Hose crimping - a comprehensive guide

Hose Crimping

What is hose crimping?

Hose crimping is the process that involves bonding a hose to a metal tip. This allows you to later connect it to a pressure source. To crimp a hose, you need both the aforementioned tip and a collet (also known as a hose ferrule).

Industrial hoses are one of the most popular transmission cables because they combine simplicity of execution with features such as tightness and flexibility. But no worries - we will not delve into the construction of the hose. After all, everyone knows what such a hose looks like.

However, this does not change the fact that, in some situations, the hose must have additional features to connect it to the machine, for example.

Then the right tip plays a key role. In order to connect it to the hose in a tight and durable way, it is necessary to carry out the crimping process. What is the crimping process, and can you do it yourself?

Find out in the article below.

Is hose crimping difficult?

Crimping a hose is, despite appearances, not a particularly difficult process. You can do this in a few simple steps, which we briefly describe below:

  1. Cut the hose to the appropriate length and clean it;
  2. Place the collet on the hose and insert the tip into the hose;
  3. Prepare the crimping machine (check the diameter of the work and the die);
  4. Place the hose in the crimping machine;
  5. Crimp the hose (i.e. press the collet);
  6. Check that the crimp is correct;
  7. Clean the hose of rubber residue and metal filings;
  8. Protect the tips from contamination.
Hose crimping steps

Do you need a more detailed guide? You will find it later in this article.

We explain here each of the above steps in detail.

Is it possible to crimp hoses by yourself?

Yes, you can crimp the hoses by yourself, but you need the appropriate equipment, i.e. a crimping machine. Without it, you will not be able to compress the collet properly.

You will find different types of hose crimping machines on the market:

  • manual,
  • pneumatic,
  • electric.

Their size and technical specifications vary as well. In addition, some are designed for small plants or domestic environments, while others are most suitable for industrial use.

There is one piece of very good news for you. Namely: in the multitude of possibilities, you can easily pick the most suitable machine for your needs.

However, please note that the crimping process must be carried out with consideration of all the parameters of the hose and the tips so that the connection is permanent and tight. In addition, also take into account the conditions in which the hose will be operating.

If you want to be sure that the crimping fulfils your expectations, use the help of professionals. As they have specialised equipment and expertise, with them, you can be sure of a job well done.

A professionally crimped hose will not give you unpleasant surprises, such as the end bursting during operation.

Hose crimping - step-by-step guide

Below, we have prepared a comprehensive step-by-step guide that will explain to you the whole process.

As you will find out in a moment, crimping hydraulic hoses (just like crimping brake hoses and crimping air conditioning hoses) is not that difficult at all.

Step 1: Prepare the tools and materials you need

Before you start work, make sure you have all the essentials with you. You will need:

  • a hydraulic hose,
  • hose tips and collets for hydraulic hoses,
  • hose grease, 
  • callipers,
  • chalk (or white marker),
  • protective goggles, 
  • protective gloves,
  • crimping machine,
  • die and crimping flange.

Step 2: Measure and cut the hose

Measure the length of hose you need and then cut it using a saw for hoses.

Attention! For exact measurements, make sure you include the cut-off factor when determining the final hose length.

Once you have cut the hose, check whether the edge is smooth. If not, use a file to apply the corrections.

Remember, also, that saws have different cutting specifications. Therefore, before you start work, compare their capabilities.

When it is all over, clean the ends of the hose. Otherwise, the presence of contaminants can lead to unnecessary troubles during crimping and even later hose operation.

Hose cutting

Step 3: Select the appropriate tips

When selecting tips, please take into account factors such as:

  • working pressure, 
  • thread (metric, inch British or American, Japanese), 
  • type (flat, spherical, conical, flanged packing),
  • fixing methods, 
  • material (in terms of corrosion resistance).

Do not underestimate this step. Selecting the appropriate tips is crucial, as the durability and tightness of the seals depend on it.

Step 4: Mark the insertion depth and assemble the tip

A good way to do this is to mark the insertion depth of the tip and collet on the hose. Take a chalk (or marker) and draw a thick line around the hose where the collet should end.

Then grease the hose if necessary (but don't do this if you are using a spiral hose).

Finally, insert the tips of the hoses into the holes of the hose and apply the collets from the outside.

Clamp and coupling installation on the hose

Step 5: Check the crimping machine and adjust its settings

Crimping machines are specifically designed to crimp specific hose diameters. So before you start work, make sure that the machine's capabilities are adequate. If necessary, adjust its parameters to your needs.

Please remember! Before crimping, always check that you have selected the appropriate diameter for the hose.

Preparing a crimping machine

Step 6: Choose a die

Clamping dies are designed for specific hoses and tips, so get one that meets your needs. You can support yourself with technical specifications to match the necessary parts exactly.

Also, grease the die with a good quality lithium-base grease.

Step 7: Place the hose in the crimping machine

Push the end of the hose into the crimping machine so that the tip of the hose appears above the die, but the collet remains inside it. If the latter also sticks out, the hose will not be compressed properly, increasing the risk of the joint bursting.

Placing the hose in the crimping machine

Step 8: Put on your protective gear

When you get to this point, put on your protective gear (goggles, ear protection and thick gloves). Always take care of your safety!

Step 9: Crimp the hose

Switch on the machine. The cylinder head will slowly move downwards. As it presses down on the flange, this will compress the die.

Do not touch the machine until the flange is near the very bottom of the die. Then the crimping machine should finish the operation by itself.

Newer machines have a built-in safety system, so if the die is moved, they will stop crimping.

Crimping the hose

Step 10: Check the crimping

Check the line you drew on the hose. If it is no longer there at the base of the collet, this means that the hose or collet has moved during crimping. No matter how tight such a joint may seem, it is not a good crimp.

On the other hand, if the line is in place, you can be sure that you have correctly crimped the hose.

Checking the hose crimp

Step 11: Clean the hose

After work, remove any contaminants from inside the hose - especially if you are crimping larger diameter hoses. You'll do this with a hose brush or a coupled air gun.

Repeat the process until rubber particles or metal filings no longer fall out of the inside.

Attention! If the rubber fragments fall out all the time, there is a risk of serious damage to the hose!

Clean the hose of remnants of rubber and files after crimping

Step 12: Lock the tips

Once you have cleaned the hose, you can still lock the crimped tips so that absolutely nothing can get inside. You can do this by using plastic caps or heat shrink caps.

All you have to do is put the cap on the tip and heat it for a few seconds while it protects the hose from debris.

These caps are available in a wide range of sizes, so you can easily find a suitable solution for your needs.

Protect the hose coupling from contamination

How much does hose crimping cost?

Crimping is a relatively low-cost service. However, the final price depends on the type and size of the hose, as well as how many lines you want to prepare in that manner.

In general, you don't actually need to prepare yourself for a huge cost. Therefore, if you are interested in professional help in this area, by all means go for it.

Summary

You already know what crimping hoses is all about. Although the process in itself is not too complicated, don't treat it with neglect.

Crimping requires patience, know-how and practice, as an ill-prepared hose will be useless. If the tip is not tight, it will not only reduce the efficiency of the various machines, but also increase the risk of a dangerous failure.

That's why we remind you: if you are not up to this task, enlist the help of professionals.

A service carried out by a specialist will ensure your safety and increase your mental comfort when handling your hose equipment later on. Furthermore, it will also have a positive impact on your wallet balance, as you will avoid unnecessary failures (e.g. the hose bursting at the tip).

Photo of Bartosz Kułakowski - CEO of Hosetech sp. z o. o.

Articles author

Bartosz Kułakowski

CEO of Hosetech Sp. z o.o.

Bartosz Kulakowski is an industrial hoses and couplings specialist with over 10 years of experience. Bartosz has been present in the technical industry since 2013. He gained experience as a technical and commercial advisor in the sector of plastic conveyor belts, steel structures, industrial hoses, and connectors. Since 2016, he has specialized exclusively in hoses and connectors. In 2019 he opened his own business under the HOSETECH Bartosz Kulakowski brand and since July 2022 he has been the CEO of the capital company HOSETECH Sp z o. o. (LLC).

SPIS TREŚCI

What is hose crimping?

Is hose crimping difficult?

Is it possible to crimp hoses by yourself?

Hose crimping - step-by-step guide

Step 1: Prepare the tools and materials you need

Step 2: Measure and cut the hose

Step 3: Select the appropriate tips

Step 4: Mark the insertion depth and assemble the tip

Step 5: Check the crimping machine and adjust its settings

Step 6: Choose a die

Step 7: Place the hose in the crimping machine

Step 8: Put on your protective gear

Step 9: Crimp the hose

Step 10: Check the crimping

Step 11: Clean the hose

Step 12: Lock the tips

How much does hose crimping cost?

Summary

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