A support system is the technical basis on which attachments for demolition, deconstruction, and rock processing are operated safely and efficiently. In practice, the spectrum ranges from compact demolition robot to mini excavators and crawler excavator through to carrier vehicles such as compact loader or telescopic loaders. For hand-held tools and cylinders, hydraulic power units are also used as stand-alone support systems. The key is always the harmonious interaction of power, hydraulics, kinematics, attachment interface, and working environment—for example, when using concrete pulverizers in concrete demolition or rock and concrete splitters in natural stone extraction and tunnel construction.
Definition: What is meant by support system
A support system refers to the carrier machine (base machine) including its interfaces, which mechanically carries attachments, supplies them hydraulically, and controls them safely. This includes the undercarriage, boom kinematics, attachment interface (e.g., quick coupler or adapter plate), hydraulic supply with control circuits and—depending on the application—electrical signals for valves or sensors. A support system provides load capacity, reach, stability, and energy for tools, such as concrete pulverizers, combination shears, multi cutters, steel shears, tank cutters, or rock and concrete splitters including stone splitting cylinders. It combines power delivery, operability, and occupational safety across different applications such as concrete demolition and special deconstruction, strip-out and cutting, rock demolition and tunnel construction, natural stone extraction, and special operations.
Design and variants of support systems
Support systems can be differentiated by design and energy supply. Classic excavators (crawler or wheeled) provide high hydraulic performance and stable boom kinematics. Remote-controlled demolition equipment excels in tight or low-access zones, for example during strip-out. Compact carriers such as compact and telescopic loaders offer maneuverability in confined spaces. For hand-held or compact splitting and cutting tools, hydraulic power pack serve as a mobile energy source. Common to all these systems are defined connections, load limits, and working envelopes that must be matched to the respective attachment.
Hydraulic requirements and interfaces
Hydraulics are the heart of the support system. Decisive factors are flow rate, operating pressure, and the type of control (single- or dual-circuit, single- or double-acting, return/leak-oil routing). Concrete pulverizers typically require double-acting control circuits with sufficient flow for fast opening and closing as well as stable pressure levels for high crushing forces. Rock and concrete splitters work, depending on design, via hydraulic pressure for wedge actuation; with stone splitting cylinders, hydraulic power pack with suitable couplings, pressure stages, and safety valves are often used.
Typical design values
- Flow rate: tune to the tool’s speed behavior (e.g., open/close a concrete pulverizer quickly)
- Operating pressure: adequate for peak loads; for splitters, for the defined splitting pressure
- Return/leak oil: depressurized return and leak-oil line per tool specifications
- Control: proportional or load-pressure-compensated for precise work
Interfaces and media routing
Adapter plates, quick couplers, rotary feedthroughs and—if required—rotators or tiltrotators influence media routing. For cutting and jaw tools, robust hose routing and kink protection are important to prevent damage from repeated load cycles.
Sizing and load capacity: selection by tool and application
The sizing of a support system is determined by tool mass, center of gravity, geometry, and the required working reach. For concrete pulverizers, the load alternations due to “gripping” reinforced concrete must also be considered. With rock and concrete splitters, the weight load is often lower, but stability during the splitting process is crucial.
Key criteria
- Load capacity/residual payload of the boom for the respective reach
- Stability under dynamic load changes (outriggers, ballast, ground conditions)
- Kinematics and gripping angle for precise engagement, e.g., on beams, walls, or rock fissures
- Tool dimensions relative to jaw openings, member thicknesses, and accessibility
In practice: In special deconstruction, a lighter support system with high hydraulic density can be advantageous to control a concrete pulverizer sensitively. In rock demolition, a stable excavator with a calm stance and splitting tool can promote structurally guided separation.
Mounting, adapters, and quick couplers
Correct mechanical coupling is fundamental for safety and precision. Quick couplers shorten setup times; adapter plates ensure positive fit and force transmission. The design includes pin diameter, installation dimensions, plate thickness, and the alignment of the tool with the boom’s force line.
Rotation and tilt units
For combination shears, multi cutters, and tank cutters, rotators or tilt heads improve accessibility. This is particularly helpful during strip-out and cutting in tight building structures to make cuts without repositioning the carrier machine.
Application areas and typical requirements
The requirements on the support system vary widely depending on the project environment. A suitable selection supports efficiency, component protection, and work safety.
Concrete demolition and special deconstruction
- Concrete pulverizers for controlled breaking with reduced vibration
- Steel shears or multi cutters for reinforcement and profiles
- High stability and precise control of the auxiliary hydraulics
Strip-out and cutting
- Compact support systems or demolition robots for areas with limited access
- Combination shears and tank cutters for targeted separation
- Low emissions and finely metered movements for interior areas
Rock demolition and tunnel construction
- Rock and concrete splitters for low vibration levels along natural joints
- Robust hydraulics and secure support on uneven ground
- Good lighting and cab protection systems, if provided
Natural stone extraction
- Stone splitting cylinders for defined splitting lines on blocks
- Support systems with sensitive hydraulics and a steady stance
- Gentle handling to ensure the quality of raw blocks
Special applications
- Special cutting tools, e.g., for tanks, with suitable media routing
- Remotely operable support systems where hazards are elevated
- Custom adapter solutions for special component geometries
Operation with hydraulic power packs
Hydraulic power packs function as stand-alone support systems, particularly with hand-held or compact splitting and cutting tools. Essential are sufficient oil flow, stable pressure control, and effective cooling. In practice, color-coded, drip-free couplings and clear hose routing prove their worth to avoid mix-ups.
Typical applications
- Stone splitting cylinders in tunnel construction and natural stone extraction
- Precise separation in sensitive areas where the base machine cannot be used
- Ergonomic, safe hand operation with defined return and leak-oil routing
Safety, occupational safety, and environmental conditions
Safety takes precedence. Support systems must be operated stably; load charts and operating manual must be observed. Lines must be secured against tearing; shut-off valves and hose-rupture protection increase safety. Dust and noise mitigation, for example through water mist and adapted work methods, protects workers and the surroundings. When cutting tanks, media-free condition, venting, and suitable procedures are essential. All statements here are general; in individual cases, the respective regulations and manufacturer specifications apply.
Organization and communication
- Cordon off the work area, ensure signals and line of sight
- Change tools only when depressurized, with the machine secured
- Regular instruction, personal protective equipment
Maintenance, wear, and availability
Regular maintenance increases operational safety and service life. This includes oil and filter changes, inspection of hose lines, lubrication of pin bearings, checking the quick-coupler lock, and retightening bolted joints. With concrete pulverizers, check blade/tooth and jaw areas for wear; with rock and concrete splitters, the wedge or cylinder mechanism is decisive. Documented condition checks facilitate preventive maintenance.
Product matching: think tool and support system together
The optimal combination of tool and support system is achieved when geometry, hydraulics, and the working environment are harmonized. For concrete pulverizers, a base machine with sufficient auxiliary hydraulics and sensitive proportional control is recommended. For rock and concrete splitters, a steady, stable support system or a separate hydraulic power pack can be advantageous. Combination shears, multi cutters, and steel shears place special demands on cutting force and positioning; tank cutters require safe media routing and accessibility. The goal is controlled, efficient, and low-damage processing of the structural member or rock.
Sustainability and environmental influences
The use of appropriate support systems contributes to lower emissions, fewer vibrations, and material-conserving deconstruction. Splitting methods reduce vibrations compared to impact methods; precise jaw work minimizes secondary damage. Indoors, low-emission carrier machines and dust-reducing measures support occupational safety and the protection of the building fabric.