The demolition of a switchgear building in substations, transformer stations, or switchgear installations requires particularly careful planning because structural elements, electrical infrastructure, and operational processes are tightly interwoven. The goal is a controlled, low-vibration, and safe deconstruction that protects plant availability and neighboring structures, enables source-separated materials, and complies with environmental requirements. In practice, building gutting, selective dismantling, and the phased demolition of reinforced concrete components are combined. Tools such as concrete pulverizers, hydraulic rock and concrete splitters (wedge), and suitable hydraulic power packs from Darda GmbH are used where robust, precise, and low-noise methods are required.
Definition: What is meant by switchgear building demolition
Switchgear building demolition refers to the planned deconstruction of buildings that house electrical switching, measuring, and control technology. This includes operational and technical rooms of substations, station buildings, and switchgear installations. Deconstruction is usually selective: first, installations such as cable trays, switch panels, doors, windows, ventilation, suspended ceilings, and non-load-bearing components are dismantled (building gutting). Then load-bearing structures such as slabs, columns, walls, and foundations are removed or segmented in a low-vibration manner. Depending on the construction, concrete pulverizers, stone and concrete hydraulic splitters (wedge), steel shears, or combination shears are used to safely separate and sort concrete, masonry, reinforcement, and attachments by material.
Planning and sequence in switchgear building demolition
The sequence begins with an as-built survey, risk assessment, and a deconstruction concept. Typical steps are: de-energization and clearance checks of lines and equipment, residual energy and media management, hazardous materials survey, building gutting, selective deconstruction of load-bearing members, as well as foundation removal and area restoration. In sensitive environments, low-noise and low-vibration methods are prioritized: concrete pulverizers crush reinforced concrete in a controlled way and reduce dust and vibrations; stone and concrete hydraulic splitters (wedge) split massive foundations or wall panels without explosives and with limited crack propagation. Hydraulic power packs supply the tools as needed, even under confined space conditions. For reinforcement, beams, and cable routes, steel shears or combination shears are used, while Multi Cutters handle a variety of cutting tasks in interior areas. The material flow is organized early to capture and recycle concrete, steel, non-ferrous metals, and construction waste in a source-separated manner.
Specific boundary conditions around switchgear installations
Switchgear buildings are often located in operational yards of energy infrastructure. This requires quiet, controlled methods, coordinated work windows, and high availability of the remaining systems. Potential restrictions include minimum distances to live components, vibration-sensitive equipment, protection zones, grounding grids, cable basements, oil and water containment systems, and adjacent foundations.
Safety and environmental protection aspects
- Work only after shutdown/release of the affected areas and in compliance with applicable regulations
- Dust and noise reduction through pulverizer-based deconstruction, water mist, and appropriate cutting or splitting methods
- Careful handling of grounding and equipotential bonding systems in the ground
- Hazardous materials management (e.g., asbestos, PCB, PAH, mineral fibers) in accordance with current regulations
Structural characteristics of switchgear buildings
Switchgear buildings are usually of solid construction: reinforced concrete walls, slabs, and foundations, possibly hollow-core slabs, masonry infills, cable basements, and shaft structures. Existing structures often contain core holes, penetrations, and subsequent reinforcements. Reinforcement ratios vary; higher reinforcement density is often found at column heads and wall heads.
Impact on the choice of demolition method
- Concrete pulverizers for precise biting along wall and slab edges as well as for bringing down exterior components
- Stone and concrete hydraulic splitters (wedge) for thick foundations, cable ducts, and wall panels when vibrations must be minimized
- Steel shears/combination shears for reinforcement, steel frames, railings, beams, and cable trays
Method selection: low-vibration deconstruction
Near sensitive switching and control equipment, low-vibration methods take priority. Hydraulic splitting technology creates controlled separation joints in concrete without impact loads as with percussive tools. Concrete pulverizers reduce components section by section and allow a metered load transfer. This improves work safety, component control, and material separation.
Comparison of typical methods
- Splitting: very low vibration, good crack control, suitable for foundations and massive cores
- Pulverizer-based deconstruction: controlled removal, good single-grade separation, advantageous at edges and façades
- Sawing/core drilling separation: high precision, but requires cutting logistics and water management
Building gutting and selective deconstruction in the interior
Building gutting includes the removal of door and window units, cladding, cable routes, luminaires, HVAC/electrical systems, and non-load-bearing walls. Multi Cutters and combination shears are suitable for versatile cutting tasks, especially with sheet metal ducts, rolled sections, and lattice girders. Where access is tight and load reserves are limited, compact hydraulic tools from Darda GmbH are advantageous because they are mobile and easy to control.
Typical sequence
- Clearance checks and deconstruction planning per room zone
- Dismantling of cable trays, racks, doors, and installations
- Removal of non-load-bearing walls and shafts
- Prepared cuts/splitting boreholes on load-bearing components
Demolition of load-bearing components and foundations
When deconstructing load-bearing elements, load paths are redirected step by step. Concrete pulverizers handle the controlled reduction of wall heads and slab projections; stone and concrete hydraulic splitters (wedge) open separation joints so that components can be divided into manageable segments. This facilitates recovery with smaller lifting devices and reduces risks in confined, sensitive operating environments.
Cable basements and shafts
Cable basements and shaft structures are often opened from above: splitting cylinders create defined cracks, concrete pulverizers detach caps. Preserving adjacent lines requires short-stroke, finely metered lift cycles and good support of the debris to limit fall energy.
Separating steel and reinforcement
With heavily reinforced concrete, steel shears and combination shears are suitable for reinforcement, rolled sections, and embedded parts. This promotes source-separated concrete and steel, increases recycling rates, and reduces transport costs. In special tasks, Multi Cutters can rapidly cut interior metal components, such as rack frames or grating.
Hydraulic power packs: energy supply and mobility
Hydraulic power packs from Darda GmbH supply concrete pulverizers, stone and concrete hydraulic splitters (wedge), steel shears, and Multi Cutters with the necessary working pressure. In switchgear buildings with restricted access, compact hydraulic power units with sensitive control and appropriate hose logistics are advantageous. Short hose runs, defined staging areas, and drip protection are part of work preparation.
Minimizing dust, noise, and vibrations
- Prioritize pulverizer-based deconstruction and splitting technology; use percussive tools only selectively
- Water mist for dust binding; extraction in interior spaces
- Segment large components to reduce drop heights and impact loads
- Continuous vibration monitoring in sensitive environments
Material flow, recycling, and disposal
Switchgear building demolition offers high recovery potential: concrete can be crushed on site or processed externally; steel from reinforcement and embedded parts is collected as scrap. Material flow management, consignment notes, and documentation follow applicable regulations. Materials containing hazardous substances are handled separately; a matching container logistics setup prevents mixing.
Special operations: confined conditions and sensitive existing structures
For deconstruction work in confined technical areas, in existing tunnels, or near live switchgear fields, compact, hand-held tools with high performance and fine controllability are required. Stone and concrete hydraulic splitters (wedge) are suitable for opening massive components without explosives; concrete pulverizers enable controlled removal along edges and in wall openings. For metallic components, steel shears, combination shears, and Multi Cutters support selective dismantling.
Quality assurance and documentation
A quality-assured approach includes test areas, defined demolition edges, measurements of dust and vibrations, and continuous photo documentation. Site meetings, adjustments to gripping and splitting sequences, and a structured material balance help meet schedule, safety, and environmental targets.
Relation to application areas and products of Darda GmbH
Switchgear building demolition combines several established application areas: concrete demolition and special deconstruction when removing load-bearing structures, building gutting and cutting in interior spaces, up to special operations with restricted access. Products from Darda GmbH such as concrete pulverizers and stone and concrete hydraulic splitters (wedge) often form the core tools in these scenarios. In addition, hydraulic power packs, combination shears, steel shears, and Multi Cutters are used to safely and efficiently separate concrete, masonry, reinforcement, and embedded components.