Loading

Loading is the interface between equipment, construction site and the transport chain. In concrete demolition and deconstruction, in gutting works and rock excavation through to tunnel construction, a cleanly organized loading operation determines whether concrete demolition shears, hydraulic splitters, compact hydraulic power units as well as hydraulic shear and cylinders arrive intact, on schedule and efficiently at the next job site. The following article consolidates fundamentals, practical know-how and concrete guidance on loading hydraulic excavator attachments and handheld tools and their accessories – objective, precise and aligned with the requirements of the application areas of Darda GmbH. Reliable loading also contributes to cost control, minimizes downtime and supports compliance with recognized rules of technology.

Definition: What is meant by loading?

Loading means the loading and unloading of objects, machines and tools onto suitable transport vehicles. This includes lifting, positioning and securing the load as well as documenting the process. Loading encompasses the selection of loading aids, the use of lifting devices and slinging gear, the application of lashing equipment and the control of load distribution. The goal is an operationally safe load that protects people, equipment and infrastructure and reliably enables the transport performance. Typical roles include the person in charge of load securing, the crane or lifting equipment operator and the signaler.

Importance of loading in demolition, deconstruction and natural stone extraction

In the application areas of concrete demolition and special demolition, gutting works and cutting, rock excavation and tunnel construction, natural stone extraction and special operations, loads are often compact, heavy and provided with projections (jaws, blades, couplings). This requires loading with attention to center of gravity, fixing points, sensitive assemblies (hydraulic connection, hydraulic hose line, sealing faces) and the cleanliness of the power packs. Especially with concrete demolition shears and stone and concrete splitting devices, the combination of high density, irregular geometry and sharp-edged areas is typical – the load securing must ensure both form-fit and force-fit and protect edges. Effective measures reduce transport damage, protect lashing equipment from premature wear and preserve the service life of hydraulics and mechanics.

Practical guide: Procedure for professional loading

A clear sequence prevents errors, saves time and reduces risks. The following guide provides a proven thread – detailed manufacturer instructions must also be observed. Define responsibilities for each step and agree standardized hand signals and stop commands before starting.

Step 1: Preparation and hazard analysis

• Clarify load data: mass, dimensions, center of gravity, lifting points.
• Check equipment condition: lock moving parts, relieve pressure, fit protective caps.
• Select the transport vehicle: loading area, payload, lashing points, anti-slip.
• Plan the lifting device: crane, forklift, excavator with hook block; load capacity and reach.
• Secure the work area: ground bearing capacity, traffic routes, weather, lighting.
• Verify the rating and integrity of lashing points and slinging gear; observe identification tags.
• Define exclusion zones, signal routes and emergency procedures.
• Prepare edge protection and anti-slip materials in sufficient quantity and correct sizes.

Step 2: Pick up the load

• Select slinging gear: chains, round slings, spreader beams; apply edge protection.
• Hit the center of gravity: rig symmetrically, perform a test ground lift, check tilt.
• Use tag lines, keep people at a safe distance, keep the swing area clear.
• Maintain safe sling angles; avoid routing over sharp edges or hydraulic components.
• Never remain under suspended loads; move the load slowly and without jerks.

Step 3: Positioning and stowing

• Set the load down ready for tie-down lashing: full-surface support, anti-slip mats, dunnage.
• Establish form-fit: stops, chocks, pallet or steel racks.
• Keep sensitive areas clear: no load on hose lines or quick couplings.
• Respect minimum distances to front wall or side structures unless rated as load-bearing.
• Use blocking to prevent rolling or shifting of cylindrical components.

Step 4: Lashing and securing

• Select the lashing method appropriately: tie-down lashing, direct lashing, diagonal lashing.
• Size lashing equipment and protect it from damage; check pre-tensioning force.
• Use edge protection and corner protectors; check locks.
• Aim for lashing angles that provide effective restraint; minimize slack and keep lashing paths short.
• Cross-check lashing capacity against load mass, friction conditions and intended transport dynamics.

Step 5: Documentation and pre-departure check

• Loading record, visual check, photos if required.
• Recheck after the first few kilometers and when weather conditions change.
• Document the sign-off by the person responsible for load securing; archive inspection notes.

Equipment-specific particulars for loading

Hydraulic tools and power packs from Darda GmbH have differing loading requirements depending on design. The following notes are general and do not replace manufacturer information. If transport positions are specified on the device, these have priority.

Concrete demolition shears

• Fully close the jaws and secure against unintentional opening.
• Cover pivot points and teeth to prevent damage to loading surfaces.
• Use identifiable lifting points; observe the center of gravity (often in the cylinder area).
• Depressurize hydraulic hose lines and fit couplings with protective caps.
• Protect cutting edges and cylinders from impact; avoid point loads on housings.

Stone and concrete splitting devices as well as stone splitting cylinders

• Retract splitting wedges completely; secure moving parts.
• Protect piston rods; do not route lashing over sealing faces.
• Prefer transporting devices such as Rock Splitters upright in suitable racks to minimize impact loads.
• Bundle and secure hose lines to prevent whipping and chafing during transport.

Hydraulic power packs

• Transport upright, avoid tipping loads; use vibration dampers.
• Exclude leaks; provide drip trays or absorbent pads.
• Fit connection couplings with dust protection; neatly bundle lines.
• Close fuel and hydraulic reservoir caps; secure switchgear and covers.

Combination shears, multi cutters, steel shear and tank cutters

• Close and lock cutting jaws; cover cutting edges.
• Apply edge and blade protection; do not stack loads above them.
• For tank cutters additionally ensure the surrounding area is free of residues; plan spark protection for the loading zone.
• Use guards on exposed blades and provide secondary retention where required.

Load securing: Combining friction-lock and form-fit correctly

Safe loading combines anti-slip underlays, form-fit stowage and correctly sized lashing equipment. Decisive factors are clean contact surfaces, short lashing paths, sufficient pre-tensioning forces and the protection of all contact points. For compact tools, direct lashing to robust points has proven effective, supplemented by tie-down lashing for vibration damping. Edge protection prevents damage to both load and lashing equipment. Take into account the expected transport dynamics (braking, cornering, road condition) and choose lashing configurations that maintain security even if friction is reduced by moisture or dust.

Typical lashing equipment and aids

• Lashing chains with tensioners for high pre-tensioning forces.
• Ratchet straps with ratchets and long-lever tensioners, in protective sleeves against abrasion.
• Anti-slip mats, dunnage, blocking bars, support chocks.
• Load-handling attachments such as spreader beams, pallet fork attachment and special racks.
• Edge protectors with sufficient radius and reinforcement to distribute forces.

Choice of vehicle and loading areas

The choice of transport vehicle depends on mass, geometry and number of devices. Flatbed trucks and box bodies require different securing strategies. On low loaders, load distribution across the axles is essential; for vans with a tail lift, the payload reserve is critical. For tunnel and special operations, maneuverable carrier vehicles with good lighting solutions and anti-slip floors are advantageous. Clarify the load-bearing capacity of front walls and side structures and use only approved lashing points with documented ratings.

Load distribution and center of gravity

• Place the center of gravity low and close to the vehicle’s longitudinal axis.
• Observe axle loads and total payload; stow multiple devices evenly.
• Use center-of-gravity markings on devices when available.
• Avoid stacking loose accessories on tools; use separate, labeled containers.

Loading in special operating environments

Construction sites differ: subsoil, space constraints, lighting and traffic routing vary widely. Loading must adapt to the situation. Environmental influences such as moisture, dust and temperature fluctuations require adapted protective measures for surfaces, seals and connections.

Concrete demolition and special demolition

• Tight working space: use compact lifting devices and short chains; clear signal communication.
• Dust and dirt: protect couplings immediately; keep lashing points clean.
• Offcuts and reinforcement: keep loading areas clear of sharp-edged construction debris.

Gutting works and cutting

• Lightweight, frequent transloads: standardized racks and roll pallets.
• Equipment protection inside buildings: edge protectors at doors, ramps and elevators.
• Noise and vibration constraints: plan quiet time windows and use low-noise aids where possible.

Rock excavation and tunnel construction

• Uneven ground: temporary loading platforms, load distribution mats.
• Poor visibility: additional lighting and reflective markings on loads.
• Humid environment: corrosion protection on exposed metal surfaces, anti-slip underlays.

Natural stone extraction

• Short-distance transports between the extraction face and the yard: robust racks, quick lashing concepts.
• Dusty conditions: regular cleaning of lashing equipment to preserve value.
• Temperature fluctuations: check pre-tensioning after cooling or heating phases.

Special operations

• Deviating geometries and equipment combinations: create individual stowage plans.
• Caution with sharp tool edges: double covering, protective hoods.
• Confined access routes: pre-measure clearances and define alternative paths.

Protecting hydraulics and mechanics during loading

The service life of hydraulic tools also depends on loading. Contamination and impacts can be avoided with simple measures.

• Release hydraulic pressure, clean quick couplings and close them with dust caps.
• Bundle hose lines without kinks, protect against chafing, keep ends elevated.
• Cover sealing faces, piston rods and blade surfaces; use cushioning pads.
• Pack loose parts (bolts, inserts, blades) separately and label them.
• Prevent metallic abrasion and chips from contacting sealing areas; use clean covers.

Documentation, labeling and responsibilities

For traceable processes, clear responsibilities and lean documentation are useful. A loading record can include equipment, serial number, mass, lashing equipment, lifting points, number of photos and the responsible person’s name. Labeling on racks and boxes facilitates unloading on site. Legal requirements and recognized rules of technology must be observed; binding assessments are made on a case-by-case basis by competent persons. Digital checklists and photo documentation help standardize quality across teams and sites.

Quality and efficiency factors

Recurring loading operations benefit from standardized racks, protective elements and fixed procedures. Good ergonomics reduces the risk of errors and injuries, shortens cycle times and protects materials. Continuous improvement based on incident analyses and periodic training maintains a consistently high level of safety and efficiency.

Practical optimizations

• Equipment racks with defined lifting and lashing points.
• Anti-slip mats permanently assigned to the vehicle and kept clean.
• Labeled boxes for accessories such as couplings, bolts, blades, edge protection.
• Regular training on the correct lashing method and checking pre-tensioning force.
• Color coding of slinging gear by capacity and length to speed up selection.

Common mistakes in loading – and how to avoid them

• Unclear center of gravity: test before the lift and adjust lifting points.
• Missing edge protection: lashing equipment can be damaged – use corner protectors.
• Pressure in hydraulic hose lines: depressurize before transport.
• Jaws/blades unsecured: mechanically lock and cover.
• Insufficient anti-slip: place mats underneath, clean surfaces.
• Overreliance on non-rated vehicle structures: use only approved lashing points.

Checklist for daily loading

1. Identify the device, check mass and center of gravity.
2. Close, lock and secure moving parts.
3. Relieve hydraulics, clean couplings and cover.
4. Select suitable lifting device and slinging gear, check condition.
5. Test ground lift, center-of-gravity check, attach tag line.
6. Stow with form-fit, place anti-slip underneath.
7. Lash (select method), use edge protection, check pre-tensioning force.
8. Documentation and visual check; re-tension after a short driving distance.
9. Confirm sign-off by the responsible person; ensure documents travel with the load if required.

Materials and equipment overview for loading

• Slinging gear: chains, round slings, shackles, spreader beams.
• Lashing equipment: straps, chains, ratchets, long-lever tensioners.
• Protective elements: edge protection, mats, caps, cushioning pads.
• Loading aids: pallets, racks, chocks, blocking bars.
• Cleanliness/leak protection: cloths, plugs, drip trays.
• Identification and inspection: tags, logs, storage sleeves for certificates.

Maintenance and care after loading

After transport, lashing and slinging gear should be checked for abrasion, cut points and corrosion. Devices are cleaned externally, protective caps remain in place until installation at the job site. Visual inspections of blade surfaces, teeth, piston rods and seals help avoid consequential damage. Defective or out-of-spec equipment must be withdrawn from service and replaced; inspection results are documented for traceability.