Hydraulic Hose Pressure Chart Explained: Sizes, Working Pressure & Burst Ratings

Hydraulic hoses are essential components in fluid power systems, providing flexible pathways for transmitting hydraulic fluid under pressure. They are used extensively in industries where high-force motion and power transmission are required, including:

• Construction equipment
• Manufacturing machinery
• Agriculture systems
• Mining equipment
• Oil & Gas operations
• Mobile hydraulics
• Industrial automation

Unlike rigid hydraulic tubing or piping, hydraulic hoses allow movement, vibration absorption, and flexible routing within complex machinery.

However, hydraulic systems often operate under extreme pressure conditions, ranging from 1,000 psi to over 10,000 psi depending on the application. If a hose is improperly selected or exceeds its rated pressure capability, failures can occur, including:

• Hose bursts
• Fluid leaks
• Equipment damage
• Environmental spills
• Production downtime
• Safety hazards for personnel

This is where a Hydraulic Hose Pressure Chart becomes critical.

A hydraulic hose pressure chart provides standardized information about hose performance characteristics, allowing engineers, technicians, and maintenance teams to properly select hoses based on:

• Hose size
• Working pressure
• Burst pressure
• Safety factor
• Hose construction type
• Temperature limitations

These charts are commonly based on recognized industry standards such as:

• SAE J517
• ISO 18752
• EN 853
• EN 856

Understanding how to read and apply a hydraulic hose pressure chart is essential for ensuring:

• Safe hydraulic operation
• Proper hose selection
• Improved equipment reliability
• Reduced maintenance costs
• Compliance with industry standards

In this guide, we will explain Hydraulic Hose Pressure Charts, including pressure ratings, sizing systems, standards, pressure calculations, and practical hose selection methods.

1. What Is a Hydraulic Hose Pressure Chart?

A Hydraulic Hose Pressure Chart is a technical reference table used to display the allowable pressure ratings and dimensional information of hydraulic hoses.

It serves as a practical engineering tool for selecting the correct hose for a hydraulic system.

Because hydraulic hoses vary significantly in construction, reinforcement design, and size, pressure charts help users quickly identify the appropriate hose specifications for a given application.

Definition of a Hydraulic Hose Pressure Chart

A hydraulic hose pressure chart is a standardized table that provides key performance data for hydraulic hoses.

The chart typically lists information such as:

• Hose size
• Inside diameter (ID)
• Outside diameter (OD)
• Maximum working pressure
• Minimum burst pressure
• Bend radius
• Reinforcement type

These charts allow users to compare different hose families and determine suitable operating limits.

Purpose of a Pressure Chart

Hydraulic hose pressure charts are primarily used to ensure correct hose selection and safe hydraulic system operation.

Without pressure charts, selecting hydraulic hoses would be difficult and highly prone to error.

The chart helps support several important engineering tasks.

Hose Selection

Pressure charts help engineers match the hose to the hydraulic system requirements.

Important selection factors include:

• Operating pressure
• Flow rate
• Hose diameter
• System configuration

Proper selection minimizes failure risk.

System Design

During hydraulic system design, pressure charts help determine:

• Required hose class
• Pressure compatibility
• Routing considerations

This improves overall system performance.

Safety Verification

Hydraulic pressure charts help verify whether the selected hose can safely withstand expected operating conditions.

This is especially important for:

• High-pressure systems
• Mobile equipment
• Safety-critical hydraulic circuits

Maintenance Planning

Maintenance personnel frequently use pressure charts during:

• Hose replacement
• Equipment servicing
• Troubleshooting

Accurate chart interpretation helps avoid installing under-rated hoses.

Key Information Found in a Hose Pressure Chart

Most hydraulic hose pressure charts contain several standard technical parameters.

Understanding these values is essential for proper chart reading.

Hose Size

Hydraulic hoses are commonly identified using:

• Nominal size
• Dash size system

Examples include:

• -4 hose
• -6 hose
• -8 hose
• -12 hose

Hose size strongly affects flow capacity and pressure capability.

Inside Diameter (ID)

The inside diameter determines the internal flow passage.

ID directly affects:

• Flow velocity
• Pressure drop
• System efficiency

Outside Diameter (OD)

The outside diameter affects:

• Installation clearance
• Clamp selection
• Routing space requirements

Working Pressure

One of the most important values shown on a hydraulic hose pressure chart is:

Maximum Working Pressure (MWP)

This represents the maximum continuous operating pressure allowed for the hose.

Burst Pressure

Pressure charts also include:

Minimum Burst Pressure

This value indicates the pressure level at which catastrophic hose failure may occur during testing.

Minimum Bend Radius

Many charts also provide minimum bend radius requirements.

Excessive bending can damage hose reinforcement layers and reduce pressure capability.

Why Pressure Charts Matter

Hydraulic hose pressure charts are not simply catalog references — they are essential engineering tools.

Using the correct pressure chart helps organizations achieve safer and more reliable hydraulic operation.

Preventing Hose Failure

Incorrect hose selection is a major cause of hydraulic failures.

Pressure charts help reduce risks such as:

• Overpressure bursts
• Reinforcement failure
• Premature hose wear

Improving System Reliability

Correct hose pressure selection supports:

• Stable hydraulic performance
• Longer service life
• Reduced downtime

Supporting Industry Compliance

Many hydraulic applications require compliance with recognized standards.

Pressure charts help users align hose selection with:

• SAE requirements
• ISO standards
• Manufacturer specifications

Understanding a Hydraulic Hose Pressure Chart is the foundation for safe hydraulic system design and maintenance.

2. Understanding Hydraulic Hose Pressure Ratings

Pressure ratings are among the most important technical specifications shown in a hydraulic hose pressure chart.

They define the pressure limits a hose can safely withstand during operation and help engineers select hoses that match system requirements.

Understanding pressure ratings is critical because hydraulic systems frequently operate under:

• Continuous pressure loads
• Pulsating pressure cycles
• Pressure spikes
• Shock loading conditions

Incorrect interpretation of pressure ratings can result in serious consequences, including:

• Hose bursts
• Hydraulic leaks
• Equipment failure
• Operator injury

Several pressure terms commonly appear in hydraulic hose specifications.

Working Pressure Explained

The most frequently referenced hydraulic hose rating is:

Maximum Working Pressure (MWP)

This represents the maximum continuous pressure that a hydraulic hose is designed to safely handle during normal operating conditions.

Working pressure is sometimes referred to as:

• Rated pressure
• Operating pressure
• Maximum allowable operating pressure

Purpose of Working Pressure Ratings

Working pressure ratings help ensure that the hose can operate safely without excessive stress on its reinforcement structure.

Manufacturers establish these ratings based on:

• Hose construction
• Reinforcement layers
• Material strength
• Industry standards

Continuous Operating Conditions

Working pressure applies to normal continuous service conditions.

It does not represent:

• Short-duration pressure spikes
• Burst limits
• Extreme shock loading

Hydraulic systems should ideally operate below the hose’s maximum working pressure.

Example Working Pressure Ratings

Typical hydraulic hose working pressure examples may include:

Actual ratings vary depending on:

• Hose size
• Manufacturer
• Standard requirements

Burst Pressure Explained

Another important specification shown in hydraulic hose charts is:

Minimum Burst Pressure

Burst pressure defines the minimum pressure level at which hose failure occurs during destructive testing.

What Burst Pressure Means

Burst pressure represents the hose’s ultimate structural failure limit.

At this pressure level, the hose may experience:

• Reinforcement rupture
• Tube separation
• Catastrophic failure

Because burst testing destroys the hose sample, it is performed under controlled laboratory conditions.

Burst Pressure vs Working Pressure

A common misunderstanding is assuming a hose can operate near its burst pressure.

This is incorrect.

Burst pressure is not an operating limit.

It is a testing threshold used to establish safe design margins.

Typical Burst Pressure Example

A hose rated at:

Working Pressure = 5,000 psi

may have:

Burst Pressure = 20,000 psi

This reflects a common 4:1 safety factor.

Proof Pressure Explained

Hydraulic hose specifications may also reference:

Proof Pressure

Proof pressure testing verifies manufacturing quality and hose integrity.

Purpose of Proof Testing

Proof pressure is a controlled test pressure used during production or qualification testing.

The purpose is to verify that the hose can safely withstand pressure above its normal operating level.

Proof Test Characteristics

During proof testing:

• Pressure is increased to a specified value.
• The hose must remain intact.
• No leakage or structural damage should occur.

Unlike burst testing, proof testing is non-destructive.

Safety Factor in Hydraulic Hoses

Hydraulic hose pressure ratings incorporate built-in safety margins.

This safety margin is commonly expressed as a:

Safety Factor

What Is a Safety Factor?

The safety factor represents the relationship between:

Burst Pressure ÷ Working Pressure

It provides additional protection against unexpected operating conditions.

Common Hydraulic Hose Safety Factors

Many hydraulic hose standards use:

4:1 Safety Factor

Example:

Safety Factor:

20,000 ÷ 5,000 = 4:1

Why Safety Factors Matter

Safety factors help protect systems against:

• Pressure surges
• Material aging
• Installation errors
• Dynamic operating conditions

They play an essential role in hydraulic system safety.

Pressure Cycle Considerations

Hydraulic systems rarely operate under perfectly stable pressure conditions.

Most applications experience changing pressure loads.

Pulsating Pressure

Many hydraulic systems generate repetitive pressure fluctuations.

Examples include:

• Pump operation
• Actuator cycling
• Valve switching

Repeated cycling can accelerate hose fatigue.

Pressure Spikes

Short-duration pressure spikes may temporarily exceed normal working pressure.

Common causes include:

• Rapid valve closure
• Pump shock loads
• Load reversal events

Pressure spikes are a common cause of premature hose failure.

Shock Loading

Certain equipment experiences severe transient loading conditions.

Examples include:

• Excavators
• Hydraulic breakers
• Mining equipment

Shock loading increases reinforcement stress and may require higher-rated hoses.

Understanding hydraulic hose pressure ratings is essential for safe and reliable hydraulic system design.

3. Hydraulic Hose Pressure Chart Basics

Reading a hydraulic hose pressure chart correctly is essential for selecting the appropriate hose for a hydraulic application.

Although different manufacturers may format charts differently, most hydraulic hose pressure charts follow similar technical principles.

Users must understand:

• Hose sizing systems
• Pressure data
• Dimensional information
• Standard terminology

Standard Hose Size Designations

Hydraulic hoses are commonly identified using standardized sizing systems.

One of the most common methods is the dash size system.

Common Hydraulic Hose Sizes

Examples of widely used hydraulic hose sizes include:

These sizes correspond primarily to inside diameter (ID).

Why Hose Size Matters

Hose size directly affects:

• Flow capacity
• Pressure drop
• Velocity
• Pressure capability

Incorrect sizing may lead to:

• Excessive heat generation
• Reduced efficiency
• Premature component wear

Dash Size System Explained

The dash system is widely used in hydraulic engineering.

The dash number generally represents:

1/16 inch increments of hose inside diameter

Dash Size Calculation Examples

Examples:

• -4 hose = 4/16 inch = 1/4 inch
• -8 hose = 8/16 inch = 1/2 inch
• -12 hose = 12/16 inch = 3/4 inch

This system simplifies hose identification across manufacturers.

Reading Pressure Chart Data

Hydraulic hose charts contain multiple technical values.

Understanding how to interpret these values is essential.

Pressure Ratings

Charts commonly display:

• Working pressure
• Burst pressure
• Proof pressure

Pressure values may be shown in:

• PSI
• Bar
• MPa

Dimensional Data

Charts frequently include:

• Inside diameter (ID)
• Outside diameter (OD)
• Minimum bend radius

These parameters influence installation design.

Construction Information

Many charts also specify:

• Braided reinforcement
• Spiral reinforcement
• Thermoplastic construction

Hose construction strongly affects pressure capability.

Metric vs Imperial Charts

Hydraulic hose charts may use different measurement systems depending on region and manufacturer.

Imperial Measurement System

Common imperial units include:

• Inch sizes
• PSI pressure ratings

This format is widely used in:

• United States
• SAE hydraulic systems

Metric Measurement System

Metric charts typically use:

• Millimeters (mm)
• Bar pressure ratings

Metric formats are common in:

• Europe
• ISO systems
• International hydraulic applications

Typical Hydraulic Hose Pressure Chart Example

A simplified pressure chart may look like this:

This example illustrates a common engineering trend:

larger hoses often have lower pressure ratings.

Understanding chart basics is essential before selecting hydraulic hoses.

4. SAE Hydraulic Hose Pressure Standards

The hydraulic industry relies heavily on standardized hose specifications to ensure performance consistency and safety.

One of the most widely used standards is:

SAE J517

This standard establishes requirements for many common hydraulic hose types.

Overview of SAE Hose Standards

SAE J517 is published by the Society of Automotive Engineers (SAE).

It defines dimensional, performance, and pressure requirements for hydraulic hoses.

SAE hose standards are widely used in:

• Mobile hydraulics
• Construction equipment
• Agricultural machinery
• Industrial hydraulic systems

Purpose of SAE Hydraulic Standards

SAE standards help provide:

• Uniform pressure classifications
• Consistent sizing systems
• Interchangeability between manufacturers

This improves engineering compatibility.

SAE 100R1 Pressure Ratings

SAE 100R1 is one of the most common hydraulic hose classifications.

It uses:

Single-wire braid reinforcement

Typical Applications

SAE 100R1 hoses are commonly used for:

• Medium-pressure hydraulics
• Mobile equipment
• General industrial systems

Pressure Characteristics

Typical working pressure ranges:

1,300–3,000 psi

depending on hose size.

SAE 100R2 Pressure Ratings

SAE 100R2 hoses use:

Two-wire braided reinforcement

They offer higher pressure capability than SAE 100R1 hoses.

Common Applications

Typical uses include:

• High-pressure hydraulic circuits
• Construction machinery
• Agricultural systems

Pressure Ratings

Typical working pressures:

2,250–6,000 psi

depending on hose diameter.

SAE 100R12 and SAE 100R13 Ratings

Heavy-duty hydraulic systems often require higher-performance hose designs.

Common examples include:

• SAE 100R12
• SAE 100R13

These hoses typically use spiral wire reinforcement.

Heavy-Duty Applications

Common applications include:

• Mining equipment
• Offshore hydraulics
• High-pressure industrial machinery

Pressure Performance

Typical ratings may include:

4,000–6,000 psi+

depending on size and construction.

SAE Spiral vs Braided Hose Ratings

Hydraulic hoses generally use either:

• Braided reinforcement
• Spiral reinforcement

Braided Hose Characteristics

Advantages:

• Good flexibility
• Moderate pressure capability
• Lower cost

Spiral Hose Characteristics

Advantages:

• Higher pressure capacity
• Improved fatigue resistance
• Better shock-load handling

Spiral hoses are commonly selected for severe-duty hydraulic systems.

Understanding SAE hydraulic hose pressure standards is essential for interpreting hydraulic hose pressure charts and selecting appropriate hose types.

5. ISO and EN Hydraulic Hose Standards

While SAE standards dominate many North American hydraulic applications, global industries also rely heavily on ISO and European EN standards for hydraulic hose design, pressure classification, and performance requirements.

These standards help create internationally recognized specifications for:

• Hydraulic hose construction
• Pressure capability
• Testing methods
• Dimensional requirements
• Product interchangeability

Understanding ISO and EN standards is essential for engineers working with international equipment and global industrial projects.

ISO Hydraulic Hose Standards

The International Organization for Standardization (ISO) publishes hydraulic hose standards used throughout many industries worldwide.

One of the most important modern standards is:

ISO 18752 — Rubber Hoses and Hose Assemblies for Hydraulic Applications

Purpose of ISO 18752

ISO 18752 was developed to simplify hydraulic hose classification by focusing on performance levels rather than construction design alone.

The standard helps classify hoses according to:

• Pressure performance
• Flexibility requirements
• Impulse cycle capability

This approach gives manufacturers greater design flexibility.

Performance-Based Classification

Unlike some traditional hose standards that focus heavily on reinforcement construction, ISO 18752 emphasizes:

Performance classification.

Key performance factors include:

• Pressure capability
• Durability
• Fatigue resistance
• Flexibility

ISO Pressure Classes

ISO 18752 commonly uses pressure classes such as:

Actual ratings vary by hose design and manufacturer.

EN Hydraulic Hose Standards

European hydraulic systems frequently use EN (European Norm) hose standards.

Several EN standards are widely recognized in fluid power industries.

Common examples include:

• EN 853
• EN 856
• EN 857

EN 853 Hydraulic Hose Standard

EN 853 primarily covers wire braided hydraulic hoses.

Common categories include:

• EN 853 1SN
• EN 853 2SN

Typical Applications of EN 853

EN 853 hoses are commonly used in:

• Mobile hydraulics
• Agricultural machinery
• Industrial equipment

They are frequently selected for medium to high-pressure applications.

EN 856 Hydraulic Hose Standard

EN 856 covers spiral reinforced hydraulic hoses.

These hoses are designed for demanding applications requiring:

• High pressure capability
• Strong fatigue resistance
• Severe-duty operation

Typical EN 856 Hose Types

Examples include:

• EN 856 4SP
• EN 856 4SH

These hoses are widely used in:

• Mining equipment
• Offshore hydraulics
• Construction machinery

EN 857 Hydraulic Hose Standard

EN 857 focuses on compact braided hydraulic hose designs.

Typical categories include:

• EN 857 1SC
• EN 857 2SC

These hoses are often used when reduced outside diameter and tighter bend radius are desired.

Pressure Classification Systems

ISO and EN standards classify hydraulic hoses using performance-based pressure categories.

Pressure classifications help engineers compare:

• Pressure capability
• Reinforcement strength
• Service suitability

Working Pressure Categories

Hydraulic hose classes commonly span:

• Low pressure systems
• Medium pressure hydraulics
• High pressure applications
• Severe-duty service

Pressure selection must match actual operating requirements.

Impulse and Fatigue Performance

Many ISO and EN standards also emphasize:

• Impulse testing
• Pressure cycling durability
• Fatigue resistance

These requirements help simulate real-world hydraulic operating conditions.

Comparing SAE vs ISO vs EN Charts

Hydraulic engineers often encounter multiple standards across equipment platforms.

Understanding differences between these systems improves hose selection accuracy.

SAE Standards

SAE standards commonly emphasize:

• Construction type classification
• North American industrial applications
• Familiar R-series hose categories

Examples:

• SAE 100R1
• SAE 100R2
• SAE 100R13

ISO Standards

ISO standards frequently emphasize:

• Performance-based classification
• Global compatibility
• Flexibility in hose design

EN Standards

EN standards are widely associated with:

• European hydraulic systems
• Defined reinforcement categories
• Metric industrial applications

Understanding ISO and EN standards helps users properly interpret hydraulic hose pressure charts used in global industries.

6. Hydraulic Hose Pressure Chart by Hose Type

Hydraulic hoses are available in multiple construction designs.

Each hose type has unique pressure characteristics, flexibility properties, and application suitability.

A hydraulic hose pressure chart often organizes ratings according to hose construction category.

Braided Hydraulic Hose Pressure Chart

Braided hydraulic hoses use wire braid reinforcement wrapped around the hose core.

They are among the most common hydraulic hose designs.

Single Wire Braided Hoses

Single braid hoses typically provide:

• Moderate pressure capability
• Good flexibility
• Lower weight

Common standards include:

• SAE 100R1
• EN 853 1SN

Double Wire Braided Hoses

Double braided designs offer:

• Higher pressure capability
• Improved reinforcement strength

Examples include:

• SAE 100R2
• EN 853 2SN

Typical Braided Hose Pressure Range

Typical braided hose pressure ratings:

Actual ratings vary by size.

Spiral Hydraulic Hose Pressure Chart

Spiral hydraulic hoses are designed for heavy-duty, high-pressure service.

Instead of braided reinforcement, these hoses use multiple spiral wire layers.

Advantages of Spiral Hoses

Key advantages include:

• Higher pressure capability
• Better shock-load resistance
• Improved fatigue life

Typical Applications

Spiral hoses commonly appear in:

• Mining machinery
• Offshore systems
• Excavators
• Heavy construction equipment

Common Spiral Hose Standards

Examples include:

• SAE 100R12
• SAE 100R13
• SAE 100R15
• EN 856 4SP

Typical Spiral Hose Ratings

Working pressures may commonly range from:

4,000–6,000 psi+

depending on hose size and design.

Thermoplastic Hydraulic Hose Ratings

Thermoplastic hydraulic hoses use synthetic polymer materials rather than conventional rubber construction.

These hoses provide unique advantages for specialized applications.

Thermoplastic Hose Characteristics

Benefits include:

• Lightweight construction
• Chemical resistance
• Low moisture absorption

Common Applications

Thermoplastic hoses are often used for:

• Aerial lifts
• Lubrication systems
• Hydraulic tools
• Specialty industrial systems

Pressure Capability

Certain thermoplastic hoses may offer:

• High pressure performance
• Compact construction

Pressure capability depends on reinforcement design.

PTFE Hydraulic Hose Pressure Ratings

PTFE hydraulic hoses use a polytetrafluoroethylene inner tube.

These hoses are commonly selected for demanding chemical and temperature environments.

Advantages of PTFE Hose

Key advantages include:

• Excellent chemical resistance
• High temperature capability
• Low friction characteristics

Typical Applications

PTFE hoses frequently appear in:

• Chemical processing
• Aerospace systems
• Pharmaceutical applications
• High-temperature hydraulic service

Pressure Ratings

PTFE hydraulic hose pressure capability depends on:

• Reinforcement design
• Hose size
• Manufacturer specifications

Understanding hose type differences helps engineers correctly interpret hydraulic hose pressure charts and select the most suitable construction.

7. Hydraulic Hose Size vs Pressure Relationship

Hydraulic hose size and pressure rating are closely related.

A common engineering principle is:

as hose diameter increases, pressure capability often decreases.

Understanding this relationship is critical for proper hydraulic system design.

How Hose Diameter Affects Pressure Rating

Hydraulic hoses must withstand internal pressure loads.

Larger hose diameters generally experience greater internal force under pressure.

This influences allowable working pressure.

Internal Force Considerations

As inside diameter increases:

• Internal surface area increases
• Hoop stress increases
• Reinforcement loads increase

Because of these effects, larger hoses frequently have lower pressure ratings.

Small Hose High Pressure Examples

Smaller hydraulic hoses often provide the highest pressure capability.

1/4 Inch Hose Example

A 1/4 inch hose may commonly support:

5,000–6,000 psi working pressure

depending on hose construction.

3/8 Inch Hose Example

A 3/8 inch hose may offer:

4,000–5,000 psi pressure capability

depending on hose family.

Large Hose Pressure Limitations

Larger hydraulic hoses usually prioritize flow capacity rather than maximum pressure.

1 Inch Hose Example

Typical 1 inch hydraulic hose ratings may be lower than smaller sizes.

Common pressure ranges include:

2,000–4,000 psi

depending on hose construction.

2 Inch Hose Example

Large industrial hoses may support:

• High flow volume
• Reduced velocity

but often at lower pressure ratings.

Flow Rate vs Pressure Tradeoffs

Hydraulic system design involves balancing:

• Pressure requirements
• Flow requirements

Selecting a hose purely based on pressure without considering flow may create problems.

Undersized Hose Risks

Using hoses that are too small may cause:

• High flow velocity
• Excessive pressure drop
• Heat generation

Oversized Hose Risks

Excessively large hoses may create:

• Installation difficulty
• Increased cost
• Reduced pressure capability

Engineering Selection Considerations

Proper hose sizing should consider:

• System operating pressure
• Required flow rate
• Temperature conditions
• Installation constraints

Understanding the size-versus-pressure relationship helps ensure safe and efficient hydraulic system performance.