose One hose is required to connect the compressor to the filter/regulator/lubricator. You then need a work hose to connect to your tool. Various options are available. You can buy a coiled hose (like the coiled cord on a telephone handset), or a non coiled hose. Hoses are usually made from rubber or plastic. Plastic is quite rigid and can crack over time. Rubber is more flexible. Air hoses have various internal diameters. This becomes an issue if you are using a tool which uses a lot of air. A hose with a small internal diameter will cause a pressure drop and less power will be available to the tool. A very long hose will also have the same effect, dropping pressure. This is analogous to an electrical extension cord dropping voltage if it is of inadequate gage or too long when powering a high powered tool which requires high current
  4. Air Tool The tool will have a cubic feet / minute (CFM) rating. The air compressor should be cable of supplying this flow rate

Source
Filter, regulator, lubricator unit. The filter has an automatic drain for releasing water when pressure is released
Filter, regulator, lubricator unit. The filter has an automatic drain for releasing water when pressure is released | Source

Typical Air Tools

Various types of air tools

Air shears for cutting sheet metal
Air shears for cutting sheet metal | Source
Cutting head of air shears
Cutting head of air shears | Source
Framing nailer for light gage nailing of timber
Framing nailer for light gage nailing of timber | Source
Air drill
Air drill | Source
Air drill with coiled air hose
Air drill with coiled air hose | Source
Tire inflator
Tire inflator | Source
Air blow gun which can be used for blowing away dust, water, drying etc
Air blow gun which can be used for blowing away dust, water, drying etc | Source

Air Tools Usually Have a Quick Release Push Fit Connector

Quick release push fit connectors on an air hose and air tool. Air hoses can be permanently attached to tools using screwed fittings. However quick release fittings are more convenient
Quick release push fit connectors on an air hose and air tool. Air hoses can be permanently attached to tools using screwed fittings. However quick release fittings are more convenient | Source

Sealing an Air Fitting - BSP and NPT Threads

Internationally, air fittings follow the BSP (British Standard Pipe) standard. In the U.S., the NPT (National Pipe Thread) standard is used. Both standards are based on inch measurements rather than metric. NPT and BSP threads differ in profile, diameter for a specific size thread, and pitch. So they are incompatible. It may be possible to mate threads of both types but they may not seal very well, however adapters are available. A pipe thread size refers not to the external diameter of the threads, but originally referred to the internal diameter of a steel pipe for which the thread was intended. Low power tools generally have a 1/4 inch BSP or NPT female port into which a quick release adaptor can be screwed. High power tools such as impact wrenches used to remove bolts from truck wheels usually have larger 3/8 or 1/2 inch ports. Fittings may have tapered threads which become wedged as they tighten, forming a good seal. Air fittings can be sealed using teflon (PTFE) tape. The tape should be wound clockwise looking from the entry point of the fitting. Apply a few layers to form a tight seal.

Links to the BSP and NPT standards on Wikipedia:

NPT threads

BSP threads

Adding an Adaptor to a Tool

This tool was supplied with a 1/4 inch BSP male coupler / nipple which was glued into place. I could have used it with a hose with a female screw fitting on the end, however I wanted it to be quick release so I could easily remove it from the hose rather than having it permanently screwed on.

This particular tool was supplied with a 1/4 inch BSP male coupler / nipple which was glued into place. It requires a female quick fitting adaptor to be attached. (Alternatively the nipple could have been replaced with an adaptor with a male thread)
This particular tool was supplied with a 1/4 inch BSP male coupler / nipple which was glued into place. It requires a female quick fitting adaptor to be attached. (Alternatively the nipple could have been replaced with an adaptor with a male thread) | Source
Wind the PTFE tape tightly in a clockwise direction down the length of the threads. Apply a few layers of tape
Wind the PTFE tape tightly in a clockwise direction down the length of the threads. Apply a few layers of tape | Source
Source
1/4 inch BSP quick release adaptor with female threads
1/4 inch BSP quick release adaptor with female threads | Source
Screw the adaptor onto the tool
Screw the adaptor onto the tool | Source

Alternative Fittings

I could have replaced the nipple in the tool with these adaptors

Two different types of male adaptors. The one on the left is recommended as it has a larger internal diameter and results in less pressure drop when used with tools.
Two different types of male adaptors. The one on the left is recommended as it has a larger internal diameter and results in less pressure drop when used with tools. | Source

How to Fit a Connector to a Hose

Fitting a barbed, quick release adapter to a hose. This fitting then plugs into the outlet coupler of an air compressor (or the coupler on the end of another hose if you want to get more range)

Barbed fittings are necessary when connecting to hoses (Off the shelf, made up hoses will generally have fittings permanently crimped onto the end of the hose)
Barbed fittings are necessary when connecting to hoses (Off the shelf, made up hoses will generally have fittings permanently crimped onto the end of the hose) | Source
Cut the end of the hose square. This useful tool for cutting hoses and light pvc tubing is fitted with a widely available "Stanley" type knife blade
Cut the end of the hose square. This useful tool for cutting hoses and light pvc tubing is fitted with a widely available "Stanley" type knife blade | Source
Slide a hose clip onto the hose, and push the adaptor on. Some soapy water may help to lubricate surfaces if the adaptor is a tight fit
Slide a hose clip onto the hose, and push the adaptor on. Some soapy water may help to lubricate surfaces if the adaptor is a tight fit | Source
Push the clip so that it lies halfway along the barb, and tighten with a screwdriver
Push the clip so that it lies halfway along the barb, and tighten with a screwdriver | Source

Reading an Air Gage (Gauge)

The scale on an air gage is marked in bar, PSI, kPa or a combination of the measurement systems

The blue scale is bar,  the outer scale is PSI, the green scale is kPa
The blue scale is bar, the outer scale is PSI, the green scale is kPa | Source

How Do Air Tools Work?

Air tools such as nail guns use a piston and cylinder arrangement just like in an internal combustion engine. Air pressure acting on the large surface area of a piston accelerates it rapidly until it collides with a nail head, driving it forward. Tools such as drills have a rotary air motor. Air pressure acting on the surfaces of the motor give it torque and cause it to turn. Air hammers have a double acting piston which is rapidly moved backwards and forwards as air valves rapidly change the side of the piston which the air acts on

Safety When Using Air Tools and Compressors

  • Wear goggles when using tools which can throw up debris e.g. air grinders, air blow guns and air chisels
  • De-pressurise hoses before connecting / disconnecting from tools and compressor
  • Don't allow compressed air to blow onto skin or an open wound (This can potentially cause "the bends")

Tool and Compressor Maintenance

  • Drain water from compressor every time it is used
  • Check oil level regularly and change oil at intervals as specified by manufacturers recommendations
  • Lubricate tools before use by dropping oil into air entry port of tool or use a lubricator. Clean and lubricate moving parts of tools

Power Craft is the registered trade mark of Aldi GmbH & Co. KG

Aldi in no way endorses this article.

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    • Writer Fox profile image

      Writer Fox 2 years ago from the wadi near the little river

      Fantastic article! You are a real expert in power tool technology. Enjoyed and voted up!

    • eugbug profile image
      Author

      Eugene Brennan 2 years ago from Ireland

      Thanks for the comments - Hopefully it will help someone out there!........

    • Instronline 16 months ago

      Thanks for sharing this information.This is real great information about air filter ,regulator and lubricant control.This will help us to improve quality of our tools.

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