Pipe supports are central components and structures in plant, industrial and infrastructure construction. They carry, guide and secure pipelines in plants and on pipe racks, accommodate movements and transfer loads into foundations or load-bearing structures as part of the support system. In deconstruction, during strip-out as well as when cutting steel and concrete components, pipe supports play a special role because they significantly influence cutting sequences, load redirection and the choice of suitable separation and crushing methods. This contribution explains the design, function, types, load assumptions and the proper handling of pipe supports in existing structures — with practical references to tools such as concrete pulverizers, rock and concrete splitters, steel shears, Multi Cutters, combi shears and tank cutters, as well as to the fields of application concrete demolition and special demolition, strip-out and cutting, rock excavation and tunnel construction, natural stone extraction and special operations.
Definition: What is meant by pipe supports
At its core, a pipe support is a bearing or support element for pipelines that takes forces and allows or limits movements. The term is used in practice in two ways: first as a designation for load-bearing and guiding elements of pipelines (e.g., fixed supports, sliding/guide supports, sliding bearings, spring hangers, constant supports) on structures, pipe racks and consoles; second as a short form for pipe storage in the sense of an orderly, safe and material-appropriate storage of pipes on the construction site or in the depot. Common to both meanings is that stability, safety, freedom of movement and protection of the pipeline and/or its surroundings must be ensured within the overall support system.
Design, types and operating principle of pipe supports
Depending on their use, pipe supports consist of steel structures, bearing plates, sliding materials, dampers, clamps, consoles, supports and foundations. Their operating principle results from the interaction of load transfer and movement accommodation. Essential types are:
- Fixed supports: Fix the pipeline in one position; take horizontal and vertical forces as well as moments; no relative movement at the support point.
- Sliding or guide supports: Allow longitudinal displacements (thermal expansion) and provide transverse guidance; limited force transmission in selected directions.
- Sliding bearings: Minimize friction using sliding pairs (e.g., metal/PTFE) and allow controlled displacements.
- Elastomer bearings, spring and constant supports: Reduce dynamic effects, compensate load fluctuations and limit vibrations.
- Support pedestals, pipe clamps, consoles: Connection components for clamping, clamp fastening or bearing on girders, frames and pipe racks.
In steel building construction, pipe supports are often integrated into frames and bracing of pipe racks. Bearing heads and supports are frequently fixed in concrete foundations; here the connectors (anchors, dowels, head plates) determine stiffness and load-bearing behavior.
Loads, expansion and vibrations
Design takes into account self-weight, operating contents, insulation, wind and snow loads, thermal expansion, pressure surges, vibrations and, where applicable, earthquakes. A practice-oriented approach typically follows this logic:
- Determine the permanent and variable loads of the pipeline including attachments.
- Define fixed and sliding supports for controlled guidance and expansion compensation.
- Verify supports, bearing plates, anchors and foundations for ultimate and serviceability limit states.
- Evaluate dynamic effects (vibrations, pressure surges) and select suitable damping and/or support systems.
Thermal expansions are accommodated by sliding and guiding principles or by elastic elements. Systems prone to vibration benefit from vibration isolators, spring supports and suitable clamping solutions that transfer loads without promoting resonance.
Pipe supports in existing assets: inspection, repair and deconstruction
In existing plants, condition, degree of corrosion, anchor connections and whether the lines are free of media influence the procedure. For dismantling, clear separation and lifting plans, temporary shoring and a sequence that safely redirects residual loads are crucial.
Preparation and survey
- Investigate pipe contents and ensure lines are media-free (drain, flush, inerting if necessary).
- Record support points (fixed/sliding), anchors and foundations including any damage.
- Define separation points, lifting points and temporary supports for load redistribution.
Cutting, downsizing, splitting
Different methods are suitable for cutting and downsizing depending on material and geometry. Steel shears, combi shears and Multi Cutters cut profiles, consoles and girders of typical pipe racks. Tank cutters can be used when dismantling large pipe and vessel segments. For concrete components, concrete pulverizers are effective on bearing heads, column heads and foundation zones; massive blocks can be split in a controlled manner using rock and concrete splitters or rock splitting cylinders. Hydraulic power units supply these tools; output and operating pressure must be matched to the respective tool and material thickness.
Foundations and bearing heads
Foundations, bearing benches and crane girder bearings made of concrete are often removed in stages: expose the reinforcement with concrete pulverizers, split compact segments with rock and concrete splitters, transport away in manageable fractions. Anchor plates and head bolts can be separated after unloading with steel shears or Multi Cutters. A sequential approach reduces uncontrolled cracking and makes handling of the remaining pieces easier.
Pipe supports in industrial plants and on pipe racks
Pipe racks are load-bearing steel frames with crossbeams and bracing for multiple pipe runs. Pipe supports act as the interface between the pipeline and the load-bearing structure: They guide the pipes, minimize friction, allow expansion and transfer loads into the frames. Deconstruction is often carried out modularly: suspending sections of the pipe runs, separating the supports, dismantling the consoles and finally cutting the frames using steel shears or combi shears. If the racks are supported on mass concrete foundations, bearing consoles and foundations can be efficiently removed with concrete pulverizers and rock and concrete splitters as part of the support system.
Pipe storage on the construction site: storage and logistics of pipes
Pipe storage means the safe, material-specific placement and stacking of pipes on the construction site or at the plant. The goal is to avoid damage and rolling movements and to ensure ergonomic retrieval.
Principles of safe storage
- Uniform bearing on suitable supports, chocks and interlayers; protection against rolling.
- Limited stack heights, sufficient clearances, clear load markings.
- Material-appropriate bearing (steel, cast iron, plastics, composites) and protection against edge pressure.
- Separation by dimensions and grades for safe retrieval and logistics.
Coordination with deconstruction works
During strip-out and cutting operations, storage areas should be positioned so that transport routes are short and cut-offs can be placed without cross traffic. This reduces crane time and minimizes hazards from swinging loads.
Materials, corrosion protection and fire protection
Pipe supports and consoles are usually made of structural steel; stainless steel, coated sliding surfaces or elastomers are added where needed. Corrosion protection (coating, hot-dip galvanizing) and fire protection (shielding, fire protection cladding if necessary) must be planned to suit the plant. In deconstruction, attention must be paid to contaminated surfaces, coating residues and potential hazardous substances; separation methods and dust extraction should be selected accordingly.
Standards, planning and documentation
The planning, construction and deconstruction of pipe supports follow recognized engineering practice. This includes structural verifications, fire protection requirements and operational specifications. For deconstruction, separation and lifting plans, approvals, qualification certificates and complete documentation of the waste management chain are essential elements of careful preparation.
Areas of application and typical uses
- Concrete demolition and special demolition: Dismantling of bearing heads, columns and foundations. Concrete pulverizers for selective removal, rock and concrete splitters for massive blocks.
- Strip-out and cutting: Selective separation of pipe runs, consoles and frames using steel shears, Multi Cutters, combi shears; tank cutters for large pipe and vessel segments.
- Rock excavation and tunnel construction: Temporary pipe supports for utility and dewatering lines in headings; robust, vibration-insensitive support concepts are advantageous.
- Natural stone extraction: Safe pipe storage for process and dewatering lines in the quarry; separation and relocation when moving plants.
- Special operations: Deconstruction in sensitive areas with increased requirements for spark-free work, vibration control and sectionalization; hydraulic power packs supply separation and downsizing tools with the required performance in the support system.
Occupational safety and environmental protection
When working on pipe supports, controlling residual contents, avoiding uncontrolled movements and ensuring protection against falling are paramount; appropriate fall protection must be provided. Dust, noise and spark emissions should be minimized; residual media, coatings and cements may require special attention during disposal. Personal protective equipment, safe lifting operations and clear communication of the cutting sequence contribute significantly to safety.
Practical tips for planning deconstruction works on pipe supports
- Consolidate as-built data: support types (fixed/sliding), anchors, foundations, media-free status, coatings.
- Provide temporary shoring and account for load redistribution in the cutting sequence.
- Select separation points so that handling weights and lengths remain manageable.
- Plan tool integration: concrete pulverizers and rock and concrete splitters for concrete; steel shears/combi shears/Multi Cutters/tank cutters for metal; size hydraulic power packs to match performance needs.
- Define material flow: sectioning, intermediate storage, removal, recycling fractions.
- Coordinate interfaces with adjacent trades (crane, logistics, disposal) at an early stage.