Commissioning

Commissioning is the transition from assembly or delivery to the safe, documented use of a work tool. In the context of hydraulic tools and splitting technology, it includes the systematic checking, setting, and testing of the hydraulic power pack, concrete demolition shears, as well as hydraulic wedge splitters and concrete splitters under realistic conditions. The aim is demonstrable operational readiness, fulfillment of the intended function, and a safe start in the application areas of concrete demolition and special demolition, building gutting and cutting, rock breakout and tunnel construction, natural stone extraction, and special operations. A structured commissioning process also defines responsibilities, acceptance criteria, and documentation artifacts for traceable approval.

Definition: What is meant by commissioning?

Commissioning refers to the planned procedure by which machines, tools, and systems are put into operation for the first time as intended and under supervision. This includes checking assembly conditions, adjusting parameters such as hydraulic pressure and flow rate, functional tests without and with load, creating test and handover protocols, and instructing operating personnel. For tools from Darda GmbH – such as concrete demolition shears or hydraulic wedge splitters and concrete splitters – the focus is on ensuring that the hydraulic system is leak-tight, correctly coupled, matched to the proper energy supply, and controllable in the respective application. In practice, this start-up is complete only when the defined acceptance values are met and documented.

Commissioning sequence: step by step

A practical sequence is divided into preparations, technical inspections, function and load tests, documentation, and instruction. A structured approach with clear checkpoints has proven effective to avoid subsequent downtime, leakages, or misapplications. Defining go-no-go criteria for each phase reduces rework and secures a reproducible quality level.

Preparations and prerequisites

Before starting, prepare the work area, machine, and tool. The following points are essential:

• Check completeness: tool, hydraulic power pack, hoses, quick coupling, safety equipment, lubricants, operating manual.
• Clarify compatibility: required hydraulic pressure, flow rate, return capacity, connection sizes, hydraulic fluid quality, temperature range.
• Secure the workplace: safety fence/barriers, utility power isolation, stability, load-bearing capacity of the subsoil, keeping hazard zones clear.
• Conduct a hazard analysis: behavior of the structural element, stresses in concrete or rock, possible spalling, controlled fracture guidance.
• Provide PPE and rescue plan: eye and hand protection, hearing protection, emergency paths, first-aid means.
• Make documentation available: current operating manual, torque specifications, maintenance plans, commissioning checklist and protocol templates.

Setting the hydraulic power pack and energy supply

The hydraulic power pack provides pressure and flow rate. It must be matched to the connected tool so that performance, temperature, and service life remain within limits; consider matching hydraulic power units for specification alignment. Duty cycle, ambient temperature, and cooling capacity must be taken into account.

Essential parameters

• Pressure (bar): Set the target value according to the manufacturer’s specification; check safety valves. Excessive hydraulic pressure leads to overloading, too little to insufficient performance. Where available, set pressure ramp-up gently to protect components.
• Flow rate (l/min): Adjust delivery so cycle times and cooling are appropriate. Too little increases cycle time, too much generates unnecessary heat. Verify that the power pack can maintain flow under load without cavitation.
• Hydraulic fluid quality: Select viscosity according to ambient temperature, ensure cleanliness; document filter condition. Air release characteristics and water content influence responsiveness and wear.
• Hose routing: Kink protection, abrasion protection, sufficient length and pressure rating. Connect quick coupling cleanly, tight, and without stress. Avoid tight radii and contact with sharp edges.
• Return line and case drain: Ensure sufficient return capacity and low backpressure; if a case drain is required, route separately and filter appropriately.

Commissioning of concrete demolition shears

Concrete demolition shears are used for selective concrete demolition, building gutting, and controlled demolition/separation. Their commissioning focuses on the hydraulic control, the kinematics of the jaw openings, and the stability of the carrier machine. Interface adaptation to the carrier, correct circuit selection (single or double acting), and compliance with permissible operating weights are critical.

Inspection and adjustment steps

1. Mechanical check: inspect bolts, bearing points, blades or teeth, jaw play, and end stops; lubricate grease points. Check wear indicators where present.
2. Couple hydraulics: connect pressure and return lines correctly; perform a short leakage test at reduced pressure. Connect a case drain if required by the tool.
3. Function without load: cycle open/close several times; observe noise, synchronization, end positions; assess temperature rise. Verify that any automatic cycles can be interrupted safely.
4. Functional load: perform a test cut on a non-load-bearing structural element; assess cutting force, fracture pattern, jaw guidance, and return behavior. Monitor for pressure spikes and unexpected vibration.
5. Fine adjustment: adapt pressure limiting, throttles, or valve settings to cycle times and material. Document final settings and compare with target ranges.

Application-specific notes

• Concrete demolition and special demolition: observe the load-bearing structure, define demolition sequence, provide shoring. Keep low vibration levels and secure falling edges.
• Building gutting and cutting: precision over feed rate; apply dust suppression, check cut edges. Use minimal necessary pressure to avoid microcracks.
• Special operations: check and document additional equipment (protective enclosure, catch devices). Establish exclusion zones with clear signage.

Commissioning of hydraulic wedge splitters and concrete splitters

Hydraulic wedge splitters and concrete splitters, as well as associated rock splitting cylinders, generate defined splitting forces to open components or rock in a controlled manner. Commissioning focuses on correct borehole preparation, centering of the wedges, and the matched working pressure. Cleanliness, lubrication, and exact alignment determine the fracture quality.

Borehole and alignment

• Produce borehole diameter and depth according to tool requirements; deburr edges, remove chips.
• Plan the split line, define spacing and sequence of settings; provide spall/edge protection.
• Place the cylinder without stress; align the marked wedge direction.
• Record borehole geometry and spacing in the commissioning protocol for repeatability.

Hydraulics and wedge set

1. Initially apply reduced hydraulic pressure, check for leakage and return flow.
2. Observe wedge stroke; ensure uniform splitting motion without jerking.
3. Increase working pressure step by step to the target value; assess splitting noises and crack propagation.
4. Perform multi-hole settings in a coordinated manner to avoid uncontrolled fractures.

Specifics by application area

• Rock breakout and tunnel construction: consider the stress state in the rock, provide relief borehole; keep vibrations low. Secure the roof and flanks against rockfall.
• Natural stone extraction: focus on the quality of the fracture pattern; clean split faces through correct wedge lubrication and borehole care. Avoid overheating by pacing cycles.
• Concrete deconstruction: account for reinforcement; plan combined use with concrete demolition shears for cutting and splitting. Protect adjacent components from spalling.

Inspection and measurement values during commissioning

Measurable criteria increase the significance of commissioning. Relevant quantities include:

• System pressure: Rise under load, stability, set point of the pressure relief valve. Record maximum and steady-state values.
• Flow rate/cycle time: Open/close times for concrete demolition shears; wedge-stroke time for splitters. Compare with target windows.
• Temperature: Oil temperature in the power pack after warm-up; avoid overheating. Note ambient temperature and duty cycle.
• Tightness: Visual inspection after 10-15 minutes of operation; pay particular attention to connection points and hose bends. Wipe and recheck to detect seepage.
• Noise and vibration: Changes indicate cavitation, air in the system, or bearing issues; monitor noise emission. Investigate persistent rattling or squeal immediately.
• Return backpressure: Measure where possible; excessive values impair performance and increase heat input.

Documentation, acceptance, and instruction

Traceable documentation is the core of commissioning. It includes test protocols, set parameters, and release for operation. Instruction ensures that operators and maintenance personnel use the tool correctly. Define acceptance criteria and responsibilities before testing begins to streamline handover.

Contents of the handover

• Protocol with date, location, tool and power pack data, measured values, and special notes.
• Notes on maintenance intervals, lubrication points, permissible operating limits.
• Instruction topics: safe handling, signs of malfunction, emergency stop, daily visual check.
• Practice exercise under supervision: one complete work cycle on the target material.
• Verification of safety devices and protective covers: function tested, condition documented.
• Appendices: torque data for bolted joints, spare parts list, and consumables overview.

Legal requirements may vary by region, application, and machine. The information in the operating manual is authoritative; these notes do not replace an individual hazard analysis.

Typical sources of error and how to avoid them

• Incorrect power pack matching: Remedy: set hydraulic pressure/flow rate as specified, check return capacity.
• Contaminated quick coupling: Remedy: clean before coupling, use protective caps, check the oil filter condition.
• Air in the hydraulic system: Remedy: bleed, perform multiple load cycles, watch for cavitation.
• Unsuitable boreholes (splitters): Remedy: adjust diameter/depth, keep borehole clean, lubricate wedges.
• Missing support of the workpiece: Remedy: stabilize with shoring, plan the demolition sequence, clear the safety distance around the hazard zone.
• Excessive return backpressure: Remedy: increase hose cross-section if required, check for crushed lines and clogged filters, verify separate case drain routing.

Application-specific commissioning notes

Concrete demolition and special demolition

Observe structural analysis, secure load transfer, document the demolition sequence. Operate the concrete demolition shears initially with conservative parameters, then adapt to material and component thickness. Maintain visibility at the cutting point and use suitable cutting edges for the reinforcement content.

Building gutting and cutting

Precise tool guidance, low emissions, and clean separation joints are the priority. Route hydraulic hose line so that no tripping hazards are created. Coordinate with dust and water management to protect adjacent areas.

Rock breakout and tunnel construction

Plan low-stress splitting sequences; in confined spaces ensure ventilation and monitor oil temperature. Define communication paths within the team. Mark escape routes and secure the area above and behind the work front.

Natural stone extraction

Check splitters for uniform wedge stroke and reproducible fracture edges. Document field trial/test to ensure quality. Adjust wedge lubrication and cycle times to preserve surface quality.

Special operations

Unusual materials or positions require test cuts or test splits and, if necessary, additional protective measures. Select parameters conservatively and increase step by step. Introduce hold points in the protocol for intermediate assessment.

First operating hours and follow-up inspection

The first hours of operation are crucial. Retighten screw connections, re-lubricate bearing points, check filter condition. Compare measured values with the commissioning protocol and correct deviations promptly. Recheck quick couplings after thermal cycling and inspect hoses for abrasion after the first shifts.

Putting other tools safely into operation

In addition to concrete demolition shears and hydraulic wedge splitters/concrete splitters, comparable fundamentals apply to combi shears, multi cutters, steel shears, and tank cutters. Particular attention is paid to cutting clearances, blade condition, and compliance with the specified material thickness. Observe maximum permissible plate or profile thickness and maintain the recommended clearance gauge.

Quick check

• Inspect cutting and guiding surfaces, observe wear limits.
• Check hydraulic functions without load, then apply controlled load.
• Keep guards and covers mounted and functional.
• Verify the function of emergency stop and interlocks prior to load application.

Practical commissioning checklist

• Work area secured and team instructed
• Tool mechanically inspected and lubricated
• Hydraulic power pack set (hydraulic pressure/flow rate), tightness confirmed
• No-load function run successful
• Load test on representative material with comparison to target values
• Protocol created, parameters documented, release granted
• Instruction and handover to operating personnel completed
• Emergency stop, guards, and safety devices tested and documented
• Environmental measures implemented (dust, noise, fluid handling) and responsibilities assigned

Careful commissioning increases process safety, extends the service life of Darda GmbH tools, and ensures predictable results in all relevant application areas. Consistent documentation and measured-value tracking enable continuous improvement across projects.