why do hydraulic hoses burst


Why Do Hydraulic Hoses Burst?


Hydraulic hoses play a crucial role in various industries such as construction, agriculture, and manufacturing. They are responsible for transmitting hydraulic fluid to power equipment and machinery. However, these hoses are also prone to failures, and one of the most common issues is hose bursting. In this article, we will explore the reasons why hydraulic hoses burst and how to prevent such occurrences.

1. Understanding Hydraulic Hoses:

To better understand why hydraulic hoses burst, it is essential to comprehend their construction and function. Hydraulic hoses are made of flexible rubber or thermoplastic compounds reinforced with layers of braided steel or wire. The layers provide strength and increase resistance to high pressure. The hoses connect different hydraulic components, allowing the transmission of fluid, enabling the system to operate.

2. Overheating:

One of the primary causes of hydraulic hose bursting is overheating. Hydraulic systems frequently generate a significant amount of heat due to the high pressure and friction involved in their operation. Overheating can weaken the hose materials, leading to cracks and subsequent bursting. It is crucial to monitor and regulate the system's temperature to prevent such failures.

3. Excessive Pressure:

Excessive pressure is another common reason for hydraulic hose bursts. The hydraulic system is designed to operate within specific pressure limits. If the pressure exceeds the system's tolerance, it can cause the hose to rupture. This can occur due to malfunctioning relief valves, restricted fluid flow, or incorrectly adjusted pressure regulators. Regular maintenance and inspection are necessary to ensure pressure is within optimal limits.

4. Abrasion and Wear:

The constant movement and vibrations in hydraulic systems can lead to abrasion and wear of the hydraulic hoses. As hoses rub against surrounding equipment or components, they can be damaged over time. When the protective outer layer of the hose wears down, the reinforcement layers become vulnerable. This wear weakens the hose's structural integrity, making it more prone to bursting. Proper routing and secure clamping of hoses can minimize abrasive contact and extend their lifespan.

5. Improper Installation:

Incorrect installation processes can lead to hydraulic hose bursts. Improper routing, twisting, or bending of the hoses can create excessive stress concentrated in specific areas. This stress weakens the hose and increases the chances of it bursting during operation. Following manufacturer guidelines and using appropriate fittings and connectors are crucial during installation. Additionally, training employees on proper installation techniques can help prevent these failures.

6. Age and Degradation:

With time, hydraulic hoses naturally age and degrade. The continuous exposure to environmental elements, such as heat, UV radiation, and chemicals, can deteriorate the hoses' materials. As the rubber or thermoplastic compounds degrade, they lose their flexibility and strength, making them more susceptible to bursting. Regular inspection and replacement of aging hoses are essential to avoid unexpected failures.

Preventative Measures:

While hydraulic hose bursts can lead to severe consequences, implementing preventive measures can significantly reduce the risks. Here are some recommendations:

1. Conduct regular inspections: Regularly inspect the hydraulic system and hoses for signs of wear, cracks, or leaks. Promptly replace any damaged hoses before they fail catastrophically.

2. Proper maintenance: Follow the manufacturer's recommended maintenance schedule, including fluid changes, filter replacements, and system checks. Well-maintained hydraulic systems are less likely to experience hose bursts.

3. Temperature control: Monitor and regulate the system's temperature to prevent overheating. Install heat shields or use insulated tubing when necessary.

4. Pressure monitoring: Ensure pressure valves, regulators, and relief systems are appropriately set and functional. Regularly monitor pressure levels to prevent excessive pressure leading to hose bursts.

5. Correct installation techniques: Adhere to proper installation methods, including correct routing, clamping, and securing of hydraulic hoses. Train employees on the importance of installation procedures to avoid errors.


Hydraulic hose bursting can cause significant downtime, safety hazards, and costly repairs. Understanding the reasons behind these failures and implementing preventive measures is crucial for any industry utilizing hydraulic systems. By addressing issues such as overheating, excessive pressure, abrasion, improper installation, and aging hoses, the risks of hydraulic hose bursts can be significantly minimized, ensuring efficient and safe operations.


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