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Complete Guide to Job-Site Hydraulics for the Construction Industry

Hydraulic power is a reliable force-amplifier at the construction site, used to lift, push, pull, position and torque, among other processes. If your organization is looking to add to its hydraulic resources, this guide to job-site hydraulics will assist with identifying the right components for the job, along with proper hydraulic equipment maintenance and selecting the right equipment supplier.

Key Hydraulic Components for the Construction Industry

The construction industry relies on an impressive array of hydraulic technologies to get the job done. From dirt work to finishing work, here are the hydraulic tools typically needed at the work site:

    • Hydraulic pumps and power units – Hydraulic pumps deliver fluid power to other system components and are a principal part of any hydraulic power unit (HPU). HPUs also include a fluid reservoir and a motor, packaged together into a single unit. When selecting a hydraulic pump or HPU, choose one that can achieve your needed flow and pressure ratings, as well as one that’s compatible with your preferred valve set and fittings.

       

       

    • Hydraulic cylinders – Hydraulic cylinders are a linear type of actuator responsible for converting fluid power into linear force. At the jobsite, you’ll usually see hydraulic cylinders integrated into heavy machinery, but they’re also part of hand-held demolition or site preparation tools, like vibratory rammers.

       

       

    • Hydraulic jack systems – Hydraulic cylinders and hydraulic jacks are interchangeable terms in many contexts, but hydraulic jack systems often refer to hydraulic cylinders that are connected to other components that apply force for various applications. For example, post-tensioning jack systems are designed to tension concrete and use a pair of hydraulic cylinders to secure the tendon and tension it prior to it being anchored.

       

       

    • Hydraulic torque wrenches – Hydraulic bolting tools include torque wrenches, bolt tensioners and tools used to access damaged fasteners, like spreaders and nut splitters.

       

      Hydraulic torque wrenches are a frontline tool for construction crews, used throughout the project. When searching for a torque wrench, the most important consideration is whether it’s compatible with the fasteners your crews are likely to encounter in the field. Fortunately, some hydraulic torque wrenches are designed for versatility, with a cassette-like build that can be switched out quickly to accommodate a variety of fasteners. Further, some torque wrenches are designed to work in limited access scenarios, which is relevant for crews working on pipelines and with certain types of infrastructure (like wind turbines).

Hydraulic cylinders are built into a variety of construction tools and machines, including:

    • Excavators
    • Hammers
    • Pile drivers
    • Compactors and rollers
    • Concrete pumps
    • Cranes
    • Lifts and elevated work platforms

Hydraulic maintenance is essential to keeping your heavy machinery in the field and ready to mobilize.

Accessories and Fittings for Your Construction Hydraulics

Hydraulic equipment can be augmented or adapted to fit into any system using various accessories and fittings to expand the equipment’s capabilities. To prevent downtime and to ensure your crew is prepared for anything, the following hydraulic accessories and parts are recommended:

    • Hydraulic fittings – Hydraulic fittings are used to connect various hydraulic components together, and they’re available in many designs to facilitate smooth coupling. Examples include JIC fittings (used in metal-to-metal connections), O-rings, NPT fittings, compression tube fittings (bite-type fittings), rotary fittings (swivels), flange fittings, elbows and crosses (for routing hydraulic lines) and quick-disconnect fittings, among others. Hydraulic fittings are inexpensive and replaceable, so it’s recommended that construction crews keep an inventory on hand when an existing fitting sustains damage or corrosion.

    • Hydraulic hoses and manifolds – Hydraulic hoses (or lines) are available in several diameters and materials, each with their own pressure and temperature rating. This includes hydraulic lines made from rubber, thermoplastics and specialized polymers (PTFE, for example). Some hydraulic hoses are reinforced to contend with extreme pressures and many types of hydraulic lines are also purpose-designed for various applications, like concrete pumping or serving as return lines.

      Hydraulic manifolds act like a splitter for your hydraulic system, diverting fluid power to several distinct lines to drive multiple tools at once (like several hydraulic cylinders in tandem used to lift a damaged foundation).

    • Hydraulic controls and gauges – Hydraulic controls allow operators to maintain a safe distance while utilizing the HPU, hydraulic pump or hydraulic cylinder. They can be paired with most pump and cylinder models and are important in settings where access is limited or risk is elevated.

      Hydraulic gauges give operators a clear look at the pressures and temperatures inside the system and are important monitoring and safety tools. Select fluid filled hydraulic gauges to reduce the impact of vibration on the gauge itself and to ensure a more accurate reading.

    • Hydraulic stressing accessories – Hydraulic stressing accessories are needed to facilitate post-tensioning jack operation and include several smaller components. Examples include nose pieces (and nose bodies), grippers, gripper blocks, gripper handles, gripper retainer plates, wedges and wedge seaters. These typically only need to be switched out when a component has sustained damage, but it’s important to keep replacements on hand to prevent downtime.

    • Hydraulic spreaders – Hydraulic spreaders aren’t a standard construction tool, but they do provide needed access in settings where damaged materials cannot be easily removed from the site. For instance, demolition crews may require a hydraulic spreader to push or pull apart damaged materials.

These hydraulic accessories and tools are an effective complement to your existing hydraulic resources and can add to your team’s in-field capabilities or execute specialized tasks.

What is Included in Hydraulic Systems for the Construction Industry

Commercial construction projects demand advanced hydraulic technologies, with each component working in concert. Full hydraulic systems are designed to deliver unmatched levels of power with excellent reliability, as each piece of hydraulic equipment is designed for maximum compatibility.

Full hydraulic systems are common in the construction industry, as they include the following critical components:

    • The hydraulic power unit (HPU) – The system’s HPU is the primary part of every hydraulic system used in construction and consists of the hydraulic pump, the pump’s fluid reservoir and a motor. The HPU is a standalone, fully encapsulated piece of equipment that can provide fluid power wherever it’s needed on site.

    • Hydraulic fluid filtration – Hydraulic fluid must be aggressively filtered to prevent contamination from fouling the fluid and damaging the system. Equipment for this includes suction strainers and return filters, as well as breathers and in-line disposable filters. If necessary, some hydraulic systems are protected by a kidney loop with a dedicated filtration loop before hydraulic fluid is returned to the reservoir.

    • Hydraulic valve sets – Hydraulic systems rely on a combination of directional, check, control and relief valves to ensure efficient, safe control of the hydraulic fluid. These valves may be manually or electronically operated using a servo. It’s especially important to check valve specifications before integrating them into your existing hydraulic system. Flow, pressure and temperature ratings must be verified before acquisition.

    • Hydraulic accumulators – Hydraulic accumulators store pressurized hydraulic fluid and are therefore like energy containers that can be called on when needed. For example, hydraulic accumulators can provide a burst of pressure to smooth out flow shocks and help the system maintain necessary pressures when it drops for any reason.

    • Hydraulic actuators – Hydraulic actuators are any tool that converts fluid power into some type of linear force. All hydraulic cylinders are considered actuators under this definition, but it also includes actuators that deliver rotary motion, like those needed for winches and augers.

    • Hydraulic hoses, tubing and fittings – No hydraulic system is complete without the hoses, lines and fittings needed to connect everything together. When putting together a full hydraulic system, all lines should be matched to the system’s needs, in terms of line diameter and length, and material.

    • Hydraulic sensors and monitoring instruments – Hydraulic systems are designed to operate within an optimal pressure and temperature range to facilitate ideal hydraulic fluid flow conditions. To ensure those pressure and temperature settings are on target, operators place pressure gauges, flow meters and temperature settings in the line. Ideally, these sensors should be located near hydraulic elements that are more likely to cause or be affected by adverse operating conditions. For example, temperature sensors are often placed near the heat exchanger to verify that it is functioning properly.

    • Communication systems – Modern hydraulic systems run on sophisticated CAN bus management and control technology. This technology can monitor sensor information, actuate valves and perform other tasks to free up operators for other roles.

How Hydraulic Tools Help with Torquing and Fastening

Hydraulic equipment delivers power in many ways, and construction sites need that power in many forms. Torquing and fastening are one example, essential for concrete work, steel work, framing, HVAC work, roofing and many other construction applications. To perform these essential fastening tasks, construction crews rely on hydraulic bolting tools like torque wrenches. Hydraulic torque wrenches are a popular and proven option for fastening applications for the following reasons:

    • Hydraulic torque wrenches deliver precision power – Hydraulic torque wrenches (and bolt tensioners) are designed to deliver intense torquing forces with mathematical precision. Construction fasteners must be tightened within extremely narrow tolerances and torque wrenches are built to do this. Regular torque wrench calibration is recommended (in accordance with ISO standards) to maintain this torquing accuracy and ensure all fasteners are properly secured.

       

    • Hydraulic torque wrenches are versatile and adaptable – Some hydraulic torque wrenches (cassette models) are built with an interchangeable cassette design that can be switched out when encountering a different fastener design or size. If you don’t know what fasteners to expect in the field, or if your operators must handle a variety of bolt and fastener designs, a cassette-style hydraulic torque wrench will ensure your crews are ready for the job.

       

    • Hydraulic torque wrenches are easy to transport and maintain – Hydraulic torque wrenches are small, lightweight tools that can be thrown into any worker’s toolbox. They are easy to handle, and although all hydraulic tools should be occasionally inspected by an expert hydraulic technician, torque wrenches are easier to maintain than most other hydraulic tools. In general, they just need the occasional cleaning and lubricating, though the wrench will need to be disassembled to do so.

In addition to hydraulic torque wrenches, some construction companies also invest in hydraulic nut splitters and spreaders. Both are particularly useful for demolition and maintenance crews who may have to access corroded or damaged fasteners to complete the job. Here’s a summary of both:

    • Hydraulic nut splitters – Hydraulic nut splitters are small tools that exert intense, but precise force to damaged or corroded fasteners that can’t be removed through other means.
    • Hydraulic spreaders – Hydraulic spreaders are another tool that construction teams may rely on to deal with damaged fasteners, panels and other materials. They’re available in jaw and collet-like designs, and the best option for the job depends on the application.

Daily and Weekly Maintenance for Construction Hydraulic Systems

Hydraulic systems operate at their best when they’re maintained on time. Hydraulic equipment maintenance minimizes the risk of hydraulic fluid contamination (the number one cause of system failures) and other common causes of system downtime. As such, your operator crews should prioritize on time hydraulic maintenance that includes the following:

    • Hydraulic fluid levels and inspections – The quality of your hydraulic fluid is closely tied to the overall health of your hydraulic system. To keep it in optimal shape, check fluid levels prior to operation and ensure they are adequate for the job. Further, hydraulic fluid should be sampled and checked for contamination regularly. Small amounts of contamination may be undetectable visually at first, but lab analysis can reveal it, so send fluid samples to the lab when it’s time for an inspection.

    • Hydraulic filter checks and replacement – Hydraulic fluid filters are usually designed with visual indicators that trip when the filter needs to be cleaned or replaced. Your operators should stay on top of these filters and switch them out when necessary.

    • Hydraulic leak inspections – Hydraulic leaks are major contamination and efficiency risks and should therefore be a focus for your maintenance crews. Following shutdown, give the equipment a full visual inspection and note if fluid residues are building up on the equipment or if fluid is pooling anywhere around the system. If so, it’s time to isolate the leak and schedule a repair.

    • Hydraulic part replacement – Some hydraulic parts such as seals, bearings and gears are prone to early wear and failure if not replaced on time. It will take a full equipment inspection to identify which parts are overly worn, but it’s important to replace these components on time to prevent issues from developing from within. For instance, worn parts may shed contamination into the fluid and result in cavitation.

    • Hydraulic system monitoring – If your operators know what it looks or sounds like when your hydraulic equipment is under distress, they can react before a catastrophic equipment failure occurs. This includes listening for unusual operating noises (whining, banging or gurgling), noting pressure drops and noting the presence of hydraulic fluid. These signs may point to something more concerning.

    • Expert hydraulic equipment inspections – Full hydraulic equipment inspections are recommended annually or when the equipment needs troubleshooting to source a problem. These inspections should only be performed by an experienced hydraulic equipment technician, as mistakes during assembly or disassembly may introduce contamination into the system.

Safety Considerations for Hydraulic Equipment at the Construction Site

Equipment safety is a priority when hydraulic machinery is onsite. Extreme forces, pressurized fluids and heat/electrical hazards are all potential dangers to workers, but there are safety measures that every job site can take to reduce risk, including:

    • Regular hydraulic equipment inspections – Vigilance is the most important part of any hydraulic equipment maintenance routine. Regular equipment inspections ensure that your hydraulic tools are never compromised to the point that they pose a safety risk. Make them a regular part of your company’s maintenance routine.

    • Maintain safe operating pressures – Before operating a new piece of hydraulic equipment or returning a piece of equipment to operation following service, verify that the system is calibrated properly and that the equipment in question is rated for the pressures expected during operation.

    • Provide personal protective equipment (PPE) – Personal protective equipment isn’t necessary for most construction roles, but when operating hydraulic equipment, it’s important to equip workers with eye wear and work gloves to prevent injury.

    • Implement proper startup and shutdown procedures – Prior to starting the system up, if hoses have been reconnected or maintained to any degree, bleed any trapped air out of the system first before fully pressurizing the system. And when shutting down the equipment, first relieve system pressures by offloading it through a relief or bypass valve. Once that’s done, lock out the engine or motor before additional service.

    • Know how to handle hydraulic fluid leaks – Hydraulic fluid leaks are a major contamination threat and should therefore be addressed immediately. If a leak is suspected, shut the system down and check for leaks using a piece of paper or other material. Never use your hands to look for leaks, as even minute amounts of highly pressurized fluid can cause serious injury.

    • Route hydraulic hoses through safe zones – All hydraulic lines should be carefully routed through low traffic areas free of pinch or crush hazards. Ensure nothing will interfere with or kink the lines before starting operation.

    • Observe fire safety procedures – Fire and explosion risks should be managed around hydraulic equipment, as the presence of extreme pressures and potentially flammable fluids can cause a dangerous chain reaction if not accounted for upfront. To reduce these risks, consider using nonflammable hydraulic fluids and select equipment rated for Class I, Division I environments.

An Expert Hydraulic Equipment Supplier Can Work with Construction Companies to Address Their Power Needs

Experienced hydraulic equipment suppliers frequently work with companies in the construction space and in other heavy-duty industries to help outfit their hydraulic needs. This includes customizing hydraulic systems with the right hydraulic pumps, actuators, valves and other hydraulic tools for the job.

Look for a supplier like Flickinger Machine who has experience working with construction companies that operate in environments like yours. In fact, we can also provide expert maintenance and priority access to replacement components, so you’ll have a valuable partner if your hydraulic equipment experiences performance issues or downtime in the field.

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