Construction power supply

Construction power supply is the temporary electrical power supply for construction, demolition, and installation projects. Without a safe and high-performance supply, machines, tools, and infrastructure come to a standstill—from the hydraulic power pack for hydraulic splitters through concrete pulverizers to tunnel ventilation. Well-conceived construction power supply planning ensures operational safety, productivity, and noise control and creates the basis for precise work in concrete demolition and special demolition, building gutting and concrete cutting, rock excavation and tunnel construction, natural stone extraction as well as special operations.

Definition: What is meant by construction power supply

Construction power supply refers to the time-limited, standards-compliant provision of electrical energy on construction sites. It includes the connection to the public grid or to an alternative source (e.g., generator), distribution via main and sub-distribution boards, protective and measuring equipment, cable routing to the consumers, as well as organizational measures for operation, inspection, and documentation. Typical operating voltages are 230 V (single-phase) and 400 V (three-phase), provided via CEE plug systems (e.g., 16 A, 32 A, 63 A, 125 A). The goal is a safe, adequate, and accessible power supply that takes changing construction states, environmental conditions, and load profiles into account.

Core components and structure of a construction power supply system

A resilient construction power supply system consists of feed-in, distribution, protection, cable routing, and consumers. Working together, they create the prerequisites to reliably operate hydraulic power packs for hydraulic splitters, concrete pulverizers, hydraulic shears, and further drives—indoors, outdoors, or underground.

Construction power supply in practice: planning, sizing, and operation

In planning, connected load, load distribution, cable lengths, voltage drop, protection concept, and environmental conditions are considered holistically. In operation, regular visual and functional inspections, clear responsibilities, tidy cable routing, and documented adaptation to construction progress are crucial. This minimizes failures, fulfills safety requirements, and keeps power delivery for hydraulic drives, pulverizers, and cutting technology stable.

Feed-in: grid, generator, or hybrid solution

Depending on the location, different feed-in types are available. Each has effects on performance, emissions, acoustics, and logistics—important aspects, for example, in special demolition in sensitive interior areas or in rock excavation in remote zones.

Grid connection

• Advantages: Constant voltage and frequency, low local emissions, low noise emission; ideal for building gutting and concrete cutting in buildings and for electric hydraulic power packs.
• Particularities: Registration and coordination with the grid operator; sufficient capacity at the grid connection point; protection and metering via construction power supply distribution boards with a metering device.

Generator operation

• Advantages: Independence from the grid, mobile use in natural stone extraction, rock excavation, and special demolition.
• Particularities: Sizing reserve for inrush currents of hydraulic power packs and electric motors; exhaust and noise control; fuel logistics; grounding and protective measures as with grid operation.

Hybrid supply

• Combinations: Grid plus mobile storage or generator with power management to reduce peak loads, decrease generator size, and improve acoustics in noise-sensitive zones.

Construction power supply distribution and protection

A robust distribution supplies energy and protects people and equipment. When working with concrete pulverizers as well as hydraulic splitters, residual current protection is essential—especially in wet or conductive environments.

Main and sub-distribution boards

• Main distribution board with main switch, meter, surge protection, residual current and overcurrent protection.
• Sub-distribution boards close to the work areas (e.g., demolition section, tunnel heading, sawing and cutting stations) with clearly labeled outlets for 230 V/400 V.

Protective devices

• Residual current device (RCD): Select to suit the application environment and the connected consumers; maintain selectivity between stages.
• Miniature circuit breaker (MCB): Match characteristics to the starting behavior of motors to avoid nuisance tripping.
• Grounding and equipotential bonding: Install to standards, inspect regularly, document.

Cables and plug-and-socket devices

• Mechanically robust, oil- and weather-resistant rubber-sheathed cables (e.g., H07RN-F) with sufficient cross-section.
• CEE sockets 16 A/32 A/63 A/125 A and 230 V sockets with protective earth contact, each protected against splashing water and dust.
• Routing over cable bridges, suspensions, and protective conduits to avoid crushing, tripping, and malfunctions.

Power planning for hydraulic drives, concrete pulverizers and splitting technology

Hydraulic power packs that feed hydraulic splitters or concrete pulverizers impose characteristic requirements on the construction power supply: high inrush currents, continuous power delivery, and temporary peak loads. Proper sizing prevents voltage dips that can noticeably reduce tool performance.

Load acceptance and inrush currents

• Starting reserve: Dimension generators and grid feeders so that short-term multiple currents at start-up are safely absorbed.
• Soft start/variable frequency drive: Where permissible, they help reduce switching peaks and maintain the selectivity of protective devices.

Voltage drop and cable lengths

• Minimize cable length: Short runs to power packs and concrete pulverizers improve voltage conditions.
• Adjust cross-section: Larger conductor cross-sections reduce voltage drop and heating—important with continuous load in concrete demolition.

Phase load distribution

• Three-phase loads: Even phase loading to avoid neutral conductor overload and voltage asymmetries.
• Single-phase loads: Distribute across multiple sub-distribution boards to avoid local overload.

Construction power supply in concrete demolition and special demolition

In demolition and deconstruction work, the supply of hydraulic power packs, saws, drilling systems, dust extraction plant, and water treatment is central. Electrically driven power packs enable low-emission operations indoors. To ensure that concrete pulverizers and hydraulic splitters deliver consistently high performance, stable 400 V feeders with suitable protection, sufficient reserve, and clean plug logic are required.

Typical consumers

• Hydraulic power packs for concrete pulverizers, hydraulic shears, and Multi Cutters.
• Drilling and cutting technology, core drilling rigs, cut-off grinders, slab saws.
• Dust extraction plant and filtration systems, pumps for water supply and wastewater.
• Dust protection and noise control infrastructure, lighting, measuring equipment.

Construction logistics

• Place distribution close to the work: Minimize voltage drop and travel distances, reduce re-plugging.
• Load management: Stagger start sequences for power pack, pulverizer, and auxiliary consumers; avoid peaks.

Construction power supply in rock excavation, tunnel construction and natural stone extraction

In tunnel construction, in quarries, and in special operations the grid connection is often distant. Generators and hybrid storage solutions are selected so that hydraulic power packs for rock-splitting cylinders and concrete pulverizers start reliably and are supplied stably over long shifts. Additional consumers such as ventilation fans, lighting, and communication increase the base load.

Environmental conditions

• Moisture and dust: Observe the ingress protection ratings of the equipment, protect plug connections against splashing water and mud.
• Temperature: Provide adequate ventilation of generators and distribution boards; size conductor cross-section for heating.
• Mechanical load: Secure cable routes against edges, traffic routes, and rockfall.

Safety, inspections and documentation

Temporary electrical installations must be inspected before commissioning and at regular intervals. A competent person assesses visual condition, protective measures, measured values, and functionality. Results are documented and updated when changes are made to the installation. Safety training, clear responsibilities, and labeling of distribution boards increase operational safety.

Organizational measures

• Appointment of a responsible person for the construction power supply installation.
• Fixed inspection intervals and protocols; labeling of tested distribution boards and cables.
• Fault and emergency plan, e.g., in case of RCD tripping or grid outage.

Cable management, lighting and auxiliary infrastructure

Tidy cable routing and adequate lighting are basic prerequisites for efficient work—especially when using concrete pulverizers in confined areas or when splitting concrete and rock.

Best practices for cable routing

• Crossings via cable bridges; stow spare lengths neatly.
• Clean cables regularly and check for damage; remove defective cables from service immediately.
• Color and number coding for outlets and consumers.

Work and safety lighting

• Glare-free, low-shadow illumination of the work zone.
• Independent emergency lighting in critical areas, particularly underground.

Energy efficiency, emissions and acoustics

Electrically driven hydraulic power packs help reduce local emissions and noise emission—an advantage when working in buildings and in tunnels. Load management, soft start, and demand-based switching of consumers lower energy demand and generator size. Careful placement of power packs and distribution boards reduces noise emission and improves communication in the workplace.

Practical levers

• Demand-based operation: Run power packs only when needed, avoid idling.
• Peak shaving: Define start sequences; stagger consumers that do not have to run simultaneously.
• Observe efficiency: Service hydraulics and electric motors regularly; keep filter systems clean.

Typical design values and practical orientation

In practice, clear reserves at the feed-in, short cable lengths, and generous placement of distribution boards have proven effective. For 400 V consumers with motor drives—such as hydraulic power packs for hydraulic splitters or concrete pulverizers—dimensioning should allow inrush currents without voltage dip. The selectivity of RCDs and MCBs should be chosen so that a local fault does not shut down the entire construction site.

Checklist for getting started

1. Determine power demand: continuous load, inrush peaks, simultaneity.
2. Select feed-in type: grid, generator, hybrid.
3. Plan distribution: main/sub-distribution boards, protective devices, plug systems.
4. Size cables: cross-section, length, ingress protection.
5. Balance phase loads; define start sequence.
6. Organize inspection, documentation, and labeling.

Reference to products and application areas of Darda GmbH

The performance of hydraulic splitters, concrete pulverizers, hydraulic shears, or Multi Cutters in electric operation depends directly on the quality of the construction power supply. In building gutting and concrete cutting in buildings, a low-emission, stable 400 V supply enables hydraulic power packs to run with constant output. In concrete demolition and special demolition outdoors, robust, short-circuit-proof distribution ensures trouble-free motor starts. In natural stone extraction, rock excavation, and tunnel construction, mobile generators or hybrid solutions provide the necessary energy for hydraulic power packs; properly sized cable routes and protective devices safeguard equipment and personnel even under harsh conditions.

Legal and technical notes in general form

Temporary electrical installations on construction sites must be designed, operated, and maintained in accordance with the applicable rules of technology. This includes suitable protective measures, regular inspections by qualified persons, and documentation of the results. Specific requirements may vary by country, grid operator, project, and environment. It is advisable to coordinate planning and execution with qualified specialist companies and to observe manufacturer instructions.