When a hydraulic hose fails, it’s often much more serious than a regular maintenance issue. For heavy equipment operators in Southern and Central California, it can mean massive costs associated with halted projects. And while temporary construction equipment rental is always an option, least you want is to incur extra expenses. The repairs are often expensive, too, along with environmental fines. That’s not even the worst part: these failures can cause serious injuries.
These tubes are made to be flexible, working as the arteries of hydraulic systems. But that flexibility and the many connecting points lead to a lot of structural weakness.
Overlooking their maintenance can bring your entire job site to a standstill and risk much more. So in this post, we’ll look at common causes of hydraulic hose failure and how to prevent problems.
At a Glance: Common Causes of Hydraulic Hose Failure
|
Cause |
Description |
Mitigation |
|
Abrasion |
Hoses rubbing against machine surfaces or debris weaken over time. |
Install protective sleeves, reroute contact points. |
|
Improper Routing |
Bends, kinks, or sharp angles near fittings increase stress and cracking. |
Follow OEM routing diagrams, use proper brackets. |
|
High Temperatures |
Heat exposure causes hardening, leading to cracks and leaks. |
Use heat-resistant hoses, maintain airflow barriers. |
|
Tube Erosion |
High-velocity fluids wear down internal hose walls, leading to leaks. |
Ensure proper filtration and monitor flow rates. |
|
Contamination |
Dirt, metal, and water particles degrade hose materials from within. |
Maintain strict fluid cleanliness protocols. |
|
Improper Assembly |
Incorrect crimping or mismatched fittings can cause catastrophic blow-offs. |
Train technicians thoroughly, follow assembly specs. |
Real-World Impacts of Hydraulic Hose Failure
There are a lot plenty of headlines that reveal just how pervasive a problem hydraulic hose failure is.
· In May 2022, Pacific Gas & Electric’s long-running chromium-ground-water-remedy project near Needles hit a snag when a drilling rig’s hydraulic hose ruptured at the ER-2 borehole. Pressurized oil atomized into a fine spray that spattered field crew, equipment, nearby creosote bushes and wooden safety rails. This contaminated nearby soil and hard surfaces in the fragile desert ecosystem.
· In October 2023, a FedEx Boeing 757 experienced a hydraulic hose failure, causing a leak in its landing gear system. This forced an emergency landing in Chattanooga, Tennessee and made national headlines.
These are only a couple of examples from recent years.
Knowing how much of an issue this can be, let’s look at risks and mitigation strategies.
What are the Risks of Hydraulic Hose Failures?
Hydraulic hose failures have been the cause of so many jobsite issues. Key risks include:
· Injection Injuries: High-pressure fluid leaks can penetrate the skin. These can be some of the most serious injuries your team could face.
· Fire Hazards: Leaked fluids are flammable. And they can ignite on contact with hot surfaces or sparks.
· Slip and Fall Accidents: Spilled fluids create slippery surfaces, increasing the likelihood of workplace accidents.
· Environmental Contamination: Leaks can lead to soil and water pollution, harming ecosystems and potentially resulting in regulatory fines.
· Equipment Damage and Downtime: Failures can cause machinery to malfunction, leading to costly repairs and project delays.
Prevention Strategies for Job Sites
As we’ll see, regular maintenance and prompt attention to hydraulic systems are the major weapons we have in the fight against hydraulic hose leaks.
1. Routine Inspections: Daily checks for wear, chafing, or leaks should be standard practice.
2. Proper Hose Routing: Prevent stress points with correct installation techniques.
3. Use High-Quality Components: Stick with OEM-approved hoses and fittings designed for your specific equipment.
4. Predictive Maintenance Tools: Leverage IoT sensors and real-time diagnostics to monitor hose health.
5. Ongoing Training: Equip your maintenance teams with up-to-date knowledge on assembly best practices.
Keeping Hydraulic Systems Strong
Hydraulic hoses need to be taken seriously. They’re essential to all the work you do, and yet they are also very fragile.
It’s even more important for contractors in California. Here, environmental compliance is non-negotiable. So staying proactive is both the right thing to do and smart business.
