Rock Excavation Equipment: Complete Guide to Hydraulic Breakers for Excavators

When you need to break rock efficiently, the hydraulic breaker (also called a hydraulic hammer) is your primary excavation tool. We design our breakers to mount on excavators from 0.5 tons to 55 tons, providing the impact force necessary to fracture granite, limestone, concrete, and other hard materials. The right equipment selection depends on three factors: your excavator's operating weight, the rock hardness you're breaking, and your required productivity level.

What is Rock Excavation Equipment?

Rock excavation equipment refers to attachments that generate impact force to fracture solid materials. A hydraulic hammer converts the excavator's hydraulic pressure into rapid, concentrated strikes through a piston-driven mechanism. The piston hits a working tool (typically a moil point) at 200-1,400 beats per minute, depending on the breaker size. This repeated impact creates fracture lines in the rock, allowing efficient excavation without explosives.

The equipment consists of a cylinder body assembly housing the piston, a control valve that directs hydraulic flow, and an accumulator that stores energy between strikes. The front cylinder guides the working tool and contains wear-resistant bushings. Understanding how these components work together helps you maximize equipment performance and longevity.

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Hydraulic Breaker Selection Based on Excavator Weight

Your excavator's operating weight determines which breaker models will perform reliably. We match breakers to carriers using a ratio that prevents both underpowered performance and excessive stress on the excavator's hydraulic system.

For a 20-ton excavator working in a quarry, the BLT-135 provides the correct balance. Its 135mm chisel diameter and 160-180 bar working pressure deliver sufficient breaking force for medium to hard rock. If you're operating a 30-ton machine in mining applications, the BLT-155 offers higher pressure capability (200-220 bar) for more aggressive breaking.

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Proper sizing prevents common operational issues and extends equipment life. Matching the breaker to your specific job requirements ensures optimal productivity without overworking your carrier.

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Critical Specifications for Rock Breaking Performance

Working pressure directly determines your breaking force. Our BLT-155 operates at 200-220 bar, generating stronger impact than standard breakers in its class. This higher pressure creates deeper penetration in hard rock formations like granite or basalt.

Impact rate affects productivity differently based on material hardness. For concrete demolition, the BLT-100's 350-700 bpm delivers rapid fracturing. When breaking solid rock, the BLT-175's lower 130-200 bpm rate concentrates more energy per strike, creating effective crack propagation through dense material.

The accumulator plays a crucial role in maintaining consistent impact energy. It stores hydraulic pressure between strikes and releases it during the impact phase. Our breakers use 55-60 bar accumulator pressure on most models, with higher pressure (65-70 bar) on larger units like the BLT-185. This stored energy ensures each strike delivers maximum force regardless of slight variations in the excavator's hydraulic system.

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Chisel diameter indicates the breaker's overall capacity. A 155mm chisel handles significantly larger rock volumes than a 100mm tool. The larger diameter also provides better stability when breaking irregularly shaped boulders, reducing tool deflection during impact.

Matching Oil Flow and Pressure Requirements

Your excavator's hydraulic system must supply both adequate flow volume and pressure. The oil flow specification determines the breaker's maximum impact rate. Our BLT-135 requires 100-150 l/min to achieve its rated 350-500 bpm frequency. If your excavator supplies only 120 l/min, the breaker operates within specification but toward the lower frequency range.

Relief pressure settings protect both the breaker and excavator. We set relief valves at 210 bar for the BLT-135, preventing excessive pressure spikes that could damage seals or stress the excavator's pump. Your excavator's system pressure should not exceed the breaker's relief valve setting during operation.

Oil temperature affects viscosity and system response. In cold climates, allow hydraulic oil to reach operating temperature before beginning rock breaking. We recommend maintaining oil temperature between 40-70°C for optimal breaker performance. Higher temperatures reduce oil viscosity, potentially causing internal leakage and reduced impact energy.

Proper hydraulic system compatibility prevents premature wear and ensures the breaker delivers rated performance throughout its service life.

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Rock Excavation Applications Across Industries

Quarry operations demand consistent breaking of large rock volumes. Operators use breakers to size oversize material, break boulders too large for primary crushers, and excavate rock faces in areas where drilling and blasting aren't practical. The BLT-155 and BLT-165 models see heavy use in quarries processing 27-38 ton excavators, providing the combination of impact energy and operating speed needed for production environments.

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Mining applications require breakers that handle abrasive rock and operate in challenging conditions. Underground mining uses compact breakers like the BLT-100 on smaller excavators in confined spaces. Surface mining operations deploy larger units like the BLT-175 and BLT-185 for breaking rock during overburden removal or ore extraction.

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Demolition contractors break concrete foundations, bridge piers, and building structures. The controlled breaking pattern of hydraulic hammers prevents damage to adjacent structures. Medium-sized breakers (BLT-100 to BLT-135) handle most demolition projects, offering sufficient force to fracture reinforced concrete while maintaining precise control.

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Road construction teams use breakers to remove existing pavement, break rock for base preparation, and excavate through bedrock when extending road cuts. The ability to work in urban environments without blast vibration makes hydraulic breakers essential equipment for infrastructure projects. Some contractors choose hydraulic breakers specifically to avoid the regulatory complexity and safety concerns associated with explosive methods.

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From Our Field Engineers: Quarry Operation Success

Last month, a limestone quarry in Ontario contacted us about frequent tool breakage with their existing breaker. They were running a 32-ton excavator with a competitor's 150mm breaker, breaking boulders ranging from 0.5 to 2 cubic meters. The operation was going through working tools every 40 hours due to excessive side loading when breaking irregular shapes.

We recommended switching to our BLT-155 model. The larger 155mm chisel diameter provided better stability against side forces, and the higher 200-220 bar working pressure allowed the operator to break boulders with more direct, vertical strikes rather than angled impacts that caused tool bending. Three months later, their tool life extended to 120 hours, and their breaking productivity increased by approximately 20% because the operator spent less time repositioning for difficult angles.

The lesson: matching chisel diameter to the typical rock size you're breaking matters as much as matching the breaker to your excavator weight. When breaking large, irregular boulders, going up one size class in breaker can actually reduce operating costs despite the higher initial equipment investment.

Proper maintenance practices also contributed to this success. Regular lubrication and wear part inspection prevented secondary damage that often shortens tool life.

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The industry trend toward higher working pressure in hydraulic breakers reflects the demand for greater breaking force without adding equipment weight. Traditional breakers for 27-33t excavators operated at 160-180 bar, but our BLT-155 achieves 200-220 bar working pressure while maintaining optimal oil flow efficiency at 180-240 l/min. This 15-20% pressure increase translates directly to stronger impact energy, allowing operators to break harder rock formations or work faster in medium-hardness materials.

This technological advancement benefits contractors working in challenging geology. Where a project previously required a larger excavator and breaker, operators can now achieve the same breaking force with their existing 30-ton excavator by selecting a higher-pressure breaker. The trend will likely continue as hydraulic component manufacturers develop seals and valves capable of withstanding even higher pressures while maintaining reliability over thousands of operating hours.

About the Author

The BEILITE technical team consists of engineers and field service experts with over 15 years of hands-on experience in hydraulic breaker design, application, and maintenance. We are committed to sharing our deep expertise to help you maximize your equipment's performance and lifespan.

Need Help Selecting the Right Rock Excavation Equipment?

Contact our technical specialists for a personalized equipment recommendation based on your excavator model, rock conditions, and production requirements. We provide detailed specification comparisons and can arrange demonstration units for qualified projects.

FAQs

Q: Can I use a hydraulic breaker on rock harder than granite?

A: Yes, hydraulic breakers effectively break quartzite, basalt, and other hard formations. Select a breaker with higher working pressure (200-220 bar range) and use a moil point working tool for maximum penetration. The key is matching the impact energy to the rock's compressive strength and allowing the tool to create progressive fractures rather than expecting immediate breaking.

Q: What's the minimum excavator size for effective rock excavation?

A: Excavators as small as 1.5 tons can break rock effectively with properly matched breakers like our BLT-53. However, productivity depends on rock hardness and required volume. For commercial quarry work, excavators in the 18-40 ton range (using BLT-135 to BLT-175 breakers) provide the best balance of breaking force and operating economics. Mini excavator owners should explore specialized compact breaker options designed for smaller carriers.

Q: How do I know if my excavator supplies enough oil flow for a breaker?

A: Check your excavator's hydraulic specifications for auxiliary circuit flow at rated pressure. Compare this to the breaker's required oil flow range. For example, the BLT-155 requires 180-240 l/min. If your excavator supplies 200 l/min, you're within the optimal range. Operating below the minimum flow reduces impact frequency and can cause overheating.

Q: What maintenance does rock excavation equipment require?

A: Lubricate the working tool every 2 hours of operation using chisel paste. Inspect bushings weekly for wear. Check accumulator nitrogen pressure monthly (55-60 bar for most models). Replace wear parts like bushings and tools based on visual inspection rather than time intervals, as wear rate varies significantly with rock hardness and operator technique.

Q: Can the same breaker work in both quarry and demolition applications?

A: Yes, hydraulic breakers are versatile across applications. Change the working tool based on the material: use moil points for rock, blunt tools for secondary breaking, and narrow chisels for concrete cutting. The BLT-100 through BLT-155 models handle both environments effectively, though quarry work typically causes faster wear due to abrasive rock particles.

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