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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
Step by step: Execution of breakthroughs
- Define boundaries and mark: establish axes, dimensions, tolerances; set up dust and protection zones.
- Preparatory separation cuts or core drilling: define edges, reduce stresses, reveal reinforcement.
- 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.
- Removal and logistics: secure, lift, and transport released pieces; observe the load-bearing capacity of the transport route and haulage logistics.
- Edge finishing: follow-up work for defined edge quality, e.g., for installing frames, utilities, or fire protection solutions.
- Cleaning and documentation: separate and dispose of residual materials; record the dimensions and quality of the opening.
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.
Breakthroughs in rock and tunnel construction
In rock breakout 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.
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.
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.
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.
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.
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.
- Ceiling opening: Shafts and penetrations; temporary shoring, step-by-step releasing with splitting cylinders, steel separation with steel shears.
- Enlarging existing openings: Near-edge processing with shears, re-splitting for dimensional corrections, edge finishing for installed components.
- Openings in steel and mixed constructions: Use of combination shears, multi cutters, and tank cutters depending on the material mix and safety requirements.