{"id":19463,"date":"2025-11-13T12:14:39","date_gmt":"2025-11-13T11:14:39","guid":{"rendered":"https:\/\/www.darda.de\/?page_id=19463"},"modified":"2026-04-29T09:27:03","modified_gmt":"2026-04-29T07:27:03","slug":"secondary-breakage","status":"publish","type":"page","link":"https:\/\/www.darda.de\/en\/knowledge\/secondary-breakage","title":{"rendered":"Secondary breakage"},"content":{"rendered":"<div class=\"wissen-inhaltsbereich\">\n<p>Secondary breakage refers to the targeted follow-up processing of already detached structural elements or rock blocks to reduce them to manageable sizes, expose reinforcement, or adjust geometry. In deconstruction, rock excavation and tunnel construction, this work step directly follows the primary demolition and determines occupational safety, cycle time, noise and vibration levels, as well as recycling quality. Frequently, <em>concrete pulverizers<\/em> or <a href=\"https:\/\/www.darda.de\/en\/product-overview\/hydraulic-rock-and-concrete-splitters\">hydraulic rock and concrete splitters<\/a> are used, supplied by <a href=\"https:\/\/www.darda.de\/en\/product-overview\/hydraulic-power-units\">compact hydraulic power units<\/a>. Properly planned, secondary breakage enables controlled, low-emission, material-specific fragmentation &#8211; from selective concrete demolition to natural stone extraction. It also influences operator exposure and overall site productivity; key indicators include fragment size distribution, peak particle velocity (PPV), A-weighted sound levels (LpAeq), and tool utilisation. When aligned with logistics and recycling requirements, secondary breakage supports compliant disposal and high recovery rates.<\/p>\n<h2>Definition: What is meant by secondary breakage?<\/h2>\n<p>Secondary breakage is the <strong>secondary size reduction<\/strong> or <strong>further separation<\/strong> of already detached concrete and masonry elements, steel and mixed composites, or rock and natural stone blocks. The aim is to transfer components into transport- and sorting-capable fractions, expose reinforcing steel, and create the prerequisites for haulage, reuse, or material recycling. In contrast to primary demolition (e.g., cutting, sawing, drilling, blasting), secondary breakage acts locally, in a controlled manner, and is generally <em>low-vibration<\/em>; typical methods are hydraulic <strong>pressing, splitting, cutting and crushing<\/strong>, for example with concrete pulverizers or rock and concrete splitters. <em>In practice, the focus lies on predictable fracture paths, low edge damage, minimal dust, and cleanly exposed rebar to enable efficient downstream processing.<\/em><\/p>\n<h2>Process, methods and tools in secondary breakage<\/h2>\n<p>Secondary breakage follows a simple logic: first the suitable attack point is selected, then the component geometry is assessed with regard to reinforcement, stresses, and support conditions. Subsequently, suitable tools are used to release, split, cut, or crush the components in a controlled way. Hydraulic power packs provide the necessary output, while shears, pulverizers, split cylinders and special devices perform the actual separation work. A short verification step with visual checks and, if required, measurements of vibration and noise ensures that parameters such as pressure, stroke and cycle rate are optimally set.<\/p>\n<ul>\n<li><strong>Typical sequence<\/strong>: identify attack points and support conditions; define target fragment sizes; predrill or precut where helpful; execute splitting or crushing in controlled cycles; expose and cut reinforcement; sort and clear promptly.<\/li>\n<\/ul>\n<h2>Methods and tools at a glance<\/h2>\n<p>Depending on material, component thickness, degree of reinforcement and environmental sensitivity, different methods are combined. The most important tool groups in secondary breakage are:<\/p>\n<ul>\n<li><strong>Concrete pulverizers<\/strong>: For controlled crushing of concrete and masonry and for exposing reinforcement. Advantages include precise placement, low edge damage, and good material separation quality.<\/li>\n<li><strong>Rock and concrete splitters<\/strong>: Split massive components or rock blocks using wedge-based static forces. The method is <em>low-vibration<\/em> and suitable for noise-sensitive areas or works near load-bearing structures.<\/li>\n<li><strong>Rock splitting cylinders<\/strong>: For pinpoint initiation of desired fracture lines in rock or thick concrete; often in combination with predrilled initiation points.<\/li>\n<li><strong>Combination shears<\/strong>: Combine crushing and cutting functions, helpful when switching between concrete crushing and cutting lighter steel inserts.<\/li>\n<li><strong>Multi Cutters<\/strong>: For clean cutting of lines, cables, pipes and lighter steels, ideal for pure-type material separation in secondary breakage.<\/li>\n<li><strong>Steel shears<\/strong>: For load-bearing sections, thick reinforcement bundles or more massive steel components that must be cut after exposure.<\/li>\n<li><strong>Tank cutters<\/strong>: For controlled sectioning of vessels, tanks, and double-walled hollow bodies during deconstruction, particularly when sparking must be minimized.<\/li>\n<li><strong>Hydraulic power packs<\/strong>: Provide the required output for mobile pulverizers, shears and splitters; the choice of pressure and flow rate influences force, cycle time and efficiency. Modern units support adjustable pressure\/flow, energy-efficient standby modes and quick-couplers to reduce changeover times.<\/li>\n<\/ul>\n<h2>Fields of application and typical workflows<\/h2>\n<p>Secondary breakage is established across several industries. The appropriate tools and sequences differ according to building material, boundary conditions and target sizes.<\/p>\n<h3>Concrete demolition and special deconstruction<\/h3>\n<p>In selective deconstruction, secondary breakage is used to reduce elements step by step, expose reinforcement and separate materials by type. <strong>Concrete pulverizers<\/strong> are the central tool here; <em>rock and concrete splitters<\/em> are used where vibration, noise and dust are particularly critical. Coordinated sequencing from less to more constrained sections, with early reinforcement exposure, shortens cycles and improves sorting quality.<\/p>\n<ol>\n<li>Component analysis: geometry, support conditions, reinforcement routing, removal direction<\/li>\n<li>Pre-cutting\/pre-drilling of desired fracture lines (if required)<\/li>\n<li>Secondary breakage with concrete pulverizer or splitter in controlled cycles<\/li>\n<li>Expose and cut reinforcement using Multi Cutters or steel shears<\/li>\n<li>Sort by material fractions and load out<\/li>\n<li>Final trimming and housekeeping for clean interfaces and safe transport<\/li>\n<\/ol>\n<h3>Strip-out and cutting<\/h3>\n<p>In strip-out, secondary breakage is used to create openings, exploit embrittlement and release embedded items. After sawing or drilling, <em>breaking<\/em> with the concrete pulverizer often follows to form edges or bring components to transport size. Cold-cutting approaches and targeted splitting help to reduce sparks and fumes in sensitive interiors.<\/p>\n<h3>Rock excavation and tunnel construction<\/h3>\n<p>After primary loosening (e.g., blasting or milling), oversize pieces arise that must be reduced for workflow and conveying. <strong>Rock splitting cylinders<\/strong> and <strong>rock and concrete splitters<\/strong> enable controlled, <em>low-vibration<\/em> secondary size reduction, even in restricted cross-sections or near sensitive lining elements. Compliance with project-specific PPV limits and minimised flyrock risk are typical control targets.<\/p>\n<h3>Natural stone extraction<\/h3>\n<p>In natural stone extraction, raw blocks are secondarily broken so that usable geometries and smooth fracture surfaces are maintained. Static splitting methods minimize microcracks, benefiting surface quality and downstream processing. Orientation along bedding, joint sets and cleavage planes increases yield and surface integrity.<\/p>\n<h3>Special applications<\/h3>\n<p>In areas with heightened protection requirements &#8211; such as hospitals, laboratories, industrial plants or for tanks and vessels &#8211; <em>precise<\/em>, <em>low-vibration<\/em> secondary breakage is crucial. <strong>Tank cutters<\/strong>, Multi Cutters as well as concrete pulverizers and splitters are combined to limit sparking, noise and vibration. Hazard assessments for confined spaces and potentially explosive atmospheres, alongside method statements, provide additional safeguards.<\/p>\n<h2>Selection of the appropriate method<\/h2>\n<p>The choice of pulverizer, splitter, shear or a combination is based on technical, organizational and environmental criteria:<\/p>\n<ul>\n<li>Component properties: thickness, compressive strength, aggregates, degree and position of reinforcement<\/li>\n<li>Accessibility: working space, lifting equipment, visibility, attack points, edges<\/li>\n<li>Environment: vibration and noise control, dust limits, neighborhood, building statics<\/li>\n<li>Process goals: target fragment size, type purity, reusability, conveying logistics<\/li>\n<li>Resources: availability of the hydraulic power pack, tool change times, operator competence<\/li>\n<li>Safety: fall, crushing and cutting hazards, safe load handling, emergency-stop concepts<\/li>\n<\/ul>\n<p>A structured selection matrix, small-scale test passes and parameter logging (pressure, flow, stroke rate) support reproducible decisions and reduce rework.<\/p>\n<h2>Process organization, safety and environment<\/h2>\n<p>Secondary breakage significantly influences site logistics and compliance with protection targets. The following have proven effective in practice:<\/p>\n<ul>\n<li><strong>Occupational safety<\/strong>: Bracing components, protection against falling parts, clear exclusion zones, safe hose routing, regular functional checks of the hydraulics.<\/li>\n<li><strong>Vibration and noise control<\/strong>: Prefer static splitting methods or precise crushing with concrete pulverizers; choose stroke rate and pressure moderately, set contact points according to plan.<\/li>\n<li><strong>Dust and water management<\/strong>: Wet in a targeted manner, retain and dispose of water; prioritize low-emission work sequences.<\/li>\n<li><strong>Material separation<\/strong>: Pure fractions through early exposure and cutting of reinforcement with Multi Cutters or steel shears; short routes to sorting.<\/li>\n<li><strong>Documentation<\/strong>: Recorded masses, fractions, transport routes and reuse rates secure quality and verification.<\/li>\n<li><strong>Monitoring<\/strong>: Spot measurements of PPV, airborne dust and sound levels during critical steps; adjust parameters where thresholds are approached.<\/li>\n<li><strong>Permits and communication<\/strong>: Align working hours, transport windows and protection measures with local requirements and stakeholder expectations.<\/li>\n<\/ul>\n<h2>Sizing in secondary breakage: practical guidelines<\/h2>\n<p>The target size should be aligned with transport equipment, grapple width, container size and downstream crushing\/screening stages. Uniform piece sizes shorten cycle times and facilitate sorting. For heavily reinforced components, it is often efficient to first crush the concrete with the <strong>concrete pulverizer<\/strong>, expose the reinforcement, and only then cut it with <strong>steel shears<\/strong> or <strong>Multi Cutters<\/strong>. In noise-sensitive or structurally critical situations, <em>splitting<\/em> with <strong>rock and concrete splitters<\/strong> is suitable to trigger load redistribution in a controlled way with minimal edge cracking.<\/p>\n<ul>\n<li>As a rule of thumb, the maximum fragment edge length should be around 40 to 60 percent of the grapple jaw width to enable secure handling.<\/li>\n<li>Manual handling is avoided; where unavoidable, fragment mass must remain within permissible lifting limits and have non-sharp edges.<\/li>\n<li>Predrilling for splitters: select hole diameter and spacing according to splitter size and tensile strength; closer spacing is required for high-strength or heavily reinforced concrete.<\/li>\n<\/ul>\n<h2>Example workflow in building deconstruction<\/h2>\n<ol>\n<li>Pre-survey: component assessment, reinforcement analysis, boundary conditions (noise, vibration, dust)<\/li>\n<li>Primary separation: sawing\/drilling or mechanical separation to produce manageable segments<\/li>\n<li>Secondary breakage: crushing with <strong>concrete pulverizers<\/strong> or <em>splitting<\/em> with <strong>rock and concrete splitters<\/strong>, adjusted to the target fragment size<\/li>\n<li>Expose and cut: reinforcement with <strong>Multi Cutters<\/strong> or <strong>steel shears<\/strong>; separate pipes\/cables<\/li>\n<li>Sorting: provide concrete, steel, masonry, lines and special substances separately<\/li>\n<li>Loading and haulage: adapt piece sizes to grapple\/container; keep routes short<\/li>\n<li>Monitoring and optimisation: check noise, dust and PPV; adjust pressure, stroke rate and attack points as required<\/li>\n<li>Documentation: record quantities, fractions, and disposal or recycling routes<\/li>\n<\/ol>\n<h2>Quality and recyclability<\/h2>\n<p>High-quality secondary breakage creates clean edges, defined piece sizes and cleanly exposed reinforcement. This improves the recyclability of concrete rubble as <em>recycled construction material<\/em> and shortens process times in downstream crushing and screening plants. In natural stone extraction, careful splitting yields low-crack blocks, simplifying further processing. Clearly separated fractions with low contamination enable high recovery rates for aggregates and metals; typical targets include a high reinforcing steel recovery rate with minimal concrete adherence and low fines generation. The appropriate combination of <strong>concrete pulverizers<\/strong>, <strong>rock and concrete splitters<\/strong> and suitable shears, supplied by matching hydraulic power packs, enables efficient, safe and environmentally compatible secondary breakage &#8211; in concrete demolition, in rock excavation and in tunnel construction alike.<\/p>\n<\/div>\n","protected":false},"excerpt":{"rendered":"<p>Secondary breakage refers to the targeted follow-up processing of already detached structural elements or rock blocks to reduce them to manageable sizes, expose reinforcement, or adjust geometry. In deconstruction, rock excavation and tunnel construction, this work step directly follows the primary demolition and determines occupational safety, cycle time, noise and <a class=\"moretag\" href=\"https:\/\/www.darda.de\/en\/knowledge\/secondary-breakage\">read more&#8230;<\/a><\/p>\n","protected":false},"author":9,"featured_media":0,"parent":14846,"menu_order":0,"comment_status":"open","ping_status":"open","template":"tmpl\/template-wissen.php","meta":{"_acf_changed":false,"footnotes":"","_members_access_role":[],"_members_access_error":""},"class_list":["post-19463","page","type-page","status-publish","hentry"],"acf":[],"yoast_head":"<!-- This site is optimized with the Yoast SEO plugin v28.3 - https:\/\/yoast.com\/product\/yoast-seo-wordpress\/ -->\n<title>Secondary Breakage for Concrete &amp; Rock Demolition<\/title>\n<meta name=\"description\" content=\"Guide to secondary breakage for demolition, deconstruction and rock excavation \u2713 safe low-vibration size reduction.\" 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