In a busy quarry, a hydraulic hose may be a small part of a much larger machine, but its failure can have a significant impact. A stopped screener can interrupt production, leave operators and supporting plant idle, and put pressure on output targets.
A recent callout to Haughmond Hill Quarry demonstrated how quickly one hose failure can affect an operation — and the value of combining a fast response with checks for further problems.
One hose failure, a wider production impact
At Haughmond Hill, a damaged hydraulic hose brought a screener to a standstill, halting production of Type 1 aggregate and high-value 65PSV chippings. The interruption affected 3,000 tonnes of production.
The costs associated with the stoppage were substantial: £1,000 per hour for the screener being offline, plus £500 per hour for idle operators and plant. Together, these represented £1,500 per hour in downtime costs.
For quarry teams working towards production forecasts, delays like this can have consequences beyond the affected machine. Keeping equipment available is essential to maintaining the flow of material through the site.
A breakdown can also reveal a safety concern
The issue at Haughmond Hill extended beyond the failed hose. The damaged hose had rubbed through an electrical wire, creating a potential safety risk.
This made it essential to understand the cause of the failure and address the surrounding damage. Simply replacing a hose without considering its routing and clearance could leave the conditions that caused the problem unresolved.
In this instance, the response addressed both the immediate breakdown and the rubbing issue.
Fast local support helped restore production
Following a call from the site, Pirtek attended within 20 minutes. With the machine isolated, the fault was diagnosed and the damaged hose replaced.
The replacement was re-routed to provide better clearance. Pirtek also surveyed the machine for further hose weaknesses and resolved additional concerns with the site’s approval.
Production resumed, helping the quarry protect its forecast output. The wider checks also provided an opportunity to address potential problems before they resulted in another stoppage.
Looking beyond the immediate repair
Emergency support is vital when equipment fails. However, a breakdown can also highlight the value of taking a more proactive approach to hose maintenance.
At Haughmond Hill, surveying the machine revealed additional concerns that could be tackled during the visit. Identifying those weaknesses early helped reduce the risk of further disruption.
For quarry operators, planned hose inspections offer an opportunity to review hose condition and identify areas requiring attention. They also create space to plan maintenance around operational needs, rather than waiting for a failure to dictate the timing.
Supporting production through planned maintenance
Hydraulic hose maintenance should form part of the wider conversation about equipment availability, site safety and production planning.
The Haughmond Hill callout illustrates three practical priorities:
- Access to responsive local support when a breakdown interrupts production.
- Addressing the cause of a failure, including hose routing and clearance.
- Checking for further weaknesses that could lead to future downtime.
Pirtek supports mining and quarrying operations with emergency hydraulic hose replacement, preventative inspections and Total Hose Management. From an urgent callout to a planned site visit, the aim is to help customers keep their equipment working and manage hose maintenance more effectively.
Keep your quarry moving
A single hose failure can have a significant cost. Fast support helps restore production, while planned inspections can help identify small issues before they become disruptive breakdowns.
To discuss hydraulic hose support or arrange a local Pirtek site visit, request a visit online or call 0800 38 24 38.
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