Operational safety is the foundation for trouble-free processes and the avoidance of accidents in concrete demolition, special demolition, rock excavation and natural stone extraction. Wherever hydraulically powered tools such as concrete demolition shear, hydraulic splitter, Multi Cutters, hydraulic shear, steel shear, tank cutters, rock wedge splitter and powerful mobile hydraulic power units are used, high forces act on structural elements, rock and operating personnel. This knowledge article from Darda GmbH compiles practice-relevant know-how and classifies it professionally: from the definition through typical hazards to concrete measures for safe, plannable and efficient use.
Definition: What is meant by operational safety
Operational safety is the condition in which work equipment, workplaces and processes are designed so that risks to people, property and the environment are reduced to an acceptably low level. It covers the entire life cycle: selection of suitable work equipment, hazard analysis, instruction, safe operation, regular inspection, maintenance and orderly decommissioning. In practical deconstruction this means: tools and hydraulic systems remain controllable, residual hazards are known and safeguarded by organizational, technical or person-related measures. The goal is controlled force application—for example when separating with concrete demolition shear or when controlled splitting of concrete and natural stone—without unwanted side effects such as component drop, hose burst, sparks or uncontrolled crack propagation.
Core principles of operational safety
Operational safety is based on three interlocking levels. Technical safeguards address hazards at the source, organizational measures structure the workflow, and person-related measures strengthen the action reliability of employees.
Technical protective measures
- Tool and power pack selection matched to the task (e.g., component thickness, reinforcement content, rock hardness, space constraints).
- Pressure limitation and safe energy control in hydraulic systems (e.g., correctly set working pressure, functioning emergency-stop devices).
- Secure couplings, sufficient burst pressure and correct hose bend radius; protection against abrasion and crushing.
- Stable setup, safe load paths and shoring so that resulting forces (shear, pressing and splitting forces) are introduced into the structural element in a controlled manner.
- Good visibility of the work area and sufficient lighting, especially in shafts, tunnels and in special operations.
Organizational measures
- Hazard analysis with work and rescue concept; clear roles (operator, signaler, barricade post).
- Barrier and marking of the hazard area; keep fall and slewing areas clear.
- Work release and communication rules (hand signals, radio), unambiguous stop signals.
- Planned workflow: sequence of separation and splitting operations, intermediate shoring, waste management chain.
Person-related measures
- Targeted instruction on the tools used (e.g., concrete demolition shear, hydraulic splitter, hydraulic shear) and the associated hydraulic power packs.
- Appropriate personal protective equipment: head, eye and face protection, cut-resistant gloves, safety shoes, hearing protection, and, depending on dust exposure, suitable respiratory protection.
- Occupational health care and break management for dust-, noise- and vibration-intensive activities.
Typical hazards and risks in demolition and natural stone extraction
Deconstruction and splitting work are characterized by high energies, sharp-edged workpieces, moving parts and changing environmental conditions. Typical hazards include:
- Hydraulic high pressure: leakage, hose burst, unintentional uncoupling under pressure.
- Uncontrolled crack formation and falling components on concrete structures; rock breakout, wedge cracks and subsequent fall in rock.
- Crushing hazard and cutting hazards at shears and Multi Cutters; entrapment in the rotation/slewing area.
- Dust (especially quartz-bearing fine dust when drilling), noise emission and vibrations.
- Kickback and reaction forces during splitting; settlements on subgrades with low load-bearing capacity.
- Fire and explosion hazards when opening containers; sparks and heat input during tank cutting.
- Electrical, media-related and structural residual hazards (hidden utility lines, service runs, stresses in the structure).
Safe use of concrete demolition shear
Concrete demolition shear enable controlled separation of reinforced concrete and masonry—low in vibration and precise. Operational safety here arises above all from prepared load paths, matched pressing pressure and safeguarding of the surroundings.
Step-by-step practical guide
- Secure the work area: cordon off, define the drop zone, provide shielding against splinters.
- Assess the component: material, reinforcement layout, load transfer, possible restraint forces; plan shoring.
- Select a suitable tool: jaw opening, shear force, weight and accessibility; check compatibility with the hydraulic power pack.
- Connect hydraulics safely: relieve pressure, clean couplings, lock correctly; test run at low load.
- Define the separation sequence: from the edge to the center, from non-load-bearing to load-bearing areas; rework reinforcement in a controlled manner (e.g., with steel shear).
- Apply the shears in measured steps: short, controlled cuts; observe component movement; advance intermediate shoring.
- Relieve pressure and set the tool down: release only after standstill and securing of the component; keep transport routes clear.
Special notes for building gutting and cutting
In existing buildings, utility lines, shafts and built-in components must be considered. Survey line routing, isolate media and empty areas. Confined spaces require additional ventilation, dust suppression and clear communication paths. For ceiling opening and wall opening provide fall protection and do not overestimate residual load-bearing capacity.
Safe use of rock and concrete splitters
Rock and concrete splitters work on the wedge principle in predrilled holes. The advantages are low vibration levels, high precision and deliberately guided cracks. Operational safety here depends on a consistent borehole grid, correct wedge positioning and continuous observation of crack propagation.
Work preparation
- Plan the drilling pattern: adapt hole diameter, depth and spacing to the material and the intended fracture line.
- Remove drill cuttings, clean and, if necessary, wet the holes; minimize dust by wet drilling or dust extraction.
- Anticipate crack direction: consider existing joints, reinforcement, natural fractures and weak zones.
Execution
- Position splitting cylinders or wedges centrally and flush; lubricate wedge faces if specified by the manufacturer.
- Build up pressure slowly; observe crack formation; in case of lateral movements, stop work and start anew.
- Continue cracks in a controlled manner: activate adjacent holes sequentially, set intermediate supports, secure component movement.
- After the splitting operation, relieve pressure, withdraw wedges without tension, remove fragments in an orderly manner.
Special operations underground and in tunnel construction
Underground, ventilation, lighting, escape routes and communication require particular planning. Rock assessment and crown support are mandatory. In potentially hazardous atmospheres, hot work is permitted only after careful release and with appropriate protective measures.
Hydraulic safety for power packs, hoses and couplings
Hydraulics is the energy base for concrete demolition shear, hydraulic shear, Multi Cutters, steel shear, rock wedge splitter and tank cutters. Operational safety here means: control pressure, ensure tightness, detect leaks quickly.
- Always depressurized before coupling: switch off the power unit, relieve pressure, dissipate residual energy.
- Check hoses for abrasion points, pinching, blistering; maintain bend radii, avoid kinks.
- Keep couplings clean; use protective caps to prevent particles from entering the hydraulics.
- Never search for leaks with your hand; if suspected, stop work, secure the system, have it checked by qualified personnel.
- Test the emergency stop function regularly; label controls clearly, prevent unintentional actuation.
Selection, maintenance and inspection of work equipment
The selection of suitable tools and power packs is based on the task, material properties and environmental conditions. Maintenance and periodic inspections ensure long-term function and contribute significantly to operational safety.
Daily visual and functional inspection
- Tool condition: shear arms, blades, wedges, splitting faces for cracks, breakouts and excessive wear.
- Hydraulics: tightness, couplings, hoses, protective devices, pressure gauges; clean oil levels.
- Operation: emergency stop, dead-man switches, control levers move smoothly, clear neutral position.
- Environment: standing areas, shoring, lighting, barriers and clear rescue routes.
Maintenance and documentation
Maintenance intervals are based on usage intensity and manufacturer specifications. Replace each wear part in good time, monitor oil quality and change filters. Document inspection and maintenance records. Use only approved spare parts and have work carried out by qualified personnel.
Lifecycle and decommissioning
In the event of recurring anomalies, indications of cracking or exceeded operating limits, an in-depth inspection is appropriate. Work equipment that is no longer operationally safe must be labeled, taken out of service and properly disposed of or repaired.
Workplace organization, communication and cordoning
Clear work organization reduces errors and makes hazards manageable. Especially in team operations—for example when using concrete demolition shear and steel shear simultaneously—unambiguous communication is crucial.
- Define and cordon off the hazard area; specify and enforce minimum safety distance.
- Assign a signaler; agree visual or radio signals; define unambiguous stop signals.
- Plan material flow: remove fragments safely, define intermediate material storage, keep routes clear.
- Consider weather and surroundings: moisture, cold or heat affect footing, visibility and hydraulics.
Minimize dust, noise and vibrations
Health protection is part of operational safety. When drilling for splitting operations, bind dust with water or dust extraction. Choose separation sequences so that low vibration levels act on sensitive areas. Limit noise sources locally, coordinate working times and wear appropriate hearing protection. Provide suitable respiratory protection when sustained dust occurs.
Use personal protective equipment (PPE) purposefully
PPE supplements technical and organizational measures. Proven choices include a hard hat, safety glasses or face shield, cut- and puncture-resistant gloves suitable for the tool, safety shoes with toe protection, hearing protection and—depending on the activity—respiratory protection with adequate filter class. At edges and on slabs, collective fall protection has priority; otherwise provide suitable personal protection.
Legal and normative orientation (general, non-binding)
Applicable occupational safety regulations, recognized rules of technology and manufacturer information are authoritative. These include hazard analysis, operating instructions, training, inspection obligations and the safe handling of energy sources. For special activities such as opening containers or working in confined spaces, release processes and additional protective measures are provided. Concrete implementation is always site- and task-specific.
Practical references from the fields of application
Concrete demolition and special demolition
In deconstruction sections in load-bearing zones, concrete demolition shear enable controlled separation operations once loads have been removed from the system. Hydraulic shear and steel shear complement the reworking of reinforcement. Reaction forces must be absorbed by shoring, drop paths must be kept clear and fragments secured promptly.
Rock excavation and tunnel construction
Rock and concrete splitters as well as rock wedge splitter allow low-vibration solutions in sensitive areas. Decisive factors are a coherent drilling pattern, securing the crown and slopes and guiding crack propagation. Communication and visibility must be organized particularly well in tunnel tubes.
Natural stone extraction
When splitting blocks, wedges are set so that the crack follows the natural joint system. Proper shielding against splinters, secure standing areas and defined escape routes are mandatory. Crane operations are timed to the moment when the block is free and can be guided stably.
Building gutting and cutting
In building gutting, hydraulic shear and Multi Cutters are versatile. Utility lines must be identified and isolated beforehand. When opening tanks and containers—such as with tank cutters—increased caution, clearance measurements and coordinated protective measures against ignition sources apply. Hot work only after release and with appropriate monitoring.
Checklist: safe work release
- Hazard analysis prepared, measures defined.
- Tool and power unit selection checked, compatibility ensured.
- Hydraulic connections clean, coupled depressurized, function tested.
- Barriers set, responsibilities and signals clarified.
- PPE complete, rescue equipment available, first aid organized.
- Dust and noise protection planned, disposal and transport logistics prepared.
- Workplace tidy, escape and transport routes clear.