WIRTGEN Cold Recycler & Soil Stabilizer WR 240: Rehabilitated 22 Km Road Near Hapur

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.

NBM&CW March 2020

Click Here
To Know More / Contact The Manufacturer
Please fill in your details, we will contact you as soon as possible
Choose Title from the listPlease let us know your name.
Please let us know your Designation.
Invalid Input
Please let us know your email address.
Please let us know your City.
Please let us know your Contact Number.
Please brief your query.
Our other value-added services:

To receive updates through e-mail on Products, New Technologies & Equipment, please select the Product Category(s) you are interested in and click 'Submit'. This will help you save time plus you will get the best price quotations from many manufacturers, which you can then evaluate and negotiate.

Equipment & Machinery
Invalid Input
Building Products
Invalid Input

MOBISCREEN EVO screens in action

The MOBISCREEN EVO Mobile Screens are being manufactured by the Wirtgen Group in India at its local production and assembly plant in Pune. The mobile screening plants in the MOBISCREEN EVO line are successful all over the world Read More ...

Condition Monitoring - Oil Sampling Analysis in Construction & Mining Machines

Bhaskarudu Peddakotla, Consultant – Construction and Mining Machinery, suggests that machine owners should implement condition monitoring and thereby become self-reliant in maintaining their assets and enhancing Read More ...

Condition Monitoring Through Data Downloading

Leverage technology, educate and motivate team members, and minimise operating cost, advises Bhaskarudu Peddakotla, Consultant for Construction and Mining Equipment. Equipment availability is critical for profitability Read More ...

WIRTGEN Slipform Paver SP 1600 – the world’s largest paver - comissioned for construction of Vadodara-Kim Expressway

The world’s largest concrete slipform paver was comissioned at Patel Infrastructure on February 25th, 2020 for the construction of 8-lane Vadodara-Kim Expressway, a part of the Mumbai-New Delhi Expressway. The SP 1600 Read More ...

Skid Steer Loader: Scoring high on versatility and applicability

Manufacturers of skid steer loaders are banking on the versatility of the equipment and foresee its growing demand as an efficient application-driven machine NBM&CW reports. Though the skid steer loader market in India Read More ...

Preventive Maintenance through Condition Monitoring – Mining and Construction Equipment

The present competitive business environment demands higher utilization of equipment to the tune of 6000 hrs per year unlike the olden days of 2500 – 3000 hrs. To meet the present utilization level, machine availability has Read More ...

Mobile Cranes for Urban Infra Development

Mobile crane manufacturers are designing cranes that can address the execution complexities at urban development sites that have restricted space and a high population density. Some of the new products on offer are at the concept Read More ...

CE Industry Finding Opportunity in Adversity

Industry captains in the construction and equipment manufacturing sector of India discuss solutions to deal with the current challenges and the way forward once the lockdown is lifted. No doubt, Covid-19 has thrown a formidable Read More ...

WIRTGEN GROUP Machines Construct Yogyakarta International Airport

The first plane to land at the new Yogyakarta International Airport (YIA) on the Indonesian island of Java was an A320 from Jakarta. Eleven slipform pavers from Wirtgen played a key role in the airport’s construction. Once completed Read More ...

Asphalt Pavers: Doing More With Less

A host of new interventions are helping pavers deliver higher productivity, better paving quality and surface finish, along with speed for faster completion of projects. NBM&CW reports. Manufacturers are giving a facelift to Read More ...

WIRTGEN GROUP Machines Driving Construction of New Istanbul Airport

After just three years of construction, the world's biggest airport (measured by passenger num-bers) started operation in 2018 initially with two runways, expanded to three by 2019 and, by the end of the project in 2028 Read More ...

Pavement preservation, Restoration and Drainage solutions from AIC Infrastructures

Kritarth Raja, Managing director of AIC infrastructure offered a perspective of Aviation Infrastructure at EXCON Bangalore 2019. Besides being a MD of an aviation infrastructure company he has been instrumental in introducing Runway Read More ...

New road rehabilitation techniques from Neha Infra Services

Director, Chetan Kanakia of M/s. Neha Infra Services (Mumbai), a road rehabilitation service provider, shared information on the company’s road rehab technologies and supporting service. He stressed on the importance of Read More ...

Caterpillar unveils new products for Indian market

Caterpillar, the global heavy equipment manufacturer, announced the launch of its new products for the Indian region. With the introduction of the new Next Gen Cat® 120 Motor Grader, Caterpillar aims to deepen its presence in Read More ...

Leeboy launches new series of compact motor graders

Leeboy India Construction Equipment, one of the leading manufacturers of motor graders and other construction equipment in India, launched their new series of compact motor graders for India and other developing markets Read More ...

WIRTGEN GROUP: Construction 4.0 - Working Environment of The Future

At HAMM, developers are thinking not only about the next machine generation; but are also focused on the effects that current megatrends will have on road building, in general, and on compaction, in particular. Here, the globally Read More ...

New Building Material & Construction World

New Building Material & Construction World
MGS Architecture

Modern Green Structures & Architecture

Modern Green Structures & Architecture

Lifting & Specialized Transport

Lifting & Specialized Transport

Indian Infrastructure & Tenders Week

Indian Infrastructure & Tenders Week