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 levels are required, the decision between concrete pulverizer and hydraulic splitter moves early into the focus of planning.
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 survey, hazard analysis, selection of methods and equipment, scheduling, construction logistics, personnel and scheduling, quality assurance, environmental protection, as well as documentation. 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, concrete pulverizer, 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.
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.
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. 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.
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.
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.
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.
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.
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.
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.
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.
Takt planning
Setup times, tool changes, drilling times, splitting operations, material removal as well as repetition rates are transparently mapped in the takt plan.
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.
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.
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.
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.
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.
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.
Natural stone extraction
Splitting direction and blockiness determine wedge positions and splitting forces. Focus on repeatability, dimensional accuracy, and gentle handling of the material.
Special operations
Confined spaces, monument protection, sensitive existing structures. Equipment with reduced emission, short setup times, precise cutting and splitting sequence.
Equipment selection and parameterization
- Concrete pulverizer: jaw opening, crushing and cutting force, own weight, reach, operator concept.
- Hydraulic splitter: splitting force, wedge geometry, drill hole diameter, split travel, required operating pressure.
- Attachment shear / multi cutters: changeable jaws, versatility in mixed construction methods.
- Steel shear / cutting torch: cutting force, cutting geometry, spark and ignition protection concept.
- Hydraulic power pack: pressure/flow rate, cooling, power supply, transport and setup.
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.
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.
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.
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.