An industrial crane is a central lifting device in production, maintenance and deconstruction. In practice, it combines load capacity, reach, and precise positioning of components and tools. In conjunction with hydraulic cutting and splitting tools from Darda GmbH – such as concrete demolition shears or rock and concrete splitters – an industrial crane enables controlled workflows in concrete demolition, building gutting, rock breakout and tunnel construction as well as in special operations with high demands on safety and dimensional accuracy.
Definition: What is meant by industrial crane
An industrial crane is a crane system for lifting, lowering, and moving loads within a defined working area. This includes bridge and gantry cranes in halls, tower cranes on construction sites, as well as mobile and crawler cranes. Characteristic features include a hoist, load handling devices (e.g., hooks, spreader beams), a travel or slewing mechanism, and a control system. Industrial cranes move loads linearly (trolley/crane runway) or radially (boom/slewing gear) and allow repeatable positioning – a prerequisite for the safe setup and guidance of heavy attachments and components.
Role of the industrial crane in concrete demolition and special deconstruction
In concrete demolition and special deconstruction, the industrial crane serves as a load-bearing and finely controllable positioning aid. It holds components under load while concrete demolition shears create controlled separations. It also inserts rock and concrete splitters into boreholes or places rock splitting cylinders along predefined splitting lines. This creates predictable fracture paths and allows fall directions and residual tensile forces to be safely controlled. Hydraulic power packs often remain on the ground; the crane only guides the tool and the hose bundles. In special operations – for example when deconstructing hard-to-access core areas – the crane also brings combi shears, multi cutters, steel shears, or tank cutters into the work zone and stabilizes the component until the cut is fully completed.
Crane types and their suitability for typical applications
Bridge and gantry cranes in industrial halls
Bridge and gantry cranes are ideal for strip-out and cutting within existing buildings. They offer linear, low-vibration load guidance via crane runway and trolley. This facilitates the precise application of concrete demolition shears to beams, walls, or slabs. During the dismantling of heavy machine foundations, rock and concrete splitters can be positioned precisely while the crane relieves the loads and controls them safely.
Tower, mobile and crawler cranes on the construction site
Outdoors, tower cranes as well as mobile and crawler cranes are required when reach, radius, and off-road capability are decisive. They position concrete demolition shears and combi shears on high or far cantilevering components and enable the safe lowering of detached segments. In tunnel construction or rock breakout, mobile or crawler cranes bring rock splitting cylinders and hose bundles over shafts or benches precisely to the point of use.
Interfaces to hydraulic tools and power packs
Lifting tackle and attachment points
Tools from Darda GmbH have defined lifting or carrying points. With hooks, shackles, chain slings, and spreader beams, the load attitude is set. Decisive is a stable center of gravity to avoid transverse pull on the tool and to ensure setting accuracy. For delicate components, a short spreader helps to introduce the clamping forces of the concrete demolition shear parallel to the component.
Power supply via hydraulic power packs
Hydraulic power units (power packs) provide operating pressure and oil flow for concrete demolition shears, rock and concrete splitters, multi cutters, steel shears, or tank cutters. They are positioned as vibration-free and well-ventilated as possible. The crane only guides the hose bundles. Large bending radii of the hoses, kink protection, and chafe-free routing protect the hydraulics from damage and avoid unnecessary pressure spikes.
Control and coordination
Crane motion is synchronized with tool guidance. During the cutting or splitting phase, vertical movement is kept minimal to limit dynamic loads. A clear system of hand signals and radio protocol between the crane operator and the tool operator increases process safety.
Planning and load case analysis
Careful work planning reduces risks and increases productivity. In addition to load capacity, load case analysis plays a central role, especially with sudden releases of components or when breaking with splitting cylinders.
- Load analysis: Consider the self-weight of the tool, the components, additional loads (hoses, spreaders), and possible adhesions.
- Center of gravity: Choose suspension points so that the tool jaws or splitting wedges can be applied steadily.
- Work path: Define collision-free paths for crane hook, trolley, hose bundles, and components.
- Intermediate states: Secure partially relieved components; factor in possible residual forces and composite reinforcement.
- Weather and environment: Assess wind, visibility, dust generation, and vibrations – especially for mobile and tower cranes.
Practical examples from the application areas
Concrete demolition and special deconstruction
The industrial crane holds beams or wall panels under pre-load while concrete demolition shears cut the reinforcement. For massive blocks, rock and concrete splitters can create fracture joints along rows of drilled holes; the crane catches the segments in a controlled manner.
Strip-out and cutting
In halls, a bridge crane moves concrete demolition shears, multi cutters, or tank cutters to corridors, shafts, and girders. Smooth crane motions improve cut quality and reduce rework.
Rock breakout and tunnel construction
During excavation, the crane supports placing rock splitting cylinders in drillholes and keeps protective structures or ventilation ducts clear. The tool runs off the hydraulic power pack at the portal, while the crane holds position precisely.
Natural stone extraction
In the extraction of blocks, rock and concrete splitters enable defined planes of separation. A gantry crane lifts blocks vertically out, minimizes edge spalls, and reduces the number of unplanned fractures.
Special operation
In contaminated or confined zones, the crane introduces tools without contact. Combi shears or steel shears can be applied to hard-to-reach components with an extended suspension, while the power supply remains remote.
Safety, work organization, and legal framework
Safe crane operations require trained personnel, suitable lifting tackle, and a clear distribution of tasks. Barriers, defined communication channels, and lines of sight are essential. Weather limits, permissible inclinations, and setup conditions (e.g., outrigger pressures for mobile cranes) must be observed. Legal and normative requirements as well as generally accepted rules of technology must be taken into account; individual on-site assessments remain indispensable and cannot be replaced by generalizations.
- Minimize vibrations: smooth trolley travel, gentle hoisting, use of tag lines.
- Edge protection: protect hose bundles and lifting gear from sharp edges.
- ATEX zones: When using tank cutters, avoid ignition sources and use suitable work equipment.
Checklist: Preparing a crane operation with concrete demolition shear or splitter
- Check tool data: self-weight, dimensions, permissible orientation, lifting points.
- Match crane parameters: load capacity at the planned radius and lifting height, hoisting speed, available spreaders.
- Clarify hydraulics: pressure, oil flow, hose lengths, couplings, tightness.
- Assess the component: reinforcement, bond, stresses, possible residual forces, escape paths.
- Secure the work area: barriers, escape routes, keeping the load path clear, set-down areas.
- Define communication: hand signals, radio channel, command structure.
Common mistakes and how to avoid them
- Underestimated additional loads: include hose bundles, spreader, and residual adhesions.
- Wrong center of gravity: perform a dry lift first and correct the attitude before setting the tool.
- Excessive dynamics: avoid rapid hoisting reversals; during splitting and cutting, build up tension slowly.
- Inadequate edge protection: protect hoses and chains against chafing and crushing.
- Unfavorable hose routing: allow sufficient bend radius and longitudinal play to protect couplings.
Key figures and performance parameters
Key figures of an industrial crane include load capacity over the radius, lifting height, hoisting and trolley travel speed, positioning accuracy, and the available spreader technology. For hydraulic tools, operating pressure, oil flow, gripping or splitting force, and self-weight are relevant. The combination of both systems must be selected so that load, reach, and process force fit together – particularly with large-volume concrete elements or heavy steel sections.
Environmental and emissions aspects
Precise crane operation reduces noise, dust, and vibrations because fewer corrective cuts and fractures occur. Hydraulic power packs can be positioned in areas with lower noise exposure; shorter cutting times due to good interaction between crane and tool reduce total energy. Where possible, material is divided into manageable segments, which reduces transport routes and handling.