Concrete processing comprises all work carried out on concrete and reinforced concrete for production, adaptation, repair or deconstruction. It ranges from precise cutting through targeted splitting to controlled crushing. At the center are methods that influence the composite of cement paste, aggregate and reinforcing steel safely, efficiently and with the lowest possible emissions. In practice, hydraulic systems are frequently used — such as concrete pulverizers or rock and concrete splitters — which, in combination with hydraulic power packs, operate powerfully and in a controlled manner. Concrete processing takes place across diverse application areas, including concrete demolition and special demolition, building gutting and concrete cutting, rock excavation and tunnel construction, natural stone extraction as well as special applications in the industrial context.
Definition: What is meant by concrete processing
Concrete processing refers to the targeted modification of concrete components by cutting, splitting, breaking, crushing, milling, drilling or surface treatment. The aim is either to create openings, adapt geometries, expose reinforcement, perform controlled dismantling as part of selective deconstruction, or economically remove larger cross-sections. The methods are guided by member thickness, the reinforcement density, the environmental conditions (noise, vibration, dust) as well as structural and logistical boundary conditions. Hydraulic tools — such as concrete pulverizers, combination shears, multi cutters, steel shears and rock and concrete splitters with suitable hydraulic wedge splitter — are established solutions when robust, repeatable and low vibration levels processing is needed.
Physical principles of concrete processing
Materials behavior is crucial for choosing the appropriate method: concrete is strong in compression but weak in tension; reinforcing steel carries tensile forces and ensures ductility. Processing methods leverage these properties — relying on compressive and wedge effect during splitting or on shear and bending loads during gripping and breaking.
Concrete and steel in composite
In reinforced concrete, the bond between reinforcement and cement matrix ensures load transfer. During deconstruction, concrete and steel often need to be separated. Concrete pulverizers break the concrete and cut the exposed reinforcing steel. Steel shears support the work when larger sections of reinforcing steel or profiles must be cut. When splitting with hydraulic wedge splitter, the wedge effect opens microcracks that propagate into defined separation planes — ideal for massive, lightly reinforced members.
Influencing factors on processability
- Strength class and age of the concrete (higher strength demands higher splitting or cutting forces)
- Reinforcement density and arrangement (dense reinforcement mesh requires cutting- and shear-capable tools)
- Member thickness and accessibility (massive concrete foundation vs. slender walls)
- Environmental requirements (vibration, noise, dust, water handling)
- Structural boundary conditions (residual load-bearing capacity in the existing structure, shoring, sequence of steps)
Methods and procedures: cutting, splitting, crushing
Concrete can be processed in different ways. In practice, methods are often combined to work with low emissions, quickly and selectively. Hydraulic systems with suitable tool geometry are central building blocks.
Hydraulic splitting with rock and concrete splitters
During splitting, hydraulic wedge splitter generate very high transverse tensile stresses in the member via wedges. The separation plane follows borehole lines and material weaknesses and enables a low vibration levels opening of massive cross-sections. Typical applications are foundations, bridge bearings, block and rock removal, thick walls and natural stone extraction. Hydraulic power packs provide the necessary energy; the splitting action is precisely controllable and can be repeated section by section.
Gripping, shearing and breaking with concrete pulverizers
Concrete pulverizers combine crushing and cutting forces. They size-reduce concrete bodies and sever reinforcement; combination shears and multi cutters broaden the scope to different material combinations. For reinforced members, separation cuts in slabs and walls, and for preparing transportable pieces, this method is particularly suitable. Steel shears are used in addition when massive steel profiles or tightly bundled reinforcement must be cut.
Cutting and preparatory separation
Sawing and drilling (for example, for openings or anchor points) are often combined with hydraulic splitting or work with concrete pulverizers. In special deployments — for example during the deconstruction of plants — a cutting torch can play a role for safely cutting steel plates, while adjacent concrete foundations are processed with pulverizers or splitting technology.
Application areas and typical uses
Concrete demolition and special demolition
In selective deconstruction, substance is removed in a structured way. Concrete pulverizers are suitable for breaking members in a controlled manner and severing reinforcement; rock and concrete splitters open massive cross-sections without blasting. This reduces vibrations, protects adjacent members and yields separated fractions for recycling.
Building gutting and cutting
In existing structures, accessibility and restrictions on dust and noise are paramount. Pulverizers enable targeted removal inside buildings; splitting technology offers advantages when nearby inhabited areas or sensitive installations must be protected. Multi cutters and steel shears support the separation of non-concrete components and exposed steel parts.
Rock excavation and tunnel construction
Splitting technology transfers from concrete to rock: hydraulic wedge splitter create separation surfaces in rock where blasting works are not possible or not desired. In tunnel and adit work, blocks can be released in a controlled way and recovered safely. The combination with pulverizer work facilitates size reduction for removal.
Natural stone extraction
In natural stone extraction, the quality of the fracture surface is decisive. Splitters enable the defined release of blocks along drill rows with high reproducibility. Downstream size-reduction steps can be performed with concrete pulverizers or shears to achieve formats suitable for transport and processing.
Special application
In industrial plants, at infrastructure nodes or on tight construction sites, tailored combinations are required: a cutting torch separates plates, while pulverizers and splitting technology process adjacent concrete members. The advantage lies in the controllability of forces and the reduced introduction of vibrations into sensitive environments.
Tool systems and hydraulics
Hydraulic tools unfold their performance in coordinated systems. These include hydraulic power packs as the energy source, hydraulic hose lines and quick couplings as well as the actual attachments or handheld tools. Careful selection and maintenance are crucial for safety, performance and service life.
Hydraulic power packs
Hydraulic power packs provide the required flow rate and pressure. Important aspects are power supply, pressure regulation, temperature management and compatibility with the connected tools. Short hose runs, reliable quick couplings and clean hydraulic fluid improve response speed and minimize downtime.
Planning, preparation and execution
- Survey of existing conditions: clarify material, reinforcement, utility lines, supports, joints and load paths.
- Method selection: weigh criteria such as member thickness, reinforcement density, accessibility, emissions and construction logistics.
- Deconstruction concept: set the sequence, plan shoring, organize removal and material storage.
- Occupational safety and environment: dust suppression and noise reduction measures, ground vibration monitoring, management of media (water/oil).
- Execution: establish drilling patterns, plan splitting cycles, coordinate pulverizer and shear work, protect cut edges.
- Follow-up: separate concrete and steel, clean surfaces, check quality, document disposal/recycling.
Documentation and quality assurance
Visual inspection of fracture surfaces and cut edges, monitoring of crack formation in adjacent members, measurements of vibrations and noise as well as complete work documentation ensure execution quality. This facilitates coordination with planning, site supervision and disposal companies.
Safety, health and environment
Concrete processing requires prudent action. The applicable regulations must be observed; protective measures are to be defined project-specifically. The aim is to minimize risks and conserve resources.
- Personal protective equipment and trained operation of the hydraulic systems
- Dust suppression and noise reduction measures, monitoring of vibrations in sensitive environments
- Media management: avoid leakage, safe handling of hydraulic fluid and water
- Consider hazards from residual stresses in members and spring-back
- Selective separation of fractions for high-quality recycling
Performance metrics and selection criteria
The appropriate method results from a structured assessment. In addition to performance and precision, emissions, occupational safety and site logistics count.
- Member geometry: thickness, length, bearing, accessibility
- Material mix: concrete strength, reinforcement density, inlays (e.g., utility lines)
- Emission requirements: vibrations, noise, dust, water
- Cycling: removal rate per shift, coordination of trades
- Post-processing: separation quality, purity for construction waste separation for recycling
Practical guidance for tool selection
For massive, lightly reinforced members, rock and concrete splitters with hydraulic wedge splitter offer a low vibration levels solution. For reinforced concrete and selective deconstruction, concrete pulverizers have proven themselves, complemented by hydraulic demolition shear or multi cutters for mixed materials. Steel shears are sensible when concentrated steel cross-sections must be cut. In specific industrial applications, a cutting torch can segment steel tanks, while adjacent concrete is removed with pulverizers or splitting technology.
Tools and systems from Darda GmbH are used in these contexts when robust hydraulics, controllable forces and reproducible results are required. Decisive are expert planning and safe, emissions-conscious execution — from the first borehole to the final cut.