A substation—often also called a switchyard or transformer station—is a central node in the power grid. Voltage levels are converted here, electrical energy is distributed, and switching operations are coordinated. Beyond high-voltage technology, massive structural works define the setting: concrete foundations, cable ducts, switchgear buildings, noise barrier walls, and steel structures. In new construction, expansion, modernization, or deconstruction, construction-related activities are therefore always in focus. These work packages apply controlled methods for concrete and steel processing, for example with concrete pulverizers or rock and concrete splitters from the Darda GmbH portfolio—not for the electrical equipment itself, but for building components around the facility.
Definition: What is meant by substation
A substation is a stationary, operationally secured facility of the electrical power supply that serves transformation between different voltage levels, the switching of circuits, and grid coupling. Core elements are transformers, switchgear (AIS or GIS), busbars, and protection and control systems. In addition, extensive structural components are part of the facility: foundations and machine foundations, equipment and operations buildings, cable ducts, grounding and drainage systems, internal roadways, and, where applicable, noise-control and enclosure structures. These structures are predominantly made of reinforced concrete and steel, which must be selectively processed or deconstructed when adapting the site.
Structure and components of a substation
The technical configuration comprises primary electrical equipment (transformers, circuit breakers, disconnectors), secondary equipment (measurement, protection, control, and communication systems), and the civil/structural facilities. The civil substructures in particular—concrete foundations for transformers and equipment frames, switchgear and operations buildings, cable ducts, transformer pits, transformer rails or crane runways, fence and gate systems, steel frames for covers—form the core of what is processed with mechanical methods during modification, repair, or deconstruction. Here, concrete pulverizers for the low-impact removal of reinforced concrete components and rock and concrete splitters for low-vibration separations are especially relevant.
Lifecycle: new build, expansion, modernization, and deconstruction
Over a substation’s lifecycle, phases of intensive construction activity alternate with long operating periods. In new construction, earthworks and concrete works dominate; during expansion or retrofits, interfaces with the existing asset arise that require special care. Modernizations often increase the share of selective interventions: cable routes are relocated, foundations adjusted, openings created in walls, or noise control upgraded. In deconstruction—for example after a grid reconfiguration—the focus is on controlled dismantling and separation of structural systems. Tools such as concrete pulverizers and rock and concrete splitters support this, because they work precisely, with low vibration, and with finely metered force, thereby protecting adjacent components and infrastructure.
Construction and deconstruction aspects: concrete, steel, and earthworks
The civil components of a substation are designed for robustness. Concrete exhibits high strength, dense reinforcement, and often tight mix designs (oil containment basins, watertight concrete). Steel structures—from cover frames to support racks—are corrosion-protected and structurally connected. For interventions this means cutting, splitting, and crushing must be material-appropriate and low in emissions. That minimizes vibration, dust, and noise and protects nearby equipment. Particularly proven here are concrete pulverizers for selective concrete removal and rock and concrete splitters for controlled separation joints in massive blocks and foundations.
Foundations and pedestals
Transformer and equipment foundations, cable foundations, and machine pedestals often have large cross-sections and dense reinforcement. Splitting techniques can deliberately break load paths; concrete pulverizers then size-reduce the reinforced concrete with a modest tool envelope. This also enables work in confined areas.
Cable routes and switchgear buildings
Cable ducts and basements, penetrations in switchgear and operations buildings, as well as shafts require precise openings without unnecessary edge damage. Mechanical splitting followed by removal with concrete pulverizers reduces secondary damage and facilitates subsequent reconstruction.
Noise control, enclosures, and ancillary structures
Noise barrier walls, transformer roofs, and enclosures made of reinforced concrete or steel are adapted for modernizations. Steel components can be cut with shears; concrete members are separated in a controlled manner and removed section by section.
Tools and methods for the controlled deconstruction of structural systems
For material-appropriate deconstruction around substations, hydraulic tools are suitable that combine high performance with fine controllability and can be integrated into existing construction logistics.
Concrete pulverizers
Concrete pulverizers size-reduce reinforced concrete elements through crushing force and bite pressure. They are suitable for slabs, walls, beams, cable duct covers, and foundation upstands. Advantages include low vibration, targeted removal, and good separating action at reinforcement when used with suitable cutting zones.
Rock and concrete splitters
Rock and concrete splitters create controlled crack formation in massive components. They are ideal for thick foundations, massive blocks, oil containment basins, or heavily reinforced areas where sawing or drilling is of limited benefit. The technique is low-vibration and low-dust.
Hydraulic power units
Hydraulic power units supply the tools with the required output. Their compact design facilitates use in confined plant areas and supports a mobile, modular approach to selective deconstruction.
Steel shears, combination shears, and multi cutters
For steel components such as frames, grating, railings, cover structures, and support scaffolds, steel shears, combination shears, and multi cutters are an option. They enable safe sectioning of profiles, plates, and reinforcement—especially in connection with step-by-step, controlled removal.
Rock splitting cylinders
Rock splitting cylinders transfer the advantages of splitting technology to rocky ground. For extensions or new cable routes in rocky terrain, these cylinders can open corridors and excavations with low vibration—particularly where blasting or impact tools are excluded for environmental or permitting reasons.
Tank cutters
Tank cutters are used for specialized deconstruction tasks on cleared, cleaned, and emptied steel vessels or inserts. In the context of substations, this concerns exclusively structural or secondary steel components, not operational systems filled with media.
Application areas and typical scenarios in and around substations
Practical tasks touch on several recognized application areas and can be covered with suitable methods:
- Concrete demolition and special deconstruction: Selective removal of foundation edges, wall openings, deconstruction of oil containment basins and transformer pedestals with concrete pulverizers and splitters.
- Strip-out and cutting: Removal of installations in operations buildings; cutting of steel frames, cable duct covers, and secondary steel parts with shears and multi cutters.
- Rock excavation and tunneling: Low-vibration opening of cable routes or expansion areas in rocky subsoil with rock splitting cylinders.
- Natural stone extraction: Transferred technique: splitting methods in natural stone provide experience that can be applied to hard, stony soils around the facility.
- Special operations: Work in confined spaces, in sensitive areas with stringent noise and dust minimization requirements, and under complex logistics.
Safety, environment, and permits
Work in or on substations requires careful planning and authorization. Fundamental are a robust safety concept, coordination with the operator, and compliance with relevant regulations. Structural interventions take place only within an authorized work zone. Environmental aspects—such as protection of soil and water, the safe handling of potentially contaminated construction materials, and low-emission work with respect to dust, noise, and vibration—are integral to planning. Mechanical methods such as splitting and pulverizer-based removal support these goals through low secondary emissions and precise controllability. Legal frameworks can vary regionally and must be observed on a project-specific basis.
Materials and construction methods in the context of deconstruction work
Substation structures consist of dense concretes, reinforcing steel, possibly coated steels, and mineral backfills. For deconstruction, understanding the matrix and bonding is crucial: splitting exploits natural separation planes; concrete pulverizers reduce components into transportable fractions; steel shears cut profiles and reinforcement. The result is purer material streams and an improved basis for recycling and recovery, aligning with the requirements of sustainable construction.
Planning, documentation, and quality assurance
Structured documentation—from as-built survey through deconstruction concept to verification—ensures quality and traceability. In practice, a step-by-step approach with clean cuts and defined work cycles has proven effective. Tools from Darda GmbH support this through compact designs and the ability to control removal quantities precisely. Complete photo documentation, measurements of emissions, and coordination of logistics (access routes, intermediate storage, haul routes) round off quality management.
Emission and immission control in sensitive areas
Substations are often located near residential or commercial areas. Therefore, noise mitigation, dust reduction, and the limitation of vibrations are critical. Mechanical methods such as splitting and pulverizer-based removal offer advantages here. They can be combined with water misting, shielding, and a coordinated construction schedule to protect the surroundings as effectively as possible.