Base load describes the permanently present, non-avoidable load or power demand in a system. In the context of deconstruction, demolition, and extraction, this concerns two levels: the permanent loads in structures and rock, and the baseline demand for pressure and flow rate in hydraulic drives. Anyone who wants to use concrete demolition shears, rock and concrete splitters, or hydraulic power packs safely and efficiently must combine both perspectives: the base load in the material and the base load in the drive.
Definition: What is meant by base load
Base load is the portion of load or power that occurs continuously, independent of short-term peaks. In the structural system, these are permanent loads such as self-weight, support and composite loads; in rock, the in-situ stresses. In hydraulics, base load denotes the unavoidable pressure and power demand of a hydraulic power pack in idle or holding mode, including flow losses, leakage gap losses, and control pressure. This base load forms the starting point for any working load, for example when closing a concrete demolition shear or generating splitting forces with rock and concrete splitters.
Base load in day-to-day deconstruction: hydraulics and structure in interaction
In practice, the permanent loads of the structure or rock act together with the hydraulic base load. Before splitting cylinders are set or concrete demolition shears are applied, load paths, supports, and constraints must be understood. In parallel, the hydraulic power pack is configured to meet the base load demand efficiently while providing sufficient reserves for load peaks. The balance between structural base load and power pack base load determines cycle time, cutting sequence, tool selection, and energy efficiency.
Base load in hydraulic systems: significance for power packs and tools
Hydraulic power packs deliver pressure and flow. Even at idle, there is a base load from recirculation losses, control pressure, and throttling losses. This affects temperature, energy demand, and the response time of tools, for example of concrete demolition shears or rock and concrete splitters.
Standby pressure and flow rate
A minimum pressure is maintained so that valves switch, shears hold, and split wedges can be positioned in a controlled manner. Excessive standby pressure increases heat generation; too low reduces responsiveness and holding force. The goal is a demand-oriented base load point with stable control.
Energy efficiency and temperature balance
The hydraulic base load directly affects energy consumption. Optimized line cross-sections, short hose lengths, low throttling shares, and suitable pump characteristics reduce idle losses. A good temperature balance protects seals and reduces viscosity effects—important for uniform splitting and cutting forces.
Safety and pressure limitation
Pressure relief and check functions protect the system and operators from impermissible conditions. The design follows recognized engineering practice and is matched to the maximum closing, cutting, and splitting forces. Notes do not replace an individual hazard assessment.
Base load in structures and rock: understanding load paths
Permanent loads (self-weight, support reactions, prestress) and the stress states present in rock form the base load against which work is performed. Those who know the load paths can place rock splitting cylinders precisely, apply concrete demolition shears safely, and plan cutting sequences to avoid uncontrolled cracking.
Load transfer and cutting sequence
Before the first cut, the load transfer is defined: Where are the supports? Which components are contributing? Only then does the cutting and splitting sequence follow. A common, proven approach is to proceed from relieved areas to highly loaded nodes, accompanied by temporary shoring.
Splitting tension versus compressive load
Splitting tools preferably work along existing planes of weakness. If a component is highly loaded in compression, it tends to close split openings. In that case, small-area pre-openings, controlled relief cuts, or switching to segmented split points help.
Edge distances, reinforcement, prestressing
Reinforcement and prestressing redirect loads and can deflect split fronts. Sufficient edge distances, pilot drillings, and a deliberate approach to reinforcement anchors increase safety and precision when using concrete demolition shears and splitters.
Determining the base load: methods and key parameters
The determination of base load depends on the task and relies fundamentally on measurement, calculation, and experience.
- Structure: As-built survey, material properties, geometry, load assumptions according to recognized standards; deformation or crack monitoring if required.
- Rock: Geological profile, stratifications, joint sets, in-situ stresses; test boreholes and simple orientation trials.
- Hydraulics: Measurement of pressure, temperature, and flow in standby and partial load; assessment of leakage shares and response times.
Practical guide: from base load to work planning
- Existing conditions analysis: structure/rock, accessibility, media, safety zones.
- Load model: permanent loads, partial loads, potential load redistributions.
- Method selection: cutting, splitting, shear operation—combined according to target geometry.
- Tool sizing: closing and splitting forces, strokes, cutting lengths.
- Power pack design: base load point, delivery flow, pressure reserve, cooling.
- Cutting and splitting sequence: from relieved to loaded; intermediate shoring.
- First step and control: trial cut/trial split, check measurements.
- Cycling and monitoring: observe temperature, pressure profile, crack and deformation behavior.
Application examples: accounting for base load correctly
Concrete demolition of a reinforced concrete slab
The slab carries permanent loads from self-weight and attachments. After temporary shoring, the base load is reduced. Subsequently, multi-cutters cut the edges, and concrete demolition shears release panels in controlled sections. The hydraulic power pack maintains a moderate standby pressure to limit heat while still providing holding force.
Natural stone extraction in the quarry
In-situ stresses and joint systems define the base load in the rock. Rock and concrete splitters utilize joint orientations. Pre-drilling with appropriate spacing guides the split front. A steady hydraulic base load point prevents jerky load peaks and delivers reproducible splitting results.
Cross passage in tunneling
Lateral pressure and overburden form the base load in the rock mass. Segmented splitting with rock splitting cylinders and concurrent support limits redistributions. Hydraulic power packs operate with a stable base load and sensitive control to proceed in a controlled manner within confined space.
Distinction: base load, partial load, and load peaks
Base load is permanent. Partial load describes the variable range above it when tools are actively working but not yet at maximum. Load peaks occur briefly, for example when cutting through particularly tough reinforcement or during the initial setting of split wedges. For planning and power pack design the rule is: base load efficient, partial load stable, peaks safely controllable.
Typical mistakes and how to avoid them
- Unclear load paths: clarify load redistributions and support reactions before starting.
- Excessive standby pressure: leads to heat and inefficient operation; adjust the base load point.
- Missing intermediate shoring: base load in the component remains too high; risk of collapse or cracking.
- Unsuitable cutting sequence: split front runs uncontrolled; revise the sequence.
- Ignored reinforcement/prestressing: possible tool overload; plan pre-openings and cutting strategies.
Sizing splitting and shear operations from the base load
Target forces, edge distances, and piece sizes are derived from the structural or rock base load. This yields closing forces for concrete demolition shears and splitting forces for rock and concrete splitters. The hydraulic power pack is designed so that base-load operation is efficient while also providing sufficient reserve for working phases.
Safety and responsibility
Work on the load-bearing system or in rock is carried out on the basis of appropriate planning and in compliance with recognized engineering practice. Assessing the base load and its effects requires expertise. The information provided is general and does not replace case-by-case verification.
Documentation and verification
Documentation includes load assumptions, measurements at standby and under load, tool and power pack parameters, as well as the cutting and splitting sequence actually executed. Clean traceability supports quality, safety, and the optimization of future projects.
Checklist: keeping the base load in view
- Permanent loads in the component/rock mass identified?
- Hydraulic base load (pressure/flow) measured and assessed?
- Intermediate shoring and sequence defined?
- Tool and power pack reserves available for peaks?
- Monitoring of temperatures, pressures, and crack patterns set up?