Reaching new heights: igus® helps Kocurek Excavators enhance performance and reduce downtime

For Kocurek Excavators Limited, performance is not simply about achieving greater reach, but about delivering reliable, controlled operation. As a UK-based OEM specialising in bespoke excavator modifications for the construction and demolition sectors, Kocurek has built its reputation for solving complex engineering problems. A key enabler of that capability has been its long-standing use of igus® energy chain systems.

Founded in 1983, Kocurek has grown into a globally recognised leader in excavator front-end equipment and base machine modifications. Its telescopic demolition booms, used worldwide, can reach up to 76 metres on a 200 tonne excavator while handling heavy tools. Achieving this level of performance meant overcoming a fundamental engineering constraint: how to safely and reliably manage hydraulic systems across a constantly extending structure.

The challenge of controlled motion

In conventional excavators, hydraulic lines are routed using fixed pipework, with minimal hose movement. Telescopic booms remove that simplicity entirely. Kocurek needed to support over 35 metres of hydraulic hose within systems extending up to 25 metres, often handling over a dozen hoses simultaneously.

Without a defined routing solution, hoses risked tangling, rubbing, or sustaining damage during operation. This results in increased wear and costly downtime, which threatens vital precision and safety requirements.

Kocurek addressed this challenge by integrating igus® energy chains, specifically the E4.80 triple-strap system, into its telescopic boom designs. These chains provide a guided pathway that controls hose movement, maintains separation, and enforces consistent bending radii throughout the extension cycle.

This shift delivered an immediate performance benefit, and with more than 120 telescopic booms now using igus® energy chains worldwide, the solution has become a cornerstone of Kocurek’s product performance. It controls hose movement, protecting against wear, and preventing tangling in complex hydraulic systems.

Kocurek refined the system through real-world feedback and significantly enhanced both durability and reliability.

Key developments include:

• Standardised hose sizing to minimise stress caused by pressure pulsing
• External guide systems to prevent lateral movement and maintain alignment along the boom
• Heavy-duty internal dividers, ensuring hoses remain securely positioned despite pressure-induced contraction and expansion

These refinements have resolved early challenges such as hose displacement within the chain and resulted in a far more robust and repeatable system.

Measurable performance gains

The impact of igus® technology on Kocurek’s equipment has been substantial:

• Improved reliability through consistent hose management and reduced failure points
• Extended component life, thanks to better protection from wear and mechanical stress
• Reduced maintenance, lowering downtime and operating costs
• Enhanced overall machine capability, enabling safe operation at extreme heights

For Kocurek, these energy chains have not only solved a routing challenge but enabled a step change in product performance. By combining intelligent motion control with continuous engineering refinement, the company has ensured its equipment can operate reliably at the limits of modern demolition and construction.

Beyond the boom

The benefits extend beyond telescopic applications. Kocurek also employs TX1, igus® heavy-duty bearings, within machinery jacking systems capable of breaking down 200+ tonne excavators into transportable components under 54,000kg.