Low cost and high quality are two of the most important criteria when it comes to rehabilitating roads. The WIRTGEN cold recycling train has yet another advantage: roads can be re-opened to traffic in no time. A WR 240 cold recycler and soil stabilizer demonstrated this advantage on a 22km-long job site near Hapur, where cars returned to the road after just 2.5 hours.

WR 240

The country road between Hapur and Kithore is one of the most important links in the Hapur district. It was in poor condition with potholes, cracks and ruts, which were degrading the asphalt pavement. The decision was made to rehabilitate the road using the economical and resource-saving cold recycling method. In this process, a WIRTGEN pave train mills and granulates the damaged asphalt layers, binds the material again by adding a binding agent, compacts it and then directly re-paves it. This is therefore referred to as an “in situ” method (performed in place). “We use all the milled material and process it specifically for this purpose, obtaining a high-quality construction material. We save a lot of time and money in this way, while minimizing the environmental impact,” says Ram Kumar, Site Manager for the contractor, Seema Construction, in praise of cold recycling, a proven process worldwide that offers an excellent alternative to traditional methods. This job site alone extends over more than 22km.

Rehabilitation Method Proven Worldwide
Another important advantage of the cold recycling method is the fast turnaround: in most cases there is no need for a complete closure of the road. This was the case in Uttar Pradesh, where traffic continued to flow in the second lane. Each rehabilitated section of the country road was re-opened to traffic after just 2.5 hours, despite the fact that the cold recycling pave train does not simply pave a temporary surface, but rather gives a sustainably durable, high-quality, cold recycled layer.

Different pavement structures and combinations of machinery are possible when employing this method. At the job site near Hapur, cement was first spread onto the damaged asphalt by an SW 16 MC binding agent spreader from WIRTGEN systems partner STREUMASTER, which was followed by a tank truck that supplied the WIRTGEN WR 240 cold recycler and soil stabilizer with water. The WR 240 is equipped with the new DURAFORCE milling and mixing rotor, which thoroughly mixed the damaged layers (the asphalt surface course as well as the binder and base courses) together with the pre-spread cement, and added water in a variable mixing chamber and then redeposited the material. A grader then took care of the profiling and various HAMM rollers – in this case a 311 D compactor and an HD 99 tandem roller – compacted the new cold recycled layer. With its new surfacing, the recycled road has a high bearing capacity and a long service life. In the final step, a conventional surface course is usually paved on top as a wearing course.

Cold Recycling Saves Money and Speeds Up Jobs
Many road construction companies are unaccustomed to using cement when rehabilitating bituminous asphalt layers. But adding this binding agent is standard practice in cold recycling. Together with the bitumen contained in the damaged pavement, it helps to stabilize the cold recycled layer and make it durable in the long term. Other possible binding agents include bitumen emulsion and foamed bitumen. But one material can be dispensed with in all cold recycling applications: there is no need to add newly processed aggregate. The method hence conserves resources and is very cost-effective in many respects: mix lorries do not need to be provided to transport mix to the job site, reducing fuel consumption and CO2 emissions. In addition, roads need not be blocked to traffic for extended periods and, more importantly, they need not be closed entirely. Traffic flows benefit and the cost to public budgets is reduced as well. These criteria were also deciding factors in the contract award for rehabilitation of the road between Hapur and Kithore by the cold recycling method – and the project was completed sooner than planned.

HAMM compaction technology for the final touches: the 311 D compactor and HD 99 tandem roller in operationHAMM compaction technology for the final touches: the 311 D compactor and HD 99 tandem roller in operation

Cold Recycling in situ: In-Place Laydown of Road Pavements
Over time, increasing car and lorry traffic causes structural damage to the individual layers of asphalt carriageways and compromises their load-bearing capacity. As a recycler, the WR corrects these defects quickly, economically and without wasting resources, because it is equipped with a powerful DURAFORCE milling and mixing rotor as well as advanced injection systems. In a single pass, the cold recycler uses its milling and mixing rotor to remove the asphalt pavement, granulate it, inject precisely metered volumes of binding agent and water and then mix the material. The new base courses, which are paved in situ, boast a very high load-bearing capacity as a result. Possible additives or binding agents include cement, water, bitumen emulsion and foamed bitumen. High-precision dosing, consistently high mix quality, simple, well-structured machine operation and accurate levelling guarantee optimum results. The machines in the WR series are ideally suited to applications in all performance ranges, from recycling thin asphalt layers on quiet minor roads to recycling up to 250 mm-thick asphalt layers on heavily travelled motorways.

WIRTGEN DURAFORCE Milling and Mixing Rotor: A Rotor For Every Requirement
Cold recycling saves money and speeds up jobs demanding varying field conditions which constantly bring new challenges for cutting tools used in cold recycling and soil stabilization. For their WR series, WIRTGEN has developed a solution that is more than a match for even the most extreme requirements in both applications - the new DURAFORCE milling and mixing rotor. This development marks the end of unprofitable tool changing times, maximizing lucrative operating times instead.

Requirements on the milling and mixing rotor in cold recycling applications: Steady milling process to prevent oversized particles and to ensure high-quality results. High milling performance and low wear even in hard, abrasive material to ensure high economic efficiency. Compliance with the specified grading curve to ensure the lasting structural integrity of the new base layer. Homogeneous mixing of the binding agents to ensure high adhesion (bonding strength) between the individual particles and thus maximum bearing capacity.

Combined with the intelligent distribution of material, the streamlined geometry of the holding bases supports an optimal distribution of forces, particularly the peak loads generated by transverse forces. The robust edge ring segments are highly accessible and can be replaced quickly and easily.

Tried-and-tested forging process: The holder bases of the DURAFORCE milling and mixing rotor are given an intelligently designed 3D geometry using the tried-and-tested forging process. In addition to even load distribution and thus maximum stability, this process results in an optimum flow of material and homogeneous mixing of construction material.
Milling Drum

With its centrepiece, the DURAFORCE milling and mixing rotor, the WR series guarantees success in cold recycling and soil stabilization. Soil stabilization is a process for improving the load-bearing capacity of soils by adding a binding agent, such as lime, cement or combinations of the two.
Fayat’s road construction equipment of Marini & Dynapac and Secmair
The Fayat Group was present at Excon 23 with all its brands. Fayat Road Equipment division showcased products that cover the full road life cycle. They included technologies from Marini and Dynapac for road construction with a recycling

Read more ...

Ashitech offers upgraded Asphalt Batch Mix Plants
Gujarat-based asphalt batch mix plant and allied products manufacturer, Ashitech is upgrading the functions of its asphalt batch mix plants and other products. The product advancements are being made to ensure their optimum usage.

Read more ...

Ammann India: Track Paver, battery-operated Tandem Roller & Soil Compactor
Ammann India launched several new products, including a 7m track paver and a 9m track paver (both of which are entirely indigenous), a battery-operated 2-ton tandem roller, and a 5-ton soil compactor, making it the only company in India

Read more ...

Wirtgen’s cold milling, concrete paving, and surface mining equipment
Wirtgen’s technologies, solutions and applications are designed to enable smarter, safer and more sustainable road construction processes and more efficient extraction and processing of materials in quarries and open cast mines.

Read more ...

Arx's Motor Graders, Blast Hole Drill Rigs & Dust Suppression Systems
The motor graders displayed by Arx Mining and Construction Equipment India, comprised the G3200 of 32 tons, G2100 of 21 tons and G1200 of 12 tons. The Arx Graders come with the latest driveline from Western Europe, and have a high

Read more ...

Vibrant's Asphalt Batch Mix Plants of 100 tph to 260 tph capacities
Hyderabad-based, asphalt batch mix plant manufacturer, Vibrant, has carried out advancements in its entire range of asphalt batch mix plants for their optimum usage, informed Kranthi Kumar Ravuri, CEO, Vibrant. “We offer plants

Read more ...

Alltech’s 120 tph Mobile Asphalt Batch Mix plant
Gujarat-based Alltech displayed its new 120 tph mobile asphalt batch mix plant, designed and manufactured at the company’s facility in Mehsana, complete with chassis, bins, burner, hopper and screens...

Read more ...

UNITER's Hydrostatic Self- Propelled paver for Road Widening
UNITER Engineering Products has developed a Self-Propelled Road Widener Model UWNR4, the first of its kind in India. This machine is capable of laying material for road widening and side shoulders...

Read more ...

KESAR: One-stop solution for road building contractors
KESAR has positioned its company as a one-stop solution for road building contractors with its wide range of products that include Asphalt Batch Mix Type Hot Mix Plant, Asphalt Drum Mix Type Hot Mix Plant...

Read more ...

Waken Multitech Asphalt and Wet Mix Pavers with Tailored Efficiency
Akshay Patel, Director of Waken Multitech, informs that our asphalt and wet mix pavers now come equipped with advanced features. These enhancements not only contribute to a reduction in operating costs but also allow for the customization of the pavers

Read more ...

Coninfra Machinery's Higher Capacity Drum & Asphalt Batch Mix Plants
According to Saumil Shah, Director, Coninfra Machinery, the company is geared up to venture into the higher capacity of 200-400 tph drum & asphalt batch mix plants once market demand escalates.

Read more ...

Vögele New-Gen Dash 5 Road Pavers for Large-Scale Projects
The future in road building is here with Vögele’s latest-generation SUPER 1900-5(i) and SUPER 2100-5(i) Road Pavers. These Highway Class pavers are the best in class whether on highways or handling other demanding large-scale projects. The SUPER 1900-5(i)

Read more ...

Wacker Neuson a Reliable Partner for 175 years
The foundation for Wacker Neuson’s success story was laid by Johann Christian Wacker in 1848, when he set up a blacksmith shop in Dresden. Since then, the company has introduced innovations time and again, which have revolutionized construction

Read more ...

CASE remains committed to Skill Development of the country’s youth
CASE Construction Equipment is commemorating its skill development initiative and enabling employability of aspiring youth by providing them with vocational training at its Skill Development Centre in Pithampur. It is also celebrating a successful year

Read more ...

Fayat Asphalt Batch Mix Plants, Paving And Compaction Solutions
Fayat Road Equipment Division is positioning its brand more competitively in the Indian market for asphalt batch mix plants, paving and compaction solutions through Marini and Dynapac brands, as it is keen to expand its business volume in India, reveals

Read more ...

JCB VM 117 Single Drum Soil Compactor Offers Unmatched Fuel Efficiency
The JCB VM 117 single drum soil compactor comes with a 74 hp JCB ecoMax 444 engine and boasts a range of advanced features that enable high productivity, reliability, and operator comfort. With an operating weight of 11,400 kg and a drum width of 2100

Read more ...

Arx Motor Graders for Roads, Mining & Heavy Construction Sites
Arx offers a range of motor graders with finely tuned drivelines that offer optimal torque and speed balancing, along with a lock-up clutch that ensures high efficiency under no load conditions. Arx motor graders also have telematics for machine health and

Read more ...

Apollo AP600 Wheeled Hydrostatic Sensor Paver offers High Productivity
The Apollo AP600 Wheeled Hydrostatic Sensor Paver is a reliable and durable paving solution that offers superior quality, productivity, and ease of operation. With the Apollo AP600 Wheeled Hydrostatic Sensor Paver’s CEV IV emission standard engine

Read more ...

Ashitech's Premium Asphalt Batch Mix Plant, Drum & Wet Mix Plants
Ashitech’s line of products include the asphalt batch mix plant, drum mix plant, wet mix plant, distributor, decanter and broomer. “All our products are efficient and help save around 12 to 15% of fuel consumption compared to our competitors. We offer

Read more ...

Kennametal India's Tungsten Carbide Hard Metal High Strength Tools
Kennametal is keen to leverage its expertise in hard metal tooling to position itself more strongly in the Indian market for construction and mining industry. Informs Rohit Reddy, Deputy General Manager – Earth Cutting Tooling Business, at Kennametal

Read more ...