The wall cut is among the most precise methods in concrete and masonry deconstruction. It refers to the controlled cutting of vertical elements such as interior and exterior walls made of reinforced concrete, concrete, masonry, or natural stone to create openings, separate components, or deconstruct segment by segment. In practice, the wall cut is often combined with hydraulic separation and splitting methods, such as concrete pulverizers or rock and concrete splitters, to ensure detachment, stress relief, and safe handling of wall segments—low-vibration, dimensionally accurate, and predictable.
Definition: What is a wall cut
A wall cut is the sawing separation of vertical wall components using diamond-impregnated tools (e.g., wall saw, ring saw, or wire saw). The aim is a geometrically defined, clean cut joint for openings, enlargements, or orderly deconstruction. Depending on material thickness, reinforcement content, and accessibility, a wall cut can be executed solely by sawing or in combination with hydraulic splitting, crushing, or shearing to release the sawn component, reduce its size, or cut reinforcement. The method is part of selective concrete demolition and is used in strip-out, special demolition, tunnel and rock works, as well as conversions and extensions.
Fields of application: Where wall cuts are used in practice
Typical use cases include door and window openings, emergency exits, shaft and breakthrough openings for service runs, accessibility adaptations, slab connections at wall heads, and segmented deconstruction of wall sections. In concrete demolition and special demolition, walls are often first sawn and then controlled-demolished with concrete pulverizers, with reinforcement separated by steel shears or combination shears. In strip-out and cutting, wall cuts offer a low-dust, low-vibration way to modify load-bearing structures without damaging adjacent areas. In rock excavation and tunnel construction, vertical separation cuts are made for recesses, shafts, or portals and then relieved with rock wedge splitters where sawing alone is insufficient. In natural stone extraction, vertical separation cuts enable dimensional block removal, which is then released with rock and concrete splitters. For special deployments—for example in sensitive existing buildings or industrial zones with restrictions on water or sparks—the wall cut is specifically combined with hydraulic splitting to reduce emissions and separate components with minimal vibration.
Overview of methods: from diamond wire sawing to hydraulic splitting
The choice of method depends on component thickness, reinforcement level, accessibility, emission requirements, and geometry.
Wall saw (diamond blade saw)
Precise rail-guided operation, high dimensional accuracy, ideal for straight openings. Wet cutting reduces dust and cools. Reinforcement is cut through; large cross-sections may require cutting from both sides or supplementing with wire sawing.
Diamond wire saw
For very thick, heavily reinforced walls or inaccessible geometries. Flexible redirection enables complex paths and deep cuts. Well-suited for combination with segmental lifting.
Ring saw/hand chain saw (diamond)
Handheld tools for edge areas, corners, and finishing. Suitable for minimizing over- or undercuts where wall saws reach their limits.
Core drilling and stitch drilling
Core holes in corners reduce overcuts and provide mounting points for lifting gear. Stitch drilling can relieve cut lines or enable the placement of rock wedge splitters.
Hydraulic splitting and gripping
Rock and concrete splitters separate thick walls in a controlled manner along predrilled zones when water-intensive sawing, sparks, or vibrations are to be avoided. Concrete pulverizers grip and size pre-sawn segments, reduce edge breakouts, and facilitate disposal. Steel shears, combination shears, and multi cutters separate reinforcement, embedded parts, and profiles. These tools are powered by suitable hydraulic power units, matched to pressure and flow rate.
Planning and structural analysis: Load paths, fixation, and sequence
A wall cut intervenes in the load path. Before starting, load transfer, temporary shoring, and the rigging process must be clarified. As a rule, structural aspects should be assessed by a competent person. The sequence follows the principle: secure – cut – release – remove.
- Define cut geometry, tolerances, and edge quality
- Determine component thickness, reinforcement location (e.g., with scanning), and embedded items
- Select fixing and lifting points; size anchors/dowels and rigging gear
- Temporary shoring of adjacent components if required
- Plan for emissions: water management, slurry, noise, dust, vibration
For the rigging process, segment sizes are chosen so that weight, center of gravity, and gripping edges are safely manageable. Here, concrete pulverizers support stable grasping and controlled detachment of sawn pieces.
Materials and wall assemblies: Particularities to consider
Reinforced concrete and prestressed concrete
High reinforcement content requires robust sawing systems; friction and sparks must be controlled. In sensitive areas, a combined approach (pre-cut, then splitting with rock wedge splitters) can reduce vibrations and water demand.
Masonry
Varying block strengths and joints lead to variable cutting speed. Mechanical splitting after a shallow relief cut limits spalling.
Natural stone and composite walls
In natural stone walls and sandwich assemblies, crack behavior is non-uniform. Predrilling and defined splitting wedges or rock and concrete splitters ensure a controlled separation path.
Equipment support in wall cuts: Splitting, gripping, separating
Wall cuts are often supplemented by hydraulic tools to improve safety, quality, and workflow:
- Concrete pulverizers: For gripping and subsequently breaking remaining webs, trimming edges, and reducing size for transport.
- Rock and concrete splitters as well as rock wedge splitters: For low-vibration separation along predrilled lines, e.g., where water cannot be used or vibrations must be minimized.
- Steel shears, combination shears, multi cutters: For reinforcement, beams, plates, and embedded items in the wall cross-section.
- Hydraulic power units: To supply the hydraulic tools, adaptable to performance needs and site conditions.
- Cutting torch: Where walls include integrated steel plates, containment spaces, or adjacent tank structures, steel-side separation may be required.
Areas of application in detail
Concrete demolition and special demolition
Selective deconstruction relies on dimensionally accurate cuts to control loads and protect adjacent components. The interplay of wall saw, concrete pulverizer, and steel shear enables dismantling into transportable units.
Strip-out and cutting
In existing buildings, wall cuts are used for new layouts, shafts, and service routes. Dust, noise, and vibration management take priority. Hydraulic splitting is an alternative where water must not be used.
Rock excavation and tunnel construction
Vertical separations at portal walls, adit connections, or rock ribs can be realized by sawing and subsequent splitting. Rock wedge splitters ensure controlled fracture paths with minimal edge influence.
Natural stone extraction
Wall cut as a vertical separation cut defines block geometries. After the initial cut, release is often performed with rock and concrete splitters to control fracture patterns.
Special deployments
Confined spaces, explosion protection, or sensitive neighborhoods require low-emission methods. Combined strategies of short saw lines and hydraulic splitting are proven in such cases.
Occupational safety, emissions, and environment
- Dust and slurry: Wet cutting binds dust; slurry must be collected and disposed of properly.
- Noise and vibrations: Choose processes and sequence to minimize impact on sensitive areas.
- Interface risks: Locate lines; secure electrical and media-carrying systems in advance.
- Load handling: Keep lifting gear, attachment points, and routes clear; use only trained personnel.
Legal requirements may vary by region. Safety and environmental protection measures must always comply with applicable regulations; this does not replace case-by-case assessment.
Quality assurance and tolerances
Key aspects are dimensional accuracy, squareness, edge quality, and surface finish. Overcuts can be limited by corner core holes and handheld finishing cuts. The tolerances to be specified belong in the scope description; checks are performed with a tape measure, straightedge, and visual inspection. Concrete pulverizers can properly dress edges without damaging the cut joint.
Procedure: From preparation to acceptance
- Investigation: Review drawings, locate reinforcement and lines, analyze material.
- Concept: Cut geometry, segmentation, lifting and securing points, emissions planning.
- Setup: Install rails, create guide points, core drill corners and lifting points.
- Separation: Saw according to plan; where useful, use relief drilling and hydraulic splitting.
- Release: Grip with concrete pulverizers, break remaining webs, separate reinforcement with steel shears.
- Removal: Secure segments, lower or lift out, organize routes and storage areas.
- Finishing: Clean edges, produce surfaces, documentation and visual inspection.
Avoiding common mistakes
- Insufficient securing: Properly support before the final cut; consider center of gravity.
- Missing corner treatment: Without corner drilling, overcuts and edge spalling may occur.
- Underestimated emissions: Plan water management, slurry handling, and noise control early.
- Tool mix: For high reinforcement content, combine mechanics—e.g., sawing plus rock and concrete splitters and steel shears.
Decision aid: Choosing the right method
- Thickness up to mid-range, good accessibility: Wall saw, optional finishing with concrete pulverizer.
- Very thick/swelling walls or complex geometry: Wire saw, segmental lifting.
- Sensitive environment (water/sparks limited): Core drilling and hydraulic splitting with rock wedge splitters.
- High reinforcement content: Sawing plus steel shear/combination shear for embedded items.