Air hoses are a vital part of many industrial, commercial, and domestic systems. Whether you're powering pneumatic tools, operating air compressors, or running machinery in manufacturing plants, a reliable air hose ensures consistent airflow and optimal performance. At Integraflex, we supply a wide range of industrial air hoses designed to handle various applications – from light-duty DIY projects to high-pressure, heavy-duty industrial setups.
In this comprehensive guide, we’ll walk you through how to choose the right air hose for your application, whether you’re running a small compressor or powering professional equipment in an industrial setting. We’ll cover air hose materials, fittings, sizes, and commonly asked questions, helping you make an informed purchase.
Why Choosing the Right Air Hose Matters
If you use air tools or an air compressor in your workshop, garage, or factory, one piece of equipment is often overlooked, the air hose. Choosing the wrong hose can lead to poor performance, wasted energy, or even safety issues.
Your compressed air hose acts as the vital link between your compressor and your tools. If it’s too narrow, too long, or made from the wrong material, it can reduce air flow, waste compressor power, and even damage your tools.
Choosing the correct hose ensures:
- Maximum efficiency
- Proper air pressure delivery
- Tool longevity
- Workplace safety
- Energy savings
In short, take time to choose the right air hose, and your entire setup will perform better.
What to Consider When Choosing an Air Hose
When shopping for an air hose, there are five key factors to evaluate:
- Hose Size (Diameter & Length)
- Air Hose Material
- Air Compressor Fittings Types
- Working Pressure & Temperature
- Application/Environment
How to Choose the Right Size Air Hose
Diameter and length are critical for performance.
Diameter
Most air hoses come in standard internal diameters:
- 6-8mm bore size: Air hose bore sizes between 6mm and 8mm are suitable for a variety of light-duty to medium duty applications. They are mainly used with handheld air tools, including: inflating tyres, spray guns and other small workshop tasks where air pressure and flow are relatively low.
- 10mm bore size: 10mm bore size is the most common size for industrial air tools needing higher flow. Commonly used in applications that require a moderate to high airflow, to power a range of air tools such as: impact wrenches, grinders and sanders.
- 13mm bore size: Often used for large volume tools or high-powered compressors, where a high air flow rate is required. Often used in automotive applications, such as brake and suspension systems, as well as in workshops and construction applications.
At Integraflex we offer a wide range of bore sizes, up to 127mm, to fit a accommodate a wide range of air hose applications. The higher the bore size, generally the more demanding the application. Our air hoses featuring an internal diameter of 127mm are suitable for ventilation systems, extractor fans, tumble dryers and hot air applications.
There are a few main considerations when choosing the right size air hose:
- Check your air tool’s flow requirement (CFM rating)
- Match the hose diameter to minimise pressure drop
- For longer hoses (10m or more), increase hose size to maintain flow
At Integraflex, we stock a wide range of air hoses in multiple diameters and lengths, explore our air hose collection.
Length
- Short hoses (up to 5m) are ideal for stationary compressors
- Medium hoses (5 to 10m) suit general workshop setups
- Long hoses (10 to 30m) provide flexibility but increase pressure loss, so choose a larger diameter if needed
Air Hose Material
The air hose material you choose affects flexibility, durability, weight, and temperature range.
Here’s a comparison of common air hose materials:
|
Material |
Pros |
Cons |
| PVC (Polyvinyl Chloride) | Affordable, lightweight and good abrasion resistance | Can become stiff in cold weather |
| Hybrid (rubber/PVC/polyurethane/blends) | Combines flexibility and lightness, good for general use | More expensive than PVC |
| TPE (Thermoplastic Elastomer) | Very flexible, excellent durability, performs well in cold | More expensive than PVC |
| PU (Polyurethane) | Extremely lightweight, highly flexible, abrasion resistant | Limited temperature range on lower-cost grades |
How to choose?
- For DIY or light trade use indoors: PVC hoses are often ideal
- For colder environments or rugged use: rubber hoses perform best
- For portable setups: hybrid or PU hoses provide the right balance of flexibility and weight
Air Compressor Fitting Types
The type of air compressor fittings at the ends of your hose determines how it connects to your compressor and tools.
Common UK fitting types include:
- Jubilee clips
- Jubilee clips, or hose clips are often used in air hose applications in order to secure the hose. Featuring a worm drive mechanism that provides a secure and adjustable grip on the hose to prevent leaks and ensure a tight connection. Often manufactured from stainless steel, jubilee clips are highly durable and resistant to corrosion.
- Quick release couplings
- Often used in air hose applications, quick release fittings provide an easy connection and disconnection in a compressed air system. They offer versatility due to various configurations and sizes as well as providing a leak free connection.
- Leverlock couplings
- Where speed and reliability are important, leverlock couplings are useful for connecting or disconnecting hoses. The lever-operated locking mechanism offers a quick and secure connection. Leverlock couplings can also be used with various materials, making them extremely versatile.
At Integraflex, we supply air hose assemblies, with fittings already installed, or plain ended hoses, ready for use with fittings of your choice.
Working Pressure and Temperature
It is essential to ensure that any air hose you purchase is rated to handle the maximum working pressure of your air compressor. If the hose is not rated for the correct pressure, it can fail under load, posing a serious safety risk as well as compromising the performance of your tools.
For light-duty air tools, such as airbrushes, nail guns, and smaller inflators, a hose with a working pressure rating of up to 150 PSI is typically sufficient. However, for professional workshops or industrial environments, where larger tools like impact wrenches, sanders, or spray equipment are used, an air hose should be rated up to at least 300 PSI to ensure safe and consistent operation.
In addition to pressure, it is important to consider the temperature range the hose will need to withstand. Certain materials behave differently in various climates. For example, PVC air hoses offer good abrasion resistance and low cost but can become stiff and brittle in very cold conditions. Standard PVC hoses typically perform well between -10°C and +60°C, but may not be ideal for outdoor winter use or unheated workshops.
Rubber air hoses are known for excellent flexibility and durability across a wider temperature range. These hoses remain pliable even in sub-zero environments and typically perform well between -30°C and +80°C, making them a preferred choice for cold-weather applications or demanding industrial settings.
Polyurethane (PU) and hybrid hoses offer a good balance of light weight and flexibility. Their temperature ranges can vary depending on the exact blend used in manufacture, so it is always recommended to check the product specifications carefully to ensure suitability for your intended environment.
Taking both pressure rating and temperature performance into account is key when selecting the best air hose for your compressor and application.
Application and Environment
When selecting the right air hose, it’s important to think carefully about where and how the hose will be used, as this will influence the best material and construction for the job.
For example, if you’re working primarily in an indoor workshop, particularly a controlled environment where temperature fluctuations are minimal, a PVC hose or hybrid hose is usually a great choice. These hoses are lightweight, cost-effective, and flexible enough for bench work or light tool use. Hybrid hoses, which blend PVC, rubber, and polyurethane, provide an extra edge in flexibility and durability, making them well-suited to everyday workshop tasks.
If you need a hose for outdoor work or mobile applications, such as on a construction site, in an exposed garage, or when operating portable compressors, flexibility in cold weather becomes a key consideration. In these situations, a rubber hose is often the best option. Rubber hoses remain supple even in freezing temperatures and are highly resistant to wear and tear. Alternatively, polyurethane (PU) hoses are also excellent for outdoor use, offering lightweight handling with good cold-weather performance and resistance to kinking.
For the most demanding environments, such as heavy industrial applications or construction work, you should select a premium-grade rubber hose or a high-quality hybrid hose. These options offer exceptional durability, abrasion resistance, and flexibility, allowing them to stand up to rough handling, dragging over surfaces, and continuous heavy use. They also cope well with temperature extremes and can deliver long service life under challenging working conditions.
By carefully matching your hose to your specific application and environment, you’ll get better performance, improved safety, and greater value from your air system.
Frequently Asked Questions
How do I choose air compressor hose size?
Start by checking the CFM (cubic feet per minute) requirement of your most air-hungry tool.
- For 1 to 5 CFM: 6mm or 8mm hose is suitable
- For 5 to 15 CFM: a 10mm hose is recommended
- For more than 15 CFM: use a 13mm hose or larger
Also, factor in hose length, the longer the hose, the more pressure drop occurs, so larger diameters may be needed for long runs.
What is the best air hose material for cold weather?
Rubber is the best choice for cold environments because it remains flexible even in sub-zero temperatures. PVC tends to stiffen in the cold. Hybrid and PU hoses offer good cold-weather performance, check the temperature ratings when selecting your hose.
How long should my air hose be?
Use the shortest hose length that will still reach your work area. The longer the hose, the more pressure drop you will experience. For most workshops or garages, a 5m to 10m hose is sufficient. Larger industrial setups or mobile operations may require hoses from 15m to 30m.
Can I use an air hose for water?
Some air hoses, particularly those made from rubber, can handle water, but always check the manufacturer’s recommendations. For regular water use, we recommend selecting a hose specifically rated for water applications, view our water hose collection.
Professionally Manufactured Air Hose Assemblies
Integraflex excel in manufacturing hose assemblies. Whether clamped , crimped or swaged, our expert assembly technicians will ensure your air hose is manufactured to standard operating procedures that ensure lengths are accurate and consistent and most importantly end fittings are secured safely and compliant with sound engineering practice, making the whole assembly safe and fit for purpose.
To guarantee safety and traceability, Integraflex will hydrostatically test your air hose assembly to 1.5 x the maximum working pressure for an agreed amount of time, typically 3 minutes. The pressurized assembly is checked for any leaks or drips, bulges and movement of end fittings which could be a pre-cursor to a catastrophic failure.
Once the assembly has passed test, it is fitting with a permanent and unique hose identification number which will denote date of test, test pressure and date of next test. This information is critical for auditing hose management programmes and also gives users peace of mind that the hose has been professionally constructed and tested.
Integraflex will record your hose in a dedicated asset register which allows users to download and print pressure test certificates for any audit purposes.
Speak to the team at Integraflex about your air hose assembly requirements.
Conclusion
To choose the right air hose, always consider:
- Size (diameter and length)
- Air hose material
- Air compressor fittings types
- Working pressure and temperature
- Application and environment
At Integraflex, we supply a wide selection of air hoses, available in PVC, rubber, hybrid, and PU materials, with different fittings and lengths to suit every application. If you're looking for a durable, safe and efficient solution for transferring compressed air, you've come to the right place. Our collection of air compressor hoses and industrial air hoses is carefully curated to deliver performance, flexibility and longevity in every job.
If you are still unsure what is best for your compressor or tools, our team is here to help, simply contact us and we will provide expert advice.