TECHNICAL BULLETIN · GAOKE RUBBER & PLASTICS

GAOKE | Misfitted Hydraulic Hoses Are Potential  Bombs: Essential Anti-Burst Installation Guide  

Within industrial environments, the hydraulic hose performs a deceptively vital function: it is the primary transmission medium through which hydraulic pressure is maintained across a system. Any compromise in fluid delivery — whether through reduced flow or pressure loss — directly impacts production efficiency and poses measurable risks to operational safety. Critically, installation quality is among the most consequential factors in hose performance. Inadequate installation practices may result in fluid leakage under normal operating conditions or, in more severe cases, catastrophic hose failure. 

The following guidelines, presented by Gaoke, address the principal requirements for correct hydraulic hose installation and their role in ensuring both system integrity and workplace safety.

I. Avoid Twisting and Torsion

Among the factors influencing hydraulic hose longevity, torsional deformation during installation warrants particular attention. Controlled testing indicates that a rotational deviation of just 7° is sufficient to reduce service life by approximately 80% — a disproportionate consequence relative to the magnitude of misalignment. The effect is compounded in dynamic applications where connected components undergo relative displacement and the hose is required to flex within a single plane; under these conditions, any pre-existing twist amplifies mechanical stress concentrations along the hose structure. It follows that installation procedures must ensure complete elimination of torsional loading, as even marginal twisting measurably impairs both pressure resistance and operational durability.

II. Allowance for Length

During installation, a certain length allowance shall be reserved for hoses to accommodate hose expansion and contraction induced by pressure fluctuations.A length allowance of 3% to 5% is generally recommended.

III. Minimum Bend Radius Requirements

Excessive bending is strictly prohibited. The bend radius of the hose shall be no less than 10 to 12 times its outer diameter to prevent collapse and deformation at the bent section.No bending at hose root sections. Bending at the root of fittings on both ends of the hose is strictly prohibited, and a straight segment with a length no less than 1.5 times the hose outer diameter must be retained.

IV. Proper Hose Length

Hose length selection shall take its expansion and contraction characteristics into consideration to avoid excessively long or short installation lengths.Excessively long hoses will bring unnecessary extra costs, while overly short hoses may rupture due to insufficient space for expansion and contraction.

V. Precautions for Pipe Clamp Installation

The positioning of pipe clamps must account for the geometric changes a hydraulic hose undergoes when pressurised. At locations where bending movement occurs, the hose experiences both directional deflection and dimensional change; restraining the hose at these points through clamping impedes natural movement and generates stress concentrations incompatible with long-term structural integrity. Clamps should therefore be applied solely to straight sections of the hose assembly, where positional stability under pressure is maintained and the risk of clamp-induced mechanical damage is effectively eliminated.

VI. Avoid Abrasion

Where possible, prevent direct contact between the hose and other components, or route the hose away from surrounding objects to reduce abrasion.

VII. Select Suitable Fittings

Select appropriate hose fittings to make full use of installation space and reduce unnecessary hose consumption.

Select appropriate hose fittings to ensure the bending plane of the hose aligns with its movement direction and prevent hose twisting.

Select proper hose fittings to avoid excessively small bend radii and reduce additional stress.

VIII. Keep Clear of Heat Sources

Hydraulic hoses shall be routed away from heat sources such as diesel engine exhaust pipelines during installation, so as to prevent aging or damage of the hoses caused by high temperature.

Choose Gaoke Rubber & Plastic, Choose Professional Assurance!We not only supply high-quality, high-performance hydraulic hose products, but also advocate scientific and standardized installation and application practices.

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