Protective wall

A protective wall is a technical safety system that protects people, structures, and installations from hazards arising from demolition works, cutting, and splitting operations. It confines effect zones, intercepts debris and fragments, reduces noise and dust, and separates work zones from traffic and occupancy areas. In deconstruction, rock excavation, tunnel construction, interior demolition, and natural stone extraction, the protective wall is planned and operated as a temporary or permanent barrier. In combination with tools such as concrete demolition shear and hydraulic wedge splitter, it enables a controlled, safe workflow.

Definition: What is meant by a protective wall

A protective wall is a statically dimensioned barrier made of rigid or modular elements that reduces risks on the construction site and in industrial environments from impact, falling parts, flying fragments, pressure and sound waves, sparks, and fluid or gas release. It can be executed as a massive wall (e.g., concrete), as a modular mobile unit (e.g., water- or sand-filled elements), as a steel plate, or as a composite system. In demolition works it serves hazard reduction at the source through shielding and energy absorption and is part of an overall safety concept including work methods, tool selection, and work planning.

Tasks and protection levels of a protective wall

Depending on the application, protective walls perform different tasks: they screen off lines of sight and effect zones, absorb kinetic energy, transfer loads into the subsoil, and reduce secondary effects such as dust and noise propagation. Depending on the hazard situation, protection levels are defined, such as fragment protection, impact protection, fire protection, or noise control. For deconstruction with hydraulic tools such as concrete demolition shear and hydraulic wedge splitter, fragment and impact protection take precedence, while spark and heat protection are relevant when cutting metals. The choice of system is based on hazard analysis, component geometry, working method, and spatial constraints.

Protective wall in concrete demolition and special deconstruction

In concrete demolition and special deconstruction, the protective wall separates the demolition zone from sensitive areas such as traffic routes, utilities, façades, machinery, or pedestrian walkways. It enables orderly crushing and sorting, protects operators and third parties, and reduces operational interruptions in the surroundings.

Controlled deconstruction with concrete demolition shears

Concrete demolition shears break components by controlled squeezing and shearing. The resulting fracture edges and piece weights are manageable, keeping kinetic energies lower than with breaker hammers. A properly sized protective wall still intercepts breakout pieces and fragments, especially with prestressed or heavily reinforced substance. The shielding allows work in confined environments close to existing structures without damaging them.

Crack control with stone and concrete splitters

Hydraulic wedge splitters initiate cracks along defined lines, thereby reducing uncontrolled spalling and flying parts. In combination with a protective wall, fracture paths can be planned so that the energy is dissipated within the component while the barrier safely retains remnants and fragments. The result is calm processes with high control and reduced requirements for exclusion zones.

Temporary protective walls for interior demolition and cutting

In interior demolition and cutting in existing structures, light, modular, and easily relocatable protective walls are often used. They separate work areas within buildings, protect traffic routes, and mitigate dust and noise. For work with combination shears, multi cutters, or steel shear, the barrier must be designed to also retain spring-back of metal components. Where a cutting torch is used in special operations, additional focus is on heat protection and minimizing sparks; the protective wall can have fire-retardant surfaces or replaceable sacrificial plates.

Rock excavation and tunnel construction: barriers and catch systems

In rock excavation and tunnel construction, protective walls and catch systems serve as primary protective measures against falling blocks, spalling, and pressure waves. In combination with hydraulic wedge splitter, the rock mass is opened in a controlled manner; protective walls and catch meshes limit the effect zone, deflect fragments, and protect traffic routes or equipment. In tunnel and gallery areas, robust, non-combustible protective walls separate the working face and the equipment park (hydraulic power pack) to protect personnel and infrastructure from mechanical impact.

Natural stone extraction: fragment and impact protection

In natural stone extraction, protective walls confine break-out areas and protect routes, vehicles, and storage areas from ejected pieces. By using hydraulic wedge splitter, block sizes and fracture lines can be planned; the protective wall acts as a complement that absorbs the remaining kinetic energy and shields the environment. Mobile, relocatable elements make it easier to adapt to the respective workplace.

Materials and designs of protective walls

The design is based on hazard, available space, subsoil, and transport logistics. Common solutions are:

• Massive elements: concrete blocks, reinforced concrete slabs, composite panels with high energy absorption.
• Modular systems: stackable block elements, water- or sand-filled barriers for rapid setup.
• Steel plates and support frames: replaceable impact and fragment protection plates on frame structures.
• Wood and composite solutions: multi-layer configuration for dust, fragment, and visual protection in interior environments.
• Special systems: sound-absorbing noise barrier wall, fire-retardant panels, transparent polycarbonate shields for visual control.

Dimensioning, setup, and energy absorption

Dimensioning follows the hazard analysis. Relevant influencing factors are component mass, potential throw and spalling paths, working direction of the tool, residual stresses, subsoil bearing capacity, and distances to protected assets. Practical principles:

1. Plan sufficient height and length so the entire effect zone is fully screened, including a safety margin.
2. Ensure stability: provide verification against overturning and sliding via self-weight, ballasting, or anchorage.
3. Consider impact capability: select materials with adequate ductility and impact resistance; avoid butt joints.
4. Ensure visibility and communication: provide openings only in a controlled manner and limit them to what is necessary.
5. Define clearances: specify minimum distances between the work tool, protective wall, and protected assets to avoid rebound.
6. Check the subgrade: ensure load-bearing capacity, evenness, and drainage; prevent settlement.

Protective wall and working methods: interaction with technology

The choice of method significantly influences the requirements for the protective wall. Hydraulically operated tools (e.g., concrete demolition shear, hydraulic wedge splitter) generally generate lower dynamic shocks than breaker hammers. This can simplify the design of the protective wall but does not replace case-by-case verification. Compact hydraulic power units are suitably positioned behind the protective wall, with protection against impact, ventilation, and safe hose routing. When cutting steel sections with combination shears, multi cutters, or steel shear, stored elastic stresses are to be expected; the protective wall should have edges and deflection surfaces that mitigate spring-back.

Dust, noise, and emissions mitigation

Protective walls contribute to reducing dust and noise. In sensitive environments—such as interior demolition or densely built-up areas—they are combined with dust protection (multi-layer, tightly joined panels), optional viewing windows, and sound-absorbing surfaces. A clean cutting by concrete demolition shear or a planned use of hydraulic wedge splitter additionally reduces emissions at the source, which further lowers the protection demand.

Legal and organizational aspects

The selection and setup of protective walls should be based on a documented hazard analysis and take into account applicable technical regulations, recognized rules of practice, and company procedures. Responsibilities, exclusion zones, escape routes, and inspection intervals must be defined. Information on load-bearing capacity, ballasting, and assembly must be available on site. Legal requirements may vary depending on location and activity; in case of doubt, seek expert advice.

Planning sequence and checklist for practice

A structured sequence supports reliable implementation:

1. Identify hazards: component condition, prestressing, reinforcement, media, surroundings.
2. Select the method: prefer concrete demolition shear or hydraulic wedge splitter for controlled processes, if suitable.
3. Define the protection level: determine requirements for impact, fragment, fire, and noise protection.
4. Select the system: determine material, geometry, modular system, transport, and installation concept.
5. Verify stability and energy absorption; plan subsoil preparation and ballasting.
6. Setup and logistics: access routes, crane and lifting device, erection sequence, deconstruction.
7. Regulate operation: sightlines, communication, exclusion zones, inspections, maintenance.
8. Documentation and briefing: setup plan, operating limits, emergency measures.

Special use cases and special operations

For special operations with elevated risks—such as opening tanks or deconstruction in ATEX zone—protective walls with fire-retardant surfaces, additional impact layers, or decoupled damping elements may be required. Fluid release, sparks, and thermal effects must be considered in the design. The method should be chosen to minimize energy releases; controlled techniques with hydraulic tools support this.

Maintenance, inspection, and deconstruction

Protective walls must be checked prior to commissioning and regularly during use. Damaged impact faces or connecting elements must be replaced. During deconstruction, the sequence is chosen so that residual hazards remain controlled: first decouple the work equipment, then remove ballasting, then secure and relocate modules. Clear communication and visual control are essential.