Safety equipment is indispensable in concrete demolition, building gutting, rock excavation and tunnel construction. Wherever hydraulic tools such as hydraulic rock and concrete splitters, concrete demolition shears, steel shears, combination shears, multi cutters, cutting torches as well as associated hydraulic power units are used, specifically selected personal protective equipment increases safety, reduces downtime and supports the quality of the work. This article from the knowledge of Darda GmbH combines fundamental knowledge with practical guidance for selecting and using protective equipment in the applications mentioned.
Definition: What is meant by safety equipment
Safety equipment comprises all personal and organizational protective measures that protect employees from mechanical, physical, chemical and ergonomic hazards. At its core, this includes personal protective equipment (PPE) such as helmet, eye and face protection, respiratory protection, hand protection, hearing protection, foot and body protection as well as fall protection. In addition, tool-specific protective means are included, for example protective sheaths for high-pressure hydraulic hose lines of hydraulic power packs. Safety equipment is not an option, but an integral part of work planning and the hazard analysis on the construction site.
Core components of safety equipment in concrete and rock work
The choice of PPE depends on the task, tool and environment. In the context of hydraulic splitters, concrete demolition shears and other hydraulic tools, the following components have proven effective:
Head, eye and face protection
- Industrial safety helmet with chin strap, with shock absorption if required for work in tunnels or confined areas.
- Eye and/or face protection against chips, splinters and kickback: close-fitting safety goggles, often combined with a visor for cutting and shearing operations.
Respiratory protection against dust and fumes
- Concrete and natural stone processing generates fine dust (including quartz-bearing). Particulate-filtering masks with high collection efficiency, with powered air support where appropriate, increase effectiveness.
- For tank cutting operations and in poorly ventilated areas, provide respiratory protection appropriate to the medium.
Hearing protection
- Noise emissions from hydraulic power packs, cutting and shearing operations require suitable hearing protection (e.g., earmuffs or banded hearing protection, with integrated radio for communication where appropriate).
Hand and arm protection
- Cut- and abrasion-resistant gloves for work on sharp-edged components, while maintaining good grip on oily surfaces.
- For high-pressure hydraulics, ensure puncture-resistant properties; gloves must preserve dexterity and tactile feel.
Foot and leg protection
- Safety footwear at least with toe protection, puncture-resistant sole and slip-resistant tread; water-repellent for wet work, heat-resistant for spark exposure.
- Gaiters or leg protectors for work with sparks and chips (e.g., cutting torches, steel shears).
Body protection, visibility and fall protection
- Durable, high-visibility workwear; for edges, sharp reinforcing steel or cutting operations, cut- and abrasion-resistant materials are useful.
- When working at height: full-body harness with suitable connectors and anchor points; define a rescue concept in advance.
Hazards in demolition and cutting work with hydraulic systems
The main risks arise from crushing, shearing and tensile forces at tools, high hydraulic pressure, noise emissions, vibration, dust, and uncontrolled movements of components. High-performance safety equipment addresses these points specifically.
Crushing and shear points
With concrete demolition shears, steel shears, combination shears and multi cutters, high cutting forces occur. Hand protection, face protection and a safe operating position at a distance from the tool reduce the risk of injury.
Hydraulic pressure and hose management
High-pressure lines can whip or release fluid if damaged. Hose protective sheathing, orderly routing, visual inspection before use and suitable hand protection are essential. Ensure zero pressure when coupling and wear splash protection.
Dust, chips and kickback
When splitting concrete and rock as well as when biting off reinforcement, particles are generated. Respiratory protection, safety goggles/visor and robust clothing minimize exposure. Wet methods can further reduce dust levels.
Noise and vibration
Hearing protection is mandatory. To reduce hand–arm vibration, ergonomic grips, planned breaks and task rotation help. Gloves with damping can complement measures but do not replace technical controls.
Safety equipment tailored to products and applications
PPE must fit the tool and the application area. The following practical allocations apply in the Darda GmbH environment:
Hydraulic splitters
- Focus: flying fragments, falling components, crushing hazard. Recommendation: helmet with visor, safety goggles, hand protection with good grip, safety footwear with ankle protection, respiratory protection depending on dust exposure.
- Rock excavation and tunnel construction: additional helmet-mounted lighting, communication hearing protection and high-visibility clothing.
Concrete demolition shears
- Focus: shear forces, sharp-edged fragments, reinforcement splinters. Recommendation: face protection, cut-resistant gloves, leg and foot protection, close-fitting clothing without loose parts.
- Concrete demolition and special demolition: cordon off the hazard area, spotter with clear hand-signal communication.
Steel shears and combination shears
- Focus: metal chips, sharp-edged remnants, noise. Recommendation: visor, hearing protection, cut- and puncture-resistant gloves, leg protectors, flame-resistant clothing if necessary.
Multi cutters
- Focus: changing cutting tasks, different materials. Recommendation: modular PPE with quickly swappable visor and respiratory protection; hand protection with abrasion and cut resistance.
Cutting torches
- Focus: sparks, heat, potentially hazardous atmospheres. Recommendation: heat-protection gloves, flame-resistant protective clothing, face protection, suitable respiratory protection and fire watch readiness with extinguishing agents.
Hydraulic power packs
- Focus: noise, hot surfaces, high-pressure fluids. Recommendation: hearing protection, heat-resistant gloves for maintenance work, safety goggles, orderly hose routing with protective sheathing.
Hazard analysis as the basis for PPE selection
Before starting work, a hazard analysis must be carried out. It considers the tool type (e.g., concrete demolition shear or hydraulic splitter), material properties, access situation, overhead work, weather, emissions and the qualification of the employees. From this, the required PPE components, organizational measures (barricading, spotter, communication rules) and technical protective measures are derived.
Correct selection, adjustment and care of PPE
Safety equipment only protects if it fits, is worn and maintained. A systematic approach helps avoid critical gaps.
Selection
- Identify hazards (mechanical, chemical, thermal, electrical, atmospheric).
- Specify PPE with adequate protection performance and ergonomic fit.
- Check compatibility (e.g., helmet with hearing protection and visor, respiratory protection under the visor, full-body harness under the jacket).
Adjustment
- Correct sizing, fit check for respiratory protection, adjustment of straps and belts.
- Individual labeling so personal equipment remains clearly assigned.
Care and storage
- Cleaning according to manufacturer instructions, dry and UV-protected storage.
- Immediately remove damaged PPE from service; replace upon visible wear or at the end of the recommended service life.
Work organization: instruction, visibility and communication
Training conveys the correct use of PPE and the specific risks in demolition and cutting work. High-visibility clothing and clear hand signals are essential in limited visibility or high-noise conditions. A coordinated communication concept (e.g., radio integrated into hearing protection) facilitates coordination between operators of concrete demolition shears, splitters and spotters.
Seasonal and environmental conditions
Heat, cold, moisture and dust influence PPE effectiveness. Breathable, weather-appropriate layers, slip-resistant soles on wet surfaces and additional lighting in tunnels or at dusk increase safety and comfort. In dust-intensive phases, a consistent respiratory protection strategy with an appropriate filter class is recommended.
Documentation, inspection intervals and responsibilities
Regular inspection of helmets, full-body harnesses, connectors and safety goggles as well as documentation of the results ensure transparency. Orientation to recognized rules of technology and relevant standards can help define inspection intervals and criteria. Responsibilities for procurement, maintenance and replacement should be clearly defined.
Avoid common mistakes with protective equipment
- Insufficient face protection when working with concrete demolition shears or steel shears.
- Wrong gloves: too smooth, too stiff or without cut protection for sharp-edged materials.
- Unsuitable or poorly fitting respiratory protection for dust-intensive tasks.
- No communication concept in noisy environments, although several trades are working simultaneously.
- Neglected hose routing on hydraulic power packs, missing protective sheathing.
Practice-oriented checkpoints before starting work
- Hazard analysis updated and understood.
- PPE complete, fitting and undamaged; spares available on site.
- Tool-specific risks clarified (e.g., crushing points at hydraulic splitters, shear areas at concrete demolition shears).
- Hydraulic hose lines checked, orderly routed, protected; work area cordoned off.
- Communication and rescue concept defined, first-aid supplies ready for use.