Utility line installation is a central component of construction and infrastructure projects—from residential buildings to industrial facilities, and from inner-city civil engineering to tunnels. Those who install cables, pipes, and service lines safely, in compliance with standards, and for long-term performance must plan routes, open structural elements, create openings, and adapt built-ins. Especially in existing buildings and in special demolition, this creates an interface with controlled processing of concrete and rock. Precise, low-vibration methods are suitable here, such as the splitting of concrete structural elements or the controlled crushing of reinforced concrete, as made possible with concrete demolition shears or stone and concrete splitters from Darda GmbH. The goal is always a material-friendly, safe, and efficient approach that clears pathways for lines without impairing structural integrity or adjacent uses.
Definition: What is meant by utility line installation
Utility line installation encompasses the planning, construction, and execution of routes for electrical power, data communication, water and wastewater, gas, district heating, and process media. This includes selecting the routing, opening and adapting structural elements, protection and fastening systems, pulling-in and supporting the lines, as well as pre-commissioning tests. Utility line installation covers both new construction and repurposing/modernization within existing structures—including strip-out and localized deconstruction where pathways, shafts, recesses, or openings must first be created.
Planning, routing, and structural boundary conditions
The quality of a utility line installation is determined in the planning phase. Routes run conflict-free, accessible, and compliant, without weakening the load-bearing structure or impairing fire safety, acoustics, and usage. In existing structures the rule is: investigate first, then open—and do so with the lowest possible vibration.
Pre-investigation and as-built survey
Before starting, drawings, reinforcement data, and existing lines must be checked. Where uncertainties remain, low-destructive locating methods help. For openings in reinforced concrete, a concept that minimizes cracking and vibration is recommended, e.g., splitting instead of impact energy.
Routing concept and coordination
Routes should be short, with few crossings, and service-friendly. Interdependencies between trades are coordinated early. Where openings, blockouts, or installation shafts are missing, these are created selectively as part of utility line installation.
Collaboration with special demolition
For interventions in load-bearing elements or tight interior spaces, the use of compact, hydraulic tools has proven effective. Concrete demolition shears and stone and concrete splitters from Darda GmbH enable controlled openings—for example, for riser zones or large-format line bundles.
Construction methods: open-cut, trenchless, and within existing structures
Depending on the context, open-cut methods, trenchless methods, or building element opening measures are combined.
Open-cut method in the ground
Utility trenches are constructed with suitable shoring, drainage, and bedding. Protective conduits and separation layers ensure durability. In compacted concrete or rock break-up at the trench end, splitters can gently loosen material.
Trenchless methods
Press drilling and guided drives reduce surface interventions. Launch and reception pits often require precise openings in foundations or shafts; low-vibration concrete processing helps protect adjacent structures.
Utility line installation in buildings
Openings, chases, and recesses are created in slabs, walls, and shafts. For reinforced concrete elements, concrete demolition shears offer controlled removal, while stone and concrete splitters divide massive members into defined blocks—ideal for sensitive uses or strict emission requirements.
Openings, chasing, and recess work in concrete
Pathways in concrete are created by opening, separating, and targeted removal of material. The aim: defined edges, low vibration, and protection of reinforcement where it must be retained.
Controlled separation with concrete demolition shears
Concrete demolition shears grip elements and crush them with high precision. This method reduces impact energy, minimizes crack propagation, and facilitates deconstruction in occupied buildings, hospitals, or production areas.
Splitting massive elements
Stone and concrete splitters generate controlled splitting forces to loosen thick walls, columns, or foundation areas. This helps when enlarging installation shafts or creating openings with the lowest possible vibration.
Steel cutting and rebar exposure
For reinforcing steel, cable trays, pipe supports, or profiles, steel shears, combination shears, or multi cutters are used. This allows targeted exposure of reinforcement, adaptation of service routes, and conflict-free removal of metallic built-ins.
Routing in rock and tunnels
In tunnel and rock environments, cable routes, pipe supports, and cross-passages are created in confined spaces. Low vibration, safety, and controlled fracture patterns are key.
Rock removal and recesses
Rock splitting cylinders enable loosening of rock for cable recesses, distribution shafts, or line supports. The advantage: targeted forces without blasting vibrations, suitable for sensitive tunnel operations.
Mounting surfaces and supports
Smooth mounting surfaces for brackets or switch cabinets are created through controlled removal. In reinforced concrete tunnel linings, concrete demolition shears assist in pinpoint openings for penetrations.
Strip-out and cutting for pathways in existing structures
During refurbishments, lightweight partition walls, old installations, and built-ins must be removed. A selective strip-out creates space for new routes before adapting load-bearing elements.
Space for riser zones and switch cabinets
Concrete demolition shears help with high-volume yet precise removal of concrete—for example, to create cabinet recesses or riser shafts. Combination shears and multi cutters cut accompanying constructions made of sheet steel or structural steel sections.
Protection of sensitive environments
In hospitals, laboratories, or office buildings, a dust- and low-vibration approach is crucial. Splitting concrete minimizes vibration and protects adjacent uses.
Safety, emissions, and site logistics
Safety and emission control are essential criteria in utility line installation—especially in existing buildings and under ongoing use.
Occupational safety and emissions
Dust, noise, and vibration must be reduced through suitable methods, extraction, and water misting. Low-vibration methods such as splitting or controlled crushing with concrete demolition shears improve the protection of people and structures.
Hydraulic power packs and power supply
Hydraulic power packs provide the required power for concrete demolition shears, splitters, steel shears, and tank cutters. Thoughtful power and hose routing increases efficiency, reduces setup times, and improves occupational safety.
Material selection, protection, and installation quality
The durability of lines depends on correct support, protective measures, and fastening. Quality becomes predictable when standards are implemented systematically.
Principles of installation quality
- Install lines free of stress; maintain bend radii and expansion paths
- Mechanical protective conduits and route covers in highly stressed areas
- Separation distances between media as per codes; crossings with protective measures
- Ensure elevation, slope, and drainage for pipelines
- Properly execute and document fire stop
- Maintain consistent labeling, color coding, and as-built documentation
Testing, documentation, and commissioning
Final steps include leak testing, pressure or functional testing, earthing and insulation measurements, and verification of fire protection measures. Complete documentation (route plans, test protocols, photos) facilitates maintenance and later adaptations.
Special applications and special deployment
In industrial plants, on factory sites, or when retrofitting technical centers, pathways often have to be created under confined, safety-sensitive conditions. Tank cutters are used when legacy systems or tank vessels must be properly dismantled to enable new routes. In such special deployments, compact hydraulic tools with precise force control and low spark generation are advantageous.
Typical mistakes in utility line installation and how to avoid them
- Insufficient as-built survey: Plan locating and probing early.
- Uncoordinated openings: Coordinate openings and chases with structural and fire safety.
- Wrong methods: In sensitive environments, prioritize low-vibration processing (splitting, concrete demolition shear).
- Inadequate fastening: Design system fixings for structural performance and corrosion protection.
- Missing documentation: Record routing, fire stops, and tests without gaps.
Areas of application and link to utility line installation
Utility line installation intersects numerous application areas: During concrete demolition and special demolition, new routes are created in load-bearing structures. During strip-out and cutting, spaces and shafts are cleared. In rock excavation and tunnel construction, recesses and supports for cables and pipes are created. In natural stone extraction, splitting techniques can be used for installation pathways. In special deployment within industrial environments, tank cutters, steel shears, and multi cutters enable the safe exposure of routes.