In construction, fit-out describes both interior fit-out and deconstruction-oriented strip-out of components. In the context of refurbishment, renovation and selective deconstruction, it involves the controlled removal, separation and renewal of structures—from building gutting to opening walls and slabs. Low-emission methods, precise workflows and careful construction waste separation play a central role. Tools such as the concrete pulverizer and hydraulic wedge splitter are frequently used, supported by hydraulic power pack units as well as cutting and shearing tools for concrete, steel and composite materials. The goal is a safe, plannable and resource-efficient approach in existing buildings, in infrastructure construction and in industrial environments.
Definition: What is meant by fit-out
Fit-out refers, on the one hand, to the construction and refinement of the interior areas of a structure (interior fit-out). On the other hand, in technical usage it stands for the selective deconstruction of components: the removal of non-load-bearing and—after structural release—also load-bearing elements, the creation of openings, the separation of reinforcement, utilities and attachments, as well as the orderly disposal and recycling of the arising materials. Deconstruction-oriented fit-out is closely linked to building gutting and cutting, precise concrete demolition and deconstruction and special demolition. Methods such as crushing with a concrete pulverizer or controlled splitting with a hydraulic wedge splitter enable low-vibration, noise-reduced and targeted operations that are particularly required in existing structures and sensitive environments.
Process and work steps in fit-out
Fit-out typically follows a structured process that accounts for safety, building physics and construction sequencing. From the survey of existing conditions to handover, the steps are carefully planned and documented.
Typical process
- Survey of existing conditions: Review of drawings, investigation of construction materials, identification of utilities, reinforcement and connections.
- Permits and shutdowns: Secure and de-energize electrical systems, media lines and mechanical systems, including utility power isolation.
- Hazardous substance survey: Check for potential hazardous substances; if necessary, separate remediation.
- Building gutting: Removal of non-load-bearing components, claddings, installations, finishes and fixtures.
- Selective deconstruction: Creation of openings, removal of load-bearing parts after structural release, component separation.
- Logistics and material flow: Construction waste sorting, intermediate storage, haulage logistics, documentation for recycling.
- Quality assurance: Measurements (ground vibration monitoring, noise emission, dust exposure), rework and acceptance.
Method selection
Depending on the task, mechanical, hydraulic and thermal methods are combined. A concrete pulverizer is suitable for crushing and separating reinforced concrete parts, while a hydraulic wedge splitter splits components in a controlled manner along defined separation joints—low in vibration and without impact energy. Steels and sections are cut with a steel shear, hydraulic demolition shear or multi-purpose cutters; a cutting torch is used for specialized industrial objects in special demolition. The energy supply is provided by suitable hydraulic power pack units.
Methods in deconstruction-oriented fit-out
Crushing with a concrete pulverizer
The concrete pulverizer grips and crushes components in defined bites. Reinforcing steel can be severed in the process or exposed and then cut with a steel shear. The method is suitable for concrete demolition and special demolition, for removing wall slabs, column heads and slab edges, as well as for creating door and window openings.
Splitting with a hydraulic wedge splitter
The hydraulic wedge splitter works on a wedge principle with high, locally confined pressing pressure. It produces separation joints without impact, with low vibration and reduced dust. This is advantageous in sensitive areas of existing structures, for heritage elements, in hospitals or laboratory buildings, as well as in tunnel construction and in natural stone extraction. Splitting enables precise edges and minimizes consequential damage.
Cutting, shearing, separating
- Steel shear and hydraulic demolition shear: Controlled cutting of sections, reinforcement, utilities and sheets.
- Combination shears: Combine gripping, crushing and cutting for changing materials.
- Cutting torch: Tailored cutting technology for vessels, boilers and thick-walled shells in special demolition.
Application areas of fit-out
Building gutting and cutting
In existing buildings, claddings, installations and non-load-bearing walls are removed, openings are cut and components are separated. The concrete pulverizer and hydraulic demolition shear support the source-separated handling of concrete, masonry, metal and composite materials.
Concrete demolition and special demolition
For complex interventions in load-bearing structures, controlled, low-vibration methods are important. The hydraulic wedge splitter introduces defined separation joints; the concrete pulverizer crushes the separated parts so they can be safely transported away.
Rock excavation and tunnel construction
In underground areas and where adjacent buildings are close, low-vibration technology is often used. Splitters and wedge cylinders reduce blasting vibrations and minimize impacts on neighboring structures. These approaches are standard in rock demolition and tunnel construction.
Natural stone extraction
Targeted splitting produces natural fracture surfaces and improves yield. The method is precise and protects adjacent layers.
Special operations
Industrial plants, power stations or chemical facilities have special requirements regarding emissions, sparks and process safety. Cutting torches, steel shears and hydraulic separation technology are used, supported by tailored permit and safety procedures.
Planning, structural analysis and safety in fit-out
Structural release and construction stages
Before intervening in load-bearing components, structural analyses and releases are required. Temporary shoring and defined construction stages ensure residual load-bearing capacity during fit-out.
Occupational safety and emissions
- Vibrations: Splitting methods and pulverizers reduce vibrations compared to breaker hammers.
- Noise and dust: Hydraulic separation technology, dust extraction and mist/wetting systems lower emissions, including noise control measure and dust suppression.
- Hazardous substances: Survey, separate remediation and sealed work areas protect personnel and surroundings.
Material separation, recycling and sustainability
Source-separated handling increases the recycling rate and reduces disposal costs. The concrete pulverizer facilitates exposing reinforcement; the hydraulic wedge splitter creates clean separation faces that simplify further processing. Recyclable fractions such as concrete debris, steel, non-ferrous metals and natural stone are collected separately and returned to the cycle.
Hydraulic power packs and energy supply
The hydraulic power pack reliably supplies shears, cutters and splitting cylinders with operating pressure and flow. Design is based on required drive power, hose lengths and environmental influences. A well-matched hydraulics setup reduces energy losses, improves controllability and supports smooth, precise tool movements.
Selection criteria for methods and tools
- Material and component thickness: Density, reinforcement ratio, composite and layer build-up determine the crushing or splitting strategy.
- Environmental conditions: Vibration limits, noise insulation, dust limits and accessibility influence the method.
- Precision requirements: Dimensional accuracy of openings, protection of adjacent components, rework.
- Logistics: Dimensions of handling pieces, lifting devices, routing and intermediate storage.
- Safety: Shutdowns, shoring, emergency exits and monitoring system.
Quality assurance and documentation
A structured fit-out includes measurement and verification concepts. Protocols on shutdowns, material flows and emissions, photo documentation, surveying of openings and test reports on construction stages ensure traceability. Tests of residual load-bearing capacity and visual inspections of separation faces minimize risks in subsequent construction phases.
Practice-oriented application cases
- Openings in reinforced concrete walls: Marking, surveying, shoring; splitting along drill lines with a hydraulic wedge splitter, finishing with a concrete pulverizer, cutting reinforcement with a steel shear.
- Removing slab edges: Section-by-section biting with a concrete pulverizer, controlled lowering of fragments, source-separated handling.
- Dismantling industrial tanks: Media-free, inerted; cutting with a cutting torch, cut edge reinforcements with a steel shear, safe handling and disposal.
- Rock breakout in tunnel heading: Splitting instead of blasting in sensitive zones, reduced vibrations and protection of adjacent structures.
Readability, efficiency and result quality in fit-out
Successful fit-out combines precise planning, suitable methods and well-matched hydraulics with qualified execution. The concrete pulverizer and hydraulic wedge splitter broaden the spectrum between mechanical removal and cutting methods and contribute to low-emission, controlled results in existing buildings, in special demolition and in underground construction.