Hose press

Hose presses are key tools for assembling and maintaining hydraulic hoses. Wherever hydraulic tools such as concrete demolition shear, rock and concrete splitters, combination shears, or tank cutters are used, correctly crimped hoses ensure performance and operational safety. In fields such as concrete demolition and special deconstruction, gutting and cutting, rock excavation and tunnel construction, as well as natural stone extraction, professional crimping ensures that power units and connected tools operate reliably, are leak-tight, and remain within tolerance. In addition, high-quality crimping minimizes unplanned downtime, supports compliance with applicable standards, and contributes to sustainable operation through leak prevention and extended service life.

Definition: What is meant by a hose press?

A hose press is a hydraulic or electrohydraulic press for crimping hose fittings onto hydraulic hoses. The fitting is applied to the hose with a defined crimp dimension using segmented press jaws. The result is a force- and form-fit connection with high pressure resistance and low leakage risk. Hose presses are designed for different hose types (braided and spiral hoses), nominal sizes, and pressure ranges. In practice, the machine is also referred to as a hose crimping machine or crimping press and performs a controlled radial compression of the ferrule so that reinforcement layers and sealing surfaces interact as intended.

Design and operating principle of a hose press

Hose presses essentially consist of a press head, segmented press jaws (inserts), a drive unit, and measuring or adjustment mechanics for the crimp dimension. The crimping process evenly reduces the outer diameter of the fitting and presses its ferrule into the hose material and its reinforcements. The crimp dimension is defined via stop rings, spacer plates, or a fine adjustment on the device. Modern devices feature scales, end stops, or digital displays to reproducibly maintain the required crimp size. Depending on the application, drives can be manual, electric, or engine-driven for mobile use; quick-change jaw systems, integrated lighting of the crimp area, and protective covers further support safe, repeatable operation.

Relevance when used with concrete demolition shears and rock and concrete splitters

Hydraulic concrete demolition shear and rock and concrete splitters require pressure-resistant, vibration- and abrasion-resistant hose lines. Pressure spikes during demolition, impact loads, and abrasive environments demand a precise crimp dimension and suitable fittings. Professionally executed crimping reduces downtime, prevents leaks, and protects power units as well as valves from cavitation and contamination. In addition, correctly dimensioned assemblies limit flow losses, help maintain response times under pulsating loads, and reduce the risk of micro-movement between ferrule and fitting body that can otherwise promote fretting and premature failure.

Components: hose, fitting, and press jaws

Hose types

• Braided hose: 1SN/2SN (DIN EN 853) for medium pressures
• Multi-spiral hose: 4SP/4SH (DIN EN 856) for high pressures and pressure spikes
• Textile-reinforced lines (DIN EN 854) for lower pressures and return lines
• Application note: Cover compounds with enhanced abrasion resistance or flame retardancy are advantageous in demolition, tunnel construction, and rock excavation environments.

Fittings

• Straight, 45°, and 90° elbows for tight installation spaces
• Female thread, male thread, flanges depending on the connection to power units and tools
• Ferrules matched to the hose type, if necessary with inside/outside skiving
• Compatibility: Geometry, thread form, and sealing principle must correspond to the hydraulic interface to avoid flow restrictions and sealing mismatches.

Press jaws

• Jaw sets in graduated diameters
• Tapered lead-ins for clean centering
• Interchangeable and marked with the target dimension
• Calibration and go/no-go rings or gauges for verifying the achieved crimp size

Step by step: crimping a hydraulic hose

1. Check configuration: determine hose type, nominal size, pressure range, fitting, and required crimp dimension according to the data sheet.
2. Cut the hose to length: cut square, deburr the ends, perform skiving if required (inside/outside as specified).
3. Slide on the fitting: insert the hose up to the stop, do not damage the reinforcement.
4. Select the press jaw: insert and lock the jaw set corresponding to the target crimp dimension.
5. Set the crimp dimension: set the stop/scale, make a trial crimp, check the dimension with a gauge.
6. Crimp: crimp the fitting evenly, ensure a concentric seat.
7. Inspection: measure the ferrule’s outside diameter, check ovality, inspect the sealing surface.
8. Mark/document: record batches, dimensions, and date; perform a pressure test if required.
9. Cleanliness and protection: flush components if necessary, cap the hose ends, and maintain cleanliness to prevent particle ingress.
10. Functional check: verify minimum bend radius, absence of twist, and correct orientation of angled fittings before commissioning.

Quality assurance and dimensional accuracy

The crimp dimension is the key quality parameter. It depends on hose construction, fitting, and operating pressure. Too small a dimension can damage the hose; too large a dimension leads to leaks. For applications with concrete demolition shear or in natural stone extraction, trial crimps, random sampling measurements, and proof pressure tests should be firmly established. Test plans with tolerance windows, incoming inspection of fittings, and regular calibration of the press are advisable. Documented measuring methods (e.g., calibrated ring gauges or digital calipers), defined rework rules, and traceable batch data increase process capability and reduce rework and warranty risk.

Safety and standard notes

Hydraulic systems involve high energy densities. Generally accepted rules of technology, e.g., requirements for hydraulic hose assemblies according to relevant DIN/EN and ISO standards, should be observed. These include product-specific hose standards (e.g., DIN EN 853 to 857) and fundamental safety rules for hydraulic systems. Specifications for operating and test pressures, temperature ranges, and media compatibility of hose assemblies must always be observed. These notes are general in nature and do not replace an individual assessment of the specific case. Applicable safety provisions for pressure testing and installation, including pressure relief procedures and guarding of rotating or moving parts, must be followed.

Selection criteria for hose presses in demolition and deconstruction environments

• Crimp range and jaw capacity: coverage of the required nominal sizes including spiral hoses
• Repeatability: stable crimp dimensions even in series production
• Usability and mobility: workshop or mobile press for use on the construction site
• Documentation: gauges, scales, optional digital logging
• Robustness: protection against dust, moisture, and mechanical impacts
• Throughput and ergonomics: cycle time, accessibility of the crimp zone, and quick-change jaws for reduced setup time
• Power supply and noise: suitable drive type for the environment and acceptable sound levels in confined spaces

Practical relevance: power units, concrete demolition shears and rock and concrete splitters

Hydraulic power units supply the working pressure for concrete demolition shear, rock and concrete splitters, combination shears, multi cutters, steel shears, and tank cutters. The connection is made via hose assemblies with suitable fittings. With frequent tool changes and harsh conditions, swiveling connections, abrasion-resistant covers, and well-guided hose routing are advisable. If a tool is used intensively in tunnel construction or during gutting, preventive hose inspection and, if necessary, replacement of complete hose pairs is recommended to avoid pressure losses and asymmetric tool behavior. Observing minimum bend radius, avoiding torsion during installation, and selecting the correct nominal size for the targeted flow help maintain tool performance and reduce heat generation.

Maintenance, care, and typical failure patterns

Preventive measures

• Regular cleaning of press head and jaws, light lubrication of guides
• Check hoses for cracks and abrasion, add protective spirals
• Observe calibration intervals of the hose press
• Inspect dies for wear, corrosion, or damage; replace if markings become illegible or dimensions drift

Common causes of failures

• Incorrect crimp dimension or unsuitable jaw set
• Insufficient hose preparation (angled cut, burr, missing skiving where required by the fitting)
• Contaminated components that damage sealing surfaces
• Unsuitable hose/fitting combination for the pressure or temperature range
• Torsion introduced during assembly, excessive bend radii, or kinking close to the ferrule

Ergonomics and occupational safety

A press with good accessibility and secure workpiece holding reduces the risk of injury. Protection against pinch points, clear visibility of the crimping area, and reliable emergency-stop functions are important. When working with hydraulic hoses, cut-resistant gloves, eye protection, and orderly storage are advisable. Pressure relief before disconnecting lines is mandatory. Adjustable working height, adequate illumination of the crimp zone, and intuitive controls (e.g., foot pedal or two-hand operation as appropriate) further enhance safe, efficient handling.

Documentation and traceability

In professional demolition and special deconstruction, structured documentation helps: hose types used, fittings, crimp dimensions, date, and operator. Serial numbers of power units and associated tools can be assigned. This enables maintenance cycles to be planned and reduces downtime. Digital recording with batch numbers, calibration status of measuring equipment, and optional QR code labels on assemblies improves traceability and simplifies audits and field service.

Material and environmental aspects

Hydraulic oil, seals, and hose materials must be compatible. Leak prevention through correctly crimped fittings protects the environment and the construction site. Old parts must be properly disposed of. A clean assembly environment reduces particle ingress into the hydraulic system, protecting valves, cylinders, and control blocks. Where applicable, the use of compatible low-toxicity or biodegradable hydraulic fluids, spill prevention measures, and recycling of metal components support responsible resource management.

Terminology in context

In common usage, hose press, crimping tool, and crimping machine are used synonymously. Press jaws are also called inserts; the target dimension is referred to as the crimp dimension or crimp size. Fittings comprise the ferrule and the connection form (e.g., thread or flange). In conjunction with tools such as concrete demolition shear or rock and concrete splitters, compatibility of fitting, nominal size, flow, and pressure must always be ensured. The term skiving denotes the removal of inner and/or outer cover material as specified by the fitting system so that the ferrule engages the reinforcement as designed.