How much does a compressed air leak cost per year?

At the preliminary May 2026 U.S. industrial average of 8.71 cents per kilowatt-hour, a continuously supplied 1/16-inch equivalent opening at 100 psig models to $529–$841 per year, a 1/8-inch opening to $2,113–$3,360, and a 1/4-inch opening to $8,453–$13,442. The ranges apply DOE’s 0.61 sharp-edged and 0.97 well-rounded factors at 18 kW per 100 CFM and 8,760 hours; they are gross modeled costs, not measured repair savings.

What does one CFM of compressed air cost?

Supplying one CFM continuously for 8,760 hours uses 1,576.8 kWh at the page’s 18 kW per 100 CFM reference assumption. That equals $137.34 per year at the May 2026 U.S. industrial average and $143.17 at Indiana’s May 2026 average; replace both the specific-power and electricity inputs when facility data are available.

Why does the calculator give a range instead of one number?

DOE’s table instructs readers to multiply its uncorrected flow by 0.61 for a sharp opening and 0.97 for a well-rounded opening. The well-rounded result is about 59% higher than the sharp-edged result, so an unknown opening shape is reported as a range rather than silently assigned one factor.

Is a 1/8-inch leak a measurement?

No. It is an equivalent-orifice input: the model asks how much air DOE’s table assigns to a round opening of that nominal diameter at a stated pressure. Threads, seals, gaskets, cracks, and other real leak paths need not match that geometry, which is why measured flow is a stronger input than equivalent hole size.

Will I actually save the amount the calculator shows?

Not necessarily. The headline output is the gross electricity cost required to produce the escaping air; actual avoidable electricity depends on the compressor system’s response after demand falls. NREL’s simplified method applies a compressor control adjustment factor, and actual realized reduction requires comparable system-power measurement or a more detailed analysis.

Should I use the state average or a facility electricity rate?

Use a facility-approved electricity input for a facility decision. EIA’s state values are preliminary average revenue per kilowatt-hour across each state’s industrial sector, useful for a consistent geographic comparison but not a tariff or a plant-specific marginal rate; demand and fixed charges require separate treatment.

What kW per 100 CFM value should I enter?

Use verified compressor performance or metered system data where available. The page’s 18 kW per 100 CFM default is the reference assumption in DOE’s worked example, not an industrywide measurement, and every calculated energy and dollar result changes in direct proportion to this input.

How much does system pressure change the cost?

For the 1/8-inch DOE equivalent opening, the May 2026 U.S. sharp-edged gross estimate is $1,560 at 70 psig, $2,113 at 100 psig, and $2,568 at 125 psig. The 125-psig result is about 65% higher than the 70-psig result because DOE’s published flow rises from 18.62 to 30.65 CFM before the same shape and energy factors are applied.

What is a reasonable compressed-air leakage percentage for a plant?

The April 1998 Compressed Air Challenge/DOE fact sheet says a typical poorly maintained plant will likely have leakage equal to 20% of compressed-air production capacity and that proactive programs can reduce leakage below 10%. DOE’s August 2004 tip sheet says leaks often waste 20%–30% of compressor output and identifies 5%–10% of total system flow as a typical cost-effective reduction target.

Why do published leak-cost figures differ?

The reviewed sources publish different units, operating schedules, electricity rates, specific-power assumptions, and levels of methodological detail, so they cannot all be collapsed into one defensible apples-to-apples range. Table 10 records what each source actually discloses, while this page fixes the scenario and exposes every input.

Where do the $523, $2,095, and $8,382 figures come from?

They appear in Compressed Air Systems Fact Sheet #7 from April 1998, which states a five-cent electricity rate, constant operation, and an efficient compressor. A reconstruction using the later December 2000 DOE flow table, 8,760 hours, 0.184 kW per CFM, and no shape factor reproduces the three rounded figures within one dollar of total absolute error, but the 1998 fact sheet does not disclose enough inputs to prove that this was its original calculation.

Can this calculator use pressure-decay data?

Yes, when qualified facility personnel have already gathered the system volume, pressure change, elapsed time, and local atmospheric pressure. The calculator applies NREL’s equation, Leak Flow SCFM = [(V × ΔP) ÷ (time × atmospheric pressure)] × 1.25; this page does not provide a procedure for isolating or manipulating a pressurized system.

Does the state table include demand charges or local utility tariffs?

No. The state table applies EIA’s preliminary May 2026 industrial average revenue per kilowatt-hour to one standardized leak scenario. It does not model demand charges, time-of-use periods, ratchets, taxes, fixed charges, power-factor provisions, local utility schedules, or negotiated facility terms.

Fort Wayne Air Compressor Repair Research

Compressed Air Leak Cost Calculator: 2026 State Data

Last verified: July 29, 2026 · Electricity data: May 2026, preliminary · EIA release: July 23, 2026 · Dataset version: 2026-05-v2

The strongest result from this Compressed Air Leak Cost Calculator is that a continuously supplied 1/8-inch equivalent opening at 100 psig models to $2,113–$3,360 per year at the preliminary May 2026 U.S. industrial average, using DOE flow data. The range is reproducible rather than a point estimate, and every line below names its year, qualifier, and source so the figure remains intelligible when read outside the page.

What are the key compressed air leak cost statistics?

A continuously supplied 1/8-inch equivalent compressed-air opening at 100 psig has a modeled U.S. gross electricity cost of $2,113–$3,360 per year at the preliminary May 2026 industrial average of 8.71¢/kWh, 18 kW per 100 CFM, and 8,760 annual hours. (U.S. DOE Compressed Air Tip Sheet #3 and EIA Table 5.6.A; calculated and verified July 29, 2026.)
The same standardized 1/8-inch leak models to $1,079–$1,717 per year in New Mexico and $10,164–$16,162 in Hawaii, a 9.42× difference driven by the May 2026 state industrial electricity averages alone. (EIA Table 5.6.A and DOE leak-flow data; calculated July 29, 2026.)
Supplying one CFM continuously for one year uses 1,576.8 kWh at the 18 kW per 100 CFM reference assumption—$137.34 at the May 2026 U.S. industrial average and $143.17 at Indiana’s. (DOE reference specific power and EIA Table 5.6.A; calculated July 29, 2026.)
DOE assigns 25.22 CFM to a 1/8-inch equivalent opening at 100 psig before shape correction—15.38 CFM with its 0.61 sharp-edged factor and 24.46 CFM with its 0.97 well-rounded factor. (U.S. DOE, Compressed Air Tip Sheet #3, revised August 2004.)
DOE’s 0.61 and 0.97 opening-shape factors make the well-rounded result about 59% higher than the sharp-edged result before electricity price, runtime, specific power, or compressor control is considered. (DOE Tip Sheet #3; ratio calculated July 29, 2026.)
Compressed Air Systems Fact Sheet #7 published annual figures of $523, $2,095, and $8,382 for 1/16-inch, 1/8-inch, and 1/4-inch leaks in April 1998, using $0.05/kWh, “constant operation,” and an “efficient compressor.” (Compressed Air Challenge / U.S. DOE, April 1998.)
One transparent reconstruction using the later December 2000 DOE flow table, 8,760 hours, 0.184 kW/CFM, and no shape factor returns $524, $2,095, and $8,382—one dollar of total absolute error after rounding—but the 1998 fact sheet does not disclose enough inputs to prove that this was its original calculation. (Reconstruction by Fort Wayne Air Compressor Repair Research, July 29, 2026.)
DOE’s two official Tip Sheet #3 editions publish different flow matrices: at 100 psig, the August 2004 values are 2.44%–3.13% lower than the December 2000 values, including 6.31 instead of 6.5 CFM for a 1/16-inch opening. (DOE/GO-102000-0988 and DOE/GO-102004-1964; compared July 29, 2026.)
The August 2004 DOE worked example prints three revised line items totaling $55,378 but retains a printed total of $57,069, a $1,691 inconsistency; the exact formula recalculates the three lines to $55,377.63. (DOE Tip Sheet #3; recalculated July 29, 2026.)
NREL warns that applying an average measured kW/CFM value “frequently results in overestimated savings,” and its 2021 simplified method assigns a 0.30 control adjustment factor to inlet modulation—modeled avoidable electricity equal to 30% of gross for that control case. (NREL, Chapter 22: Compressed Air Evaluation Protocol, January 2021.)
The April 1998 fact sheet says a typical poorly maintained plant will likely leak 20% of compressed-air production and proactive programs can reduce leakage below 10%; DOE’s August 2004 tip sheet says leaks often waste 20%–30% and identifies 5%–10% of total system flow as a typical cost-effective reduction target. (Compressed Air Challenge / DOE, 1998; U.S. DOE, 2004.)
The preliminary U.S. industrial electricity average was 8.71¢/kWh in May 2026, 5.1% above May 2025’s 8.29¢/kWh. (U.S. EIA, Electric Power Monthly and Electricity Monthly Update, released July 23, 2026.)
Indiana’s preliminary May 2026 industrial average was 9.08¢/kWh, 4.25% above the U.S. average of 8.71¢; BLS separately reported a 2022 Indiana manufacturing location quotient of 2.04, 541,112 manufacturing jobs, and a 19.8% manufacturing share of employment. (EIA, May 2026; BLS, 2022 data.)
DOE states that leak flow is proportional to the square of equivalent orifice diameter, so doubling the modeled diameter produces about four times the airflow when pressure and the other model inputs stay fixed. (U.S. DOE, Compressed Air Tip Sheet #3.)

A single 1/8-inch equivalent opening, supplied around the clock at 100 psig, models to $2,113–$3,360 per year in gross electricity cost at the preliminary May 2026 U.S. industrial average. The range is not decorative: DOE publishes separate sharp-edged and well-rounded corrections, and the compressor control system determines how much of the gross cost can become avoidable electricity after a repair.

The page and its 52-record dataset join DOE’s flow table, NREL’s control-response method, and EIA’s current state prices without presenting a model as a measurement. The home-state layer uses Indiana’s 9.08¢/kWh preliminary May 2026 average and does not relabel it as a Fort Wayne or Allen County tariff.

How does the Compressed Air Leak Cost Calculator work?

Enter the strongest airflow evidence available, then enter specific power, annual pressurized hours, and an electricity price. The calculator returns gross energy and cost first; it shows a control-adjusted estimate only when a numeric NREL factor is selected and all three simplified-method eligibility statements are affirmed.

Equivalent-orifice mode is limited to DOE’s published 70–125 psig range and labels any between-row result as a site-produced linear interpolation. The official reference inputs and benchmark outputs remain present in static HTML below the interactive component.

1. Choose the airflow input

Calculation method

Equivalent opening

System pressure, psig

Opening shape

2. Enter the energy basis

Compressor specific power, kW per 100 CFM18 kW/100 CFM is the reference assumption in DOE’s worked example. Replace it with verified facility data where available.

Annual pressurized hours

Electricity-price preset

Electricity price, cents per kWhState presets are preliminary May 2026 EIA industrial averages, not facility tariffs.

3. Optional control-adjusted estimate

Trim-compressor control

The selected compressor remains the trim machine over the affected load range.Its power response is predictable over that range.The leak reduction will not change which compressors operate.

Reference result: A continuously supplied 1/8-inch equivalent opening at 100 psig models to 15.38–24.46 CFM and $2,113–$3,360 per year at the May 2026 U.S. industrial average, 18 kW/100 CFM, and 8,760 hours.

Estimated leak flow: 15.38–24.46 CFM
Power supporting the leak: 2.77–4.40 kW
Average energy per calendar day: 66.46–105.68 kWh
Average energy per calendar month: 2,021.48–3,214.49 kWh
Energy per year: 24,257.81–38,573.89 kWh
Average cost per calendar day: $5.79–$9.20
Average cost per calendar month: $176.07–$279.98
Gross annual cost: $2,112.85–$3,359.79
Three-year gross cost: $6,338.56–$10,079.36
Five-year gross cost: $10,564.27–$16,798.93
Control-adjusted annual estimate: Not shown until a control factor and all three eligibility statements are selected.
Confidence classification: Equivalent-orifice model — moderate; range shown because geometry is unknown.
Formula and source status: DOE 2004 table at 100 psig × 0.61–0.97 × 0.18 kW/CFM × 8,760 h × $0.0871/kWh. EIA price: preliminary May 2026 U.S. average.

What does a compressed air leak cost per year?

At the preliminary May 2026 U.S. industrial electricity average of 8.71¢/kWh, a continuously supplied 1/8-inch equivalent opening at 100 psig models to $2,113–$3,360 per year, and a 1/4-inch opening models to $8,453–$13,442. The width of each range is DOE’s own sharp-edged versus well-rounded correction, not an editorial confidence interval.

The result moves in direct proportion to electricity price, annual pressurized hours, and compressor specific power. Realizable electricity reduction is a separate question addressed in the control section.

Table 1 — Annual gross electricity cost of one continuously supplied leak at 100 psig
Equivalent opening	DOE flow, cfm	Sharp-edged, cfm	Well-rounded, cfm	U.S. annual cost	Indiana annual cost
1/64 in	0.40	0.24	0.39	$34–$53	$35–$56
1/32 in	1.55	0.95	1.50	$130–$206	$135–$215
1/16 in	6.31	3.85	6.12	$529–$841	$551–$876
1/8 in	25.22	15.38	24.46	$2,113–$3,360	$2,203–$3,503
1/4 in	100.90	61.55	97.87	$8,453–$13,442	$8,812–$14,013
3/8 in	227.00	138.47	220.19	$19,017–$30,241	$19,825–$31,525

Source: U.S. Department of Energy, Minimize Compressed Air Leaks, Compressed Air Tip Sheet #3, revised August 2004, for flow, 0.61/0.97 shape factors, and the 18 kW/100 CFM reference assumption; U.S. Energy Information Administration Table 5.6.A for preliminary May 2026 U.S. and Indiana industrial averages. Assumes 8,760 annual hours. Calculated by Fort Wayne Air Compressor Repair Research and verified July 29, 2026.

Why can a leak run 8,760 hours instead of one shift?

A leak flows whenever the line behind it remains pressurized, which need not equal production time. Use actual annual pressurized hours; the standardized tables use 8,760 solely to make jurisdictions and leak sizes comparable.

Table 2 — Operating-hour scaling factors for the 8,760-hour reference tables
Operating pattern	Annual hours	Multiply 8,760-hour table by
One shift, 250 days	2,000	0.228
Two shifts, 250 days	4,000	0.457
Three shifts, 250 days	6,000	0.685
Continuously pressurized	8,760	1.000

Source: Calculated as annual hours ÷ 8,760 by Fort Wayne Air Compressor Repair Research, July 29, 2026. The labels are reference schedules, not claims about any facility.

What does “1/8-inch leak” mean in this model?

It does not mean someone physically measured a round hole. DOE’s table is an equivalent-orifice model: it assigns airflow to a nominal round opening at a stated pressure, while actual leak paths can occur at threads, seals, gaskets, valves, fittings, hoses, tubes, cracks, and other geometries. Equivalent hole size is therefore an airflow-model input, not a direct measurement. That is why the calculator places measured flow above pressure decay, equivalent orifice, and plant-percentage screening.

How much air escapes at a given hole size and pressure?

DOE publishes uncorrected leak flow for six equivalent opening sizes at 70, 80, 90, 100, and 125 psig. At 100 psig the matrix runs from 0.40 CFM for 1/64 inch to 227 CFM for 3/8 inch before the 0.61 or 0.97 opening-shape factor is applied.

For the 1/8-inch row, moving from 90 to 100 psig raises the published uncorrected flow from 23.10 to 25.22 CFM, an increase of about 9.2%. The calculator interpolates only between official pressure rows and does not extrapolate beyond the published range.

Table 3 — DOE compressed-air leakage rates in CFM by supply pressure and equivalent orifice size, before shape correction
Pressure, psig	1/64 in	1/32 in	1/16 in	1/8 in	1/4 in	3/8 in
70	0.29	1.16	4.66	18.62	74.4	167.8
80	0.32	1.26	5.24	20.76	83.1	187.2
90	0.36	1.46	5.72	23.10	92.0	206.6
100	0.40	1.55	6.31	25.22	100.9	227.0
125	0.48	1.94	7.66	30.65	122.2	275.5

Source: U.S. Department of Energy, Minimize Compressed Air Leaks, Compressed Air Tip Sheet #3, DOE/GO-102004-1964, revised August 2004. DOE instructs readers to multiply the table by 0.97 for well-rounded openings and 0.61 for sharp ones. Transcribed and checked against the official PDF July 29, 2026.

How much does the DOE shape correction change the result?

The ratio between DOE’s well-rounded and sharp-edged factors is 0.97 ÷ 0.61 = 1.59. Several reviewed calculators do not offer both DOE shape cases, so their point estimates cannot be assumed to represent the same geometry.

Table 4 — Annual gross cost of one 1/8-inch equivalent opening at each DOE pressure, May 2026 U.S. industrial average
Pressure, psig	Sharp-edged annual cost	Well-rounded annual cost
70	$1,560	$2,481
80	$1,739	$2,766
90	$1,935	$3,077
100	$2,113	$3,360
125	$2,568	$4,083

Source: DOE Tip Sheet #3 flow values and shape factors, 18 kW/100 CFM, 8,760 annual hours, and EIA’s preliminary May 2026 U.S. industrial average of 8.71¢/kWh. Calculated and verified July 29, 2026.

The 125-psig result is about 65% higher than the 70-psig result because the same energy and price inputs are applied to DOE flows of 30.65 and 18.62 CFM.

What does a compressed air leak cost in each state?

The standardized 1/8-inch leak models to $1,079–$1,717 per year at New Mexico’s preliminary May 2026 industrial average and $10,164–$16,162 at Hawaii’s, a 9.42× price-driven spread. Twenty-seven states and the District of Columbia were above the 8.71¢/kWh U.S. benchmark in EIA’s May 2026 table.

The reviewed calculator and reference pages did not publish this joined 52-record table with both DOE shape cases and a current state-rate layer. The contribution here is the transparent assembly and calculation; DOE remains the source of flow and EIA remains the source of electricity prices.

Table 5 — Annual gross electricity cost of one 1/8-inch equivalent compressed-air opening by state and D.C.
Jurisdiction	May 2026 industrial ¢/kWh	Sharp-edged	Well-rounded
Alabama	7.89	$1,914	$3,043
Alaska	31.36	$7,607	$12,097
Arizona	7.54	$1,829	$2,908
Arkansas	6.69	$1,623	$2,581
California	20.20	$4,900	$7,792
Colorado	9.47	$2,297	$3,653
Connecticut	16.76	$4,066	$6,465
Delaware	10.69	$2,593	$4,124
District of Columbia	14.60	$3,542	$5,632
Florida	8.99	$2,181	$3,468
Georgia	7.04	$1,708	$2,716
Hawaii	41.90	$10,164	$16,162
Idaho	7.21	$1,749	$2,781
Illinois	10.20	$2,474	$3,935
Indiana	9.08	$2,203	$3,503
Iowa	6.62	$1,606	$2,554
Kansas	8.12	$1,970	$3,132
Kentucky	7.13	$1,730	$2,750
Louisiana	6.88	$1,669	$2,654
Maine	14.48	$3,513	$5,585
Maryland	11.22	$2,722	$4,328
Massachusetts	19.94	$4,837	$7,692
Michigan	9.43	$2,288	$3,638
Minnesota	9.80	$2,377	$3,780
Mississippi	7.50	$1,819	$2,893
Missouri	7.89	$1,914	$3,043
Montana	6.97	$1,691	$2,689
Nebraska	9.25	$2,244	$3,568
Nevada	7.61	$1,846	$2,935
New Hampshire	17.04	$4,134	$6,573
New Jersey	14.57	$3,534	$5,620
New Mexico	4.45	$1,079	$1,717
New York	9.55	$2,317	$3,684
North Carolina	7.78	$1,887	$3,001
North Dakota	8.27	$2,006	$3,190
Ohio	9.87	$2,394	$3,807
Oklahoma	6.17	$1,497	$2,380
Oregon	8.55	$2,074	$3,298
Pennsylvania	10.31	$2,501	$3,977
Rhode Island	22.18	$5,380	$8,556
South Carolina	7.23	$1,754	$2,789
South Dakota	9.78	$2,372	$3,773
Tennessee	6.45	$1,565	$2,488
Texas	6.33	$1,536	$2,442
Utah	8.10	$1,965	$3,124
Vermont	12.59	$3,054	$4,856
Virginia	10.53	$2,554	$4,062
Washington	7.24	$1,756	$2,793
West Virginia	9.48	$2,300	$3,657
Wisconsin	9.00	$2,183	$3,472
Wyoming	9.12	$2,212	$3,518
United States	8.71	$2,113	$3,360

Standardized basis: 100 psig · DOE uncorrected flow 25.22 CFM · 0.61 and 0.97 shape factors · 18 kW/100 CFM · 8,760 hours · preliminary May 2026 EIA industrial average revenue per kWh · no compressor-control adjustment.

Source: U.S. Energy Information Administration, Electric Power Monthly Table 5.6.A, May 2026, released July 23, 2026, for preliminary industrial average electricity prices; DOE Compressed Air Tip Sheet #3, August 2004, for leak flow, shape factors, and reference specific power. Compiled and calculated by Fort Wayne Air Compressor Repair Research; verified July 29, 2026. State values are not facility tariffs, and the dollar figures are modeled gross costs rather than measured savings.

Why is an EIA state average not a facility rate?

EIA defines average revenue per kilowatt-hour as total monthly revenue divided by corresponding monthly sales for a sector and geography. Table 5.6.A is a consistent state comparison, but it does not state a specific customer’s tariff, marginal energy price, demand charges, fixed charges, time-of-use periods, taxes, or negotiated terms.

For facility analysis, replace the preset with an electricity input approved for that facility’s purpose. A blended bill-per-kWh figure and a marginal energy rate answer different accounting questions when non-energy charges are material.

What does the May 2026 data vintage mean?

EIA labels Table 5.6.A preliminary and based on a cutoff model sample from Form EIA-861M. The page carries the data month, release date, and preliminary status in the visible copy and in both downloads rather than presenting a current monthly estimate as final annual census data. The table should be regenerated after each chosen EIA refresh, not merely re-dated. Dataset version 2026-05-v2 (a field-rename update of v1, renaming kW power fields to remove the misleading annual_ prefix) remains tied to May 2026.

Why can repair savings be smaller than the leak’s gross cost?

Everything in Tables 1, 4, 5, and 11 is gross cost: the electricity required to produce the modeled escaping airflow. A compressor consumes less electricity after demand falls only to the extent that the operating system and its controls respond, so gross cost and avoidable electricity must remain separate ledgers.

NREL’s January 2021 protocol warns that applying an average measured kW/CFM value frequently overestimates savings. Its simplified method uses a Compressor Control Adjustment Factor, while its more detailed CFM-bin method evaluates operating bins and system behavior directly.

Table 6 — NREL 2021 compressor control adjustment factors
Compressor type and control method	Adjustment factor
Reciprocating — on/off	1.00
Reciprocating — load/unload	0.74
Oil-free rotary screw — load/unload	0.73
Oil-injected rotary screw — load/unload, 1 gal/cfm storage	0.43
Oil-injected rotary screw — load/unload, 3 gal/cfm storage	0.53
Oil-injected rotary screw — load/unload, 5 gal/cfm storage	0.63
Oil-injected rotary screw — load/unload, 10 gal/cfm storage	0.73
Rotary screw — inlet modulation	0.30
Rotary screw — inlet modulation with unloading	0.30
Rotary screw — variable displacement	0.60
Rotary screw — variable-speed drive	0.97
Centrifugal	Evaluate the actual part-load control range; do not assign one universal factor

Source: National Renewable Energy Laboratory, Chapter 22: Compressed Air Evaluation Protocol, January 2021, Table 5 and centrifugal-control discussion. Checked against the official NREL document and OSTI record July 29, 2026.

When does the simplified control adjustment belong in the result?

The calculator requires three confirmations before multiplying gross cost by a numeric factor: the selected compressor remains the trim machine over the affected range, its power response is predictable there, and the leak reduction will not change which compressors operate. Those gates are a conservative application of NREL’s simplified trim-compressor method, not a substitute for system data.

When the operating sequence is complex, unknown, or centrifugal, the page leaves the gross result visible and does not manufacture one universal avoidable-energy number. NREL describes CFM-bin analysis as the more detailed approach.

What does the adjustment look like in the Indiana reference case?

Gross annual cost × CCAF = modeled control-adjusted annual cost. Indiana’s 1/8-inch sharp-edged reference result of $2,203 becomes about $1,630 at a 0.74 factor and $661 at a 0.30 factor. Both remain models. Actual realized energy reduction requires comparable post-change system-power measurement or an analysis that accounts for the compressor sequence and production conditions.

Where did the standard compressed-air leak cost figures come from?

A recurring set of industry figures—$523, $2,095, and $8,382 per year for 1/16-inch, 1/8-inch, and 1/4-inch leaks—appears in Compressed Air Systems Fact Sheet #7 from April 1998. The fact sheet states $0.05/kWh, constant operation, and an efficient compressor, but it does not print the underlying airflow values or specific power.

That means the missing assumptions can be reconstructed only as candidates, not uniquely recovered as historical fact. The closest tested candidate is preserved below because it is reproducible and informative, with the limitation stated beside it.

Which transparent reconstruction comes closest to the 1998 figures?

The published dollar ratios are consistent with diameter-squared scaling. Using the later December 2000 DOE 100-psig flow row as a candidate basis, the first assumption set below reproduces the three rounded figures with one dollar of total absolute error.

Table 7 — Candidate assumption sets tested against the April 1998 figures
Assumption set	1/16 in	1/8 in	1/4 in	Total absolute error vs. published rounded dollars
8,760 h, 0.184 kW/cfm, no shape factor	$524	$2,095	$8,382	$1
8,000 h, 0.20 kW/cfm, no shape factor	$520	$2,080	$8,320	$80
8,760 h, 0.18 kW/cfm, no shape factor	$512	$2,050	$8,199	$239
8,760 h, 0.20 kW/cfm, no shape factor	$569	$2,278	$9,110	$957
Published in April 1998	$523	$2,095	$8,382	—

Source: Published dollar figures and disclosed $0.05/kWh/constant-operation assumptions from Compressed Air Challenge / U.S. DOE, Compressed Air System Leaks, Fact Sheet #7, April 1998. Candidate airflow values from the later December 2000 DOE Tip Sheet #3. Reconstruction calculated by Fort Wayne Air Compressor Repair Research, July 29, 2026. The closest fit is a reconstruction, not proof of the 1998 calculation.

The candidate set that fits best is 8,760 hours, approximately 0.184 kW/CFM, and no shape factor. Because the 1998 page does not disclose the airflow table or specific power, the page does not convert that fit into a claim about what its authors actually used.

Which opposing assumptions make the old $523 figure look current?

Using an uncorrected DOE table value instead of the 0.61 sharp-edged case raises the modeled airflow by about 63.9%. Using $0.05/kWh instead of the May 2026 U.S. average of $0.0871/kWh lowers the price input by about 42.6%; those assumptions move the result in opposite directions. That helps explain why the 1998 figure of $523 happens to sit near this page’s current $529 U.S. sharp-edged benchmark while representing a different model and price basis. Proximity does not make the assumptions interchangeable.

How did DOE’s official leak-flow table change between 2000 and 2004?

DOE published Compressed Air Tip Sheet #3 in December 2000 and revised it in August 2004. Both official PDFs remain available, and the later revision reduces every cell in the 100-psig row by about 2.4%–3.1%.

Table 8 — DOE Tip Sheet #3 leak-flow change at 100 psig
Equivalent opening	December 2000, cfm	August 2004, cfm	Change
1/64 in	0.41	0.4	−2.44%
1/32 in	1.6	1.55	−3.13%
1/16 in	6.5	6.31	−2.92%
1/8 in	26	25.22	−3.00%
1/4 in	104	100.9	−2.98%
3/8 in	234	227	−2.99%

Source: U.S. DOE, Compressed Air Tip Sheet #3, DOE/GO-102000-0988 (December 2000) and DOE/GO-102004-1964 (revised August 2004). Compared cell by cell and percentage changes calculated July 29, 2026.

This page uses the August 2004 revision for all current reference calculations. The December 2000 row appears only in the document history and the explicitly labeled 1998 reconstruction.

What arithmetic inconsistency remains in the August 2004 DOE worked example?

Both editions use a chemical-plant example with 7,000 hours, $0.05/kWh, 18 kW/100 CFM, and the 0.61 sharp-edged factor. The December 2000 printed line items and total are consistent after rounding, while the August 2004 revision updates the three line items but leaves the old $57,069 total.

Table 9 — Audit of the DOE Tip Sheet #3 worked example
Line item	Dec. 2000 printed	Dec. 2000 recalculated	Aug. 2004 printed	Aug. 2004 recalculated
100 leaks, 1/32 in at 90 psig	$5,765	$5,764.50	$5,611	$5,610.78
50 leaks, 1/16 in at 90 psig	$11,337	$11,336.85	$10,991	$10,990.98
10 leaks, 1/4 in at 100 psig	$39,967	$39,967.20	$38,776	$38,775.87
Sum of printed line items	$57,069	$57,068.55	$55,378	$55,377.63
Total printed in the document	$57,069	—	$57,069	—
Discrepancy	none	—	$1,691 versus the printed line-item sum	$1,691.37 versus the exact recalculation

Source: Printed line items, inputs, and totals from DOE/GO-102000-0988 and DOE/GO-102004-1964. Exact values recalculated from each document’s own formula and inputs by Fort Wayne Air Compressor Repair Research, July 29, 2026.

Against the August 2004 printed line items, $57,069 is $1,691 high. Against the exact August 2004 recalculation, it is $1,691.37 high, or about 3.05%; the discrepancy is visible in the official PDF and reproducible from its printed numbers.

How do published compressed-air leak cost estimates compare?

The reviewed sources do not all price the same opening under the same rate, runtime, specific power, or shape assumption. A forced single range would therefore imply comparability that the source disclosures do not support.

Table 10 records the publisher’s own figure and the assumptions visible with it. “Reproducible” means the published number can be reconstructed from the inputs that source itself states; it is not an assessment of source quality.

Table 10 — Published compressed-air leak figures and their disclosed assumptions
Source	Figure published	Rate stated	Hours stated	Shape factor	Reproducible from disclosed inputs?
Compressed Air Challenge / DOE, Fact Sheet #7, Apr. 1998	$523 for 1/16 in; $2,095 for 1/8 in; $8,382 for 1/4 in	$0.05/kWh	"Constant operation"	Not stated	No; only a non-unique reconstruction is possible
DOE Tip Sheet #3, Dec. 2000	Worked example	$0.05/kWh	7,000	0.61	Yes
DOE Tip Sheet #3, Aug. 2004	Worked example	$0.05/kWh	7,000	0.61	Line items yes; printed total is inconsistent
ifm	About $47 for 1/64 in, $198 for 1/32 in, $800 for 1/16 in, and $12,812 for 1/4 in	Not stated with those figures	Not stated with those figures	Not stated	No
Fluid-Aire Dynamics	About $35 per CFM per shift-year	About $0.08/kWh	Per shift; 24/7 multiplier 4.2	Not stated	Partially
AirCompressors.com calculator	Variable output	$0.12/kWh default	4,000 default	Not offered	Defaults disclosed; source basis not stated on the calculator page
Seattle City Light	About $1,400 per audible leak per year	Not stated	Not stated	Not stated	No
This page	$529–$841 for 1/16 in at the U.S. benchmark	8.71¢/kWh, preliminary May 2026 EIA average	8,760 reference hours	0.61–0.97 range	Yes

Source: Each publisher’s own page or document, retrieved and checked July 29, 2026. The comparison covers the sources listed and does not claim to exhaust every compressed-air calculator or publication online.

What does a compressed-air leak cost in Indiana and northeast Indiana?

Indiana’s preliminary May 2026 industrial average was 9.08¢/kWh, compared with 8.71¢ nationally. At that price, the standardized 1/8-inch, 100-psig reference opening models to $2,203–$3,503 per year in gross electricity cost.

BLS reported that Indiana had the highest 2022 manufacturing employment concentration among states, with a 2.04 location quotient, 541,112 manufacturing jobs, and manufacturing equal to 19.8% of total employment. Within Indiana manufacturing employment, transportation equipment accounted for 25.8%, fabricated metal products 10.4%, food manufacturing 8.1%, and machinery manufacturing 8.0%. Those labor statistics establish manufacturing context; they do not measure compressed-air demand or local electricity tariffs.

Table 11 — Annual gross cost of one continuously supplied leak at 100 psig, Indiana preliminary May 2026 industrial average
Equivalent opening	Sharp-edged	Well-rounded
1/64 in	$35	$56
1/32 in	$135	$215
1/16 in	$551	$876
1/8 in	$2,203	$3,503
1/4 in	$8,812	$14,013
3/8 in	$19,825	$31,525

Source: DOE Tip Sheet #3 flow values and shape factors at 18 kW/100 CFM and 8,760 hours, priced at Indiana’s preliminary May 2026 industrial average of 9.08¢/kWh from EIA Table 5.6.A. Calculated and verified July 29, 2026.

Why is there no Fort Wayne or Allen County electricity-rate preset?

EIA Table 5.6.A publishes state and national values, not a Fort Wayne or Allen County industrial rate. This dataset therefore contains no local rate and does not put a local label on Indiana’s statewide average. For a facility calculation, enter an electricity basis supplied or approved for that facility. Demand, time-of-use, fixed, tax, and other non-energy terms require separate treatment when they matter to the decision.

How can leak flow be estimated without inventing precision?

Four input routes are preserved because facilities do not all start with the same evidence. Measured flow is the strongest calculator input; a pressure-decay estimate describes total system leakage; an equivalent opening models a nominal geometry; and loaded/unloaded timing is a plant-level screening method.

NREL’s leak-down equation is: Leak Flow SCFM = [(system volume ft³ × pressure change psig) ÷ (elapsed time minutes × local atmospheric pressure psia)] × 1.25. The calculator accepts measurements already gathered by qualified facility personnel and does not provide a procedure for performing the test.

Table 12 — Confidence hierarchy for compressed-air leak-flow inputs
Method	What it needs	What the result represents	Calculator classification
Measured flow	Metered or instrument-derived CFM/SCFM	Flow observed under the measurement conditions	Highest available calculator tier
Pressure-decay values	Known system volume, recorded pressure change, elapsed time, local atmospheric pressure	Estimated total system leakage	High when the entered measurements and volume are reliable
Equivalent orifice	Nominal diameter, pressure, and known or ranged opening shape	Modeled flow for a nominal round opening	Moderate; use a range when shape is unknown
Loaded/unloaded screening	Compressor capacity and recorded loaded/unloaded time	Rough total system leakage during the recorded condition	Low; not a single-leak measurement

Source: NREL, Chapter 22: Compressed Air Evaluation Protocol, and Compressed Air Challenge / DOE Fact Sheet #7 for method equations and screening relationships. The ordering and calculator labels are the stated editorial assessment of Fort Wayne Air Compressor Repair Research, verified July 29, 2026.

Safety boundary

Compressed-air systems store energy, and active leaks are pressurized jets. Isolation, lockout, pressure-decay testing, and work near an active leak belong to qualified facility personnel following the site’s procedures; this page supplies calculations, not hazardous-work instructions.

OSHA’s separate cleaning-use rule, 29 CFR 1910.242(b), says compressed air may not be used for cleaning except where reduced to less than 30 psi and then only with effective chip guarding and personal protective equipment. That citation is limited to cleaning use and is not presented as a leak-testing procedure.

How was this calculator and dataset built and verified?

This page joins three official source layers that otherwise have to be reconciled manually: DOE leak-flow values and shape factors, NREL compressed-air evaluation methods, and EIA state industrial electricity prices. The state table is an original derived dataset, but its inputs remain attributable to those agencies and its outputs remain models rather than measurements.

All source retrieval, recalculation, page-table generation, and download generation for version 2026-05-v2 were completed on July 29, 2026. The visible last-verified date reflects that pass rather than a cosmetic re-date.

Leak flow. We retrieved both official editions of DOE’s Compressed Air Tip Sheet #3: DOE/GO-102000-0988 from December 2000 and DOE/GO-102004-1964, revised August 2004. We transcribed both five-by-six flow matrices and compared them cell by cell; the August 2004 revision supplies every current reference calculation.

Shape correction. Both DOE editions state that well-rounded openings use a 0.97 multiplier and sharp openings use 0.61. The page reports both when geometry is unknown and does not substitute an unreported midpoint.

Specific power. The static tables use 18 kW per 100 CFM because DOE uses that value in the worked example printed in both Tip Sheet #3 editions. It is explicitly labeled a reference assumption, not an observed fleet average; the calculator accepts a replacement value.

Operating hours. The standardized dataset uses 8,760 hours so every jurisdiction is compared on the same basis. The model applies only while the line remains pressurized, and Table 2 supplies transparent scaling for other annual-hour inputs.

Electricity prices. We transcribed the industrial May 2026 values for all 50 states, the District of Columbia, and the U.S. total from EIA Electric Power Monthly Table 5.6.A. EIA released the table July 23, 2026, labels the values preliminary estimates based on a cutoff model sample, and identifies Form EIA-861M as the source.

Equivalent-orifice calculator. Exact DOE values are used at 70, 80, 90, 100, and 125 psig. Between those rows the browser component uses piecewise linear interpolation and labels the interpolation in the formula output; it rejects pressure values below 70 or above 125 rather than extrapolating.

Pressure-decay calculator. The page implements NREL’s 2021 leak-down equation from values already recorded by qualified facility personnel. The 1.25 multiplier is retained exactly as published; no isolation, opening, plugging, or system-manipulation instructions are supplied.

Plant-level screening. Loaded/unloaded mode applies the Compressed Air Challenge/DOE screening relationship to entered compressor capacity and recorded timing. It is labeled low confidence and total-system screening, not a measurement of an individual leak.

Control-adjusted output. We transcribed NREL’s 2021 Compressor Control Adjustment Factors from the official protocol. The calculator requires all three conservative eligibility statements before displaying a numeric adjusted estimate and declines to assign one universal factor to a centrifugal compressor.

State dataset construction. One script generated the 52 state/D.C./U.S. records, all six leak sizes, both shape cases, the page’s state table, the CSV, and the JSON. Each download carries the source URLs, data month, release date, verification date, assumptions, and modeled-versus-measured status.

The provenance audit. We recomputed both DOE worked examples from their printed inputs. For the 1998 figures, we tested candidate assumption sets against the published dollars and retained the closest reconstruction while stating that the original document does not disclose enough inputs for unique recovery.

Quality checks. We independently recalculated the Indiana, U.S., New Mexico, and Hawaii 1/8-inch rows; checked every DOE table cell against the source; verified the six Indiana size results against the dataset; parsed the final JSON; checked 52 CSV rows and all required columns; and compared the rendered Markdown table values with the downloadable records.

Verification status. Every consequential external number published here was read against the original issuing document or dataset and every derived number was regenerated from those inputs. No secondary transcription is used as the authority for DOE, NREL, EIA, OSHA, or BLS claims.

What we did not do. We did not measure airflow, compressor power, electricity price, or post-repair savings at any facility. We did not survey plants, estimate a Fort Wayne tariff, or present the state calculations as observed outcomes.

annual gross cost
= DOE uncorrected flow in CFM
× opening-shape factor
× (specific power in kW per 100 CFM ÷ 100)
× annual pressurized hours
× (electricity price in cents per kWh ÷ 100)

What does this compressed-air leak data not show?

The page resolves the arithmetic and provenance questions it can resolve, but it cannot turn a standardized model into a facility measurement. The limitations below define the boundary of every calculator result, static table, and downloaded record.

Equivalent orifice is a model, not a measurement: Real leak paths need not resemble a round opening, and pressure at the leak can differ from a header-gauge reading. The table answers a standardized airflow-model question.
The opening shape may be unknown: DOE’s 0.61 and 0.97 factors create a 1.59× high-to-low span. Where geometry is not known, the range is the published result.
Specific power is an input: The 18 kW/100 CFM basis comes from DOE’s worked example. Actual compressor and system specific power can differ with machine design, pressure, condition, controls, sequencing, and operating point.
Gross cost is not measured savings: Tables 1, 4, 5, and 11 do not apply compressor-control response. Even a control-adjusted calculator output remains a model until system power is compared under appropriate operating conditions.
May 2026 state prices are preliminary averages: EIA’s table is based on a cutoff model sample and reports average revenue per kWh for state industrial sectors. It is not a local utility schedule or a facility-specific price.
Demand and non-energy charges are outside the state model: The dataset does not separately model demand charges, time-of-use periods, ratchets, fixed charges, taxes, power-factor provisions, or negotiated terms. A blended effective bill rate may not equal the marginal value of one avoided kWh.
The DOE pressure range is 70–125 psig: The calculator interpolates between published rows and does not extrapolate outside them. Interpolation is produced by this site, not printed by DOE.
One opening is not a system: The state and size tables price one standardized equivalent opening. Total plant leakage, compressor sequencing, storage, production variability, and pressure profile require system-level evidence.
The 8,760-hour benchmark is conditional: It assumes the line remains pressurized continuously. Use actual pressurized hours rather than production hours when they differ.
No city or county electricity rate is asserted: The source dataset provides state values, so the page publishes no Fort Wayne or Allen County rate. No county manufacturing-establishment count or local compressed-air load estimate is included.
Rounding can hide cents, not method: Page tables round annual dollars to the nearest dollar for scanning. The CSV and JSON retain cents and additional flow and kWh precision.

What is included in the downloadable dataset?

The downloads contain 52 records: all 50 states, the District of Columbia, and the U.S. benchmark. Each record contains the May 2026 industrial average, all six DOE opening sizes at 100 psig, both shape-corrected flows, annual kWh, annual gross costs, source URLs, data status, release date, verification date, and the shared model assumptions.

The CSV is flat for spreadsheet use; the JSON adds structured source, basis, DOE matrix, NREL factor, and formula objects. The files are public, ungated, and versioned to the EIA data month.

Dataset identifier: FWACR-LEAK-2026-05-v2
Dataset version: 2026-05-v2
Data period: May 2026
Verification date: July 29, 2026
Record count: 52

The versioned filenames are immutable. A future data refresh should publish a new month/version rather than overwrite the files identified above.

What are this page’s citation details?

This block provides neutral bibliographic metadata so the page, date, and dataset version remain unambiguous outside the site. The organizational author is Fort Wayne Air Compressor Repair, and version 2026-05-v2 is tied to the May 2026 EIA data used on the page.

Citation details
Publication	Fort Wayne Air Compressor Repair Research
Page title	Compressed Air Leak Cost Calculator: 2026 State Data
URL	https://fortwayneaircompressorrepair.com/research/compressed-air-leak-cost-calculator/
Last updated	July 29, 2026
Dataset version	2026-05-v2
Dataset identifier	FWACR-LEAK-2026-05-v2
Organizational author	Fort Wayne Air Compressor Repair

What else should readers know about compressed-air leak cost?

These answers address the recurring interpretation questions that remain after the calculator and tables. Each answer uses the same DOE, NREL, and EIA basis as the main page and preserves the distinction between modeled gross cost and measured savings.

How much does a compressed air leak cost per year?: At the preliminary May 2026 U.S. industrial average of 8.71 cents per kilowatt-hour, a continuously supplied 1/16-inch equivalent opening at 100 psig models to $529–$841 per year, a 1/8-inch opening to $2,113–$3,360, and a 1/4-inch opening to $8,453–$13,442. The ranges apply DOE’s 0.61 sharp-edged and 0.97 well-rounded factors at 18 kW per 100 CFM and 8,760 hours; they are gross modeled costs, not measured repair savings.
What does one CFM of compressed air cost?: Supplying one CFM continuously for 8,760 hours uses 1,576.8 kWh at the page’s 18 kW per 100 CFM reference assumption. That equals $137.34 per year at the May 2026 U.S. industrial average and $143.17 at Indiana’s May 2026 average; replace both the specific-power and electricity inputs when facility data are available.
Why does the calculator give a range instead of one number?: DOE’s table instructs readers to multiply its uncorrected flow by 0.61 for a sharp opening and 0.97 for a well-rounded opening. The well-rounded result is about 59% higher than the sharp-edged result, so an unknown opening shape is reported as a range rather than silently assigned one factor.
Is a 1/8-inch leak a measurement?: No. It is an equivalent-orifice input: the model asks how much air DOE’s table assigns to a round opening of that nominal diameter at a stated pressure. Threads, seals, gaskets, cracks, and other real leak paths need not match that geometry, which is why measured flow is a stronger input than equivalent hole size.
Will I actually save the amount the calculator shows?: Not necessarily. The headline output is the gross electricity cost required to produce the escaping air; actual avoidable electricity depends on the compressor system’s response after demand falls. NREL’s simplified method applies a compressor control adjustment factor, and actual realized reduction requires comparable system-power measurement or a more detailed analysis.
Should I use the state average or a facility electricity rate?: Use a facility-approved electricity input for a facility decision. EIA’s state values are preliminary average revenue per kilowatt-hour across each state’s industrial sector, useful for a consistent geographic comparison but not a tariff or a plant-specific marginal rate; demand and fixed charges require separate treatment.
What kW per 100 CFM value should I enter?: Use verified compressor performance or metered system data where available. The page’s 18 kW per 100 CFM default is the reference assumption in DOE’s worked example, not an industrywide measurement, and every calculated energy and dollar result changes in direct proportion to this input.
How much does system pressure change the cost?: For the 1/8-inch DOE equivalent opening, the May 2026 U.S. sharp-edged gross estimate is $1,560 at 70 psig, $2,113 at 100 psig, and $2,568 at 125 psig. The 125-psig result is about 65% higher than the 70-psig result because DOE’s published flow rises from 18.62 to 30.65 CFM before the same shape and energy factors are applied.
What is a reasonable compressed-air leakage percentage for a plant?: The April 1998 Compressed Air Challenge/DOE fact sheet says a typical poorly maintained plant will likely have leakage equal to 20% of compressed-air production capacity and that proactive programs can reduce leakage below 10%. DOE’s August 2004 tip sheet says leaks often waste 20%–30% of compressor output and identifies 5%–10% of total system flow as a typical cost-effective reduction target.
Why do published leak-cost figures differ?: The reviewed sources publish different units, operating schedules, electricity rates, specific-power assumptions, and levels of methodological detail, so they cannot all be collapsed into one defensible apples-to-apples range. Table 10 records what each source actually discloses, while this page fixes the scenario and exposes every input.
Where do the $523, $2,095, and $8,382 figures come from?: They appear in Compressed Air Systems Fact Sheet #7 from April 1998, which states a five-cent electricity rate, constant operation, and an efficient compressor. A reconstruction using the later December 2000 DOE flow table, 8,760 hours, 0.184 kW per CFM, and no shape factor reproduces the three rounded figures within one dollar of total absolute error, but the 1998 fact sheet does not disclose enough inputs to prove that this was its original calculation.
Can this calculator use pressure-decay data?: Yes, when qualified facility personnel have already gathered the system volume, pressure change, elapsed time, and local atmospheric pressure. The calculator applies NREL’s equation, Leak Flow SCFM = [(V × ΔP) ÷ (time × atmospheric pressure)] × 1.25; this page does not provide a procedure for isolating or manipulating a pressurized system.
Does the state table include demand charges or local utility tariffs?: No. The state table applies EIA’s preliminary May 2026 industrial average revenue per kilowatt-hour to one standardized leak scenario. It does not model demand charges, time-of-use periods, ratchets, taxes, fixed charges, power-factor provisions, local utility schedules, or negotiated facility terms.

Which primary sources support this page?

DOE, NREL, EIA, OSHA, and BLS are cited for the technical, price, safety, and manufacturing facts they issue. Publisher-owned pages are listed separately only for the figures attributed to them in the comparison table.

U.S. Department of Energy, Office of Energy Efficiency and Renewable Energy. Minimize Compressed Air Leaks, Compressed Air Tip Sheet #3, DOE/GO-102004-1964, revised August 2004. https://www.energy.gov/sites/prod/files/2014/05/f16/compressed_air3.pdf — Retrieved, visually checked, transcribed, and recalculated July 29, 2026.
U.S. Department of Energy, Office of Industrial Technologies. Minimize Compressed Air Leaks, Compressed Air Tip Sheet #3, DOE/GO-102000-0988, December 2000. https://www.energystar.gov/sites/default/files/buildings/tools/compressed_air3.pdf — Retrieved, visually checked, transcribed, and recalculated July 29, 2026.
Compressed Air Challenge and U.S. Department of Energy. Compressed Air System Leaks, Compressed Air Systems Fact Sheet #7, April 1998, Rev. 0. https://www.compressedairchallenge.org/data/sites/1/media/library/factsheets/factsheet07.pdf — Retrieved and checked July 29, 2026.
U.S. Energy Information Administration. Electric Power Monthly, Table 5.6.A, “Average Price of Electricity to Ultimate Customers by End-Use Sector, by State, May 2026 and 2025,” released July 23, 2026. https://www.eia.gov/electricity/monthly/epm_table_grapher.php?t=epmt_5_6_a — Retrieved and transcribed July 29, 2026.
U.S. Energy Information Administration. Electricity Monthly Update — End Use, May 2026. https://www.eia.gov/electricity/monthly/update/end-use.php — Retrieved July 29, 2026.
U.S. Energy Information Administration. Glossary, “Average revenue per kilowatthour.” https://www.eia.gov/tools/glossary/?id=electricity — Retrieved July 29, 2026.
National Renewable Energy Laboratory. Benton, N., and P. Bonn. Chapter 22: Compressed Air Evaluation Protocol, Uniform Methods Project, January 2021, NREL/TP-5C00-77820. https://www.nrel.gov/docs/fy21osti/77820.pdf — Official record: https://www.osti.gov/biblio/1762439. Checked July 29, 2026.
U.S. Department of Labor, Occupational Safety and Health Administration. 29 CFR 1910.242(b), “Compressed air used for cleaning.” https://www.osha.gov/laws-regs/regulations/standardnumber/1910/1910.242 — Retrieved July 29, 2026.
U.S. Bureau of Labor Statistics. A look at manufacturing jobs on National Manufacturing Day, 2022 data, published October 6, 2023. https://www.bls.gov/opub/ted/2023/a-look-at-manufacturing-jobs-on-national-manufacturing-day.htm — Retrieved July 29, 2026.

Publisher-owned sources used only in Table 10

ifm. How much do compressed air leaks cost your facility? https://www.ifm.com/us/en/us/energy-optimization/compressed-air-f/how-much-compressed-air-leaks-cost-your-facility — Retrieved July 29, 2026.
Fluid-Aire Dynamics. Compressed Air Leak Calculator. https://fluidairedynamics.com/pages/leakage-cost-calculator — Retrieved July 29, 2026.
AirCompressors.com. Compressed Air Leak Savings Calculator. https://aircompressors.com/news-insights/compressed-air-leak-savings-calculator — Retrieved July 29, 2026.
Seattle City Light. Compressed Air Operation Tips & Best Practices. https://www.seattle.gov/documents/Departments/CityLight/CompressedAirTips.pdf — Retrieved July 29, 2026.

Last verified: July 29, 2026 · Dataset version: 2026-05-v2

Fort Wayne Air Compressor Repair Research is the independent research and reference section of fortwayneaircompressorrepair.com.

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