Zone Valve Box Workshop Assembly

Zone Valve Box Assembly: Workshop Production Photos

September 17, 2026

These workshop photographs follow the assembly of a Kersai medical gas zone valve box, from the box housing and copper pipe runs to the ball valves, pressure gauges, gas identification plates and the finished units.

The box shown here is the horizontal inlet and outlet type, fitted with brass ball valves, a pressure gauge for each gas line and colour-coded identification plates. The gas configuration is selected per project; the units in these photographs are built for two to three gas services, such as oxygen, medical air and vacuum. See the full zone valve box range for the other layouts.

Box Housing and Inner Panel

The white housing and its inner panel frame are assembled first, so that the pipe runs, valves and gauges can be mounted on a stable base.

Copper Pipe Runs and Ball Valves

Each gas line is formed from copper pipe and fitted with a brass ball valve, a pipe clamp and a pressure gauge connection. The photographs below show the first and second gas lines being positioned inside the box body.

Copper pipe runs and brass ball valves fitted inside the box body.

Fitting the second gas line with its ball valve, pipe clamp and pressure gauge.

Pressure Gauges

A pressure gauge is mounted on every gas line so that the pressure can be read and monitored during daily use and maintenance. The completed interior view shows two gas lines with their ball valves and gauges.

Mounting a pressure gauge inside the box with a power driver.

Completed interior with two gas lines, ball valves and pressure gauges.

Gas Identification and Inlet and Outlet Pipes

Each gas service is identified by a colour-coded plate in line with the applicable standard, and the inlet and outlet pipes are capped to keep the pipe ends clean and protected in the workshop.

Gas identification plates for oxygen, medical air and vacuum, with the inlet and outlet pipes capped for protection.

Pipe Path Gas-Tightness Check

Before the box is closed, the assembled pipe path is checked for gas tightness. The photograph below shows a pipe and valve section during this check.

Gas-tightness check on the assembled copper pipe and valve section of the zone valve box.

Completed Zone Valve Boxes

The finished units carry the gas identification plates, the pressure gauges and the caution instructions on the front cover, with the inlet and outlet pipes ready for connection on site.