Dismantling logistics describes the planned organization of selective deconstruction—from safe disassembly through sorting and haulage to the recycling of the resulting material flows. It combines technology, schedule control, and occupational safety into a structured process that works equally in buildings, industrial plants, tunnels, and rock. Particular emphasis is placed on low-emission methods, such as controlled splitting and the cutting of reinforced concrete. In practice, this means: tools such as concrete pulverizers or hydraulic wedge splitters are not considered in isolation, but as components of a coordinated logistics chain—including hydraulic power units, material flow, intermediate storage, and disposal.
Definition: What is meant by dismantling logistics
Dismantling logistics refers to the totality of all measures for planning, controlling, and executing dismantling and deconstruction works, including material and information flows. This includes recording the existing conditions, defining separation and disassembly concepts, providing personnel and equipment as needed, managing material flows, safe on-site transport, intermediate storage, and organized haulage for recycling or disposal. Dismantling logistics creates clear interfaces between deconstruction, building gutting and cutting, concrete demolition and special demolition, rock excavation and tunnel construction, as well as special operations. The goal is a safe, efficient, and low-emission sequence with high material purity.
Tasks and objectives of dismantling logistics
The central tasks are structuring the work steps, minimizing risks and emissions, and safeguarding schedule and quality. In buildings, infrastructure structures, and industrial plants, this particularly means:
- Developing separation concepts (e.g., splitting instead of impact work, using shears/pulverizers instead of large-scale destruction)
- Planning material flows (concrete, steel, non-ferrous metals, wood, mineral constituents, potentially hazardous substances)
- Selecting equipment and tools to suit member thickness, reinforcement, and surroundings
- Defining access points, load-bearing capacity, and transport routes
- Organizing intermediate storage, container logistics, and haulage logistics
- Ensuring occupational safety, noise, dust, and vibration control
- Structuring documentation, proof, and quality assurance
An essential objective is to reduce vibrations and secondary damage. Concrete pulverizers and hydraulic wedge splitters play an important role here, as they enable controlled separation cuts and splitting operations with high precision and thus separate material types more cleanly.
Planning: From the survey to takt scheduling
Every dismantling logistics concept starts with a sound survey and a disassembly concept. Building on this, the sequence is divided into takts so that personnel, tools, and transports work together rhythmically and with minimal disruption.
Survey and separation concepts
- Recording member thicknesses, reinforcement, stress directions, and embedded components
- Identifying utility runs, lines, residual energies, and residual risks
- Material flow analysis (fractions, purity levels, potential contaminants)
- Selection of suitable separation and splitting methods with the lowest possible emissions
For massive members and noise-sensitive environments, splitting methods are often planned. Hydraulic wedge splitters reduce vibrations and facilitate subsequent sorting. For wall- and slab-adjacent elements with reinforcement, the use of concrete pulverizers is advisable; they bite off the concrete and expose the steel.
Takt scheduling and construction sequence
- Expose and strip out (non-load-bearing components, claddings, installations)
- Prepare separation joints or borehole grids for splitter cylinders
- Splitting or pulverizer/shear use for controlled disassembly
- Cut off and bundle the reinforcement
- Sort, intermediate store, and haul away by fractions
Access, load-bearing capacity, and routes
The load-bearing capacity of routes, slabs, and secondary beams must be clarified in advance. Hydraulic power packs are to be positioned to minimize hose lengths, pressure losses, and changeover times. Bottlenecks, escape routes, and crane lifts must be factored into the takt.
Processes and material flow in deconstruction
Dismantling logistics directs material and information from the intervention point to recycling. A clear flow avoids crossings, waiting times, and contamination.
- Selective deconstruction on the member (pulverizer or splitting process)
- Initial sorting at the source (e.g., separating the steel directly after the pulverizer’s bite)
- Transport to the defined intermediate storage (short routes, clear labeling)
- Fine sorting, size reduction as needed, weighing, and documenting
- Loading, haulage, and proof
Tools such as concrete pulverizers increase separation precision directly at the source, as concrete and reinforcement can be separated in one step and continued in separate flows. Hydraulic wedge splitters produce reproducible break edges that are easier to grab, lift, and stack logistically.
Equipment selection and deployment strategy
The choice of equipment is based on member thickness, reinforcement level, environmental sensitivity, and accessibility. In dismantling logistics, the equipment is embedded in an overall system that considers takt times, noise and vibration values, and material quality.
- Concrete pulverizers: Selective biting/crushing of reinforced concrete, exposing and separating reinforcement; suitable for slab edges, walls, beam ends, and areas with sensitive emission limits.
- Hydraulic wedge splitters with rock splitting cylinders: Controlled splitting of massive members or rock; ideal in noise-sensitive areas, in tunnels, and where low vibration levels are required.
- Hydraulic power packs: Power supply for pulverizers, shears, and splitter cylinders; sized according to throughput, line length, and parallel operation.
- Combination shears and Multi Cutters: Versatile cutting and gripping for mixed materials and installations.
- Steel shears: Cutting structural steel, pipes, and beams; useful after exposing reinforcement or when dismantling steel structures.
- Cutting torch: Cutting work on steel tanks and vessels, used under strict safety rules, preferably after complete emptying, cleaning, and clearance measurements.
A typical strategy combines splitting steps for volume reduction with pulverizer or shear work for clean separation and dimensional accuracy. This keeps material fractions clean, and the logistics can handle the fractions without multiple handling.
Application areas and interfaces
Dismantling logistics ties the deployed methods to the respective environment and its requirements.
Concrete demolition and special demolition
For load-bearing members, controlled disassembly is paramount. Hydraulic wedge splitters reduce vibrations, while concrete pulverizers expose and separate reinforcement. Special demolition often requires staged work with close monitoring of settlements and vibrations.
Building gutting and cutting
Before demolition, interior trades are removed and members are prepared. Multi Cutters and combination shears support mixed materials. Concrete pulverizers perform precise separations on reinforced concrete members before steel shears cut sections and reinforcement to size.
Rock excavation and tunnel construction
Hydraulic rock and concrete splitters create defined separation joints that make onward conveying of material easier. Logistics focuses on short routes, safe intermediate storage, and reliable power supply to the hydraulic power packs.
Natural stone extraction
In natural stone extraction, controlled splitting increases block quality and reduces rejects. Dismantling logistics ensures organized haulage, labeling by grades, and segregated storage.
Special operations
In sensitive areas—such as listed structures, plants with residual media, or confined inner-city sites—precise, low-vibration methods are required. Concrete pulverizers and splitter cylinders allow a measured approach with high separation precision and plannable takt times.
Occupational safety, environment, and permits
Dismantling logistics integrally considers safety and environmental protection. Requirements for dust, noise, vibrations, water, and fire protection must be reflected in the planning and continuously monitored during execution. Legal and regulatory requirements must be observed depending on the project situation. Statements here are of a general nature and do not replace case-by-case review.
- Clarify safety zones, fall protection, load and crane geometries
- Document hazard analyses, briefings, permits, and clearance measurements
- Minimize emissions (e.g., via splitting and pulverizer/shear techniques, wetting, protective enclosure)
- Label waste fractions, maintain proofs, ensure purity levels
- Check equipment condition (pressure, hoses, jaws, cylinders), coordinated with takt times
Transport, intermediate storage, and disposal
Material purity and short routes determine logistic success. Fractions are separated early, clearly labeled, and stored to exclude contamination and mixing.
- Early separation at the source (concrete, concrete with reinforcement, steel, non-ferrous metals, wood, mineral residues)
- Plan intermediate storage according to load-bearing capacity and accessibility
- Schedule container logistics and haulage windows
- Select recovery routes according to regional options
- Weigh, document, and create proofs
The concrete pulverizer creates clean fractions at the source, while the use of hydraulic wedge splitters reduces fines from breakage. Both simplify loading, weighing, and proof.
Digitization and documentation
Model-based planning, structured checklists, and digital logs increase transparency and controllability. Component catalogs, takt plans, equipment operating times, measurements of vibrations and noise emission, as well as material flow data are recorded continuously. This helps to size hydraulic power packs to demand, plan maintenance, and detect bottlenecks early.
Key figures and quality assurance
Key figures support the control of dismantling logistics. Important metrics include throughput per takt, waiting times, rework rate, fraction purity, vibration and noise values, and accident-free performance. Test plans define acceptance criteria, such as:
- Borehole spacing and split pattern (splitter cylinders) within defined tolerances
- Jaw wear and cutting quality (concrete pulverizer, shears) documented
- Fraction purity in intermediate storage above defined minimum values
- Transport times and haulage punctuality within the permitted corridor
Typical mistakes and practical solutions
- Unclear material flows: Introduce early separation with pulverizer/splitter directly at the member, standardize labeling.
- Undersized hydraulic power packs: Calculate power demand per takt, include reserves.
- Bottlenecks on transport routes: Define one-way traffic, buffer areas, and fixed time slots.
- Excessive emissions: Prioritize splitting methods and pulverizer/shear technology; reinforce enclosures, wetting, and monitoring.
- Lack of takt scheduling: Create smaller, defined work packages; standardize equipment changeovers.
Practical example: Selective deconstruction of a reinforced concrete slab
- Remove coatings and non-load-bearing layers (strip-out)
- Mark the grid field, make the boreholes for hydraulic wedge splitters
- Split the slab into manageable segments with defined break edges
- Grab the segments and bite off the concrete with the concrete pulverizer, expose reinforcement
- Cut the exposed steels with steel shears or Multi Cutters
- Initial sorting at the intervention point, separate haulage of concrete and steel
- Fine sorting at intermediate storage, weighing, and documentation
- Loading by fractions and haulage to recycling
The takt follows equipment availability and haulage windows. Hydraulic power packs are positioned to keep hose runs short and enable quick changeovers between pulverizer, shear, and splitter cylinder.