Pipeline systems are the invisible backbone of hydraulic applications in demolition, deconstruction and rock processing. They connect the hydraulic power pack with tools such as concrete demolition shears, hydraulic wedge splitters, combination shears, Multi Cutters, steel shears, tank cutters and stone splitting cylinders. Through these line networks, pressure fluids are transported safely, efficiently and with minimal losses. In practice, the quality of the piping decisively determines precision, force delivery, operator convenience, service life and operational safety—from concrete demolition through building gutting and cutting to rock breakout, tunnel construction, natural stone extraction and special operations.
Definition: What Is Meant by a Pipeline System
A pipeline system is the technically coordinated interaction of pipes, hose lines, fittings, couplings, manifolds, valves, filters, test ports and seals for guiding a medium—typically hydraulic oil in demolition and splitting technology. It serves the controlled transfer of pressure and flow between the energy source (hydraulic power pack) and the consumer (e.g., concrete demolition shears or hydraulic wedge splitters). Essential factors are pressure resistance, leak-tightness, vibration and abrasion resistance as well as application-specific sizing to ensure the required forces are provided safely and reproducibly during operation.
Design and Construction of a Hydraulic Pipeline System
Hydraulic pipeline systems consist of rigid pipework and flexible hose lines. Rigid pipes ensure low pressure drop and high durability, while flexible hoses compensate movement, vibration and assembly tolerances. They are complemented by components for flow guidance and condition monitoring.
Central Components
- Pipes (steel, stainless steel, coated): main runs for high pressure and return.
- Hose lines (rubber/thermoplastic with wire braid or spiral): movable connection areas; observe bend radius.
- Fittings and couplings (e.g., cutting ring, ORFS, flat-face quick couplings): detachable, tight connections.
- Manifold blocks and valves: control, load holding, pressure limitation, switching.
- Filters and screens: protection from particles, stabilization of oil quality.
- Measurement points (gauge ports, test ports): monitoring of pressure and temperature.
- Sealing systems (O-rings, sealing cones): leak-tightness under varying pressure and temperature conditions.
- Protection (abrasion protection, heat protection, kink protection): durability in harsh environments.
Hydraulic Pipeline Systems in Demolition, Deconstruction and Rock Processing
In practice, pipeline systems connect the hydraulic power pack with tools and cylinders. The requirements vary depending on tool characteristics and the operating environment.
Concrete Demolition Shears
Concrete demolition shears require controlled, often pulsating force peaks with fine controllability at the same time. The pressure line must absorb peak loads, while return and drain lines are sufficiently sized to limit pressure spikes and heat input. Short, streamlined routing improves response time.
Hydraulic Wedge Splitter for Rock and Concrete
Splitting systems operate with very high local pressures in the cylinder. For comparable tooling, rock and concrete splitters also require low pressure losses, high impulse resistance and reliable tightness. In borehole environments, abrasion protection is crucial; in rock breakout and tunnel construction, resistance to moisture and dust is essential.
Combination Shears, Multi Cutters, Steel Shears and Tank Cutters
These tools demand continuous flow rate and reliable pressure retention. Pipe cross-sections must be selected to ensure both maximum cutting force and thermal stability. Pressure surge damping and clean deflections increase component service life.
Planning and Sizing
Robust design is based on media, pressure ratings, flow and operating conditions. The goal is stable operation with minimal pressure drop, high energy efficiency and safe guidance.
Key Criteria
- Operating pressure and pressure spikes: select pressure-resistant components with sufficient safety margin.
- Flow rate: choose internal diameters and lengths so that flow velocity remains within the recommended range.
- Pressure drop: gentle bends, few transitions, smooth internal surfaces.
- Temperature: adapt materials and seals to the temperature window.
- Vibration: place flexible elements strategically; provide abrasion protection.
- Installation and service: ensure accessibility of couplings, filter points and test ports.
- Compatibility: verify media compatibility of materials and seals.
Materials and Corrosion Protection
In dusty, humid and abrasive environments, coated steels and stainless steel have proven themselves. Hose lines with highly abrasion-resistant covers and corrosion-resistant fittings extend service life. In tunnel and coastal environments, a consistent corrosion protection system has priority. For natural stone extraction, additional cut protection and abrasion protection are relevant.
Joining Techniques and Couplings
Fittings with elastomer-based sealing lines (e.g., flat-sealing) reduce micro-leakage. Flat-face quick couplings facilitate tool-side changes under harsh conditions and minimize contamination ingress. Cutting ring fittings are proven for rigid pipes; for frequent coupling, locking systems increase operational safety and reduce downtime.
Pressure, Flow and Energy Efficiency
The interaction of pump curve, valve control and piping network determines dynamics and efficiency. Oversized lines increase mass and cost; undersized lines cause heat and power loss. The goal is a balanced cross-section selection and streamlined routing between the hydraulic power pack and the tool.
Reducing Pressure Drop
- Use bends instead of sharp angles; choose large radii.
- Reduce transitions and adapters.
- Keep surface roughness low; ensure clean assembly.
- Correct hose lengths; no twisting; maintain bend radius.
- Regular cleaning/filter replacement to minimize particles.
Assembly, Commissioning and Leakage Test
Professional assembly prevents later leaks and failures. Route lines without stress, avoid chafing points, and set supports at appropriate intervals. After assembly, perform controlled filling and bleeding, followed by a leakage test and functional test under increasing load. Test ports allow verification of target values without intervening in the piping.
Maintenance, Inspection and Replacement
Regular visual inspections and condition measurements increase availability and safety. Hose lines are subject to natural aging; rigid pipes require inspection for corrosion and mechanical damage. Filter condition and oil cleanliness are closely related to valve and cylinder service life, especially for concrete demolition shears and hydraulic wedge splitters, whose performance strongly depends on a clean medium.
Typical Signs That Action Is Needed
- Soft spots, blisters, cracks or chafing on hose lines.
- Oil film on fittings, recurring drip leaks.
- Elevated oil temperatures, noticeable performance losses.
- Changed noise behavior (cavitation, flow noise).
- Loosening on holders, clamps, protective components.
Safety and Environment
Hydraulic pipeline systems operate at high pressures. Expert assembly, the use of suitable components and protection against hose whip in the event of hose failure are essential. Preventing leaks protects employees and the environment; drip leaks must be avoided and media handled professionally. Requirements from generally accepted engineering practice and relevant standards must be observed.
Application-Specific Requirements
Concrete Demolition and Special Demolition
High power density with varying loads requires surge-resistant lines and safe switching. For concrete demolition shears, precise positioning movements are desired; to achieve this, flow paths must be streamlined and measurable.
Strip-Out and Cutting
In buildings, low noise emissions, clean coupling changes and drip-free connections are important. Short, flexible connections facilitate tool changes between Multi Cutters, steel shears and tank cutters.
Rock Breakout and Tunnel Construction
Humid, abrasive environments demand excellent corrosion and abrasion protection. For hydraulic wedge splitters and stone splitting cylinders, robust, shock-resistant piping with protective packages is appropriate; easily accessible test points simplify diagnostics.
Natural Stone Extraction
Dust, slurry and fluctuating temperatures require resistant outer covers, dust-tight couplings and easy cleanability. Long line runs between the power pack and the tool must be planned with low pressure losses.
Special Operations
For atypical media, extreme temperatures or tight installation spaces, individual piping concepts with special sealing systems and tailored supports are beneficial; documented tests provide operational safety.
Integration with Hydraulic Power Packs and Controls
The power pack supplies pressure and flow, the pipeline system distributes, dampens and protects. In mobile or stationary setups, appropriately sized hydraulic power units ensure a stable supply. With appropriate sizing of pressure, return and drain lines as well as the placement of pressure relief and check functions, the response of concrete demolition shears, hydraulic wedge splitters, combination shears and other tools can be finely tuned.
Media Quality and Filtration
Clean, correctly conditioned hydraulic oil is a prerequisite for low-wear operation. A filter concept adapted to the pipeline system (suction, pressure and return filters) prevents damage to valves, cylinders and seals. Cleanliness requirements depend on pressure rating, valve technology and tool sensitivity.
Documentation, Labeling and Traceability
Clear labeling for lines, couplings and test points simplifies maintenance, rapid troubleshooting and safe tool changes. Manufacturing and test documents support traceability and help make replacement intervals predictable.
Sustainability and Resource Efficiency
An energy-efficiently designed pipeline system reduces losses and heat, extends oil service life and lowers maintenance effort. Preventing leaks conserves resources and the environment. Durable materials and modular connection technology simplify repairs instead of complete replacement.
Practice-Oriented Design for Concrete Demolition Shears
For mobile concrete demolition shears, a compact routing with short, protected flexible sections near the tool and rigid main lines between the hydraulic power pack and the boom is recommended. Test ports close to the consumer help fine-tune the closing torque precisely; streamlined transitions keep heating low and ensure consistent performance even during longer operations.
Terminological Classification
In common usage, pipeline system, piping system, pipework and line network are partly used synonymously. Technically, the pipeline system includes both rigid pipe sections and flexible hose lines, including all associated connection elements, test points, protective and fastening elements. For applications with concrete demolition shears, hydraulic wedge splitters and other tools from Darda GmbH, this holistic view is crucial to ensure function, safety and maintainability in everyday use.