Mixed-in-place process

When mixing in-place / in-situ, a cold recycler granulates the existing pavement while mixing in binders and water homogeneously at the same time. This method produces a new construction material mixture in a single operation. The cold recyclers are equipped with a powerful milling and mixing rotor and highly efficient injection systems.

Perfectly arranged picks on the milling and mixing rotor, paired with a high-powered mechanical rotor drive, guarantee maximum milling and mixing performance – an essential prerequisite for fully homogeneous mixes. In addition, hard-wearing quick-change toolholder systems ensure optimum pick rotation, easy pick replacement and continuous operation for extended periods of time.

  • Recycling at larger working depths
  • Processing road construction materials in-situ
  • Improving the bearing capacity
  • Extremely short construction periods
  • Tremendous cost savings

Portfolio in cold recycling

State-of-the-art cold recyclers are big, high-performance machines. During the past 20 years, Wirtgen has invested heavily in developing this technology and their current range of high-performance machines pays testament to the advances that have been achieved.

A separate Streumaster binder spreader usually pre-spreads binding agents such as lime or cement. Following behind, the powerful milling and mixing rotor installed in the cold recycler / soil stabilizer mixes the asphalt layer in need of rehabilitation or the non-load-bearing soil with the pre-spread binder. Water is provided via a hose connection coupled to a water tanker truck and injected into the mixing chamber via an injection bar. The recycled material is levelled off by a pressurized scraper blade at the rear rotor plate to create a perfectly even surface. In a final step, the soil is compacted by suitable HAMM earth compactors."

Soil stabilization

The milling and mixing rotor mixes the existing soil, any required amounts of pre-spread lime or cement and water to produce a homogeneous mix.

  1. Milling and mixing rotor

  2. Pre-spread binder

  3. Processed, homogeneous soil-binder mixture

Cold recycling

The milling and mixing rotor granulates the asphalt, injects any required amounts of binder and water and mixes the construction material mixture.

  1. Injected foamed bitumen

  2. Pre-spread cement

  3. Recycled, homogeneous construction material

  4. Injected water

  5. Milling and mixing rotor

Cold recycling with integrated paving screed

Where specified, cement is pre-spread by a STREUMASTER binder spreader which is followed by water and binder tanker trucks. The milling and mixing rotor installed in the W 240 CR / W 240 CRi granulates the asphalt layers. The pre-spread cement is mixed in at the same time while water and bitumen emulsion or foamed bitumen are injected into the mixing chamber via injection bars. The recycled construction material is transported to the rear of the machine via the primary conveyor and paved true to grade and slope by the VÖGELE paving screed with integrated spreading auger. Final compaction of the material is then effected by HAMM rollers.

Recycling material with the W 240 CR / W 240 CRi (Down-cut)

  1. Milling and mixing rotor

  2. Damaged asphalt layer

  3. Injection bars for water and binders

  4. Paving screed

  5. Spreading auger

  6. Pre-spread cement

  7. Primary conveyor for material transfer to the paving screed

The robust milling and mixing rotor granulates the damaged asphalt pavement. The granulated material is mixed with injected binders and water in the mixing chamber, thus creating a new homogeneous mix in an in-situ process.

Due to the helical design of the milling and mixing rotor, the recycled mix is conveyed towards the centre and subsequently transported to the paving unit via the primary conveyor. The spreading auger distributes the material evenly ahead of the variable paving screed which then paves it true to grade and slope.

Cold recycling with integrated rear loading

Where specified, cement is pre-spread by a STREUMASTER binder spreader which is followed by water and binder tanker trucks. The milling and mixing rotor granulates the asphalt layers. The pre-spread cement is mixed in at the same time while water and bitumen emulsion or foamed bitumen are injected into the mixing chamber via injection bars. The recycled construction material is picked up by the conveyor system and transported right into the material hopper of the VÖGELE asphalt paver for placing. Final compaction of the material is then effected by HAMM rollers.

Recycling material with the W 380 CR / W 380 CRi (Down-cut)

  1. Pre-spread cement

  2. Milling and mixing rotor

  3. Injection bars for water and binders

  4. Damaged asphalt layer

  5. Primary conveyor and discharge conveyor for material transfer to the asphalt paver

The robust milling and mixing rotor granulates the damaged asphalt pavement. The granulated material is mixed with injected binders and water in the mixing chamber, thus creating a new homogeneous mix in an in-situ process.

Due to the helical design of the milling and mixing rotor, the recycled mix is conveyed towards the centre and subsequently transported to the material hopper of the asphalt paver via the conveyor system comprising primary and discharge conveyor. The asphalt paver then paves the material true to grade and slope.


DURAFORCE
milling and mixing rotor

Click here for further information on the powerful DURAFORCE milling and mixing rotor.

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Quick-change toolholder system HT22

Click here for further information on the hard-wearing HT22 quick-change toolholder system.

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GENERATION Z picks

Click here for further information on the GENERATION Z picks.

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Product program

Click here to view the WIRTGEN product portfolio of the WR model range in the cold recycler and soil stabilizer division.

To the product program

Product program

Click here to view the WIRTGEN product portfolio in the cold recycler division.

To the product program

Market-leading and cutting-edge products for the Road and Mineral Technologies business sectors are constructed at the WIRTGEN brand headquarters in Windhagen, Rhineland-Palatinate. With its innovative, high-performance and cost-efficient products and technologies for cold milling, soil stabilization, hot and cold recycling, concrete paving and surface mining, WIRTGEN leads the world market in road construction and repair, as well as in mining natural rock and pay minerals.

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