Brick is one of the oldest and most versatile building materials. It shapes façades, load-bearing walls, vaults and interior walls in new construction as well as in existing buildings. In deconstruction, refurbishment and when creating openings, brick masonry presents particular requirements: it is strong in compression but brittle, and the joints are often weaker than the brick. For selective separation and controlled removal, hydraulic tools are therefore often used. In many situations, concrete pulverizers (concrete crushers) and hydraulic wedge splitters—depending on the wall build-up—can be used in a targeted manner to work with low vibration levels, precisely, and with reduced dust exposure.
Definition: What is meant by brick
Brick refers to a masonry unit made of fired clay or clayey raw materials. Bricks are fired at high temperatures and thereby achieve their characteristic strength and durability. They are manufactured as solid bricks or perforated bricks (high-perforation bricks) and used as facing bricks (e.g., clinker) or as backing bricks. The decisive product properties—such as bulk density, compressive strength, water absorption and frost resistance—are described in standards. In the structure, bricks are bonded with mortar to form masonry; the load-bearing behavior results from the interaction of brick and joint.
Manufacturing, properties and formats of bricks
Bricks consist predominantly of clay, loam and mineral aggregates. After shaping (extrusion, hand-molded, pressed brick) they are dried and fired at about 900–1,200 °C. Modern perforated bricks are often made porous to reduce weight and improve thermal insulation. Key properties:
- Compressive strength classes: depending on the application, typically in the range of 6–20 N/mm² for masonry bricks, significantly higher for clinker bricks.
- Bulk density: influences load-bearing capacity, airborne sound insulation and heat storage capacity.
- Water absorption and frost resistance: decisive for exterior masonry and plinth areas.
- Fire performance: brick is non-combustible and temperature-resistant.
Common formats are NF, DF, 2DF, 3DF up to large-format precision bricks. Thin-bed mortar can improve dimensional accuracy and load-bearing behavior. Bond patterns (running, header, English bond) control load transfer and crack distribution, and joint types (struck, brushed, pressed) determine appearance and durability.
Load-bearing behavior and construction types of brick masonry
Brick masonry primarily carries compressive forces; tension and bending are limited by bond patterns, ring beams, lintels and supports. The mortar (lime, lime-cement, cement or lightweight mortar) acts as a load-distributing layer. Decisive for deconstruction and openings is the determination of material parameters (e.g., strength class, joint quality) as well as the load path in the existing structure. Mixed masonry can contain natural stone, slag blocks or concrete inclusions that influence the separation method.
Influence of perforation patterns and bulk density
High-perforation bricks with thin webs react more sensitively to localized impact stress. This argues for cutting or clamping methods with dosed pressure, as provided by concrete pulverizers. Solid bricks and clinker bricks withstand localized loads better, but can produce brittle fracture surfaces, which must be considered during sorting and when preserving exposed faces.
Brick masonry in deconstruction: selective, low vibration, source-separated
In deconstruction, brick walls are often dismantled selectively—for example during building gutting, partial demolition or when creating new openings. The goal is a low-vibration, controlled separation with the lowest possible dust and noise generation as well as source-separated separation of construction materials for recycling. Mechanical impact tools do accelerate removal, but can promote crack formation in adjacent areas and increase dust emissions. Hydraulic methods often allow a more precise approach.
Concrete pulverizers on brick masonry
Concrete pulverizers can—using adapted jaw geometry and dosing—clamp, crush or bite masonry off in segments. They are suitable for:
- opening wall areas (door, window openings) with temporary shoring and chip-free edge formation,
- removing facing walls or cladding shells with reduced vibration,
- separating mixed masonry when concrete inserts or mortar bridges are present.
Important are controlled feed, short strokes and working along the joints to limit spalling. Water spray systems help to bind dust. In interior spaces, compact, handheld units with a hydraulic power pack are advantageous, as they are low-emission.
Hydraulic wedge splitters in the brick context
Hydraulic wedge splitters are used primarily for concrete and rock. In the brick context they are useful when massive components are adjacent or embedded—for example foundations, concrete lintels, reinforced concrete supports or natural stone plinths. In practice, rock and concrete splitters perform low-stress splitting operations so components can be pre-loosened before brickwork is removed manually or with concrete pulverizers. This reduces transmission of vibration to sensitive facing brickwork, e.g., on listed façades.
Tools and methods at a glance
The choice of tools depends on wall build-up, accessibility and emission requirements:
- Concrete pulverizers: precise biting, clamping and crushing of masonry, suitable for partial demolition, openings and building gutting.
- Hydraulic wedge splitters: for adjacent concrete components, piers, plinths and mixed masonry; enable controlled pre-splitting without impact.
- Combination shears and multi cutters: cutting metal profiles, masonry anchors, rails and installations within brick walls.
- Steel shears and tank cutters: for special applications when steel components or containers are integrated in brick structures.
- Hydraulic power packs: supply the hydraulic tools; flow rate, working pressure and portability are decisive, especially in tight existing buildings.
Areas of application related to brick masonry
Brick is used in many construction tasks. The following application areas show how hydraulic cutting and splitting methods can be integrated.
Concrete demolition and special demolition
In mixed constructions made of concrete and brick, the concrete portions are first segmented—e.g., with concrete pulverizers—while brick walls are followed up with low vibration levels. Wedge splitters detach heavy concrete parts at supports to reduce loads before the brickwork is deconstructed. This minimizes vibrations and collateral damage.
Building gutting and cutting
In gutting works in existing buildings, low emissions are crucial. Hydraulic tools operate without gasoline exhaust and with a low noise level. Multi cutters and combination shears cut fittings, anchors and lines, while concrete pulverizers create wall openings. This protects adjacent masonry and facilitates source-separated sorting.
Rock excavation and tunnel construction
This area relates to brick only indirectly, for example at connections of tunnel structures to existing basements made of brick masonry. Wedge splitters reduce vibrations in rock, while adjacent brick structures are secured and adapted with controlled pulverizer work.
Natural stone extraction
Bricks do not occur in quarries. Relevance arises when natural stone façades and brick cladding appear together. Splitting and pulverizer work must be tuned to the different fracture mechanics of natural stone and brick.
Special applications
In sensitive environments—laboratories, clinics, museums—low-vibration methods are in demand. Controlled size reduction of masonry with concrete pulverizers and pre-splitting at heavy nodes help avoid operational disruptions and damage to collections or equipment.
Planning, investigation and process
Thorough investigation is the foundation for safe and efficient work in brick masonry. Good practice includes:
- Existing-structure analysis: construction age, brick type (solid brick, high-perforation brick, clinker), mortar type, bond patterns, any coatings and paints.
- Exposure and probing: test openings to determine layers, bond and inserts (e.g., steel, concrete, wood).
- Structural stability concept: temporary shoring, sequence of removal, load redistribution; for load-bearing walls a structural analysis by qualified personnel is required.
- Method selection: pulverizers, wedge splitters, cutting technology—matched to the building condition, emission targets and degree of reuse.
- Emission management: dust suppression (water spray system), extraction, compartmentation, noise control measures.
- Logistics and disposal: source-separated construction waste separation of brick rubble, mortar residues, metals and wood; short transport routes.
- Documentation: tracking of material flow, quality of separation, photo documentation.
Occupational safety, emissions and environment
Brick dust contains fine quartz-bearing particles; therefore respiratory protection, good ventilation and dust binding are essential. Water spray systems or adjusted cutting speeds reduce emissions. Noise control must be considered—even with quieter hydraulics. Coatings, plasters or joint sealants can contain hazardous substances; a preliminary indicative investigation is sensible. Measures must comply with generally accepted technical rules and regulatory requirements; they do not replace a case-by-case assessment.
From an environmental and resource perspective, source-separated separation is important. Depending on purity and regional requirements, brick rubble can be used as recycled aggregate. Facing bricks and clinker can in part be reused if they are removed with minimal damage. Low-vibration methods with concrete pulverizers and prior splitting of large components increase the chance of preserving material.
Typical damage and refurbishment techniques
Common damage patterns are frost spalling, salt exposure, cracks due to settlement and weathered joints. In refurbishment, damaged bricks are selectively replaced, joints renewed and moisture causes remedied. When creating openings in load-bearing brick walls, lintels or frames are installed; the masonry is locally removed in a controlled manner with concrete pulverizers or—where adjacent concrete components are present—after prior splitting. Reliable shoring and a step-by-step approach are indispensable.
Creating openings: gentle approach
For clean reveals, the joints are first followed, then brick courses removed segment by segment. Concrete pulverizers limit breakout and facilitate preserving exposed faces. For massive lintels or reinforced concrete inserts, pre-splitting can reduce loads before removal proceeds.
Standards, key values and quality assurance
Applicable technical rules govern bricks and masonry. Important aspects include the specification of strength classes, bulk density ranges, water absorption and requirements for mortar. For planning, deconstruction and conversion, assessment by qualified specialists is decisive. On-site tests (rebound, core drilling, probings) and visual inspections of joint quality safeguard the construction process. The information in this article is general in nature and does not replace a project-specific assessment.
Practice-oriented tips for tool selection
- Thin interior walls, sensitive facing surfaces: concrete pulverizers with fine dosing, work along joints, dust binding.
- Mixed masonry with concrete cores or lintels: pre-split first, then reduce the masonry in segments.
- Confined spaces, sensitive environments: compact hydraulic power units with low emissions, short hose runs, staged removal.
- Recycling target: remove bricks as intact as possible, mechanically separate mortar residues, record metals separately.
The methods mentioned can be implemented in practice with tools from Darda GmbH when adapted to component thickness, material and accessibility. Decisive are careful investigation, realistic sequence planning and consistent emissions and safety management.