Rubber hoses and hose assemblies - Wire braid reinforced compact type for hydraulic applications - Specification; German version EN 857:2015
1Key Takeaways
This European Standard specifies the technical requirements for two types of steel braid reinforced compact hoses and hose assemblies with nominal inside diameters from 6 to 25, types 1SC and 2SC. They are suitable for use with: ——hydraulic fluids conforming to ISO 6743-4, except HFD R, HFD S and HFD T, in the tempera…
2Expert Interpretation
An in-depth look at the DIN EN 857:2016-09 standard for wire braid reinforced compact hydraulic hoses, covering the technical requirements, dimensional specifications, performance testing, and certification requirements for both 1SC and 2SC models. Suitable for use in ISO 6743-4 hydraulic oil, water-based fluid, and water-based media applications.
Standard Overview and Technical Evolution
DIN EN 857:2016-09 is the technical specification for steel wire braid reinforced compact hydraulic hoses published by the European Committee for Standardization (CEN), replacing the 1997 version. This standard was developed by CEN/TC 218, a technical committee with the British Standards Institution (BSI) as secretariat, with participation from the German Technical Standards Committee for Elastomers (NA 045-02-12 AA).
Scope of application and product types
This standard applies to two types of steel wire braid reinforced compact hydraulic hoses and hose assemblies with nominal inner diameters of 6 to 25:
- Type 1SC: Single-layer steel wire braid reinforced hose
- Type 2SC: Double-layer steel wire braid reinforced hose
Applicable media include hydraulic oils according to ISO 6743-4 (except HFD R, HFD S and HFD T), water-based fluids and water in hydraulic systems. The operating temperature range varies from -40°C to +100°C depending on the type of media.
Construction and material requirements
The hose construction must include an oil-resistant and water-resistant synthetic rubber inner liner, one or two high-strength steel wire braid reinforcement layers, and an oil-resistant and weather-resistant synthetic rubber outer layer. Hose assemblies may only be manufactured using fittings whose functionality has been verified in accordance with clauses 6.1, 6.3, 6.4 and 6.5 of this standard. 0.4
Performance Requirements and Test Standards
Hydraulic Performance Requirements
| Nominal Inside Diameter | Maximum Working Pressure (bar) | Proof Pressure (bar) | Burst Pressure (bar) | Number of Pulse Test Cycles |
|---|---|---|---|---|
| 6 | 225/400 | 450/800 | 900/1600 | 150,000/200,000 |
| 10 | 180/330 | 360/660 | 720/1320 | 150,000/200,000 |
| 16 | 130/250 | 260/500 | 520/1000 | 150,000/200,000 |
| 25 | 88/165 | 176/330 | 352/660 | 150,000/200,000 |
Note: The data format in the table is 1SC type/2SC type
Environmental adaptability requirements
- Low temperature flexibility: No cracks at -40°C (EN ISO 10619-2 Method B)
- Fluid resistance:
- Oil resistance: 100°C for 168 hours, lining volume expansion ≤25%
- Water-based fluid resistance: 70°C for 168 hours, volume expansion lining ≤25%, outer layer ≤100%
- Water resistance: 168 hours at 70°C, volume expansion liner ≤25%, outer layer ≤100%
- Ozone resistance: no cracking and deterioration (EN ISO 7326)
- Abrasion resistance: mass loss ≤0.5g after 2000 cycles (Appendix A)
Quality control and testing requirements
Type testing and routine testing
Appendices B and C of the standard specify the type test and routine test requirements for produced hoses in detail:
- Type test: performed upon initial product certification, after product changes and every 5 years
- Routine test: performed every 3000 meters of production length or every 12 months
- Factory Inspection: Each hose must undergo dimension verification and verification pressure test before storage or sale
Key Test Items
| Test Items | Test Standard | Acceptance Criteria | Test Frequency |
|---|---|---|---|
| Hydrostatic Test | EN ISO 1402 | No Leakage | Each Hose |
| Impulse Test | EN ISO 6803 | 150,000/200,000 Times | Type Test |
| Adhesion Strength | EN ISO 8033 | ≥2.5 kN/m | Type test |
| Abrasion test | Appendix A | ≤0.5g mass loss | Routine test |
Marking and traceability requirements
The hose must be marked with the following information at intervals of up to 500mm: manufacturer's logo, standard number EN 857, model (1SC/2SC), nominal inside diameter, year and quarter of production. The hose assembly must be marked with the assembler's logo, maximum working pressure and assembly date.
Labeling Example
- Hose: XXX/EN 857/16/1Q15
- Hose assembly: XXX/160bar/1501
Technological Evolution and Major Changes
Compared with the 1997 edition, the major technical changes in the 2016 edition include:
- Updated normative references
- Adjusted inner diameter tolerance requirements
- Modified abrasion test method (due to withdrawal of ISO 6945)
- New Normative Appendix A (Abrasion Test Procedure)
- New Normative Appendix B (Type Test and Routine Test)
- New Informative Appendix C (Production Acceptance Test)
Implementation Recommendations and Application Guidance
Selection Recommendations
Select the appropriate hose type based on actual operating conditions: Type 1SC is suitable for medium pressure applications, and Type 2SC is suitable for high pressure applications. Pay special attention to media compatibility; this standard explicitly excludes the use of castor oil- and ester-based fluids.
Installation and Usage Precautions
- Strictly adhere to the minimum bend radius requirements to avoid excessive bending, which may degrade performance.
- Note the temperature limit; the maximum operating temperature for water-based fluids is 70°C.
- Regularly inspect the hose's appearance and replace it promptly if worn or aged.
- Use verified fittings to ensure connection reliability.
Key Quality Control Points
Manufacturers should establish a comprehensive quality management system, focusing on raw material inspection, production process control, finished product inspection, and traceability systems. In particular, strengthen monitoring of wear resistance and bond strength, as these are key indicators affecting hose service life.
This standard provides authoritative technical guidance for the selection and use of hoses in hydraulic systems. Implementation should be based on specific application scenarios and equipment requirements to ensure safe and reliable operation of hydraulic systems.