Hydraulic tools put immense force at your fingertips. Powered by hydraulic oil at pressures of up to 700 bar, they make it possible to move extremely heavy loads with precision and control. For example, a hydraulic cylinder weighing just 2.6 kg can lift a 20,000 kg load, while hydraulic systems can also move loads of 500,000 kg horizontally with ease. The key to working safely is maintaining complete control over that force.
In this knowledge hub, hydraulic specialist Holmatro and lifting and hoisting specialist Mennens explain everything you need to know about working safely with high-pressure hydraulics.
Operating hydraulic tools at pressures of up to 700 bar demands expertise and careful preparation. Seemingly minor oversights can have serious consequences. What are the main risks? What should you look out for? How can you prevent accidents and avoid costly downtime? Holmatro and Mennens share their knowledge, practical guidance, and best practices for safe hydraulic operations.
Download our whitepaper
What should you look out for? What are the key risks? How can you prevent accidents and avoid costly downtime?
This white paper provides practical guidance for working safely with hydraulic systems. From storage and transport to inspection, testing, and maintenance, you'll gain valuable insights into the key considerations for safe and reliable hydraulic operations.
This whitepaper is only available in Dutch!
Hydraulic repair and inspection
Our service workshops are equipped with professional, specialist hydraulic test facilities for the repair and inspection of hydraulic equipment. Several Mennens locations are certified **Holmatro Premium Service Centres**, where we can thoroughly test, repair, and recertify your hydraulic equipment in accordance with the applicable standards.
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Safe working with hydraulics: Mennens Premium Service for Holmatro
With Holmatro's industrial hydraulic tools, Mennens provides flexible, controlled solutions for virtually any lifting or positioning application. To ensure these tools continue to operate safely and reliably, regular inspection, testing, and maintenance are essential.
These services are available through the Mennens Premium Service Centres. Thanks to specialist training from Holmatro, Mennens is authorised to inspect (dynamic testing), maintain, repair, and recertify hydraulic equipment in accordance with the EKH guidelines. This helps improve safety, minimise downtime, and extend the service life of your hydraulic tools.
Working with hydraulics? Remember BRAIN
Follow the BRAIN principle to work safely with hydraulic equipment:
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B – Be prepared: Read the instructions carefully and use the equipment only for its intended purpose.
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R – Remove hazards: Keep your work area tidy and create a safe working environment.
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A – Always wear PPE: Use the appropriate personal protective equipment for the task.
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I – Inspect your equipment: Carry out pre-use inspections and ensure periodic maintenance and testing are performed.
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N – Never use damaged equipment: Remove defective tools from service immediately.
Learn more
Explore these expert articles from Holmatro and Mennens:
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Toolbox talk: safe working with hydraulics
Why is it so important to work safely with hydraulic tools? What are the main risks?
The Safe working with hydraulics toolbox talk introduces the fundamental principles of working with high-pressure hydraulic systems. Using practical examples, it helps participants recognise potential hazards and understand how to apply the correct safety measures before, during, and after using hydraulic equipment.
You can request the toolbox talk here.
Holmatro and Mennens: a complete service partnership
Helping organisations work safely, efficiently, and confidently with hydraulic tools—that is the shared goal of Holmatro and Mennens.
Holmatro is a leading manufacturer of high-quality hydraulic equipment, while Mennens is a specialist in lifting solutions and a one-stop shop for lifting expertise.
This close partnership enables us to support organisations throughout the entire lifecycle of their hydraulic equipment. In addition to supplying high-quality hydraulic tools, we provide expert advice, inspection and maintenance services, training, and practical knowledge to help you meet your operational challenges safely and efficiently.
Visit the Holmatro website to learn more.
Check out our videopodcasts about hydraulics
The podcasts are only available in Dutch!
Podcast summary: what is hydraulics?
Hydraulics is a technology that uses pressurised fluid to generate force and power equipment. In industrial applications, a distinction is generally made between low-pressure hydraulics (up to 350 bar) and high-pressure hydraulics (typically 500–700 bar).
High-pressure hydraulic systems are used in demanding applications such as lifting bridges and viaducts, installing offshore wind turbine foundations, and rerailing trains. Because these systems store enormous amounts of energy, safe working practices are essential. To put their power into perspective, a compact hydraulic cylinder can generate enough force to lift a load equivalent to four stacked elephants.
Working with hydraulics also involves significant risks if users are unaware of the forces and pressures involved. Regular inspection and testing of hydraulic equipment, combined with proper training and knowledge, are essential to minimise these risks and ensure safe operation.
Podcast summary: safe working with hydraulics
Hydraulics transfers force by using fluid under pressure. While this makes hydraulic systems extremely powerful, it also means that incorrect use can lead to serious accidents, injuries, and equipment damage.
Unsafe situations often arise through the use of unsuitable or damaged components, or because users lack sufficient knowledge of hydraulic systems and their maintenance.
One example is combining components with different pressure ratings—for instance, using a 2,000 bar pump, a 350 bar hydraulic hose, and a 700 bar cylinder in the same system. Likewise, installing low-pressure fittings designed for compressed air in a 700 bar hydraulic system can create extremely dangerous situations.
The consequences can include hydraulic leaks, high-pressure fluid escaping at high velocity, or failure of pressure relief systems. In the worst cases, this can result in severe injuries, such as hydraulic injection injuries, or cause heavy loads to shift or fall during lifting operations.
To work safely with hydraulics, equipment should be inspected, tested, and maintained at regular intervals, while knowledge and awareness should be developed throughout the organisation. A simple but important measure is to inspect hydraulic hoses regularly for wear, damage, or kinks before use. Dynamic testing—where hydraulic cylinders are tested under simulated operating conditions in a dedicated test frame—helps verify that equipment continues to perform safely and reliably.
Understanding the risks and applying the correct safety measures are the foundations of safe hydraulic operations.
