Long-reach excavators, also referred to as long-reach or high-reach excavators, are specialized machines for work on distant or elevated areas. In concrete demolition, special demolition, and refurbishment works they enable controlled material removal outside hazard zones. In practice they are frequently combined with hydraulic excavator attachments such as concrete pulverizers, attachment shears, or steel shears, as well as complementary methods like hydraulic rock and concrete splitters to separate components appropriately by material, minimize vibrations, and cleanly sort valuable materials. This contribution combines fundamental knowledge with practical guidance for planning, selection, and deployment.
Definition: What is a long-reach excavator?
A long-reach excavator is a hydraulic excavator with an extended boom and stick designed for large vertical and horizontal reach. Hallmarks include modular boom packages, reinforced undercarriages with additional counterweight, as well as special working range diagrams to maintain tipping stability. Long-reach excavators are used in the demolition of tall structures, on slopes, revetments, and hard-to-access building areas. With the greater reach, they can guide tools such as hydraulic demolition shear and concrete pulverizer, Multi Cutters, or steel shears to positions that would be unreachable with standard booms.
Design, reach, and structural features
Long-reach concepts are based on extended upper and lower arms, sometimes with inserts or telescopic modules. Greater reach reduces the permissible tool mass at the stick tip, which is why lightweight, high-performance attachments with strong cutting or crushing force are preferred. Key features:
- Reinforced slew ring bearings, ballasting, and widened undercarriages for tipping stability
- Working range diagrams with load-moment curves for defined tool weights
- Quick couplers and additional hydraulic circuits for shears, crushers, and cylinders
- Dust suppression and optional water-carrying lines along the boom
Application areas and typical tasks
Long-reach excavators are used in multiple application areas, especially in concrete demolition and deconstruction. The combination with tools from Darda GmbH supports controlled separation, selective deconstruction, and low-vibration methods.
Concrete demolition and special demolition
- High-reach demolition of façades, slab edges, and cantilevers with concrete pulverizers
- Pre-cutting reinforcement using steel shears or Multi Cutters
- Controlled lowering of components for near-ground further processing
Strip-out and cutting
- Selective deconstruction of attachments, beams, pipe bridges, and plant components
- Cutting structural steel with steel shears and Multi Cutters
- Follow-up work at ground level with attachment shears and concrete pulverizers
Rock excavation and tunnel construction
- Cleanup at portal areas and support structures with shears
- Low-vibration loosening of brittle zones using hydraulic wedge splitters
- Material handling over large distances from outside the hazard zone
Natural stone extraction
- Releasing and separating blocks during extraction with rock wedge splitters
- Gentle separation along joint systems for quality assurance
- Transport of released units with long outreach
Special applications
- Work on riverbanks, dams, and hydraulic structures with long reach
- Risk minimization at contaminated sites through distance operation
- Special tasks such as dismantling tanks with a cutting torch from a safe standoff
Work methods in conjunction with hydraulic attachments
For high-reach demolition, a sequential approach has proven effective: long-reach excavators create access and pre-loosen components, concrete pulverizers and attachment shears separate concrete and masonry, steel shears cut reinforcement and steel profiles. Large elements are set down in a controlled manner or removed piece by piece. On the ground, secondary crushing is carried out with high precision and reduced noise. For massive cross-sections or sensitive structures, hydraulic wedge splitters complement the method to initiate cracks in a targeted way and produce brittle fracture without impact energy.
Tool selection and sizing on the long boom
Tool selection is based on material, geometry, and permissible loads at the stick tip. Key criteria:
- Tool weight and load moment relative to reach
- Hydraulic performance (flow rate, working pressure) and required closing forces
- Jaw opening, blade geometry, and cutting edges for concrete, steel, or composites
- Vibration and noise control requirements of the surroundings; advantage for hydraulic wedge splitters under strict limits
- Changeover strategy: Multi Cutters and attachment shears cover variable tasks with one carrier
Secondary crushing and selective deconstruction at ground level
After large components are set down, compact tools from Darda GmbH ensure efficient further processing. Concrete pulverizers open up components, expose reinforcement, and generate defined particle sizes for recycling. Attachment shears and Multi Cutters accelerate separation of different material fractions. Where vibrations or emissions are critical, hydraulic wedge splitters enable quiet, crack-controlled removal with minimal edge effects.
Low-vibration methods in sensitive environments
Near vibration-sensitive equipment, historic fabric, or in densely built districts, methods with reduced dynamics are required. Targeted splitting with rock wedge splitters reduces vibrations and protects adjacent components. In tunnel construction and at portal areas, stress states can be relieved in a controlled manner before shears remove the exposed zones. This makes material separation predictable and prevents damage from uncontrolled breaks.
Safety, environmental conditions, and legal framework
In principle, stability verification, working range diagrams, and exclusion zones must be observed. Tipping stability, subsoil parameters, wind load, and vibration input must be accounted for in the work plan. Different requirements may apply to dust protection and noise control depending on project and location; a water spray system directly on the boom, suitable dust extraction, and coordinated timing of shear cycles contribute to emission reduction. Guidance on permits, traffic safety, and disposal must always be checked for the specific project.
Planning, logistics, and site organization
Using a long-reach excavator requires areas for assembly and ballasting, secured access routes, and clear material flow. Recommended:
- Pre-analysis of the structural system with demolition sections and load paths
- Definition of set-down points for secondary processing with concrete pulverizers and attachment shears
- Provision of hydraulic power units for handheld hydraulic wedge splitters
- Coordination of cycle times to avoid downtime during tool changeovers
Example sequence: high-rise demolition with a long-reach excavator
- Set up exclusion zones, verify working range diagrams, activate dust suppression
- Pre-cut façade elements and cantilevers with concrete pulverizers
- Cut reinforcement and steel girders with steel shears or Multi Cutters
- Controlled lowering of larger segments into secured areas
- Secondary crushing on the ground with concrete pulverizers and attachment shears
- Low-vibration finishing of massive nodes with hydraulic wedge splitters
- Construction waste separation of fractions and haulage logistics
Technical parameters and selection criteria
Typical long-reach systems achieve substantial vertical heights and outreaches; permissible tool weights decrease with increasing reach. Decisive factors:
- Carrier working range diagram with approved tool masses
- Hydraulic performance data (working pressure/flow rate) for shear and crusher operation
- Structural reserves at the boom head (pins, bearings, quick coupler)
- Additional requirements such as water routing and spark protection when using the cutting torch
Maintenance, inspection, and documentation
Regular visual and functional checks increase availability and safety. Check lubrication points, pins, bushings, and hydraulic hose lines, leak tightness and temperature behavior of the circuits, as well as the condition of cutting edges and crusher jaw plates on concrete pulverizers and Multi Cutters. For hydraulic wedge splitters, ensure correct borehole geometry, controlled crack propagation, and proper operation of the hydraulic power pack. Complete documentation supports quality and safety requirements.