Breakthrough

A breakthrough refers to the deliberate creation of an opening in concrete, masonry, natural stone, or steel structures. Whether wall openings, ceiling openings, or openings for doors, windows, shafts, or technical installations – execution requires careful planning, a suitable method, and precise tools. In practice, non-explosive methods and hydraulic technology are preferred to minimize vibrations, ensure edge quality, and protect adjacent components. Especially in concrete demolition and special deconstruction as well as in rock demolition and tunnel construction, controlled splitting and cutting methods have proven effective. Tools such as concrete demolition shears and stone and concrete splitters are frequently used, supported by hydraulic power packs. In many specifications, the term also covers precise penetrations and cut-outs for utilities where dimensional stability and low emissions are critical.

Definition: What is meant by a breakthrough?

A breakthrough is understood as the controlled removal of material to create a new opening in an existing component or rock. The term covers different construction methods and materials: reinforced concrete, masonry, natural stone, or steel. Typical objectives include creating door and window openings, penetrations for utilities, ventilation, cable trays, elevator shafts, and enlarging existing openings. In contrast to large-area demolition, the focus in a breakthrough is on dimensional accuracy, protection of adjacent components, limited emissions (noise, dust, vibration), and preserving the residual load-bearing capacity of the remaining structure. Depending on the application, the result must be ready for subsequent trades, for example with defined edge roughness for bonding, corrosion-protection-compliant steel cuts, or clearances for fire protection systems.

Methods and tools for precise breakthroughs

The choice of method depends on the material, component thickness, degree of reinforcement, accessibility, and requirements for vibration and noise control. In practice, hydraulic and non-explosive methods have proven effective because they are controllable, efficient, and gentle on materials. Frequently, methods are combined in a planned sequence, for example pre-cutting or core drilling to define boundaries, followed by splitting and shear work to release material sections.

Non-explosive splitting technique in concrete and natural stone

Stone and concrete splitters as well as stone splitting cylinders generate controlled splitting forces in the borehole. After drilling, the cylinders are inserted and pressurized hydraulically. In this way, components can be released in defined blocks – ideal for large-format wall and ceiling openings with high edge quality. Power is supplied by hydraulic power packs, which provide constant pressure. Advantages include low vibration, reduced noise levels, and a very controlled crack pattern, which is particularly relevant in special demolition, during building gutting and cutting, and in natural stone extraction. Borehole diameter, pitch, and direction of force must be matched to the structure and any detected reinforcement to guide the crack and achieve repeatable results.

Concrete demolition shears for near-edge openings and demolition edges

Concrete demolition shears are frequently used to break components near edges, define edges, or enlarge openings step by step. They grip the material and crush it in a controlled manner; the resulting pieces are easy to handle. In concrete demolition and special demolition, slab or wall areas can thus be removed in sections before the final opening is produced. In combination with pilot boreholes or separation cuts, dimensional accuracy can be precisely controlled. The technique offers low-dust, low-vibration removal, benefiting sensitive environments and adjacent operations.

Combination shears and multi cutters for mixed structural systems

Combination shears and multi cutters are suitable when concrete, masonry, and metallic inserts (e.g., sections, beams) need to be separated in a single operation. For breakthroughs in areas with embedded parts or on façade constructions, they enable flexible work steps from dismantling to exposing the opening. Where different materials meet, interchangeable jaw geometries and careful sequencing help maintain edge quality and reduce rework.

Separating reinforcement and steel

For cleanly cutting reinforcement steel, sections, or embedded parts, steel shears are used. They ensure a clear separation of concrete and steel, which facilitates disposal and recycling. For steel-intensive components, the sequence “release concrete – cut steel” can improve occupational safety and process reliability. Where ignition sources must be minimized, cold-cutting approaches provide a suitable alternative to thermal cutting.

Openings in tanks and special structures

For special tasks – such as the safe opening of tanks or steel vessels – tank cutters are used. In special operations, it is important to select a suitable method that minimizes spark generation, ignition sources, and emissions, where required. The approach depends on the substances in the vessel, access conditions, and safety requirements. Typical measures include gas measurements, hot-work permits, inerting where necessary, and a defined extraction concept for released sections.

Planning, structural analysis and permits at a glance

Every breakthrough intervenes in the existing structure. Therefore, sound planning and verification of the structural effects are essential. The goal is to maintain the load paths of the building and avoid cracking or settlement. Depending on the project, permits or notifications may be required. Procedures and responsibilities are governed by applicable standards and regulations; individual checks are carried out by the competent specialist bodies. Digital as-built data and scans can increase planning reliability and reduce on-site surprises.

Preliminary investigation and existing-conditions survey

• Clarify component type, thickness, material, and reinforcement location (e.g., by reinforcement detection).
• Identify utilities, cavities, embedded parts, and anchors.
• Assess accessibility, working space, and the load-bearing capacity of adjacent areas.
• Plan protective measures against dust, noise, vibration, and falling objects.
• Compare plans with reality using measurement and scanning; define tolerances.
• Clarify hazardous substances and contamination; determine handling and disposal routes.
• Coordinate shutdowns of building services and temporary rerouting for uninterrupted operation.
• Plan water management for wet drilling or cutting and prevent uncontrolled discharge.

Structural system and temporary stabilization

• Assess load redistribution and internal forces; provide necessary shoring.
• Consider the edge stability of the opening and the remaining cross-sections.
• Plan the installation of frames, lintels, or reinforcements where necessary.
• Account for dynamic effects from equipment and sequencing to avoid unintended cracking.
• Define lifting points, intermediate supports, and removal paths for released blocks.

Permits and coordination

• Prepare method statements and risk assessments; obtain required approvals or notifications.
• Arrange hot-work permits or work-in-confined-spaces permits where applicable.
• Coordinate with stakeholders for timing, access routes, noise windows, and emergency egress.
• Establish QA documentation, including inspection points and acceptance criteria.

Step by step: Execution of breakthroughs

1. Define boundaries and mark: establish axes, dimensions, tolerances; set up dust and protection zones. Use visible, durable markings and ensure reference to fixed control points.
2. Preparatory separation cuts or core drilling: define edges, reduce stresses, reveal reinforcement. Where required, core holes also serve as insertion points for splitting cylinders and lifting gear.
3. Material release:
   • Use stone and concrete splitters to split adjacent to core holes and release blocks.
   • Use concrete demolition shears to remove near-edge areas or enlarge the opening.
   • Use steel shears to cut reinforcement and sections.
4. Removal and logistics: secure, lift, and transport released pieces; observe the load-bearing capacity of the transport route and haulage logistics. Plan intermediate storage and disposal streams for concrete, steel, and mixed fractions.
5. Edge finishing: follow-up work for defined edge quality, e.g., for installing frames, utilities, or fire protection solutions. Where necessary, grind or trim edges, treat cut steel against corrosion, and prepare surfaces for bonding.
6. Cleaning and documentation: separate and dispose of residual materials; record the dimensions and quality of the opening. Update as-built documentation and archive inspection evidence.

Influencing factors on the choice of methods

• Material and build-up: Degree of reinforcement, aggregates, strength class, masonry bond, or type of natural stone influence splitting and cutting behavior.
• Component thickness and geometry: Large thicknesses favor borehole splitting; thin components require considerate gripping or cutting techniques.
• Vibration and noise: Non-explosive splitting and hydraulic shears reduce emissions while maintaining control.
• Accessibility and working space: Compact tools and powerful hydraulic power packs are advantageous in confined conditions.
• Safety and environmental protection: Dust, water, oils, and chips must be controlled; suitable protective measures are to be provided.
• Cost-effectiveness: Dimensional accuracy, sequencing, and repeatability support on-time and cost-secure processes.
• Schedule and site logistics: Work windows, transport routes, and disposal capacities influence method selection and batch sizes.
• Compliance and documentation: Requirements for proof of vibration, noise, and structural verification can steer the approach.

Breakthroughs in rock and tunnel construction

In rock demolition and tunnel construction, rows of boreholes are often used to control stresses and predetermine fracture lines. Stone and concrete splitters develop high splitting forces that open rock in a controlled manner – for crosscuts, niches, or utility conduits. Low vibration protects nearby structures and reduces risks in sensitive areas such as galleries or existing structures. Monitoring of deformations and vibration levels supports risk control during progress.

Natural stone extraction and block splitting

In natural stone extraction, splitting techniques are used to gently release blocks along natural joints. This creates precise separation planes with minimal loss. The technique is transferable to construction tasks where natural stone masonry must be opened. Careful orientation to the grain and joint system ensures predictable splitting behavior.

Quality criteria and tolerances

• Dimensional accuracy: Opening dimensions, axis reference, and squareness must be maintained; pilot boreholes facilitate boundary accuracy.
• Edge quality: Smooth, low-spall edges reduce rework and facilitate subsequent trades.
• Crack control: A targeted sequence of cuts and splits minimizes unintended cracking in the existing structure.
• Clean separation of reinforcement: Clean cuts support corrosion-protection-compliant further processing.
• Surface condition: Defined roughness or keying surfaces enable reliable bonding and installation of frames or linings.
• Verification: Measured dimensions, photos, and acceptance records form the basis for handover and invoicing.

Measuring and documentation methods

• Use calibrated measuring tools or total stations to verify axes and clear widths.
• Employ 3D scanning or photogrammetry where complex geometries or tight tolerances apply.
• Record vibration and noise where required and include results in the project file.

Occupational safety, emissions and environment

Execution is carried out with personal protective equipment and suitable working procedures. Dust and noise protection, management of separating/cutting agents, and the safe routing of hydraulic hose lines are essential aspects. Hydraulic power packs must be set up securely; leakage and emergency-stop concepts must be in place. Waste is separated, with concrete and steel sent for recycling; water-bearing methods must be operated with retention. Additional measures include lockout-tagout for utilities, fall protection at openings, ergonomic handling of released blocks, and safe hoisting with certified lifting gear.

Special boundary conditions in existing buildings

During building gutting and cutting in occupied buildings, escape routes, fire protection, and quiet hours must be considered. Low-vibration techniques such as splitting and shear work offer advantages here because they interfere less with adjacent uses. Time windows for noisy work, dust containment concepts, and coordinated logistics reduce disruptions and improve project reliability.

Typical use cases

• Wall opening: Doors, windows, and technical openings in load-bearing and non-load-bearing walls; combination of separation cuts, splitting technique, and concrete demolition shears. Provision for lintels or frames is planned in advance.
• Ceiling opening: Shafts and penetrations; temporary shoring, step-by-step releasing with splitting cylinders, steel separation with steel shears. Particular attention is paid to fall protection and removal paths.
• Enlarging existing openings: Near-edge processing with shears, re-splitting for dimensional corrections, edge finishing for installed components. Interfaces to fire stopping and MEP installation are considered.
• Openings in steel and mixed constructions: Use of combination shears, multi cutters, and tank cutters depending on the material mix and safety requirements. Cold-cutting approaches are preferred where sparks must be avoided.