How to Choose the Appropriate Hydraulic Hose: Explained

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Choosing the right hydraulic hose for a high-pressure industrial tool application like Hydraulic Torque Wrenches can be a challenge, especially for those who are new to hydraulic tools or experienced technicians working on a new project. Whether you’re replacing an existing hose or setting up a new system, you need to ensure that the hose you select has the correct pressure rating, diameter, and length. It should also possess the right material properties for your specific application. If you’re looking for more information about hydraulic hoses and fittings you can reach out to the experts at Hyfit Hydraulics.

The consequences of making the wrong choice are significant, as it could lead to hose failures resulting in downtime, damage, the need for cleanup, and even potential personal injury. This article aims to provide clarity by delving into the fundamental concepts and terminology related to hydraulic hoses. Additionally, we will explore the various materials available, the range of sizes to choose from, and the different coupler options.

How to Choose the Appropriate Hydraulic Hose

As you make your choice of a hydraulic hose, there are certain factors that should be taken into consideration.

Hose Materials

It’s important to take into consideration the operating conditions that the hose will be subjected to. The outer layer or covering of a hose is available in various synthetic rubber materials. Some compositions may be advantageous for scenarios prone to abrasion, although they might not offer as much flexibility when bending.

Among the most prevalent materials are fluoropolymers, silicone, elastomers, metal, and thermoplastics. Additionally, composite or laminated materials are frequently encountered.

Fluoropolymer Hose: This is a type of hose made from a class of synthetic polymers known as fluoropolymers. Fluoropolymers are characterized by their excellent resistance to chemicals, extreme temperatures, and other harsh conditions. These hoses are widely used in various industries due to their unique properties.

Opting for rubber or elastomeric hydraulic hoses is a prudent decision if flexibility is a priority. On the other hand, a fluoropolymer hose boasts a resilient flex life along with exceptional resistance to corrosion and chemicals, making it apt for elevated temperatures.

Metal Hoses: Metal hoses, also known as flexible metal hoses or metallic hoses, are specialized types of hoses that are constructed using metal materials, typically stainless steel or other alloys. These hoses are designed to handle a wide range of applications in various industries, offering unique advantages over traditional rubber or plastic hoses.

They effectively manage elevated temperatures and the conveyance of high-flow materials. They exhibit the capacity to withstand substantial pressures while offering a choice between flexibility and rigidity.

Neoprene Hoses: This is a commonly favored synthetic cover material, that retains its flexibility across a broad temperature spectrum while effectively resisting abrasion. Most rubber hoses demonstrate satisfactory performance within a temperature range of -40°C (-40°F) to 100°C (212°F).

When contrasted with rigid tubing, flexible hoses prove effortless to install and route. Their pliability mitigates noise and vibrations, dampens pressure fluctuations, and facilitates movement between components.

Thermoplastic Hydraulic Hoses: This exhibits a notably compact minimum bend radius and excels in kink resistance. Comparatively, thermoplastic hoses are significantly lighter than their rubber counterparts. These hoses typically feature an inner tube crafted from copolyester or nylon, which is then either braided or spiral wrapped with a synthetic reinforcement fiber rather than steel. Synthetic fiber is also crucial for electrically non-conductive hoses with an orange cover, such as those designed for aerial lift applications.

In several instances, the outer covering of thermoplastic hoses will consist of polyurethane, contributing to an extended shelf life compared to rubber hoses. Furthermore, this polyurethane outer layer offers enhanced flexibility at low temperatures, including as low as -60°C (-75°F), and boasts increased resistance to UV radiation and chemical substances.

Inside Diameter and Length

Ensuring the proper inside diameter of a hose holds paramount importance. Should the diameter be insufficient for a given flow rate, it can lead to heightened linear velocity, subsequently inducing elevated friction and turbulence. This dual effect invariably culminates in noticeably escalated system pressure and heat levels.

The accurate determination of hose length is crucial to accommodate the dynamic bending and flexing that occurs as machinery moves and articulates. This consideration extends to preventing undue stress at crimped fittings. Even a hose that links components in a completely linear trajectory may experience a contraction of up to 4% at maximum pressure. Therefore, an allowance for additional length becomes imperative during the assembly process.

Nonetheless, an overly elongated hose introduces flow restrictions, contributing to increased system pressure and diminished overall efficiency. The utilization of an excessively lengthy hose also necessitates a larger inner diameter to avert unwarranted restriction and friction.

Weight and Space

When choosing a hose, an additional factor to ponder is the significance of weight and space, which frequently comes into play with mobile machinery. In such cases, opting for hoses equipped with a thin-wall inner tube becomes pertinent. Recent developments in synthetic rubber compounds have enabled heightened wall strength, leading to the creation of end products with reduced outer diameters.

Certain manufacturers have transitioned to a reinforcement wire featuring an oval cross-section, departing from the conventional round design. This alteration contributes to additional outside diameter (O.D.) reductions and reductions in hose weight. These hoses with diminished O.D., often categorized as compact models in various catalogues, also boast markedly more compact bend radiuses.

Pressure Rating

Selecting a suitable hose necessitates choosing a maximum working pressure (WP) rating that meets or preferably surpasses the typical maximum pressure of the hydraulic system. It’s essential to ensure that momentary pressure spikes within the hydraulic system remain below this pressure rating. Should hose fittings possess a rating lower than the selected hose’s working pressure, the entire hose assembly aligns with the lower rating of the fittings.

Burst pressure serves as an inherent safety margin for hydraulic hoses. Hose manufacturers ascertain burst pressure through a destructive test. Some hose applied to the common series of 100R hydraulic hoses, not only categorizes leakage but also assesses the potential separation of the hose from the fitting. It’s worth noting that a burst failure need not result in a complete and violent disintegration of the hose. Typically, the burst pressure rating of a hydraulic hose is at least four times the working pressure rating, if not greater.


In hydraulic design, hoses play a substantial role and should not be considered minor components. Relying solely or primarily on economic factors for hose selection can significantly elevate human risks. A burst failure of a hose always leads to a catastrophic event. Under the best circumstances, such a failure might result in production downtime or raise concerns about environmental contamination. In more dire situations, individuals could sustain severe injuries or even lose their lives.

Hydraulic hoses are available in a diverse array of design variations and materials. Choosing the appropriate type for your specific application requires a thorough grasp of multiple factors. You now possess the foundational understanding necessary to correctly identify the suitable hydraulic hose for your requirements.

Where to buy Hydraulic Hoses

If you’re seeking to buy hydraulic hoses compatible with TorcStark tools, you can acquire them from the nearest TorcStark distributor within your vicinity. TorcStark holds unparalleled expertise in the design and production of hydraulic hoses, couplers, bolting tools, and more.

In contrast to well-established bolting equipment brands with over a century of presence in Europe and the United States, we distinctly stand out in terms of both product quality and pricing. Currently, TorcStark not only manufactures and offers hydraulic hoses, but we have also expanded our range to encompass nut and bolt tightening tools utilizing both electricity and gas as power sources.