Hose whip restraint for hydraulic hoses to prevent the whipping effect

Hydraulics are characterized by sometimes extremely high operating pressures, and a hose whip restraint helps to increase safety. For construction machinery or demanding stationary systems, an operating pressure of 500 bar and more is normal.

As long as the system runs without faults, this operating pressure poses no danger. However, if a hydraulic line bursts or tears off, a dangerous situation can quickly arise. The loose hose end then whips around at high speed, spraying hot, high-pressure hydraulic fluid. This poses a life-threatening risk to bystanders. The hose whip restraint is a simple, inexpensive, and very reliable method to mitigate this danger.

How a hose whip restraint works

The hose whip restraint for hydraulic hoses consists of three components:

• Wire with loop
• Flange
• Cut protection

The wire with loop is attached to the hydraulic hose behind the quick-release coupling. To prevent the wire from working its way into the hose during normal operation, the cut protection is placed underneath. Galvanized steel is used as the material for the wire. Steel offers high tensile strength. The galvanization keeps corrosion away from the wire.

The flange is attached behind the connection coupling, and the wire is hooked in with a clamp. If the hydraulic coupling detaches, the hose whip restraint prevents the pressurized line from whipping around. This significantly reduces the danger to bystanders. Furthermore, no other hydraulic elements are damaged. The hose whip restraint thus not only serves occupational safety but also limits the resulting damage.

Legal regulations for hose whip restraints

The installation of a hose whip restraint may be required as part of CE marking or a safety inspection. The restraint used must precisely match the local conditions. These include the diameter of the lines to be secured, the operating pressure, and the hose material. The use of hose whip restraints is specified in the following regulations:

• DIN EN ISO 201 “Plastics and rubber machines – Injection moulding machines – Safety requirements”
• DIN EN ISO 12100 “Plastics piping systems – Polyethylene (PE) fittings – Test method for resistance to bending between supports”
• Machinery Directive 2006/42/EC
• BG Information Sheet 015
• DGUV 113-20 “Hydraulic hose lines for safe use”
• DGUV 209-70 “Safety during hydraulic maintenance”
• DIN EN ISO 4413 “Hydraulic fluid power – General rules and safety requirements for systems and their components”

Compliance with all regulations is in the interest of occupational health and safety and operational reliability. Violations of machinery safety can result in heavy fines in the event of damage. It is therefore recommended to have complex hydraulic systems operating under high pressures inspected by an external CE expert.

Installation of the hose whip restraint

Installing a hose whip restraint is very simple. The only thing to ensure when installing these inexpensive but effective safety components is that the system is not under pressure. This applies to all work on hydraulic systems. It should be switched off, depressurized, and cooled down. This not only makes the work easier but also eliminates all hazards.