On-Site Hose Manufacturing
Assemblies crimped to specification where the machine is standing.
Making a hose is not complicated, but there are three or four places to get it wrong, and every one of them shows up later as a failure rather than immediately as an obvious mistake.
What actually matters when a hose is made up
The crimp diameter. Every ferrule has a specified crimp diameter published by its manufacturer. Under-crimp and the assembly can blow off the fitting under pressure. Over-crimp and the die bites into the wire reinforcement, which then corrodes and fails months later somewhere that looks nothing like a manufacturing fault.
Matching the components. Hose, ferrule and insert are designed as a set. Mixing a ferrule from one manufacturer with an insert from another can produce something that looks right, crimps to the right diameter and is not rated to anything, because nobody ever tested that combination.
Cleanliness. Cutting hose produces fine rubber and wire debris inside the bore. Blowing it through and capping the ends is the difference between a clean repair and putting swarf into a pump you will be replacing next year.
Length and orientation. Covered on the hose repair page, but it is the single most common thing done badly by someone working from a catalogue rather than the machine.
Batch work for fleets
If you run the same plant repeatedly, the same six or seven hoses go. It is worth having them on a shelf.
Bring us the pattern assemblies, or let us work through the machines in your yard, and we will make up a labelled and capped set. Your own fitter can then change a hose in twenty minutes without anyone calling us out, and we would rather sell you that than a callout at midnight.
What is included
- Hose cut and crimped on the van with a calibrated crimper and the correct die for the ferrule.
- Skived or non-skive as the fitting design requires, not whichever is quicker.
- Batch runs for fleet maintenance: bring us the pattern assemblies and we will make the set.
- Assemblies labelled and capped so the right one goes on the right machine weeks later.
Detail
| Wire braid | EN 853 1SN and 2SN |
|---|---|
| Spiral | EN 856 4SP and 4SH |
| Crimp control | Calibrated crimper, manufacturer crimp charts |
| Marking | Assemblies labelled with date and machine |
Common questions
Can you make up a batch for our fleet?
Yes. Give us the pattern assemblies or the machines and we will make a labelled set you can keep on the shelf. For a fleet that runs the same plant, having the six hoses that always go already made up turns a breakdown into a ten minute job for your own fitter.
How do you know the crimp is right?
Every ferrule has a published crimp diameter from its manufacturer. We crimp to it with the matching die and check it. A crimp that is out by half a millimetre will either not hold or will damage the reinforcement.
What is skiving and does my hose need it?
Skiving removes a layer of the hose cover or lining so the fitting grips the wire reinforcement directly. Some fitting designs require it and some are designed to be fitted without it. Doing it to a non-skive fitting, or skipping it on one that needs it, is a common cause of assemblies that blow off under pressure.
Do you supply just the hose without fitting it?
Yes, we are happy to make up assemblies for your own fitters to install. The warranty covers the assembly itself in that case rather than the installation.
Machine down? We can usually be with you the same day.
Tell us the machine, the hose and where you are. We will tell you honestly whether we can reach you and what it will cost before we set off.