Comprehensive refurbishment is a deep intervention in existing buildings in which the substance is preserved, but load-bearing and non-load-bearing components are selectively deconstructed, strengthened, or renewed. The focus is on structural stability, building physics, fire protection, and future-proof use. Especially in existing structures, low vibration levels, controlled demolition plays a central role. Tools such as concrete pulverizers and hydraulic rock and concrete splitters enable precise work in confined spaces, during ongoing operations, or in sensitive environments—typical situations for comprehensive refurbishment in the urban context.
Definition: What is meant by comprehensive refurbishment
Comprehensive refurbishment refers to the near-complete renewal of a building down to its load-bearing core structure. Frequently, fit-out elements, non-load-bearing walls, finishing trades, installations, and in some cases load-bearing elements are deconstructed, strengthened, or replaced. The goal is to restore or improve structural and technical quality for changed use, higher energy efficiency, improved airborne sound and fire protection, or the elimination of damage. Comprehensive refurbishment is to be distinguished from pure modernization (predominantly superficial measures) and from complete demolition (deconstruction down to the excavation pit). Essential are a sound as-built survey, structural analysis, and low-emission deconstruction using suitable methods.
Basic principles and goals of comprehensive refurbishment
Comprehensive refurbishments follow the principle of selective deconstruction: hazardous substances are recorded separately, components are separated by type for demolition sorting, structures are temporarily stabilized with shoring, and then specifically demolished or strengthened. Key goals are the preservation of valuable building substance, the reduction of noise, low vibration levels and dust, and the reusability of materials. Methods such as controlled crushing with concrete pulverizers or crack control using hydraulic wedge splitters support safe, quiet, and precise work in existing buildings.
Differentiation, triggers, and typical objectives
Triggers for comprehensive refurbishment include changed user requirements, energy upgrades, the remediation of structural damage (e.g., chloride contamination or concrete carbonation), new fire protection concepts, or the merging of rooms. Hazardous substance remediation (e.g., materials containing asbestos) and the adaptation of building services are also part of it. Objectives range from strengthening individual components to reorganizing the entire building core.
Construction process and phases of comprehensive refurbishment
A structured process minimizes risks, costs, and construction time. Typical phases:
- As-built survey: building diagnostics, probes, rebar location, material testing
- Planning and permits: structural analysis, fire protection, construction logistics, waste disposal logistics
- Building gutting: selective strip-out, utility isolation, construction waste separation
- Deconstruction/demolition works in the existing structure: openings, partial demolition, foundation demolition
- Strengthening: structural reinforcement, grouting, new load-bearing elements
- Rebuild of technical trades: pipe routing, shafts, systems
Investigations and planning as the foundation
Before interventions, plans must be reconciled with the actual condition. Locating reinforcement, utilities, and voids reduces surprises. Based on these findings, methods are selected: sawing and drilling techniques, controlled crushing with concrete pulverizers, or low-stress separations using hydraulic wedge splitters. In confined conditions, compact hydraulic solutions help.
Gutting and selective deconstruction
When removing non-load-bearing components, safety and the reduction of noise and dust are paramount. Hydraulic tools such as combination shears, multi cutters, and concrete pulverizers allow precise separation of metal, composite materials, and concrete. For massive components, hydraulic wedge splitters offer a low vibration levels alternative when impacts or explosives are excluded.
Methods of concrete demolition in existing structures
The choice of method depends on component thickness, reinforcement content, accessibility, emission limits, and scheduling. Methods are often combined to reduce emissions and release components in a controlled manner.
Concrete pulverizers: controlled crushing
Concrete pulverizers crush concrete locally through high shear and compressive forces. Advantages include low vibration levels, well-controllable fracture guidance, and reduced secondary damage to adjacent components. Typical applications are wall openings, removing slab edges, removing parapets, and the deconstruction of stairs in existing buildings. In combination with suitable power units, performance is adapted to the environment (indoor/outdoor).
Hydraulic wedge splitters: low-stress and explosive-free
For splitting, boreholes are made and controlled cracks are generated using the wedge principle or hydraulic cylinders (e.g., rock wedge splitter). The method is low vibration levels, low dust, and explosive-free. It is suitable for massive foundations, thick walls, column heads, and for work in sensitive areas. In basements or densely built neighborhoods, components can be released piece by piece—an advantage in special demolition.
Cutting and separating components
Wall saws, wire saws, and core drilling are often combined with hydraulic tools. Multi cutters and tank cutters separate plates, lines, and vessels; steel shears cut reinforcement and sections. This combination enables clean joints and safe lifting operations before components are finally treated with concrete pulverizers or by splitting.
Combination shears and steel shears for metal deconstruction
Combination shears combine cutting and crushing for mixed materials. Steel shears are suitable for beams, reinforcement, and anchors. In plant rooms and shafts, steel structures can thus be selectively removed, simplifying the subsequent concrete work.
Hydraulic power packs and energy supply
Hydraulic power packs deliver the required performance for pulverizers, shears, and splitting cylinders. Indoors, low-emission, quiet power units are advantageous; outdoors, more powerful variants can be used. Important are adequate hydraulic hose line lengths, pressure/flow matching, and safe hose routing. This keeps tools efficient and controllable.
Safety, emissions, and structural stability
Safety begins with temporary stabilization: underpinning, shoring, and load transfer must be planned before deconstruction. Vibrations, noise, and dust must be minimized; water spray system, dust extraction plant, and encapsulation help achieve this. For sensitive neighboring buildings, low vibration levels methods such as hydraulic wedge splitters or concrete pulverizers help. Statements regarding permits, occupational safety, and environmental requirements must be made project-specifically and in compliance with applicable rules.
Application areas in comprehensive refurbishment
Comprehensive refurbishment integrates various application areas that dovetail seamlessly in planning and execution.
Concrete demolition and special demolition
Partial preservation of the structure while creating openings requires precise methods. Concrete pulverizers crush components in a controlled manner, while hydraulic wedge splitters release massive elements with low vibration levels. In this way, even thick components can be divided into transportable pieces. Further guidance is available under concrete demolition and special deconstruction.
Gutting and cutting
In gutting, fit-out components, pipe routing, and metal components are separated. Multi cutters, tank cutters, combination shears, and steel shears ensure clean cut edges and safe dismantling before load-bearing components are processed.
Rock excavation and tunnel construction
In the course of underpinning, new elevators, or deep pits, rock or very hard concrete may be encountered. Splitting methods prove their worth in these situations because they work quietly and in a controlled manner, protecting the surroundings.
Natural stone extraction
The splitting technique originates from natural stone extraction. This know-how is valuable in existing structures when natural stone masonry is to be selectively released or supplemented. Splitters guide cracks along desired lines—an advantage when preserving visible stone surface.
Special operations
In hospitals, laboratories, or operating office buildings, limits for noise and vibrations are strict. Hydraulic tools and splitting methods enable work in existing structures with reduced emissions, short shutdown times, and high process reliability.
Sustainability and resource conservation
Selective deconstruction promotes reuse and recycling. Lower vibrations protect the remaining substance, reduce consequential damage, and avoid unnecessary material use. The targeted use of concrete pulverizers and hydraulic wedge splitters reduces energy demand and transport volumes because components are separated where it makes structural sense.
Selecting suitable methods
For economical and safe execution, a methodical assessment is recommended:
- Component geometry: thickness, reinforcement ratio, accessibility
- Environmental requirements: limits for noise, dust, and vibrations
- Structural stability: required intermediate states and shoring
- Logistics: piece weights, lifting points, transport routes
- Schedule and cost: cycle, parallelization, material flows
Often, the combination is decisive: separation cuts for clear load paths, followed by crushing with concrete pulverizers and, where necessary, low-stress splitting of massive zones.
Practical examples and typical work steps
Example: Opening in a reinforced concrete wall
- Investigation and structural analysis: locate reinforcement, plan load transfer, install temporary shoring.
- Preparation: set up dust suppression and water spray system, encapsulate the work area.
- Separation cuts/core drilling: define the opening and protect adjacent areas.
- Crushing: release remaining areas in a controlled manner with concrete pulverizers, cut reinforcement with steel shears.
- Edge finishing: rework for installing new lintels or frames.
Example: Removing a foundation block in the basement
- Check access and load-bearing capacity, ensure protection of the surroundings.
- Plan boreholes: define grid and depth according to block dimensions.
- Splitting: use hydraulic wedge splitters or rock wedge splitter, guide cracks in a targeted manner.
- Segmenting: lift pieces, cut remaining reinforcement with steel shears.
- Haulage: short routes, construction waste separation, clean construction site with efficient haulage logistics.
Documentation and quality assurance
Measurement logs, photo documentation, and ongoing coordination between execution and planning ensure quality. Material certificates, disposal documentation, and structural approvals are part of complete deconstruction documentation. Success factors are transparent sequencing, defined interfaces, and clear responsibilities.
Common sources of error and how to avoid them
- Insufficient investigation: leads to hits on utilities and reinforcement—thorough locating prevents stoppages.
- Missing planning for intermediate states: always verify and secure temporary load-bearing capacity.
- Unsuitable methods: in sensitive areas, prefer low vibration levels methods such as concrete pulverizers and splitting devices.
- Inadequate emission control: define dust, noise, and water management at an early stage.
- Underestimated logistics: define piece weights, lifting points, and disposal routes in advance.
Legal framework at a glance
Permits, occupational safety, and environmental and disposal rules must be observed on a project-specific basis. These include requirements from the construction code, fire protection and emission control, as well as specifications for the waste management chain with separate recording of material streams. Schedules, quiet hours, and neighbor protection must be coordinated early. The statements are to be understood in general terms and do not replace project-specific review.