Hydraulic systems are the backbone of many industrial applications - powerful, compact and efficient. However, their reliability depends on an often underestimated element: the correct routing of hydraulic hose lines. What may seem trivial at first glance is actually decisive for safety, service life and costs.

Improperly laid hose lines can lead to leaks, loss of performance or even serious accidents. This is precisely why DGUV Rule 113-020 defines clear specifications for the safe use of hydraulic hose lines - regardless of whether they are used in stationary or mobile applications.

Incorrect routing occurs more frequently than expected - and it has consequences:

• Kinks or excessively tight bending radii put a strain on the hose line and shorten its service life.

• Torsion and twisting can occur during installation and lead to leaks later on.

• Contact with sharp edges or hot surfaces will damage the hose cover.

• There is no room for manoeuvre - for example with working cylinders or swivel arms - which results in tensile stress.

Overall, this increases the risk of pressure loss, hose bursts and personal injury - an unnecessary safety risk that can be avoided with good planning.

DGUV Rule 113-020 "Hydraulic hose lines and hydraulic fluids" specifies how hose lines must be installed, operated and maintained in order to minimise health and safety risks. The employer is personally liable for compliance with this rule.

Some key points:

• Minimum bending radii must be observed

• Installation without torsion or buckling load

• Mechanical protection against external influences

• Secure fastening with suitable holders

• Labelling and documentation of the hose lines

• Regular inspection and timely replacement

These requirements apply equally to stationary and mobile systems - i.e. also on construction sites, in agricultural engineering or when used on vehicles.

Hydraulic hose lines must be installed carefully and in compliance with certain guidelines in order to ensure safe and reliable operation. To give you a simple overview, we have summarised a few basic points that you should pay attention to:

1. Choose the right length
   The hydraulic hose line must be long enough to avoid kinks and tensile loads during operation.
   
2. Observe the bending radius
   The minimum bending radius specified by the hose manufacturer must not be undercut, as otherwise the service life of the hose lines may be reduced.
   
3. Ensure torsion-free installation
   During installation, ensure that the hose line is not twisted.
   
4. Avoid chafing
   The hose line should be laid as freely as possible so that there is no abrasion of the upper hose cover. If you cannot guarantee a freely laid hose line, a chafe guard can be fitted.
   
5. Use secure fastening
   Hose clamps - from STAUFF, for example - ensure secure guidance, prevent uncontrolled movements and undesirable stress caused by the hose line's own weight.

With our wide range of hydraulic hoses, fittings and system components, we offer solutions that not only meet the technical requirements, but also help to implement the DGUV specifications in compliance with regulations.

Examples from practice:

• STAUFF hoses and fittings are designed for high pressures and tight bending radii and are certified accordingly.

• STAUFF hose clamps reliably secure hose lines against movement and vibration.

We will be happy to assist you in selecting and designing the right components for your application.

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