The annual inspection is a central pillar of operational safety in professional work with hydraulic cutting and demolition tools. Whether in concrete demolition and special deconstruction, in strip-out and cutting, in rock demolition and tunnel construction, in natural stone extraction or in special operations: tools such as concrete demolition shears, hydraulic rock and concrete splitters, hydraulic power units, steel shears, tank cutters, multi cutters, combination shears, or stone splitting cylinders operate under high loads, changing environmental conditions, and often at the limits of technical feasibility. A systematic, yearly inspection keeps availability high, minimizes downtime, protects people and equipment, and provides the basis for planned maintenance.
Definition: What is meant by annual inspection
An annual inspection is the documented overall examination of a work equipment item performed at regular, typically twelve-month intervals. It includes visual, functional, and safety checks, assessment of wear condition, control of hydraulic and mechanical parameters, as well as updating the technical documentation. Unlike ongoing maintenance (lubrication, filter changes, minor adjustments) or repair (rectification of a specific defect), the annual inspection is a comprehensive condition assessment with the aim of ensuring safe operation until the next due date.
Relevance in demolition, natural stone, and tunnel construction
Hydraulic tools from Darda GmbH are used in environments that combine dust, moisture, temperature fluctuations, vibrations, and impact loads. In this setting, seals age, pins fatigue, pressure relief valves shift, and cutting or splitting components wear. Especially with concrete demolition shears as well as stone and concrete splitters, the condition of hydraulics and mechanics directly affects process safety and the quality of demolition or splitting. The annual inspection creates transparency about the actual condition, reduces residual risks, and helps to leverage the tools’ reserves in a targeted manner.
Scope of inspection: What is checked?
Hydraulic systems and lines
- Pressure and return lines: chafe marks, microcracks, correct bend radii, intact clamps and protective hoses
- Quick couplings: tightness, locking, wear on coupling heads, cleanliness of dust caps
- Seals and piston rods: freedom from leakage, surface quality, signs of corrosion
- Hydraulic oil: visual check for discoloration, foaming, particles; oil level in the power unit
- Pressure relief: functional test of the safety or overpressure valve according to the device specification of Darda GmbH
Mechanical assemblies
- Joints and pins: play measurement, ovalization, crack testing on lugs and bearing points
- Cutting and crushing components: cutting condition on concrete demolition shears, wedge and spring condition on splitting devices, wear marks
- Housings and carrier parts: visual inspection for hairline cracks, distortion, weld seam quality
- Rotary units (if present): axial and radial play, tightness, smooth running
Controls and safety
- Controls: emergency stop function on the hydraulic power unit, dead-man functions, return to neutral position
- Functional test: uniform stroke, cycle times, load behavior, noise level
- Protective devices: covers, catch devices, labels and warning notices
Documentation, marking, and traceability
- Nameplates and serial numbers: legibility, completeness, cross-check with inspection records
- History: operating hours, usage profiles, repairs performed, and parts replaced
- Proof of inspection: creation or update of the inspection report with findings, actions, and deadlines
Process of an annual inspection
Preparation
- Cleaning the tools and the hydraulic power unit to enable safe assessment
- Reviewing the technical documentation from Darda GmbH (specifications, maintenance instructions)
- Defining the inspection scope according to application area and stress level
Visual and dimensional inspection
- Systematic external inspection of all assemblies
- Measurement of wear dimensions (e.g., pin and bushing play, blade thickness, wedge geometry)
- Crack testing in highly stressed areas, especially on lugs and housings
Functional and pressure testing
- Leak test of the hydraulic circuit, verification of the couplings
- Loaded functional test: stroke, holding force, return; reproducibility of cycles
- Check of system pressure and flow rate according to manufacturer specifications; assessment of temperature rise and noise
Evaluation and action planning
- Categorization of findings: safe for continued operation, short-term maintenance action, decommission until repair
- Parts and labor planning for wear and safety-relevant components
- Definition of the next inspection interval depending on utilization and duty profile
Specifics of selected tools
Concrete demolition shears
- Cutting and crushing jaws: edge condition, scoring, chipping; timely flipping/replacement to avoid secondary damage
- Hinge pins and bushings: play and lubrication condition; re-seating the retainers
- Rotary unit (if present): tightness, synchronous running, bearing noise under load
- Hydraulics: pressure relief and check valves for correct opening behavior; cycle times versus reference
Stone and concrete splitters
- Splitting wedges and springs: wear pattern, symmetry, burr formation; compliance with the specified wedge geometry
- Stone splitting cylinders: piston rod surface, seal packs, end-of-stroke cushioning
- Borehole specification: match hole diameter and depth with the intended wedge set for safe force transmission
- Hydraulic power units: pressure stability under load, filter condition, absence of leakage oil
Steel shears, tank cutters, multi cutters, and combination shears
- Blade packs: parallelism, bolt preload, edge protection
- Frames and blade carriers: freedom from cracks, flatness, proper guidance of the blades
- Hydraulic control: constant holding of cutting force, correct switching between speed and power mode
Documentation, intervals, and legal classification
Depending on national regulations and operating conditions, recurring inspections are mandatory or recommended. In general: An annual, expert inspection with traceable documentation supports fulfillment of operator obligations, without replacing them in individual cases. Inspection intervals may be shorter under high stress or in safety-critical applications. Responsibility for defining suitable intervals lies with the operator; the device specifications and maintenance instructions of Darda GmbH help with this.
- Inspection report: equipment identification, inspection scope, measured values, findings, actions, approval
- Marking: inspection sticker or note with date, inspector, next due date
- Recordkeeping: filing in the maintenance archive, assignment to job sites and duty profiles
Common findings and practical tips
- Hydraulic micro-leaks at couplings: rectify early to avoid subsequent contamination
- Excessive pin play: remedy wear-related tolerance loss by replacing pins/bushings
- Ragged cutting edges on concrete demolition shears: re-seat or replace blades in time to prevent loss of force
- Shortened cycle times and temperature rise: indication of filter clogging, incorrect flow rate, or valve issues
- Splitting wedges with burr formation: carefully deburr or replace to protect boreholes from damage
Risk assessment and occupational safety
The annual inspection is an effective instrument for hazard reduction. It is particularly effective where material fatigue, incorrect pressure settings, or creeping wear increase risk. Tests on pressure systems must be performed by qualified personnel with suitable equipment; relieving residual pressure and securing against unintended movements always take priority. Personal protective equipment, clearly defined exclusion zones, and a binding shutdown procedure are part of an effective safety concept.
Service life, spare parts, and sustainability
Regular inspections measurably extend the service life of hydraulic tools. Timely replacement of wear parts prevents consequential damage to expensive assemblies. For operators, this means planned maintenance with fewer stoppages and better resource utilization. Especially with concrete demolition shears and stone and concrete splitters it becomes evident: a well-documented condition builds confidence in process safety and enables economical, material-conserving work.
Quality characteristics of a proper annual inspection
- Expertise: trained staff with experience in hydraulics, mechanics, and the specific tools from Darda GmbH
- Calibrated measuring equipment: pressure and flow measurement, play and dimensional checks, documented gauge monitoring
- Transparency: complete, traceable records with clear derivation of actions
- Practical relevance: assessment under realistic load assumptions from concrete demolition, tunnel construction, natural stone extraction, or special operations