Leaks in industrial hose systems are more than an inconvenience. They waste product, reduce efficiency, and can expose workers to health and safety risks. In industries handling fuels, chemicals or powders, even small leaks can quickly lead to environmental hazards, expensive clean-ups and downtime.
The good news is that most leaks can be prevented. By carrying out regular checks and using the right testing methods, hose systems can be kept safe, reliable and compliant. At JML Henderson, we provide assemblies and testing services designed to reduce the risk of leaks and give operators confidence in every connection.
Why Leaks Happen
Hoses and couplings are put under constant stress. Over time, this pressure, combined with environmental factors, causes weaknesses to develop. The most common reasons for leaks include:
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Wear and abrasion - outer covers scuffed against machinery or surfaces, eventually breaking through to reinforcement layers
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Chemical attack - certain chemicals weaken hose linings if the wrong material is used
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Heat exposure - hoses not designed for high temperatures may harden, crack or lose flexibility
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Connection failures - poorly fitted or corroded couplings and clamps are common leak points
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Age and fatigue - all hoses degrade over time, even if not in constant use
Recognising these issues early is key to preventing leaks.
Signs of a Potential Leak
Not all leaks appear suddenly. Many build up over time, giving you warning signs along the way. During inspections, look out for:
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Moisture or staining near couplings or along the hose length
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Blisters, bulges or swelling in the hose wall
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Cracks or splits, especially near bends and ends
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Corrosion on fittings or clamps
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Loss of pressure in the system compared to normal operation
Catching these signs early means action can be taken before the leak becomes a major failure.
Why Testing Matters
Visual checks alone aren’t enough. Many faults only show up under pressure. That’s why hydrostatic pressure testing is an essential part of hose maintenance.
At JML Henderson, hoses are tested to BFPA best practice. This involves filling the hose with water and gradually increasing pressure while checking for leaks, bulges or weak points. For conductive hoses, electrical continuity checks can also be carried out to confirm compliance with ATEX requirements.
Testing provides clear documentation too. Certification confirms that a hose assembly has been inspected and proven safe, giving operators peace of mind and supporting compliance during audits.
Preventing Leaks Through Good Practice
Leak prevention isn’t just about testing - it’s about adopting a proactive approach. Here are some simple steps operators can take:
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Choose the right hose material - using a hose designed for the specific product, temperature and pressure reduces the chance of failure
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Inspect regularly - routine checks catch wear, abrasion and connection issues early
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Service hoses instead of replacing - re-ending or shortening can extend life and cut costs
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Tag hoses for traceability - knowing when a hose was last tested makes inspections and audits easier
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Store correctly - avoid kinks, crushing or UV exposure that can weaken hoses over time
These steps reduce downtime, improve safety and keep costs under control.
The Role of Couplings and Clamps
Many leaks don’t start in the hose itself - they happen at the connection points. A poorly chosen or badly fitted coupling can compromise an otherwise good hose assembly.
That’s why JML Henderson supply a complete range of high-quality couplings and clamps, including Camlock, Storz, DIN 11851 and Unicone. By matching the right connection to the product and environment, leaks are significantly reduced.
Each coupling is fitted and inspected in-house, with assemblies pressure-tested before dispatch. This ensures that every hose leaves the workshop ready for service.
How JML Henderson Help Reduce Leaks
Our approach is built on experience and attention to detail. We support leak prevention by:
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Supplying hoses in materials proven to resist abrasion, heat and chemical attack
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Fitting assemblies with the correct couplings for each duty
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Pressure testing and certifying to BFPA standards
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Offering re-ending, servicing and inspections to extend hose life
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Providing hose tagging and documentation for traceability
This combination of quality products and rigorous testing means customers can rely on their hose systems to perform safely and efficiently.
Final Thoughts
Leaks are one of the most common causes of downtime in industrial hose systems. They waste product, increase costs and put people and the environment at risk. But with the right approach, they are also one of the most preventable issues.
By choosing the right hoses and couplings, carrying out regular inspections, and making use of testing and servicing support, operators can keep their systems safe, compliant and reliable.
At JML Henderson, our tested, certified and traceable hose assemblies are designed to give confidence in every connection - reducing the risk of leaks and keeping operations moving.
