In hydraulic systems, the “channels” are often overlooked — yet hydraulic hoses are in fact the critical link through which hydraulic fluid is pumped, passes through valves, drives actuators, and then returns to the reservoir. Like blood vessels, they carry hydraulic medium, endure pressure shocks and environmental stress. A proper understanding of the structures, characteristics and applications of various hydraulic hose types helps engineers, maintenance personnel and designers to make informed decisions in routing, selection and maintenance — avoiding “the wrong hose”, system downtime, fluid leakage, or equipment damage. This article will first review hose types, then cover key selection considerations, and finally summarise when and why each type is appropriate and important.
Overview of Hose Types
Although there are many varieties of hydraulic hoses, we can categorise them from three dimensions: function + structure + material, considering reinforcement method, applicable pressure range and material differences.
Braided Hoses
Hydraulic braided hoses is the most common and versatile type. Typical structure: a flexible inner tubing (usually oil-resistant synthetic rubber) + reinforcement layer of metal wires or textile braiding + an outer protective cover.
Structural advantages & limitations:
The braided reinforcement layer gives the hose good flexibility and a small bending radius, facilitating routing in space-constrained environments.
However, in very high pressure, strong pulse environments (e.g., large diameter tubes, large flow pumps, mining equipment), its pressure resistance and impact resistance are inferior to spiral-type hoses.
Applications: Construction equipment, industrial machinery, agricultural machinery where flexible routing is needed and in standard to medium-high pressure zones (for example a few thousand psi or less).
Selection tips: If your system has tight routing spaces, needs high flexibility, and pressure is not extremely high, braided is a good choice. But if pulses or impacts are large, pressure is high, then choose carefully.
Spiral (Wound) Hoses
Compared to braided, spiral hoses are structurally more reinforced: multiple layers of steel wire wound in a spiral fashion, thus providing significantly higher pressure and impact resistance.
Structural advantages & limitations:
Excellent high‐pressure and pulse resistance, suitable for heavy-duty, mining, oil-drilling, and engineering machinery or extreme environments.
But flexibility is poorer, and the minimum bending radius is large — routing must allow generous space.
Applications: Heavy hydraulic systems, large-flow and high-pressure operating environments such as mining transport hydraulics, hydraulic main drives, excavators, etc.
Selection tips: When system pressure, pulses, impacts are significant (for example large diameter cylinders, large pump systems), use spiral type. During installation, leave sufficient bending radius and avoid tight bends which may lead to fatigue failure.
Thermoplastic Hoses
Thermoplastic hoses are made from synthetic materials such as polyamide (PA), polyester and polyurethane (PU), featuring lightweight, chemical resistance and UV resistance. Characteristics:
Lighter and more flexible; suitable for medium to high but not extreme high pressure applications.
The material resists chemical corrosion, UV exposure, and suits gas, chemical or water transport in certain scenarios.
Applications: Pneumatic systems, chemical liquid transmission, spray-clean operations, and environments requiring rapid routing or replacement.
Selection tips: Confirm the chemical compatibility of the medium (e.g., chemical agents, cleaning liquids), the temperature range, and material lifetime. If pressure or pulse is excessive then this type is not recommended.
Other Types
Beyond the three “structural reinforcement main streams” above, there are other hose types defined by function or application environment:
Transfer hoses for hydraulic oil conveyance
Return-line hoses for low-pressure return from actuator to tank
Push-on or quick-connect hoses for low-pressure, rapid assembly
Fleet hoses for trucks, buses, trailers, mobile air-brake systems and heavy-duty equipment
Specialty hoses for high-temperature, chemical, ultra-low-temperature, food/medical-grade applications
PTFE hoses (polytetrafluoroethylene) for chemical, pharma, food-grade service
Suction hydraulic hoses designed for vacuum or suction service These classifications reflect more of the purpose and application environment rather than just the reinforcement structure. In real systems, multiple types may be used in combination: e.g., the main pump output may use spiral type, a medium-pressure branch uses braided, a return line uses return‐line hose, a chemical cleaning circuit uses thermoplastic or specialty hose.
Key Selection Factors
Understanding hose types is one thing — the more critical part is the selection process. Hose selection affects performance, system life, safety and maintenance cost. The following are core dimensions:
Pressure rating: The hose’s rated working pressure must exceed the system’s maximum operating pressure and take into account shocks/pulses.
Temperature range: This includes ambient, oil temperature, coolant, and environment. Exceeding material limits will drastically shorten life.
Fluid compatibility: The type of hydraulic oil, its additives, chemical cleaning fluids, external environment chemicals may react with hose material — compatibility must be verified.
Flexibility & bend radius: Does the routing path restrict space? Is the minimum bend radius acceptable for the routing? Braided types are advantageous here.
Reinforcement type: Determines hose performance in pressure, pulse and lifespan. Braided, spiral, textile‐reinforced each have strengths and weaknesses.
Environmental conditions: Exposure to UV, chemical erosion, abrasion, vibration, oil mist, dust; need for anti-static, flame-resistant, explosion-proof features.
End‐fittings & connections: Hose to equipment connections, sealing, clamps, assemblies must match; after installation check for stretch, twist, compression.
Safety standards & lifespan: Selection should reference industry standards (e.g., SAE, EN), manufacturer test data. Cost should not be the sole determinant — quality directly influences system reliability.
Conclusion
Hydraulic hoses may seem just a part of the “fluid transport network”, but in a hydraulic system they play a critically important role. Correct hose selection not only enhances system performance but also determines maintenance intervals, failure rates, personal and equipment safety. When choosing, adopt the following steps:
Clearly define your hydraulic system’s operating parameters: maximum pressure, pulse frequency, temperature, media, routing space.
Based on those parameters select the hose type (e.g., main execution circuit uses spiral type, mid-pressure branch uses braided type, return line uses return hose, chemical cleaning line uses thermoplastic or specialty hose).
Consider environmental specificity (chemicals, abrasion, UV, anti-static etc) and select the appropriate cover material or specialty hose.
Verify end‐fittings, installation space, minimum bend radius, and allow for maintenance replacement space.
Prioritise brands with reliable certification, data support and global service networks to minimize risk.
