Pipeline rerouting is a demanding construction and installation task in both existing facilities and new builds. It combines as-built investigation, route planning, demolition works on concrete and masonry, targeted dismantling of steel and plastic pipelines, and new construction including testing and documentation. It frequently occurs in the context of building refurbishment, plant modifications, infrastructure projects, tunnel and pipeline construction, as well as the expansion or optimization of utility networks. In all phases, close coordination with structural analysis, building services, plant engineering, and site management is essential. Where routing passes through load-bearing components, concrete ducts, or rock, controlled hydraulic methods are used, for example with concrete crushers or rock and concrete splitters from Darda GmbH—especially where low vibration, precision, and compact tools are required.
Definition: What is meant by pipeline rerouting
Pipeline rerouting refers to the planned and documented relocation of an existing pipeline section to a new location or alignment, including all necessary ancillary measures. These include decommissioning of the existing line, safe separation and dismantling, structural intervention in wall, slab, floor, or terrain structures, creation of the new route (including protective conduits, supports, brackets), tie-in to the existing network, and leak-tightness and functional tests. The term covers pipelines for water, wastewater, district heating, gas, compressed air, fire protection, process media, and comparable systems in buildings, industrial plants, transportation and tunnel structures, as well as in municipal utility construction.
Planning, as-built survey, and route selection
The process starts with an as-built survey: drawings, exploratory openings, and locating methods provide information on position, material, nominal diameter, operating pressure, temperature, and medium. These data determine permissible construction methods and the safety concept. In addition to hydraulic and thermal design, the structural impact on building components must be considered, especially for breakthroughs, chases, or undermining of foundations. Route selection accounts for intersecting services, escape and rescue routes, fire protection, maintenance access, and assembly and transport routes on the construction site.
Pipeline data and operating conditions
Pipe materials (steel, ductile iron pipe, stainless steel, PE-HD, PP, PVC), joints (welding, flange, push-in socket, press-fit systems), corrosion protection, insulation, and static support (clamps, brackets, supports) are decisive for the new alignment. Media and operating parameters define minimum clearances, protective measures, and the test regime. Additional, project-specific requirements apply in potentially explosive or hygienically sensitive areas.
Construction methods and working practices
The choice of method is governed by available space, ground conditions, structural considerations, media type, and schedule. A basic distinction is made between open-cut work with visible excavation or openings and trenchless methods. In existing buildings, interventions are component-related with selective demolition and precise openings; in outdoor areas, guided horizontal drilling, pipe jacking, or relining methods can also be considered.
Open-cut method in existing structures
In buildings, bridges, shafts, or ducts, rerouting often requires opening concrete bodies, enlarging existing shafts, or creating new openings. Here, concrete crushers have proven effective for controlled reduction, and the rock and concrete splitter for low-vibration opening of massive components. Compact, hydraulically driven tools from Darda GmbH allow small, incremental deconstruction steps that protect the existing structure and facilitate adjustments at the excavation face.
- Producing wall and slab openings for new pipeline routes
- Selective removal of concrete encasements and foundation beams
- Enlarging chases and recesses for pipe clamps and brackets
Trenchless methods
Guided drilling or relining reduces surface interventions and traffic disruption. However, launch and reception pits must be constructed and secured. Where routes encounter rock or blocky material, rock splitting cylinders can be used to widen the pit in a controlled way, for example in rock demolition and tunnel construction. This approach enables accurate edges, minimizes secondary damage, and makes subsequent laying or pulling-in of the pipeline easier.
Dismantling and cutting existing sections
Safe decommissioning is a prerequisite for any rerouting. After draining, flushing, and securing against re-pressurization, existing pipelines are separated using methods appropriate to the material. For steel pipelines, pipe racks, route supports, or inserts, steel shears, Multi Cutters, and Combi shears are suitable. Where vessels or tanks are encountered along the route, deconstruction is often supported by tank cutters. Depending on the task, low-spark, low-vibration, or low-emission working may be required; the selection of cutting technology is based on project-specific requirements.
- Strip-out and cutting of confined plant rooms and shafts
- Selective separation of branches, nozzles, and supports
- Preparation of flange faces, sockets, or weld edges
Handling concrete encasements, foundations, and reinforced-concrete ducts
Pipelines are often routed in concrete channels or potted in concrete. Small, precise steps are considered most protective for exposing them. Concrete crushers enable targeted fragmentation of concrete without biting into steel. Rock and concrete splitters open massive sections of defined thickness, guiding cracks in a controlled manner. This approach is particularly advantageous where low-vibration methods are required, such as near sensitive plant, in historic buildings, or in densely populated technical areas.
Protection of the existing structure
Construction-phase monitoring, dust and noise mitigation, vibration control, and clean cutting reduce consequential damage. Sections should be planned so that pipe hangers can be relieved and rebuilt in sequence without unduly impairing the existing load-bearing capacity.
Work in rock and tunnels
In tunnel and gallery construction and in rocky terrain, pipeline niches, cable ducts, and crossings must be constructed. Rock splitting cylinders create controlled separation planes in natural stone so that pipe beds, supports, or openings can be formed precisely. In tight environments typical of rock excavation and tunnel construction, compact hydraulic tools are practical because they allow on-site adjustments without large-scale blasting or cutting operations.
Hydraulic power supply and equipment combinations
Hydraulic tools are supplied by hydraulic power units. For use in buildings, shafts, or tunnels, hose routing, pressure and flow rate, heat input, and return-flow safety must be considered. The combination of power pack and tool (e.g., concrete crushers, Combi shears, rock splitting cylinders) is matched to the component and work progress. This facilitates switching between concrete removal, steel cutting, and rock processing without overloading site logistics.
Safety, environmental, and health protection
Pipeline rerouting requires coordinated protective measures. These include barriers, signage, safe media drainage, cleaning where necessary, appropriate ventilation, and gas-free clearance in confined spaces. Personal protective equipment, dust and noise mitigation, and orderly material logistics contribute to safety. Legal and regulatory requirements can vary by region and project and must be clarified in advance.
- Secure the work area and clearly establish the media state
- Cut, dismantle, and properly dispose of the existing pipeline
- Open components and create openings correctly
- Install, support, and connect the new route
- Test for tightness and function; complete documentation
Quality assurance, leak-tightness, and documentation
Quality assurance includes visual inspections, dimensional checks, leak or pressure tests, and documentation of the pipeline routing. Support spacing, expansion paths, firestopping, corrosion protection, and insulation thicknesses are recorded. Reliable as-built documentation facilitates future inspections, maintenance, and modifications.
Typical challenges and solutions
Challenges include confined space, ongoing operations, unknown as-built conditions, and sensitive adjacent areas. Solutions lie in careful takt planning, trial areas for opening components, and the selection of precise tools. In situations with limited working space, compact, hydraulic hand tools have proven effective, e.g., concrete crushers for selective concrete removal or rock and concrete splitters for controlled opening, to avoid collateral damage and ensure installation dimensions.
Application areas at a glance
Rerouting occurs in various technical environments and ties into the following areas of application:
- Concrete demolition and specialized deconstruction: Selective removal of concrete channels, foundations, brackets, and wall openings for new routes; precise component separation with concrete crushers.
- Strip-out and cutting: Dismantling of pipe routes in existing plants; cutting of steel supports, sections, and inserts with Multi Cutters or Combi shears.
- Rock excavation and tunnel construction: Creating niches, launch/reception pits, and pipe beds in rock with rock splitting cylinders.
- Natural stone extraction: Related techniques for controlled splitting of rock, transferable to routing in stony subsoil.
- Special applications: Work in sensitive environments such as hospitals, laboratories, control rooms, or listed buildings with requirements regarding vibration, dust, and noise.
Material and joint selection for new routes
Material selection depends on medium, temperature, pressure, corrosion environment, and fire protection. Steel and stainless-steel pipes are common for high temperatures and pressures; ductile iron is frequently used in utilities; PE-HD and PP are established for cold media and wastewater. Joints range from welding and flanges to push-in sockets and press-fit systems. Protective conduits, bedding, penetrations, and elastic supports accommodate movement, settlement, and acoustic requirements. Careful detailing minimizes later rework.
Site logistics, equipment selection, and sequencing
An orderly workflow reduces downtime and improves quality. Helpful measures include short transport routes, clearly defined laydown areas, coordinated crane operations, and an equipment fleet geared to speed and precision. Hydraulic power packs feed the required tools, while concrete crushers, Multi Cutters, and steel shears enable seamless switching between concrete and steel work. Takt plans map demolition, dismantling, installation, and testing in manageable steps.
Specifics in industrial plants and building services
In production facilities, energy centers, and building services, rerouting is often tied to shutdown windows. Short takt times, low emissions, and reliable dimensional accuracy are central. When relocating walkways, frames, and brackets, Combi shears and steel shears support selective deconstruction. For installations such as tanks or vessels along the new route, the use of tank cutters enables orderly removal before the new pipeline is installed.
Removal of decommissioned sections
Decommissioned pipelines, supports, and inserts are removed systematically. In concrete channels, selective removal is often performed with concrete crushers, and for massive cross-sections with rock and concrete splitters. On the steel line, Multi Cutters and steel shears perform the separation. The goal is a tidy, load-capable environment for the new construction without unnecessary interventions in the existing structure.
Documentation, surveying, and commissioning
Upon completion, position, elevations, material, dimensions, firestopping, and test values are recorded. The documentation serves maintenance and future modifications. Commissioning includes functional tests and, where applicable, flushing and venting; procedures and acceptance criteria must be defined for the project and agreed within the team.
Time and cost factors
Influencing factors include accessibility, ground conditions, media complexity, permits, coordination with other trades, and the share of selective demolition. An experience-based takt concept, early investigations, and the choice of suitable hydraulic tools help reduce risks, ease interfaces, and increase execution reliability.