Dust removal describes all technical and organizational measures to reduce dust emissions on construction sites, in quarries, and during deconstruction works. Especially in concrete demolition and special demolition, in rock excavation and tunnel construction, or in natural stone extraction, mineral dust is generated that can impair visibility, burden machinery, and endanger workers’ health. Tools such as concrete pulverizers, hydraulic rock and concrete splitters, combination shears, multi-cutters, steel shears, tank cutters, as well as the associated hydraulic power pack, shape the type and quantity of dust generation—and thus the requirements for effective dust suppression and extraction.
Definition: What is meant by dust removal
Dust removal means the targeted prevention, binding, separation, or dilution of airborne particles. This includes coarse particles as well as respirable fine dust from concrete, mortar, rock, or reinforced concrete. In accordance with the state of the art, dust removal combines low-dust methods, technical protective measures (water mist, point extraction, filters), organizational rules (workflows, logistics, zoning), and—subordinately—personal protective equipment. The goal is to minimize emissions at the source, reduce exposures, and limit environmental impacts.
Importance of dust removal in concrete demolition and special demolition
Concrete demolition and deconstruction release mineral dust, especially when breaking, separating, milling, or blending in dry fines. With force-driven tools featuring cutting or pressing action—such as concrete pulverizers and stone and concrete splitters—particle sizes and quantities differ significantly from those produced by percussive hammering or dry sawing. Pressing splitting and grasping/crushing generally generate fewer fine grinding dusts than abrasive processes; nevertheless, fine, respirable fractions are created when the cement matrix is fractured. A consistent dust removal strategy therefore considers process selection, the sequence of work steps, material wetting, and the spatial guidance of airflows to align visibility, health protection, and construction logistics.
Types of dust and emission sources in demolition and rock works
The generation and behavior of dust particles depend on the method, the material, and the processing intensity. Typical sources include:
- Cutting and crushing concrete components with concrete pulverizers (spalling the concrete cover, breaking the core concrete, exposing the reinforcement)
- Splitting rock and concrete using stone and concrete splitters or rock splitting cylinders (less abrasion, but microcracks with fine dust release)
- Dry sawing, milling, and drilling processes (pilot lines for splitting cylinders, joint cutting during strip-out)
- Material handling, drop edges, stockpile formation, and transport on unbound surfaces
- Secondary breaking and sorting of concrete debris as well as handling of reinforcement
- Cutting steel, tanks, and sections with steel shears, multi-cutters, or tank cutters (more metal fume and particles here, less mineral dust)
Dust removal methods: wet, dry, and combined
Measures that act at the source and are complemented by extraction and airflow control are effective. In practice, a coordinated combination has proven successful:
Wet methods and water mist
Fine water droplets bind particles before they disperse. Spray rings, nozzle arrays, or mobile mist units generate a droplet spectrum that yields high contact probability with dust. With concrete pulverizers and splitting, targeted pre-wetting of the separation joint and the fracture zone has proven effective. Adequate water volumes, uniform wetting, and the avoidance of visibility impairment are important.
Dry dust removal and point extraction
Where water is unsuitable (e.g., in sensitive interior areas, near media lines, or under freezing conditions), point extraction at the emission source and mobile filtration units with multi-stage separation are used. Cyclones, cartridge filters, and fine dust filters can be combined with negative-pressure units. Tightly guided capture directly on tools or within enclosures increases separation efficiency.
Combined solutions
With changing materials or large volumes, coupling wetting and extraction is recommended. Water binds the dust plume, and the residual concentration is reduced by air cleaning. Tailored airflow (supply, capture, exhaust) prevents secondary emissions.
Specifics when using concrete pulverizers
Concrete pulverizers grip, crush, and shear concrete. This leads to a particle distribution with less grinding dust but fracture-induced fine dust. For effective dust removal, the following points are crucial:
- Wet components before gripping, mist the joints on the air-facing side, and continue wetting the fracture edge immediately after the first crack
- Release fragments as close to the ground as possible, reduce drop heights, and wet drop points
- Plan material flow: short paths, moist intermediate storage, early separation of reinforcement
- Extract within enclosures or negative-pressure zones during interior demolition and strip-out
Specifics when using stone and concrete splitters
Splitters transfer controlled hydraulic forces into boreholes or joints. This reduces mechanical vibrations and can decrease dust release compared to grinding processes. Note the following:
- Low-dust pilot boreholes with water feed or effective borehole extraction
- Moisten separation joints to bind emerging microparticles early
- Plan splitting sequences so that mist zones remain small and effective
- Briefly re-wet fracture surfaces before relocating
Dust removal in rock excavation and tunnel construction
In tunnels and underground, air volumes and escape routes are limited. Therefore: minimize emissions at the source, control airflow, and ensure fresh air. In rock excavation, splitting cylinders reduce the need for percussive hammering; however, the pilot borehole is a critical emission point and should be executed with water flushing or effective extraction. Ventilation flows must be designed so that dust plumes do not reach occupied areas.
Strip-out and cutting in existing buildings
During strip-out, dust and, depending on the material, fine coating and plaster particles are generated. Indoors, enclosures with negative pressure, point extraction on tools, and multi-stage filters are central. When cutting steel with steel shears, multi-cutters, or tank cutters, mineral dust is less prominent; instead, metallic particles and fume are the focus: capture hoods and appropriate filtration concepts are required. Water may only be used if the building fabric and building services allow it.
Natural stone extraction: breaking and moving with low dust
When extracting and sizing natural stone, splitting, wedging, and controlled breaking often produce less fine dust than abrasive sawing. Effective measures include low-dust drilling techniques, spray mist along drop edges, covered conveyor routes, and cycle-controlled wetting at transfer points. Routes are kept damp to limit resuspension by traffic.
Hydraulic power packs and logistics
Hydraulic power packs influence dust indirectly: airstreams and waste heat can displace dust plumes, and exhaust gases from combustion engines can intensify resuspension. Units are therefore positioned upwind or outside dust-critical zones. Hose routing should be planned so that extraction and misting equipment are not obstructed and no leaks bind fine dust or re-entrain it.
Planning, organization, and evaluation
Hierarchy of measures
Priority is given to low-dust methods, followed by technical measures, organizational control, and finally personal protective equipment. This tiered model helps reduce exposure sustainably.
Dust measurement and documentation
To verify effectiveness, observations of visibility, indicative real-time measurements, and—if required—gravimetric methods are suitable. Measurement and test routines are defined project-specifically. Results are used to adjust dust removal and for transparent communication.
Occupational safety and health
Mineral dusts, especially fine quartz fractions, can be relevant to health. Employers define protective measures based on a hazard assessment. These include effective source control, ventilation, zoning, cleaning with industrial vacuums of an appropriate dust class, and—subordinately—appropriate respiratory protection. The notes are general in nature and do not replace legally binding requirements.
Environmental aspects and neighborhood protection
Water-based dust removal must not result in uncontrolled discharge of slurries. Wastewater is routed, sediments are retained, and treated if necessary. Dust at the property boundary is reduced through wetting, windbreaks, and clean traffic areas. Noise and dust control should be considered together so measures do not negate each other.
Maintenance, cleaning, and operation
Dust removal is only reliable if components are maintained. Nozzles and hose lines must be clear, filters cleaned or replaced in good time, and enclosures remain tight. Water quality affects nozzle service life; in freezing conditions, suitable operating media and protective measures are required. Work areas are wet-cleaned or vacuumed with suitable equipment; dry sweeping is avoided.
Practical tips for common applications
Concrete demolition and special demolition
- Plan pre-cracking with a concrete pulverizer to be low-dust, wet break points, keep material flow short
- Position extraction points close to the fracture zone; use negative-pressure rooms for interior works
- Minimize drop edges, wet transfer points
Rock excavation and tunnel construction
- Drilling with water feed or drill-dust extraction; splitting operations executed sequentially
- Align ventilation so dust is carried away from work areas
- Keep haul roads damp, limit speeds
Natural stone extraction
- Prefer low-dust separation methods; enclose or wet transfer points
- Cover conveyors, spray purposefully at turnovers
- Regular cleaning without dry resuspension
Selection of methods in combination with tools
The choice of dust removal is guided by the tool and the material:
- Concrete pulverizers: pre-wetting, point extraction within enclosures, short drop heights
- Stone and concrete splitters: low-dust drilling, joint wetting, sequential splitting sequences
- Combination shears (e.g., HCS8) and multi-cutters: wetting or dry capture depending on the material
- Steel shears and tank cutters: focus on fume and particle capture, appropriate filters