Hydraulic hoses are the lifelines of fluid power systems. They transfer pressurized fluid between components, allowing machines to lift, haul, dig, and perform with precision. But even the best- built hose has a lifespan, and when failure hits, it doesn’t just mean a leak. It could mean lost productivity, damaged equipment, or even serious safety risks. Understanding the most common types of hose failure is the first step in preventing them. 

Abrasion: The Silent Hose Killer

One of the most frequent and avoidable causes of hose failure is external abrasion. When a  hose rubs against metal surfaces, other hoses, or moving parts during operation, the outer cover wears down over time. Eventually, the reinforcement layer is exposed and vulnerable to failure.

You can often spot early-stage abrasion by looking for scuffed or thinning areas on the hose cover. The fix? Use protective sleeving or proper routing techniques to keep hoses from rubbing against hard surfaces and check clamps regularly to make sure they’re doing their job.

Improper Routing and Kinking

Improper routing is a repeat offender in the world of hose damage. If a hose is bent past its minimum bend radius, kinked, or twisted during installation, internal stress builds up fast. That stress weakens the reinforcement and restricts fluid flow, setting the hose up for early failure. Kinks don’t always happen overnight either; they can develop slowly from poor routing choices
that force the hose into awkward or unsupported angles. The best defense is smart planning: use angle adapters, avoid sharp bends, and ensure the hose has enough length to move naturally.

Fitting Detachment: When Connections Go Wrong

A catastrophic and dangerous failure type is fitting detachment. This is when the hose separates from its fitting under pressure. This is often the result of incorrect assembly, using the wrong crimp specs, or skimping on proper testing. Not only can this cause total system failure, but it can also pose serious safety risks to nearby workers.

To avoid detachments, always use manufacturer-specified crimping equipment and follow exact assembly procedures. Kitting services like those offered by Omni Services can also help ensure consistency across high-volume builds.

Burst Hose: When Pressure Pushes Too Far

Burst failures are dramatic and often indicate the hose was pushed well past its pressure rating. Overpressurization might happen during system spikes, surges, or if the wrong hose type is used for the application. Sometimes burst hoses show warning signs like ballooning or soft spots, but in many cases, they fail without warning.

This is why matching hose specs to system requirements is non-negotiable. That includes pressure ratings, fluid compatibility, temperature exposure, and bend radius.

Cover Blisters and Internal Erosion

Not all hose failures come from outside damage, some happen from within. Cover blisters, for example, can appear when incompatible fluids or high temperatures degrade the hose materials. Internal erosion, on the other hand, happens when fluid velocity is too high or when contaminants scrape away at the hose walls.

Signs of this failure type may include fluid leaks, strange bubbling on the outer cover, or a loss of pressure in the system. Prevent this by verifying chemical compatibility and flow requirements before installation, and using appropriate filtration to reduce internal contamination.

Aging and Environmental Exposure

Over time, hoses naturally degrade — especially when exposed to UV rays, extreme temperatures, ozone, or harsh chemicals. Cracked, dry, or brittle hose covers are telltale signs of aging. And if hoses are stored improperly (sunlight, moisture, or high heat), they may fail before they even make it into service.

That’s why storage and inspection protocols are just as important as proper installation. Rotate inventory, store hoses in a cool, dark environment, and inspect before installation.

In Conclusion..

Hose failure isn’t just inconvenient. It can be costly, dangerous, and often entirely preventable. With the right design, installation, and maintenance practices, you can significantly extend hose life and system performance.

Whether you’re managing a mining operation like Sandvik or building a mobile fleet from the ground up, partnering with a supplier like Omni Services ensures you get not just the hose — but the expertise, support, and strategy to keep your equipment running and your team safe.

Need help preventing hose failure in your operation? Get in touch with Omni Services to talk hose selection, assembly and routing for any fluid transfer system.