Special equipment comprises technical solutions designed for demanding tasks in demolition, deconstruction, rock cutting/processing, and natural stone extraction. They are deployed when standard tools reach physical, spatial, or safety limits. Typical examples include concrete pulverizers, rock and concrete splitters, hydraulic splitting cylinders, combination shears, Multi Cutters, steel shears, tank cutters, and the associated hydraulic power packs. Combined with precise working methods, they enable controlled separating, splitting, crushing, and dismantling of concrete, masonry, natural stone, steel, and composite structures—low in vibration, low in emissions, and with high repeatability.
Definition: What is meant by special equipment
Special equipment refers to machines, attachments, and hand-held hydraulic systems designed for specific tasks in structural and geotechnical practice. Characteristic features include application-specific kinematics and force transmission (e.g., shears, jaws, splitting wedges), high power density via hydraulics, compact construction for confined workspaces, and a precise, controllable effect. Special equipment provides support in particular for concrete demolition and special deconstruction, for strip-out and cutting, for rock excavation and tunnel construction, for natural stone extraction, and for special operations with stringent safety or environmental protection requirements.
Hydraulic operating principles and designs
The majority of special equipment is hydraulically operated. A hydraulic power pack provides the required pressure and flow rate, which is routed through hydraulic hose lines to cylinders, motors, or valves. This yields three core operating principles: splitting (force acts radially via wedges or splitting cylinders into a drilled or natural structure), shearing/jaw action (two opposing blades or jaws generate concentrated shear and crushing force), and cutting/separating (continuous cut via blade geometry, rotating tools, or specialized cutting heads). The choice of principle depends on the material, component geometry, accessibility, and the required cut or fracture quality.
Typical special equipment and their tasks
Concrete pulverizers are used for the controlled size reduction of reinforced concrete and heavily reinforced components. They combine high shear force with effective crushing to selectively separate the matrix and reinforcement. Rock and concrete splitters—often built as compact splitting cylinders—use the splitting principle for low-noise, explosive-free separations in foundations, walls, slabs, or natural stone blocks. Combination shears combine the breaking of concrete and cutting of reinforcing steel in one tool and are suitable for selective deconstruction. Multi Cutters extend the application range to different materials and profile geometries. Steel shears focus on the efficient cutting of beams, sections, plates, and rebar. Tank cutters are designed for the safe opening and segmenting of vessels, silos, and tanks where sparks, vapors, or residual media require particular caution. Hydraulic power units complete the system and deliver application-optimized pressure/flow values, often with fine control for precise, repeatable workflows.
Fields of application: From deconstruction to natural stone extraction
In concrete demolition and special deconstruction, concrete pulverizers enable a structured removal of slabs, walls, columns, and foundations. For massive cross-sections, the removal concept can be supplemented with splitting cylinders to induce stresses and exploit controlled cracking. For strip-out and cutting of fixtures, lines, routes, and light steel structures, Multi Cutters, steel shears, and tank cutters are used—with a focus on clean cut edges and minimized secondary damage. In rock excavation and tunnel construction, rock and concrete splitters offer a low-vibration alternative to produce breakouts, cross-section corrections, or niches without affecting the surroundings. In natural stone extraction, splitting cylinders and stone splitters support the gentle release and sizing of blocks along natural joints or targeted rows of boreholes. For special operations—for example in sensitive areas with stringent limits on vibration, noise, or emissions—the operating principles and tools can be combined as required.
Selection criteria and sizing
The selection of special equipment depends on material, component thickness, reinforcement ratio, accessibility, and quality requirements for the result (cut appearance, fracture path, reusability). Important parameters include splitting force or cutting/shearing force, jaw opening and depth, blade or wedge geometry, operating pressure and flow rate of the hydraulic system, and self-weight relative to hand-held use or carrier machine. For concrete pulverizers, force progression, blade position, and rebar clearance are decisive; for rock and concrete splitters, borehole diameter, wedge angle, and body length influence the splitting effect. A matched hydraulic power pack ensures the tool continuously achieves its rated performance and remains finely controllable.
Working methods: Splitting, shearing, cutting
Splitting starts with borehole planning (diameter, depth, pattern). Splitting cylinders are inserted; the wedges extend, generate radial pressure, and produce defined crack patterns. This allows massive elements to be subdivided into transportable, manageable segments. In shearing, concrete pulverizers or combination shears act with high forces on a small contact area; the concrete matrix is crushed, reinforcement is cut or exposed, which facilitates material-segregated separation. Cutting of steel components is performed with steel shears or Multi Cutters; tank cutters enable safe openings of vessels, often with organizational measures to minimize sparks, dust, and fumes. The methods can be combined on a project basis, for example splitting to pre-widen cracks followed by size reduction with concrete pulverizers.
Safety, emissions, and environmental protection
Work with special equipment requires a careful hazard analysis, coordinated work instructions, and suitable personal protective equipment. Hydraulic methods are generally low in vibration and noise; nevertheless, vibrations, noise emission, and dust emission should be monitored and minimized through appropriate measures (e.g., wet cutting, dust extraction, shielding). During tank cutting and when separating coated components, be mindful of possible vapors or coating residues. Safety and environmental protection requirements must always be reviewed on a project-specific basis; binding assessments can only be made case by case by authorized bodies.
Operation, care, and service life
Reliable operation depends on clean hydraulic connections, intact hydraulic hose lines, and correctly set pressure/flow values. Wedges, blades, and jaws are wear parts and should be inspected regularly and adjusted or replaced as needed. Proper storage, lubrication, and cleaning increase service life; seals and bolted joints should be checked at regular intervals. Hydraulic power packs require maintenance intervals based on operating hours, including filter replacement and hydraulic oil analysis. Documented personnel training supports reproducible quality and reduces downtime.
Planning and logistics on the construction site
Deployment planning includes access routes, set-up areas, load transfer, utilities supply, and handling of separated segments. For concrete pulverizers, crane or carrier machine operations must be coordinated; for rock and concrete splitters, the drilling concept (pattern, depth, sequence) must be aligned with the desired fracture path. Disposal concepts benefit from demolition sorting already during demolition: steel, concrete, and natural stone are collected separately, which simplifies transport, recycling, and post-processing. Forward-looking segmentation reduces lifting loads and improves occupational safety.
Distinction from alternative methods
Compared with breaker hammers or blasting methods, hydraulic special equipment is often quieter, low-vibration, and more precisely controllable. This is especially relevant in sensitive environments, historic structures, ongoing operations, or densely built-up areas. Mechanical methods such as pneumatic hammers/jackhammers are justified for coarse removal but can cause higher secondary damage and dust exposure. The decision on a method should consider boundary conditions, permitting, and the desired outcome.
Quality characteristics and documentation
Quality is evidenced by reproducible cut and fracture patterns, adherence to dimensional tolerances, low secondary damage, and predictable cycle times. Simple, robust operation and fine controllability support consistent results. Project-accompanying documentation—such as drilling and splitting grids, cutting sequences, machine parameters, and photo logs—facilitates verification and the optimization of future deployments.