5 Common Causes of Hydraulic Hose Failure & How to Prevent Them

03 Feb 5 Common Causes of Hydraulic Hose Failure & How to Prevent Them

Hydraulic hoses are critical components in many industries, including mining, construction, agriculture, transport, and manufacturing. They carry fluid under high pressure and allow machines to perform heavy-duty work every day. When a hydraulic hose fails, the result is often costly downtime, damaged equipment, and serious safety risks.

At HYCO, we work with industrial clients across South Africa and regularly see hose failures that could have been prevented. Understanding why hoses fail is the first step to improving safety and extending the life of your hydraulic systems. Below are the five most common causes of hydraulic hose failure, along with practical ways to prevent them.

1. Excessive Pressure

The Problem

One of the most common causes of hydraulic hose failure is operating above the hose’s rated pressure. When pressure exceeds the hose’s working limit, it puts extreme stress on the internal reinforcement. Over time, this can lead to leaks, fitting blow-offs, or sudden hose bursts.

Pressure spikes are especially dangerous. Even if the average operating pressure seems safe, short bursts of high pressure can weaken the hose and cause failure without warning.

How to Prevent It

• Always choose a hose with a working pressure higher than your system’s maximum pressure

• Allow a safety margin for pressure spikes

• Avoid running hoses close to their maximum rating

• Regularly check pressure levels in your system

Selecting the correct pressure-rated hose from the start is one of the most effective ways to prevent failure.

2. Incorrect Hose Selection

The Problem

Not all hydraulic hoses are designed for the same applications. Using the wrong hose type for the fluid, temperature, or environment can cause rapid deterioration. For example, some hose linings are not compatible with certain oils or chemicals, leading to swelling, cracking, or internal breakdown.

Using a hose designed for low-pressure applications in a high-pressure system is another common mistake.

How to Prevent It

• Match the hose material to the fluid being used

• Check temperature ratings for both the fluid and environment

• Use hoses designed for the specific application

• Speak to a supplier if you are unsure

Correct hose selection improves performance and reduces maintenance costs.

3. Poor Installation and Routing

The Problem

Even the best-quality hose can fail if it is installed incorrectly. Common installation issues include:

• Hoses bent tighter than the minimum bend radius

• Twisted hoses

• Hoses rubbing against sharp edges or moving parts

• Excessive tension on fittings

These issues weaken the hose structure and cause early failure.

How to Prevent It

• Follow the manufacturer’s installation guidelines

• Ensure the hose is not twisted during installation

• Allow enough slack for movement and vibration

• Use clamps and guides to prevent rubbing

• Respect the minimum bend radius

Proper routing greatly increases hose lifespan and system reliability.

4. External Damage and Environmental Exposure

The Problem

Hydraulic hoses often operate in harsh environments. Exposure to sunlight, heat, chemicals, abrasion, and impact can damage the outer cover. Once the cover is compromised, the internal reinforcement becomes vulnerable to moisture and corrosion, leading to failure.

Abrasion is one of the biggest contributors to hose damage in industrial environments.

How to Prevent It

• Use hoses with abrasion-resistant covers

• Install protective sleeves or guards

• Keep hoses away from sharp edges and hot surfaces

• Replace hoses that show signs of external damage

Protecting the outside of the hose is just as important as maintaining internal pressure limits.

5. Age, Wear, and Lack of Maintenance

The Problem

Hydraulic hoses have a limited service life, even if they appear to be in good condition. Over time, hoses harden, lose flexibility, and weaken internally due to pressure cycles, heat, and chemical exposure.

Many failures occur because old hoses are left in service for too long without inspection or replacement.

How to Prevent It

• Perform regular visual inspections

• Look for cracks, bulges, leaks, or stiffness

• Replace hoses according to recommended service life

• Keep maintenance records

• Do not wait for a hose to fail before replacing it

Preventative maintenance is far cheaper and safer than emergency repairs.

Why Preventing Hose Failure Is So Important

Hydraulic hose failure does not only cause downtime. It can also:

• Injure operators and technicians

• Damage surrounding equipment

• Contaminate the environment

• Increase operating costs

In high-pressure systems, a sudden hose burst can be extremely dangerous. Preventing failure protects both people and machinery.

The Role of Quality Hoses and Fittings

Using high-quality hoses and fittings plays a major role in preventing failures. Poor-quality components may not meet pressure ratings, may wear out faster, or may not seal correctly.

Reliable fittings are just as important as the hose itself. A weak or incorrect fitting can cause leaks or blow-offs even if the hose is in good condition.

Choosing a trusted supplier ensures your hose assemblies are built to handle real-world conditions.

How HYCO Helps Reduce Hose Failure

At HYCO, we specialise in supplying hydraulic hoses, fittings, couplings, and accessories for demanding industrial environments. Our team understands the challenges faced by businesses operating heavy equipment every day.

We provide:

• Expert advice on hose selection

• Custom hose assemblies built to specification

• High-quality, pressure-rated hoses and fittings

• Reliable products designed for safety and durability

By working with HYCO, you reduce the risk of hose failure and improve the overall performance of your hydraulic systems.

Hydraulic hose failure is often caused by a combination of excessive pressure, incorrect selection, poor installation, environmental damage, and lack of maintenance. The good news is that most of these issues are preventable.

By choosing the right hose, installing it correctly, protecting it from damage, and maintaining it properly, you can greatly extend hose life and improve safety. Investing in quality components and expert support makes a measurable difference.

If you want to reduce downtime, improve safety, and protect your equipment, start by addressing the common causes of hydraulic hose failure today.

Contact HYCO

Address: Wadeville, Johannesburg, South Africa
Phone: +27 (0)11 824 4344
Email: info@hyco.co.za
Website: www.hyco.co.za

HYCO – Your trusted partner for hydraulic hoses, fittings, and industrial solutions.