Work preparation

Work preparation is the key to safe, on-schedule, and cost-effective operations in concrete demolition, special demolition as well as in rock excavation and tunnel construction. It links analysis, method selection, equipment and resource planning with quality assurance and documentation. This applies to selective building gutting, concrete separation/cutting just as much as to natural stone extraction and special operations. Where low vibration limits are required, the decision between concrete pulverizer and hydraulic splitter moves early into the focus of planning. Early alignment with stakeholders and permitting bodies strengthens feasibility and shortens mobilization.

Definition: What is meant by work preparation?

Work preparation means systematically planning, structuring, and controlling all preparatory measures that enable a smooth and safe workflow on the construction site. These include existing-condition surveys, hazard analysis and risk assessment, selection of methods and equipment, scheduling, construction logistics, personnel allocation, quality assurance, environmental protection, as well as documentation (method statement). In the context of demolition, deconstruction, building gutting, rock excavation, and tunnel construction this especially includes the methodical decision whether components are separated, cut, or split – for example with concrete pulverizer, hydraulic splitter, attachment shear, multi cutters, steel shear, or cutting torch – and how the hydraulic power pack should be sized for them (see Power Units).

Methodical work preparation in demolition, deconstruction, and rock works

The methodical work preparation follows a clear sequence: First define objectives and boundary conditions (e.g., residual load-bearing capacity, noise and vibration limits, dust suppression, fire protection). Based on that, carry out the survey of structure, reinforcement, geology, and existing utilities. Then perform the hazard analysis with protective measures and decide on the technical method: splitting with hydraulic rock and concrete splitters for massive, vibration-sensitive components or in rock; separating with concrete pulverizer, combinations of concrete pulverizer, multi cutters, steel shear, or cutting torch for defined cut edges and dismantling units. After that, match hydraulic power pack and excavator attachment capacity, plan the construction logistics (access, cranes and lifting devices, disposal, construction site waste container, water and power supply), define cycles and sequences, and set quality and measurement points. Finally, organize documentation, communication, briefings, and approvals. These steps form the common thread for deployments in concrete demolition and special demolition, building gutting and cutting, rock excavation and tunnel construction, natural stone extraction, as well as special operations.

1. Define targets and constraints: structural performance after intervention, emissions, working windows, interfaces.
2. Survey and verify: drawings, tests, probing, utilities, neighboring assets.
3. Assess risks and controls: engineered protections, fire and dust concepts, emergency access.
4. Select method and tools: split, separate, or cut with suitable attachments and consumables.
5. Dimension equipment: hydraulic power pack, hose routing, lifting gear, carriers.
6. Plan process and logistics: sequences, takt, waste streams, traffic routes, permits.
7. Assure quality and document: hold points, inspection and test plan, photo log, approvals.

Objectives and tasks of work preparation

The objectives are safety, predictability, quality, and cost-efficiency while considering the environment, neighborhood, and protection of existing structures. Essential tasks are:

• Safety management: hazard analysis, rescue and emergency concept, training.
• Method planning: decision split/separate/cut; selection of concrete pulverizer, hydraulic splitter, attachment shear, multi cutters, steel shear, cutting torch.
• Resource planning: sizing of hydraulic power pack, tools, hydraulic hose line, adapter plate, wear parts.
• Process and takt: sequences, sections, handovers, drying times, setup times.
• Logistics: accessibility, traffic routes, lifting device, waste disposal logistics, container service.
• Quality and monitoring: measurement and test plan, vibration and dust control, approvals.
• Documentation: reports, photo documentation, quantity takeoff, records, handover protocols.
• Stakeholder and permit management: coordination with owners, operators, and authorities including lead times for approvals.

Survey of existing structure, material, and surroundings

Structural and component analysis

Determine cross-sections, concrete compressive strength class, reinforcement density, prestressing systems, joints, bonding agents, and connections. Include non-destructive testing and selective exposure where needed for verification. Relevance: selection of the concrete pulverizer (jaw opening, cutting or crushing capacity) and estimation of split travel for hydraulic splitter.

Material and hazardous substance survey

Record coatings, chloride contamination, asbestos, PCB, PAH as well as embedded components. Define a low-contamination approach and separate disposal, preferably with low-emission methods and low-dust separation cuts. Where required, establish a sampling plan and lab analyses with release criteria.

Geology and subsoil

In rock excavation and tunnel construction: rock classes, jointing, bedding, water conduction. Splitting direction and wedge positions for rock wedge splitter are derived from this. Consider water ingress control and support measures for stability.

Utilities, media, neighborhood

Utility location and exposure of utilities, shut-off and draining concepts, fire protection. Define limits for noise emission, dust, and vibrations, monitoring points, and work windows. Set trigger values, escalation rules, and communication paths for exceedances.

Decision aid: split, separate, or cut

The methods are chosen according to component thickness, reinforcement level, accessibility, emission requirements, and demolition objective:

• Hydraulic splitter: low vibration levels, pinpoint, suitable for massive components, sensitive areas, rock, and tunnels; planning focus is on drilling pattern, wedge set, and splitting sequence.
• Concrete pulverizer: efficient crushing of concrete and masonry, selective deconstruction, good control of fracture lines; selection by jaw opening, crushing force, weight, and mounting.
• Attachment shear / multi cutters: flexible for mixed materials, ideal for varying cross-sections and reinforcement contents.
• Steel shear: separating profiles, rebar bundles, tanks, and steel structures.
• Cutting torch: controlled opening and segmenting of vessels with defined safety measures.

A frequent combination is pre-cutting of reinforcement and breaking with concrete pulverizer, followed by controlled splitting of thick cores with hydraulic splitter to minimize vibrations, noise, and secondary damage. As a rule of thumb, choose splitting for massive, restraint-rich parts and choose separating when defined edges, speed, and material selectivity are paramount.

Hydraulic power pack: design and supply

Hydraulic power packs are matched to operating pressure, flow rate, and load cycles of the tools used. Relevant points:

• Performance matching: sum of consumers, simultaneous use, reserves for peak loads.
• Hose management: lengths, cross-sections, check and safety valves, quick coupling systems.
• Power supply: electrical feed, waste heat, ventilation, if necessary, exhaust routing; use indoors only with suitable units.
• Operating cycles: takt times, cooling phases, maintenance windows, oil quality and filtration.
• Environmental safeguards: drip trays and spill kits, hose burst protection, low-noise enclosures where required.

For rock wedge splitters, the constant provision of the required operating pressure is essential; for concrete pulverizer, crushing force, cycle time, and operability must be considered. A precise sizing prevents performance drops, overheating, and increased wear. Clarify interfaces if carrier hydraulics are used alternatively or in combination.

Process planning, sequences, and takt

Cutting and splitting sequence

First relieve, then separate or split – the order prevents unintended load redistribution. Define segment sizes, gripping points, and load paths for safe setting down. Where lifting is involved, prepare a lifting plan with assigned roles and verification of capacities.

Temporary safeguards

Plan shoring, suspension points, and lifting clamp/tongs in advance. Concrete pulverizers often work in combination with lifting devices; splitters require secure wedge positions and safety distance zones. Use taglines and verify rated capacities including dynamic factors.

Takt planning

Setup times, tool changes, drilling times, splitting operations, material removal as well as repetition rates are transparently mapped in the takt plan. Include buffers for cleaning, inspection, and approvals to stabilize output.

Construction logistics and site setup

• Access and traffic routes: load-bearing capacity, ramps, bottlenecks, escape routes.
• Material flow: construction site waste container placement, construction waste sorting, intermediate storage, weighing and records.
• Dust and noise reduction: water spray system, dust extraction plant, encapsulation, work time windows.
• Workplaces: safe work platform for operators, lighting, weather protection.
• Site energy and media: water management, electrical distribution, cable and hose routing with protection against damage.

Safety, health protection, and permits

The measures are based on generally accepted rules of technology and legal requirements, which must be checked depending on the project. These include hazard analysis, training, SiGe coordination, where applicable permits (e.g., hot work), barricading concepts, and emergency plans. When working with hydraulics, pay attention to pressure tests, kink protection, leak detection, and safe depressurization. For concrete pulverizer, steel shear, and cutting torch, consider sparks, cut edges, and crushing points; with hydraulic splitter, plan safety fence and covering measures against uncontrolled fragments. Implement lockout/tagout for utilities and specify silica dust control, fire watch, and handling of explosive atmospheres where applicable.

Quality assurance and monitoring

• Measurement and test plan: vibration, dust, and noise measurements, crack monitoring, settlement checks.
• Tool condition: wedges, cutting edges, jaws, bolts, pivots; replacement per specifications.
• Records: photo documentation, test protocols, material and disposal records.
• Acceptances: section and interim acceptances, release points for follow-up steps, documented hold points.

Application areas: specific aspects in work preparation

Concrete demolition and special demolition

Focus on residual load-bearing capacity, controlled segmentation, vibration control, and dust suppression as specified for concrete demolition and special deconstruction. Concrete pulverizer for structural opening, hydraulic splitter for massive nodes or foundation. Typical elements include slabs, walls, beams, piers, and bases.

Building gutting and cutting

Selective dismantling, separating of installations and components. Multi cutters and steel shears for profiles, concrete pulverizer for breakthroughs, cutting torch for defined openings under protective measures. Emphasize contamination control and protection of remaining finishes.

Rock excavation and tunnel construction

Joint analysis, drilling pattern planning, water flow, and monitoring. Rock wedge splitters enable controlled splitting sequences where vibrations must be limited. Sequence control and support coordination are essential for face stability.

Natural stone extraction

Splitting direction and blockiness determine wedge positions and splitting forces. Focus on repeatability, dimensional accuracy, and gentle handling of the material. Plan lifting and packing to preserve edge quality.

Special operations

Confined spaces, monument protection, sensitive existing structures. Equipment with reduced emission, short setup times, precise cutting and splitting sequence. Define micro-takt with tight control of debris and access.

Equipment selection and parameterization

• Concrete pulverizer: jaw opening, crushing and cutting force, own weight, reach, operator concept, wear lining, carrier class compatibility.
• Hydraulic splitter: splitting force, wedge geometry, drill hole diameter, split travel, required operating pressure, drilling system compatibility.
• Attachment shear / multi cutters: changeable jaws, versatility in mixed construction methods, cutting geometry and maintenance access.
• Steel shear / cutting torch: cutting force, cutting geometry, spark and ignition protection concept, shielding and slag management.
• Hydraulic power pack: pressure/flow rate, cooling, power supply, transport and setup, remote control and monitoring options.

Digital tools in work preparation

Digital survey, 3D/4D models, collision-checked sequences, mobile checklists, and continuous documentation improve transparency and decision quality. Sensors for vibration, dust, and noise provide real-time data for approvals and takt adjustments. A common data environment with version control, QR-coded equipment, and telemetry for operating hours streamlines coordination and reporting.

Key figures, costing, and control

• Performance values: takt times per cut/split, drilling meters per hour, tons per shift.
• Setup and changeover times: tool and wedge changes, repositioning, hose management.
• Emission indicators: vibration and noise levels, fine dust concentration.
• Quality indicators: dimensional accuracy, fracture pattern, rework rate, downtime.
• Cost metrics: unit rates per meter or cubic meter, cost per ton, energy consumption per output unit.

Sustainability and resource efficiency

Selective deconstruction, construction waste separation, reuse, and recycling must be defined already in work preparation. Methods such as controlled splitting reduce secondary damage and facilitate source-pure recovery. Documented material flow and optimized transport routes reduce emissions and costs. Preference for low-noise work windows, energy-efficient power packs, and suitable hydraulic oils can further reduce environmental impact.

Avoid typical mistakes

• Underestimated reinforcement or jointing → preliminary checks, trial steps, alternative wedge or pulverizer configurations.
• Undersized hydraulic power pack → plan performance matching and reserves.
• Poor hose and coupling management → avoid pressure losses, leaks, and downtime.
• Unclear cutting and splitting sequence → define takt and release points, communicate visually.
• Missing emissions management → limit and monitor dust, noise, and vibrations in advance.
• Insufficient stakeholder communication → clarify access, shutdowns, and neighborhood constraints before mobilization.
• Permit lead times ignored → schedule hot work and street occupancy permits with buffers.