In construction, deconstruction and natural stone extraction, heavy load describes all activities in which very large masses, bulky structural elements or highly resistant materials must be safely controlled, separated, split, cut or moved. In practice, this concerns thick-walled reinforced concrete components, heavily reinforced foundations, massive rock benches, steel tanks and vessels, as well as large-format natural stone blocks. Tools such as concrete pulverizers or hydraulic rock and concrete splitters enable controlled, blast-free processing under tight space constraints and high safety requirements. Darda GmbH is present in these applications with hydraulic tools that have proven themselves for concrete demolition and special demolition, building gutting and cutting, rock excavation and tunnel construction, natural stone extraction, as well as special operations.
Definition: What is meant by heavy load
Heavy load refers to loads and tasks which, due to mass, dimensions, material strength, location or boundary conditions, require special methods, equipment and levels of protection. The spectrum ranges from separating high-strength reinforced concrete to splitting rock and dismantling tanks. Characteristic features include very high resistance to crushing or separation, limited accessibility and the need to introduce forces in a targeted and controlled manner. Heavy load work therefore does not just mean “a lot of weight,” but above all the safe control of forces, energy and risks in the interaction of construction material, tool and process.
Understanding heavy load: forces, geometry and boundary conditions
The planning of heavy load tasks is based on a clear classification of the acting mechanisms. In addition to dead load and inertia, these include local compressive and tensile stresses, shear along cracks, bending at thickened cross-sections, friction at bearing surfaces and restraint due to reinforcement or embedded components. For concrete, brittle fracture mechanisms with crack initiation and propagation dominate; for steel, ductile flow and notch sensitivity; for natural stone, anisotropic split behavior along joints. Geometry—wall thickness, reinforcement ratio, edges, recesses—determines whether concrete pulverizers or stone and concrete splitters are the more economical and safer choice. Tight workspaces, missing reserve capacity in existing structures, and requirements concerning vibrations and emissions shape the boundary conditions.
Load types and stresses in practice
Heavy load operations often combine static and dynamic effects. Impact loads during breaking, changing lever arms when gripping and holding components, pressure pulsations in the hydraulic system, and material spring-back require a calm, controlled working method and the right tool configuration. Forces introduced into reinforced components must take rebar removal and restraint into account, while in rock the in-situ stress field and the orientation of existing joints determine the splitting direction. In tank and steel construction, thermal effects, edge hardness and corrosion layers also come into play.
Heavy load in concrete demolition and special demolition
Heavy concrete demolition involves thick walls, massive columns, bridge caps and foundation blocks. Concrete pulverizers crush reinforced concrete in a controlled manner by breaking the concrete and exposing the reinforcement; hydraulic demolition shears can combine cutting and breaking where needed. Where cross-sections are too massive or vibrations must be limited, users turn to stone and concrete splitters with rock wedge splitters: borehole-based wedge systems introduce defined splitting forces that open up components along the desired line. Hydraulic power packs provide the required pressure and flow for consistent performance even over long cycles. For the deconstruction of heavy bridge elements, a sequence of pre-separation (cutting the reinforcement), pre-breaking, splitting, and final size reduction for transport is suitable.
Procedure for massive reinforced concrete components
First, the component is assessed structurally to understand residual load-bearing capacity, load paths and supports. Splitting grooves are then drilled or gripping points defined. Concrete pulverizers open separation joints and reduce cross-sections; stone and concrete splitters generate predictable crack patterns without blasting effects. Reinforcement is cleanly separated with steel shears or multi cutters. This produces manageable, transportable sections that do not cause uncontrolled breaks.
Rock excavation, tunnel construction and natural stone extraction
In rock, controlled splitting dominates. Stone and concrete splitters with rock wedge splitters enable blast-free separations along a row of boreholes—an advantage in urban areas, near listed neighboring buildings, and in tunnel heading. The forces act radially, and the crack front progresses along the planned line. In tunnel construction, niches, benches or cross passages can be efficiently worked out. In natural stone extraction, raw blocks can be released in bedding-oriented alignment, improving quality and yield and producing better fracture surfaces.
Heavy load underground
Under confined conditions and with limited ventilation, the low emissions and finely metered energy delivery of hydraulic systems come into their own. Hydraulic power packs can supply multiple cylinders, allowing work cycles to be synchronized and forces to be built up step by step.
Building gutting and cutting: heavy load in existing structures
Building gutting often involves heavy built-ins, beams, machine foundations and thick floor slabs. Concrete pulverizers and multi cutters separate concrete and metal in a coordinated sequence. Steel shears cut profiled beams, rebar bundles and plates, while hydraulic demolition shears switch flexibly between gripping, breaking and cutting. The combination of pre-drilling, splitting and cutting creates openings for new access routes while simultaneously reducing loads for temporary shoring.
Load handling, shoring and transport of heavy sections
Heavy load does not end with separation. Safe holding, setting down and transporting are integral parts. Key points are load distribution, center-of-gravity position, lifting points, tip-over stability and coordination with the lifting device. Shoring must be sufficiently stiff and load-bearing; bearing surfaces must be protected against crushing. Lifting is performed with simultaneous, calm movements. For internal transport, clear routing, communication rules and exclusion zones must be defined. All information and assessments are general in nature and do not replace project-specific planning or verification.
Hydraulic power packs and energy supply
Heavy load tools unleash their performance via high-pressure hydraulics. Reliable hydraulic power units provide pressure and flow matched to the tool type and task. Thermal reserve, filtration and stable control are decisive so that concrete pulverizers, stone and concrete splitters, steel shears, hydraulic demolition shears or multi cutters operate continuously with consistent force. Longer lines and rerouting require consideration of pressure losses. Forward-looking cycle planning prevents temperature spikes and keeps downtime low.
Tool selection: concrete pulverizers, stone and concrete splitters and alternatives
The choice of tool depends on material, cross-section, reinforcement, accessibility and the target size of the sections. Concrete pulverizers are the first choice for breaking reinforced concrete with moderate thicknesses and sufficient accessibility. Stone and concrete splitters come into their own where cracks must be induced in a targeted and low-vibration manner, for example with very thick cross-sections or in sensitive environments. Hydraulic demolition shears add flexibility with changing materials, steel shears handle the clean separation of structural steel and reinforcement. Multi cutters cover mixed construction materials. For tanks and thick-walled pipelines, tank cutters are designed for clean cuts, for example when dismantling large tanks in special operations.
Decision parameters
Key parameters are the required splitting or cutting force, jaw opening, accessibility, permissible vibrations, desired crack guidance, removal performance per cycle, and the available energy supply. A practice-oriented setup often combines pre-breaking with concrete pulverizers and downstream splitting for thick core zones.
Materials: concrete, steel and natural stone under heavy load
Concrete has high compressive strength but low tensile and flexural tensile strength. Cracking preferentially occurs in tension zones; reinforcement bridges cracks and creates restraint that influences splitting work. High-strength concretes require higher initial forces but often deliver clearer crack lines. Steel behaves ductilely but is sensitive at notches, welds and work-hardened zones; uniform cutting forces reduce burr formation. Natural stone is anisotropic: bedding, stratification and joints determine the splitting direction. These properties guide the choice between concrete pulverizers and stone and concrete splitters and influence drilling pattern, cycle sequence and force buildup.
Safety and occupational safety in heavy load operations
Occupational safety has top priority. Typical risks include uncontrolled breaks, impact effects, pinch points, hydraulic leaks under pressure, and suspended loads. Protection zones and communication paths must be clearly defined; loads must never be moved over people. Personal protective equipment, clear hand signals or radio protocols, and regular tool inspections reduce risks. The notes in this text are general in nature and do not replace a project-specific hazard analysis or regulatory requirements.
Planning, documentation and quality assurance
Heavy load projects begin with an as-built assessment: drawings, exploratory openings, material testing and rebar locating. This is followed by method planning with demolition and splitting sequence, drilling patterns, interfaces to lifting and conveying means, emission concepts and emergency routines. During execution, crack patterns, temperatures of the hydraulic power packs, tool conditions and vibrations are documented. A final inspection of edges, dimensional accuracy and separation progress ensures target achievement.
Environmental aspects and emissions
Heavy load operations generate noise, dust and vibrations. Targeted splitting with stone and concrete splitters reduces vibrations; breaking with concrete pulverizers lowers secondary crushing work. Spray-water dust suppression, adapted working time windows and quiet hydraulic cycling reduce immissions. Material separation at the source facilitates construction waste separation and recycling of concrete and steel and reduces transport of heavy mixed materials.
Typical failure patterns and how to avoid them
Insufficient drilling depth or misaligned drilling patterns lead to unpredictable crack paths during splitting. Too little splitting or cutting force produces crushing rather than clean separation. Overheated hydraulic power packs reduce performance and service life; unsuitable jaw geometries of concrete pulverizers increase tool wear. Remedies include careful pre-planning, realistic performance assumptions, intermediate cooling phases, regular maintenance, and adapting the cycle sequence to material behavior.
Dimensional and performance metrics
For classifying heavy load tools, splitting force, cutting force, jaw opening, cylinder stroke, cycle time, required hydraulic pressure and flow are decisive. With concrete pulverizers, jaw geometry influences initial bite and crack initiation; with stone and concrete splitters, wedge geometry and borehole diameter and spacing determine effectiveness. For steel shears, hydraulic demolition shears and multi cutters, blade hardness, kerf and clamping range are relevant measures. Matching these parameters to the component and workflow determines efficiency and edge quality.
Practical application examples
During the deconstruction of a massive machine foundation slab, the top layer is broken with concrete pulverizers, rebar bundles are cut with steel shears, and the core is released via rows of boreholes with stone and concrete splitters. In a tunnel project, niches are produced blast-free with rock wedge splitters to meet vibration limits. When dismantling a large tank, tank cutters cut panels into manageable segments, while hydraulic demolition shears separate reinforcements. In a quarry, splitters release bedding-oriented blocks that are then further processed with minimal rework. These examples show how heavy load tasks can be solved safely and efficiently through the coordinated interaction of tool, hydraulics and process.
Special operation: unconventional heavy load situations
Special operations include situations with extremely limited access, contaminated areas, underwater sections, or complex hybrid structures. Here, the fine metering capability of hydraulic tools pays off. Concrete pulverizers work gently at sensitive interfaces, while stone and concrete splitters produce the necessary separation effect without explosives. In combination with adapted logistics and temporary shoring, even exceptional heavy load tasks can be predictably controlled.