In basement foundation construction, diaphragm wall grabs (such as the Bauer GB 46 series) feature a cable and hydraulic hose reel that must operate continuously at high frequencies, dropping down and pulling up tens of meters underground. Under immense working pressure, the main driving hydraulic hose is the component subjected to the most severe stress.
A Real-World Case Study at VHE: A 60-meter hydraulic hose on a reel was ruptured and suffered outer cover wear, but the damage was localized to a section of only about 20 meters. Discarding the entire 60-meter, 6-wire spiral hose to buy a new one would be a massive financial waste for the contractor, especially when the remaining 40 meters were still in perfectly usable condition.
This was exactly the urgent situation our partner encountered right at the construction site. The hose system of their diaphragm wall grab had a damaged 20m section out of a 60m total length (1.1/4" 6-wire spiral hose).
Initially, to save the time and effort of dismantling the massive hose coil, the contractor proposed that the VHE team bring a hose crimping machine to the site. The customer wanted to rotate the reel drum to the exact damaged location to cut, connect, and crimp the flange fittings directly on the reel.
However, after VHE technicians conducted a direct on-site survey, we realized this approach was unfeasible and carried significant risks. To properly crimp fittings for a 6-wire spiral hose withstanding 420 bar of pressure, a heavy-duty hydraulic crimping machine with a 1,000-ton crimping force and bulky dimensions is required. Transporting and operating such heavy machinery in a cramped, unstable construction site environment cannot guarantee the absolute precision needed for the joint. A single minor error during on-site machining could lead to bursting or oil leakage as the reel winds and unwinds under high loads.
Following VHE's consultation and technical analysis, the customer fully agreed with the most optimal and secure solution: removing the entire hose from the reel. VHE immediately dispatched a specialized transport vehicle to the site, bringing the whole hose coil directly back to our workshop for measurement and machining.
In-depth Processing Capability at VHE's Workshop
At VHE's machining workshop, equipped with specialized machinery, the hose restoration process was carried out swiftly and with the utmost precision:
- Accurate Measurement and Preparation: The hose was fully rolled out. Our technical team precisely measured and cut off the damaged 20m section. The remaining 40m of good hose was cleaned, and its cross-sectional surface was prepared for the connection.
- Specialized Replacement Materials: The 20m replacement section utilized the 6K 1.1/4” Alfabiotech (R15-20) hydraulic hose. This is a 6-wire spiral hose offering exceptional abrasion resistance, specifically designed for ultra-high-pressure hydraulic reel systems.
- Interlock Crimping Technique for a "Dead-lock" Joint: To ensure the connection between the 40m old hose and the 20m new hose can withstand immense burst pressure (working at 420 bar), VHE utilized two sets of 9K 1.1/4” Interlock flange fittings combined with R13 1.1/4” Interlock ferrules. Thanks to the modern machinery at our workshop, the internal and external rubber skiving process was executed perfectly. The ferrule's teeth bite deep and lock directly onto the 6 steel wire layers of the hose, creating an extremely robust bond that prevents kinking or leaking when the reel coils.
- Inspection and On-site Delivery: The joint was crimped using specialized workshop machinery to ensure absolute concentricity. Once completed, technicians connected the sections to form a complete 60m hose assembly, which was then delivered back to the construction site for the customer to install onto the reel.
The decision to bring the hose back to the workshop instead of applying a makeshift on-site fix proved to be entirely correct. VHE not only helped the partner restore their equipment system to stable and absolutely safe operation but also effectively optimized material replacement costs. When dealing with high-pressure hydraulic systems, extreme caution, standard machinery, and systematic procedures are always VHE's top priorities.
The Optimal Solution from VHE
Through the real-world case study above, it is evident that resolving hydraulic hose issues for heavy machinery is not simply a matter of "replace what's broken." It is a technical calculation problem aimed at optimizing costs while ensuring absolute safety for the operating system. Localized damage on long hose coils is very common, and proper isolation and standardized restoration can save massive budgets for contractors.
Leveraging our advantage of owning a heavy-duty hydraulic crimping machine system at our workshop, a well-stocked inventory of international standard materials (such as Alfabiotech hoses and Interlock fittings), and a team of practical technicians, VHE confidently delivers in-depth hydraulic hose measurement, machining, and maintenance services.
Customers and contractors facing similar issues with diaphragm wall grab hose reels, piling rig hoses, or requiring ultra-high-pressure hydraulic hose machining, please contact the VHE team immediately.
- Consulting & Support: 0903 067 588
- Email: [email protected]
