Haulage logistics describes the planned organization of material outflow from demolition, deconstruction, and extraction processes through to safe handover to intermediate storage, recycling plants, or disposal routes. In practice, it connects the work at the structure—such as size reduction with concrete demolition shears or controlled splitting with hydraulic rock and concrete splitters—with the continuous removal via internal routes, loading points, and external transports. Its goal is a disruption-free, safe, and resource-efficient material flow that meets cycle times, reduces emissions, and preserves the selectivity of material streams.
Definition: What is meant by haulage logistics
Haulage logistics is the entirety of planning, control, and execution measures that ensure the material outflow from the point of processing (e.g., concrete demolition, strip-out, rock extraction) through to loading and handover to downstream recovery or disposal. This includes sizing of pieces, selection of suitable means of transport, design of internal traffic routes, pacing of loading and waiting times, intermediate storage, and documentation of material flows. Haulage logistics is interface management: it synchronizes tools and equipment (such as concrete demolition shears, rock and concrete splitters, combination shears, hydraulic power packs) with transport and loading to ensure throughput, safety, and quality of separation of material fractions.
Tasks and objectives of haulage logistics
Haulage logistics combines operational and tactical tasks to buffer peak loads, avoid downtime, and use capacities efficiently. Key objectives include adherence to cycle and time windows, safe traffic management, pure separation by type, and cost-efficient loading. Constant coordination between material generation (e.g., by concrete demolition shears or rock and concrete splitters) and material removal is essential.
- Ensure a continuous material flow without backlogs or material shortages at the loading points
- Size transportable piece dimensions depending on crane load, container size, payload, ramp geometry, and conveying technology
- Pace loading cycles (excavators, wheel loaders, cranes) and container turnover to minimize waiting times
- Fractional capture (concrete, reinforcing steel, non-ferrous metals, wood, plastics, contaminated materials) for high-quality recovery
- Safety-compliant traffic guidance with clear pedestrian and vehicle routes, sight zones, and signalman concepts
- Minimize dust, noise, and vibration through suitable work sequences, watering, cushioning, and adapted pacing
- Document masses and material flows (weigh tickets, delivery notes) and align dispatching with disposal companies
- Transparent KPI control (t/h, utilization, cycle time, buffer levels) and proactive bottleneck elimination
Process chain from demolition to loading
The process chain begins at the structure and ends at the handover point. The better the transitions are planned, the smoother the removal runs. Tools and equipment from Darda GmbH—such as concrete demolition shears, rock and concrete splitters, rock splitting cylinders, combination shears, Multi Cutters, steel shears, or tank cutters—shape the piece formation and thus the haulage strategy. Hydraulic Power Units provide the energy for constant and reproducible work cycles.
Material preparation and size reduction
Concrete demolition shears create defined break edges and expose reinforcement, which facilitates downstream sorting and gripping with loading equipment. Rock and concrete splitters as well as rock splitting cylinders allow low-vibration, crack-controlled dismantling into transportable blocks—advantageous for load limitations or sensitive environments. Steel Shears cut reinforcing steel to manageable lengths; combination shears and Multi Cutters cover changing material mixes. Tank cutters are used in special operations with thin-walled, contaminated, or potentially explosive vessels.
Piece sizes, lot formation, and buffers
- Piece size is determined by crane hook load, internal container dimensions, conveyor belt width, debris chute cross-section, truck payload, and floor access
- Lot formation follows cycle planning: generation and removal performance are decoupled via buffer areas
- Splitting and cutting patterns are selected to ensure grip-ability, tipping stability, and stackability
- Rebar bundles are shortened, bundled, and separated before removal
Means of transport and internal routes
The choice of means of transport depends on terrain, structure geometry, and throughput. Crawler excavators, wheel loaders, dumpers, conveyors, debris chutes, cranes, and lifting devices form the internal transport chain. Their performance is determined by route quality, ramp gradients, turning areas, and defined one-way systems.
Loading and interface management
Loading into skip or roll-off containers, skips, big bags, or trucks is cycle-bound. Dust and noise are reduced by short drop heights, cushioning, covers, and mist/water spraying. A clear interface between loading point and dispatch reduces idle times and misroutes. Weighing and documentation make material flows transparent.
Specific requirements by application area
Concrete demolition and specialized deconstruction
Load-bearing capacity, low vibration, and selectivity are crucial here. Rock and concrete splitters produce structure-friendly piece sizes, concrete demolition shears separate concrete and reinforcement. Removal often proceeds floor by floor via cranes, debris chutes, or temporary ramps with tightly paced container logistics.
Strip-out and cutting
Selective deconstruction is dominated by small-scale material streams. Multi Cutters and combination shears support the separation of heterogeneous materials. Haulage logistics relies on short carry distances, mobile collection points, and temporary use of existing elevators or crane lifts; time-window management in occupied buildings is central.
Rock excavation and tunnel construction
In underground works, loaders, conveyors, mine cars, and ramps determine mucking capacity. Rock splitting cylinders and rock and concrete splitters enable controlled block formation with minimal edge loosening—beneficial for load securing and reduced wear on conveying equipment. Ventilation, dust suppression, and emergency routes are integral parts of haulage logistics.
Natural stone extraction
Preserving block quality takes priority. Splitters produce dimensionally accurate raw blocks handled by cranes or wheel loaders. Cushioning at support points, short drop heights, and clean traffic areas prevent edge breakouts and safeguard the value chain through to the plant.
Special applications
For tanks, plants, or sensitive components—such as in industrial settings—tank cutters and specialized shears are used. Haulage logistics takes into account potential hazardous substances, tight packaging, and separate collection points. Legal requirements for transport and disposal should generally be observed and coordinated with the competent authorities; this does not replace individual legal review.
Role of hydraulic power packs and tool coordination
Hydraulic power packs provide constant power for concrete demolition shears, rock and concrete splitters, and other tools. Coordinated pressure and flow-rate control shortens work cycles and reduces setup times. Tool changes are integrated into cycle planning so that generation and removal operate at matched performance and buffer areas remain small.
Planning, dispatching, and control
Throughput and container requirements are derived from mass and density assumptions. Cycle plans define generation, buffering, and removal performance. Bottleneck management (loading point, crane, access road) and time-window control with disposal companies ensure the availability of empty containers and prevent backlogs in public areas. Weather, lighting, and winter service must be included in route planning.
KPIs and digitalization
- Throughput (t/h) and turnaround time per transport means
- Utilization of loading and lifting equipment, container turnover per shift
- Buffer levels at collection points and loading points
- Digital delivery notes, weigh tickets, and track-&-trace of containers
Environmental, safety, and legal aspects
Occupational safety starts with clear responsibilities, barriers, and sight zones. Traffic routes are kept free of tripping and impact hazards; signalers secure maneuvering and crane operations. Dust is reduced by watering, misting technology, and adapted drop heights; noise by pacing, cushioning, and technical measures. Waste regulations, transport permits, and documentation obligations should be checked in advance and integrated into dispatching; the following notes are general and non-binding.
- Separate capture of fractions for high-quality recycling
- Suitable load securing and covering of containers
- Keep rescue and escape routes clear, ensure adequate lighting levels
- Regular training of personnel on traffic and communication rules
Best practices for alignment with concrete demolition shears and rock and concrete splitters
The quality of piece formation determines grip-ability, stackability, and loading performance. In practice, close alignment of processing with the removal chain has proven effective.
- Design splitting and cutting patterns to container size, crane load, and grab width
- Shorten and bundle reinforcement with steel shears before removal
- Keep drop paths short, cushion support areas, protect edges
- Dimension buffer areas and clearly signpost them (fractions, flow direction)
- Align cycle times of tool cycles, crane lifts, and container exchanges
Typical mistakes and how to avoid them
- Oversized pieces: pre-crack early with concrete demolition shears or split into transportable units with splitters
- Missing buffers: plan defined intermediate storage to cushion peak loads
- Unclear traffic routes: establish one-way systems, turning areas, and sightlines
- Mixing of fractions: signposted collection points and short routes to sorting
- Uncoordinated container logistics: fix time windows with disposers and keep reserve containers available
Checklist for site preparation
- Mass calculation, density assumptions, and target throughput (t/h)
- Define piece sizes in coordination with concrete demolition shears and rock and concrete splitters
- Route guidance, ramps, turning areas, and one-way concept
- Container types, quantities, reserve, and staging areas
- Buffer zones, signage, and fraction layout
- Dust and noise protection, lighting, weather plan
- Safety concept with signalers, escape routes, and communication rules
- Dispatching with disposers, weighing, and documentation workflow