Compressed Air Hoses: Hidden Hazards Under Pressure

High Pressure Risks:

• Air at 620–830 kPa can cause hoses to whip violently if they fail.
  
• The release of energy is nearly instantaneous and unpredictable.
  

Incorrect Hose Selection:

• Using non-air-rated hoses, such as garden or water hoses, can result in bursting.
  
• These hoses lack the necessary reinforcement for compressed air.
  

Connection Failures:

• Poor-quality clamps or incorrectly installed couplers may loosen over time.
  
• Missing safety devices increase the risk of dangerous hose whip if disconnection occurs.
  

Lack of Inspection and Maintenance:

• Worn, damaged, or poorly stored hoses are far more likely to fail unexpectedly.

Select the Right Hose and Clamps:

• Use air-rated hoses:
  
  
  • Designed to withstand pressure with reinforced internal layers.
    
  • Clearly marked with maximum pressure ratings.
    
  • Resistant to oil, chemical exposure, and temperature variations.
    
• Use appropriate clamps:
  
  
  • Distribute pressure evenly.
    
  • Resist loosening from vibration or tension.
    

Inspect Equipment Thoroughly:

Daily Inspections:

• Check hoses for:
  
  
  • Cuts, bulges, abrasion, kinking, or flattened sections.
    
  • Signs of oil or chemical degradation.
    
  • Loose fittings or missing safety features.
    

• Inspect clamps and couplings:
  
  
  • Ensure tight fit, correct size, and alignment.
    
  • Check locking pins or threads for damage.
    

Install Safety Devices:

• Use whip checks or safety cables:
  
  
  • Prevent hoses from whipping violently if they disconnect.
    
  • Regularly inspect for damage and correct installation.
    
• Install pressure relief valves (required for hoses over 13 mm in diameter):
  
  
  • Prevent explosive pressure release.
    
  • Test valves routinely for correct function.
    

Follow Safe Operating Practices:

Before Use:

• Inspect hoses, clamps, and safety devices.
  
• Confirm all equipment is rated for the pressure being used.
  
• Ensure hoses are routed away from walkways and sharp edges.
  

During Operation:

• Remain alert for air leaks, hissing, or hose movement.
  
• Keep a safe distance from operating hoses.
  

Maintain and Store Properly:

Storage:

• Coil hoses neatly and store in cool, dry areas away from sunlight and chemicals.
  

Maintenance:

• Replace damaged components promptly.
• Document inspections and corrective actions.