Failures in Pneumatic Tubing: Main Causes and How to Prevent Them in Industrial Applications

In industrial applications, failures in pneumatic tubing are rarely associated exclusively with the material itself. In most cases, the root cause lies in improper specification relative to actual operating conditions.

This misalignment compromises the performance of the pneumatic system as a whole, leading to significant impacts such as unplanned production downtime, loss of operational efficiency, increased maintenance costs, and reduced component service life.

Proper specification of pneumatic tubing requires a comprehensive technical analysis, considering not only the product itself but the entire application context.

Below, we highlight the main causes of failures in pneumatic tubing in industrial environments.

Chemical Incompatibility

Industrial environments expose pneumatic tubing to various chemical agents, such as oils, solvents, and process vapors. When there is incompatibility between the material, the conveyed fluid, and the surrounding environment, the following may occur:

- Material degradation;

- Swelling;

- Cracking and fissuring.

Proper material selection is essential to ensure tubing durability and system reliability.

Temperature Outside the Recommended Range

Each material has specific operating temperature limits. Exposure to elevated temperatures or constant thermal fluctuations may lead to:

- Loss of mechanical properties;

- Deformation;

- Reduced pressure resistance.

Materials such as polyurethane (TPU), polyamide (PA), and polyethylene (PE) must be selected based on actual application conditions, rather than solely on nominal catalog values.

Bend Radius Below the Minimum Limit

Failure to comply with the minimum bend radius is a common cause of tubing failure. This condition may result in:

- Increased internal stresses;

- Reduction of flow cross-section;

- Permanent deformation.

As a consequence, partial or total restriction of fluid flow may occur, leading to significant system failures.

Repeated Flexing Cycles

In dynamic systems, pneumatic tubing is subjected to continuous movement cycles (such as vibration, bending, or torsion). Without proper specification, this may cause:

- Material fatigue;

- Formation of microcracks;

- Premature rupture.

The analysis must consider the material behavior throughout the entire operational cycle, not only under static conditions.

Improper Material Selection

Material selection should not be based solely on system pressure or dimensional requirements. It is essential to evaluate:

- Chemical environment;

- Operating temperature;

- System dynamics;

- Required flexibility;

- Expected service life.

Correct specification is critical to ensuring reliability and predictability of the pneumatic system.

How to Prevent Failures in Pneumatic Tubing

Preventing failures requires an integrated technical approach based on:

- Assessment of real operating conditions;

- Analysis of environmental variables;

- Understanding of system dynamics;

- Definition of performance requirements over time.

This approach reduces failure rates, increases component durability, and improves overall operational efficiency.

Applied Engineering in Pneumatic Tubing Specification

At Mantova, pneumatic tubing specification is driven by applied engineering and field analysis. Our process includes:

- Detailed technical evaluation of the application;

- Careful material selection;

- Performance testing;

- Strict process control.

This methodology enables the development of solutions with high reliability, dimensional stability, and consistent field performance.

Talk to a Specialist

If you are looking to increase the durability of your pneumatic systems or eliminate recurring failures, our team is ready to support you with the most appropriate technical specification for your application.