As construction equipment electrifies, its piping needs change. An electric machine has no engine exhaust — but it gains a demanding thermal-management system: coolant piping that keeps the battery, electric motor, and power electronics in their safe operating range. For anyone who makes or sources machine piping, the work is shifting from hot exhaust gas to leak-tight, pressure-rated coolant lines.
Here's what cooling and thermal piping does on electric construction equipment, how it differs from a diesel exhaust system, and what to look for when specifying it.
Why electric equipment needs thermal management
Batteries, electric motors, and power electronics (inverters and converters) all generate heat. Lithium-ion battery packs are the most temperature-sensitive: they perform best, last longest, and stay safest within a fairly narrow window — roughly 15–35°C. Too hot and the cells degrade (and, in the worst case, risk thermal runaway); too cold and capacity and charging suffer. So an electric machine trades the engine's exhaust system for a cooling system that actively manages these temperatures.
What the cooling system looks like
Most higher-power electric equipment uses liquid cooling. A coolant — typically a water-glycol mix — is pumped through cooling plates and channels around the battery pack, motor, and power electronics, then out to a radiator or chiller to shed the heat, and back again. Connecting all of it is a network of coolant pipes, hoses, and fittings. That piping network is the new equivalent of the exhaust system, in terms of the fabrication involved.
From exhaust to coolant piping — what changes
The manufacturing skills carry over, but the priorities shift:
- Temperature — exhaust handles gas up to ~800°C; coolant piping runs at moderate liquid temperatures, so extreme heat resistance matters less.
- Leak-tightness — a coolant leak is far more serious than a small exhaust leak; it can damage the battery or electronics, so sealing is paramount.
- Pressure — the coolant loop is a pressurised liquid system, so pipes, hoses, and joints must hold pressure without weeping.
- Corrosion & cleanliness — the coolant and the internal surfaces must not corrode or shed debris into the loop.
Requirements for cooling / coolant piping
- Leak-free construction — sound welds and joints, verified by pressure and leak testing
- Corrosion resistance — material suited to the coolant and the operating environment
- Flexible sections — to absorb vibration and movement between components (e.g. corrugated metal hose or coolant-rated flexible hose)
- Exact routing and fit — coolant lines are packaged tightly around the battery and drivetrain, so fit is model-specific
- Correct pressure rating — matched to the cooling loop
Materials
- Hard pipe — stainless steel or aluminium, for corrosion resistance and a clean internal surface
- Flexible hoses — coolant-rated EPDM or silicone, reinforced, and metal corrugated hose where more durability is needed
- Fittings and connectors — sealed, leak-tight, correct for the loop
Why fit and quality matter more here
On a diesel machine, a minor exhaust leak is a nuisance. On an electric machine, a coolant leak can reach the battery or power electronics — turning a small piping fault into an expensive failure or a safety issue. That raises the bar: cooling piping has to be leak-tight, pressure-tested, corrosion-resistant, and fitted precisely to the machine.
What to look for
- Pressure and leak testing of every assembly
- Corrosion-resistant material matched to the coolant and environment
- Flexible sections to absorb vibration between components
- Routing and fittings made to the exact machine layout
- Clean internal surfaces, free of debris
Frequently asked questions
Do electric machines still need piping if they have no exhaust?
Yes. They trade the exhaust system for a thermal-management (coolant) system — piping and hoses that cool the battery, motor, and power electronics.
What material is used for coolant piping?
Stainless steel or aluminium hard pipe, plus coolant-rated flexible hoses, matched to the coolant and the operating environment.
Why is a coolant leak such a big deal on electric equipment?
Because the coolant runs next to the battery and power electronics — a leak can damage them, not just lose coolant, so leak-tight, tested piping is essential.
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