Hose Repair: Tips to Extend Hose Life Before Buying a New One

Hose Repair: Tips to Extend Hose Life Before Buying a New One

Leaking Garden Hose

Industrial Hose & Hydraulic Hose Repair

There are many reasons for repairing your high-quality hoses and hydraulic hoses rather than simply buying a new one. First, hoses and fittings can be expensive equipment, so repair is often a more economical option than buying a new one. Another reason for repairing a hose is that often you’re in a time-critical jam or can’t wait for a new hose, such as when your equipment has broken down on-site during a construction or farming operation. If you need to get up and running right away, fixing a hydraulic hose may be your best option, so you’ll probably find yourself running to the nearest hose repair shop.

Types of Damage

When it comes to industrial hoses, the types of damage fall into four basic categories:

  1. Damage immediately behind the hose end: Anywhere you have a crimp, or banded connection naturally undergoes more stress when there’s any movement on the hose.
  2. Local external damage: Such as a scratch, dent, or impact damage.
  3. Overall external wear due to dragging: For example, in cleaning applications where the hose is regularly moved around and dragged on the ground or concrete. The other cause of external abrasion is simply the constant vibration of the hose in high-pressure applications. The vibrations from the pump cause it to rub on the ground and wear the outer coating. There’s not much that can be done to prevent this kind of damage—it’s the nature of this type of application. 
  4. Long-term use fatigue: When your hose fails because it’s gotten old with use, you know you’ve gotten the maximum lifetime out of the hose.

Replacing the Crimp

It’s simple to replace a hose-end—but there are two caveats to this. First of all, it shortens the hose’s length, so it’s only helpful in installments where you can afford to have a slightly shorter hose.

Eaton Weatherhead Hose BundleSecondly, particularly in fixing a hydraulic hose, it’s necessary to have the proper crimp spec. The crimp fitting is designed to meet SAE standards that guarantee the fit between the hose and end so the hose can withstand the high pressure required. What this means is that you need to have the ends from the same manufacturer as the hose. If you go to an Eaton Weatherhead manufacturer or supplier like TCH, we can only fit the Eaton Weatherhead hoses with Weatherhead ends. If you have Parker, Gates, or any other type of hose, you need to find a repair house that features those parts. Even the smallest deviation in the connection between the hose and end can cause a deterioration in performance, or even worse, be hazardous.

Often, we get people in our shop who want us to crimp to a different hose type, but it simply won’t work. Any decent repair technician will send you away if they don’t have the right match. Before you take a trip down to the repair shop, make sure they stock the manufacturer you need.

Making a Break

Tractor with industrial water hoseOften hoses will incur damage from impacts, such as a tractor running over the hose, a falling rock, or other impact types. The easiest way to deal with that kind of damage is by cutting and mending the hose. There are two ways to cut and mend a high-pressure or hydraulic hose.

The first way is to use a mender by putting a physical piece inside the hose and crimping it on both ends. The other way to mend a hose is to put two threaded pieces on either side of the splice and put a coupler in the middle. Sometimes people try to repair their hoses with duct tape. That might reduce the spraying, but at 3000 PSI of pressured liquid inside of your hose, obviously, duct tape isn’t a safe solution.

The second method is to splice and repair when the damage gets too bad in one particular spot. It’s possible to splice multiple times, though it’s not ideal. Every time you splice and fix a hydraulic hose or any hose, it degrades the hose slightly, both in terms of the length and in terms of the pressure loss of the liquid running through the hose. For basic cleaning applications, that can be fine. But if you are doing high-pressure spraying for sanitation, you really don’t want to splice more than once. Why? As the hose’s function is reduced, the water pressure goes down, and the time for cleaning goes up.

We’ve seen hoses with as many as six splice and repair joints, which may seem like it’s saving money, but is probably more trouble than it’s worth if you’re doing serious work.

Watch for Abrasion and Exposed Wires

When it comes to local external damage, a hose can be fixed with a cover repair if you catch the problem early enough. If you immediately care for any scratch on the cover of a hydraulic or high-pressure hose, you can protect the reinforcement. All hoses have a protective cover that ensures the reinforcement wire doesn’t get damaged internally.

However, if you ignore scratches or dents, they can corrode, which leads to either full replacement, splicing, or repairing. If you see an abrasion or exposed wires and are trying to hold off on a full replacement, you can add plastic spiral guards, metal spiral guards, or abrasion-resistant plastic sleeves to protect the area that is damaged. What’s important is that you protect the reinforcement wires from additional abrasion and corrosion.

Long-Shot Saves

Industrial steel millSituations, where you have to get your hose repaired right away, are common. Maybe your equipment has stopped right in the middle of a production run or during a harvest, and you can’t wait until the delivery of a new part. We understand. If it’s urgent, we find a way.

As an example, sometimes a hose and the port won’t be the same size. If there’s a small jump, say from 1 inch to 1.5 inches, we can find a fitting to reduce the size—but if it’s a big jump, like from 2 inches to half an inch, there’s a major mismatch. In a real emergency, we will fit a system with several stages of jumps from a larger to smaller or smaller to larger fitting. It’s not ideal, but if you’re really in a pinch, that is a repair that we’ve seen work at least temporarily until the system could be reconfigured.

A Hard Break: When It’s Time for a New Hose

When your hose is worn out from long-term, high-pressure use, it’s time to celebrate. You’ve gotten every last drop of use from your investment, and it’s time for a new hose. Wear and distortion can’t be fixed. When you have a hose, especially a hydraulic hose, the pressurizing and de-pressurizing of the tube eventually will reduce its ability to function and maintain high pressure. It’s worth remembering that there is no “forever hose” that lasts a lifetime. Even the highest quality hoses will wear out over extended use.

Conclusion

TCH Industries Hose Repair ShopIndustrial hoses and hydraulic hoses are designed for long-term use, and in many instances, replacement is a better option than fixing a hose. Hydraulic hose repair can extend the lifetime of a hose, get you out of a bind when something breaks down on a job site, or save a bit of money. Whatever the need, our service center is designed to get you back up and running when anything breaks down. The Hose Pros are standing by to help!

TCH Industries

We. Are. Hosers.

Our focus and obsession is the distribution and fabrication of hose for industry and hose related products. Founded nearly 40 years ago, we are proudly owned and operated by the same family. Our manufacturing partners are some of the biggest and best names: Eaton, Parker, Dixon Valve, Hose Master, Brennen, Hannay Reels, and many others.

In short, we are a customer-centric hose company filled with happy professionals who can help you meet all your hose related needs. If you have any questions, please reach out to us by filling out the form below!

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Most Common Types of Industrial Hoses

Most Common Types of Industrial Hoses

Industrial Hoses

Industrial Hose

To hose industry insiders, the term ‘industrial hose’ is a broad term encompassing everything that isn’t metal, Teflon, hydraulic, and composite hose. Others say it’s all hose except for hydraulic hose. For people outside of the hose industry, ‘industrial hose’ seems to refer to any and every hose: a heavy-duty 4-wire hydraulic hose, a large-bore stainless hose; these could easily be referred to as an industrial hose from someone who doesn’t directly deal with hose for industry on a consistent basis.  

When someone is in need of industrial hoses, the specific application is generally what drives the title of the type of hose that is requested. They need a brewery hose, a chemical hose, steam hose, or an air hose. Oftentimes, the end-user of hoses isn’t necessarily using the term ‘industrial hose,’ but the specific use the hose was designed for.  

For most manufacturers, if you crack open their catalogue, you’ll typically find a remarkably similar layout of their industrial hose offering. Though this can make things easier when comparing manufacturers, we’re still talking about catalogues that are oftentimes four- to five-hundred pages long. There are tons of options.  

We’re going to make understanding the options easier to chew. 

Air & Multi-Purpose Hose

Industrial Air HoseAt the high-pressure end of the spectrum, you’re going to find steel-braided, nitrile hose that will handle pressures up to 1,500 psi air. Keep in mind that this is extremely high for an air hose. These types of hoses will typically be seen at heavy construction sites, mines, quarries, and plants/mills. From there, we work our way into the ‘medium-duty’ hoses. These hoses typically have nitrile tubes and covers for good oil resistance, fabric braid reinforcement and handle pressures between 400-600 psi. In the 200-300 psi range, we have air and multi-purpose hoses for shop air and water, which are offered with EPDM rubber with lesser oil resistance and lower cost, or nitrile and other oil resistant materials. 

Push-On Hose

Another favorite offering in this category is push-on hose. This hose uses a special barbed end that does not require a ferrule or clamp. These types of hose are usually really flexible, even when cold, and can be field repaired with only a knife to cut the end off since no ferrule is required. 

When choosing your air or multi-purpose hose, it really comes down to two important questions: do you have a high-, medium-, or low-pressure requirement? And what kind of requirement do you need for oil resistance? As always, it’s important to keep in mind specialty requirements, such as heavy-duty abrasion resistant covers like carboxylated nitrile found on the Bulldog Gold hose. These hoses are going to take a beating, and we’ll make sure they’re able to handle it. 

Chemical Hose

Chemical hoses are rather consistent throughout various manufacturers, and you’re essentially dealing with hose tubes that are UHMW or XLPE. There of course are others like FEP, high-purity EPDM for acid, and Nylon tube paint hoses are often listed in the chemical section too, but they are a specific use, specialty hose. Once you’ve decided which tube option suits your specific application, you’ll need to cover your pressure and temperature requirements. Various chemicals will need a certain tube material to handle the temperature or high-pressure chemical applications; though, high pressure and chemicals aren’t generally associated. 

Considering the use for your hose, is it suction and discharge or transfer only, you may need to consider the necessity of a helical wire. So that’s about it for most chemical applications: choose UHMW or XLPE for the tube and then decide if a helical wire is necessary. When you break down chemical hose into the few necessary requirements, it is pretty straight forward. 

Food & Beverage

We can break down food and beverage hoses relatively easilyWe’re essentially left with the decision of whether our hose is transferring an oil/fatty product or non-fatty food product. There is, of course, dry material transfer, which will have a natural rubber tube; though, with wet food applications we typically see chlorobutyl tubes for non-fatty, and mainly nitrile for oil/fatty substances.

Industrial Food and Beverage Hose

Once you’ve decided the tube material necessary for the product being transferred, we’ll need to make sure the hose cover is suitable to the environment. In the food industry, we’ll obviously see environments where these fatty and oily substances will be coming into contact with the exterior of the hose as well. A nitrile cover will be perfect for these instances. Whereas EPDM covers will handle situations where the environment is not oily. 

Like chemical hoses, our next consideration is temperature. With food, we’ll see some remarkably high temperatures mixed with the necessity of steam and CIP (clean-in-place) cleaningThese hoses will need to be able to withstand short bursts of steam for cleaning.  

In the beverage market, we see more food-grade PVC and specialty hoses for wineries and breweries, which are typically chlorobutyl. Again, just as food transfer, we need to consider sanitary and cleaning requirements for beverage hoses. 

Lastly, as we discussed with both food and beverage, cleanliness is a crucial element in a food processing environment. Washdown hoses are designed to handle pressure for cleaning, sometimes over 1,250 psi. 

At this point, we’re beginning to see that, even with so many different applications and specific industries within industrial hose, we’re dealing with a similar formula when calling out the perfect spec for our job. 

LPG Hose

Liquefied petroleum gas (or propane delivery) hoses tend to be a breed of their own. In this category, it’s important to note the certification requirements. The first is UL21. This indicates Underwriters Laboratories ensures safety, security, quality, and performance expectations of the hose. There’s also CGA Type 1—Canadian Gas Association—which serves as the voice of Canada’s natural gas and delivery industry. 

Industrial Compressed Gas HoseWe tend to see LPG hoses for applications such as grills, heaters, tow motors, construction, and residential use. For these applications, hoses are constructed with multiple textile plies of reinforcement for flexibility and kink resistance, and a perforated cover resistant to mild chemicals, oil, and ozone.  

When working with natural gas, we’re talking about miniscule molecules that can permeate standard rubber hose construction. As pressure increases, so will the rate of permeation, and the accumulation of natural gas can lead to dangerous consequences, proving the importance of selecting the proper hose construction for your LPG requirements. 

Material Handling

Applications for the transfer of dry or abrasive substances, such as sandblasting and concrete or asphalt transfer, require specific hose construction to handle prolonged abrasion during use. Material handling hoses are almost always made of natural rubber or SBR (styrene butadiene rubber). We’re no longer dealing with oil and oil resistance; instead, our most important consideration is now abrasion and choosing a thick tube to handle it. Secondly, our assembly construction will tend to differ with the type of substances transferred in material handling applications. Because of the highly abrasive materials, these assemblies should have a smooth transition between the tube of the hose and its end, which is why we usually internally expand ends on material handling assemblies. Otherwise, the abrasive material will eat away at the hose end until there is no hose barb left.  

Hot Air Blower hose is a specialty hose in the material handling category. Hot air reacts with hose materials much differently than ambient air. These hoses not only handle the higher temperatures of air, but they will also handle them consistently. Hot air can wreak havoc on standard hose materials.

Petroleum Transport

Nine times out of ten, petroleum transport hoses will have a nitrile tube and cover. Nitrile handles petroleum better than any of its counterparts, and, as you can imagine, where there’s petroleum being transferred, chances are there’s going to be petroleum encountering the outside of the hose as well. As with any application, you’re left with determining size, pressure, and temperature ratings of your application. 

Now, another consideration—depending on the system you’re working with—is the bend radius requirement of your assembly. If you find yourself needing more flexibility, corrugated covers increase ease of bending because of the shape of the cover. The material of the assembly will stay the same regardless.

PVC Hose

Industrial PVC HosePVC (polyvinyl chloride) hoses see an awful lot of uses. Applications such as potable water, beverage dispensing, chemical dispensing, multipurpose air, and water, and many, many more. PVC is in a category all its own that reaches into a lot of the categories discussed prior, so what we see is a category not defined by its use, but rather its material.  

Layflat Hose

A popular type of PVC hose is layflat hose. The hose can ‘lay flat’ because it has no helical wire and is only used in discharge or positive pressure applications. These are easy to roll up and transport and found in agriculture, construction, industry, and mining.

Steam Hose

Steam hose, to an extent, runs the gamut when it comes to construction: there’s EPDM, nitrile in instances where oil resistance is needed, and chlorobutyl in more premium varieties, like when you need a hose that is going to stand the test of time. Most of these will handle temperatures north of 406°F for saturated steam and 450°F for superheated steam, with pressures up to 250 psi. on average.  

Due to the dangerous nature of steam at higher temperatures and pressures, this is one of the few hose applications where we see a safety factor of 10:1 vs the standard 4:1. Steam can be incredibly dangerous. Depending on the type, temperature, and saturation, steam isn’t always visible, so an increased safety factor is prudent.

Water Hose

Industrial Water HoseThis may seem like a rather straightforward category of industrial hose. To an extent, it can be. Water hose is generally made from one of three materials: EPDM or SBR for suction and PVC for discharge. For the most part, EPDM is the most common tube for water hose, especially when the hose is being used as a transfer hose. If your application is suction, your hose will require a helical wire to prevent the hose from collapsing. 

Through experience—and, yes, failure—we’ve learned that you need to be extra careful when it comes to temperature ratings of water hoses. If you have an application where the temperature is anywhere near the upper limit of your hose (for example: a hose rated up to 180°F, and your application reaches 170°F), you want to move to a hose designed to handle a higher temperature.

Welding Hoses

Welding Hose

Welding hoses are possibly the easiest to visually identify. You have green hose for oxygen, and a red hose for burning gas. The hose commonly comes as twin-line; however, you can buy these lines individually. Welding hoses are rated to either Grade-T, which has greater oil resistance (in a steel mill or a shop), or Grade-R, which will have reduced resistances to oil.  

Needless to say—though, we’ll say it anyway—when dealing with something that can be as dangerous as burning hose, it’s important to know your application and the environment in which these hoses are being used to ensure safety. When it comes down to it, choosing a welding hose isn’t much more complicated than deciding whether you need Grade-T or Grade-R. We carry Grade-T for most calls. 

Hopefully, this overview of industrial hose helped ease some confusion on the seemingly limitless options out there. Remember that most hoses are called out by their application: Steam hose, cement hose, brewery hose etc. If your application is a little less straightforward think of it in terms of construction. 

  1. What tube material will handle the media and temperature? 
  2. What reinforcement is required? Steel braid, textile spiral, helical wire for suction? 
  3. What cover will protect the reinforcement and handle the environmental conditions best? 

Once you answer these three questions you will be well on your way. After that, you can always call The Hose Pros at TCH and we’ll think through it with you. 

TCH Industries

We. Are. Hosers.

Our focus and obsession is the distribution and fabrication of hose for industry and hose related products. Founded nearly 40 years ago, we are proudly owned and operated by the same family. Our manufacturing partners are some of the biggest and best names: Eaton, Parker, Dixon Valve, Hose Master, Brennen, Hannay Reels, and many others.

In short, we are a customer-centric hose company filled with happy professionals who can help you meet all your hose related needs. If you have any questions, please reach out to us by filling out the form below!

  • This field is for validation purposes and should be left unchanged.

 

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