Hydraulic Hose Failures Under Pressure: Burst vs Pinhole vs Coupling Blow-Off Explained

Learn the causes of hydraulic hose failures, including burst, pinhole, and coupling blow off, and how Broda Hose keeps your equipment safe and running smoothly.

Hydraulic systems power some of the hardest-working equipment in Australia — from excavators on mining sites to tractors in the outback. But even the most rugged systems can experience hydraulic hose failures, and understanding why they happen is key to keeping your operations running smoothly.

Let’s take a closer look at the three most common types, including burst, pinhole, and coupling blow off, what causes them, and how to prevent them.

Burst Hydraulic Hose Failures: When Pressure Overloads

A burst hose is dramatic and often dangerous. It usually happens when the internal structure of the hose can no longer handle the pressure it’s subjected to.

Common causes include:

•  Over-pressurisation: Exceeding the hose’s rated working pressure can cause its inner tube and reinforcement layers to rupture.
•  Age and fatigue: Rubber hardens and weakens over time, reducing flexibility and pressure tolerance.
•  Improper routing: Tight bends or rubbing against sharp surfaces create stress points where the hose can split open.

When a burst occurs, hydraulic fluid escapes rapidly, creating a sudden loss of system pressure and potential for injury or fire hazards. Prevention involves regular inspections, replacing ageing hoses before they reach the end of their service life, and ensuring the correct pressure rating for each application.

Pinhole Leaks: The Silent Threat

While bursts are immediately noticeable, pinhole leaks are the silent offenders of hydraulic hose failures. They start as tiny perforations, often invisible to the eye, that gradually worsen over time.

Key characteristics of pinhole leaks:

•  They usually form from internal abrasion, where the fluid’s pressure erodes the inner tube.
•  External wear, such as rubbing against machinery or exposure to UV light, can also lead to micro-cracks.
•  Even a minuscule leak can spray fluid at high velocity, penetrating skin or damaging nearby components.

Pinhole leaks can go unnoticed, so regular maintenance is essential. Check for moisture, oil, or pressure drops, and contact Broda Hose for prompt inspection and replacement.

Coupling Blow-Off: When Connections Fail

Coupling blow-off is one of the most alarming hydraulic hose failures — when the hose end literally detaches from the fitting under pressure. This usually happens because of improper assembly, damaged fittings, or incorrect crimping.

To help you spot and prevent coupling issues, here are some critical points to remember:

•  Incorrect crimping: Using the wrong crimp diameter or tool for the hose type can lead to an insecure connection.
•  Contaminated fittings: Dirt or debris inside the fitting can weaken the bond between the hose and the ferrule.
•  Improper insertion depth: If the hose isn’t pushed far enough into the fitting before crimping, it’s likely to blow off under load.
•  Thermal cycling: Extreme temperature changes cause expansion and contraction that gradually loosen couplings.

Why Trust Broda Hose for Reliable Hydraulic Solutions

When your equipment is on the line, you need experts who understand the difference between a quick fix and a lasting solution. At Broda Hose, we specialise in diagnosing and preventing hydraulic hose failures before they cost you time or safety. Our technicians are fully trained, using high-quality materials and precision tools to ensure every hose is assembled and installed to meet Australian standards.

Don’t wait for the next failure. Contact us for expert advice, reliable replacements, and peace of mind under pressure.

Related Blog Articles:
Hydraulic System Maintenance Checklist for Heavy-duty Machinery
Broda Hose — Emergency Hydraulic Hose Replacement: Trusted Mobile On-site Repair Experts

Optimized by: Netwizard SEO