Stable structures require stable foundations.

Nature does not always provide the ideal ground conditions – whether for civil engineering or structural
engineering projects. Quite often, the existing soil requires preliminary treatment to improve its bearing
capacity. In other places, massive rock formations need to be levelled. What methods are used for laying
the foundations?

Soil and rock construction

1. Soil compaction
2. Soil stabilization
3. Routing operations

1.Roads require a stable foundation to be built on. That is why earthmoving operations need to
be carried out prior to paving a road’s base, binder and surface course layers. What are the
rolling techniques used in soil compaction? In which way will the ground structure influence
compaction results?

Nature doesn’t always provide the ideal foundation for the construction of roads: natural rock. In the
majority of cases, the ground is unstable, offering insufficient bearing capacity. Earthmoving operations are
therefore usually the first step in the construction of a new road. When the course has been defined and set
out, the ground underlying the new road needs to be prepared.
Stable ground will carry the road
Compaction is the single most important process in soil construction. Its job is to reduce the volume of
pores in the soil to be compacted, which are filled with water and air. Compaction will give soil the desired
properties: Its resistance to stresses induced by traffic and climate will be improved by increasing its
stability while simultaneously reducing its tendency to swell due to water absorption. The latter will
additionally make the soil resistant to frost.
Cohesive and non-cohesive soils
The process is different for different types of soil. Experts distinguish between cohesive and non-cohesive
soils. In cohesive soils like loam, clay or silt, the particles in the soil bond to one another. In non-cohesive
soils like gravel or sand, the particles lie side by side without bonding. Soil types can be distinguished as
follows in terms of compactability: water-retaining soils, fine grained cohesive soils, coarse grained non-
cohesive soils, fine and coarse grained mixed soils, and rock.
Dynamic compaction is highly effective
Dynamic compaction of soils by means of vibrating or oscillating compaction equipment has proved to be
particularly effective in earthmoving operations. Compaction is generated by the combined action of the
vibrating or oscillating roller drum and the weight of the machine itself. Applying a dynamic load achieves
significantly higher compaction effects than applying just the weight force.
Compaction requires more than just weight
The intensity of compaction is governed by three influencing factors: displacement of the roller drum,
meaning the amplitude of the vibration or oscillation, rate of recurrence of the vibration or oscillation,
meaning the frequency, and duration, meaning the roller’s travel speed. When these parameters are set
correctly, the specified density can be achieved in considerably less roller passes.
The right technique for any type of soil
Cohesive soils are compacted most effectively using single-drum compactors with padfoot drums applying
high amplitudes of approx. 1.8 mm. Non-cohesive soils are best compacted using smooth drums and low
amplitudes of between 0.5 mm and 1 mm. The ground has now been prepared to serve as a base for the
upper road structure – unless its moisture content is too high. Excessively wet soils require additional
stabilizing.

Single-drum compactors with padfoot drum play their ace in particular when working on wet mixed soils:
Trapezoidal studs on the drum produce impressions in the soil, increasing the total surface and enabling the
soil to dry.

2. Getting the water out.

Road construction requires a stable base. How to improve the nature of existing soil? What are
the binding agents used for this purpose.

Extremely cohesive and wet soils are not suitable for compaction by rollers. In such cases, the existing soil
needs to be stabilized first to improve its bearing capacity and prepare it as a suitable base for the upper
pavement structure. Stabilization is a method of soil improvement, its goal being to permanently bind the
water in the soil.
Lime and cement provide stability
This goal is achieved by mixing binding agents – in particular lime or cement – into the soil. Cement
stabilization is particularly suitable for making subsoils permanently resistant to traffic loads, ingressing
water and frost. Soils that require stabilizing are often very muddy, so that the stabilizing operation needs to
be carried out by powerful, all-wheel driven machinery. Wirtgen soil stabilizers are therefore equipped with
large, deep-treaded tyres, offer excellent traction, and feature a powerful travel drive system. Their mixing
rotors are capable of mixing pre-spread binding agents into the soil at depths of up to 50 cm in one single
working pass. Soil stabilization reduces the water content, turning the soil into a crumbly, stabilized mixture
that is ideally suited for compaction by single-drum compactors.
Stabilizing the subgrade: The milling and mixing rotor installed in the Wirtgen soil stabilizer is mixing the soil
with pre-spread cement.

3. Building roads through stone and rock.

Before commencing the actual road building operation, the prerequisites for doing so need to be
established first. Heavy equipment is used where roads are to be built on rocky ground. How to
create a precise ground level in hard rock? What are the methods used?
Hard rock to the core
Road builders are confronted not only with subsoils that are excessively soft or instable, but also with bases
that are extremely hard – too hard for roads to be built to the specified level without preparing the ground
first. This difficulty typically arises when a road is to be built in mountainous terrain or in other areas where
the ground is rocky or extremely hard. When that is the case, routing operations need to be carried out first.
Cutting through rock with no explosion, no dust
Routing operations are frequently carried out on ground which consists of limestone, slate, or granite, but
also in other types of rock. Blasting is a common method for removing hard rock, and is accompanied by the
inevitable nuisances of noise, dust, and heavy vibrations.
Being gentle on the mountains
Where blasting is not feasible because houses, industrial estates or railway lines are located in the
immediate vicinity of the job site, routes are often produced by cutting through the rock with surface
miners. This environmentally friendly method is capable of cutting rock without causing any damaging
vibrations and is therefore gentle both on the mountains and on their inhabitants.
Carved in stone with pin-point precision
Routing operations involve cutting a path through hard rock. Surface miners cut the rock by means of a
cutting drum fitted with tungsten carbide tools, and load it onto trucks or dumpers via their slewing
discharge conveyor, all in one single working operation.
Reusing the cut material
The cut material is of uniform size and can therefore be reused as backfill without requiring additional
treatment. Surface miners produce a clean and precisely levelled surface which is ideally suited as a base for
the road to be built.
Producing a stable floor in the tunnel
Routing operations in tunnel construction are no different from those in open terrain. Drilling or blasting of
the tunnel tube creates an uneven floor surface that needs to be both lowered and levelled. The same
method is applied when lowering the floor of an existing tunnel for the purpose of increasing the tunnel’s
headroom. Surface miners remove the existing rock layer by layer until a clean and stable floor surface has
been produced, enabling the construction work to continue on a precisely profiled ground level.

A surface miner carrying out routing operations on rocky ground.

New road construction

New roads open up the world.

The construction of a new road – whether from asphalt or concrete – requires the production of an
excellently bonded pavement structure, beginning with a stable base layer and going all the way to a
precisely levelled surface course. What are the most important criteria to be considered? What methods
need to be applied? What machines used?

1.construction of base layers

Base layers are the foundation.
The base layer of a road lays the foundation for the upper pavement structure. It must offer
excellent bearing capacity, be capable of withstanding a broad range of different climatic
conditions, and remain functional over several decades. What materials are used for the
construction of base layers? What properties do they need to possess?
A strong base for the upper road structure
Roads must be capable of withstanding the loads imposed by traffic irrespective of weather conditions. The
body of a road is constructed from different layers of different thicknesses, depending on the anticipated
traffic load.
A layer for the tough job
The lowest layer in the upper road structure is built mainly from granular mineral aggregate. The main
function of base layers is to reduce the loads induced by traffic to such an extent that the underlying
subgrade is protected from deformation. The required bearing capacity is achieved by using a mixture of
gravel, chippings and crushed sand that needs to be compacted to the required density.
A gravel layer to protect against frost
Roads are exposed to particularly high stresses when the water contained in the pavement structure begins
to freeze. Water expands when freezing, which can lead to frost damage that will sooner or later have an
impact also on the road surface. This is prevented by a so-called frost blanket which usually consists of a
mixture of gravel and sand, supplemented by crushed mineral aggregate. When compacted, these layers of
frost-resistant materials conduct water away from the upper pavement layers, reducing tensions very
effectively at the same time.
The mix makes all the difference
Granular base layers are often overlaid with a bituminous or hydraulically bound base layer, with either
bitumen, or cement or lime respectively, used as binding agents. A well-graded mixture of mineral
aggregate with a fairly high percentage of crushed stone is characteristic of bound base layers.
Bituminous bound base layers
When using mixes containing bitumen as a binding agent, the resulting base layer is called an asphalt base
layer in hot or cold application – depending on whether hot mix or cold mix is used. Bituminous base layers
in hot application consist of well-defined mineral aggregate mixtures and road bitumen.
Hydraulically bound base layers
When the mineral aggregate mixture is bound with cement or lime, the resulting base layer is called a
hydraulically bound base layer. Mineral aggregate mixtures used for this type of base layer consist of
uncrushed gravel or coarse aggregate, chippings, and crushed or natural sand. Ever more frequently, these
mixes also contain a percentage of recycled construction materials.

There are many ways to build a base layer: Placing a base layer with a Vögele road paver.

2. asphalt paving
Asphalt paving requires an exceptionally high degree of meticulous logistical planning and
management. Care needs to be taken that sufficient quantities of mix are available on site all the
time, and that the mix will not cool down prematurely. What types of machines are used for
asphalt paving? What is the sequence of operations?

There is one machine team which has made itself indispensable to asphalt paving for many decades: road
paver and road roller. Very simply put, asphalt is placed by the paver and compacted by the roller.
Conveying in longitudinal direction
The asphalt paving gang is always “headed” by the truck driver. He reverses his truck up to the paver to
dump the asphalt material into the paver’s receiving hopper. Two independently operating, slightly inclined
scraper conveyors then transport the material to the rear part of the machine. Using slightly inclined
conveyors permits increased discharge heights, while additionally enabling increased paving thicknesses
without pressing the mix into the auger chamber.
Reversing the direction of movement
The belt speed is controlled in proportion to the filling level at the end of the scraper conveyor. To prevent
the loss of paving mix when repositioning the machine, the material can be drawn back by briefly reversing
the belt’s direction of movement.
Conveying in transverse direction
Two independently controlled, rotating feeding augers located between the paver and paving screed spread
the material evenly in front of the screed. The augers can be extended so as to fully adapt the conveying
width to the machine’s paving width.
Sensor control of feeding auger
The auger’s speed of rotation is controlled by sensors in proportion to the head of mix in front of the screed.
This feature enables the mix quantity to be fully adapted to requirements when paving in bends or at
varying paving thicknesses. The auger’s direction of rotation can be reversed if necessary, transporting the
mix from the periphery towards the centre.
Supply of mix and job site logistics
The hot mix should be covered when delivered by charging trucks to ensure that the paving operation is
carried out in the most suitable time frame. To guarantee continuous paving, the capacity of the asphalt
mixing plant always needs to be higher than the paver’s laydown capacity.
Continuous supply of material
If the paver stops moving due to lack of material, disruptive lateral joints occur as a result of the paved
layer cooling down. When paving standard mix, the paving temperature should be higher than 110°C to
allow an as large time frame as possible for compaction.
Pre-heating the paving units
All paving units need to be heated prior to commencing the paving operation to prevent the mix from
sticking to sensitive parts of the machine. Last but not least, the screed needs to be adjusted to the correct
paving width.
Using the screed for pre-compaction
Modern road pavers allow the compaction systems of the paving screed to be controlled in accordance with
specific requirements. High-density screeds, in particular, are capable of achieving excellent density values.
Optimum final compaction
Compaction effected by the high-density screed enables the rollers which follow behind the paver to achieve
the overall final density specified by the client in fewer roller passes. In most cases, the road paver is geared
for either high density or fast advance speed, both of which have an effect on the number of roller passes
required.
Modern road pavers achieve tremendous performance rates: The Super 2500 from Vögele is capable of
paving at widths of up to 16 m, and can achieve paving rates of up to 1,500 tons per hour.

3.asphalt compaction

Packing strength into the asphalt road.

Compaction is the final procedure in road construction, its goal being to produce a surface
texture of high quality. What aspects need to be considered in asphalt compaction? When
compacting an asphalt road, what impact will the road’s location or ambient temperatures have
on the compacting operation?

The goal of asphalt compaction is to create a pavement that offers maximum evenness and stability, while
simultaneously increasing both traffic safety and riding comfort. Compaction aims at producing a road
surface of maximum regularity and skid resistance, and at creating a permanent bond between the various
asphalt layers. Compaction by rollers results in an extremely tight interlock between the individual particles
of the mineral aggregate, which enables a high degree of stability, excellent resistance to wear, and
permanent evenness to be achieved. Rollers reduce the void content in the asphalt, making it more resistant
to loads and more durable.
Questions to be clarified prior to commencing work
What type of mix will be compacted, and what are the thicknesses of the individual layers? Where’s the job
location? On a motorway, in a residential area, on a bridge? The answers to these questions will determine
the type of roller to be used for compaction. What will be the paving width and paving speed? That will
determine the number of rollers to be used.
Getting the rollers ready
Rollers are heavy road construction machines used for compacting hot and therefore flexible asphalt
pavements. To prevent them from causing damage to the new asphalt surface, they must not come to a halt
during the compacting operation. For precisely that reason, machine maintenance is of particular
importance. In addition to that, checks need to be carried out prior to commencing work to make sure that
the drum is clean, that fuel and engine oil are available in sufficient quantities, and that the water tank has
sufficient water for the drum spray system.
The effect of temperature on the compaction result
The basic rule applies that the higher the temperature of the paved mix, the better will be the compaction
result. However, there are no generally applicable rolling temperatures. The ideal temperature range
depends on the composition of the asphalt mix, layer thickness, and type of binding agent used.
The different roller passes
An experienced roller driver begins compaction at the seams – for instance, the lateral joints to the existing
lane. Starting from there, he compacts along the edge of the pavement. In bends, the lane with the smallest
radius is compacted first. The next pass is to press down the pavement. In most applications, dynamic
compaction is used for the subsequent main compaction phase. Dynamic compaction means that the roller
drums are made to vibrate either horizontally (oscillation) or vertically (vibration), thus achieving a
significantly higher compaction effect. The operation is completed by a final roller pass that will “iron out”
any remaining irregularities in the asphalt pavement or surface to produce a perfect surface finish.

The manoeuvrable small tandem rollers with operating weights ranging from 1.4 to 4.2 tons impress with
their high power of compaction.

4.inset concrete paving

Building concrete pavements with modern road construction plant.

Concrete is an exceptionally durable material, and is therefore highly suitable in particular for
arterial roads that need to withstand extremely high loads caused by heavy traffic. What is the
sequence of operations when paving concrete slabs? What machines are used for concrete
paving?

The standard method of slipform paving is used mostly for large-scale paving applications. Roads, airport
runways, and other large traffic surfaces exposed to exceptionally high loads are usually built with the inset
paving method. The following sequence of operations is typical of inset paving: Trucks dump the concrete in
front of the machine. The slipform paver then performs the following work steps: It distributes the concrete
material across the full paving width by means of a spreading auger or spreading plough, and shapes the
concrete slab by means of the paving mould. Concrete vibrators inside the mould vibrate at high
frequencies, consolidating the concrete by expelling the air entrapped in the material.
On dowel bars, tie bars, and joints
The slipform paver keeps moving all the time during the paving operation, its working speed ranging from 1
to 2 m per minute. The machine is capable of inserting dowel bars or tie bars into the freshly paved concrete
in the same operation, their purpose being to reinforce the new pavement. Joints will be cut into the
concrete above these equally spaced reinforcing elements later to ensure that cracks, which are inevitably
caused by loads and temperature fluctuations, are transmitted into the concrete pavement in a controlled
manner.
A burlap drag finish produces the required grip
A finishing beam and super smoother mounted at the rear of the slipform paver remove any irregularities in
the new concrete pavement. A burlap drag finish is often applied to produce the required grip, resulting in a
surface texture of precisely defined roughness. Uniform hardening is ensured by spraying a curing
compound on the freshly paved concrete using a texture curing machine.

Concrete roads were first built in the 19th century. Today, the highly stable material is laid in an
economically efficient and highly precise paving operation by giant “road building plant”, the so-called
slipform pavers.

5.Offset concrete paving

Slipforming special jobs like bicycle paths, traffic barriers or kerbs.

Instead of placing pre-fabricated concrete parts in a manual operation, the required profiles can
also be produced by slipform pavers in offset application. What applications can offset concrete
paving be used for? What are the advantages of slipform paving when compared to manual
construction?

Kerbs, barriers in the central reservation of motorways, gutters for water drainage – moulded concrete parts
are available in many different shapes. It is, however, much easier and more economically efficient to
produce such profiles using the slipform paving technology. Slipform pavers typically produce these so-
called monolithic profiles in offset application.
A broad variety of special jobs
Offset paving offers a tremendous variety of profile shapes and sizes, as the paving mould is mounted on
the side of the paver and can have nearly any given contour. Standardized moulds are available for
commonly used shapes like the New Jersey profile used for traffic barriers on motorways. For all other
profiles, the moulds are customized to the application in question.
Economically efficient method
Offset applications range from road boundaries and safety barriers with a maximum height of 2 m to
artificial runoffs or narrow paths. Offset paving using slipform pavers is an extremely fast and efficient
method when compared to manual construction with pre-fabricated concrete parts.
Cast into a homogeneous whole: 2-m high concrete noise barrier.

Road rehabilitation
A new life cycle for worn-out roads.
Roads are exposed to tremendous loads that will sooner or later leave their marks on them. A time will
come when every road will be in need of a general overhaul. But no two damage patterns are alike. Which
rehabilitation methods offer a cure for distressed roads? What are the differences between them? Which are
suitable to be carried out as mobile roadworks?

1.replacing the pavement

Replacing the pavement is one of the standard methods in road rehabilitation. What are the
challenges posed by this rehabilitation method? What machines are used for replacing the road
pavement? What are the methods used for building a new pavement?

The challenge of road rehabilitation lies in removing only those layers of a road structure that are actually
damaged. Additional conditions frequently stipulate that the flow of traffic must be maintained in spite of
extensive reconstruction measures. In view of these prerequisites, the choice of suitable rehabilitation
methods in a construction project is often narrowed to one single option: removing the damaged pavement
layers by means of cold milling machines.
Milling and loading in one operation
The tools that cold milling machines use for removing road layers were originally developed for the mining
industry. So-called point-attack cutting tools, fitted to a rotating milling drum on the underside of the
machine, bite into the road at precisely the specified depth. No material is too hard for these tools: Cold
milling machines are even capable of rehabilitating concrete pavements. Whether asphalt or concrete: The
material is milled and then directly loaded on trucks to be transported from site, all in one single pass.
Ahead of the traffic jam
Because traffic is often slow-moving in the area of the job site, car drivers mock the massive cold milling
machines by saying that they’re always first in the traffic jam. Few bear in mind, however, that
rehabilitation projects using cold milling machines are mostly carried out as mobile roadworks. Alternative
methods would involve a much greater effort. Cold milling of road pavements is unrivalled in terms of both
logistics and speed of execution.
Road milling machines are team players
Not all cold milling machines are as big as a whole apartment. Some models are as small as a passenger
car. On many job sites, machines of different sizes frequently work as a team, each one playing its own
aces: The large milling machine removes the large surfaces, while the small one takes care of milling off the
pavement around “nuisances”, such as manhole covers or kerbstones.
Paving and compacting using pavers and rollers
Typical of rehabilitation methods using cold milling is that the damaged pavement layers are usually
replaced with asphalt – irrespective of whether the distressed pavement consisted of asphalt or concrete.
The new surface course or asphalt road structure is paved by road pavers prior to conventional compaction
by rollers.

2.fine milling

New grip for old roads.

In many road rehabilitation projects, fine milling offers an economically efficient alternative to
expensive, time-consuming full rehabilitation measures. What damage patterns are suitable for
rehabilitation by fine milling? What are the special characteristics of fine milling drums?

Many countries are investing less money in maintaining their road network despite increasing traffic loads.
The result is a growing demand for fast and economically efficient solutions that are capable of taking the
edge off hazardous stretches of road. Fine milling is such a method, and is predominantly used where
bumps and wheel ruts, or slippery surfaces pose an acute danger to traffic safety.
Large numbers of tools improve the surface texture
Fine milling is a modification of the standard cold milling method, the difference being that the cutting tools
on the drum are arranged at much narrower intervals. One speaks of fine milling when the so-called tool
spacing is 8 mm or less. These special milling drums are fitted with a much larger number of cutting tools
than standard milling drums.
New grip for the road
The goal of fine milling is to produce a new, precisely defined surface texture. Even though fine milling
drums are not capable of eliminating damages that are located deep within the pavement structure, they
can produce an even pavement surface with excellent grip.
Rehabilitation in one single pass
After installing a fine milling drum in the milling drum housing, the cold milling machine cuts grooves into
the pavement at intervals of between 8 mm and 3 mm and at a maximum depth of 50 mm, producing a fine
surface texture in just one machine pass. Additional work steps, such as paving a new surface layer, are
usually not required.
Restoring the skid resistance: new grip for slippery surfaces.

3.paving thin layers hot

Perfectly bonded layers withstand traffic loads.

Replacing the entire pavement at full depth is not necessary when damages are limited to the
road surface. Paving thin layers in hot application is a viable option for rehabilitating such roads.
How does the method work? What are the advantages of paving thin layers in hot application?

Rehabilitation methods that can be carried out both quickly and with economic efficiency are becoming
increasingly important worldwide. Paving thin layers in hot application is such a method, offering an
exceptionally economical alternative to full pavement rehabilitation. Paving thin layers in hot application is
eminently suitable for roads in need of rehabilitation but with damages limited to the surface, or poor grip,
or pronounced surface irregularities. The surface properties of worn-out roads, such as grip, evenness and
noise reduction, can be improved significantly for extended periods of time.
Perfect bond between layers is vital
In a preliminary operation, surface deformations are removed by cold milling machines fitted with fine
milling drums to create an even, slightly roughened road surface. The road texture produced by fine milling
offers an ideal base which ensures an excellent bond with the thin pavement layer to be applied. Paving thin
layers in hot application is typically carried out by a road paver with an integrated spray module.
Spraying the tack coat
When using a paver with integrated spray module, the paver seals the base by spraying a tack coat of
polymer-modified bitumen emulsion with a minimum bitumen content of 60% in an automated operation,
and then applies a 1.2 cm to 2.0 cm thin asphalt surface course in a second operation immediately
afterwards, but all in one single pass. When a conventional road paver is used, the bitumen emulsion needs
to be sprayed in a separate operation prior to applying the new, thin pavement layer.
Rollers create an even road surface
Compaction is a big challenge when paving thin layers in hot application, as it requires the layers to be
compacted uniformly but without causing irregularities in the surface. Moreover, the specified density needs
to be achieved without damaging the underlying, cold pavement layers. These prerequisites require the use
of high-quality rollers. Dynamic compaction with oscillation is the ideal compaction method. Alternatively,
such layers can be compacted using static rollers, whereas compaction with vibration is not allowed.
Economical use of material saves costs
The small layer thickness of the new surface course helps to keep the costs of this method of rehabilitation
fairly low. Paving thin layers in hot application uses 30 kg to 50 kg of asphalt mix per m² of the new surface
course, which is up to 50% less when compared to conventional “mill and fill” measures. Because it helps to
save natural resources, paving thin layers in hot application is also beneficial to the environment.

4.paving thin layers cold

Extending the life cycle of worn-out roads.

Paving thin layers in cold application offers a fast and economically efficient alternative to
replacing the entire road pavement. What damage patterns are suitable for this application? How
to produce a perfect bond between layers?

Traffic safety is jeopardized when the road surface gets slippery, when wheel ruts have dug into the
pavement, or when the road is covered with bumps and deformations. Paving thin layers in cold application
is a method that is increasingly used for restoring road surfaces to good evenness and skid resistance.
Known as “microsurfacing” in many countries around the globe, paving thin layers in cold application
prolongs the service life of damaged asphalt roads without the need for replacing the entire road pavement.
Fine milling paves the way
Cold milling machines fitted with fine milling drums prepare the road surface for application of the thin, cold
pavement layer. Fine milling removes deformations in the pavement surface. It works at a maximum milling
depth of 50 mm, reprofiling the pavement by means of modern levelling technology to produce a level
surface.
Optimum bond between layers
The slightly roughened surface texture produced by fine milling offers the perfect base for creating an
excellent bond with the thin layers paved in cold application. The grooves in the fine-milled profile firmly
interlock with the thin layers paved in cold application, resulting in excellent layer adhesion.
Mix for the new pavement
Once the fine milling machines have completed their preliminary operations, the paving mix for the thin,
cold pavement layer is produced directly on site by means of automotive mixing and laying machines. It
consists of a well-graded mineral aggregate mix with particle sizes ranging from 3 to 8 mm, polymer-
modified cationic bitumen emulsion, cement and water.
Two layers for a new pavement surface
The cold paving mix is distributed across the full width in two separate layers, the first being the profile, the
second the surface course layer.
Economical alternative to full pavement rehabilitation
Ever more rarely does the strained financial situation of public budgets permit cost-intensive full
rehabilitation measures to be carried out on a large scale. To ensure that the road network is maintained in
good condition, alternative methods, such as paving thin layers in cold application, are therefore more
popular than ever. Thin layers in cold application offer an economically efficient, but also fast-paced solution.
Paving as mobile roadworks
Paving thin layers in cold application is suitable to be carried out as mobile roadworks, and the road can be
reopened to traffic quickly. More than 5 million square metres of thin layers in cold application are paved in
Germany alone each year.
5.inline pave

Asphalt paving technology on the fast lane.

The demands placed on pavement rehabilitation keep growing all the time. Jobs need to be
completed ever more quickly, but with traffic continuing to move along smoothly all the same.
This is where InLine Pave plays its aces. What is the sequence of operations? What are the
logistical prerequisites that need to be met?

Road construction is facing ever-greater challenges: Roads are exposed to ever-increasing stresses caused
by ever-increasing numbers of vehicles. Rehabilitation measures need to be carried out both quickly and
with economic efficiency. Placing asphalt pavements in “hot-on-hot” application offers an efficient solution to
this problem.
Paving hot-on-hot
With InLine Pave, the binder and surface courses are paved “in line”, meaning in immediate succession,
“hot-on-hot”. The machines used for this application need a maximum space of just 3 m in width, so that
traffic can continue to move along on the adjoining lanes.
Perfect bond between layers for an extended lifespan
Very high pre-compaction of the binder course prevents the materials of binder and surface course layers
from getting mixed, guaranteeing the clean separation of both layers and an optimum surface seal. “Hot-on-
hot” paving achieves an excellent bond between the binder and surface course layers, which not only
dispenses with the need for applying a bitumen emulsion but also extends the service life of the road.

6.hot recycling

Old pavements re-mixed.

Porous and deformed surface courses can be rehabilitated using the hot recycling method. How
does hot recycling work? What prerequisites need to be fulfilled for the application of hot
recycling?

Many asphalt pavements deform or become brittle over time when exposed to heavy loads, with cracks
developing in the upper layers. Such distressed surface courses can be cured by a special recycling method:
hot recycling – a method that is always carried out in a mobile operation.
Heating the existing pavement
In a first step, a heating machine heats the surface course to up to 150°C by means of gas-operated
infrared heater panels, softening it so as to enable the recycler to scarify, remove, recycle and re-place it.
New surface course from old
Hot recycling is used solely for the rehabilitation of damaged asphalt surface courses, which is why an intact
layer structure is of vital importance. The pavement structure underlying the surface course must fully
comply with all requirements in terms of bearing capacity and frost resistance. The hot recycler processes
the existing road pavement, improving it with virgin mix, if necessary. After completion of the recycling
operation, the new surface course will fully comply with all requirements once again.
Improving the surface texture
Hot recycling improves all relevant properties of both the surface and the pavement profile, as well as the
composition of the aggregate fractions in the surface course layer. It helps to restore lacking skid resistance,
to ensure water drainage, and to eliminate wheel ruts.
Economical recycling
Hot recycling offers a tremendous saving potential. Around 85% of truck transports, and 70% of virgin mix
can be saved in comparison to replacing the pavement using a milling machine and road paver.
A practical example
An approximately 5 km long section of road is to be recycled across a width of 5 m, which equals a total
area of some 25,000 m². Assuming a weight of 200 kg per m² of surface course, the “classical” method –
replacing the pavement – would require around 200 truck transports: 100 for transporting the milled
material from site, and 100 for supplying virgin asphalt mix. 30 kg of virgin mix per m² of surface course
are added when adhering to the standards of hot recycling, which requires just 30 truck loads of 25 tons
each – 170 less than with conventional rehabilitation methods.

Old becomes new: Paving the recycled mix with the Remixer.

7.cold recycling in situ

A cold recycling train builds new roads from old.

Cold recycling in-situ is just the right technology when it comes to building a new road from old.
It is mostly carried out as mobile roadworks. What are the advantages of “in-situ” cold
recycling? How does the method work?

In roads which are exposed to very high loads by heavy traffic, damages frequently extend all the way into
the pavement subgrade. To repair these damages, the pavement structure needs to be rehabilitated at full
depth. Cold recycling gives roads new stability and strength. In contrast to “in-plant” cold recycling, the
entire “in-situ” cold recycling process is carried out in one single operation as follows: Special cold recyclers
granulate the damaged road layers – usually the surface and binder courses, as well as part of the base
layer –, mix the milled material with new binding agents, and place the recycled mix again immediately.
Adding precise quantities of binding agents
Milling and pulverizing of the existing pavement is carried out by a milling and mixing rotor fitted with
tungsten carbide tools similar to those used for cold milling. Inside the machine, the material is then
processed in a mixing chamber or compulsory mixer, in which binding agents are added by means of
microprocessor control. Some recycler models feature a so-called “variable mixing chamber”: The larger the
working depth, the larger is also the mixing chamber volume. The quantity of binding agents to be added
increases at the same time, controlled by a computer, in accordance with the machine’s working depth and
advance speed. This concept permits optimum processing of the recycling mix. Types of binding agents to
be added include bitumen emulsion, foamed bitumen, and cement.
Slurry mixer meters cement quantities
Hot bitumen for the production of foamed bitumen, bitumen emulsion, and water – which is always
mandatory – are delivered by tanker trucks. Cement can either be pre-spread as a powder ahead of the cold
recycler or added using a so-called slurry mixer. The slurry mixer precisely meters the correct quantity of
cement, mixes it with water to obtain a cement slurry, and then transfers the liquid binding agent directly
into the mixing chamber of the recycler. Pre-spreading of the cement can then be dispensed with. The slurry
mixer prevents the development of dust and loss of material, and helps to improve the quality of the
recycled layer.
Economical and environmentally friendly
The tanker trucks supplying binding agents and water travel ahead of and are pushed by the cold recycler,
forming a so-called “cold recycling train”. Some Wirtgen cold recycler models are equipped with a paving
screed at the rear of the machine for placing the recycled mix. With all other Wirtgen cold recyclers, heavy
tandem rollers and single-drum compactors are used for compaction of the recycled mix.
A paving screed builds the new road
A thin surface course of virgin asphalt mix is usually applied on top of the cold recycled layer by standard
road pavers, and is then compacted by rollers. Short construction times and high economic efficiency are
marks in favour of this method. The fact that cold recycling “in-situ” helps to save some 600 truck
transports of construction material per kilometre of road built clearly shows the tremendous saving potential
when compared to the conventional method of replacing the pavement, which requires a much bigger effort
in terms of both logistics and personnel.

8.cold recycling in plant

Transporting the old road to the cold recycling mixing plant.

When cold recycling road pavements, contractors can choose between processing the milled
material “in-situ”, meaning on the job site, or “in-plant”, meaning in a cold mixing plant. Their
decision is influenced, however, not only by the damage patterns of the road to be repaired.
What are the advantages offered by “in-plant” cold recycling? How does it work? What kinds of
damage patterns can cold recycling “in-plant” be used for?

One speaks of cold recycling “in-plant” when the reclaimed asphalt material of roads in need of rehabilitation
is recycled in a nearby mixing plant, transported back to the job site, and then placed again by road pavers.
The method is often used with roads that are exposed to high loads by heavy traffic, and with damages
extending all the way into the pavement subgrade, but where site conditions do not allow the operation of
an “in-situ” cold recycling train.
Cold recycling mixing plant recycles 100%
When cold recycling “in-plant”, a mobile cold recycling mixing plant is usually set up in the vicinity of the job
site. Trucks deliver the reclaimed asphalt material from the job site straight to the plant. Technically
speaking, the cold recycling mixing plant and “in-situ” cold recycler perform one and the same job: The old
asphalt material is recycled 100% by adding one or several binding agents. When recycling is complete,
trucks transport the cold recycled mix back to the job site.
Road paver places the recycled mix
Road pavers use the cold recycled material to replace the old pavement of the road with two new layers. A
new surface course meeting all the requirements placed on the surface of the recycled road is placed on top
of the cold recycled base layer. The cold recycled base layer is ideally suited for compaction by heavy
vibratory rollers. Final compaction of the surface course is similar to that of other construction methods,
using oscillation rollers.
Recycling mix for stockpiling
Cold mix which has been recycled in the cold recycling mixing plant using foamed bitumen as a binding
agent is suitable for stockpiling over extended periods of time. Cold mixes do therefore not have to originate
from the same job site that they are used for later.
Re-mix aggregate fractions
“In-plant” cold recycling is mostly used for smaller contracts where setting up and supplying a recycling
train with water and binding agents would be less economically efficient. There is, however, an additional
argument speaking in favour of transporting the milled material from site: When access to the job site is
difficult from a logistical point of view, it is much easier to recycle the milled material separately in a cold
recycling mixing plant.

A Wirtgen cold milling machine is removing the asphalt pavement.

Materials mining and processing

Economically efficient mining of rock and useful minerals.
Uncrushed rock is the main source material for road construction. How are massive lumps of rock turned
into mineral aggregate with a precisely defined particle size? New mining methods offer solutions for the
selective mining of different kinds of rock. What types of machines are used for carrying out such extremely
hard work? What are the advantages of this method?

1.surface mining

Improving the yield with no explosions or damaging vibrations.

It is becoming increasingly difficult to mine the precious raw materials buried in the earth. In
what way can surface mining offer solutions to this problem? What are its applications? What
advantages does surface mining offer in comparison to conventional mining methods?
Mechanical mining of useful minerals
There is a growing demand in mineral mining for mining methods that are more economically efficient and
more environmentally compatible at the same time. Mechanical mining of useful minerals using surface
miners is therefore constantly gaining in importance. The method is applied in newly developed open-cast
mine areas or expansions of existing open-cast mines, as well as in rock construction for precise levelling
under space-restricted conditions.
Selective mining of useful minerals
Increasingly difficult geological conditions result in lower contents of useful minerals both in existing and
newly developed mineral deposits. Surface mining increases the exploitation rate of mineral deposits,
because it enables the minerals to be mined in a selective operation. Selective mining produces a high yield
of useful minerals of high purity, while saving natural resources at the same time. Mineral deposits can be
exploited right up to the peripheral areas of the mine.
Cut, crush and load in one single operation
The operating method of surface miners resembles that of cold milling machines. A special cutting drum cuts
and crushes the material before it is loaded on dumpers via a robust conveyor system. The material can
alternatively be deposited as a windrow between the miner’s crawler tracks – an option that enables surface
miners to not only save time but costs and energy as well.
No strains through damaging vibrations
The raw mineral materials are mined by cutting, not by drilling and blasting, which prevents damaging
vibrations in the immediate vicinity of the mining site.
Environmentally compatible mining method
The low levels of noise and dust developing during the mining operation are yet another mark in favour
when compared to conventional drilling and blasting methods. Surface mining permits useful minerals to be
mined effectively and without difficulty right up to residential areas or roads.
Increased efficiency
Surface miners cut and crush the minerals to be mined, producing small-sized material that is ideal for
profitable processing, because it requires only minor additional treatment. Mining bauxite, phosphate,
kimberlite or salt becomes increasingly profitable, and surface miners are capable of mining even hard lime
or granite rock of up to 260 MPa without the need for drilling and blasting.

2.mobile crushers

Crushers are on the move.

Versatility and flexibility in application are the major trump cards that mobile crushers play in
comparison to stationary crushing plants. What are mobile crushers used for? What are the
differences between the various crushing techniques? What about the hardness of the rock to be
processed?

Mobile crushers are used in quarries, in mining, on job sites, and in the recycling industry. The robust plants
mounted on crawler tracks are capable of processing both rock and recycling material, producing mineral
aggregate and recycled building materials respectively for the construction industry. When processing
natural stone or recycling material like demolition waste, concrete, asphalt, incineration ash or steel slag, an
excavator or wheel loader feeds the material into the mobile crusher. The then produced material is used for
road construction or other, similar applications.
Flexible relocation
A major advantage of mobile crushers is their flexibility in terms of moving from one location to the next.
They are suitable for transport, but can also cover short distances within the boundaries of their operating
site, whether in a quarry or on the job site, on their own crawler tracks. When operating in quarries, they
usually follow the quarry face, processing the stone directly on site.
Short setup times
Mobile crushers are loaded on low-loaders when transported over longer distances to a new location. No
more than 20 minutes to 1 hour is needed for setting the plant up for operation. Their tremendous flexibility
enables the mobile crushers to process even small quantities of material with economic efficiency.
Different crushing techniques
Crushing techniques distinguish between pressure crushing and impact crushing. Jaw crushers or cone
crushers use the so-called pressure crushing technique where material is reduced in size mainly by high
pressure between slow-moving wear parts. Impact crushers use the so-called impact crushing technique, in
which the rock is accelerated by a massive fast-moving rotor and reduced in size by impacting against
breaker walls.
Depending on material hardness
Jaw crushers are widely used for crushing medium-hard to hard rock, and are mostly used as primary
crushers. Impact crushers work as both primary and secondary crushers for processing soft to medium-hard
rock, producing larger quantities of fines. Cone crushers are used predominantly as secondary crushers for
hard rock.
Mobile screening technology and grain size
Mobile plants allow the combination of pre-screening, which prepares the rock for the crushing process, and
grading, which precisely separates defined grain sizes into different end products, to be integrated with the
crushing unit into one single machine. In the first stage, the material is screened using an active pre-screen.
After pre-screening, it is transferred to the crusher, from where it is either stockpiled via a discharge
conveyor or forwarded to a final screen or a secondary crushing stage. Depending on the specified end
product, the grains are then either graded by screening units or transported to additional crushing stages by
secondary or tertiary impact crushers or cone crushers, if required. Further, downstream screening units are
used for grading the final aggregate fractions.
Combining different types of plants
The process of pre-screening, crushing and grading described above is a common operation in mobile
materials processing, and can be varied in a number of ways. Mobile crushers with up to three crushing
stages are increasingly used in modern quarries today. Different mobile crushing and screening plants can
be combined for managing more complex crushing and screening jobs that would previously have required a
stationary crushing and screening plant.

Natural stone processing with a Mobicat MC120 Z jaw crusher.

3.stationary crushing plant

Breaking it big with stationary processing.

Stationary processing plants are specially designed for many years of use in one single, fixed
location. What types of crushing and screening equipment do they use for processing stones and
recycling material? What advantages do they offer?

Stationary processing plants are usually operated in large rock deposits. They are typically designed for a
useful life of 20 or more years. In addition to large quarries or the mining industry, stationary plants are
also used in the processing of recycling materials, such as demolition waste, concrete, asphalt, incineration
ash, or steel slag.
Made-to-measure design
Two questions need to be answered first of all when designing a stationary processing plant: Where will it be
located, and what material will be processed? To meet with the individual requirements placed on the
stationary processing plant, the entire plant is then designed and set up in accordance with prevailing local
conditions. A feature that all stationary plants have in common is that several crushing and screening units
co-operate, forming an integrated system.
Different crushing techniques
Crushing techniques distinguish between pressure crushing and impact crushing. Jaw crushers or cone
crushers use the so-called pressure crushing technique where material is reduced in size mainly by high
pressure between slow-moving wear parts. Impact crushers use the so-called impact crushing technique, in
which the rock is accelerated by a massive fast-moving rotor and reduced in size by impacting against
breaker walls.
Sophisticated screening technology
In materials processing, the quality of an end product is determined, among other things, by the number of
crushing stages and by sufficiently dimensioned screening equipment. A basic distinction is made between
pre-screening, which is important for separating the material streams prior to crushing, and grading, which
separates the different final aggregate fractions.
Pre-screening screening separates material streams
Pre-screening screening is used for separating the material streams. Contaminations are also eliminated in
this first processing stage. The material is separated via the screening surface, which usually consists of a
slotted screen or perforated plate.
Grading for the fine range
Grading determines the screening quality, meaning the quality of the end product. Grading screens have a
screening surface which consists of, for instance, a wire screen for precise separation of the medium and
fine aggregate fractions. The graded final aggregate fractions are finally discharged via belt conveyors and
stockpiled.
Use advantages consistently
Stationary processing plants enable large amounts of material to be crushed, and complex processes to be
managed. End products of superior quality are produced, complying with the standards to be adhered to in
terms of grain size and cubicity, which may differ from one market area to the next. Stationary plants play
their aces in particular when it comes to flexibility in production. The crushed aggregate can be stored in
several silos, enabling the most diverse aggregate mixtures to be produced right at the plant, and in
accordance with the requirements of the customer or end user. Yet another advantage of stationary plants:
The production can always be adapted to changing requirements in the sales markets.
Reducing the burden on the environment
Preventing the emission of dust is an important aspect of materials processing. Stationary processing plants
offer two options for doing so: They either feature water spray systems for binding the dust, or special dust
extraction systems. The entire plant can also be fully enclosed to protect the environment from dust and
noise.

Stationary processing plant, Stevin Rock, UAE.