Custom hydraulic hose assemblies with 316L ends, crimped and tagged

This is the job known in the field as "getting a hydraulic hose made", "hose crimping" or "hose swaging": the hose is cut to length, its stainless steel ends are crimped, and the assembly is prepared in the workshop and shipped ready to install. A hose assembly consists of the hose, two end fittings and the crimp that joins them. Most hoses that cause problems in the field do not fail because of the hose itself, but because of the wrong end standard, an end that does not match the hose, a faulty crimp, or the hose being kinked or twisted during installation. That is why we build each hose assembly not just from its diameter and length, but together with the two ports it connects and the route it will follow.

Scope

• End geometries: straight, 45° and 90° hose ends to suit different line layouts and installation orientations.
• Connection standards: BSP, JIC/UNF (37° flare seat), NPT, metric (24° cone, DIN 2353/ISO 8434-1; known in the field as Ermeto-type) and SAE Code 61/62 flange ends; ORFS (O-ring face seal) ends on request.
• End material: AISI 316/316L stainless steel ends and nuts for environments with saltwater, humidity, cleaning chemicals or corrosive fluids.
• Hose type: wire-braided or spiral-reinforced construction selected by working and surge pressure, fluid and temperature; compatibility of the inner tube material with the fluid.
• Replacement hose: re-assembly to the same length, end type and orientation angle using the removed old hose as a sample.

How is it prepared?

Measurement and end identification

Overall length is measured by the widely accepted method, from the sealing surface of one end to the sealing surface of the other. On female swivel nut ends, the reference is the cone or O-ring seat inside the nut, not the nut face; on elbow ends, the measurement is taken to the centerline of the sealing surface. The measuring points are confirmed with you at order. On assemblies with elbows at both ends, if the orientation angle between the ends is not specified, the hose ends up twisted when connected on the machine. If the port standard is unclear, it is identified with a thread pitch gauge and diameter measurement.

Cutting and cleaning

The hose is cut square and clean; chips and dust from cutting are cleaned out of the hose bore. Contamination is one of the leading causes of valve and pump failures in hydraulic systems; a clean bore ensures the assembly does not carry dirt into the system at first start-up.

Crimping

The end must be suited to the hose type being used. The crimp diameter is set to the value specified by the hose and end manufacturer; after crimping, the diameter is measured and the end is checked for full seating on the hose. Under-crimping brings the risk of leaks and the end blowing off the hose, while over-crimping damages the reinforcement layers.

Testing and tagging

Pressure and leak-tightness verification is carried out depending on the application. Every assembly is tagged with its end type, length and order information; the ends are closed with protective caps and the assembly is prepared for shipment.

Installation notes: bend radius and twisting

• The hose must not be bent tighter than the minimum bend radius specified by the manufacturer; the bend should not start right at the end fitting, and a straight length should be left after the end.
• The hose must not be installed twisted; the layline printed on it should remain straight. Twisting strains the reinforcement layers and shortens service life.
• Under pressure, hose length may shorten or lengthen slightly; the line should not be installed fully taut.
• On moving connections, abrasion and pinch points should be checked, and clamps or protective sleeves used where necessary.

Quality control

• Check of end standard, angle and hose match against the order information
• Crimp diameter measurement and end seating check
• Check of overall length and elbow orientation angle
• Pressure and leak-tightness verification depending on the application
• Final check of tags, protective caps and packaging

Information required for ordering

• Hose inside diameter and overall length, together with the points it was measured from
• Working pressure, surge pressure if any, fluid and temperature
• Connection standard, size and angle of both ends (straight, 45° or 90°)
• On assemblies with elbows at both ends, the orientation angle between the ends
• Quantity and, if required, the need for a protective sleeve

Applications by sector

Deck machinery, crane and steering hydraulics on ships; pipe handling and hoisting equipment on drillships; press and mill roll lines in rolling mills; corrugator and actuator lines in paper and board mills; flexible connections on fire pump sets; mobile hydraulics in the defense industry; ground support and test equipment in aviation; transfer lines in chemical and food plants.

Lead time

Made-up hose assemblies are typically prepared within 5-15 business days; the time varies with end type, quantity and hose stock availability. Stainless steel hose ends from stock are typically ready to ship within 1-3 business days. For plants with a planned maintenance shutdown, if the list of hoses to be replaced is shared in advance, the assemblies can be prepared to match the shutdown date.