A monitoring system captures, evaluates, and documents technical and environmental conditions on the construction site and at the tool. In the fields of concrete demolition, special demolition, rock excavation, tunnel construction, natural stone extraction, and special applications, it provides the foundation for safe processes, reproducible quality, and robust proof of performance. Especially with hydraulically powered tools—such as concrete demolition shears or rock and concrete splitters—structured monitoring supports precise control of forces, pressures, and movements and helps protect the building fabric, equipment, and surroundings.
Definition: What is meant by monitoring system
A monitoring system is understood as the ordered whole of sensing, data acquisition, evaluation, display, and alarming that records technical processes and environmental conditions continuously or at defined intervals. The goal is early detection of deviations, control of thresholds, and documentation for quality assurance, occupational safety, and environmental compatibility. Such a system can be arranged locally at the tool, at the power unit, on the structure, or in the surroundings and serves the condition monitoring of work equipment, structures, and environmental effects.
Tasks and benefits of a monitoring system in demolition and extraction
In combination with tools such as concrete demolition shears, rock and concrete splitters, combination shears, steel shears, multi cutters, tank cutters, rock splitting cylinders, and the associated power units, a monitoring system performs key tasks:
- Safety: Compliance with load, pressure, and vibration limits; protection of personnel and surroundings.
- Quality: Verifiable, repeatable results when separating, splitting, or cutting; controlled crack formation in concrete or rock.
- Availability: Early detection of wear and deviations to avoid downtime.
- Documentation: Complete records of measurements for site management, subcontractors, and authorities.
- Environment: Limitation of noise, dust, and vibrations in urban areas as well as protection of adjacent structures.
Typical components of a monitoring system
Depending on the task and area of application, proven assemblies are used:
- Sensing: Pressure and temperature sensors on the hydraulic hose line, displacement and force transducers on cylinders and shears, vibration sensors on structures, microphones for sound levels, particle sensors for dust, humidity and gas sensors for special scenarios.
- Acquisition unit: Data logger or evaluation unit with an appropriate sampling rate, time-stamping, and storage.
- Displays and alarms: Visual and acoustic signals, threshold displays, logs.
- Power supply: Mains, battery, or hydraulically coupled power supply, depending on mobility.
- Interfaces: Analog or digital inputs for sensors; secure handover to site management or machine control systems.
Relevant measurands for hydraulic splitting and cutting operations
For targeted monitoring of concrete demolition shears and rock and concrete splitters, the following measurands are particularly relevant in practice:
- Hydraulic pressure and flow rate: Decisive for available splitting and cutting force as well as the speed of the operation.
- Oil temperature: Indicator of load, energy input, and efficiency of the hydraulic system.
- Stroke and displacement measurement: Control of cylinder movement, detection of blockages or asymmetric loading.
- Force or stress measurement: Assessment of actual gripping, cutting, or splitting forces.
- Vibrations: Protection of adjacent structures, compliance with defined limits in the surroundings, especially in special demolition and tunnel construction.
- Noise and dust exposure: Guidance for emission reduction measures in urban areas.
Integration into products and workflows
An effective monitoring system integrates into the work process without hindering it. For concrete demolition shears, pressure and displacement detection can take place directly on the cylinders and lines. For rock and concrete splitters, pressure sensors on the splitting cylinders and displacement transducers on the wedges provide valuable indications of material behavior, friction, and splitting progress. Hydraulic power units are monitored with temperature and flow sensors to ensure a consistent energy supply. The display of threshold violations is clearly visible at the work area or at a central operating point.
Specifics by application area
Concrete demolition and special demolition
In the deconstruction of load-bearing components, vibration and crack monitoring support the protection of the remaining structure. Concrete demolition shears benefit from precise force and pressure control to set demolition edges deliberately and limit loading into adjacent components.
Strip-out and cutting
In selective separation, clean cut edges and low emissions are important. Monitoring of oil temperature, noise emission, and dust supports process stability. Combination shears and multi cutters are tuned to efficient cutting sequences via stroke and pressure signals.
Rock excavation and tunnel construction
Here, control of vibrations, gas releases, and humidity plays a central role. Rock splitting cylinders and rock and concrete splitters require a precise pressure ramp; displacement and force measurements indicate early on whether splitting wedges are seating correctly.
Natural stone extraction
To preserve block quality, the splitting force is finely dosed. Monitoring wedge movement, pressure profile, and micro-vibrations helps steer crack paths and minimize material losses.
Special applications
With tank cutters, steel shears, or in sensitive areas, the combination of temperature, gas, and spark monitoring increases safety. Documented measurement series support the release of individual work steps.
Planning and implementation of a monitoring system
Planning begins with a clear definition of objectives: Which risks should be controlled, which proofs provided? Building on this, measurands, sensor positions, and thresholds are defined. For concrete demolition shears and rock and concrete splitters, a prioritized selection is recommended: hydraulic pressure, oil temperature, and displacement are often the most informative values. Responsible parties place vibration sensors at critical points of the surrounding structure. Commissioning includes a functional test and, if required, calibration.
Data evaluation, alerting, and documentation
A good data strategy makes the system effective:
- Capture: Adequate sampling rate, unambiguous time base, clear measurement point labels.
- Evaluate: Trend analysis, comparison with reference phases, plausibility checks.
- Alert: Multi-stage warning and shutdown concepts with defined response paths.
- Document: Logs with measurements, events, and actions; traceable and audit-proof.
Calibration, care, and operation
Periodic checks are necessary for reliable results. Pressure sensors on hydraulic hose lines are verified using reference gauges, displacement transducers are verified via reference strokes. Visual inspections ensure sensors are secure and cables are routed with protection. Dust and noise sensors require scheduled cleaning and functional checks. Measurement intervals and test cycles depend on intensity of use and environmental conditions.
Typical deviations and countermeasures
- Unexpected pressure spikes: Check for line constrictions, air in the system, or changed material properties; adjust the working method.
- Rising oil temperature: Check cooling, flow, and filters; reduce continuous load.
- Noisy vibration signals: Check sensor mounting, isolate interference sources, relocate measuring points.
- Deviating displacement measurement: Adjust displacement transducers, check for play or cylinder tilting.
Safety, occupational safety, and environment
A monitoring system supports compliance with technical rules and regulatory requirements. Limits for vibrations, noise, and dust are defined on a project-specific basis and monitored as a precaution. Legal requirements may vary by project and location; careful coordination with the responsible bodies is advisable. Documented monitoring facilitates approvals, reduces liability risks, and contributes to the protection of employees, residents, and the building fabric.
Future topics: condition-based maintenance and remote monitoring
With connected sensing, tools and power units can be operated on a condition-based basis. Data series yield indicators that point early to wear or misalignment. For concrete demolition shears and rock and concrete splitters, this means plannable maintenance, more efficient deployment planning, and more stable process quality—especially advantageous with varying materials and confined construction sites.
Practical checklist to get started
- Define objectives: safety, quality, environment, or a combination.
- Select measurands: pressure, temperature, displacement, vibration, noise, dust.
- Define sensor positions: tool, power unit, structural surroundings.
- Agree limits and responses: warning, stop, root cause analysis.
- Plan documentation: measurement intervals, log structure, responsibilities.
- Set calibration and care: test cycles, visual inspections, cleaning.
- Evaluate experience: identify trends, adapt measures, secure knowledge.