Efficient hot recycling the internationally recognized method. The World of Wirtgen Hot Recyclers

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1 Efficient hot recycling the internationally recognized method. The World of Wirtgen Hot Recyclers

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3 Breathing new life into old roads. ROADS ARE EXPOSED TO TREMENDOUS STRESSES INDUCED BY TRAFFIC LOADING BUT ALSO TO FREQUENTLY CHANGING WEATHER CONDITIONS. THESE INFLUENCING FACTORS GRADUALLY LEAD TO DAMAGES MAINLY IN THE SURFACE COURSE OF ASPHALT ROADS. REHABILITATION OF THE TOP- MOST LAYER IS OFTEN CONSIDERED THE BEST SOLUTION FOR PRESERVING THE ROAD NETWORK, WHICH REPRESENTS A NATIONAL ASSET. STATE-OF-THE-ART HOT RECYCLING FULLY MEETS THIS PREREQUISITE FROM BOTH AN ECONOMICAL AND ENVIRONMENTAL POINT OF VIEW. WIRTGEN HAS NOT ONLY DEVELOPED THE REMIX METHOD BUT IS ALSO THE DRIVING FORCE BEHIND ITS ONGOING IMPROVEMENT AND IS INEXTRICABLY TIED TO ITS NAME.

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5 CONTENTS REHABILITATION OF SURFACE COURSES USING STATE-OF-THE-ART HOT RECYCLING 6 7 FROM AN IDEA TO BREAKTHROUGH TECHNOLOGY 8 9 OPERATING PRINCIPLE AND COMPONENTS OF A HEATING MACHINE OPERATING PRINCIPLE AND COMPONENTS OF A REMIXER TWO RECYCLING OPTIONS: REMIX AND REMIX-PLUS EFFECTIVE HEATING OF THE SURFACE COURSE GENTLE SCARIFICATION AND HOMOGENEOUS MIXES CUTTING-EDGE PAVING TECHNOLOGY HOT RECYCLING TRAIN WITH A PROVEN TRACK RECORD AROUND THE GLOBE KNOW-HOW FOR PREMIUM QUALITY SERVICE THAT YOU CAN DEPEND ON HOT RECYCLING CONQUERS THE WORLD ENVIRONMENTAL PROTECTION IN FOCUS 30 31

6 06 07 Rehabilitation of surface courses using state-of-the-art hot recycling Rehabilitation of the damaged bituminous pavement is completed quickly in a single machine pass. OLD BECOMES NEW IN RECORD TIME Provided that the lower pavement layers are intact in terms of bearing capacity, hot recycling is the most economical and environmentally friendly rehabilitation method for asphalt surface courses. Many different types of surface damage extending to a depth of up to 5 cm on main traffic arteries, minor roads, motorways or airports such as rutting, cracking, lack of skid resistance, pavement irregularities, incorrect aggregate composition or excessive bitumen content are repaired by the high-performance machines from WIRTGEN on a large scale and in an extremely short period of time. They scarify the previously heated pavement in order to thoroughly recycle it in an in-situ process. Virgin mix and binding agents are added to the process depending on the damage pattern. After final compaction by rollers, the recycled pavement can be reopened to traffic quickly as soon as it has cooled down. In addition, the machines compact design enables traffic to pass along smoothly on adjacent lanes during the recycling process. The cost-efficient technology is gentle on resources as it reuses 100 % of the valuable source material and requires only small amounts of new construction materials. The quality of the recycled pavement can be improved in line with specific requirements, fulfilling the highest demands when recycling is complete.

7 1 The adjacent lane is heated in a slightly overlapping pattern to guarantee an excellent, seamless material bond. 1 2 Hot recycling requires only small amounts of new construction material. 3 Traffic passes along next to the moving roadworks. 2 3

8 08 09 From an idea to breakthrough technology 1976 The Repaver is used to rehabilitate pavements using the hot recycling process Heating machines preheat the damaged asphalt pavement in preparation for the Repaver WIRTGEN develops the FRP 300 and FRP 600 joint repavers for the rehabilitation of joints In the Remix-Plus process, a surface course is paved right on top of the remixed base WIRTGEN builds the FRP 1000 mini Remixer for pavement rehabilitation WIRTGEN offers the Remixer 2500 for small to medium-sized projects.

9 1979 The Remix method optimizes the functional properties of the recycled material. HOT RECYCLING GAINS ACCEPTANCE In the mid-1970s, WIRTGEN developed a method for the economically efficient rehabilitation of damaged bituminous road surfaces. Based on the revolutionary idea to replasticize roads by means of heat, the first hot recycler was developed in That was the beginning of WIRTGEN s success as a recycling contractor, operating their own fleet of hot recyclers The new Remixer 4500 offers a variable working width ranging from 3.0 m to 4.5 m WIRTGEN perfected the heated process with much passion and pioneering spirit, and evernew, successful inspirations marked the path of this innovative technology. The equation set up back then is working out just right today, when economically efficient and environmentally friendly construction methods are called for. The first Repaver rolled off the assembly line in 1976, leading WIRTGEN s future contracting fleet of hot recyclers. The development of the Remix process in 1979 represented a quantum leap in the quality of hot recycled asphalt road surfaces. The fully redesigned Remixer 4500 breaks new ground in the hot recycling industry.

10 10 11 Operating principle and components of a heating machine 2 GAS TANK Liquid-gas tank system with filling level indicator to supply energy to the infrared radiators. 1 WINCHES Two hydraulically driven winches to lower the front and rear heating panels from transport into working position. 7 7 HEATING SYSTEM Infrared radiator elements adjustable to the specified working width for effective heating of the surface course and underlying base.

11 EFFECTIVE HEATING OF ASPHALT SURFACE COURSES In the first step of the innovative recycling process, the self-propelled panel heating machine travels right ahead of the Remixer, heating up the damaged asphalt pavement by means of infrared radiators to a depth of up to 5 cm. Adjustable heating power enables the damaged surface to be softened by gently heating it to the specified temperature. Full control of the propane combustion process ensures high heating output while keeping gas consumption low. The total working width of the heating panels can be adjusted in increments to a maximum width of 4.5 m. Paired with smooth, hydraulic all-wheel steering, the heating panels in pivoting design ensure perfect work results even in narrow bends. The operation of the heating machine is perfectly tailored to working in tandem with the Remixer. 3 POWER UNIT Fuel-efficient, powerful diesel engine for high drive power. 4 OPERATOR S PLATFORM Walk-through operator s platform with controls arranged within easy reach for easy operation GAS PRESSURE REGULATOR Centrally arranged gas pressure regulator for effective control of the heating performance in the various heating zones. 6 ALL-WHEEL STEERING All-wheel steering system for excellent manoeuvrability.

12 12 13 Operating principle and components of a Remixer 4 METERING BIN 5 GAS TANKS Storage container for continuously adjustable discharge of virgin mix onto the belt conveyor. Liquid-gas twin-tank system with filling level indicator to ensure energy supply to the infrared radiators. 3 BELT CONVEYOR Heavy-duty scraper conveyor to forward and add virgin mix to the recycling process. 2 BINDER TANK Heated binder tank for the storage of bituminous binding agents RECEIVING HOPPER Large hopper to receive virgin mix from the truck.

13 RECYCLING IN A SINGLE WORKING PASS The damaged surface course is heated, scarified, mixed and placed again immediately by the self-propelled WIRTGEN Remixer and all in a single machine pass. Depending on the type of surface damage to be repaired, virgin mix and binders are added to the recycling process. A large receiving hopper accepts virgin mix from a truck. From here, a belt conveyor forwards the material to a metering bin where it is added to the recycling process. Binders such as hot bitumen are carried on-board separately in a heated binder tank. Working in tandem with the heating machine driving ahead, the Remixer s infrared radiators heat up the asphalt surface course to a depth of up to 5 cm. Gentle heating is guaranteed thanks to the machine s adjustable heating power. The overall working width of the heating panels can be adjusted in increments to a maximum width of 4.5 m. 6 POWER UNIT 7 OPERATOR S PLATFORM Fuel-efficient, powerful diesel engine for high drive power. Walk-through operator s platform with controls arranged within easy reach for easy operation. 8 PAVING SCREED 6 Tried-and-tested VÖGELE paving screed including spreading auger and hydraulic tamping and vibrating unit for perfect paving results TWIN-SHAFT COMPULSORY MIXER Heated mixer with high-strength internal lining to ensure homogeneous mixing of the scarified asphalt pavement, binder and virgin material. 11 HEATING SYSTEM 10 SCARIFIER SHAFTS Infrared radiator elements adjustable to the specified working width for effective heating of the surface course and underlying base. Scarifier shafts adjustable to the specified working width and fitted with carbide tools for gentle scarification of the pavement material.

14 14 15 Two recycling options: Remix and Remix-Plus MULTI-FACETED HOT RECYCLING In the Remix process, rotating scarifier shafts installed in the Remixer scarify the heated asphalt pavement with binders being injected at the same time. A scraper blade removes the scarified material, conveying it into the mixer. Here, virgin mix is added via the belt conveyor and mixed with the reclaimed pavement material. The spreading auger then spreads the discharged mix on the preheated subgrade, enabling the paving screed to precisely pave and pre-compact it true to line and level. REMIX PROCESS Working direction Similar to the Remix process, Remix- Plus is also used to recycle and replace deformed asphalt surface courses. In the process, however, the conveyor deposits high-quality virgin mix on top of the remixed layer behind the levelling screed where it is then distributed by the second spreading auger. In a final step, the mix is compacted by the screed to produce a thin, cost-efficient wearing course in hot-in-hot application. 6 5 REMIX-PLUS PROCESS Working direction

15 1 Scarifier shafts Shafts fitted with carbide tools for gentle scarification of the pavement material 2 Injection system System governing the addition of binding agents 3 Twin-shaft compulsory mixer Heated mixer with high-strength internal lining for homogeneous mixing of the scarified pavement, binder and virgin material 4 Belt conveyor Heavy-duty scraper conveyor to forward and add virgin mix to the recycling process 5 Spreading auger Spreading auger for even distribution of the recycled material 6 Paving screed VÖGELE paving screed with hydraulic tamping and vibrating unit Scarifier shafts Shafts fitted with carbide tools for gentle scarification of the pavement material 2 Injection system System governing the addition of binding agents 3 Twin-shaft compulsory mixer Heated mixer with high-strength internal lining for homogeneous mixing of the scarified pavement and binder 4 Spreading auger 1 Spreading auger for even distribution of the recycled material 5 Levelling screed Screed placing the surface course treated with a binding agent prior to overlaying with a new, thin surface layer 6 Belt conveyor Heavy-duty scraper conveyor to transport virgin mix behind the levelling screed 7 Spreading auger 2 Spreading auger for even distribution of the virgin material 8 Paving screed VÖGELE paving screed with hydraulic tamping and vibrating unit

16 16 17 Effective heating of the surface course 1 The Remixer s heating panels heat up the pavement continuously to the specified temperature. 1 EXPERTISE THAT GOES REALLY DEEP The effective combination of heat and infrared radiation enables the heater panels to heat the asphalt pavement uniformly to the specified depth and without causing thermal damage to the binding agent. The infrared heaters are fed with propane gas. To increase the heating performance, hydraulically driven fans blow additional oxygen into the heating zone. The heating power can be adjusted to requirements via pressure control valves. Complete heating circuits or individual heating elements can be switched on or off separately in accordance with requirements. The adjacent lane is also heated in a slightly overlapping pattern to ensure an excellent, seamless material bond. Field experience shows that performance increases with the number of heating machines used. This has led many contractors to use two or even more heating machines in large projects or in cold weather conditions. 2

17 3 2 In-depth heating: infrared radiation penetrates the asphalt to create a deep heating effect. 3 Blowers guarantee an effective heating output. 4 Gas pressure in the four heating zones of the panel heating machine can be adjusted by means of pressure control valves. 4

18 18 19 Wear-resistant carbide tools mounted on the scarifier shafts in a helical pattern. Gentle scarification and homogeneous mixes MASTERPIECES OF TECHNOLOGY The heavy-duty variable scarifier is comprised of rotating scarifier shafts fitted with carbide tools arranged in a helical pattern. It ensures gentle scarification of the preheated asphalt pavement without destroying its grain structure. The working depth is continuously adjustable via a highly precise automatic levelling system. The overlapping arrangement of the scarifier shafts offers an even higher degree of flexibility, for it enables hydraulic, continuous adjustment of the working width. Thanks to the centrally divided rear scarifier shaft, even the rehabilitation of roads with a central crown poses no problem at all. The heated heavy-duty twin-shaft compulsory mixer is fitted with powerful, counter-rotating shafts which homogeneously mix the scarified pavement, binding agents and virgin material. The precise formulation of the binders to be added is established by means of sampling and systematic laboratory testing.

19 Variable working width thanks to the overlapping arrangement of the scarifier shafts in two rows. 2 The working width of the scarifier shafts can be adjusted hydraulically via heavy-duty guides. 3 Thorough mixing is ensured by counter-rotating shafts in the compulsory mixer.

20 20 21 Cutting-edge paving technology BY THE PROS FOR THE PROS We rely on high-tech elements made in Germany also for paving the new surface course to maximum perfection and true to line and level. That is why hot recyclers from WIRTGEN are equipped with state-of-the-art VÖGELE paving screeds. Variable working width, an innovative electrical heating system and a long service life are the hallmarks of the tried-and-tested machine components. The screed can be continuously adjusted hydraulically to working widths from 3.0 m to 4.5 m to guarantee the broadest possible range of applications. Hydraulic adjustment makes it easy to also produce surface courses with a central crown. An integrated automatic levelling system ensures paving of the recycled mix precisely to the specified level. A sensor-controlled spreading auger installed in front of the screed distributes the material evenly across the full working width. Reliable pre-compaction of the surface course is ensured by the screed s tamping and vibrating unit.

21 1 2 1 The Remix-Plus process uses two heavy-duty, independently operating paving screeds. 3 2 The spreading auger spreads the recycled material evenly in front of the paving screed. 3 To maintain the specified working depth, the crew is supported by tried-and-tested WIRTGEN levelling technology.

22 22 23 HM 4500 Remixer 4500

23 Hot recycling train with a proven track record around the globe. WIRTGEN IS THE INDUSTRY LEADER Experience gained over several decades makes WIRTGEN the industry leader in hot recycling. We have set new standards by producing special machinery for this economical process. No other manufacturer offers this winning combination of Remixer and heating machine they are the most advanced hot recycling tandem worldwide. The Remix process recycles the surface course with added virgin material and / or binders while the Remix-Plus process involves paving of an additional thin surface course of virgin asphalt material.

24 24 25 Expertise for premium quality STATE-OF-THE-ART PRODUCTION METHODS WIRTGEN sets high standards in quality. We meet these standards with fully qualified staff, state-of-the-art manufacturing methods and a highly refined quality assurance system. Our highly skilled employees excel in competence, many years of know-how and a high degree of personal responsibility in the different manufacturing divisions. Automated manufacturing methods combined with modern manufacturing facilities and a high degree of vertical integration produce durable, heavy-duty machines that always win the upper hand in tough job site conditions. In-house production of a large number of equipment options and special components permits many different, customer- specific equipment combinations. The use of high-quality materials ensures the machines function and long service life.

25 1 2 1 State-of-the-art hard- and software are the tools of trade of our engineers and technicians. 3 2 High-quality welding work is performed exclusively by highly qualified specialists. 3 Production benefits from our extensive expertise in cutting technology.

26 26 27 Service that you can depend on CUSTOMER SUPPORT IS AT THE TOP OF OUR AGENDA We operate on a global basis and are present locally whenever it comes to providing professional customer support. Customer service at WIRTGEN is perfectly organized: an extensive network of strong service centers is spread around the globe. In the rare case that problems arise, fully qualified service engineers from our service companies will be present on your location quickly to provide active support, thus avoiding time losses due to long travel times. Ongoing, in-depth training courses ensure that the staff at our subsidiaries is always up to date with the very latest technology. Paired with the high availability of spare parts worldwide and reliable on-time delivery, this service concept keeps downtimes to an absolute minimum.

27 Training our staff for the benefit of our customers. 2 Spare parts can be supplied worldwide in the shortest time. 3 One of our subsidiaries is sure to be at your doorstep, too.

28 28 29 Hot recycling conquers the world THE INTERNATIONALLY RECOGNIZED METHOD HAS PASSED THE TEST Germany has been the birthplace of the innovative hot recycling technology. From here, it quickly spread across Europe to overseas and the Far East. The hot recycling technology is mainly applied in countries across Asia, like China or Thailand, but is also a widespread and standardized construction method in the industrialized countries of Western Europe, the CIS or Australia. Numerous WIRTGEN hot recyclers are currently in operation around the globe, rehabilitating many different types of asphalt roads.

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30 30 31 FULL REUSE WIRTGEN has made the protection of our environment a corporate policy long ago. The hot recycling technology impressively reflects our endeavours to keep environmental pollution by our machines as low as possible: the reclaimed asphalt pavement is fully reused in the hot recycling process, which saves rare and valuable natural resources. Optimized, effective combustion of the propane gas guarantees high heating performance at low gas consumption. The environment is not polluted by additional truck transports as only small amounts of virgin material need to be hauled to the construction site. Hot recycling is carried out as a moving job site and minimizes disruptions to traffic, which reduces strain on the environment. In addition, our fuel-efficient engines comply with the most stringent international emission standards. HOT RECYCLING > shortens construction times. > is a resource-efficient process. > dispenses with the need to create stockpiles. > minimizes environmentally harmful disruptions to traffic. > reduces the number of truck transports to the construction site. > reduces the amount of virgin mix required.

31 Environmental protection in focus

32 Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes. Performance data depend on operational conditions. Nr EN-01/16 by WIRTGEN GmbH Printed in Germany. WIRTGEN GmbH Reinhard-Wirtgen-Str Windhagen Germany Phone: +49 (0) / Fax: +49 (0) / Internet: info@wirtgen.comn