Lifting installation

Lifting installations are indispensable in concrete demolition, strip-out, tunnel construction, and natural stone extraction. They provide the basis for holding, lifting, lowering, or precisely positioning components in a controlled manner – often in combination with hydraulic demolition tools such as concrete demolition shears or rock and concrete splitters from Darda GmbH. This ensures loads are safely controlled, separation cuts become plannable, and workflows are organized efficiently and with low vibration. In practice, a lifting installation – also described as a lifting system or hoisting setup – supports segmented dismantling, maintains defined cut gaps, and reduces hazards in confined work areas.

Definition: What is meant by a lifting installation?

A lifting installation is a technical system for vertical or horizontal movement as well as for holding loads. It typically consists of a load-bearing system (e.g., gantry, beam, spreader), a hoisting device (e.g., chain hoist, winch, hydraulic jack), load handling attachments and rigging, as well as a control system. In the demolition and deconstruction context, lifting installations are used to relieve components of load while they are being separated, split, or crushed. As a result, components can be removed in a controlled manner and transferred into defined laydown or transport positions. The term also covers temporary, modular arrangements that can be adapted to changing construction states.

• Purpose: hold, guide, and move components safely under changing load conditions.
• Typical variants: portal gantries, spreader beams, tripods, and suspended systems adapted to site constraints.
• Control scope: from manual hoists to coordinated multi-hoist setups with load indication.

Use and significance in deconstruction and demolition

Lifting installations increase occupational safety and process quality by guiding loads, minimizing residual stresses, and preventing uncontrolled movements. In conjunction with concrete demolition shears, for example, walls, slab panels, or foundation heads are first picked up and held, then separated gently, and finally lowered in a controlled manner. With rock and concrete splitters, lifting installations support the workflow by cleanly releasing split blocks or component segments and enabling speedy removal. Additional benefits include reduced rework on cut faces, protection of adjacent structures, and improved adherence to dimensional tolerances during partial dismantling.

Understanding loads: load capacity, load cases, and boundary conditions

The sizing of a lifting installation is based on the mass, center of gravity, and shape of the load. Concrete components have high specific weights; reinforcement, embedded parts, and composites influence real behavior. Dynamic effects (starting, setting down, swinging), impacts on edges, and friction at guide points must be considered. Key planning parameters include load capacity, safety factors, support and attachment points, clearances for guiding the load, and the condition of the ground for tripods, gantries, or supports. Appropriate allowances are made for weather, access, and potential center-of-gravity shifts during separation.

• Typical load cases: static suspension, partial support during cutting, extraction from frictional contact, tilt-out and rotation maneuvers.
• Influencing factors: surface condition, rigging angles, stiffness of components, and interaction with the building structure.
• Verification: adequate capacity and stability with suitable safety margins per applicable rules and regulations.

Interaction with hydraulic demolition tools

In combination, lifting installations and Darda GmbH tools bring out their strengths: loads are held while tools separate, split, or cut. This keeps component movements controlled, cut gaps open in a defined manner, and removal proceeds with minimal disruption. Coordinated sequences and clear communication ensure that separating forces and lifting forces complement each other without introducing unintended stresses.

Working with concrete demolition shears

Before size reduction, the component is picked up, the center of gravity determined, and the load secured. The concrete demolition shear then breaks down the structure – e.g., by biting through webs or cutting remaining connections. The lifting installation acts as guidance and prevents uncontrolled rotations. After separation, the segment can be moved to the intended set-down position without introducing additional load spikes into adjacent components. Shallow rigging angles and progressive lowering further limit side loads and protect edges.

When splitting concrete and rock

Rock and concrete splitters generate high splitting forces with low vibration. A lifting installation takes up the emerging blocks at an early stage so they can be cleanly extracted after release. This reduces edge breakouts, avoids jamming in the split, and accelerates subsequent logistics. Pre-tensioned rigging and clearly defined lift paths keep fragments stable once the crack propagates.

Other tools in combination

Combination shears, multi-cutters, steel shears, or tank cutters also benefit from controlled load guidance: cut edges remain calm, cut gaps open evenly, and cut-out segments (e.g., from vessels or beams) can be lowered in a manner that protects both structure and process. Where heat or sparks occur, lifting accessories are selected with suitable material and temperature resistance.

Typical fields of application

Lifting installations play a practical role across numerous Darda GmbH application areas, each with specific boundary conditions:

• Concrete demolition and special deconstruction: unloading before separation cuts, holding slab segments, controlled lowering of cast-in-place components.
• Strip-out and cutting: guiding wall and slab cut-outs, picking up opening elements before set-down, combining with concrete demolition shears to reduce component size.
• Rock excavation and tunnel construction: removing split rock from the tunnel face, controlled handling in confined cross-sections.
• Natural stone extraction: picking up and relocating blocks after splitting, protecting exposed faces and edges.
• Special operations: temporary holding systems for complex geometries, working above sensitive areas, step-by-step dismantling.
• Infrastructure works: panel removal on bridge decks, abutment cutbacks, and controlled handling near traffic or rail operations.

Building blocks of a lifting installation

A capable lifting installation results from matching components tailored to the load and the environment:

• Supporting structure: gantry crane, crossbeam, spreader beam, or tripod to introduce forces into the ground or the building structure.
• Hoisting device: chain hoist, winch, pulley block, hoist unit, or hydraulic jack – manually, electrically, or hydraulically driven.
• Load handling attachments: grippers, clamps, spreader bars, drilled anchor points, adjustable rigging points near the center of gravity.
• Rigging: chains, ropes, round slings, shackles – sized for load, edges, and temperature.
• Guidance and safeguarding: pulling aids, lashing equipment, edge protectors, travel limiters, and catch devices.
• Control and monitoring: lift and lower control, load indicators, optionally displacement measurement and limit switches.
• Redundancy and protection: secondary retention where required, anti-drop measures, and suitable barriers in the hazard zone.

Planning and selection: from the load to the system

Selection starts with the geometry, weight, and center of gravity of the load. From this, the supporting structure and hoisting device are derived. Rigging points are chosen to minimize pendulum and torque. The ground and load paths must be verified; tight workspaces often require compact gantries or modular spreaders. Appropriate safety reserves are considered for site dynamics and weather (wind, moisture). Depending on the work sequence, combining with Darda GmbH tools that separate or split the component gently is recommended.

• Consider shifting centers of gravity as material is removed or as cracks propagate.
• Account for embedded items and composite action that may restrain movement longer than expected.
• Verify exclusion zones, communication channels, and emergency stop options.
• Plan for staged rigging adjustments to maintain balance through each cut or split step.

Safety and responsibility

Working with loads requires qualified personnel, suitable inspection intervals, and a careful hazard analysis. Requirements regarding load capacity, rigging techniques, and inspection markings must be observed. The statements here are general in nature and do not replace individual planning or a binding case-by-case assessment. A task-specific method statement, toolbox briefing, and clear role allocation help maintain discipline during critical steps.

Workflow: best practices in combination with demolition tools

A structured process increases safety and efficiency:

1. Analyze the component: mass, center of gravity, bonds/composites, potential residual stresses.
2. Set up the lifting installation: position the supporting structure, mount the hoisting device, establish rigging points.
3. Trial lift: raise slightly, check load distribution, readjust the center of gravity.
4. Apply tools: separate with the concrete demolition shear or release with the rock and concrete splitter while the load is held.
5. Lower and relocate: controlled lowering, handover to transport equipment, keep cutting and haul routes clear.
6. Document: record the condition of rigging, load paths, and any special occurrences.
7. Review: debrief the sequence, update the method statement, and note improvements for subsequent lifts.

Power supply and hydraulics in the system

Hydraulic power units from Darda GmbH supply demolition tools with pressure and flow. For hydraulic lifting devices, line lengths, pressure losses, and coordination of multiple consumers must be considered. It is sensible to clearly separate lifting and tool hydraulics or implement a coordinated control logic so that lifting and separation operations do not interfere with each other. Hose routing is planned to avoid pinch points and trip hazards. Color coding of circuits, quick couplers with dust protection, and physical separation of return and pressure lines support reliable operation.

Ergonomics, emissions, and environmental protection

By holding and guiding loads, lifting installations reduce manual pulling forces, lower accident risk, and support calm, precise work. In combination with concrete demolition shears as well as rock and concrete splitters, there are typically fewer vibrations, dust, and noise than with purely percussive methods. Edge and surface protection on the load handling attachments preserves component surfaces and prevents consequential damage to adjacent structures. Where feasible, select low-emission power sources and implement spill containment, dust suppression, and noise control tailored to the site.

Quality assurance, testing, and maintenance

Regular visual and functional checks of hoisting device, rigging, and connecting elements are essential components of operational safety. Inspection markings, documented maintenance, and timely replacement of worn components ensure readiness. When load cases or construction states change, lifting parameters (rigging points, angles, reserves) are adjusted. Before first use and after modifications, proof testing and functional checks of safety devices and load indicators are advisable.

Avoiding typical sources of error

Frequent causes of disruptions include unclear center-of-gravity positions, insufficient edge radii on rigging, friction contact on sharp component edges, or simultaneously activating multiple movements without coordination. Proven practices include short communication paths, clearly defined hand signals or radio protocols, and a consistent trial lift before every separation cut.

• Avoid exceeding recommended rigging angles and unintended side pulls on anchors or clamps.
• Prevent hose and cable pinch points along travel paths and near sharp edges.
• Eliminate mixed-capacity rigging that masks overloads in individual elements.
• Do not bypass limiters or interlocks; coordinate combined lifting and cutting through one lead signal.