Occupational safety in demolition, in gutting works, in rock excavation and in natural stone extraction is the foundation for safe and efficient project execution. Where hydraulics, massive structural elements and brittle rock meet, particular risks arise: crushing and cutting injuries, noise and dust, uncontrolled fractures, hydraulic pressure as well as fall and drag hazards. This article combines practice-oriented recommendations with sound background knowledge – with a direct reference to applications in which concrete pulverizers, hydraulic splitters, hydraulic power packs (see appropriate hydraulic power units), hydraulic demolition shears, multi cutters, steel shears, rock wedge splitters and tank cutters are used. The aim is to give those responsible and those executing the work clear, understandable and legally non-binding guidance for safe working practices.
Definition: What is meant by occupational safety
Occupational safety comprises all organizational, technical and personal measures that ensure the safety and health of employees at work. This includes the hazard analysis, the selection of safe working methods and work equipment, instruction, appropriate personal protective equipment (PPE) as well as the regular review of the effectiveness of protective measures taken. In construction-related trades – for example in concrete demolition, special demolition, gutting works, rock excavation, tunnel construction, natural stone extraction and special operations – occupational safety additionally includes the controlled handling of loads, energies (e.g., hydraulic pressure), environmental influences and substances (dust, noise, exhaust gases, cutting fumes).
Core principles of occupational safety in demolition and splitting work
Effective protection begins with systematic hazard analysis and continues with the selection of suitable methods (e.g., splitting rather than percussive or thermal methods where conditions permit), safe construction site setup and clear procedures for operation, maintenance and emergencies. In work with concrete pulverizers and hydraulic splitters, the priorities are control of the fracture line, safely keeping crush and shear zones clear, and the controlled introduction of forces. These principles are complemented by effective dust suppression and noise reduction measures, ergonomic work practices and robust team communication.
Typical hazards in concrete demolition, gutting works, rock excavation and tunnel construction
Hazards vary depending on the application and tool, but they follow recurring patterns:
- Mechanical hazards: Crushing, shearing and cutting points on concrete pulverizers, hydraulic demolition shears, multi cutters, steel shears and tank cutters; breaking edges and uncontrolled movements of structural elements and rock blocks.
- Hydraulic hazards: High pressure at power packs, hose lines, couplings and cylinders; potential injection injuries from leaks; whip effects in the event of hose failure.
- Physical impacts: Noise, vibrations, dust, sparks and fumes during cutting and separation; shock and ground vibration; restricted visibility.
- Organizational risks: Unclear responsibilities, missing barriers, poor communication, undocumented changes in the work plan.
- Ambient hazards: Fall and trip hazards, weather influences, confined spaces, existing utilities (lines, reinforcement), hazardous substances in older structures.
Safe work organization: from planning to execution
Preparation and hazard analysis
Before starting, structural elements and rock structures are analyzed, load transfer and stress paths are assessed, utilities are located and exclusion and protection zones are defined. The selection of work equipment (e.g., concrete pulverizers for precise nibbling, hydraulic splitters for controlled crack initiation) is based on the boundary conditions: space, noise control, vibration limits, dust requirements and time windows. Instructions, an emergency plan and communication rules (hand signals, radio) are recorded as binding.
Construction site setup
Barriers and protection areas are dimensioned to ensure that no one enters hazard zones. Hydraulic power packs are placed on stable footing, ventilated and protected from damage. Hose routing is laid without kinks or trip hazards, couplings are cleanly connected and checked while depressurized. Escape and rescue routes remain clear.
Execution
Work follows the work plan with a clear division of roles. Loads are secured, structural elements are shored before separation. The operator remains outside potential break and swing areas. In splitting work, drilling pattern, wedge direction and stress relief are coordinated; with concrete pulverizers, cut lines, reinforcement and component spring-back must be considered. Dust is minimized at the source (wet methods, dust extraction), and noise exposure is reduced by suitable methods.
Completion and control
After each work step, a visual inspection of the work equipment is carried out, deviations are documented and the next steps are released. Waste, slurry and chips are collected and disposed of in an environmentally sound manner.
PPE and collective protective measures
- Basic PPE: Hard hat, safety glasses or face shield, hearing protection, cut-resistant gloves suited to the tool, safety shoes with toe and puncture protection, close-fitting workwear. For dust: appropriate respiratory protection (e.g., FFP2/FFP3 depending on exposure).
- Collective measures: Physical shielding, barriers, catch and safety nets, installation of protective plates at hazard points, use of wet cutting or misting for dust suppression, adequate lighting.
- Ergonomics and handling: Favorable body posture, short holding times, task rotation; low-force operation where possible, use of carrying aids and suspensions if needed.
Hydraulic safety: pressure, leaks and couplings
For hydraulic power packs, hose lines and cylinders, the following applies: only couple or uncouple with the system depressurized, keep couplings clean, and remove damaged items (bulging, abrasion, kinks) from service immediately. Hose rupture protection, protective sleeves and correctly sized lines reduce risks. Pressure zones must be marked; keep hands and body away from potential leakage points. Suspected injection injury is a medical emergency – arrange immediate medical evaluation.
Safe use of concrete pulverizers
Concrete pulverizers enable controlled nibbling of concrete and masonry, including in special demolition and gutting works. The following are critical for safety:
- Stability and shoring: Secure the component before cutting; prevent uncontrolled folding or dropping.
- Cut guidance: Consider reinforcement, plan remaining cross-sections, and anticipate crack propagation.
- Keep hazard areas clear: No persons in swing or drop zones; use a signaler.
- Tool condition: Regularly check cutting edges, bolted joints and pivot points and maintain according to the manufacturer’s specifications.
Safe use of hydraulic splitters for stone and concrete
Splitting technology uses controlled wedge forces to create cracks in rock and concrete. Advantages include low vibration levels and reduced noise emission. Safety-relevant aspects are:
- Drilling pattern and wedge orientation: Borehole diameter, depth and spacing matched to the material and the desired fracture line.
- Crack control: Generously cordon off the exclusion area in the crack direction; observe material behavior; watch for precursors (crack sounds, fracture sheen).
- Hydraulic discipline: Build pressure stepwise, maintain line of sight to wedge and splitter head; on abnormalities, relieve pressure immediately and inspect.
- Post-processing: Secure loose parts, blunt sharp edges, tidy up and document.
Application specifics by work field
Concrete demolition and special demolition
Structural sequence and load transfer are central. Concrete pulverizers cut remaining cross-sections in a controlled manner; hydraulic splitters minimize vibration near sensitive structures. Load-bearing supports, temporary shoring and a clear sequence of cuts/splits prevent chain reactions. Further guidance is described under concrete demolition and deconstruction.
Gutting works and cutting
Indoors, dust and noise control, fire protection for thermal methods, and transport routes are the focus. Select tools accordingly; for tank cutting work, clearance measurements and ignition source control are essential.
Rock excavation and tunnel construction
Geology, jointing, water ingress and crown support determine the approach. Rock wedge splitters allow section-by-section stress relief; define exclusion zones generously in the fracture direction. Ventilation and visibility must be ensured. For context, see rock demolition in tunnel construction.
Natural stone extraction
For block extraction, uniform drilling patterns and reproducible splitting paths are crucial. Continuously check surface stability and the state of the quarry face; remove loose areas before follow-up work begins.
Special operations
In narrow shafts, on high-rise structures or in sensitive environments, reduced emissions (dust, noise, vibration) and compact equipment are advantageous. Plan working hours, neighborhood protection and transport routes early.
Effectively reduce noise, vibrations and dust
- Noise: Prioritize methods with lower sound emission; use enclosures, muffling and hearing protection consistently.
- Vibrations: Reduce hand-arm vibration through appropriate tool selection, short exposure times and breaks; use ergonomic grips.
- Dust: Wet cutting, point-of-source extraction, misting; suitable respiratory protection; regular cleaning instead of dry sweeping.
Qualification, instruction and communication
Only instructed personnel operate concrete pulverizers, hydraulic splitters, hydraulic power packs and shears. Instructions are workplace-specific and include hazards, protective measures, emergency procedures and tool limits. Tool changes, pressure settings and faults are practiced in advance. Regular brief meetings keep the team up to date.
Maintenance, inspection and servicing
Work equipment is regularly inspected according to the manufacturer’s specifications. This includes functional and leak tests, visual checks of hose lines, couplings and cylinders, and inspection of cutting edges, jaws, wedges and bolts. Document inspection intervals, rectify defects immediately. Use only approved spare parts; modifications to guards are not permitted.
Emergency management and first aid
Escape routes, reporting chain and first aid are defined before work begins. Typical emergencies: crushing injuries, injection injuries, eye injuries due to fragments, consequences of falls. Release pressure immediately, secure the area, provide first aid, call emergency services. Keep an eyewash bottle and dressings ready. Have lifting and rigging gear available for rapid relief of trapped structural elements.
Environmental and health protection working together
Occupational safety and environmental protection interlock: provide drip trays and absorbents, handle lubricants and hydraulic fluid carefully, collect waste separately. Clean workplaces reduce slips and dust exposure. Wherever possible, prefer low-emission methods – protecting people and the environment.
Documentation and continuous improvement
Hazard analysis, instructions, inspection logs and deviation reports are continuously maintained. Feedback from practice flows into the next planning cycle. This creates a learning system that prevents accidents and stabilizes processes.
Practice check: safe application step by step
- Cordon off the work area, mark escape routes, check lighting.
- Discuss hazard analysis and work plan; define roles and signals.
- Check tool and hydraulic system: couple while depressurized, inspect hoses/couplings, functional test.
- Put on PPE; for dust, noise and sparks activate additional protective measures.
- Secure and shore the component; define the fracture or cut line.
- Position the concrete pulverizer or hydraulic splitter as planned; apply forces in a controlled manner; monitor the exclusion zone.
- Interim check: assess crack progress/separation cut; in case of deviations stop work and adjust the plan.
- Remove the component, secure edges, clean the area; visual inspection of the tool.
- Update documentation; communicate findings to the team.
Reference to Darda GmbH
The occupational safety principles described in this article are relevant to applications with hydraulic splitting and cutting tools such as concrete pulverizers, hydraulic splitters, hydraulic power packs, hydraulic demolition shears, multi cutters, steel shears, rock wedge splitters and tank cutters. Darda GmbH is the manufacturer of these product groups; safe application is always aligned with the respective application conditions, the information from Darda GmbH and the generally accepted rules of engineering. Legal notes in this text are general and do not replace binding advice.