What Pressure Ratings Should I Look for in Industrial Hoses?
Selecting the correct pressure rating for industrial hoses is fundamental to maintaining safety, compliance, and reliable performance in manufacturing, processing, food, beverage, chemical, and pharmaceutical environments. The right pressure rating ensures your hose can handle the demands of your system, prevents failures, and extends the lifespan of your hose assemblies.
This guide explains how to understand, select, and verify industrial hose pressure ratings, with practical advice and expert insights.
For a full technical resource, visit our industrial hose pressure guide.
Understanding Industrial Hose Pressure Ratings
Industrial hose pressure ratings indicate the maximum pressure a hose can safely withstand during operation. These ratings are typically listed in bar or psi and are determined by the hose’s construction, material, diameter, and intended use. Always consider both the working pressure (maximum continuous pressure) and the burst pressure (the point at which the hose will fail).
The industrial hose pressure guide provides detailed specifications for each hose type, helping you choose the right hose for your requirements.
Working Pressure vs Burst Pressure in Industrial Hoses
Working pressure is the maximum pressure a hose is designed to handle safely in continuous operation. Burst pressure is the point of catastrophic failure, usually four times the working pressure. Always base your hose selection on the working pressure, not the burst pressure. For example, if your system operates at 10 bar, select a hose with a working pressure of at least 10 bar, ideally with a safety margin.
More information is available in the industrial hose pressure guide.
Factors Affecting Pressure Ratings in Industrial Hoses
Several factors influence a hose’s pressure rating. These include:
Hose material (rubber, PTFE, stainless steel, composite, PVC)
Wall thickness and reinforcement (braided, spiral, wire, textile)
Hose diameter (smaller diameters typically have higher pressure ratings)
Temperature of the media and environment
Age, wear, and previous use
Always consult manufacturer data and the industrial hose pressure guide for specific pressure ratings.
Temperature and Pressure Derating in Industrial Hose Selection
As temperature increases, the pressure rating of most hoses decreases, a phenomenon known as temperature derating. For example, a hose rated at 20 bar at 20°C may only be safe at 10 bar at 80°C.
Always use derating charts and consult the industrial hose pressure guide to ensure safe operation at your system’s temperatures.
Choosing the Right Pressure Rating for Your Application
To select the correct pressure rating:
Identify your system’s maximum operating pressure
Add a safety margin (typically 25% above maximum operating pressure)
Consider pressure spikes or surges
Factor in temperature derating and environmental conditions
For high-pressure applications, such as hydraulic systems or steam transfer, always use hoses specifically rated for those pressures.
For custom applications, Flextech offers custom hose assemblies.
Pressure Ratings for Different Hose Materials
Understanding the pressure ratings of different hose materials is essential for selecting the right hose for your application. Each type of hose is designed to operate safely within specific pressure ranges and environments. Below is a summary of common hose materials and their typical pressure capabilities to help guide your choice:
Rubber hoses: Commonly rated from 10 to 40 bar, suitable for air, water, and mild chemicals
PTFE hoses: Can handle 70 bar or more, excellent for high-pressure chemical and steam applications
Stainless steel hoses: Suitable for pressures up to 300 bar, ideal for extreme environments
PVC hoses: Generally lower, from 5 to 20 bar, best for light-duty and non-critical applications
Composite hoses: Typically 10 to 25 bar, used for oil, fuel, and chemical transfer
For more details, see the industrial hose pressure guide.
Pressure Testing and Certification for Industrial Hoses
Pressure testing is essential to verify hose integrity and compliance. Hoses should be hydrostatically tested to at least 1.5 times their working pressure before use and periodically during service. We recommend always requesting test certificates and documentation from your supplier with your order.
Flextech provides hose inspection and testing to ensure your hoses meet industry standards.
Safety Margins and Best Practices for Industrial Hose Pressure
Never operate a hose at its maximum rated pressure. It’s important to always include a safety margin to accommodate unexpected pressure spikes, temperature fluctuations, and natural wear over time. This precaution helps prevent premature hose failure and enhances overall system reliability. For critical or high-risk applications, consider selecting hoses with pressure ratings significantly higher than your operating requirements to provide an additional layer of safety.
Regularly inspect hoses for any signs of bulging, cracking, leaks, or other damage, and replace them promptly when issues are detected to maintain safe and efficient operation.
For guidance on safe operation, see our industrial hose pressure guide.
Common Pressure-Related Failures and How to Avoid Them
Pressure-related hose failures can include bursting, leaking at the fittings, or liner separation. These failures are often caused by exceeding the pressure rating, improper installation, or using the wrong hose type. To avoid these issues:
Always match the hose to the application’s pressure requirements
Use proper fittings and secure installation methods
Inspect hoses regularly and replace them at the first sign of wear
For troubleshooting and support, visit our industrial hose pressure guide.
Industry Standards and Compliance for Pressure-Rated Hoses
Industrial hoses must comply with standards such as EN 12115, ISO 1402, and relevant industry regulations. Compliance ensures hoses are tested for pressure, flexibility, and chemical compatibility.
We advise always requesting supporting documentation and certification for your hose assemblies.
For more information, see our quality assurance page.
Selecting High-Pressure Hoses for Special Applications
Certain industries require hoses rated for very high pressures, such as hydraulic, steam, and high-pressure gas transfer. Flextech offers a range of metal hose assemblies and PTFE hose assemblies designed for these demanding applications.
Always consult technical data and the industrial hose pressure guide when specifying hoses for critical systems.
Pressure Ratings for Food, Beverage, and Pharmaceutical Hoses
Hoses used in food, beverage, and pharmaceutical processing must not only meet pressure requirements but also comply with hygiene and traceability standards.
Flextech’s food grade hoses and pharmaceutical hoses are designed for safe operation under pressure and regular cleaning cycles.
Pressure Ratings and Hose Selection for Abrasive and Chemical Media
When handling abrasive or aggressive chemicals, pressure ratings must be paired with chemical compatibility. UHMWPE, PTFE, and FEP-lined hoses are often chosen for their high pressure and chemical resistance.
Always refer to Flextech’s chemical compatibility guide and select hoses with the right pressure rating for your specific media.
The Role of Hose Diameter in Pressure Ratings
Smaller diameter hoses generally have higher pressure ratings due to increased wall strength. However, selecting a hose with too small a diameter can cause flow restrictions and increased wear. Balance pressure requirements with optimal flow rates for your application.
For technical advice, see our industrial hose pressure guide.
Maintenance, Inspection, and Asset Management for Pressure Hoses
Regular inspection and maintenance are essential for safe operation. You should always check for bulges, cracks, leaks, or signs of wear and document all inspections and replacements in your asset management system.
Flextech’s hose asset management service can help you manage hose registers and inspection schedules.
Frequently Asked Questions: Industrial Hose Pressure Ratings
How do I determine the correct pressure rating for my hose?
Identify your system’s maximum operating pressure, add a safety margin, and consult the industrial hose pressure guide for suitable hose types.
What is the difference between working pressure and burst pressure?
Working pressure is the maximum safe continuous pressure; burst pressure is the point of failure, usually four times the working pressure.
How often should hoses be pressure tested?
Test before first use and at regular intervals, especially in critical or high-pressure applications. Flextech offers hose inspection and testing.
Can I use a hose at its maximum rated pressure?
It is best practice to operate below the maximum rating and include a safety margin for spikes and wear.
Where can I find more technical information?
Visit our industrial hose pressure guide for detailed resources.
Conclusion: Trust Flextech for Industrial Hose Pressure Ratings
Choosing the right pressure rating is essential for safety, compliance, and long-term performance. Flextech’s industrial hose pressure guide provides detailed advice, technical support, and a full range of pressure-rated hoses for every industry.
For custom solutions, technical support, or to discuss your requirements, trust Flextech as your partner in industrial hose safety and performance.