Payload

Payload is a central parameter in demolition works, deconstruction and natural stone processing. It determines which components can be safely lifted, held or set down, and it directly influences the choice of tools, carrier machine and rigging. In practice, payload is used to align component weights, load moments and sling angles—for example when sorting concrete debris with a concrete pulverizer or when controlled dismantling of components after pre-weakening with hydraulic rock and concrete splitters. Those who consistently factor in payload plan workflows more efficiently, reduce risks, and avoid impermissible loads on the machine, the construction site and the existing structure.

Definition: What is meant by payload

Payload is the permissible load that a device, a sling or a lifting device can safely take up and hold under specified conditions. It is usually stated as rated load or as working load limit and is based on normative safety factors. While payload describes the limit of a lifting or holding means, load-bearing capacity stands for the permissible bearing capacity of structural elements and soils (e.g., slabs, walls, subsoil). In deconstruction and rock excavation, both quantities must be considered together: A sling can carry a load only if the load-bearing capacity of the anchor point, any intermediate spreaders and the subsoil is ensured at the same time.

Calculating and verifying payload: units, influencing factors and safety margins

Payload is typically specified in kilograms or tonnes. The basis is a clear definition of the operating conditions: temperature range, rigging method, number of legs, angles, edge radii, condition of components, dynamic loading and environmental conditions. The nominal payload applies only when used as intended. Key point: The sling angle, the position of the center of gravity and the friction conditions significantly change the effective payload. The larger the angle between the sling leg and the vertical, the higher the leg forces and the lower the permissible load of the system.

Key influencing factors in practice

• Sling angle and number of legs: shallow angles increase leg forces; multi-leg systems distribute evenly only with symmetric loading.
• Center of gravity and load distribution: eccentric lifting points lead to unequal leg loads and torques.
• Edges, bearing and edge radius: sharp edges reduce the payload of textile slings; edge protection must be planned.
• Temperature, humidity, media: high temperatures, moisture or chemicals can reduce payload limits.
• Dynamics and vibration: jerky load changes, impacts or banging increase effective forces beyond static values.
• Condition and wear: damage, corrosion or crushing reduce payload and require a reduced operating limit or replacement.

Practical approach

1. Determine component weight (geometry, density, reinforcement content, built-in components) and allow a reserve for moisture or adherent material.
2. Select the rigging configuration (one-, two-, four-leg; direct, shortened, choke) and define the maximum sling angle.
3. Determine system payload: the weakest link (e.g., sling assembly, shackle, clamp, anchor point) governs.
4. Check environmental conditions and apply required reduction factors (temperature, edges, dynamics).
5. Ensure documentation, marking and visual inspection before the lift.

Payload in concrete demolition and specialized deconstruction

In concrete demolition, payload is relevant on two levels: during separating/splitting of components and during handling of the resulting segments. A concrete pulverizer produces manageable piece sizes that are matched to the payload of the rigging and the load charts of the carrier machine. Where appropriate, concrete crushers for controlled reduction can achieve the target size at the desired payload. Rock wedge splitters and concrete splitters reduce cross-sections or release components in a controlled manner so that the resulting fragments remain within the permissible payload of slings, clamps and grapples. This avoids excessive load peaks and uncontrolled breakage.

Aligning component weight and payload

• Pre-cut, pre-drill or pre-split until the segment weight fits the intended lifting system.
• Plan lifting points (core drilling, lifting points, use of spreaders) and verify the load-bearing capacity of the existing component.
• Use a concrete pulverizer to cut reinforcement and reduce residual cross-sections so that the permissible payload of the rigging is not exceeded.

Payload with rock and concrete splitters

Rock wedge splitters and concrete splitters act via high splitting forces and create defined separation joints. For payload planning, the decisive factor is not the splitting force itself, but the resulting segment weight and safe handling. Practical benefit: By repeated splitting, large components can be reduced to pieces below the available payload limits—an advantage on confined construction sites, with limited ceiling or floor load-bearing capacity, and with restricted carrier machines. The splitting sequence is chosen so that the center of gravity and the load path remain under control.

Payload and carrier machines: excavators, booms and attachments

The payload of a carrier machine is described by load charts. Decisive factors are boom configuration, reach, upperstructure position, subsoil and the self-weight of the attachment. Hydraulic shear (demolition shear), Multi Cutters, steel shear, concrete pulverizer or cutting torch change the load moment: the tool weight and its lever arm reduce the permissible lifting load at the tip. A careful balance between tool mass and the required cutting or breaking force is therefore necessary.

Key points from load charts

• Maximum lifting load decreases with increasing reach; higher loads are permissible close to the slew ring bearing.
• Tool changes influence the remaining payload; the heaviest configuration governs.
• Inclination, side loads and swinging movements increase the overturning moment and limit the actual payload.

Load-bearing capacity of the existing structure and payload of the rigging

In existing structures, load-bearing capacity and payload meet directly. Slabs, brackets and walls must absorb the loads from lifting points without crushing, spalling or pull-out failures. At the same time, the rigging must safely carry the planned loads at the actual angles. The rule applies: The safe load chain is only as strong as its weakest link—from the concrete structure via any embedded parts to the last shackle.

Typical check questions

• Is the subsoil sufficiently load-bearing for the carrier machine and its support forces?
• Are anchor points in the concrete sufficiently engaged, or will the area split under load?
• How does the sling angle change the system payload in the planned lift?

Rock excavation and tunnel construction: payload when moving blocks

Rock excavation generates irregular blocks with varying centers of gravity. Splitting sequences and wedge directions should be planned to produce transportable units that lie within the payload of hoists, grapples or wire-rope devices. Targeted pre-weakening with rock wedge splitters allows precise limitation of block sizes. In tunnels, restricted freedom of movement is added: the permissible payload must harmonize with the available clearance and the permissible contact pressures of the lining.

Building gutting and cutting: payload indoors

During building gutting, slab and stair loads are often limited. Breaking down into payload-appropriate units prevents overloading of corridors, landings and temporary shoring. Tools such as a concrete pulverizer or a cutting torch make it possible to separate components and lines until the individual weights can be moved with the available rigging. In addition, transport routes and intermediate storage areas must be selected so that their load-bearing capacity matches the partial weights.

Special operations: payload under special conditions

In sensitive areas—such as during asbestos remediation, in plants with residual media or in heritage structures—the permissible payload can be constrained by additional requirements. Methods with low vibration levels, such as controlled splitting, reduce dynamic load peaks. Rigging must be matched to the environment, for example heat-resistant for hot cutting with a cutting torch, or low-sparking in an ATEX zone. The rule is: as small as possible, as heavy as necessary—partial weights are tailored to the lowest safe payload chain.

Planning steps for payload-compliant work

1. Define load pick-up: geometry, material, reinforcement, possible cutting and splitting lines.
2. Calculate weight and center of gravity; provide allowances for uncertainties.
3. Tool selection: concrete pulverizer, rock wedge splitter and concrete splitter, hydraulic shear (demolition shear), steel shear, Multi Cutters or cutting torch depending on material and target size.
4. Build the payload chain: anchor points, spreaders, shackles, slings, clamps, grapples—each with documented payload.
5. Select the carrier machine according to the load chart; consider tool weight and reach.
6. Trial load and visual inspection; then controlled lifting with smooth movements.

Documentation, marking and inspection

Payload data must be clearly identifiable and legible. Rigging and lifting devices must be inspected regularly, documented and taken out of service if damaged. For practical implementation, the recognized rules of technology and relevant standards apply. Payload figures do not replace individual planning; they must always be evaluated in the context of the actual operating conditions.

Benefits of payload optimization for the site workflow

When components are divided into payload-appropriate partial weights, risks decrease, processes become more predictable and the utilization of the carrier machine and team increases. In particular, the combined use of a concrete pulverizer and rock wedge splitter and concrete splitter allows precise control of loads and optimal balancing of tool performance and available payload. The result is safe, plannable and resource-efficient workflows in concrete demolition, building gutting, rock excavation, natural stone extraction, tunnel construction and special operations.