Effective Measures to Protect Hydraulic Hoses

Common Causes of Hydraulic Hoses Damage

1. Wear and Tear

Continuous friction between the hose surface and metal edges, other pipelines, or equipment components gradually wears down the outer rubber layer, potentially exposing the reinforcing layer and causing structural damage or leaks.

2. Excessive Bending

If the bending radius of the hose during installation is less than the minimum allowable value, it weakens the reinforcing layer structure, making it prone to cracks, bulges, or even bursting over long-term use.

3. Excessive Strength

Improper installation can result in insufficient pre-stressed pulsation allowance, causing the hose to be subjected to tensile or torsional stress during pressure changes or equipment movement, accelerating fatigue damage.

4. Thermal Damage

Prolonged exposure to high temperatures (such as near engines or exhaust pipes) or consistently high ambient temperatures accelerates rubber aging, leading to hose hardening, cracking, or reduced pressure resistance.

5. Chemical Corrosion
Contact with corrosive fluids, incompatible hydraulic oils, or cleaning agents can cause the inner rubber layer to swell, become brittle, or delaminate, severely affecting sealing and strength.

6. Impact and Pressure Loss
Mechanical impacts such as falling objects, equipment crushing, or improper footing can cause hose structural deformation, internal damage, or loosening of joints.

7. UV and Ozone Exposure
Long-term unprotected outdoor use exposes the hose to UV radiation and ozone, accelerating rubber aging, causing surface cracking and hardening, ultimately resulting in loss of elasticity and sealing.

How to Effectively Protect Hydraulic Hoses

1. Installation and Layout: Preventing Structural Damage

Proper installation is the first step in protecting the hose. The key is to avoid excessive mechanical stress

Planning the Route Properly: Ensure the hose has a natural, gentle direction, strictly adhere to the minimum bending radius, and avoid sharp bends, twists, or interference with moving parts of equipment.

Proper Fixing:Use appropriate clamps, brackets, or protective sleeves to reliably secure the hose, preventing it from swaying, rubbing, or contacting sharp edges during operation.

Allowing for Excess: Sufficient length allowance (pulse allowance) must be provided for the hose during installation to absorb the expansion and contraction stress caused by pressure fluctuations and equipment movement, preventing long-term stretching or compression.

2. Environmental Isolation: Resisting External Corrosion

The environment in which the hose operates is a significant factor affecting its lifespan. Active isolation measures should be taken

Physical Protection:Install wear-resistant springs, protective sleeves, or cable trays in areas susceptible to friction, impact, or compression. This is an essential protective layer for outdoor or complex operating conditions.

Thermal Protection:Keep the hose away from high-temperature heat sources such as engines and exhaust pipes. When unavoidable, heat shields, heat-resistant sleeves, or hoses made of high-temperature resistant materials must be used.

Climate Protection: For hoses exposed to UV and ozone environments for extended periods, hoses with anti-aging outer rubber formulations should be selected, or UV-protective sleeves should be installed.

3. Media and Operating Condition Matching: Ensure Intrinsic Compatibility

Intrinsic hose damage often stems from incompatible operating conditions

Chemical Compatibility: The inner rubber layer of the hose must be fully compatible with the hydraulic oil, lubricating oil, or other fluids being transported to prevent swelling, corrosion, or decomposition.

Pressure Matching: The rated operating pressure of the selected hose must be higher than the system's maximum operating pressure, and the effects of pressure surges (pulses) must be fully considered, with sufficient safety margin.

Temperature Adaptability: The hose's permissible operating temperature range should fully cover the highest and lowest temperatures the system may experience.

4. Proactive Maintenance and Monitoring: Achieve Long-Term Operation

Protective measures are not a one-time solution; continuous maintenance is key

Establish an Inspection System: Regularly inspect the hose for signs of aging such as wear, cracks, bulges, leaks, or hardening, paying particular attention to joints and bends.

Record Keeping and Early Warning: Establish hose usage records, documenting installation dates, operating conditions, and inspection results. Implement preventative replacement plans based on service life and operating conditions, rather than waiting for failures to occur.

Professional Operation: Hose cutting, crimping, and assembly should be performed by qualified personnel to ensure reliable connections and eliminate the risk of leakage at the source.