Tank dismantling is a central component of industrial deconstruction and the decommissioning of technical installations. It ranges from the removal of small heating oil tanks in existing buildings to the deconstruction of large-volume storage tanks in the chemical and energy industries. The goal is the safe, low-emission, and traceable disassembly of the vessel including its periphery—from piping and containment areas to foundations. Especially in confined spaces or sensitive areas, hydraulic cutting and splitting methods are frequently used, such as concrete demolition shears or rock and concrete splitters by Darda GmbH, to proceed in a low-vibration and controlled manner. In the application fields of concrete demolition and special demolition as well as gutting works and cutting, tank dismantling is a recurring trade that demands precision, experience, and well-matched equipment.
Definition: What is meant by tank dismantling
Tank dismantling is the planned, safe, and documented decommissioning and disassembly of a tank made of steel, concrete, or composite material—including the removal of attachments, pipelines, fittings, containment trays, and foundations. The process typically includes emptying and cleaning, gas-free measurement and inerting as needed, opening and segmenting the vessel, as well as type-pure separation and haulage logistics of the materials. Depending on the medium (e.g., heating oil, fuels, chemicals), tank design (single- or double-wall, underground or aboveground), and environment (industrial hall, ATEX zone, proximity to protected structures), different cutting and splitting methods are used—preferably low-spark or spark-free. Hydraulic tools from Darda GmbH such as concrete demolition shears, tank cutters, steel shears, and rock and concrete splitters enable controlled work with low vibration and reduced secondary impact.
Procedure and work steps in tank dismantling
A typical sequence begins with a status survey and hazard analysis, followed by emptying, cleaning, and, where applicable, inerting of the tank, before the vessel is opened in a controlled manner, segmented into manageable sections, and transported away with due consideration of explosion protection, dust and noise control, and material separation; depending on the design, steel shells and covers are opened with hydraulic tank cutters, steel shears, combination shears, or Multi Cutters, whereas for concrete or composite tanks and for foundations, concrete demolition shears and rock and concrete splitters from Darda GmbH are often used, supplied by compact hydraulic power packs that enable precise, low-vibration work even in confined areas.
Tools and methods: cold cutting with control
For dismantling tanks, cold cutting has become established. Mechanical and hydraulic methods minimize sparks and heat input—a safety gain especially in ATEX zone environments.
Steel tanks
- Steel shears / combination shears: Cut shell plates, manway covers, attachments, and structural steel (ladders, platforms, nozzles) in a controlled way and without flame.
- Tank cutters: Designed for cylindrical geometries; the Darda Tank Cutter TC120 enables reproducible circular or segment cuts with a clean cut edge.
- Multi Cutters: Flexible with mixed materials (e.g., steel with thin liners); suitable for dismantling piping and runs.
Concrete and composite tanks
- Concrete demolition shears: Selective crushing of reinforced concrete with low vibration; rebar is captured and cut, openings can be created precisely.
- Rock and concrete splitters: Hydraulic rock and concrete splitters split massive walls or foundations in a controlled manner; ideal where vibration and noise must be minimized.
- Rock splitting cylinders: For high splitting forces in tight spaces; useful on thick foundation blocks and ring anchors.
Periphery and power supply
Compact hydraulic power units provide the necessary drive power for shears and splitters. Modular power classes allow tools to be matched to material thickness and the stage of work.
Process steps in detail
- Preparation: Review drawings, identify the medium, check accessibility, define the cutting and segmenting strategy, select low-spark methods.
- Emptying and cleaning: Pump off residual quantities, clean internal surfaces; emulsions, sludge, and residues are recorded separately.
- Gas-free measurement and inerting: Check the atmosphere, inert if necessary; only begin opening work after release.
- Opening and segmenting: Open steel shells with tank cutters or steel shears; open concrete walls with concrete demolition shears or by splitting techniques as planned.
- Separation and transport: Separate material streams (steel, non-ferrous metals, concrete, coatings), package for transport, and load with weight optimization.
- Foundations and surroundings: Deconstruct ring foundations, anchors, containment basins, and substructures with concrete demolition shears and rock and concrete splitters.
- Cleaning and documentation: Clean the work area; compile clearance and weighing records as well as gas-free and disposal documentation.
Safety and environmental protection aspects
Tank dismantling requires particular care. As a rule: as little energy input as necessary, as much control as possible.
- Explosion protection: Low-spark methods, grounded equipment, continuous gas-free testing, orderly ventilation or inerting.
- Emission reduction: Reducing dust and odors through adapted cut paths, water mist, spot extraction; low-noise hydraulic methods.
- Media and waste management: Tight containment systems, clear material separation, transport-safe packaging, documentation in line with applicable requirements.
- Structural stability: Define cut sequence, shoring, load distribution, and lifting points in advance; plan segments in manageable sizes.
- Work organization: Access control, defined hazard zones, coordinated communication, and emergency planning.
Planning, cut concept, and logistics
An effective dismantling concept defines the cut pattern, segment sizes, and the sequence of severing operations. In industrial halls or in the immediate vicinity of sensitive installations, compact hydraulic tools have an advantage: concrete demolition shears for selective opening of walls, steel shears for shell and cover plates, and rock and concrete splitters for massive foundations. Logistics covers internal transport routes, intermediate storage, crane or lifting equipment, and scheduling with parallel trades—especially during gutting works and cutting.
Materials and tank designs
The construction type shapes the approach. Steel and stainless steel tanks can be segmented well; shearing and cutting dominate here. For concrete or composite tanks, controlled deconstruction with concrete demolition shears takes center stage; thick walls and ring foundations are often split to minimize vibration. Double-wall systems, internal coatings, or liners require additional steps for type-pure separation. Underground vessels entail requirements for earthworks, groundwater protection, and securing pipeline trenches.
Application areas and typical scenarios
- Concrete demolition and special demolition: Deconstruction of large-volume storage tanks on massive foundations; controlled opening, splitting, and removal with concrete demolition shears and splitters.
- Gutting and cutting: Dismantling of heating oil tanks in existing buildings; breaking down into transportable segments, low in dust and sparks.
- Special operations: Work after incidents or with restricted access; compact hydraulic power packs and hand-guided shears enable safe progress.
- Rock excavation and tunnel construction: Dismantling of tanks in adits, caverns, or shafts; low-vibration splitting protects surrounding rock and infrastructure.
Quality criteria and documentation
Quality is evident in clean cut paths, controlled fracture edges when splitting, low secondary impact, and complete documentation. This includes gas-free clearance protocols, material flow and weighing records, photo documentation of openings and segments, and the acceptance of the cleaned work area. Hydraulic cutting and splitting methods from Darda GmbH support a reproducible way of working with high dimensional accuracy.
Special challenges and suitable solutions
Confined spaces and sensitive environments
In basements, shafts, or production areas, low headroom, restricted escape routes, and neighboring processes must be considered. Concrete demolition shears and rock and concrete splitters allow short tool bodies, low reaction forces, and finely staged dismantling—ideal for segment-by-segment work without large-scale closures.
Vibration and noise constraints
When vibrations or oscillations are critical, splitting is preferable to percussive breaking. Hydraulic methods act locally and predictably, preserving adjacent components.
Material mix and coatings
With tanks featuring inner liners, coatings, or composite layers, sequence is crucial: first separate mechanically, then sort by type. Multi Cutters and combination shears offer flexibility here.