Project Background
Expressway Spares is a trusted supplier of mining and earthmoving equipment parts, servicing customers across WA and beyond. With a growing operation and increased workshop demand, the business recently constructed a new facility in Forrestfield, including a dedicated sandblasting shed and a multi-bay service workshop.
To support both spaces, Expressway Spares needed a reliable, high-capacity compressed air system that could handle continuous use across multiple workstations, all while being future-proofed for expansion.
Air & Power was brought in to deliver a complete solution from ground-up pipework to commissioning of the equipment.
The Problem
The compressed air requirements were split between two zones:
- A sandblasting area, requiring high airflow and clean, dry air for consistent abrasive blasting
- A main workshop, servicing a range of mining equipment components using air-powered tools
The layout involved a long-distance run between the compressor installation point and the main workspace, with distribution lines passing from one building to another. Reliability, pressure consistency, and clean execution were critical.
Additionally, underground piping was required across part of the site. The system needed to be corrosion-resistant and built to eliminate future leak risks or maintenance problems.
The Solution
Air & Power delivered a two-zone system tailored to each part of the site, using Pilot Air equipment throughout.
Zone 1 – Sandblasting Shed
- Compressor: Pilot Air PAC75
- Dryer: TFD 220T
- Receiver: 2150L vertical air receiver
Zone 2 – Workshop Area
- Compressor: Pilot Air PAC22
- Dryer: TFD45
- Receiver: 2150L vertical air receiver
Each area had its own dedicated system to reduce load sharing and ensure independent performance across operations.
To support delivery across the workshop, multiple manifolds (two to four per bay) were installed for easy tool access and even pressure distribution.
Underground Piping
One of the standout elements of the install was the underground air line work:
- 63mm poly piping was selected instead of aluminium, to prevent corrosion over time
- Poly-welded runs were used throughout, with no joints underground, eliminating the risk of buried leaks or weak points
- Three separate sets of poly lines were installed, despite only needing two, allowing for future expansion without re-excavating the site
Custom Fabrication
Due to the height of the air receivers, a custom handle was fabricated for the receiver ball valves. This allows for safe, ground-level isolation of each vessel during service or shutdown.
The Results
The completed system gave Expressway Spares:
- High-capacity compressed air delivery, matched to application-specific needs
- Redundancy and independence between workshop and blasting operations
- Zero leaks and a clean, professional finish
- Future-ready infrastructure, thanks to added poly lines and thoughtful planning
Every air outlet tested to spec, and the system was commissioned on schedule. According to the client, the install was “super neat” and worked exactly as required, no leaks, no rework, and no surprises.
Why It Worked
This project succeeded because it combined three Air & Power strengths:
- Technician-led planning, not just equipment sales
- Fit-for-purpose pipework and materials, designed for long-term use
- Clean installation with future expansion in mind
Rather than oversimplifying or overcomplicating the job, we built two independent systems sized correctly to their tasks, using quality components and careful distribution layout.
The underground work sets this job apart. Welded poly lines, installed with forward thinking, mean that this system is already ready for any future additions to the site, without the need to dig up what’s already done right.
Lessons for Other Industrial Operators
If your business is expanding or building new facilities, your compressed air system needs to be scalable, serviceable, and smart from day one.
Choosing the right compressor is only part of the equation. Line materials, access, zone control, and future growth all impact the system’s performance and long-term value.
Air & Power continues to support Expressway Spares with system servicing, monitoring, and advice, ensuring their investment remains efficient and reliable as their operations grow.
