Sorting applications are a central building block in demolition, deconstruction, extraction, and processing of mineral and metallic materials. On construction sites, in quarries, and in special operations, the quality of pre-sorting determines the efficiency of the entire process chain: from selective separation to recovery. The products of Darda GmbH – including hydraulic rock and concrete splitters, concrete demolition shears, combination shears, Multi Cutters, steel shears, tank cutters as well as the associated hydraulic power packs – are understood in this context as tools that enable clean separation by type and the formation of defined piece sizes. This article classifies sorting applications in technical terms and shows, in practical terms, how to manage material flows in concrete demolition and special deconstruction, in strip-out and cutting, in rock excavation and tunnel construction, in natural stone extraction, as well as in special operations in a structured and safe manner.
Definition: What is meant by sorting applications
Sorting applications comprise all methods and work steps that serve the separation of materials by type, size, purity, and intended use. These include the selective detachment of composite materials (for example concrete with reinforcing steel), fractionation by particle sizes and piece dimensions, as well as the orderly provision of recyclable fractions. Sorting takes place both in situ on the construction site and in downstream processing steps. The aim is high material purity for recycling and reuse, the reduction of transport and disposal costs, and the increase of occupational safety through clear material flows. Tools such as concrete demolition shears, rock and concrete splitters, combination shears, Multi Cutters, steel shears, and tank cutters form the basis for controlled, plannable separation. Hydraulic power packs ensure the energy supply; dedicated hydraulic power units for tools help separation and sorting processes function reproducibly.
Fields of application and objectives of sorting in demolition and extraction
Sorting applications pursue similar objectives in different areas of use: single-grade fractions, reproducible piece sizes, safe logistics, and documented quality. In concrete demolition and special deconstruction, concrete demolition shears enable early separation of reinforcing steel and mineral construction debris directly at the component edge. In strip-out and cutting, built-ins, beams, and lines are specifically released to avoid mixed fractions. In rock excavation and tunnel construction, rock and concrete splitters create controlled crack patterns with low vibration; this produces manageable blocks that can be sorted by strength and size. In natural stone extraction, splitting supports the recovery of defined raw blocks and selection by visual quality and structure. Special operations – for example dismantling tanks or massive steel components – require tools such as tank cutters, steel shears, or combination shears to separate metals safely and make them suitable for sorting.
Typical material flows and fractions
A wide variety of fractions arise in sorting applications, weighted differently depending on the project. A clear structure facilitates workflow organization and increases the purity of recyclables:
- Mineral fractions: concrete, masonry, natural stone, fine fractions from abrasion and drill cuttings
- Metallic fractions: reinforcing steel, structural steel, plate, non-ferrous metals
- Organic and other fractions: wood, plastics, insulation materials, cables
- Special fractions: coated components, bituminous materials, potentially hazardous materials (observance of the respective requirements is necessary)
Early and mechanically clean separation plays a key role. Concrete demolition shears separate reinforcement and concrete at the source; rock and concrete splitters generate defined fragments with smooth fracture surfaces, thereby reducing mis-sorting into the wrong piles. Steel shears, combination shears, and Multi Cutters cut steel profiles, beams, and plates to transport- and storage-ready lengths. Tank cutters prepare thick-walled hollow bodies safely for removal or further metal processing.
Tools and techniques for single-grade separation
Concrete demolition shears: separation of concrete and reinforcement
Concrete demolition shears are preferably used in concrete demolition and special deconstruction. They enable targeted biting and crushing of concrete while the reinforcing steel is exposed and separated. The result is two clearly separated material flows: mineral construction debris fractions and metallic reinforcements. Direct separation at the component reduces the effort in post-sorting. In confined areas, such as during strip-out, the compact, hydraulically driven mode of operation enables a quiet and controlled approach.
Rock and concrete splitters: controlled fracture with defined piece sizes
Rock and concrete splitters create a targeted, low-vibration fracture via hydraulically applied splitting forces. In rock excavation and tunnel construction, this produces blocks that can be ordered by size and strength. In the deconstruction of massive foundations, large-format concrete bodies can be divided into manageable pieces without excessively loading surrounding structures. The controlled break promotes sortability, because edges and piece dimensions are plannable and the fractions contain fewer fines.
Combination shears and Multi Cutters: versatility in composite structures
Combination shears and Multi Cutters are designed to cut different materials in alternating layers. With mixed components – such as trapezoidal sheet on substructure, steel beams with welded plates, or installations – they enable rapid subdivision into sortable single components. This creates clearly arranged stockpiles that accelerate material handling by excavators, wheel loaders, and conveying equipment.
Steel shears: precise cutting of metallic components
Steel shears are used wherever solid material, profiles, or reinforced plate must be brought to defined lengths. Thanks to precise cutting, length standards for transport and storage can be maintained. The resulting metal fraction is uniform and readily accessible for magnetic or manual post-sorting.
Tank cutters: special operations with high safety requirements
When deconstructing tanks, vessels, or thick pipelines, the safe separation of shells and attachments is crucial. Tank cutters prepare plates for metal recovery so that orderly, stackable fractions are created. Particular attention is paid to preparation and gas-free clearance, ventilation, and an orderly sequence of work to ensure the safety of those involved.
Hydraulic power packs: energy supply and reproducibility
Hydraulic power packs ensure constant pressures and flow rates so that concrete demolition shears, splitters, shears, and cutting tools can deploy their forces reproducibly. A stable energy supply is the basis for consistent separation quality, defined cycle times, and plannable sorting performance per shift.
Process chain: from pre-sorting to removal
A structured process chain is the key to high sorting quality and occupational safety. The approach can be organized in clear, traceable steps:
- Survey and assessment: structural diagnostics, material survey, estimation of composite shares and hard-to-access components
- Planning of sorting areas: setup of marked stockpile zones, access routes, safety zones, and intermediate storage
- Selective dismantling: strip-out, separation of built-ins and utility lines, removal of easily detachable components
- Mechanical separation at the component: use of concrete demolition shears and shears to release reinforcement, splitters for controlled fractures
- Fractionation and quality assurance: visual inspection, discharge into defined stockpiles, measurement of piece sizes and purities
- Intermediate storage and documentation: labeling, weighings, record-keeping in accordance with the applicable requirements
- Haulage and handover: on-schedule logistics with suitable containers and vehicles
Early separation at the point of origin reduces mis-sorting and increases purity. Particularly effective is the combination of concrete demolition shears for reinforcing steel and rock and concrete splitters for dimensional breakdown of massive components.
Quality assurance: purity, piece size, and homogeneity
The quality of the fractions determines recovery routes and revenues. Relevant criteria are degree of purity, defined piece sizes, and homogeneity. For mineral fractions, the lower the proportion of foreign matter and fines, the better the suitability for reuse. For metals, uniform lengths and exposed cut edges facilitate handling in processing. Mechanical separation tools contribute to this because they produce directed fracture or cut surfaces and avoid mixtures from the outset. Accompanying visual inspection, if necessary supplemented by magnetic separation or brief manual re-sorting, stabilizes fraction quality.
Occupational safety and organizational aspects
Safety has top priority in sorting applications. This includes the clear separation of work and stay areas, reliable signaling between operators and ground staff, protection from falling objects, as well as measures against dust, noise, and crushing hazards. When using tank cutters, steel shears, or splitters, manufacturer-specific operating instructions and the respective regulations must be observed. The information in this article is general in nature and does not replace a project-specific risk assessment. Adequate operator qualification, regular functional checks of the hydraulic power packs, and well-documented maintenance support safe and low-disruption operation.
Particularities in rock excavation, tunnel construction, and natural stone extraction
In rock excavation and tunnel construction, controlled crack guidance is decisive to avoid unnecessarily weakening the rock mass while at the same time producing sortable blocks. Rock and concrete splitters generate cracks along defined axes, producing uniform piece sizes. These can be provided in an orderly manner along the logistics chain – from excavation to haulage. In natural stone extraction, visual and structural criteria are additionally at the forefront: structure, color, texture, and freedom from cracks. Here, precise splitting supports the selection of raw blocks as opposed to edge zones and sections with defects. The result is clearly separated material classes that can be processed efficiently at the stockyard.
Special operations: confined conditions, thick cross-sections, hollow bodies
Where spaces are tight, components are exceptionally massive, or hollow bodies require special caution, sorting applications come to the fore. Concrete demolition shears allow the segment-by-segment opening of components, while combination shears and Multi Cutters separate complex composites into their individual parts. Tank cutters prepare thick plates and curvatures so that orderly stacking becomes possible. This not only structures the material flows but also reduces the risk of uncontrolled material movements.
Planning, pacing, and cost-effectiveness
The economic side of sorting applications is decisively influenced by pacing, tool selection, and hydraulic power. Hydraulic power packs should be sized so that the required cutting and splitting forces are available with sufficient reserve. A well-coordinated fleet reduces waiting times between separation, loading, and haulage. In planning, short, repeatable cycles adapted to the respective fractions and piece sizes have proven their worth. This leads to stable daily outputs and reliable delivery capability toward processing or reuse.
Avoiding sources of error: practical tips
- Unclear stockpile organization: set up unambiguous signage and separate drop zones
- Separation too late: separate single-grade as close to the component as possible, avoid mixed fractions
- Unsuitable piece sizes: align splitting and cutting strategy with transport means and storage areas
- Insufficient energy supply: size hydraulic power packs for the tools’ peak demand
- Underestimated fines: with very brittle materials, adapt fracture guidance to limit loose fines
Forward-looking selection of concrete demolition shears, rock and concrete splitters, shears, and cutting tools – each matched to material, component thickness, and accessibility – minimizes rework and increases fraction purity.
Sustainability and resource conservation
Sorting applications make a direct contribution to resource protection. The higher the degree of purity of mineral and metallic fractions, the more efficiently they can be used in the construction materials cycle. Early, mechanical separation with concrete demolition shears and controlled piece formation by splitters reduce the need for energy-intensive downstream processing. Short transport routes through suitable piece sizes and orderly storage also reduce emissions. In this way, sorting becomes a measurable lever for sustainability in construction and raw material extraction.
Key figures and documentation
Measurable key figures create transparency: tons per hour, degrees of purity per fraction, share of re-sorting, average piece sizes, and downtimes. Traceable documentation supports compliance obligations and improves planning for future projects. Stability in key figures is achieved through even cycles, reproducible tool performance, and clear stockpile organization.