A cement plant is the heart of the mineral building materials industry: this is where clinker is produced from limestone, clay, marl, and corrective materials, and cement is made from it. The installations are complex, the processes energy-intensive, the structures massive—from the preheater tower and rotary kiln and cooler to large silos and conveyor halls. Over the life cycle of a cement plant, construction, operation, maintenance, refurbishment, and deconstruction all play an equal role. Especially when intervening in concrete and reinforced-concrete structures, precise, low-vibration methods have proven themselves. Tools such as concrete demolition shears or hydraulic rock and concrete splitters from Darda GmbH enable controlled work in sensitive areas, for example in concrete demolition and special demolition, in building gutting and cutting, as well as in special applications.
Definition: What is meant by a cement plant
A cement plant is an industrial facility for the production of cement. Core processes are raw material extraction and preparation, raw meal grinding, thermal decarbonation and sintering in the rotary kiln (clinker formation), clinker cooling, and subsequent cement grinding with the addition of gypsum and other main constituents. Cement plants comprise process-engineering units (crushers, mills, cyclone preheater, calciner, kiln, cooler), extensive storage and conveying systems, and expansive concrete and steel structures such as foundations, towers, ducts, and silos.
Structure and process chain in the cement plant
The process chain in a cement plant proceeds in clearly defined stages—from quarrying the limestone to shipping the cement. Each stage places specific demands on operation, maintenance, and, where applicable, deconstruction.
Raw material extraction and primary crushing
Within the integrated works with the quarry, production begins with natural stone extraction. Limestone and clayey components are loosened, crushed, and prepared for further processing. In addition to conventional extraction methods, hydraulic splitters from Darda GmbH can offer a low-vibration alternative for oversized boulders or in sensitive zones—such as when vibrations must be avoided or noise levels kept low. Such devices are also used in rock excavation and tunnel construction when low vibration and precision are paramount.
Homogenization and raw meal
After primary crushing, the raw materials are proportioned and blended. Raw meal grinding takes place in ball or vertical mills, followed by silo homogenization. Regular maintenance on hoppers, discharge systems, and silo cones occasionally requires controlled concrete removal—this is where concrete demolition shears prove themselves for selective corrections without unnecessarily stressing load-bearing components.
Preheater, calciner, and rotary kiln
In the multistage cyclone preheater, the raw meal is preheated, decarbonated in the calciner, and sintered to clinker in the rotary kiln. The structures are exposed to high temperatures, chemical attack, and dynamic loads. During refurbishments—for example, replacing worn linings or opening inspection openings—precise, low-vibration separation and demolition methods are crucial. Concrete demolition shears enable targeted removal of formwork, concrete layers, or anchor zones on kiln foundations and on the preheater tower, while building gutting and cutting of steel sheets, ladders, and platforms are carried out with combination shears or steel shears.
Clinker cooling and transport
After the kiln, the clinker is rapidly brought down to process temperature in the cooler and transported via conveyors, bucket elevators, and chutes. Deposits in ducts, build-ups, and wear on linings occasionally necessitate mechanical intervention. Local openings in duct sections or removal of linings are achieved with accurate cutting and shear techniques that minimize sparking and dust.
Cement grinding, storage, and dispatch
In the grinding process, clinker is ground with gypsum and other main constituents to standardized cement. In mill buildings, filter houses, and silo structures, controlled concrete and steel processing are typical maintenance tasks. Concrete demolition shears are suitable for selectively trimming concrete ribs or breakout edges, while Multi Cutters and combination shears deliver safe, controllable cuts on railings, grates, and support frames.
Structural installations in the cement plant: special requirements during interventions
The structures of a cement plant are massive and often heavily reinforced. Adjacent installations must also be protected during interventions. This results in special requirements for methods, tool selection, and sequence planning.
- Silos and silo cones: Selectively opening clogged discharges or replacing linings can be carried out in a controlled, low-vibration manner with concrete demolition shears.
- Foundations, pedestals, and machine platforms: For strengthening or partial deconstruction, hydraulic splitters facilitate separating thick concrete members without affecting surrounding equipment.
- Ducts, filter housings, and sheet-steel constructions: For precise cuts in sheet and structural steel, steel shears, combination shears, and Multi Cutters are used; tank cutters are suitable for vessels and pipelines with greater wall thicknesses.
- Reinforced concrete structures: In concrete demolition and special demolition within existing structures, concrete demolition shears allow removal while simultaneously exposing and separating the reinforcement.
Maintenance, refurbishment, and deconstruction in the cement plant
Shutdowns and partial shutdowns are demanding: time windows are tight, and the requirements for occupational safety, dust suppression, and noise control are high. Methods with low vibration and low emissions increase process safety and protect adjacent equipment.
Selective concrete removal in existing structures
Concrete demolition shears are ideal for selectively removing concrete cover, local spalls, edge corrections, and exposing reinforcement. In building gutting and cutting, combination shears support rapid separation of exposed rebar and built-in components; compact hydraulic power units from Darda GmbH provide the required power supply with a compact footprint.
Massive cross-sections and controlled splitting
For thick foundations, pedestals, or massive beams, hydraulic splitters create calm, repeatable separations via borehole splitting. Especially in special applications where vibrations or sparking must be avoided, splitting offers advantages over percussive or thermal methods.
Steel components, vessels, and piping
For sheet-metal ducts, steel frameworks, silo internals, and pipelines, steel shears, combination shears, and tank cutters have proven effective. The functional focus is on precise, controlled cuts with predictable chip and remnant sizes—an advantage in confined spaces and crane logistics.
Planning a plant shutdown: steps for efficient interventions
A structured approach shortens downtime and increases execution safety—from isolation to handover.
- Survey and isolation: Separate utilities, secure plant areas, define access and escape routes.
- Dust suppression and fire prevention: Extraction, water misting, shielding; reduce fire loads.
- Separation cuts and demolition sequence: Proceed from lightweight construction to the load-bearing structure; consider load redistribution.
- Lifting, transport, and disposal: Crane and lifting-gear scheduling, routing, sorting of materials.
- Documentation and quality assurance: Component releases, measurement records, visual inspections, and touch-ups.
Safety, dust, and emissions control
In cement plants, occupational safety and emissions reduction are priorities. Dust explosion protection, hot-work permits, and access control are integral components of responsible planning. Methods with low spark generation, reduced vibration, and minimized dust development support these goals.
- Dust minimization: Extraction, water mist, and controlled removal rates.
- Low-vibration methods: concrete demolition shears and hydraulic splitters reduce impacts on adjacent equipment.
- Safe cutting operations: Suitable cutting and shear systems and certified hydraulic power units with reliable controllability.
- Work environment: Adequate ventilation, clearance measurements, permits, and clear team communication.
Sustainability and energy efficiency in the cement plant
Cement plants reduce energy demand through efficient mill technology, heat recovery, and the use of alternative fuels; the clinker factor is reduced by suitable main constituents. In building upkeep and deconstruction, precise, material-conserving interventions contribute to less waste, fewer secondary damages, and improved recyclability. Tools such as concrete demolition shears support selective removal that enhances the separation between concrete and reinforcement.
Tool and method selection in the cement plant
The choice of the appropriate method depends on member thickness, degree of reinforcement, accessibility, environmental conditions, and requirements for noise, dust, and vibration. A clear delineation of work steps (separating, removing, lifting, disposing) improves schedule and cost reliability.
- Thick, heavily reinforced components: controlled splitting with hydraulic splitters to reduce vibrations.
- Selective demolition of concrete with visibility to reinforcement: concrete demolition shears for precise removal edges and fewer follow-on damages.
- Steel and mixed constructions: combination shears, steel shears, and Multi Cutters for profiles, sheets, and built-ins.
- Vessels and pipelines: tank cutters for defined separation cuts on round cross-sections.
- Power supply: compact hydraulic power units from Darda GmbH for mobile, controlled work.
Typical application areas in the cement plant
Practical applications group along established areas of use:
- Concrete demolition and special demolition: partial deconstruction of foundations, pedestals, silo cones, and machine platforms with concrete demolition shears and hydraulic splitters.
- Building gutting and cutting: removal of steel platforms, railings, ducts, and built-in components using combination shears, steel shears, and Multi Cutters.
- Rock excavation and tunnel construction: low-vibration loosening of rock in raw material extraction with hydraulic splitters.
- Natural stone extraction: controlled splitting of large-format limestone blocks for better processing.
- Special applications: work in sensitive areas with strict emission or vibration limits, where splitting and shear-based methods offer advantages.