Industrial Hose Failures: Top Causes and Fixes

Industrial hoses are essential to your daily operations, but a sudden failure may bring your entire project to a standstill. Understanding why these failures happen is the first step toward preventing costly downtime and ensuring a safer worksite. Use this guide to understand the top causes and fixes of industrial hose failures and gain practical solutions to keep your equipment running smoothly.

Incorrect Hose Selection

Selecting the right hose for your application is fundamental to preventing premature failure and ensuring operational safety. A hose that is incompatible with the required pressure, temperature, or type of fluid transported will quickly degrade.

The material composition of the hose might react negatively with the chemicals, or the pressure rating may be insufficient for the system’s demands, leading to a burst. Check the manufacturer’s specifications to avoid this and confirm the hose meets the demands of your job. It is always best to consult a trusted supplier for expert guidance when you are uncertain about the correct choice.

Improper Assembly

Hose assembly has a direct impact on its performance and longevity. Improperly crimped hoses or poorly attached fittings create weak points at the connections, which are common sources of leaks or catastrophic bursts under pressure. An incorrect assembly also damages the internal structure of the hose, compromising its integrity from the start.

It’s important to have trained professionals handle the assembly or to meticulously follow the manufacturer’s assembly guides for proper installation procedures. Paying close attention to the details of fittings and couplings ensures a secure and durable connection every time. Consider custom hoses from Hand Crafted Hose Company, which professionals assemble and avoid issues that may occur during operations.

Over-Pressurization

Operating a hose beyond its maximum rated pressure is a frequent cause of failure. A hose’s reinforcement layers stretch, weaken, and eventually break down when subjected to pressure levels too high to handle, leading to a sudden rupture. These pressure spikes may happen during normal operations or as a result of system malfunctions.

Prevent over-pressurization by closely monitoring the working pressures of your system and selecting a hose that comfortably handles the maximum pressure requirements. Regular inspection of your pressure gauges and system settings will maintain safe operating conditions.

Excessive Temperature Exposure

Exposure to extreme temperatures, hot and cold, severely damages the materials of an industrial hose. High temperatures may cause the hose material to soften, lose strength, and become less resistant to pressure, while extreme cold makes it brittle and prone to cracking. Over time, this thermal stress degrades the hose from the inside out, leading to unexpected failures.

You should always select hoses specifically rated for the temperature range of your application to ensure they withstand the operational heat. Proper storage away from extreme temperature fluctuations will also preserve the hose’s material integrity.

Abrasion and External Damage

The outer cover of a hose is its first line of defense against the surrounding environment. A hose’s protective layer wears away when it rubs against rough surfaces or abrasive materials, or comes into contact with sharp objects.

The compromised outer cover exposes the reinforcement layers to damage, significantly weakening the hose’s structure. Protective coverings or sleeves offer an effective shield against this type of wear and tear. Additionally, make it a practice to avoid dragging hoses across rough terrain or sharp edges whenever possible.

Kinking or Bending Issues

Forcing a hose into a bend that is tighter than its specified minimum bend radius creates a kink, which restricts flow and puts stress on the hose wall. Kinking and bending are top causes of industrial hose failure, leading to excessive bending that separates or wears the reinforcement layers, creating a weak point that is likely to fail under pressure.

Use hoses with the appropriate flexibility for applications requiring navigation through tight spaces to prevent these issues. Never force a hose into an unnatural angle, and consider using hose reels or guides to maintain a proper bend radius during use.

Improper Storage

How you store your hoses when they are not in use plays a significant role in their lifespan. Leaving hoses coiled on the ground, exposed to sunlight, extreme temperatures, or moisture, causes the materials to degrade. Improperly stored hoses may receive physical damage from someone stepping on or running over them with their equipment.

The best practice is to hang hoses on proper racks or reels, keeping them off the floor and away from potential harm. Storing them in a cool, dry, and shaded area will protect them from environmental damage and keep them in good condition.

Wear from Improper Fittings

Using the wrong fittings leads to significant problems at the connection points of your hose assembly. Fittings that are not the correct size, type, or material for the hose cause leaks, loosen over time, or fail to create a proper seal. This mismatch also damages the hose itself, creating stress points that weaken the assembly.

You must ensure your fittings are the correct size and material for your hose and that they are compatible with your equipment. Periodically check the condition of your fittings for any signs of wear or corrosion.

Neglected Maintenance

Regular inspections are key to identifying potential problems before they lead to a full-blown hose failure. Small cracks, bulges, leaks, or signs of abrasion may all be indicators of developing issues that will worsen over time if left unaddressed. Neglecting routine maintenance means these warning signs go unnoticed, increasing the likelihood of an unexpected and potentially hazardous failure.

You should establish a scheduled maintenance program to regularly inspect all your industrial hoses for weak points, damage, and proper functioning. This proactive approach ensures reliability and safety on the job.

Unexpected Surges or Shocks

Sudden and sharp increases in pressure, often called hydraulic shocks or surges, inflict severe damage on a hose. These pressure spikes may exceed the hose’s maximum working pressure in an instant, causing immediate failure or creating hidden damage that leads to a later rupture. Surges may occur when valves open or close too quickly or by other abrupt changes in the hydraulic system.

Protect your hoses from these damaging events, and install pressure relief valves or surge protectors in your system. These devices buffer and regulate high-pressure changes, safeguarding your equipment.

Take proactive steps to prevent hose failure with an understanding of its causes. Proper selection, assembly, and maintenance are essential for ensuring the safety and productivity of your operations.

Paying attention to these details will help you keep your hoses performing reliably for longer. Contact us today to discuss your hose needs and find the right solutions for your specific applications.