Work planning is the strategic and operational backbone of demanding tasks in concrete demolition, building gutting, rock excavation as well as special demolition. It connects analysis, process engineering, occupational safety and construction logistics into a traceable sequence. For applications with devices from Darda GmbH – from concrete pulverizers and rock and concrete splitters to hydraulic power packs and combination shears – this means: the right method, in the right time window, with the appropriate power unit and a team setup that minimizes risks and makes quality measurable.
Definition: What is meant by work planning
Work planning means the systematic preparation, control, and monitoring of all steps required for a safe, efficient, and compliant intervention in concrete or rock structures. This includes the selection of methods and tools, scheduling and resource planning, hazard analysis, construction site setup, coordination with other trades, and documentation. The aim is a risk-based and performance-stable execution with verifiable results.
Process and methods of work planning
Robust work planning follows a clearly structured process. An iterative approach has proven itself, in which technical findings and boundary conditions are continuously fed back and plans are adapted.
1. Initial situation and objective definition
- Inventory of structure, geology, reinforcement, access, load-bearing capacity, utility lines.
- Definition of objectives: removal quantities, permissible low vibration levels and noise emission, cuts and sequences, reuse or disposal routes.
2. Method selection and equipment logic
- Mechanical splitting, cutting, shearing, controlled deconstruction in separate construction sections.
- Matching component geometry, degree of reinforcement, environmental constraints and time window with available equipment (e.g., concrete pulverizers, rock split cylinders, combination shears, Multi Cutters, steel shears, cutting torch) and hydraulic power packs.
3. Resource and schedule planning
- Team sizes and qualifications, shift sequences, supply and waste disposal logistics.
- Schedule with buffers for weather, permits, inspections and measurements.
4. Safety and environmental management
- Hazard analysis, protective measures (dust suppression, noise control, low vibration levels), exclusion zones, emergency exits.
- Dewatering system, wastewater treatment, emissions reduction, construction waste separation.
5. Site setup and energy supply
- Staging areas, crane concept, anchor points, hose and cable routing, hydraulic power packs with sufficient drive power and reserve.
- Accessibility for haulage logistics, route guidance, lighting.
6. Execution, monitoring and adjustment
- Ongoing control of cut patterns, splitting progress, tool wear and working pressure/flow rate.
- Adjustments based on measurement data and team feedback, clean documentation.
Tool and method selection in concrete demolition
The selection of the appropriate tool is based on the goals, the structure, and the boundary conditions.
- Concrete pulverizers: suitable for selective removal, exposing reinforcement, stepwise reduction of cross-sections; advantageous in gutting works and controlled deconstruction.
- Rock and concrete splitters: hydraulic splitting with low vibration levels; ideal in sensitive environments, massive components and rock; pinpoint separation along prepared boreholes.
- Combination shears and Multi Cutters: flexible for mixed tasks when different materials must be separated in one sequence.
- Steel shears: focused on sectional and reinforcing steel; a frequent complement to concrete pulverizers for heavily reinforced elements.
- Concrete pulverizers in combination with hydraulic power packs: flow stability, pressure stability and thermal balance are essential; plan buffer times for cooling phases.
- Cutting torch (under special demolition conditions): for tank and vessel work only after thorough clearance measurement and with special protective measures.
Application areas and planning specifics
Concrete demolition and special deconstruction
In selective deconstruction, sequence and load transfer are crucial: relieve first, then separate. Concrete pulverizers generate controllable piece sizes and enable a stepwise approach. For massive cores or foundations, low-vibration splitting with rock and concrete splitters can protect the surroundings and minimize crack risks.
Building gutting and cutting
For interior work, vibration and noise limits take priority. Concrete pulverizers provide clean cut patterns on fit-out elements, split cylinders help with thick walls where sawing is limited. Logistically decisive: short routes, low-dust working methods and rapid disposal.
Rock excavation and tunnel construction
In rock, geology, bedding and stresses are decisive. Rock and concrete splitters allow controlled volume reduction when blasting works are not possible or not desired. Work planning considers drill pattern, splitting sequence, earth pressure, water inflows and the protection of existing structures.
Natural stone extraction
In quarries, the quality of the stone surface counts. Split cylinders support precise, reproducible separations along natural joints. Target sizes, block weights and lifting chains are defined in advance to optimize transport and further processing.
Special demolition
For tanks, sensitive infrastructure or contaminated sites, work planning is particularly cautious. Cutting torch and concrete pulverizers are used only after approvals, clearance measurements and with redundant safety measures. Safety fence, spark protection and firefighting water reserve are integral components.
Sequencing, separation cuts and load transfer
The sequence determines safety and pace. Proven procedures free loads early and create stable intermediate states.
- Pre-separation along clearly defined lines; marking and control measurement.
- Step-by-step removal: concrete pulverizers for edges and cantilevers, split cylinders for massive core zones.
- Shoring, temporary bearings and anchor points to be checked before starting.
- Planned steel separation: reinforcement is exposed, then cut with steel shears or hydraulic shear.
Safety, environmental and permitting aspects
Safety has priority. Planning includes hazard analysis, operating instructions, briefing and measurable limits.
- Vibrations and noise: splitting methods are often low vibration; secure limits with a monitoring system.
- Dust and water: pinpoint wetting, dust extraction, wastewater routing; protection of sensitive areas.
- Permits: work in protected areas, traffic zones or water-bearing layers only after general approval; clarify responsibilities early.
- Emergency management: routes, assembly points, first-aid equipment, reduce fire load.
Logistics, site setup and energy supply
Efficiency results from short routes and clear order. Hydraulic power packs require secured staging areas, sufficient ventilation and protection from damage.
- Access and load-bearing capacity: check surface load, ramps, floor slab loads; mark transport routes.
- Hose and cable management: avoid trip hazards, provide protection bridges, secure pressure hose lines.
- Material flow: defined buffer zones for construction debris, separate containers for recycling fractions.
- Maintenance: integrate visual inspections and pressure and temperature checks into work cycles.
Quality assurance and documentation
Quality is planned, measured and evidenced. Clear criteria help to objectify decisions.
- Metrics: daily output, piece sizes, cut accuracy, vibration and noise values, downtime.
- Documents: photo logs, measurement reports, inspection and maintenance records, handover reports.
- Feedback: evaluation for equipment selection (e.g., jaw types, splitting force, power pack drive power) for future deployments.
Digital planning aids and data
Digital surveys, building models and progress documentation support transparent work planning. Relevant data include material thicknesses, reinforcement layers, utility line routing, allowable loads and restricted areas. Visual checklists and simple dashboards increase readability and reduce error rates.
Typical planning errors and how to avoid them
- Underestimated reinforcement: plan early probing and test cuts.
- Schedules that are too tight: provide buffers for measurements, cooling phases and tool changes.
- Unclear responsibilities: fix roles, approvals and communication paths in writing.
- Inadequate emissions control: define measuring points and actively monitor limits.
- Unsuitable equipment selection: use a criteria catalog (component, environment, objective) in advance; combine concrete pulverizers and splitters.
Checklist for practice
- Clarify objectives and boundary conditions: scope of removal, limits, neighborhood.
- Component and environment analysis: load-bearing capacity, utilities, access, reinforcement.
- Define method selection: pulverizer, splitting, shearing, combinations.
- Energy and logistics: hydraulic power packs, staging areas, routes, disposal.
- Safety concept: hazards, protection measures, emergency exits.
- Schedule and resource plan: personnel, shifts, buffers.
- Measurement and QA plan: target values, logs, acceptances.
- Site start: briefing, trial section, fine-tuning.
- Ongoing control: performance, wear, emissions, adjustment.
- Completion: documentation, evaluation, lessons learned.
Practice-oriented deployment scenarios
Massive floor slab in an existing building
Low-vibration separation using rock and concrete splitters reduces risks for neighboring buildings; edge areas are trimmed in advance with concrete pulverizers to create lifting points.
Building gutting of a multi-story building
Concrete pulverizers for selective removal, steel shears for reinforcement; short internal routes, consistent dust suppression and noise control measures. Hydraulic power packs decentralized, with clear hose routes.
Rock excavation in a sensitive location
Drill pattern planning, step-by-step splitting, monitoring of vibrations and slope movements; material logistics with defined intermediate storage areas.
Cost-effectiveness and resource efficiency
Cost-effectiveness results from appropriate equipment selection, stable processes and minimal downtime. Combined methods – for example, pre-separation with concrete pulverizers and volume reduction with split cylinders – reduce emissions and transport quantities. Planned piece sizes facilitate handling and recycling.