Hydraulics transmits energy by means of pressurized fluid. In demolition, deconstruction, rock cutting/processing and natural stone extraction it enables high forces in confined spaces, precise movements, and controlled interventions in concrete, steel, and rock. Tools such as concrete demolition shear, hydraulic wedge splitter and concrete splitter as well as steel shear and cutting torch are supplied by a hydraulic power pack and together form a powerful, finely meterable system for demanding tasks in urban settings, in tunnel construction, or in special demolition.
Definition: What is meant by hydraulics
Hydraulics is the technical use of fluids for force and motion transmission. A hydraulic system converts drive power (for example from an electric motor) into pressure and flow via a pump. This energy flow reaches actuators such as cylinders or hydraulic motors through valves, lines, and hoses, which produce linear or rotary work. Pascal’s law forms the basis: pressure acts equally in all directions in an enclosed fluid, allowing large forces to be generated from moderate input power. Hydraulics can work slowly, smoothly, and with high repeatability—an essential advantage in controlled concrete demolition and in natural stone extraction.
Operating principle and system architecture
A typical system consists of a hydraulic power pack, pump, tank, filtration, pressure limitation, control and directional valves, hose lines, and the actuators. The pump generates flow, valves control direction and quantity, and cylinders or motors convert the energy into force or torque. Pressure × flow corresponds to hydraulic power; via the effective area of a cylinder this becomes splitting, cutting, or pressing force. Return lines route the fluid back to the tank; filters ensure cleanliness and thus the service life of the components.
Fundamentals of pressure transmission and flow
Three variables are decisive for the design: pressure (load capacity and achievable force), flow rate (speed and cycle time) and fluid quality (viscosity, additives, cleanliness). Pressure losses arise from lines, fittings, and valves; they generate heat and reduce efficiency. Appropriate line sizing, short hose runs, and finely tuned valve technology reduce losses and improve controllability—important for tools such as concrete demolition shear, combination shears, or multi cutters that require frequent opening and closing in short cycles.
Flow, pressure, and power working together
With increasing pressure, the achievable force grows; with higher flow rates, speeds increase, but so do pressure losses. A balanced match is crucial: massive concrete deconstruction requires high pressure levels, while economical cycle times require sufficient flow. The power pack must provide both within the intended temperature window without thermally overloading the hydraulic fluid.
Hydraulics in demolition, deconstruction, and extraction
In the application fields of concrete demolition and special demolition, building gutting and cutting, rock breakout and tunnel construction as well as natural stone extraction, hydraulics plays to its strengths: high power density, fine metering capability, and a favorable ratio of tool size to working force. Hydraulically driven concrete demolition shear disassemble reinforced concrete in a controlled manner, while hydraulic wedge splitter and concrete splitter enable non-explosive rock removal—with low vibration levels and reduced dust, which is advantageous in sensitive environments.
Concrete demolition shear: controlled reduction of components
Concrete demolition shear use the applied pressures to generate high cutting and crushing action at the jaws via cylinder forces. The hydraulics determine clamping force, jaw opening, and cycle time. For long service life, clean hydraulic fluid, correctly set pressure relief valves, and suitable flow rates are essential. In special demolition, components can be removed in sections and with low vibration through sensitive valve control.
Hydraulic wedge splitter and concrete splitter: explosive-free separation
Hydraulic wedge splitter and concrete splitter transfer pressure via wedges or splitting cylinders into boreholes. The resulting stresses lead to defined crack formation and cleanly separated segments. The hydraulics deliver the splitting force reproducibly and scalably, enabling precise cuts in hard rock during tunnel construction and natural stone extraction, as with hydraulic rock and concrete splitters.
Components of a hydraulic system
The selection and combination of components determine the performance, reliability, and maintenance effort of the system—from energy generation in the power pack to force delivery at the tool.
- Hydraulic power packs: energy source with pump, drive, tank, filtration, and cooling; provide pressure and flow.
- Valve technology: directional, pressure, and flow valves regulate direction, pressure level, and speed; load-holding functions secure positions.
- Lines and couplings: hydraulic hose lines and quick coupling connect power pack and tool; clean coupling protects against contamination.
- Cylinders and motors: linear and rotary actuators for splitting, cutting, crushing, or rotating.
- Measuring and protection components: pressure gauges, temperature sensors, safety and pressure relief valves.
Hydraulic power packs: supply and control
The power pack delivers the required pressure and flow characteristics. Appropriate filtration fineness, sufficient tank size, and suitable cooling stabilize operation even at high cycling rates such as those encountered with concrete demolition shear, combination shears, or multi cutters.
Stone splitting cylinders and actuators
Stone splitting cylinders convert pressure directly into radial splitting forces. Cylinder design (piston area, stroke, seals) determines splitting force and working travel. Precisely manufactured sealing systems and a fluid suited to the application prevent stick-slip effects and ensure constant forces.
Combination shears, multi cutters, steel shear, and cutting torch
In cutting tools, hydraulics determine cutting force via cylinder pressure and the geometry of the cutting edges. Load-dependent control enables fast approach and powerful cutting in the working range. Cutting torch and steel shear benefit from stable pressure regulation and controlled cutting speeds to minimize material deformation and burr formation.
Hydraulic fluids and cleanliness
The choice of hydraulic fluid influences efficiency, wear, and cold/heat behavior. Important factors are suitable viscosity, oxidation stability, and additives. High fluid cleanliness extends the service life of pumps, valves, and actuators—especially in mobile applications with frequent coupling between power pack and tool.
- Viscosity: high enough for lubrication, low enough for good cold-start behavior.
- Filtration: graded filter concept in pressure and return lines; regular monitoring of differential pressures.
- Clean handling: protective caps, clean coupling, low-dust environments during fluid changes.
Design: forces, cycle times, and energy demand
Dimensioning starts with the required task: needed splitting, pressing, or cutting forces, material strength, component geometry, and desired cycle times. From this result the necessary pressure and flow as well as requirements for the valve technology. For concrete demolition shear, a balance of high end force and brisk opening/closing is relevant; for hydraulic wedge splitter and concrete splitter, reliably achieving splitting force at stable fluid temperature and with reproducible cylinder motion counts.
Example consideration for concrete demolition shear
The achievable jaw force results from cylinder area and system pressure multiplied by the kinematic leverage of the jaws. The flow rate sets opening and closing speed. A match of sufficiently sized power pack, low-loss lines, and sensitive valve characteristics improves productivity and reduces heat generation.
Safety, ergonomics, and handling
Safe hydraulic work is based on depressurized coupling procedures, controlled commissioning, and functioning protective elements such as pressure relief and load-holding valves. Ergonomic aspects involve weight, hose routing, grip, and a clear view of the work area. During building gutting and cutting operations, smooth movements and constant tool guidance increase precision; in tunnel construction and special demolition, finely meterable hydraulics help avoid unwanted vibrations.
Maintenance and troubleshooting
Regular maintenance operations preserve performance and safety. Fluid condition, filters, seals, and hoses are the focus. Abnormal noises, elevated temperatures, or unstable movements indicate wear, air in the system, or contamination. A structured approach facilitates diagnosis.
- Visual inspection: check lines, couplings, sealing points, and tools.
- Functional test: verify pressure build-up, holding functions, and end positions.
- Fluid care: take samples, assess contamination level and water content.
- Filter management: replace by differential pressure or interval, work cleanly.
- Documentation: record measurements, maintenance, and observations.
Environmental and emissions aspects
Hydraulically operated tools often enable low-emission, quiet, and low-vibration work. In non-explosive rock removal, noise and dust generation are often reduced, which is advantageous in sensitive areas of special demolition and in urban zones. Careful handling of hydraulic fluids, tight systems, and suitable containment and cleaning practices support environmental protection measures.
Standards, guidelines, and state of the art
For planning, operation, and maintenance, the recognized rules of the art as well as relevant standards and safety requirements apply. These include requirements for machine and occupational safety, the safe handling of pressure equipment, and operator qualification. Careful hazard analysis, clear operating instructions, and regular training contribute to safe, legally compliant use.
Distinction from other systems and practical tips
Compared to pneumatics, hydraulics offers higher power density and finer controllability at high forces—crucial for concrete demolition shear, hydraulic wedge splitter and concrete splitter, steel shear, combination shears, multi cutters, and cutting torch. Compared to percussive methods, hydraulic solutions often enable more precise, lower-vibration processing. In practice, short, well-protected hose runs, clear markings on couplings, suitable transport protection for connectors, and consistent cleaning before coupling have proven their worth. This keeps forces and cycle times stable, and the tools work reliably over the long term—from concrete demolition through building gutting and cutting to rock breakout, tunnel construction, and natural stone extraction.