The pipeline route defines the planned and constructed alignment of pipelines in buildings, industrial plants, transportation corridors, or open terrain. It encompasses the pipe routing, the associated structures, as well as protective and load-bearing constructions. In practice, tasks around the pipeline route range from new planning and expansion to selective deconstruction. Where concrete foundations, masonry openings, or rock zones intersect the route, controlled removal techniques such as concrete pulverizers or stone and concrete splitters are used depending on the situation, for example in concrete demolition and special demolition, in rock excavation and tunnel construction, or during gutting and cutting.
Definition: What is meant by a pipeline route
A pipeline route is the spatially defined corridor in which pipelines (for example for water, wastewater, gas, district heating, process media) are routed, supported, and protected. The route comprises the alignment (route axis), width and height of the corridor, clearance and protection zones, excavations and trenches, pipe supports and bearings, pipe bridges, culverts, shafts, wall penetrations, siphon elements, casings, as well as temporary launch and reception structures. The pipeline route is therefore more than the pipe itself: it is the entirety of structural, geotechnical, and organizational measures that enable safe, durable, and accessible operation of the pipeline.
Planning and route alignment
Route planning begins with an options study and proceeds via a preferred option, permitting design, and detailed design into the construction phase. Criteria include subsoil, topography, existing assets, supply and disposal networks, nature conservation, accessibility, fire protection, cost-effectiveness, and future maintenance. Routes in buildings often run in installation shafts, plant rooms, and utility channels; in industrial plants on pipe bridges or pipe racks; in open terrain in the pipeline trench or trenchlessly. The corridor accounts for minimum clearances between media, crossings, expansion paths, fixings, and compensators. Interventions in concrete components and rock zones are identified already during planning: for openings, foundation block-outs, or removal of bearing blocks, procedures with defined force application are specified. Where low-vibration approaches are required, the use of stone and concrete splitters and concrete pulverizers can be planned early.
Construction methods for the pipeline route: open-cut, trenchless, and within existing structures
Different construction methods are available for building a pipeline route depending on boundary conditions. The selection is based on subsoil, space conditions, protected assets, schedule, and subsequent operation. Within existing structures, precise, material-preserving removal techniques are required to retain load-bearing structures and avoid impairing adjacent utility lines.
Open-cut method
The open-cut method includes earth or rock excavation, shoring if necessary, bedding, pipe installation, ancillary and protective structures, backfilling, and compaction. In rocky ground, trench construction is often carried out in sections. When noise and vibration limits apply, rock intervention can be controlled with rock wedge splitters and stone and concrete splitters. Concrete foundations for supports and anchor blocks are constructed to position and dimension; adjustments or corrections are possible selectively with concrete pulverizers.
Trenchless methods
Under roads, tracks, or water bodies, routes are often constructed trenchlessly. Typical methods include auger boring, pipe jacking, and small-diameter tunnel drives. Launch and reception pits and intermediate structures often require temporary and permanent concrete components. During deconstruction and repurposing of these structures, concrete pulverizers provide precise, near-edge removal. On rocky access routes to launch pits, stone and concrete splitters reduce vibration and flyrock.
Works within existing structures
In existing buildings and plants, wall breakthroughs, slab penetrations, niches for valves, and the deconstruction of old pipeline routes are common. Clean edges, minimal secondary damage, and controlled force application are crucial here. Concrete pulverizers separate reinforced concrete without shock loading; combination shears and multi cutters enable material separation in mixed components, for example during gutting and selective cutting.
Structural components and typical details
The pipeline route includes numerous structural details that must be closely coordinated in planning and execution: supports and brackets, anchor and abutment blocks, protective pipes, thermal insulation and fire protection systems, expansion and fixed points, shafts, inspection openings, siphon elements, pipe bridges, and transitions between construction methods. Adjustments often arise at these points during construction that require precise processing of concrete and steel.
Foundations, supports, and pipe bridges
Foundations carry point or line loads and transfer them into the subsoil. Fixed points and sliding bearings must be positioned to accommodate longitudinal expansion. During retrofit or deconstruction of bearing blocks, concrete pulverizers are used for low-vibration removal and combination shears for embedded components. Pipe bridges in plants sometimes require adaptations to cross-beams or bracing; steel shears cut sections and reinforcements with precision.
Penetrations, wall breakthroughs, and shafts
Wall and slab penetrations must be coordinated regarding fire protection and sealing. When enlarging or creating new openings, preserving edge reinforcement is important. Concrete pulverizers allow low-resonance edge finishing, for example in special demolition. Shafts require plane bearing surfaces that can be selectively reworked in case of tolerance deviations.
Selective deconstruction, expansion, and retrofit of pipeline routes
In practice, routes are often expanded or relocated. Deconstruction is performed selectively to keep adjacent systems in operation. Concrete pulverizers are suitable for dismantling foundations, abutments, upstands, and channels made of reinforced concrete. Multi cutters support the separation of inserts, sheets, and sections. Steel shears help disassemble old steel pipelines, pipe-bridge components, or brackets. Where tanks and large vessels influence the routing, tank cutters may be used for emptying and safe dismantling as part of special operations, always in compliance with operational safety requirements.
Material separation and recycling
Clean separation of concrete, reinforcement, steel, and composite materials facilitates recycling and shortens disposal routes. Tools with a defined cut line such as combination shears and steel shears support this objective in concrete demolition and gutting works.
Pipeline routes in rock and in tunnels
Routes in rocky terrain or in tunnel structures impose special demands on force application, safety, and construction logistics. Narrow workspaces, overhead work, and strict vibration limits often have to be observed. Stone and concrete splitters and rock wedge splitters enable controlled rock fracturing along planned crack lines, for example when opening a pipeline trench in rock or when adjusting anchor blocks in launch and reception pits. Power supply is provided by hydraulic power packs, matched to the required output and the working environment.
Low-vibration rock splitting
Crack formation in rock is induced along pre-drilled holes. This reduces noise, dust, and vibrations compared to percussive methods and is especially suitable when sensitive structures, lines, or equipment are located close to the route.
Safety, clearances, and protective measures
Clearance requirements between media, fire protection requirements, corrosion protection, and mechanical safeguards are essential elements of route planning. On site, protection concepts against collapse, gas, fire, and electrical hazards apply. Crossings with existing lines are documented and protected against damage. Legal requirements and authority stipulations are project-specific and should be considered early; binding provisions are set out in the applicable codes and permits.
Construction sequence and organization
An efficient construction sequence is structured into setting out, probing, exposure of utilities, temporary diversions, earth and rock works, concrete works, installation of bearings and supports, pipe laying, testing, backfilling, and surface reinstatement. In interiors and plants, dust- and low-vibration methods have proven effective, such as removal with concrete pulverizers or splitting of concrete and rock to minimize operational interruptions.
Maintenance and documentation of the route
For operation, complete as-built documentation, clear route widths (protection strips), marked fixed and sliding bearings, inspection openings, and regular visual inspections are important. During adjustments in ongoing operation, selective methods safeguard the integrity of adjacent systems. Changes are documented as-built to keep future interventions and special operations plannable.
Sustainability and resource conservation
Low-vibration removal techniques, material-preserving dismantling, and clean material separation improve reuse and recycling. Reduced vibrations protect structures and lower the need for remediation on adjacent areas. Where possible, foundations are reused or selectively adapted instead of being completely renewed.
Practice-oriented application fields
In urban district heating routes, conflict-free crossings of streets, tracks, and line bundles are key. Concrete upstands of shafts can be adapted with concrete pulverizers, while rock cuts in edge areas can be expanded with low vibration by splitting. In industrial plants, retrofits on pipe bridges require a combination of concrete removal, steel separation, and precise cutting: combination shears, steel shears, and multi cutters support the separation of components. For siphon or tunnel sections, launch and reception pits sometimes have to be constructed in rock; here, stone and concrete splitters enable controlled interventions as part of rock excavation and tunnel construction.
Selection of equipment according to subsoil and existing assets
The choice of methods depends on subsoil, vibration limits, accessibility, and material mix. In sensitive areas with residents, ongoing plant operations, or vibration-sensitive devices, concrete pulverizers and stone and concrete splitters are often advantageous. For separating reinforcement, steel sections, and pipelines, combination shears, steel shears, and multi cutters are suitable. Power supply and control are provided by appropriate hydraulic power packs, matched to throughput, hose lengths, and operating conditions.
Quality assurance and testing
Quality assurance includes positional and elevation checks of the route axis, tests of bedding and compaction, leakage and pressure tests of the pipelines, as well as concrete tests on bearing and abutment blocks. Selective removal in adjustment areas is documented; edges and bearing surfaces are checked for flatness and dimensional accuracy.
Risks, permits, and precautions
Typical risks include damage to lines, settlements, water ingress, gas and fire hazards, as well as impacts from vibrations. Before starting, utility locates, probing, and a safety and health plan are required. Permits and protective stipulations depend on location, medium, and surroundings and must be observed on a project-specific basis. Early coordination with authorities and operators reduces interface risks and facilitates the construction process.