When selecting aluminum pipe for a project, two of the most important factors to consider are wall thickness and pressure rating. These specifications directly affect the pipe’s strength, performance, and safety in a wide variety of applications — from air and fluid systems to structural supports and marine tubing.
Understanding how wall thickness influences pressure handling capacity helps engineers, contractors, and buyers make informed decisions that prevent system failures and reduce costs.
This article explores the relationship between aluminum pipe wall thickness and pressure rating, how to determine the right specification, and what to keep in mind during selection.
What Is Wall Thickness in Aluminum Pipe?
Wall thickness refers to the distance between the outer and inner walls of the pipe. It is measured in millimeters or inches and determines the overall strength and rigidity of the pipe.
A thicker wall provides:
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Greater structural integrity
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Higher pressure resistance
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Better impact tolerance
On the other hand, thinner walls reduce weight and material cost, making them ideal for low-pressure or non-load-bearing applications.
At sasaaluminum, we offer aluminum pipes in a wide range of wall thicknesses to meet the performance requirements of various industries, including automotive, aerospace, HVAC, and more.
Understanding Pressure Ratings
The pressure rating of a pipe indicates how much internal pressure it can safely handle without deforming or failing. This is typically measured in psi (pounds per square inch) or bar and is calculated based on:
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Material strength
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Wall thickness
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Outside diameter
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Temperature
For example, a pipe with a thick wall and small diameter can generally handle more pressure than a large-diameter, thin-walled pipe.
Pressure ratings are critical in:
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Pneumatic systems
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Hydraulic lines
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High-pressure gas or liquid transfer
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Steam and air delivery systems
The Relationship Between Wall Thickness and Pressure Rating
There is a direct relationship between wall thickness and pressure rating. As wall thickness increases, so does the ability of the pipe to resist internal pressure.
For example:
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A Schedule 40 aluminum pipe will handle more pressure than a Schedule 5 pipe of the same diameter.
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Schedule 80 pipe, with even thicker walls, is suitable for high-pressure systems.
Thinner pipes are more likely to deform or burst when exposed to high internal pressure. That’s why choosing the right wall thickness for your pressure requirement is essential.
sasaaluminum provides consultation and material guidance to help clients match wall thickness to operating conditions.
Common Aluminum Pipe Schedules
In practice, aluminum pipes are often categorized into schedules, which correspond to standardized wall thicknesses. While schedules such as 5, 10, 40, and 80 are more commonly associated with steel piping, aluminum pipe can also follow similar conventions.
For example:
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Schedule 5: Very thin wall, low-pressure use
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Schedule 10: Light wall, moderate flow and structural support
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Schedule 40: Standard wall thickness for general pressure applications
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Schedule 80: Thick wall for higher pressures and structural loads
Always check the actual wall thickness (not just the schedule number), especially when ordering aluminum pipe from international sources.
Factors That Influence Pipe Pressure Capacity
1. Pipe Diameter
Larger diameter pipes experience more stress under pressure and often require thicker walls to compensate.
2. Alloy Grade
Different aluminum grades have different yield strengths. 6061-T6, for example, has higher pressure tolerance than softer alloys like 3003 or 6063.
3. Temperature
As temperature increases, aluminum’s strength decreases. High-temperature applications require derating the pressure capacity.
4. Joining Method
Welded or threaded joints can become weak points. Proper reinforcement or thicker walls may be needed around these areas.
How to Choose the Right Wall Thickness
To determine the best wall thickness for your application:
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Define the maximum working pressure of the system.
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Calculate the required thickness using industry-standard formulas.
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Consider safety margins and potential pressure spikes.
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Match your required pressure with a pipe that offers slightly more than the minimum rating.
If you’re unsure, consult with technical experts. sasaaluminum offers custom sizing support and engineering recommendations based on your specifications.
Real-World Examples
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Compressed Air Lines: Often require Schedule 40 pipes to safely withstand 150–200 psi.
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Structural Frames: Don’t require pressure rating, but need enough thickness to resist bending.
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Water Irrigation Systems: Can use Schedule 10 or lighter pipes if pressure remains under 80 psi.
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High-Pressure Chemical Systems: May require Schedule 80 or reinforced aluminum pipe.
Why Choose Aluminum Pipe?
Aluminum pipe is known for being:
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Lightweight yet strong
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Corrosion-resistant
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Easy to fabricate
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Long-lasting with minimal maintenance
When combined with the correct wall thickness and pressure rating, aluminum pipes deliver excellent performance across a wide range of industries — from transportation to agriculture.
sasaaluminum supplies precision-engineered aluminum pipes tailored to your diameter, wall thickness, and pressure specifications. Our extensive inventory and technical expertise ensure you get exactly what your system demands.
Conclusion
Wall thickness and pressure rating are more than just numbers — they are the foundation of a safe, efficient, and long-lasting piping system. By carefully selecting the right aluminum pipe with appropriate specifications, you can ensure the success of your project without overspending on materials.
Whether you need lightweight tubing for construction or heavy-duty pipes for industrial pressure systems, sasaaluminum has the solution. Contact us today to get expert advice and quality aluminum piping built to perform.
Post time: Jun-27-2025