Composite hose is a multi-layer flexible conduit, thermoplastic films and fabrics carried between an inner and an outer wire helix, built for the liquid transfer duties where a single-material rubber hose cannot deliver the chemistry: petroleum products, solvents, aggressive chemicals and, in dedicated constructions, cryogenic media. Selection comes down to three variables: the liner film (polypropylene for hydrocarbons, PTFE/FEP for aggressive chemistry, polyethylene for alcohols), the wire grade (mild/galvanised steel versus 316 stainless), and conformity to EN 13765 with its minimum 4:1 burst-to-working-pressure factor. This guide is the technical reference: construction, liner grades, parameters, standards, inspection and cost of ownership. For specification pitfalls, see the companion article what every procurement engineer must know about composite hose; for a step-by-step checklist, see composite hose selection: 11 criteria.
What Is Composite Hose and How Is It Constructed?
Composite hose is assembled around a helical inner wire, over which alternating layers of polymer film and woven fabric are applied, closed out by an outer wire helix. Unlike rubber hose, which relies on a vulcanised elastomeric tube, composite hose achieves its chemical resistance and permeation barrier through thin thermoplastic films selected for the fluid category.
- Inner wire helix: maintains bore geometry under vacuum and bending; grade selected on fluid corrosivity, typically mild or galvanised steel for hydrocarbons, 316 stainless steel for acids and solvents.
- Inner film layers: the primary chemical and permeation barrier, polypropylene (PP) for petroleum products, PTFE or FEP for concentrated acids and solvents, polyethylene (PE/HDPE) for alcohols and mild aqueous media.
- Fabric plies: polyester or polypropylene cloth distributing tensile and torsional loads between wires and films.
- Outer film and cover: weather and abrasion protection, often with a PVC or PP outer wrap on heavy-duty grades.
- Outer wire helix: crush protection and, in bonded constructions, part of the electrical continuity path to the couplings.
The result is a hose that is light, flexible at small bend radii, vacuum-capable, and rated for the low-to-medium pressures typical of bulk liquid transfer, most catalogue grades carry working pressures of about 7–14 bar, always confirmed per size on the datasheet.
What Types of Composite Hose Are There?
Composite hose is classified primarily by liner film and wire specification.
Polypropylene-lined composite hose
The workhorse for petroleum products, crude oil, petrol, diesel, kerosene-type jet fuels and lubricating oils, plus many aliphatic hydrocarbons. PP liners typically serve up to about +80 °C continuous and remain usable in outdoor loading service at low ambient temperatures; verify the construction-specific minimum on the datasheet.
PTFE/FEP-lined composite hose
For concentrated acids, halogenated solvents, ketones, esters and other aggressive chemicals where PP would degrade. PTFE-lined grades carry the widest chemical envelope and the highest temperature ceilings in the composite family, construction-dependent, so take both limits from the manufacturer's datasheet rather than a family headline. Typical duties: chemical plant loading/unloading, road tanker and rail-car transfer.
Polyethylene-lined composite hose
HDPE liners suit alcohols, certain polar solvents and mild aqueous solutions where PP compatibility is borderline, with a lower temperature ceiling (around +60 °C typical). Widely used for industrial alcohol and ethanol distribution.
Cryogenic composite hose
Dedicated multi-layer constructions for LPG and LNG transfer are covered by their own standard, EN 13766, and reach cryogenic temperatures with stainless wires and specialised film packages. These are engineered products, not catalogue variants, each duty requires individual verification with the manufacturer.
Bonded and unbonded variants
In bonded (electrically continuous) hose, the inner and outer wire helices are connected through the coupling, providing an earth path along the assembly. Unbonded/isolated variants exist for cathodic-protection zones where stray currents cause electrolytic corrosion, but in flammable service they demand supplementary earthing arrangements defined by the site's ATEX assessment.
What Are the Key Specifications of Composite Hose?
Typical catalogue values, always verify against the current datasheet and the standard edition in force:
| Parameter | PP-lined | PTFE/FEP-lined | HDPE-lined |
|---|---|---|---|
| Working pressure (typical) | 7–14 bar | 7–14 bar | 7–10 bar |
| Burst pressure | ≥4 × WP | ≥4 × WP | ≥4 × WP |
| Proof test (assembly) | ≈1.5 × WP | ≈1.5 × WP | ≈1.5 × WP |
| Max. service temperature | ≈ +80 °C | highest in family, per datasheet | ≈ +60 °C |
| Vacuum capability | yes, most grades | yes | yes |
| Wire options | MS, GS, 304/316 SS | 316 SS typical | MS, GS, 316 SS |
| Typical bores | 25–300 mm | 25–200 mm | 25–150 mm |
MS = mild steel, GS = galvanised steel, SS = stainless steel.
Key takeaway: EN 13765 requires a minimum burst pressure of 4 × working pressure, verified at assembly level, not merely on the hose body. Working pressure is size- and construction-specific: read the datasheet row for your bore, never a family figure.
Two derating notes: liner chemical resistance is temperature-dependent (a film compatible at 20 °C may permeate or swell at 60 °C), and galvanised wire is not suited to sustained elevated temperatures or corrosive ambients, specify stainless wire there.
Where Is Composite Hose Used?
Petroleum and petrochemical terminals use large-bore composite hose (typically 75–250 mm) for road tanker and tank-farm transfer, with full vacuum capability for bottom-loading systems. Chemical distribution depots rely on PTFE/FEP-lined grades to move media as diverse as concentrated sulphuric acid, hydrochloric acid, methanol and toluene, simplifying inventory to one hose family differentiated by liner. Fuelling operations use PP-lined hose for tanker delivery of kerosene-type jet fuel and diesel; aviation fuelling hose is governed by EI 1529, so confirm the qualification of any specific construction for that duty with the manufacturer. Food-grade transfer (edible oils, ethanol) is possible with FDA 21 CFR 177.1520-compliant polyolefin films, and because composite liners are plastics, Regulation 10/2011/EU genuinely applies here, unlike for rubber hose. LPG/LNG transfer uses dedicated EN 13766 constructions. Sector solutions are summarised on our industries page.
One boundary worth stating plainly: composite hose is a liquid-transfer product. It is not a steam hose (steam requires EN ISO 6134 rubber constructions with bolted safety clamps), and it is not a compressed-air hose.
How Do You Select the Right Composite Hose?
The decision sequence: confirm liner compatibility with every fluid in the mix at the actual operating temperature; confirm working pressure including surge allowance and vacuum requirement for the specific bore; select wire grades for both the medium (inner) and the ambient (outer); and choose end fittings qualified by the assembly manufacturer. The full checklist lives in the companion selection article, and the parameter tables in composite hose specifications explained. If you are weighing composite against rubber for the same duty, see rubber hose vs composite hose.
Which end fittings are used on composite hose?
End fittings, aluminium, carbon steel, brass or stainless steel, must be crimped or swaged onto the hose by the assembly manufacturer and proof-tested as a complete assembly. Common terminations:
- Camlock couplings (EN 14420-7 / MIL-C-27487): the terminal-transfer standard for liquids only, never compressed air or gases. Types A/E/F are male adapters, B/C/D female couplers, DC/DP dust caps and plugs.
- Threaded ends: G/BSPP per ISO 228 (parallel, seals on washer/o-ring) or NPT (tapered, seals on the thread), the two are not interchangeable.
- Flanged ends: per EN 1092-1 or ASME B16.5 for terminal manifolds and marine connections.
- TW tank-truck couplings (EN 14420-6) and Guillemin (EN 14420-8) where national tanker practice requires them, these are distinct, non-interchangeable systems, and neither is a Camlock or a Storz.
A matching range of couplings is available under industrial fittings.
How is electrical continuity handled?
For all flammable media, specify bonded construction and verify the assembly's electrical resistance per ISO 8031 against the limits in EN 13765 and your site rules. Continuity should be tested and recorded periodically, and before transfer in high-risk terminal operations, with the hose earthed as part of the loading system. If continuity is lost, the hose is withdrawn.
How Should Composite Hose Be Installed and Maintained?
Respect the minimum bend radius, typically several times the bore diameter; operating below it crushes the wire helix, fractures the film layers and concentrates stress at the ferrule, the most common failure origin. Allow slack: length the hose for the full range of motion without tension on the couplings, and avoid compound twist-plus-bend configurations. Proof-test every new assembly hydrostatically at approximately 1.5 × working pressure before service; never use pneumatic testing as the primary test.
Inspection practice in terminal service is layered: a visual check before each use (coupling security, kinks, crushed sections, outer-wire corrosion), periodic recorded inspection with electrical continuity measurement, and hydrostatic re-testing at intervals set by the operator's code and the manufacturer's guidance.
| Failure mode | Root cause | Preventive action |
|---|---|---|
| Liner blister/delamination | Chemical incompatibility or over-temperature | Verify compatibility at operating temperature |
| Wire helix fracture | Operation below MBR; fatigue | Enforce MBR; retire on schedule |
| Coupling pull-out | Wrong ferrule specification or swaging | Certified assembly manufacturer; keep records |
| Outer wire corrosion | Wrong wire grade for ambient | Specify 316 SS outboard in aggressive environments |
| Loss of continuity | Broken bond path | Test per ISO 8031; withdraw the hose |
| Permeation leakage | Liner-media mismatch | Upgrade liner (e.g. to PTFE); do not reuse |
Service life: internal film degradation is not reliably visible from outside, so composite hose is managed on documentation, not appearance. Follow the manufacturer's stated maximum life and your operator's code, many terminal operators impose fixed retirement intervals, and withdraw immediately any hose whose manufacture date marking is illegible.
Which Standards Govern Composite Hose?
- EN 13765, the primary European standard for thermoplastic multi-layer (non-vulcanised) hoses and assemblies for hydrocarbons, solvents and chemicals. It defines hose types by duty and construction, the minimum 4:1 burst factor, assembly testing, electrical properties and marking. Specify the type with the manufacturer against your medium and duty.
- EN 13766, the parallel standard for LPG and LNG (cryogenic) composite hose assemblies.
- EI 1529: Energy Institute specification for aviation fuelling hose; confirm qualification for fuelling duties.
- ISO 8031, measurement of electrical resistance and continuity of hose assemblies.
- FDA 21 CFR 177.1520 and Regulation 10/2011/EU, food-contact compliance for the polyolefin liner films (10/2011 applies because the liners are plastics), within the EU framework of Regulation (EC) 1935/2004.
- ATEX 2014/34/EU, the installation-level frame for equipment and bonding in explosive atmospheres; marine ship-shore transfer additionally follows the terminal's and OCIMF-derived operating rules.
Always procure composite hose as a complete, tested assembly from a certified assembly manufacturer: EN 13765 conformity attaches to the tested assembly, and field-fitting couplings without documented proof testing voids it.
What Does Composite Hose Really Cost?
Composite hose typically costs 1.5–3 × an equivalent-bore rubber suction-discharge hose, depending on liner and wire. The premium usually pays back quickly: longer life in chemical service, one hose family covering a multi-product depot (fewer SKUs, simpler inspection), and avoidance of spill events whose remediation and regulatory costs dwarf any capex difference. Upgrading from galvanised to 316 stainless wire adds a modest premium but can multiply service life in corrosive terminal environments. Weigh downtime per failure event, hours of lost throughput at terminal rates, against the unit price difference, and the higher specification wins in almost every demanding duty.
Key Takeaways
- Composite hose = film + fabric layers between two wire helices; the liner film (PP, PTFE/FEP, PE) is the primary selection variable, the wire grades the second.
- EN 13765 governs; cryogenic LPG/LNG constructions follow EN 13766. Burst ≥4 × WP at assembly level; proof test ≈1.5 × WP.
- Typical working pressures are 7–14 bar and size-specific, composite hose is a liquid-transfer product, not a steam or compressed-air hose.
- Bonded construction with continuity verified per ISO 8031 is mandatory practice for flammable media; test and record, and earth the assembly.
- Service life is managed on documentation: manufacture date, proof-test records, continuity results, not visual condition.
- Buy tested assemblies from a certified assembly manufacturer, never loose hose plus field-fitted couplings.
Browse composite constructions in our industrial hoses category or via a composite hose search, and download manufacturer datasheets from the catalogues. For multi-product or aggressive-media duties, request a quotation, our engineering team matches liner, wire and couplings to your media list and pressure-tests the completed assembly before delivery.