Dust extraction plants are a central element for low-dust deconstruction, demolition and the extraction of mineral raw materials. Wherever concrete, stone, masonry or steel is processed, cut or crushed, dust, fine dust and sometimes quartz-bearing particles are generated. In conjunction with tools such as concrete demolition shears or stone and hydraulic rock and concrete splitters, and in application areas such as concrete demolition and special deconstruction, building gutting and cutting, or rock breakout and tunnel construction, the right dust extraction technology ensures better visibility, protection of personnel, less contamination of the surroundings and controlled construction logistics.
Definition: What is meant by a dust extraction plant
A dust extraction plant is a technical system for capturing, separating and safely removing airborne dusts. It typically consists of a capture device (for example hoods, suction nozzles or rings), a flow and conveying path (hoses, pipework), a fan to generate negative pressure, and a separation unit (dry filter, cyclone, wet separator). The goal is to capture dust as close as possible at the point of origin, to reduce the concentration of fine dust, and to safely collect separated substances. In the context of mineral construction materials, the focus is often on reducing quartz-bearing fine dust, for example during crushing, pressing or splitting of concrete and natural stone.
How it works and main components of a dust extraction plant
Dust extraction plants operate on the principle of point-source extraction: dust is captured where it is generated, guided via a defined airflow to separation, and then returned to the work area as clean air or discharged in a controlled manner. Fit-for-purpose design takes source, particle sizes, volumetric flow rate, pressure drop and the required separation efficiency into account.
Capture directly at the process
The most effective strategy is near-source capture. With concrete demolition shears, dust is generated primarily when the concrete is crushed and when cracking near the reinforcement; hoods, lateral suction rings or flexible suction hoses at the point of action significantly reduce emissions. With hydraulic rock and concrete splitters (including rock wedge splitters), dust is produced in particular when drilling the holes for wedges or cylinders; here, drilling dust extraction with sealing lips or drill-bit rings is appropriate. The actual hydraulic splitting usually produces less fine dust; however, secondary breakage or sorting can again release particles, which should also be captured at the point source.
Fan and flow engineering
The sizing of the fan is based on the required air volume flow and the total pressure drop of the system. Smooth hose and pipe runs, short paths, generous radii and aerodynamic fittings reduce losses. A stable negative-pressure condition is important to reliably handle fluctuating emissions during varying process steps (cutting, splitting, lifting).
Separation: dry, mechanical or wet
Depending on the dust type, different processes are combined for separation:
- Cyclone as a pre-separator for coarse particles and spark pre-separation.
- Cartridge or bag filters as dry filters for high separation efficiency even with fine dust.
- Wet separators when moist, sticky or hard-to-filter dusts occur, or when additional dust binding with water is beneficial.
For very fine fractions, highly efficient filter stages are advisable; the selection is guided by the aim of minimizing respirable particles.
Filter cleaning and service life
Automatic cleaning (for example compressed-air pulse) stabilizes the differential pressure and increases service life. An easily accessible dust collection point and tight containers facilitate safe changeover and disposal.
Monitoring and control
Key measured variables are differential pressure across the filter, volumetric flow and negative pressure. Step or frequency control adapts performance to changing processes, for example when switching between rough demolition with concrete demolition shears and precise cutting.
Applications and typical dust sources
Dust extraction plants accompany numerous steps along the process chain – from preparation to material logistics:
- Concrete demolition and special deconstruction: Crushing, breaking, separating – when using concrete demolition shears, combination shears or multi cutters, mineral dust is generated that should be extracted as close as possible at the tool edge.
- Building gutting and cutting: Drilling, sawing and cutting operations (wet or dry) produce fine dust; point extraction at core bits and sawing units reduces emissions indoors.
- Rock breakout and tunnel construction: In the underground environment, as in rock demolition and tunnel construction, airflow management with suitable negative pressure, flow-optimized guidance and filtration is central to ensure visibility and air quality.
- Natural stone extraction: Drilling, splitting and sorting generate varying dust fractions; mobile dust extraction plants at drilling stations and splitting stations improve workplace hygiene.
- Special applications: For special applications, for example with tank cutters or steel shears, metallic particles and fumes occur; suitable separators and spark pre-separators are important, especially in confined spaces.
Interfaces to tools and power units of Darda GmbH
Concrete demolition shears: low-dust crushing at the source
When crushing concrete with concrete demolition shears, the concrete matrix is mechanically crushed. Fine dust is released from cement paste and aggregates, sometimes quartz-bearing. Source-near extraction at the shear jaws, supplemented by a fine spray mist for dust binding, has proven effective indoors and in sensitive areas. The spray mist reduces dust release, while extraction captures the remaining load. Short suction paths and flexible hoses follow the movement of the shear without disrupting the workflow.
Stone and concrete splitters as well as rock wedge splitters: control drilling dust
Hydraulic splitting itself is low-dust, but drilling the holes generates fine drilling dust. Core bits with suction ring, tight contact surfaces and sufficient volumetric flow are crucial. After splitting, edge breaking and finishing can again release particles; mobile dust extraction plants within reach keep the work area clean.
Combination shears, multi cutters, steel shears and tank cutters
With metallic materials, mineral dust is less in focus than particulate emissions from chips, abrasion and sparks. Separation with spark pre-separators and robust dry filters protects filter media. In closed containers or confined spaces, particular care in airflow management is required; in general, controlled negative pressure and safe discharge of exhaust air are recommended.
Hydraulic power packs and periphery
Hydraulic power packs supply the tools; the dust extraction plant in turn requires a suitable power supply and placement so that the intake and discharge sides are positioned sensibly from a flow perspective. Separate placement minimizes mutual interference from heat and airflows.
Design and sizing: from the source to the clean airflow
The right design starts at the dust source and follows clear steps:
- Analyze dust sources: process, material, particle sizes, emission duration.
- Plan capture: hood shape, distance, approach velocity, tool movement radii.
- Determine volumetric flow: sufficient to reliably capture the dust plume; allow reserve for changing processes.
- Calculate pressure losses: line lengths, bends, fouling allowances, filter increase over service life.
- Select filter area and cleaning: suited to dust loading and fine dust fraction.
- Define airflow: recirculation or safe discharge; avoid short-circuiting of the flow.
- Review operating scenarios: interior vs exterior, changing work locations, mobility.
For work with a high proportion of fine dust, a high separation efficiency of the final stage is advisable. With changing processes, for example switching between concrete demolition shears and drilling work, stepless control helps adapt the extraction performance.
Filter media and separation efficiencies for mineral fine dusts
Mineral dusts differ in density, surface properties and hygroscopicity. Filter media with suitable surface treatment (for example membrane coating) reduce deep loading and facilitate cleaning. For very fine fractions, highly efficient final stages are common; what is important is a coherent overall concept of pre-separation, main filter and optional safety stage, so that high separation performance is combined with economical service life.
Quartz fine dust and workplace hygiene
Fine, respirable particles penetrate deep into the respiratory tract. Technical measures such as near-point extraction, sufficient negative pressure, suitable filter stages and orderly airflow are the foundation. Personal protective measures can also be advisable; these depend on the activity and local requirements.
Wet or dry dust extraction: selection by application
Wet separation binds particles in a water film and is robust against sparks and certain sticky dusts. However, sludge is produced that must be disposed of safely. Dry separation with cartridge or bag filters achieves very high separation efficiencies even with fine dust and allows dry, clean disposal of filter dust. The decision depends on the material, place of use (indoor/outdoor), temperature, water availability and desired maintenance effort.
Mobile, modular and stationary solutions
On changing construction sites, mobile dust extraction plants with a robust undercarriage, flexibly adaptable hoses and compact dimensions are in demand. In tunnels and large halls, modular systems with laid lines, distributed capture points and central separation have proven themselves. Stationary plants are used in depots, sorting or preparation areas, for example at fixed workstations for secondary breaking or sorting concrete fractions.
Operation, maintenance and safe handling
Reliable operation requires regular visual inspections, cleaning and documentation. Important points are:
- Leak-tightness of capture elements, hoses and connections.
- Monitoring differential pressure and volumetric flow; timely filter maintenance.
- Safe filter and container change with the lowest possible dust handling.
- Clear routing for supply and exhaust air to avoid airflow short circuits.
- Training employees on correct positioning of the extraction at concrete demolition shears, splitters and cutting points.
Legal requirements and regulatory specifications can vary by region and application. It is advisable to consider these in general and align the design accordingly.
Dust mitigation along the process chain
Technical dust extraction works best in combination with process-related measures:
- Prefer low-dust working methods (hydraulic splitting before crushing).
- Use water mist or spray humidification where it makes sense.
- Organize material flow: short paths, covered transfer points.
- Optimize tool selection and maintenance to avoid unnecessary abrasion.
- Segregation of work zones with negative-pressure holding in interior spaces.
Planning guide for dust extraction plants in deconstruction
For robust planning, the following guiding questions have proven effective:
- Which processes generate the majority of the dust load (for example crushing with concrete demolition shears, drilling for rock wedge splitters, cutting)?
- Where can the extraction unit be positioned closest to the source without disrupting workflows?
- How large is the required volumetric flow per capture point, and how are multiple points combined?
- Which separation technology suits the dust spectrum and the desired maintenance regime?
- How are power supply, mobility and space requirements on the construction site taken into account?
- How are dust disposal and cleaning carried out safely, especially indoors?
Particularities in tunnel construction and interior spaces
In tunnel construction, airflow guidance over longer distances is central. Negative-pressure-controlled zones, flow-optimized lines and robust pre-separators reduce loads at the tunnel face and in material transport. In interior spaces, visibility, cleanliness and protection of sensitive areas are the priority: tight enclosures, negative-pressure holding and compact dust extraction plants near the source are particularly effective here.
Environmental and sustainability aspects
Less dust means less cleaning effort and lower secondary emissions. Demand-based control reduces energy demand; long-lasting filter media save resources. With wet separation, careful handling of the resulting sludge is important; with dry filters, clean separation into recyclable material streams is an advantage where possible.
Quality criteria in selection and use
Decisive factors are a balanced relationship between capture, volumetric flow and filter performance, robust design for construction site practice, simple operation and good accessibility for maintenance. In conjunction with tools from Darda GmbH – from concrete demolition shears and stone and concrete splitters to combination shears, multi cutters, steel shears and tank cutters – a suitable dust extraction plant ensures controlled processes and high work quality without unnecessary emissions.