Pipe routing describes the planned arrangement, fastening, and guidance of lines for liquids and gases in machines, structures, and on construction sites. In the application areas of concrete demolition and special demolition, gutting works and cutting as well as rock excavation and tunnel construction, precise pipe routing determines operational safety, performance, and maintainability. This applies in particular to hydraulic systems in which hydraulic power packs supply tools such as concrete demolition shears or hydraulic wedge splitters via lines.
Definition: What is meant by pipe routing
Pipe routing (also line routing or piping routing) comprises all measures for defining the pipe run, support spans, supports/clamps, expansion concepts, and the interfaces to power packs and consumers. The objective is a flow-optimized, safe, and accessible routing that takes into account media, pressure ranges, temperature, vibrations, installation and maintenance requirements, and environmental conditions. This also includes flexible hose sections in hydraulic systems when movements must be accommodated or vibrations decoupled.
Technical fundamentals of pipe routing
Professional pipe routing is based on medium, pressure rating, temperature, environment, and mechanical loading. Essential parameters are bend radius, flow velocity, pressure loss, vibration excitation, elongation, and thermal expansion. Fixed points, sliding supports, and expansion compensators define where lines may move and where forces are introduced into the structure. Media-compatible materials, tight connection systems, and a corrosion protection-oriented design ensure the durability of the installation.
Pipe routing in hydraulic systems of concrete demolition shears and hydraulic wedge splitters
Hydraulic drives connect hydraulic power packs to the tools via lines. For concrete demolition shears and hydraulic wedge splitters, short, protected, and flow-optimized runs are crucial to ensure response times, force development, and energy efficiency.
Bend radii, flow, and pressure losses
- Observe minimum radii: Bends that are too tight increase pressure loss, heat the oil, and stress the lines. The manufacturers’ minimum bend radii must be observed.
- Select an appropriate cross-section: Dimension for the required flow rate. Diameters that are too small increase flow velocity and promote erosion and cavitation.
- Execute transitions with good flow characteristics: Use gentle transitions for reductions and branches to reduce turbulence and pressure surges.
Vibrations, movements, and protection
- Vibration decoupling: Provide flexible hose sections between rigidly piped sections and moving components.
- Abrasion and kink protection: Use protective sleeves and clamps with inserts. Do not route lines over sharp edges.
- Movement reserves: Route lines with sufficient length and suitable loops so that lifting and slewing movements can be accommodated without building up torsion.
Connection points and maintainability
- Arrange quick couplers accessibly: Position coupling points so that rapid tool changes are possible and contamination is avoided.
- Identification: Clearly mark pressure and return lines; avoid mix-ups.
- Control leakage paths: Route drip points away from hot surfaces and electrical equipment.
Pipe routing in concrete demolition, rock excavation, and tunnel construction
In harsh environments, lines must be protected against abrasion, impacts, moisture, and dirt. In tunnel and rock zones, pipe routing must be planned particularly compactly to account for constrictions, limited visibility, and changing load cases, as in rock demolition and tunnel construction.
- Protection against rockfall: Route lines behind structural protective plates or within robust pipe routes.
- Avoid tripping and snagging points: Avoid free-hanging lines; provide clear routes above head height or near the floor in protective channels.
- Water and dust management: Route additional media lines (e.g., for dust suppression) so that they do not cross or damage the hydraulic lines.
- Observe temperature zones: Keep distance from exhaust systems and hot surfaces; use heat protection sleeves where required.
Fastening, support, and expansion compensation
The fastening strategy is decisive for vibration behavior, noise development, and service life. Properly placed fixed points and sliding supports prevent restraint forces.
- Support spans: Match support spacing to pipe diameter, weight, and dynamics; use closer spacing on vertical routes.
- Fixed and sliding points: Place fixed points on robust structures; low-friction sliding supports allow longitudinal expansion.
- Expansion compensators: Use compensators, U-loops, or Z-bends to accommodate thermal expansion.
Materials, connection technology, and corrosion protection
The choice of materials depends on medium, temperature, pressure, and environment. In demolition environments, resistance to moisture, dust, and chemical influences is crucial.
- Pipes and hose materials: Steel, stainless steel, or coated pipes for rigid routes; hydraulic hoses with suitable pressure class and abrasion resistance for moving zones.
- Connections: Cutting-ring fittings, flange joints, or suitable threaded connections with media-compatible seals; clean, stress-free installation.
- Corrosion protection: Provide coatings, stainless steels, and drainage points; avoid galvanic corrosion.
Assembly, commissioning, and testing of pipe routing
Quality is created during assembly. Careful preparation, clean working practices, and documented tests ensure proper function.
- Prefabrication and trial fit: Check isometrics, label components, simulate installation position.
- Cleanliness: Keep chips, dust, and moisture away; keep ends closed until installation.
- Alignment: Install free of stress; check alignment of flanges and fittings.
- Flushing and filtration: Flush lines, check filters to protect the power pack and tools.
- Pressure and leakage test: Perform according to applicable rules; document the results.
- Functional test: Observe temperature, noises, vibrations, pressure level, and cycle times; then retighten connections as specified.
Safety, environmental, and fire protection aspects of pipe routing
Safety and environmental protection are integral parts of pipe routing. The following points are proven principles that must be adapted to the specific framework conditions.
- Avoid leakages: Double-secure stressed zones; provide containment; dispose of media properly.
- Fire protection: Seal penetrations correctly using fire stop (sealing); spatially separate flammable media and route them away from ignition sources.
- Signage and accessibility: Arrange shut-off devices so they are reachable; keep escape and rescue routes clear.
- Pressure surge management: Use soft start-up and suitable damping elements; avoid abrupt valve closures.
Typical failure patterns and how to avoid them
- Bend radii too tight: Lead to kinking, heating, and performance loss. Consistently observe minimum bend radii.
- Insufficient fastening: Vibrations cause leakages. Increase support spans and clamp quality.
- Collisions and chafe points: Plan routes to be collision-free, provide protection at contact points.
- Incorrect hose lengths: Hoses that are too short tear during movement, overly long hoses form loops. Determine lengths within the working range.
- Unclear identification: Avoid mix-ups at connection points; use color and text marking.
Pipe routing for mobile hydraulic power packs and special operations
With mobile hydraulic power packs, lines often have to be routed, secured, and redeployed quickly. In special operations, for example when working with a cutting torch, steel shears, combination shears, or multi cutters, additional media and safety requirements apply.
- Modular routes: Plug-in and clamping systems for quick changes; nevertheless secured against tension and torsion.
- Transport condition: Fix lines relieved of load, cap ends to prevent contamination.
- Interface management: Clear assignment between power pack and tool; do not swap pressure and return.
- Additional media: For thermal or fire-sensitive work, route media lines separately and protected.
Retrofit, deconstruction, and dismantling of pipelines
In gutting works and cutting environments, lines are frequently rerouted or removed. An orderly approach prevents consequential damage and shortens downtimes.
- Systematically drain and depressurize: Prevent hazards; collect residual quantities.
- Define deconstruction sequence: From peripheral to central; release fixed and sliding points without unintentionally freeing loads.
- Update documentation: Continue piping plans, markings, and test protocols to facilitate later reassembly.
Practice checklist for pipe routing
- Define medium, pressure, temperature, and environment.
- Specify the routing with fixed points, sliding supports, and expansion compensation.
- Dimension cross-sections and bend radii for proper flow.
- Decouple vibrations, provide abrasion protection.
- Arrange switching and coupling points to be accessible and clearly identified.
- Integrate corrosion protection and fire protection measures.
- Assemble cleanly, free of stress, followed by flushing and testing.
- In operation: Monitor temperatures, noises, leakages, and cycles; retighten.