The horizontal cut is a fundamental working principle in deconstruction, building gutting, and in rock excavation as well as natural stone extraction. It means separating components or rock along a horizontal plane to detach building sections in a controlled way, redirect loads, or prepare material for further processing. In practice, the horizontal cut is implemented with different methods—ranging from sawing to hydraulic splitting to biting. Especially for low vibration levels, dust-minimized, and well-controllable methods, concrete demolition shear as well as hydraulic rock and concrete splitters from Darda GmbH play a decisive role, supported by compact hydraulic power pack units for consistent performance even in confined or sensitive environments.
Definition: What is meant by a horizontal cut
A horizontal cut is a horizontally oriented separation joint in concrete, masonry, composite elements, or rock that is deliberately and controllably produced to separate components, reduce them, or divide them into manageable segments. The horizontal cut can be executed as a continuous saw cut, as a sequence of splitting operations along a row of boreholes, or as stepwise biting. Unlike a vertical cut, the horizontal cut acts directly on the support conditions and the load-bearing behavior of components—therefore shoring, load transfer, and cut sequence are decisive.
Fields of application and typical scenarios
Horizontal cuts are used wherever components or rock volumes must be separated, relieved, or segmented from below or above. In concrete demolition and special demolition these include slabs, beams, corbels, bearing zones, parapets, or the top of foundation elevation. In building gutting and cutting, horizontal separation joints serve to selectively detach non-load-bearing layers, screeds, or build-ups without affecting adjacent structures. In rock excavation and tunnel construction, horizontal split lines enable bench formation, lowering of inverts, and the production of defined steps. In natural stone extraction, the horizontal cut is used to detach raw blocks from the mass. For special demolition, for example in contaminated sites or where the surrounding load-bearing capacity is limited, low vibration levels methods with hydraulic tools are established.
Methods of horizontal cutting: sawing, splitting, biting
Several methods are available for the horizontal cut. The choice depends on the material, degree of reinforcement, cutting depth, accessibility, environmental requirements (noise, dust, vibrations), and the planned dismantling concept.
Sawing and wire/wall sawing
Sawing produces precise, clean separation joints—typically in slabs, foundation heads, or masonry layers. It requires access for machines, cooling water and slurry management, and, where necessary, measures against vibrations and noise. With high reinforcement density, effort and tool wear increase.
Horizontal splitting with stone and concrete splitters
hydraulic splitter from Darda GmbH are inserted into previously drilled, horizontally aligned rows of boreholes. The splitter cylinder generates controlled crack propagation along the planned plane. Advantages include low vibration levels, reduced noise, and a very precise, stepwise material fracture to closure. The method is particularly suitable in sensitive areas, in confined spaces, and where water or dust emissions must be minimized.
Biting and secondary crushing with concrete demolition shears
concrete demolition shear from Darda GmbH enable defined removal along a horizontal cut line—for example biting off slab edges, notching separation joints, or reworking sawn/split areas. Reinforcing steel can be partially caught or exposed for subsequent separation. The method exhibits low vibration levels and supports controlled deconstruction in sequences.
Role of hydraulic power packs
High-performance hydraulic power pack units from Darda GmbH, such as compact hydraulic power units, provide the constant energy supply for splitter cylinders, concrete demolition shear, combination shears, or multi cutters. For the horizontal cut, reproducible operating pressure and flow rates are crucial to control fracture patterns, cutting speed, and protect tool service life.
Planning, structural analysis, and safety in the horizontal cut
A horizontal cut intervenes directly in load transfer. Before work begins, structural behavior, bearing conditions, shoring, and the cut sequence must be planned. In reinforced concrete, the position of the reinforcement is decisive. prestressing system require special restraint and a qualified assessment. In existing structures, construction age classes, material variants, and composite interfaces must be considered. occupational safety includes, among other things, fall protection, load pick-up, edge protection and cut protection, safe routing of the hydraulic hose line, as well as measures against falling objects. Legal and normative requirements, such as the applicable DIN standard depending on the project context, must generally be observed.
Process in practice: from cut guidance to dismantling
A structured approach improves quality, schedule, and cost reliability. The following sequence has proven itself in deconstruction and in rock works:
- Investigation and marking: material testing, determining reinforcement/rock joints, defining the cut axis and edge distance.
- Preparation: shoring/load transfer, dust protection and measures against falling objects, set up the power supply (hydraulic power pack).
- Preparatory work: create starter pockets, expose built-in components, and, if necessary, core drilling for splitter cylinders.
- Primary separation: wire saw/wall saw cutting or horizontal splitting (row of boreholes) or scoring with concrete demolition shear along the line.
- Secondary crushing: segmenting, biting off remaining cross-sections, separating reinforcement (e.g., with hydraulic shear, multi cutters, steel shear).
- Handling and removal: load pick-up, controlled lifting or lowering, and source-separated construction waste separation for disposal or recycling; coordinate haulage logistics.
Special conditions: reinforcement, composite, moisture
The horizontal cut is influenced by material-specific factors. An adapted tool choice prevents deviations in cut path and reduces rework.
Degree of reinforcement and steel content
Transverse or densely spaced reinforcement can deflect the crack path during splitting. In such cases, a combination has proven effective: a horizontal row of boreholes for splitting and subsequent biting with concrete demolition shear along the joint before the steel content is separated with steel shear.
Composite structures and inserts
With composite slabs, concrete–steel composite, and inserts (e.g., shear studs, rails), additional separation points are required. Biting enables exposure and defined separation without extensive overcutting.
Moisture and emissions
In interior or sensitive areas, methods with low water demand and reduced dust emissions are preferred. Here, hydraulic splitter as well as concrete demolition shear from Darda GmbH are particularly suitable due to their low vibration levels, controlled working principle.
Horizontal cut in rock excavation and tunnel construction
In rock, the horizontal cut serves bench formation, layer removal, and controlled profiling—for example in producing or lowering tunnel floors. The drilling- and splitting-based approach produces defined fracture surfaces along a horizontal row of holes and avoids uncontrolled breakout. In natural stones, raw blocks can be detached along natural joints or artificially set split lines; the surface can then be reworked with concrete demolition shear or appropriate cutting tools.
Tool selection and parameters for the horizontal cut
The selection is based on material, geometry, and boundary conditions. The following factors are relevant in practice:
- Material and thickness: from masonry and reinforced concrete to massive rock benches.
- Reinforcement/prestressing: influence on crack propagation and separation strategy.
- Access: working room from above/below, feasibility of horizontal drilling, crane/lifting device options.
- Environment: requirements regarding low vibration levels, noise control measures, dust suppression, and water management.
- dismantling logistics: segment sizes, loads, gripping and cutting edges for concrete demolition shear.
- Power supply: appropriately sized hydraulic power pack for constant operating pressure.
Quality assurance and documentation
A traceable cut path, documented parameters (drilling pattern, splitting pressures, cut sequence), and orderly segmentation facilitate acceptance and source-separated further treatment. Visual inspection of separation joints, checking for edge spalls, and verifying the residual load-bearing capacity of adjacent components support the safety of subsequent work steps.
Reworking and secondary separation
After the primary horizontal cut, remaining cross-sections, edges, and reinforcement are often reworked. concrete demolition shear allow targeted removal down to the required level and the production of clean connection edges. For steel content, steel shear and suitable cutting tools are considered; with tanks or large hollow bodies, a tank cutter may be required in a special demolition scenario. The result is a controlled, stepwise deconstruction with high dimensional accuracy.
Environmental and project influences
Low vibration levels and dust-minimized methods improve working conditions and support achieving project-specific environmental goals. The drilling- and splitting-based approach as well as biting with concrete demolition shear from Darda GmbH contribute to this, especially in existing buildings, densely built-up areas, or during ongoing operations. Adapted water management, organized slurry/dust collection, and the reduction of secondary damage are integral elements of sustainable execution.