Order Custom Hose Assemblies

What are custom hose assemblies?

A hose assembly is a pressure-resistant hose kit with hose fittings at both ends, consisting of an inner liner, reinforcing layer, middle rubber layer, outer sheath (fire-retardant layer), and optional protective layer. Custom hose assemblies are designed to meet specific user needs, typically including the hose body, fittings, and protective layers, satisfying the special requirements of different industries for pressure, temperature, materials, or connection methods.

Unlike general-purpose hoses, custom hose assemblies are manufactured to meet the specific needs of a customer’s equipment. They precisely match the system’s pressure rating, media type, environmental conditions, temperature range, and installation method, resulting in more reliable, safer, and specialized hose assemblies. They are widely used in engineering machinery, agricultural equipment, industrial hydraulic systems, the oil and gas industry, automotive modification, fire protection, construction, mining, and chemical transportation.

Strongflex is a high-quality hose assembly supplier with ISO 9001:2015 certification. Strongflex is our brand and a symbol of our quality. Founded in 2001, the company has over 20 years of industry experience and a factory producing various hoses. Equipped with professional production equipment, a strict quality control system, responsible production workers, and experienced sales personnel, we can provide customized hose assemblies and fitting solutions based on drawings, samples, etc. Notably, we welcome custom hose orders exceeding 1000 meters, with discounts for bulk orders.

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Custom Hose Assemblies Specifications

Hose Customization

1. Hose Types: We offer customizable hoses covering:

• Hydraulic hose assemblies
• Pneumatic hose assemblies
• Industrial hose assemblies including water hoses, air hoses, oil hoses, material hoses, etc.
• Customized hose assemblies for special requirements, including chemical hoses, food-grade hoses, medical-grade hoses, etc.
• Fire hose assemblies
• Silicone hose assemblies for automotive, medical, and other industries
• Customized cable assemblies

2. Hose Parameters: Including hose length, inner and outer diameters, bending radius, reinforcing layers, etc. If you have samples, please send them to us, and we will measure and test them. Regarding length, you can provide the hose length or the total length of the finished product, and we will measure it.
3. Working Environment and Media Requirements: The working environment includes temperature range, pressure rating, humidity range, and whether it will be exposed to direct sunlight, friction, contact with corrosive liquids, or require anti-static properties, etc. Based on the working environment and media requirements, we will select the materials for the inner and outer layers of the hose.

Custom Hose Fittings

1. Fitting Type

Customer must provide or manufacturer recommends:

• BSP / BSPT
• Metric
• JIC 37°
• ORFS
• NPT / NPSM
• SAE Flange (3000 psi / 6000 psi)
• Banjo
• Quick Coupler
• Hydraulic fittings

2. Fitting Shape and Size

General shapes are straight, 45° elbow, 90° elbow, and special angles (30°, 60°, 120° customizable). Fitting dimensions include thread size, inner and outer diameter, and insertion length into the hose. Due to the stringent data requirements, please provide drawings, samples, or measurement data at the locations specified by our sales staff.

3. Fitting Material

• Galvanized carbon steel
• Stainless steel (304, 316)
• Brass
• Aluminum alloy

Select the fitting material based on the working environment and pressure intensity of the hose assembly.

4. Fitting Direction

For hoses with elbows at both ends, the relative angle must be provided! Use one end as the 0° (12 o’clock position) reference, and mark the other end according to the clock face, as shown in the image below:

Custom Hose Assemblies ends

If you wish to customize this type of flexible hose assembly, please take a picture of the actual device, or take a side view as shown in the image above for angle comparison.

Additional Requirements

1. Protective Sheath

• Nylon explosion-proof sheath
• Spiral protective sleeve
• Fire blanket

2. Testing and Certification

We can provide test reports for finished products, such as pressure test reports, burst test reports, etc. Please specify this when placing your order if needed.

3. Marking and Packaging

Hose trademarks and printed text can be customized. Please provide the text you wish to print. To reduce wear and tear during transportation, we offer various packaging options, including palletized transport, single-bag transport, and carton packing. All customization details should be confirmed before production begins to ensure timely, efficient, and smooth production.

Give us your customization needs

Why Hydraulic Hose Assembly Is Important

Hydraulic hose assemblies are critical components within hydraulic systems; their primary function is to interconnect various system elements, serving as conduits for the transmission of hydraulic fluid. In the diverse array of machinery utilized in industrial production, hydraulic systems rely on the transmission of power via hydraulic fluid to execute operational tasks. The principal reason why hydraulic hose assemblies are favored over separate bulk hoses and fittings is that they significantly simplify both the procurement and installation processes.

Let us first outline the key fundamental reasons highlighting the importance of hydraulic hose assemblies:

1. Medium for Power Transmission: The core function of a hydraulic system is to transmit power and energy through fluid pressure. Hydraulic hoses are responsible for conveying hydraulic fluid from one point to another; hydraulic hose assemblies facilitate the seamless matching and interconnection of various hydraulic components—such as pumps, valves, cylinders, and motors—thereby ensuring the complete and efficient transmission of energy throughout the entire system.

2. Adaptability to Complex Motion and Vibration: Hydraulic hoses possess exceptional flexibility, allowing them to flex and extend in tandem with the movements of dynamic hydraulic components. Furthermore, they are capable of absorbing the high-frequency vibrations and pressure pulses generated by hydraulic pumps—a key advantage that distinguishes hydraulic hoses from rigid piping. Purchasing pre-assembled hydraulic hose assemblies not only simplifies installation but also provides superior protection against hose detachment from fittings during equipment vibration; this is because manufacturers securely crimp or assemble the hose and fittings together, subjecting the finished assemblies to rigorous testing prior to shipment to ensure operational safety.

3. Ensuring System Sealing Integrity and Safety:

The fittings at both ends of a hose assembly—whether crimped or mechanically assembled—must be guaranteed to remain leak-free under high-pressure conditions. Pre-manufactured hydraulic hose assemblies undergo comprehensive testing—including checks for sealing integrity and pressure resistance—prior to leaving the factory, thereby guaranteeing the overall leak-tightness and safety of the hydraulic system. This process effectively eliminates the risks associated with mismatched connections. In the event of damage, replacement hoses can be systematically procured based on batch-specific information; unlike custom-assembled hoses made from bulk materials—where there is no guarantee that the hose and fittings were manufactured by the same vendor—this approach ensures perfect compatibility, thereby avoiding the increased difficulties typically associated with matching disparate components.

Equipment Needed for Assembling Hydraulic Hose

Hydraulic hose assemblies are present in almost all mechanical equipment that needs to transmit enormous forces and requires flexible movement. In other words, if you see a machine with a moving boom, a heavy object being lifted, or immense pressure being applied, it almost certainly contains a hydraulic hose assembly.

Specific applications include:
1. Construction machinery: This is arguably the most widespread application area.

Excavators: All movements of the boom, stick, and bucket, as well as the slewing and travel drives, rely on dozens of hose assemblies.

Loaders, bulldozers, and cranes: The sliding of the telescopic boom and the lifting of heavy objects all depend on the assistance of hydraulic hose assemblies.

Other construction machinery includes road rollers and concrete pump trucks.

2. Agricultural and forestry machinery:
Tractors, harvesters, and logging machines all contain hydraulic lifting systems, where the wear resistance and flexibility of the hydraulic hose assembly play a crucial role.

3. Industrial manufacturing equipment:
Injection molding machines, stamping machines, and CNC machine tools used in factories also utilize hydraulic hose assemblies, requiring the hoses to withstand significant pressure.

4. Mining Machinery

Hydraulic supports: Giant pieces of equipment used in coal mining to support the mine roof (this is one of the places with the highest density of hose assemblies). Hydraulic hose assemblies are also used in oil drilling equipment control systems.

5. Hydraulic assemblies are used in various vehicles, ships, and aerospace applications in the transportation industry.

Step-by-Step Hydraulic Hose Assembly Process

Many companies purchase individual components with the intention of assembling hydraulic hoses themselves. While this approach is indeed more cost-effective than purchasing pre-assembled hydraulic hose assemblies, there are several important considerations to keep in mind. The following steps outline the hydraulic hose assembly process in detail.

Step 1: Prepare Tools and Materials

• Hydraulic Hose: Pre-cut to the required length.
• Hydraulic Fittings: The specific hose inserts (stems) and ferrules (sleeves) that match the hose.
• Hose Lubricant: Hydraulic fluid or a specialized assembly lubricant.
• Ultra-Clean Nozzle, Cleaning Projectiles, and Sealing Caps: Used for cleaning the interior of the hose.
• Calipers: To measure the outside diameter after crimping and ensure compliance with standards.
• Marking Pen: To mark length or insertion depth on the hose.
• Safety Goggles: To protect the operator’s eyes.
• Crimping Machine: Used to securely fasten the fittings.
• Cutting Machine: A specialized abrasive wheel cutter or fine-toothed saw to ensure a perpendicular cut surface.
• Skiving Machine: Required if the specific fittings necessitate skiving (removing the outer rubber layer).

Step 2: Wear Safety Gear
Please ensure you are wearing appropriate personal protective equipment (PPE) to safeguard the operator during the cutting and crimping processes.

Step 3: Measure and Cut the Hose

If you have purchased bulk hose—which typically comes in rolls rather than pre-cut lengths—you must measure the appropriate length based on your system’s installation requirements. Mark the designated cut point with a marking pen, and then use a hose cutting machine to cut the hose perpendicularly to the required size. When measuring, be sure to account for any changes in hose length that may occur during the fitting assembly process. When cutting, ensure that the cut surface forms a precise 90-degree angle relative to the hose’s central axis; excessive deviation can compromise the integrity of the seal.

Cleaning the hose after cutting is equally important. If the cut edges are uneven or rough, use a file or sandpaper to smooth them down.

If required by the specific fittings being used, the outer rubber layer of the hydraulic hose must be skived (removed) prior to crimping. This can be accomplished using a dedicated skiving machine; alternatively, a combined cutting and skiving machine is an excellent choice.

Before installing the fittings, the interior of the hose should be thoroughly cleaned using ultra-clean projectiles. Launch a projectile from one end of the hose, allowing it to travel through the entire length, and then launch a second projectile from the opposite end to ensure a complete cleaning pass. This effectively cleans the interior of the hose, preventing cutting debris and other foreign matter from interfering with subsequent operation.

Step 4: Mark the Insertion Depth
Place the fitting stem (or the complete fitting assembly) against the cut end of the hose. Use a marker pen to draw a line on the outer wall of the hose, marking the maximum insertion limit for the fitting. This ensures that the hose is neither inserted too shallowly (resulting in an insecure crimp) nor too deeply (obstructing the fluid flow).

Step 5: Lubricate the Hose
Apply a small amount of lubricant to the end of the hose and the interior of the fitting. *Never* use lubricants containing silicone or graphite, as these can contaminate the hydraulic system.

Step 6: Assemble the Fitting
If using a one-piece fitting, simply push the entire fitting directly into the end of the hose until it reaches the proper position. If using a two-piece fitting, first slide the ferrule onto the exterior of the hose—paying close attention to its orientation—then insert the fitting stem into the interior of the hose, aligning the outer edge of the fitting with the mark you previously made.

Step 7: Crimp the Fitting
This is the most critical step and requires the use of a crimping machine and the correct dies.
1. Select Dies: Choose the correct die size based on the fitting specifications and the crimping chart provided by the manufacturer.
2. Positioning: Place the assembled hose and fitting into the crimping machine’s die cavity, ensuring it is positioned correctly.
3. Crimping: Activate the crimping machine until the dies are fully closed or the specified crimp diameter is achieved.
4. Measurement: After crimping, use a caliper to measure the post-crimp diameter of the ferrule (outer sleeve) to ensure it falls within the tolerance range specified in the technical chart.

Step 8: Final Inspection

Inspect the fitting ferrule for any cracks or signs of metal flaking. Check the paint mark you made on the hose. If the mark is no longer aligned with the base of the fitting, it indicates that the hose or fitting shifted during the crimping process. No matter how tight it may appear, this does *not* constitute a valid crimp. If the mark remains aligned, it signifies that you have successfully crimped both ends of the hydraulic hose assembly. Measure the crimp diameter at the flat surface of the hose ferrule and cross-reference it with the specified crimp diameter listed on the product label.

Never use or sell a hose assembly with an incorrect crimp diameter.

Step 9: Other Considerations
Pressure Testing: Prior to being put into service, the assembled hose assembly is recommended to undergo a static pressure test at 1.5 times the working pressure to ensure leak-free operation.
Bend Radius: During installation, ensure that the hose’s bend radius is no less than the minimum allowable bend radius; failure to do so will reduce the hose’s service life.
Cleanliness: Always maintain the cleanliness of the hose’s inner bore to prevent contaminants from entering the hydraulic system.

Custom Strongflex Hydraulic Hose Assemblies Process

fter confirming your requirements, we can compile data based on various parameters, combined with the required quantity and shipping location, to provide a quote and delivery date. Once confirmed, place the order, receive payment, and arrange production.

Regarding production, we manufacture hoses and fittings according to the materials and structure, including hose cutting, fitting and hose crimping, cleaning and rinsing, pressure testing, and packaging and shipping after passing the tests.

Most orders typically ship in 5-30 days. Specialty jobs may take longer, but our team prioritizes fast turnarounds and minimal downtime.

After-Sales Service

Strongflex high-pressure hoses not only select high-quality raw materials but also have strict quality control during the production process, precisely controlling every production step. We provide free test samples and various quality inspection reports. We offer worry-free after-sales service.

We are 100% responsible for the products we ship. In case of any problems, our experienced team provides comprehensive support. Of course, we will conduct multiple tests before shipment to avoid problems at all costs.

Five Common Mistakes in Custom Hose Assemblies

1. Focusing solely on price while neglecting the overall cost of the assembly, prioritizing cost savings over quality control, may result in a short lifespan, affecting future replacements and increasing overall costs.
2. Customizing incorrect hose assembly sizes, guessing hose dimensions, failing to perform accurate measurements, or not seeking expert help, leading to inaccurate measurements.
3. Ignoring bending radius and length, problems are only discovered during installation.
4. Providing only pressure parameters, ignoring other critical operating conditions.
5. Neglecting connector compatibility, considering only the compatibility between connectors and hoses during customization, without considering the connection between connectors and the system, resulting in improper and incomplete tight connections.