Wirtgen Group Profile

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, WIRTGEN, VÖGELE, HAMM, KLEEMANN and BENNINGHOVEN. As a technological leader, the company offers its customers mobile machine solutions for road construction and road rehabilitation, as well as for mining and processing minerals.

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Soil stabilization is proving to be the optimum solution whenever the properties of soil have to be altered to make it suitable for further roadworks. That was the case in Bloomington/ Indiana, USA, for instance, where a WIRTGEN WR 250 soil stabilizer laid a load-bearing base for the construction of a new approach road to Interstate 69.

Soil stabilization is the method of choice when it comes to ensuring the load-bearing capacity and quality of soil in preparation for road construction projects. The targeted addition of stabilizing agents can, for instance, help to reduce the moisture content of soil, which is vital for further roadworks. Compared to the process of exchanging the entire soil, soil stabilization is an economical and resource-saving method. Cost savings result from the simpler job-site logistics, for instance, with fewer lorry trips and shorter construction periods. Resources are also conserved, because all of the existing soil is used in the stabilization process with only stabilizing agents such as lime or cement being added – or a combination of both in the form of a mixed stabilizing agent.

WIRTGEN technology for soil stabilization: Versatility is key

Many invitations to tender continue to specify that the soil is to be exchanged – but this is no longer a state-of-the-art method. The Wirtgen soil stabilizer uses its powerful milling and mixing rotor to mix pre-spread stabilizing agents such as lime or cement into existing soil with insufficient bearing capacity, transforming it into a high-grade building material right on the spot.

The homogeneous mixture of soil and stabilizing agent that is produced offers a high load-bearing capacity as well as lasting resistance to water and frost, and volume stability. Typical applications include the construction of paths, roads, motorways, routes, parks and sports grounds, industrial estates, industrial plants, airfields, dams, backfilling and landfills.

Different applications: Improving soil, stabilizing soil

In soil stabilization, a distinction is made between improving the soil and stabilizing it. Lime improves the paving properties and compactability of wet, cohesive soil. This is known as soil improvement. If the aim is to stabilize the soil cement is used because it lastingly enhances the load-bearing capacity, volume stability and resistance to water and frost. Soil can be stabilized or homogenized even without the use of stabilizing agents.

Perfect stabilization: the powerful mil

Case example: Soil stabilization in Bloomington/Indiana, USA

In the soil stabilization project on Interstate 69 south of Indianapolis, the newly embanked earth first had to be stabilized in order to create the necessary load bearing capacity for the asphalt pavement of the new approach road. The contractor, Specialties Company, LLC, used lime as a stabilizing agent and took advantage of Wirtgen’s applications expertise. Lime immediately reduces the water content in the soil and binder mix. This ultimately improves compactability and increases the load-bearing capacity of the treated soil. “To achieve the optimum outcome, we always liaise closely with the applications professionals from Wirtgen. They are always on hand to offer their consulting expertise,” explains Jamie Cardiff, Equipment Manager at Specialties Company.

WIRTGEN WR 250 soil stabilizer required

When it came to choosing the machine, too, the Specialties Company’s team put their trust in the innovative technologies from Wirtgen, opting for the WR 250 wheeled soil stabilizer. The 571kW powerhouse also used, among other applications, in cold recycling for granulating asphalt, is the most powerful machine in the

WR generation and specially designed for the stabilization of heavy and boggy terrain. With this machine, daily performances of up to 15,000m2 are far from uncommon in soil stabilization applications. After the lime had been pre-spread, the high engine power and optimum traction of the WR 250 enabled it to effortlessly work through the heavy and sometimes deep soil. The WR mixed the soil and binding agent homogeneously across the entire working width of 2.4m to a depth of exactly 30cm.

Strong performance, easy operation

“Operating the machine is child’s play. The multifunctional joystick on the right armrest, for instance, gives me easy control of all the main basic functions,” says Richard Clark, describing the high operating comfort. One of the challenges was the uneven condition of the earth, which varied from very firm to loose. “The milling speeds can be controlled from the operator’s cabin, so our machine operators were able to respond directly to the frequent changes in soil conditions. This ensured a high mixing quality at all times,” Cardiff adds. It took just five days to complete the stabilization work and lay the load-bearing base for the new approach road to Interstate 69. Lorries carrying material for paving the asphalt layers began to roll onto the job site only a short while later.

With precision milling results and flexible deployment options, the Wirtgen large milling machine put in a convincing performance in the rehabilitation of two main traffic arteries between São Paulo and Brazil’s largest port.

Job for a W 200 in the Brazilian uplands

The Anchieta-Imigrantes motorway system is the main link between the metropolitan region of São Paulo and the port of Santos, the largest port in Brazil and the busiest in Latin America. Construction of the Anchieta motorway began in 1947, with Imigrantes following at the start of the 1970s. Today the Anchieta handles mainly heavy goods traffic – 95 % of its daily traffic consists of trucks – while cars predominantly use the Imigrantes. Now the two motorways are being rehabilitated over a total length of 300km. The removal of the surface and binder course was handled by a Wirtgen large milling machine of type W 200.

Precise and economic milling

The high proportion of heavy-goods vehicles and the significant traffic density place enormous strain on the asphalt surfaces, making regular maintenance vital. The contract for the current job was won by the Baixada Santista Consortium. The construction company CR Almeida, which is part of the consortium and responsible for the milling, worked alternately on both roads – northbound and southbound. While the W 200 milled the Anchieta motorway, which was closed completely, traffic was diverted to the Imigrantes motorway.

Milling rate up

For this mammoth project, CR Almeida is using the efficient W 200 large milling machine, which runs in continuous operation 24 hours a day during the rehabilitation work. This is where the powerhouse can really put its enormous capabilities to the test.

That’s because the W 200, with its powerful engine delivering a maximum power of 410 kW, is specially configured for high area outputs – whether on large sites or in confined spaces. The manoeuvrability of the large milling machine particularly proves its worth in the very narrow defiles that snake their way through the Brazilian uplands 40 km south of São Paulo, so that the W 200 was able to mill both road surfaces over a width of 2 m and to a depth of 8 cm rapidly and precisely in one operation.

Operating costs down

Milling machine operator Janderson de Souza Mota emphasises the ease of handling offered by the WIDRIVE machine control system, which links the most important machine functions together: “While the engine, for instance, sets the operating speed automatically when the milling process is started, it automatically returns to its idling speed when milling is finished. This allows us to reduce not only fuel consumption but also noise emissions.” What is more, the water required for cooling the cutting tools is regulated as a function of the engine load and milling speed. The load-dependent sprinkler unit allows a water saving of up to 20 %. “For us that means we need to fill up less water, but the service life of the cutting tools is still longer,” says the site Manager Cleiton Farias de Jesus, delighted with the much lower downtimes.

Transport made easy

With the milling work on the Anchieta motorway having been completed faster than anticipated that day, the W 200 even made up time before it was to begin its scheduled night-time job on the Imigrantes motorway. So, without hesitation, Cleiton Farias de Jesus and his team stopped at Cubatao, just a few kilometres away, in order to mill a strip a few hundred metres long over a working width of 2m, but this time to a depth of 28 cm. “The site is on the way, and the fact that we can load and unload the W 200 quickly and easily enabled us to fit this little job in today.” The folding loading belt, for instance, shortens the transport length of the large milling machine, so that it can be transported even on light low-bed trucks with a low overall weight. The weather canopy can also be folded in hydraulically for onward transport. Site Manager Cleiton Farias de Jesus says: “Ease of transport is a decisive criterion and makes the logistics a whole lot easier. This way, we can move quickly from one job to the next and always make optimum use of the W 200’s capacity.”

Job site details:

Removing the surface and binder course of the Anchieta-Imigrantes motorway system between São Paulo and the port of Santos, Brazil

Length of section: 65 km (approx.)

Working parameters:

Milling depth: 8 – 28 cm

Milling width: 2 x 2 m

Equipment:

Wirtgen W 200 cold milling machine

Machine parameters:

Milling width: 2,000 mm

Milling depth: 0–330 mm

Engine rated output: 410 kW (558PS)

 

With the mobile KMA 220 mobile cold recycling mixing plant from Wirtgen, road construction materials can be recycled or upgraded in just about any location. This avoids countless transport trips and is also sustainable and environmentally friendly. And finally, it is extremely economical – as became clear from a job at Cologne/Bonn airport at the end of 2017. There the plant, located immediately next to the job site, produced around 11,000 t of materials for a hydraulically bound base layer, using materials reclaimed locally, water and cement in the mix-in-plant process.

In autumn 2017, parts of the flight operations areas at Cologne/Bonn Airport were renovated. In this context, parts of the drainage system – including both the unbound superstructure and parts of the substructure – were also rehabilitated. The mobile cold recycling mixing plant from Wirtgen prepared the material mix.

Flexible location and formula

Alexander Weber of SAT Straßensanierung GmbH coordinated the deployment of the mobile KMA 220. “We use the cold mixing plant in projects across the country. In the last three months, for instance, it has been in Munich, before going on to the Rhineland and then to two different locations in the Hunsrück region. This works outstandingly well, because the plant is very easy to transport and the setup times are very short.”

A new location usually also means a different formula, different mineral aggregates and different binders. But that’s not a problem for Alexander Weber, because the KMA 220 can produce a wide range of mixes from new aggregates, milled material or other reclaimed road surfacing materials in an environmentally friendly process. Cement, bitumen emulsion or foamed bitumen can be added in the plant as a binder.

Short setup times save money

One of the key factors in the cost-effectiveness of the plant is its simple, time-saving transportability. This was taken into account right from the design stage, when the transport dimensions were kept within the international guidelines for road traffic. Erection and dismantling are also straightforward, because the work can be done without any special tools and no foundations are required. Instead, a combination of fixed and hydraulically extending supports provides stability.

Additional components such as the tanker truck for water or emulsion and the cement auger can be positioned on either side of the plant. And, not least, the discharge conveyor has a wide slewing range in either direction. In short, there is enormous flexibility when it comes to choosing the location.

More than 15 years of satisfaction

Volkmar Gogol is the person at SAT who is responsible for setting up the KMA 220 and putting it into operation. He has been working with cold mixing plants from Wirtgen since as far back as 1990. “I worked with the KMA 150 first, then with its successor, the KMA 200, and now the KMA 220. Over the years, the plants have been continually optimized and made more efficient. Today, I can mix between 150 and 220 t per hour with the KMA 220, depending on the material used and the formula. That amounts to as much as 2,000 t in one working day,” the experienced operator explains.

The short route to 11,000 t of hydraulically bound base in six days

In six days, the mobile KMA 220 at Cologne/Bonn airport turned some 11,000 t of recycled material into the hydraulically bound base required for a surface area of about 60 m x 600 m in the area of the taxiway. The material actually consisted of RAP from a variety of projects in the region and parts of the hydraulically bound base from a construction site neighboring the airport. To achieve the required strengths, 4.4% by volume of 32.5 R Portland cement and 1.2% by volume of water was added to the construction material. A total of six trucks transported the material from the KMA 220 straight to the installation site some 400 m away, before shuttling back again.

Tried-and-tested measuring and control technology in the KMA 220 ensures that the formula is followed. The aggregate is weighed on belt scales while on the take-off conveyor and fed continuously to the mixer. The quantities of water and binder specified in the formula are determined by microprocessor control, based on the weight of the aggregate, and then dosed precisely and added by means of the pump and flow meter. They are added directly at the twin-shaft compulsory mixer, where mixing blades made of wear-resistant carbide metal mix all components thoroughly. The result was conclusive: Even after more than 3,500 hours of operation, the KMA 220 is still mixing the construction materials in accordance with the mix design test specifications.

Economy meets endurance

The mixer, like all other components of the KMA 220, is operated hydraulically. The hydraulic pumps are driven by a powerful diesel engine delivering 129 kW (176 HP). The system saves a lot of energy: “I can mix for 10-15 hours on one tank of fuel,” says operator Gogol. The dimensions of the water tank are also impressive: Its capacity of 4,500 l supports a reliable supply of water even while the water tanker truck is being switched.

Compaction with Hamm compactor

Thanks to the large tank capacities, the preparation of the hydraulically bound base at the Cologne/Bonn airport project also proceeded smoothly. This is confirmed by David Rose (M. Eng.), Site Manager of general contractor Heinz Schnorpfeil Bau GmbH: “As a building contractor, we appreciate the benefits of the mix-in-plant process and the Wirtgen cold mixing plant. The plant keeps to the formula reliably and produces the desired quantities in the allotted time.” The KMA 220 continuously turned the recycled material into hydraulically bound base material that was then distributed over the surface of the site by a grader. Compaction was handled by a Hamm earth compactor, the H 16i.

Immediately after completion of the hydraulically bound base, a Vögele paver together with some Hamm asphalt rollers laid the 30 cm-thick asphalt surface on the hydraulically bound base layer.

By then Volkmar Gogol was already getting the KMA 220 ready for its journey to the next job site, around 150 km away in the Hunsrück. There, some 20,000 t of tar-polluted reclaimed material had to be processed in the following two weeks so that it could then be recycled economically for use in the rehabilitation of a country road.

WIRTGEN GROUP showcase highly specialized solutions for worldwide road construction

The focus of this year’s Road Technology Days held by the WIRTGEN, VÖGELE and HAMM brands was on synergies, 3D applications and networked job site processes. The climax of the event was the live machine demonstrations.

When no less than three global market leaders present their latest technology, it’s bound to draw the crowds: some 4,000 customers and road construction experts from more than 100 countries flocked to the Road Technology Days held by WIRTGEN, VÖGELE and HAMM on 19 and 20 April. On the 370,000m2 site of JOSEPH VÖGELE AG in Ludwigshafen am Rhein, the three companies of the WIRTGEN GROUP’s Road Technologies business sectors provided practical insights into the latest developments in the fields of cold milling, cold recycling, soil stabilization, paving and compaction. In addition to specialist talks by selected experts and technology exhibitions, visitors were also able to enjoy live demonstrations, factory tours and a machinery exhibition featuring around 70 exhibits. The high point of the event was a gala evening in the newly constructed 22,200m2 dispatch hall at the VÖGELE brand headquarters. “A personal and professional exchange with our international customers is very important to us,” says Domenic G. Ruccolo, CEO of the WIRTGEN GROUP. “That’s the only way we can develop tailored country- and customer-specific solutions in an industry with such diverse and highly differentiated requirements. This makes the Road Technology Days an ideal platform for exchanging knowledge and experiences.” Since 2005, the event has been held alternately at the brand headquarters of cold milling specialist WIRTGEN, road paver manufacturer VÖGELE and roller manufacturer HAMM.

The best of three worlds

At this year’s Road Technology Days, the focus was very much on the interplay between milling, paving and compaction technologies and the corresponding synergy effects for road construction contractors. Inspired by the slogan “Synergies powered by WIRTGEN GROUP”, WIRTGEN, VÖGELE and HAMM showcased coordinated machine and application technologies in operation: a total of 25 machines milled, fed material, placed asphalt and compacted on an area of around 3,000m2 in two live demonstrations. “In the live demonstrations, we’re not just presenting state-of-the-art technology and solutions for road construction: our customers also see for themselves how the machines of the WIRTGEN GROUP work together in practice and the synergies this creates for the entire road construction process. That’s why the live demonstrations have always been a key feature of our Technology Days and why they’re unique in our industry in terms of both their form and their scale,” says Roland Schug, Head of Marketing at JOSEPH VÖGELE AG, who has overall responsibility for this year’s Road Technology Days.

Digital measurement and control

Modern road construction demands high precision, perfect quality and efficient processes – which is why the Road Technology Days also offered insights into digital measuring and control systems. WIRTGEN, VÖGELE and HAMM demonstrated the latest 3D solutions in two technology presentations. The SP 15i slipform paver from WIRTGEN, for instance, can pave even the smallest of radii entirely automatically thanks to the GPS-based Autopilot. The 3D Navitronic Plus solution from VÖGELE, meanwhile, allows the layer thickness, the screed’s position and the paver’s direction of motion to be controlled automatically. And the HCQ system from HAMM measures the most important compaction parameters and shows the roller operator directly on the display where more compaction is required. Such applications save a lot of time and money – while also enabling precise implementation and high quality.

Intelligent solutions for road construction

Specialist talks by selected experts and technology exhibitions also gave visitors an overview of current and future developments in road construction. WIRTGEN presented precise levelling, cost-effective cutting and advanced recycling technologies, while VÖGELE presented the software-based process management system, WITOS Paving. The telematics solution networks road pavers, mixing plants and lorries, among others, supporting a perfectly coordinated supply of mix. All the players involved have real-time access to all data such as machine operating data and lorry loading and unloading times, allowing them to coordinate all processes precisely. HAMM demonstrated intelligent solutions for compaction, including the intuitive Easy Drive operating concept and the principle of oscillation, where tangential rather than vertical shearing forces are directed into the material to be compacted. The drum maintains constant ground contact for particularly speedy compaction.

Quality creates quality

Apart from presenting cutting-edge technologies, machinery and a sector outlook, the Road Technology Days also offered a glimpse behind the scenes at VÖGELE – the most modern road paver factory in the world. Visitors were able to explore the production facility, built in 2010 and currently being expanded with a dispatch hall and additional production facilities, on a tour covering a total of 18 stations. An interactive special exhibition entitled “Quality Management” also used display panels, videos and exhibits to demonstrate what requirements the components have to meet and what controls they have to pass through on the way to final assembly and delivery to the customer. “Quality in road construction begins with us,” says Bernhard Düser, member of the Board of Directors of JOSEPH VÖGELE AG. “Only with perfect and technically sophisticated products can our customers build high-quality roads.”

[ENDS]

From now on, the class leader W 150 CF/W 150 CFi can also be equipped with a 1,800-mm milling drum assembly. Customers therefore profit from a wider range of applications. The most powerful machine in the compact milling machine class with its 298-kW engine power, it now achieves even greater productivity and area output. The front loader will be unveiled with its new milling drum assembly at Intermat 2018.

Wide range of working widths for maximum cost-efficiency

The W 150 CF/W 150 CFi can tackle a wide array of different jobs, ranging from classic small milling machine applications such as partial road surface repairs to the removal of entire road pavements. The milling machine is therefore especially suitable for large-scale projects in confined spaces such as on urban job sites. Particularly in such conditions, the sophisticated visibility concept combined with the camera systems help the machine operator to maneuver the milling machine.

With the Flexible Cutter System, users can switch between milling drums with different working widths of 600 mm, 900 mm, 1,200 mm and 1,500 mm simply and very quickly. In addition, with the 1,500-mm working width it is possible to switch to milling drums with different tool spacings.

A new extension kit is now also available which extends the milling drum housing by 300 mm. With this kit, the W 150 CF/W 150 CFi has a working width of 1,800 mm, making it even more versatile and also ideal for surface course rehabilitation on medium to large job sites.

Efficient RAP loading

Alongside milling and cutting technology, loading conveyor construction is another of Wirtgen’s core competencies. To ensure efficient direct loading of the milled material onto trucks, the loading conveyor system of the milling machines has a high loading capacity. A larger cleat profile on the discharge conveyor of the W 150 CF/W 150 CFi guarantees optimum material transport and, with the higher conveyor speed, precise loading is also very fast. Another advantage is the extremely large conveyor slewing angle of 60° to the left and the right, which also enables milled material to be loaded under difficult site conditions such as on traffic circles or crossings.

Fast site-to-site transfer due to simple transportation 

To maximize the cost-effectiveness of milling operations, cold milling machines need to be transported quickly from one site to the next. This is especially true when the machines are as versatile in various applications as the W 150 CF/W 150 CFi. Wirtgen’s top performer therefore has an optimized machine transport weight despite its tremendous engine power.

Meanwhile, preparing the machine for transport is a time-saving process, since the hydraulically operated folding conveyor can be folded quickly. These features ensure that the high-performance milling machine is ready for action again in next to no time.

For further information
Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za

As the market leader, Wirtgen offers the widest range of cold milling machines in the industry. Customers can choose from more than 30 different types of machine, each of them also available with a variety of milling widths. The lower performance class starts with the small 45-kW milling machines and extends through compact machines with engine outputs of between 257 and 298 kW to large milling machines in the upper performance class offering power reserves of up to 753 kW. The weight of the machines ranges between 4.6 t and 44 t. At Nordbau 2017, Wirtgen is presenting the small milling machine W 50 Ri.

Wirtgen’s customer-oriented development expertise is a guarantee of innovations tailored to the needs of the market. The new solutions for cold milling developed at the brand headquarters in Windhagen are founded on practical know-how and core competences in leveling, control and cutting technology.

Efficient and sustainable: Surface course milling and selective complete removal

Cold milling is one of the first measures taken when a roadway or traffic area needs to be rehabilitated. The fast and efficient removal of asphalt and concrete surfaces through cold milling produces an even base which is true to line and level and ideal for paving surface courses in a uniform thickness. The condition of the milled surface has a key impact on the quality of the new surface course to be paved, on its service qualities and on the efficient and economical execution of the rest of the construction work.

Cold milling also has a lasting effect on the construction process when complete pavement structures are removed. Equipped with state-of-the-art milling and leveling technology, Wirtgen milling machines can remove either the complete pavement or the individual surface, binder or base course. When pavements are milled in layers, the milled material can be separated and selectively recovered according to mix type. This lays the ground for targeted reuse of the RAP.

Leveling: Wirtgen’s core technology goes far beyond the norm

One of the decisive factors in the creation of a milled surface true to line and level is precise leveling. The purpose of leveling is to regulate the milling depth or slope automatically and as precisely as possible based on a reference line. In the field, it has become standard practice to copy an existing surface.

But teamed with a wide range of sensors and applying the latest methods, the Wirtgen LEVEL PRO/LEVEL PRO PLUS leveling system can do much more than simple copying. In the multiplex system, for instance, three sensors on each side of the machine scan the height. The automatic leveling system factors all three measurements into its analysis so that the preset target milling depth is met exactly, but any unevenness in the road surface is not copied. This is a highly effective way of leveling out longitudinal undulations. If the requirements on evenness are particularly stringent, up to seven sensors can be installed on each side. What is more, defined surface profiles can be created, such as specified cross slopes on race tracks or crowns. This allows the entire road structure to be rehabilitated if necessary.

LEVEL PRO PLUS leveling system: Also for the small milling machine W 50 Ri

On small milling machines, height adjustments used to be carried out manually by lowering the lifting columns of the rear crawler units. In its latest generation of small milling machines, Wirtgen has further optimized the leveling process, offering LEVEL PRO PLUS as an option for the W 50 Ri, too – and fully integrating the system in the machine control system. Having fewer interfaces means shorter signal paths in the control systems and faster reactions between them – factors which all add up to an efficient and precise leveling process. The high degree of automation in the system also makes life easier for the machine operator.

Machine control technology optimizes processes

The progressive automation of technical processes likewise plays a key role in optimizing the milling result. With this in mind, Wirtgen put the focus firmly on process optimization along with ease of operation when advancing its small and compact milling machines.

Multifunctional armrest: Perfect control of every job with the W 50 Ri

The highlight of the operating concept is the ergonomic, individually adjustable multifunctional armrest. With this feature on board, drivers of the W 50 Ri small milling machine can now also adjust the machine height, store and automatically activate different milling depths, switch between camera views or control the cold milling machine with the fingertip steering function instead of the steering wheel. Relevant data are also presented in color on the operating display.

Cutting technology: A wide range of efficient applications

The powerful “heart” of the cold milling machine – the milling drum assembly with all the cutting technology components – also has a critical bearing on the quality, costs and performance of the milling process. Here too, as technology leader Wirtgen is continually developing cost-efficient solutions. A variety of milling drums – for fine milling, for creating rough surface structures, or the ECO cutter for a particularly high area performance, to name but a few – support many different milling applications in asphalt rehabilitation.

In addition, specially configured cold milling machines can also be used in concrete or rock milling. Other customized machine modifications allow steep incline milling on slopes of up to 35° when working on reservoirs, canals and equalizing basins. Cold milling machines are also frequently used to dig trenches for pipelaying or, when fitted with a deep milling unit and narrow cutting wheel, to mill slots. In short, the range of applications is huge.

High machine utilization with the FCS cuts operating costs – Also for the W 50 Ri

To increase the utilization of milling machines and make them more economical to operate, the milling drum in many models can be easily swapped for a differently configured milling drum thanks to the Flexible Cutter System (FCS). As a result, the milling width and/or tool spacing can be varied as required. The W 50 Ri, for instance, can be swiftly modified to carry out a new task, so that it operates extremely cost-efficiently under changing conditions.

 

The old-established roller manufacturer HAMM is offering an exhaustive range of modern, future-proof machines for road building and earthwork in 2017. The programme currently consists of 88 tandem and combi rollers, 18 pneumatic tyre rollers and 63 compactors, clearly subdivided in the weight classes customary in the market. HAMM thus covers the classic areas of application in asphalt construction and earthwork with a programme that also includes numerous specialised items such as the VC compactor and options such as dozer blades and chip spreaders. 

1. Tandem rollers

In the tandem roller segment, HAMM carries machines with operating weights from 1.5 t to 15 t and drum widths from 0.80 m to 2.14 m. All 88 tandem and combi rollers are finely graduated according to operating weight. They stand out for their ease of operation, high productivity, extensive equipment configurations and useful options.

1.1 HD CompactLine: articulated compact rollers from 1.5 t to 4.5 t

With a total of 18 tandem and 9 combi rollers in the HD CompactLine, HAMM features the widest product diversity in the compact segment. The drum widths of these articulated rollers range from 0.80 m to 1.38 m. These agile and manoeuvrable compaction machines are user-friendly all-rounders for road construction and landscaping. Among their most important features are perfect visibility thanks to a “wasp-waist” front section, low vehicle height and good transport and handling characteristics. Modern Kubota engines ensure a quiet, yet powerful drive.

The drum diameters of the compact rollers are exceptionally large. This actively helps prevent the formation of fissures and bulges and promotes high compaction quality. In addition, the machines generate very large centrifugal forces and have a high static linear load. As a result, the HD CompactLine rollers deliver top-class compaction performance. 8 models in this series are available with oscillation technology. This gentle, low-vibration and intelligent compaction mode can therefore also be used in confined construction sites such as in city centres.

HAMM also offers numerous options for this series. They include chip spreaders for the models from 2.5 t as well as a ROPS cab for the largest models in the series, the HD 13 and HD 14. In addition, various models can be equipped with the HAMM Compaction Meter (HCM) for measuring the progress of compaction and the HAMM Temperature Meter (HTM) for measuring asphalt temperature.

1.2 HD+ series: all-rounders for high-quality compaction

The multi-award-winning articulated tandem rollers in the HD+ series are available in the weight classes from 7 t to 14 t. They are ideally suited for the compaction of roads and other surfaces of all sizes. HAMM offers the machines in several versions: as “i-models” with engines meeting Tier 4 exhaust emission standards and as models with engines meeting Tier 3 exhaust emission standards. In both variants, they are available as double vibration rollers, as rollers with an oscillation and a vibrating drum, and as combi rollers.

The state-of-the-art tandem rollers in the HD+ series offer drivers an ergonomically optimised workspace with a perfect view from a panoramic cab. All models in this series are extremely easy to operate – especially those with Tier 4 engines because they come with all the benefits of the Easy Drive operating concept. When compacting, the HD+ scores highly thanks to its exceptionally even weight distribution. Perfectly smooth surfaces are created in a short time, especially in curves and on roundabouts. When reversing, the automatic transmission makes for gentle acceleration and braking; smooth asphalt layers without any bumps or hollows are the result. Among other things, the intelligent water sprinkling system on the HD+ features speed control. In addition, large water tanks ensure long, uninterrupted periods of work. The models with Tier 4 engines are also equipped ex-factory with the “Hammtronic” machine management system. It delivers optimum performance while minimising fuel consumption and ensures even, high-quality compaction by controlling the traction and vibration drives.

HAMM has also become the first manufacturer to develop a novel hybrid drive, currently employed in the HD+ 90i PH. It combines an internal combustion engine suitable for series production with a hydraulic system. As a result, the 9 t roller is able to operate with a 55.4 kW engine instead of an 85 kW power unit. The compaction power nevertheless remains unchanged. The benefits for the user are manifold, for example: no AdBlue, less maintenance, quieter operation and significant fuel savings.

1.3 DV+ series: pivot-steered tandem rollers for ultimate precision

A highlight of the pivot-steered tandem rollers in the DV+ series is the “all-round view” concept that provides an unobstructed view of the construction site and the drums. Important elements are the spacious panoramic cab, the partially glazed cab floor and a cleverly conceived frame. All models in this series also come with the benefits of the Easy Drive operating concept as they are very easy to operate. Depending on the specification, the driver’s seat may be rotated by up to 350°, allowing the driver to sit in the direction of travel at all times.

When it comes to machine technology, the DV+ series is also impressive: the combination of a powerful engine, extremely wide working widths (max. 3.05 m) plus the intelligent, precisely adjustable water sprinkling system produces excellent compaction results. In addition, there is highly flexible steering with 4 steering modes and very large track offset (max. 1.37 m). The fuel tank is especially easily accessible from below and can be filled by pressure refuelling. Moreover, the large diesel and water tanks ensure long periods of work and high productivity. 

When it comes to compaction technology, the customer has the choice of double vibration rollers, machines with a vibrating drum and an oscillation drum, and combi rollers. All vibratory rollers are fitted with split drums as standard, enabling them to satisfy the most demanding requirements.

2. Compactors for earthwork

HAMM has a total of 63 compactors for earthwork ranging from 5 t to 25 t, with working widths from 1.37 m to 2.22 m. All HAMM compactors have 3-point articulation for even weight distribution and enormous driving stability. They also stand out for their ease of operation, excellent visibility, extremely high level of safety, enormous productivity, wealth of equipment variants and useful options. 

2.1 H CompactLine series: impressively compact

The compactors in the H CompactLine with weights between 5 t and 7 t (drum widths 1.37 m or 1.68 m) feature an extremely compact design, making them ideal for small or confined construction sites. With a length of around 4.40 m, the H 7i is the shortest compactor in the world in this weight class.

In uneven terrain, the 3-point articulation ensures unrivalled driving stability and good directional stability. The traction drive by means of wheel motors brings the desired ground clearance, while the design of the front section enables a large slope angle. Added to this is the remarkable climbing ability of the H 5i / H 7i compactors of 60% and more.

The compactors are exceptionally versatile, thanks not least to the numerous options. Customers can choose between smooth and padfoot drums as well as two-part padfoot shells. A VIO drum, capable of compacting with either vibration or oscillation, is also available for the H 7i.

2.2 H series: for the big earthwork jobs

The H series compactors cover a huge spectrum of earthwork applications. The machines are available with weights from 11 t to 25 t, with smooth or padfoot drums. Thanks to the Easy Drive operating concept, all models are exceptionally easy to operate and offer many convenience features. In addition, HAMM is the only manufacturer in the world to offer a VIO drum for these compactors. Accordingly, these machines can compact with oscillation or vibration as desired.

All H series compactors have the 3-point articulation developed by HAMM. It gives them superior driving stability and manoeuvrability even in difficult terrain. Another outstanding characteristic of the H series compactors is their high linear load. Added to this is the large slope angle and enormous climbing ability that allow these compactors to work effectively even on slopes in excess of 60%. The HAMM programme also includes models with heavy-duty drive to meet special requirements regarding climbing ability. This is complemented by numerous options such as padfoot segments, vibration plates and dozer blades.

2.3 VC compactors: rock crushing and compacting

With the VC compactors, HAMM has developed a dedicated series for especially challenging applications. They crush and compact rock in one operation. The 25 t compactors, based on the H 25i and 3625 HT models, are equipped as heavy-duty machines.

Their drum is fitted with 150 tool holders. They can hold cutting tools of the type also used in mining. With the cutting tools, the vibrating drum creates extremely high point loads that crush the rock while the ground is being compacted. To hold the cutting tools, the VC compactors use a quick-change tool holder system which can also be fitted with special padfoot inserts. This enables the machines to compact particularly abrasive, cohesive soils very efficiently.

3. GRW: pneumatic tyre rollers for every market

HAMM also stands out from the crowd in the pneumatic tyre roller segment as it has done since the 1960s, when it was the first ever manufacturer to launch a pneumatic tyre roller. Today, with 18 different models, HAMM ranks among the manufacturers with the largest ranges of pneumatic tyre rollers in the world.

3.1 GRW 180 / 280: asymmetric frame provides outstanding overview

The pneumatic tyre rollers in the GRW 180 / 280 series can easily be identified from far away on account of their innovative design: their asymmetric frame makes for an outstanding all-round view and provides an unobstructed view of the outer wheels. Added to this is a sight channel, through which the driver can see the running surfaces of the wheels from the cab or platform.

An intelligent ballasting concept facilitates rapid adjustment of machine weight with even distribution of weight over both axles. For this purpose, HAMM supplies prefabricated ballast bodies in various materials, enabling each roller to be precisely equipped to suit the asphalt type, layer thickness and application.

An ingenious wheel suspension system with 2 swing arms positioned between the front wheel pairs takes care of levelling on uneven terrain and, in turn, even distribution of machine weight, irrespective of the ground characteristics. This results in very smooth surfaces thanks to the uniform surface pressure of the pneumatic tyres. Aided by an electronic control system, the hydrostatic drive facilitates precise speed setting as well as gentle, even acceleration and braking. The powerful braking system swiftly brings even the heaviest rollers in this series to a safe halt.

The Wirtgen Group South Africa contact: 
Waylon Kukard

Tel: +27 (0) 11 452 1838

Cell: +27 (0) 82 929 1449
Email: waylon.kukard@wirtgen-group.com

Web: www.wirtgen-group.com/southafrica/en/

Media contact: 
Samu Hashe
MoonDawn Media & Communications
Cell: +27 (0)79 562 3941
Email: samu@moondawnmedia.co.za 

Web: www.moondawnmedia.co.za

Media Advisory
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SURFACE COURSE REHABILITATION: COMPACT MILLING MACHINE IS A CLASS OF ITS OWN

VORO, a milling contractor based in Kassel, Germany, brought the versatility of the W 100 CFi Wirtgen compact milling machine into play when rehabilitating the surface course of a federal highway.

The B3 extends over a distance of 755 km from Buxtehude in the north of Germany through to the Swiss border in the south. The job involved milling areas of damaged asphalt on one side of the highway in the vicinity of the municipality of Jesberg in the federal state of Hesse. As the project progressed, a free flow of traffic had to be maintained on the opposite lane. A total of 1,200 m² asphalt surface course had to be removed to a depth of 4 cm. The entire milled area was divided into 13 individual sections, each 3.50 m wide and located at intervals of 50 to 100 m.

Maneuverable and versatile but as productive as its big brothers
“We decided to use a type W 100 CFi Wirtgen compact milling machine for this job, as it achieves a high area output with low fuel consumption and, with its compact design and maneuverability, can be easily transported from one job site to the next,” explained Alexander Emde, Operations Manager of VORO Straßenfräsdienst GmbH.

In the Wirtgen Compact Class, customers can choose from no less than eight models with standard milling widths ranging from 1.0 m to 1.5 m and milling depths of up to 330 mm. Combined with the Flexible Cutter System, milling widths of 8 cm to 1.5 m are possible. The entire machine range – encompassing the W 100 CF / W 100 CFi, W 120 CF / W 120 CFi, W 130 CF / W 130 CFi and W 150 CF / W 150 CFi – delivers on performance and economic efficiency. It covers classic small milling machine applications such as partial road repairs as well as the removal of entire road pavements – a task which is normally the preserve of large milling machines. Wirtgen compact milling machines are therefore not only extremely versatile. In combining the advantages of the large and small milling machine classes, implementing a uniform operating concept and, in particular, incorporating pioneering control technologies, the Wirtgen compact class is now one thing above all: The next step in the development of cold milling.

Effective operation and increased performance

The Wirtgen W 100 CFi is equipped with a powerful, 257-kW diesel engine and, despite its high capacity, meets the stringent requirements of the exhaust emissions standards EU Stage 4 / US Tier 4 Final. The drive unit is designed for a maximum milling depth of 33 cm. The mechanical milling drum drive transmits the engine torque to the milling drum with a high degree of efficiency.

“Wirtgen’s Generation X point-attack cutting tools cut through the 4-cm surface course with ease and produced very smooth and excellent milling results,” reported Sigbert Werner, milling machine operator with VORO. “The noise insulation on the machine is also very good. The engine runs very quietly at full load,” commented Werner.

In addition, the driving dynamics package supports a travel speed of up to 7.5 km/h, enabling the machine to move swiftly to the next surface to be milled. As the entire job site extended over a 1.2-km stretch, this was essential to ensure a fast milling procedure.

New control technology sets standards

The new operating concept with a multifunctional armrest and fully integrated LEVEL PRO PLUS leveling system guarantees optimum milling results. After all, it leaves the operator free to focus almost entirely on the milling work itself. “After a brief induction on the brand new control system, the machines are a great deal easier to use than ever before,” commented Sigbert Werner, describing his experiences with the new operating concept. One highlight is the ergonomic multifunctional armrest. This is used to show all important information – including the compilation and visualization of job data – in color on the operating display. Four “favorites” buttons integrated into the armrest can, for example, be programmed with any of 20 different functions. In addition to the steering wheel, the operator also has access to an extremely sensitive, fingertip steering function in the multifunctional armrest.

The large number of added and automated functions make life easier for the operator and also save time. For example, the automatic button-activated folding in of the compact milling machine’s right rear crawler track also speeded up the milling work on the B 3. The track can be folded in without lowering the milling drum or manually loosening a bolt. In addition to the “basic position”, the new “outside” position – in which the right rear crawler track is located within the cutting diameter of the drum, enabling the machine to be easily positioned along the right-hand milled cut – and the “folded in” position are possible. The first milled cut on the B3 ran alongside a safety barrier. For this reason, Werner moved the crawler track into the “folded-in” position to be able to mill along the outer edge of the roadway with the zero-clearance side. To prevent the side plate from sinking into the surface when working on loose substrate – for example gravel or on the adjacent grass verge as in Jesberg – it has an active floating position. It ensures that the side plate is lifted at specific intervals.

To support the leveling and milling process, the milling machine operator Werner was also able to use an automatic lowering function when positioning the W 100 CFi in the milled cut. When the milling drum unit reaches the surface to be milled, the lowering speed is adjusted automatically so that the milling drum slowly penetrates the material down to the set depth. In addition, the height of the crawler units can be adjusted in steps of 1 mm or 5 mm using the new millimeter height function to precisely set the milling depth. The most frequently used height settings can be stored in three height-adjustment memories and called up quickly at any time.

Optimum visibility concept for safe working on confined construction sites

As traffic continued to flow on the opposite side of the highway during the rehabilitation project and the job called for frequent machine relocations, the Wirtgen compact milling machine was the ideal candidate for these job sites. The sophisticated visibility concept enables the operator to maneuver with millimeter accuracy. The chassis of the W 100 CFi is distinctly narrower and affords the operator a better view to the front. In addition, the operator’s stand can be hydraulically displaced 200 mm beyond the edge, thus providing a perfect view ahead of the milling drum assembly and onto the front right-hand crawler track. Thanks to the camera system, the left-hand milled edge or material discharge is always clearly visible to the machine operator on the high-resolution display. “The dust extraction device on the discharge conveyor also makes work very pleasant,” Werner adds.

Best quality at top speed

The milling work was completed within a few hours. Alexander Emde was satisfied with the results: “The W 100 CFi not only created a very smooth milled surface over the entire area, but also worked with minimum wear.” It was possible to pave the new surface course immediately after the milling work had been completed. This job was done by a Vögele road paver.

Image captions:

W100CFi_00955
Working on the job site while traffic is flowing in the opposite direction is no problem for the Wirtgen W 100 CFi. The considerably narrower chassis that also provides the driver with an optimum view of the milled edge is an additional advantage here.

W100CFi_00958
With its compact dimensions and low weight, the Wirtgen W 100 CFi can be transported easily and without requiring additional permits. This is ideal for working on several sites on one day.

W100CFi_00966
The ergonomic multifunctional armrest of the Wirtgen W 100 CFi features four “favorites” buttons that can be programmed with any of 20 functions as well as a color operating display. All important information is shown on a small screen – for instance the compilation and visualization of job data.

W100CFi_00993
With the increased steering angle of the front axle, the Wirtgen W 100 CFi can describe very small turning circles. What’s more, the hydraulically operated folding discharge conveyor can be swiftly folded up, making this machine an excellent choice for tie-in milling jobs in confined conditions.

W100CFi_00949
The operator’s stand, which can be hydraulically displaced 200 mm beyond the edge, provides a perfect view ahead of the milling drum assembly and onto the front right-hand crawler track.

W100CFi_00473
The diesel engine of the Wirtgen W 100 CFi is equipped with both an oxidation catalytic converter and an SCR catalytic converter for effective exhaust gas treatment and meets the stringent requirements of the highest current exhaust emissions category EU Stage 4/ US Tier 4f.

For further information please contact:
Wirtgen SA contact:

Calvin Fennell
Business Development Manager
Tel: 011 452 1838
Cell: 072 721 3951
Email: Calvin.Fennell@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za













WIRTGEN SLIPFORM PAVER SP 500 PAVES CONCRETE IN SOUTHWEST NIGERIA

For the construction of a concrete roadway to connect the towns of Itori und Ibese in the Nigerian state of Ogun, AG-Dangote Construction Company Limited made use of the sophisticated technology offered by Wirtgen’s SP 500 slipform paver.

For this project, the contractor, a joint venture between the Brazilian company Andrade Gutierrez Company and the Dangote Group from Nigeria, relied above all on the cost-efficiency and precision of the Wirtgen slipform paver in inset application.

Operating principle of the inset method

In inset application, the concrete is either deposited right in front of the slipform paver or is fed in front of the machine from the side via a belt conveyor or side feeder. In the next step, the concrete is distributed evenly across the full paving width by a spreading auger or spreading plough. Integrated electrical or hydraulic vibrators ensure homogeneous compaction of the concrete. The inset mold forms the concrete slab to the specified thickness and width while the slipform paver advances. In addition, a dowel bar inserter can be integrated which inserts the dowel bars into the concrete as specified parallel to the paver’s direction of travel. Central tie bars or side tie bars can be inserted transverse to the concrete pavement. The surface is leveled off transverse to the paver’s direction of travel by the finishing beam. The “grinding movement” produces a small concrete roll in front of the beam which enhances the high quality of the concrete surface. In the next step, a super smoother, oscillating in a combination of lateral and longitudinal movements, ensures the final surface accuracy. Wirtgen texture curing machines such as the TCM 95 or TCM 180 then create the desired surface structure, applying a dispersion to the concrete surface which prevents the surface and edges from drying too quickly.

The longest concrete roadway in Nigeria

Before the slipform paver, which can pave concrete pavements in widths of up to 6.0 m and thicknesses of up to 400 mm as standard, was able to begin work in Itori, the substrate first had to be prepared. The construction company used compacted laterite and a 20-cm layer of crushed rock. “The SP 500 then paved the concrete quickly and cost-efficiently. At the same time, it also helps us ensure that our production quality meets the specifications for surface evenness,” explains Ashif Juma, Managing Director of AG-Dangote Construction Company Limited. The SP 500 laid down the new 7.50 m-wide and 20 cm-thick roadway in two separate passes. Extending over 24 km, the new road is the longest uninterrupted stretch of concrete roadway in Nigeria.

From raw material to building material – Wirtgen surface miners begin the process chain

To continuously provide the concrete paver with sufficient material, a steady convoy of up to 15 concrete-mixing trucks drove to the job site, depositing their loads directly in front of the machine. However, before concrete can be paved, it must first be produced. The production chain begins with limestone mining. This mineral is one of the raw materials used in cement, which in turn forms the basis of concrete. The Dangote Group extracts limestone from its open-cast mine in Ibese, where the Dangote Cement Company operates 14 Wirtgen surface miners of the type 2500 SM. The Dangote Group not only uses road construction machinery from the Wirtgen Group’s Road Technologies business sector, but also the mining technology offered by its Mineral Technologies sector. Wirtgen surface miners cut, crush and load the rock in one single operation. The rock is broken down directly during the extraction process into grain sizes that are suitable for belt conveyors, making the use of a crusher superfluous. This saves time and reduces the costs of the entire mining process. Wirtgen had already supported the Dangote Group before operations at the Ibese mine began, not only with the machinery, but also with production process planning and training for the specialists on site. This partnership has now endured for more than 15 years. It therefore stood to reason that AG-Dangote Construction Company Limited would opt to use Wirtgen technology and applications know-how for the road construction project between Itori and Ibese.

Wirtgen slipform paver delivers precision paving results

“The SP 500 not only ensured that construction project processing went off without a hitch, but also produced a paving result that impressed both us and the client. We processed more than 35,000 m³ of concrete using the Wirtgen slipform paver, and produced a very even surface,” says Juma contentedly.

Precision, flexibility and reliability are the hallmarks of the SP 500. And this also applies to the new generation of slipform payers lined up in Wirtgen’s new SP 60 Series, which comprises the SP 61/SP 61i, SP 62/SP 62i and SP 64/SP 64i models. The SP 60 Series is set to replace the globally successful SP 500 model and, like its predecessor, offers a wide range of options to meet the diverse demands of inset and offset paving – including hydraulic and electrical vibrators, dowel bar inserters, finishing equipment, swivel arms, wireless 3D control, not to mention a variety of offset molds.

For example, the side tie bar inserter, which in Nigeria inserted 12 mm-diameter tie bars into the sides of the pre-compacted concrete to securely connect the two adjacent roadways, can be selected as an equipment option with the SP 64/SP 64i. The new generation of slipform pavers combines the application diversity of the SP 500 Series with the state-of-the-art technologies of the next-larger SP 90 Series.

AG-Dangote expands its Wirtgen fleet

Work on the 24-km concrete roadway was completed after six months of construction. After completion of the paving work, a concrete cutting machine cut slits at right-angles into the road surface at intervals of 3.65 m so that the resulting joints could be filled with expandable material. These pre-determined breaking points prevent potential tension cracks. “With professional maintenance, this will ensure that the roadway lasts for at least 40 years,” says Juma, explaining the last step of the construction procedure. Thrilled with the successful outcome of the project, the Managing Director also decided to acquire additional concrete equipment from Wirtgen. AG-Dangote Construction Company Limited has expanded its fleet of road construction machines, purchasing two of the last SP 500 pavers produced, along with a TCM 95 texture curing machine.

[ENDS]

About Wirtgen SA

The Wirtgen Group South Africa is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann, Benninghoven and Ciber. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

The Wirtgen Group South Africa contact:
Waylon Kukard

Tel: +27 (0) 11 452 1838

Cell: +27 (0) 82 929 1449
Email: waylon.kukard@wirtgen-group.com

Web: www.wirtgen-group.com/southafrica/en/

Media contact:
Samu Hashe
MoonDawn Media & Communications
Cell: +27 (0)79 562 3941
Email: samu@moondawnmedia.co.za 

Web: www.moondawnmedia.co.za

Wirtgen SA to showcase full line-up of brands at bauma CONEXPO AFRICA 2018

[Johannesburg, 2 February 2018]:The Wirtgen Group South Africa will use the upcoming bauma CONEXPO AFRICA 2018 to showcase its innovative solutions for road construction and rehabilitation as well as for mining and mineral processing from across its group of internationally operating companies, comprising Wirtgen, Vögele, Hamm, Kleemann, Benninghoven and Ciber.   

The Wirtgen Group South Africa, the local subsidiary of the Wirtgen Group in South Africa, will use bauma CONEXPO AFRICA 2018 to display a range of its available solutions and a broad range of services tailored to specific requirements for all areas of road construction as well as mining and processing of minerals, to its African customer base. bauma CONEXPO AFRICA 2018, the third international trade fair for construction machinery, building material machines, mining machines and construction vehicles, will be held at the Johannesburg Expo Centre in South Africa from March 13 to 16, 2018. 

Having exhibited at the two previous editions of the show in 2013 and 2015, The Wirtgen Group South Africa rates bauma CONEXPO AFRICA as a great platform to showcase its latest technologies available, according to Waylon Kukard, Sales Manager at The Wirtgen Group South Africa. “The Wirtgen Group is the market leader in our industry and we regard Bauma as an important platform to showcase our class leading technologies to our customers and to live our ‘Close to our customers’ motto,” says Kukard. He adds that the Wirtgen Group has the second-biggest stand at Bauma Munich and The Wirtgen Group South Africa would like to build on this international success to further get closer to its local customers.

“We will showcase all our brands, namely Wirtgen, Vögele, Hamm, Kleemann, Benninghoven and Ciber,” says Kukard, adding that the range of products from these companies are relevant to the local market. With their leading technological features, the products will help local customers maximise productivity and execute top quality jobs. “Bringing products and technologies to the local market that have been successfully applied internationally provides the local industry with an opportunity to identify projects that can benefit from the international experience,” he adds.

Ahead of the show, Kukard notes the current challenging operating conditions in the local market. Testimony to this is the dramatic decline in the total equipment numbers sold during the past three to four years, largely due to the current economic conditions. For example, compaction roller sales in 2017 were down 15-20% year-on-year in the different ranges in South Africa, with 350-400 units being sold per year for the past three years. Roller sales are linked to infrastructure development and government expenditure has been very limited in the past few years and in some provinces non-existent. “The sector is currently under pressure and declining with no real growth potential in sight,” he says.

It is during such times that industry should be prepared to engage with original equipment manufacturers (OEMs) on a consultative basis to see how best to apply existing and new technologies developed by OEMs to keep operational and capital costs down, says Kukard. For example, one of The Wirtgen Group South Africa’s key focus areas at the upcoming bauma CONEXPO AFRICA 2018 is sustainability and recycling of scarce natural resources, which has been the foundation of its product development over the years.

“Resources such as bitumen, road stone, layer works, among others, can be reused rather than being discarded and replaced,” says Kukard. “The Wirtgen Group South Africa has an in-depth understanding of the niche markets that it operates in and can provide a full range of solutions, all the way from machine selection through to application and operation.”

“Even in these tough economic times, The Wirtgen Group South Africa can fall back on the strength of the Wirtgen Group internationally to be able to provide our customers with the best and latest technologies available,” concludes Kukard.

[ENDS]

About Wirtgen SA

The Wirtgen Group South Africa is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann, Benninghoven and Ciber. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

The Wirtgen Group South Africa contact:
Waylon Kukard

Tel: +27 (0) 11 452 1838

Cell: +27 (0) 82 929 1449
Email: waylon.kukard@wirtgen-group.com

Web: www.wirtgen-group.com/southafrica/en/

Media contact:
Boitumelo Mogano
MoonDawn Media & Communications
Cell: +27 (0)76 733 2615
Email: boitumelo@moondawnmedia.co.za 

Web: www.moondawnmedia.co.za

THE NEW WIRTGEN W 210 XP LARGE MILLING MACHINE: A CHAMPION PERFORMER IN ITS WEIGHT CLASS

With the W 210 XP, the Wirtgen experts have extended their comprehensive product range with a new high-performance machine. Combining tremendous engine power with an application-optimized machine transport weight, this machine has added a trump card to the deck within its class.

Professional machine with extended application range

The W 210 XP is a champion performer in its weight class. Its powerful 6-cylinder engine delivers an impressive output of 571 kW, allowing the milling pro to handle a wide range of applications, from surface course rehabilitation to complete pavement removal and fine milling jobs.

High machine utilization thanks to FCS light

The W 210 XP comes equipped with a 2-m milling drum unit as a standard feature. Units with milling widths of 1.5 and 2.2 m are also available as options. Wirtgen’s Flexible Cutter System Light (FCS Light) not only ensures greater flexibility but also high machine utilization – a key factor for the economic operation of large milling machines. Both the 2-m and the 2.2-m milling drum units are FCS Light-compatible. This allows milling drums of the same width but with different tool spacings to be fitted without difficulty as required for the job at hand.

 HT22 quick-change toolholder system: Maximum milling performance, cost-efficient operation

All the milling drums are fitted with Wirtgen’s HT22 quick-change toolholder system. The robust upper part of the system can be easily and quickly changed directly on site. This minimizes machine downtimes and increases the lifespan of the milling drum. HT22 is the all-round key to maximum milling performance and cost-efficient operation.

Ease of transport increases machine availability

Thanks to its compact dimensions and optimum machine transport weight, the W 210 XP can be easily transported from one job site to the next. As a result, the high-performance milling machine can be up and running in no time. Without the water tank content of approximately 29 t, the transport weight is low, so that the machine can also be transported on a light low-bed truck with a low gross train weight. Customers are more flexible as a result, and can get their large milling machine to its next job at a fraction of the cost.

Optimized ergonomics for high daily production rates

The ergonomically designed walk-through W 210 XP operator’s platform is a further plus point. The control elements are ideally arranged to provide a clear overview and make operation child’s play for the machine operator. Most functions can be controlled by the multi-functional joystick mounted in the armrest. In this way, the operating concept of the new W 210 XP, devised by the Wirtgen designers with great attention to detail, allows high daily production rates.

REHABILITATION OF CAMPS BAY DRIVE IN CAPE TOWN WITH WIRTGEN COLD RECYCLING TECHNOLOGIES

Camps Bay Drive is a major scenic route within the City of Cape Town and provides access to Camps Bay and Hout Bay. Based on the project brief and geometric analysis, Camps Bay Drive required widening to safely accommodate the high volumes of tourists and MyCiti bus traffic. In order to minimize the impact on traffic, the design brief targeted construction outside the summer peak tourist season and also required investigation into shortened construction periods. The key role was played by Wirtgen cold recycling technologies. In action: the mobile cold recycling mixing plant KMA 200.

The South African metropolis has large volumes of Reclaimed Asphalt (RA) stockpiled from numerous maintenance works undertaken around the City. This material has generally been used for hard stand areas and shoulder construction, In order to reuse this high quality material, WorleyParsons was tasked to investigate a more efficient and sustainable use for this material. For this reason, the use of a foamed bitumen technology was investigated and the base layer on Camps Bay Drive was constructed using 100% RA as a foamed Bitumen Stabilise Base (BSM) base layer.

Wirtgen KMA 200 mixes high quality recycling material

Originally, the project consisted of localized road widening to accommodate the proposed MyCiti buses however due to the large volume and sizes of the proposed buses, a geometric analysis resulted in the entire portion of the road being widened by 1,4 m. The proposed pavement design involved a light rehabilitation with the widening area requiring full depth construction however during construction, numerous weak horizons were discovered along the road. The pavement design implemented for construction involved the following: 

  • 50 mm AE-2 Asphalt Surfacing
  • 200 mm Foamed BSM 1 Base
  • 150 mm G5 Subbase, natural gravel
  • 150 mm G7 Selected Subbase, pioneer rock layer
  • In-situ

The project was divided into three construction sections. Section 1 from Geneva Drive to Prima Avenue, Section 2 from Prima Avenue to Rontree Avenue and Section 3 from Rontree Avenue to Houghton Road.

In order to ensure more uniformity and better quality of the mix, a static mobile mixing plant was specified for production of the BSM.

Proper Recipe is decisive

Power Construction was appointed to carry out the construction of the works with Milling Techniks carrying out the production of the BSM using their Wirtgen KMA 200.

During construction, the stockpiled RA was sent for technical testing at BSM Laboratories in Durban. The design was carried out on three design options using the two dedicated stockpiles of materials from two sources which were created for the project by the City. The design options included:

  • 100% Reclaimed Asphalt
  • 100% Reclaimed Asphalt with 10 % crusher dust
  • 100% Reclaimed Asphalt with 25 % G4 gravel material

Based on the results obtained, the most cost effective option to yield a BSM 1 was the 100% Reclaimed Asphalt mix design using 2.1 % foamed bitumen with 1 % cement.

The batching plant was set up at the Ndabeni Roads and Stormwater depot in maitland. The depot provided sufficient space to establish the KMA 220 as well as allowing for the stockpiling of the unprocessed RA, screened RA and processed BSM. The specification called for crushing of the RA to remove the oversized fractions. An alternate proposal in the form of screening the material to minus 19 mm in place of crushing the material by the contractor was accepted provided the fines fraction (0.075 mm) met the specification of 4 %. This was monitored for the duration of the project with a fines fraction of between 3 % and 4 % recorded. The screened RA was processed using the KMA to form a BSM 1 which was stockpiled for up to 7 days at the depot

In order to ensure an adequate quality of the BSM and consistency within the mixing process, Power Construction, Milling Techniks and WorleyParsons created a quality system tailored for the BSM production using the KMA. This was implemented to ensure the mix met the BSM 1 specification throughout the project. Once the BSM was produced, the material was either placed on site immediately or protected and stockpiled at the Ndabeni Depot.

BSM quality check before paving is mandatory

The BSM was paved using a heavy duty tracked paver from Power Construction in two 100 mm thick layers in the same process.

The process used to get the required 100 % Minimum Dry Density (MDD) compaction was as follows:

  • Paving 100 mm thick BSM layer and allowing for bulking of 30 to 40 mm
  • Applying primary compacting using a 12 t tandem drum roller
  • Paving the second 100 mm thick BSM layer on to the lower half of the layer
  • Applying primary compaction using a 12 t tandem drum roller
  • Applying final compaction using two pneumatic tire rollers (27 t PTR) until compaction was achieved.

Before starting with paving and compaction, a testing of the BSM was undertaken by Soillab who established a testing rig in accordance with the TG2, 2009 specification. Acceptance control was carried out on the Indirect Tensile Strength (ITS) and MDD taken from the batching plant and site samples.

The three sections identified were constructed using similar techniques, however in Section 1 and 3, the BSM was opened to traffic immediately after construction and in some cases 24 hours after construction.

Project provides important insights for cold recycling applications

The Camps Bay Drive rehabilitation project allowed for numerous lessons when dealing with BSM’s and more particularly 100 % RA BSM’s. The following lessons were learnt during the project:

  • Static mobile mixing of BSM’s should be undertaken in the summer months in the Western Cape region due to the weather conditions. Low temperatures and high moisture contents result in a poorer quality product.
  • An impact crusher should be used to crush the oversized RA. This may create more fines in the mix as well as reduce the need for stockpiling of the oversized RA
  • Planning and training of the operators prior to the trial section is crucial as this product is not an asphalt material and different placement and compaction methods apply
  • The 100 RA BSM has voids within the mix and hence when inclement weather is eminent, the BSM should be sealed to prevent the ingress of water

Cold recycling with foamed bitumen: top quality at reduced cost

The following positives were established during the product when using the 100 % BSM:

  • The design is very versatile and minor changes to the RA and mix design do not have a significant effect on the quality of the BSM
  • The material behaves extremely well under early trafficking
  • There is a large cost saving when using the 100 % TA which amounted to approx. 2,95 Euro per m². This cost only includes the material cost saving and not additional traffic accommodation and time cost savings
  • The cost could be further reduced by producing the material closer to the site or mass producing the material as the greatest cost component of the BSM production is the haul of the RA and BSM to the site

Overall, the project was a major success. During the project, approximately 8,150 t of RA (4,200 m³) was processed using 165 t of bitumen and 78 t of cement. Using the RA within the pavement structure provides a much more cost effective and sustainable solution for the future with depleting aggregate resources.




WIRTGEN GROUP AT STEINEXPO 2017 WITH WORLD PREMIERE FROM KLEEMANN

The Wirtgen Group will be showcasing tailored solutions for recycled material processing and quarry applications when it exhibits products from Kleemann and Benninghoven at the industry trade fair in Homberg/Nieder-Ofleiden, Germany, from August 30 to September 2. The world premiere of the Kleemann MC 120 PRO jaw crusher will be center stage. Both the jaw crusher – operating as part of an interlinked machine combination additionally comprising the MCO 11 PRO cone crusher and MS 953 EVO screening plant – and the MBRG 2000 granulator will show off their high productivity at a live demonstration.

Heavy-duty MC 120 PRO jaw crusher for quarry applications
Industry professionals will get their first glimpse of the new MOBICAT MC 120 PRO mobile jaw crusher from Kleemann. Developed for use in quarries, the plant is extremely durable and engineered for a high throughput of up to 650 t/h. The heart of the system is the jaw crusher itself, which has been specially designed for processing hard rock. The Continuous Feed System helps to achieve the best-possible crusher capacity utilization. It regulates the feed of material as a function of its flow. To ensure the effective prescreening of fines, the MC 120 PRO is equipped with an integrated, double-deck prescreen with an extra-large screening surface.
The PRO series of crushers are operated using the intuitive SPECTIVE control concept. All plant functions and components are controlled via a touch panel.

MCO 11 PRO cone crusher is the perfect match
Kleemann is exhibiting another representative of the PRO series: the MOBICONE MCO 11 PRO. Like the MC 120 PRO jaw crusher, this cone crusher is likewise equipped with a powerful diesel-electric drive that supports external power supply. The cone crusher also achieves a high hourly output of up to 470 tons and is the perfect match for the MC 120 PRO in the secondary crushing stage. Because the drive unit is installed in the bottom part of the plant, the MCO 11 PRO has a low center of gravity and therefore greater stability, a combination that minimizes noise and vibration. All plant components are easily accessible from the ground or from generously dimensioned platforms for maintenance and fueling.

Flexible MS 953 EVO classifying screen
The MOBISCREEN MS 953 EVO mobile triple-deck classifying screen rounds out the Kleemann machine combination. The three interlinked machines will be demonstrating their performance live at Steinexpo. The MS 953 EVO is suitable for natural stone and recycling applications at changing locations. It can easily be transported and quickly set up for operation. At the same time, the plant achieves a very high output, processing up to 500 tons of material per hour with its 9.5 m² screening surface on the top deck.

Benninghoven: Resource-saving MBRG 2000 granulator
The MBGR 2000 mobile granulator from Benninghoven breaks reclaimed asphalt into its constituent parts without destroying the original grain structure, handling blocks with an edge length of up to 1.8 m. This gentle crushing technology creates the ideal conditions for almost complete recycling of RAP in an asphalt mixing plant. Another significant advantage of this crushing technology is the much lower quantity of fines it produces – a key advantage that almost completely prevents blockages of transport paths and the parallel drum inside the asphalt mixing plant. The granulator is ideal when it comes to creating new traffic arteries from more than 90% “reclaimed” roads.

Wirtgen Group experts on hand
Experts from Kleemann and Benninghoven will also be on hand at Steinexpo 2017 to offer professional advice and answer questions about the product range, special applications, technologies and service.

For further information
please contact:
WIRTGEN GROUP
Mineral Technologies, South Africa
Contact: Lantie Van Der Merwe +27 82 306 1707
E-mail: lantie.vandermerwe@wirtgen-group.com
www.wirtgen-group.com

Media contact:
Boitumelo Mogano
MoonDawn Media & Communications
Cell: +27 (0)76 733 2615
Email: boitumelo@moondawnmedia.co.za
Web: www.moondawnmedia.co.za







THE WIRTGEN GROUP TO JOIN WITH DEERE & COMPANY

WINDHAGEN, Germany (June 19, 2017) – The Wirtgen Group announced that it has signed a definitive agreement with Deere & Company to have Deere acquire the Wirtgen Group, a privately-held international company headquartered in Windhagen that is the leading manufacturer worldwide in the road construction industry.

Stefan Wirtgen, managing partner at Wirtgen, said, “The Wirtgen Group has a legacy of technology and innovation with market-leading products and a strong focus on the customer. As we looked to the future, we specifically chose Deere as the buyer because of our long-held respect for the organization and our full confidence that Deere is dedicated to the ongoing success of the Wirtgen Group and our employees worldwide.”

Jürgen Wirtgen, managing partner at Wirtgen, added, “Our company’s strength and success comes from dedicated employees, who are focused on helping customers succeed in the road construction industry. We believe this transaction allows the company to be successful well into the future – independent of our family ownership.”

Deere plans to maintain the Wirtgen Group’s existing brands, management, manufacturing footprint, employees, and distribution network. The combined business is expected to benefit from sharing best practices in distribution, manufacturing and technology as well as in scale and efficiency of operations.

The Wirtgen Group has five premium brands with market-leading positions across the entire road construction segment spanning processing, mixing, paving, compaction and rehabilitation. The Wirtgen Group has more than 8,000 employees and sells products in more than 100 countries.

Samuel R. Allen, Deere & Company chairman and chief executive officer, said, “The Wirtgen Group’s superb reputation, strong customer relationships and demonstrated financial performance are attractive as Deere expands its reach in construction equipment to more customers, markets and geographies.”

Max Guinn, president of Deere’s construction and forestry division, said, “The Wirtgen Group strengthens Deere’s strong position in the construction equipment industry, enhances our ability to serve customers across the globe and improves Deere’s competitive position through the addition of market-leading products.”
Guinn said spending on road construction and transportation projects has grown at a faster rate than the overall construction industry and tends to be less cyclical. He added there is recognition globally that infrastructure improvements must be a priority and roads and highways are among the most critical in need of repair and replacement.

The transaction is subject to regulatory approval in several jurisdictions. The companies said they expect to close on the transaction in the fourth quarter of the 2017 calendar year.

The Wirtgen Group (www.wirtgen-group.com) is an internationally operating group of companies in the construction machinery sector incorporating the traditional product brands: Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. As technological leader, the Wirtgen Group offers its customers mobile machine solutions for road construction and road rehabilitation, plants for mining and processing minerals or recycling material and for the production of asphalt.

For further information
please contact:
WIRGEN SOUTH AFRICA
Waylon Kukard
Sales Manager
Wirtgen South Africa
Cell: 0829291449
E-mail: waylon.kukard@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica/en/

Media contact:
Boitumelo Mogano
MoonDawn Media & Communications
Cell: +27 (0)76 733 2615
Email: boitumelo@moondawnmedia.co.za
Web: www.moondawnmedia.co.za

MOBILE SCREENING PLANT SET FOR LAUNCH IN SA

[Johannesburg, 24 May 2017]: Wirtgen SA, local subsidiary of the Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation as well as mining and mineral processing, will soon be launching the much anticipated Kleemann Mobiscreen MS 703 EVO to the South African market.

Developed and designed in Germany, the Kleemann MS 703 EVO is a triple deck mobile classification screen that precisely screens out almost all types of coarse natural stone, residual construction materials and iron particulates of up to 150 mm up to four fractions. Finding application in both the mining and construction sectors, this screening plant screens out material after the initial crushing process and offers superior performance, fuel efficiency and intuitive handling.

Measuring in at 1.520 m x 4.440 m with a 75 kW engine and with a feed capacity of 350 t/h, the MS 703 EVO comes with either diesel-hydraulic or diesel-electric drive as well as a large number of screening media to achieve a variety of final grain sizes and to take different feed material. Thanks to a generously proportioned screen casing, material is well-distributed across the screen surface and its built-in peripheral platform means the screening plant is easily accessible for maintenance and screen media changing.

The plant boasts a large feed hopper which can readily accept feeding by means of a wheel loader, an excavator or directly from a crushing plant. Both folding and vibration gates are optionally available. The plant also has a special space-saving transport position, so that the most compact dimensions can be achieved should the plant be required to move to a new site; this is complemented by quick set-up times and fast screen media change capability.

Classifying screens

The Mobiscreen series from Kleemann comes with classifying screens that are renowned for their inherent flexibility, which contributes to optimal functioning and resultant output values. Suitable for a host of applications, the MS 703 EVO’s adaptability is made possible by the variety of available screen casing sizes as well as the ease and speed with which it can be transported.

Screening media on a classifying screen plant are put to the test on a daily basis and are manufactured from a special wear-resistant spring wire steel or round wire to withstand the workload and to produce consistently accurate results. Double bracing at intersections makes high mesh stability – and therefore uniform screening – a possibility, which is also influenced by grain shape, moisture content as well as the loaded volume.

Various mesh shapes and dimensions are available, including square, rectangular and harp, depending on the required application:

Square mesh screen surfaces are the most commonly used and are predominantly used in applications where a cubic shape is required. Different wire qualities and thicknesses are available: the thicker the wire, the longer service life it will have; the thinner the wire, the higher production it will ensure. Rectangular mesh screen surfaces are for screening cubic grain sizes and are often used to sort natural gravel at high throughput. The Harp screening media are used for screening damp material and difficult screening products. They boast a self-cleaning mechanism through the natural vibration of the longitudinal wires and should be inserted at the lower deck of the screen. The harp screen surface is available in different versions, including W-harp, S-harp, and Varia harp.

With fast set-up time, operator-friendly design and cost-saving features, the Mobiscreen MS 703 EVO is backed not only by Kleemann’s exacting standards, but by fully qualified service technicians available 24 hours a day as well as all recommended spares available at Wirtgen SA’s Pomona offices. Set to be launched in South Africa on 9 June 2017, the local market can expect to learn more about this dynamic new screening plant by means of road shows, demonstrations and site visits co-ordinated by Wirtgen SA.

[ENDS]

About Wirtgen SA

Wirtgen SA is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

Wirtgen SA contact:

Lantie van der Merwe
Sales Executive – Kleemann
Tel: +27 (0) 11 452 1838
Cell: +27 (0) 82 306 1707
Email: lantie.vandermerwe@wirtgen-group.com
Web: www.wirtgen-group.com/southafrica/en/

Media contact:

Boitumelo Mogano
MoonDawn Media & Communications
Cell: +27 (0)76 733 2615
Email: boitumelo@moondawnmedia.co.za
Web: www.moondawnmedia.co.za



THREE DECADES OF EXPERIENCE MAKES HAMM THE WORLD LEADER IN OSCILLATION COMPACTION

Over 30 years ago, HAMM became the first roller manufacturer to offer an oscillation drum for tandem rollers, and these rollers have become an integral part of its product offering. In the past five years alone, the specialists for compaction technology have delivered more than 3,000 machines with this innovative technology. Today, one in four of the tandem rollers made by HAMM is equipped with an oscillation drum. With more than 30 models to choose from, HAMM has by far the widest offering of oscillation rollers in the world. And only HAMM builds oscillation tandem rollers in the compact class, as well as soil compactors with oscillation compaction capability.

Successful pioneers

In the 1980s, HAMM pioneered the development of oscillation compaction and was long the only supplier in the market. Customers were quick to appreciate the benefits of this technology. In the meantime, oscillation has proved itself and become successfully established in the market.

Fast, cost-effective and high-quality

The reason for this success is simple: oscillation rollers make for fast, cost-effective and high-quality dynamic compaction. In particular, tandem rollers with one oscillation drum and one vibrating drum achieve at least the same degree of compaction as double vibrating drum rollers, but with fewer passes. Another benefit is the extremely low vibration provided by oscillation, making dynamic compaction on bridge overlays, of thin layers, and in sensitive areas — such as near hospitals, city centers, rail tracks, or industrial plants — possible for the first time. The scope of applications is enormous.

Compaction at every construction phase

Another bonus is that oscillation rollers can start dynamic compaction directly behind the paver (→ breakdown phase). They can then also deal with the main compaction (→ intermediate phase). And even with lower asphalt temperatures at the end of compaction (→ finish phase), oscillation ensures an increase in compaction without crushing the aggregate. Overall, when using oscillation rollers, the time available for compaction is significantly greater than with vibratory rollers.

Experience shows

When building oscillation drums, HAMM – unlike its competitors, which have all entered the market with this technology in recent years only – can draw on decades of experience. And it is precisely this experience that makes the difference, as Richard Evans, vice president, HAMM, explains: “You can copy technical solutions, but you can’t copy experience.”

Thanks to its wealth of experience, HAMM possesses extensive know-how in application technology. This knowledge is not confined to a few specialists in the factory, but extends to the subsidiaries all around the world. Due to the large number of oscillation rollers on the market, spare parts availability is also very high. In addition, the service engineers all over the world are thoroughly familiar with the technology and trained with regard to oscillation.

Comprehensive portfolio for asphalt paving and earthwork

The HAMM portfolio encompasses tandem rollers for asphalt paving ranging from 2.5 t to 15 t. When it comes to the pivot-steered rollers in the DV+ series, a popular choice for demanding road building projects, the share of oscillation rollers is particularly high: in 2016, around 40 percent of all DV+ series rollers were delivered with oscillation drums.

The oscillation rollers for the compact class from 2.5 to 4.5 t also experience great market demand. Hardly surprising, because HAMM is the world’s only manufacturer in this market segment. This also applies for earthwork. Customers worldwide seeking a solution for compactors with the facility to choose between oscillation and vibration find that only HAMM has the answer in the form of its VIO drums.

The oscillation principle

But what exactly happens in an oscillation drum, and how does oscillation differ from vibration? With vibration, a single unbalanced shaft generates the upward and downward movement of the drum, causing it to strike the ground at a rapid rate. In oscillation drums, on the other hand, two unbalanced shafts rotate synchronously, driven by a toothed belt. The unbalances are offset by 180° relative to one another. As a result, the drum performs a rapidly alternating forward/backward rotary movement.

Due to this movement, the drum directs the compaction force into the substrate tangentially to the front and rear in the form of shear forces. Here, unlike with vibrating drums, the compaction force acts continuously on the substrate because the drum is in contact with the ground at all times. This is why oscillation rollers compact dynamically as well as statically with their intrinsic weight the whole time.

Maximum wear resistance

HAMM’s experience of more than 30 years is also reflected in the way in which the technology is incorporated in the design. An example of this is the drum shell. On oscillation drums, it is inevitably subject to greater stresses, due to the constant ground contact, than is the case with vibrating drums.

Thanks to ongoing product and material development, the operating life of HAMM oscillation drums is today nearly the same as that of vibrating drums. This is made possible by using highly wear-resistant fine grain steel for the drum shell. Its material thickness is more than 150% greater than that of comparable competitors’ machines.

In addition, an integral reinforcing ring ensures that the drum is extremely hard-wearing. This is why HAMM confidently provides a remarkable warranty against wear of at least 4,000 operating hours. With this warranty, the manufacturer surpasses any other serious offer on the market by a wide margin.

Quality thanks to chamfered drums

To ensure that the drums leave no impressions in the still soft asphalt, especially in curves, HAMM gives all drum edges a slight chamfer. Impressions of this nature have to be re-rolled afterwards, wasting time. Otherwise, they remain visible in the asphalt and compromise quality. Both issues are avoided from the outset thanks to HAMM’s design solution. This chamfer also can be found on all of HAMM’s vibrating drums.

Low-maintenance operation

A glance at the exciter system drive inside the oscillation drum also shows that it is based on a great deal of experience. HAMM has continuously optimized the position of the unbalanced weights in the oscillation drum to enable the resulting forces to be utilized as effectively as possible.

At the same time, HAMM’s oscillation drums are designed to require very little maintenance. The toothed belt, the core element of the drive, has been perfectly attuned to the overall system: its operating life corresponds to that of the entire drum. Checking the belt tension after 2000 operating hours is all that is recommended.

Use for all layers

Oscillation rollers can be used to compact all earthwork and road building layers. They come into their own in earthwork, where re-loosening of the upper layers has to be effectively prevented, such as in garden and landscaping work. Another important application is the compaction of soils in vibration-sensitive areas, for example above gas, water and other pipework.

In asphalt paving, base courses, binder courses and surface courses can be reliably compacted with oscillation rollers. They perform especially well in the compaction of generally hard-to-compact asphalts such as SMA or in the case of polymer-modified material mixes. This is because, in contrast to vibration compaction, the effective direction of the vibrations during oscillation promotes the desired redistribution of long-chain binding agents.

Other applications include work on thin layers (surface courses, thin overlays), in vibration-sensitive areas (bridges, confined urban spaces, buildings or parking decks) and wherever the mix cools quickly (thin layers, windy or cold environments). Also of particular importance is joint compaction where the hot asphalt is to be compacted without damaging the adjoining cold asphalt.

Benefits of oscillation

Oscillation offers a wide range of benefits, enhancing efficiency, quality, productivity and profitability. Here are the most important ones:

Benefit 1: High compaction power – great efficiency.
Oscillation rollers compact very quickly. Or to put it differently: their compaction power is very high. The reason for this is the superimposition of dynamic shear forces with the permanent load from the roller’s own weight. As a result, considerably fewer passes are needed, especially on large areas.

Benefit 2: Easy operation. HAMM makes use of the laws of physics to generate vibrations in such a way that the oscillation roller is extremely easy to operate. Simply switch the machine on, and there’s nothing more for the operator to do. The appropriate amplitude is set automatically according to the rigidity of the material to be compacted. This happens so quickly that compaction is always adjusted perfectly, even with varying substrates. In this way, HAMM has eliminated the risk of operating errors due to incorrect settings.

Benefit 3: Smooth, skid-resistant surfaces. Oscillation rollers produce surfaces with excellent longitudinal evenness, resulting from the drum remaining in contact with the ground at all times. Surface rippling, on the other hand, does not occur, not even at high working speeds. Asphalt compaction with oscillation also provides good initial skid resistance, because the oscillating movement of the drum rubs off asphalt from the top surface of the pavement.

Benefit 4: Low vibration emissions. Oscillation drums do not lift off the ground while compacting. In comparison to vibrating drums, with oscillation drums only around 15 percent of the vibration is directed into the substrate around the roller. This means that oscillation rollers can also be used without problems for dynamic compaction near vibration-sensitive buildings or installations. Because the rollers are also much quieter, they help to protect the environment. Another benefit provided by low-vibration compaction is that it reduces component wear and is also perceptibly less tiring for the roller drivers.

Benefit 5: Material-friendly compaction. With vibration compaction, once a certain level of rigidity has been achieved, there is a risk of destroying the material structure or crushing the aggregate. This is not the case with oscillation: it ensures that the aggregate particles are redistributed undamaged. In this way, oscillation avoids detrimental aggregate crushing and over-compaction. Moreover, oscillation compaction produces watertight, long-lasting joints without damaging the cold asphalt.

Benefit 6: Wider temperature window. Oscillation widens the temperature window in which compaction is possible because even at lower temperatures, it can be used to compact without damage. For this reason, oscillation is particularly suited to the compaction of thin layers or on fast-cooling surfaces such as on bridges. Moreover, this characteristic increases flexibility during the construction process.

Customers worldwide are moving to oscillation

As the examples show, dynamic Dynamic compaction with oscillation has many intrinsic benefits and increases road construction quality. This is common knowledge among construction authorities and private customers alike.

That’s why it’s no surprise that both pavement owning agencies and contractors alike increasingly specify the use of oscillation rollers for compaction when quality, performance and durability are paramount.

Very recent examples include the construction of the Formula 1 motor racing circuit in Baku (Azerbaijan), where medium and heavyweight tandem rollers were used, and refurbishment work in the city of Vienna (Austria), for which the use of compact rollers with oscillation was specified.

Last but not least, oscillation has also proved its worth in large projects. Here, the rapid increase in compaction ensures an optimized process that can be carried out with fewer rollers.

Further information is available from:

HAMM AG
Gottfried Beer, Stephanie Mayer
Hammstraße 1
95643 Tirschenreuth
Germany
Telephone: +49 (0) 9631 801-95 / 98
Fax: +49 (0) 9631 801-43
E-mail: gbeer@hamm.eu, smayer@hamm.eu
Web: www.hamm.eu

WIRGEN SOUTH AFRICA

Waylon Kukard
Sales Manager
Wirtgen South Africa
Cell: 0829291449
E-mail: waylon.kukard@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica/en/

Media contact:

Boitumelo Mogano
MoonDawn Media & Communications
Cell: +27 (0)76 733 2615
Email: boitumelo@moondawnmedia.co.za
Web: www.moondawnmedia.co.za







Premium pays superior dividends

Over its 17-year existence, Road Milling and Sweeping has carved itself a niche rental business to become the largest privately-owned operator of milling machines in South Africa. With a clear understanding that the success of a business of this nature largely depends on machine uptime, the company has vested its trust in premium Wirtgen milling machines over the years, a decision that is continually paying dividends.

From humble beginnings back in 1999 with a single Wirtgen 1000C milling machine, Road Milling and Sweeping (RMS) today owns a strong 21-unit fleet of milling machines, making it the single biggest privately-owned operator of such specialised gear in South Africa. Founded by Cecil Aling and a business partner at the time, today the family-owned business is being steered by two of Cecil & Glynn Aling’s three daughters, Leigh Cameron and Lesley Kafka, who share their father’s passion for anything mechanical, but with a premium taste, of course. RMS has stuck with the Wirtgen brand for its milling equipment needs over the years, purely driven by the understanding that premium calls for premium capital outlay, but the returns, in the long run, are massive.

Road Milling’s core business is the rental of milling machines for rehabilitation of asphalt and concrete roads. The company operates on a national basis and has recently successfully completed cross-border contracts. “We work all over South Africa in terms of the milling work we do. In the past year, we have done quite a lot of cross border work,” says Lesley Kafka, general manager of RMS. “We still have got ongoing work in Lesotho that will pick up in 2017. We have also worked in Namibia, Botswana, Swaziland and Malawi.”

Kafka foresees increased cross-border work moving forward as most of the South African civil contractors spread their wings into the rest of Africa for greener pastures. This is considering that most of the cross-border contracts RMS has are with local South African companies doing work outside the country. According to Kafka, 98% of the company’s cross-border work is through the South African contracting fraternity working elsewhere in Africa.

Sticking to core business

Over the years, RMS has stuck to its core niche business of renting out milling machines, but with a few other value adds such as lowbed trucking services, road sweeping, tippers and water carts. The company now owns its own three lowbed trucks used mostly for transporting its rented milling machines to sites, but these can also be outsourced to any other customers in need of lowbed trucking. However, Kafka says sticking to the milling business only is a difficult decision from a strategic point of view. “We ask ourselves whether we need to stick to our niche or diversify the business,” says Kafka.

“Diversification has got its own pros and cons. Sometimes you become too thinly spread. Ours is a capital intensive business, so to diversify you need to invest huge amounts of capital into equipment. Diversifying is also a bit challenging in the sense that all of our people are focused on milling, our operators know how to mill and are not versed with any other work,” reasons Kafka.

But, Cameron financial manager believes that if ever the decision to expand the product portfolio is made, the immediate possible and closest option would be recyclers. She believes that recycling is aligned to what the company does and will allow it to continue dealing with the very same customer base.
RMS reports increased demand for its milling machines in the past 12-18 months. “We believe we had a fantastic year in 2016 in terms of being able to keep our machines on hire,” says Kafka. Demand is mostly driven by smaller civil engineering contractors. This is in direct contrast to some five years ago where the company would mostly deal with the bigger civil contractors.

Understandably so, this trend is because of the way civil projects are being packaged in South Africa at this stage. Projects are being packaged into smaller lots to allow smaller and upcoming contractors to have a share of the government infrastructure spend. Most of these smaller contractors lack the financial muscle to invest in their own specialised gear such as milling machines, hence the increased demand for RMS’s services.

Success drivers

For a rental business of this nature, machine uptime is a key success driver. For that reason, RMS, from its inception, has always purchased Wirtgen milling machines only. All its 21 milling machines are Wirtgen machines. Kafka explains the reasons behind the loyalty to the brand. “We started out with a Wirtgen and created a strong bond at the time,” she says, adding that the relationship has been further strengthened over the years.

RMS has also built a strong technical competence on Wirtgen machines with its own mechanical workshop equipped with strong technical capability to service these machines in-house. Led by Errol Edwards, workshop manager at RMS, the technical knowhow on Wirtgen machines goes beyond service and maintenance to include complete rebuilds of the machines in-house.

Another reason of sticking to Wirtgen, is the fact that these German-made milling machines have a good reputation among RMS’s customer base. “Wirtgen machines are popular products among our customers, in terms of their quality of work and productivity,” says Kafka.

The quality of the build and durability is another key driver for sticking it out with this range of machines. This is reinforced by the fact that the first Wirtgen 1000C which kicked off the business back in 1999 is still in operation today, and works beyond expectations.

Meanwhile, a good product is as good as its service, and aftermarket support from Wirtgen South Africa has kept this relationship intact over the years. Waylon Kukard, Wirtgen sales manager, who has become more than just a business partner, is always at hand to respond to RMS’s needs, be it technical queries, parts issues or even advice, especially at a time when the company is grappling with the idea of diversifying its product range. “We have become friends along the way. We work closely together on RMS’s plans for the future,” says Kukard.

Strong maintenance regime

Prior to the purchase of its new machine in July 2016, the previous machine RMS bought was back in 2013. According to Cameron, that speaks volumes about the quality of the build of the machines, but more importantly the strict service and maintenance regime. “Due to our strong focus on maintenance, even our first machine is still running perfectly beyond our customers’ expectations,” she says.

The longevity of this gear is also buoyed by the fact that these machines are rented out with an operator. Every operator sticks to their own machine, which, over the years, has become their daily office. “Our operators are very territorial about their machines and they look after them,” says Kafka.

A strict service and maintenance regime is followed, according to Edwards. Services, including oils, hubs, gear boxes and engine oil, are done at every 250-hour intervals. These intervals are maintained even when machines are out on sites. These services are undertaken on sites 95% of the time. Major services, such as drums and hydraulics, are done once a year, especially during the December downtime period when most machines return to the workshop.

Wirtgen undertakes services for all machines under warranty. All services are then done in-house when machines are off warranty. Continuous training of the 25 operators is also a key focus for the company, says Brian Manganyi, operations manager at RMS. It is this thorough training regime that has seen Manganyi himself raising through the ranks over the years when he started as a security guard, before he became a foreman, a supervisor and currently the operations manager.

Looking ahead, Kafka and Cameron convinced that the business will continue on a good course in 2017. “Our vision is to continually strive for excellence to further build our reputation. We always go an extra mile for our customers, delivering more than they expect.” This goes beyond the equipment to the people, constantly focusing on the people who make it happen on the ground. “Being a smaller, family-owned business, allows you to have that desire to always go out of your way for customer service.”

For further information

please contact:
Wirtgen SA contact:
Calvin Fennell
Business Development Manager
Tel: 011 452 1838
Cell: 072 721 3951
Email: Calvin.Fennell@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za







WIRTGEN 2200SM SURFACE MINER PROVES ITS METTLE IN SA DEMO AND TRIALS

[Johannesburg, 21 February 2017]: Wirtgen SA, local subsidiary of the Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation, as well as mining and mineral processing, recently put its 2200SM surface miner to the test by conducting a series of demonstrations and trials under local conditions.

Showcasing the 2200SM to various local mining companies, Wirtgen SA undertook to demonstrate to a discerning audience the capabilities of the machine in supporting and enhancing profitable mining operations in South Africa. Mike Newby, Mineral Technologies at Wirtgen SA, comments, “We wanted to show industry leaders how easily and effectively the 2200SM mines coal and selectively mines material by separating thin seams so as to minimise contamination. The machine also cuts, crushes and directly loads the coal ore in a single operation.”

“This means that delivering a final, sellable product without the need to drill, blast, load, and primary crush is possible,” says Newby, adding, “Along with drastically reduced washing costs and processes, product yields are significantly increased, making for a machine with attractive operational costs and production rate capabilities.

Tried and tested

Wirtgen SA’s 2200SM demonstrations began at two different sites in Mpumalanga, where the machine’s flawless performance proved its worth in open cast coal mines. 96% of the mined material was <53 mm and fines content (that is <1 mm size product) was less than 14% without the need for drilling, blasting and primary crushing – well within expected result parameters. Both sites were prepared by cleaning out a blocks measuring about 50 m x 100 m directly on the coal seam, after which the 2200SM took centre stage, cutting and crushing the coal and loading it directly onto the mines’ 40 ton articulated dump trucks for hauling to the final stockpile. Instantaneous production rates reach over 800 t/h in most cases and after taking into account the final effective production rates after a shift, including standard production stoppages and delays, the average production rate was more than 400 t/h. “The machine was also put to the test in sandstone interburden and with great results,” notes Newby. “This means that thin seams of coal, waste and interburden can be effectively mined selectively, easily separating the product from the waste,” he says. Wirtgen SA’s final demonstration of the 2200SM took place at another open cast coal mine in Delmas with the primary objective to improve the yield at the production plant. “The 2200SM surface miner mined highly selectively, separating coal from waste and ensuring that good, clean coal was sent to the plant with minimal contamination and no crushing required,” remarks Newby. “Once again, the machine proved its worth in this context and mine management expressed its satisfaction with the machine’s performance, committing to implement the 2200SM in future projects.” Wirtgen SA’s demonstrations and trials of its 2200SM proved highly successful and illustrated how viable an alternative this machine is to open cast mining methods. “These machines offer real capital cost savings at initial mine set-ups, improve operational yields, mine selectively, are safe and easy to operate, eliminate the need for drilling, blasting, loading, hauling and primary crushing, and significantly reduce the costs of washing,” says Newby, concluding, “Wirtgen has proven its worth the world over and we’re proud to now have the nod from an astute South African market as well.”

About Wirtgen surface miners

Wirtgen surface miners offer cutting widths ranging from 2.20 m to 4.20 m and cutting depths of between 20 cm and 83 cm and the company is the only manufacturer covering a scope of performance ranging up to 3000 t/h in coal mining with direct loading by conveyor belt.

Four models make up the product range:

• The 2200SM (with a cutting width of 2.2 m and a depth of up to 30 cm);
• The 2200/3.8 SM (with a cutting width of 3.8 m and a depth of 30cm);
• The 2500SM (with a cutting width of 2.5 m and a depth up to 65cm);
• And the big 4200SM, which cuts 4.2 m wide, up to 83 cm deep and can deliver up to 3000 t/h in coal.

Wirtgen currently has over 500 surface miners in operation around the globe, with more than 130 specifically mining coal in Mozambique, the USA, India, Australia, Europe, China, and more. Other applications include bauxite, limestone, iron ore, gypsum, salt, phosphate, oil sands, kimberlite, mudstone and even granite.

[ENDS]

About Wirtgen SA

Wirtgen SA is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

Wirtgen SA contact:

Mike Newby
Mineral Technologies
Tel: +27 (0) 11 452 1838
Cell: +27 (0) 82 788 8184
Email: mike.newby@wirtgen-group.com
Web: www.wirtgen-group.com/southafrica/en/about-us/wirtgen-south-africa/

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za







Media Advisory
Approved

WIRTGEN SURFACE MINING: MAXIMISING COAL RECOVERY BY MINIMISING CONTAMINATION AND FINES CONTENT.

[Johannesburg, 29 July 2016]: The Wirtgen Group, global leader in mobile machine solutions for road construction and rehabilitation, as well as mining and mineral processing, has recently conducted several large-scale field tests on material degradation. Findings confirm that Wirtgen surface miners offer significant advantages in the reduction of contamination experienced in normal open cast mining methods.

In the coal mining industry, the breakage of coal occurs throughout production, from extraction at the face to end use. While some of this breakage is intentional, such as during extraction and crushing, breakage occurring during transportation, stockpiling, sizing or washing is not desired. Generally speaking, breakage behaviour depends heavily on geology, but mining technology of today offers the option to reduce the amount of fines generated during production to maximize coal recovery for optimised operation as well as minimizing contamination of mined coal to increase yields.

Most coal mines measure the particle size distribution (PSD) of their plant feed to obtain information about the suitability of the feed for their processes, especially with regards to fines content. However, few mines know precisely where these fines come from and even fewer measure the fines content at the face to compare it with the plant feed data and to optimise the connecting processes.

According to Calvin Fennell, Wirtgen SA Business Development Manager, “There are a number of challenges associated with failing to optimise this connecting process. The cost of washing coal fines is higher because of the intensive processes used and the product losses that occur, all resulting in a lower rate of recovery. With increased losses, more tailings must be suitably disposed of and coal that does not meet the customer’s size requirements cannot be sold. Furthermore, coal mines have the tendency to retain moisture, which can cause problems in the downstream process.”

“On the other hand, optimising fines content and reducing contamination of the run-of-mine (ROM) coal offers numerous savings and benefits, such as a lower level of respirable and airborne dust, increasing workplace safety, reducing the risk of coal dust explosions and improving yields,” comments Fennell.

In an effort to serve its customers better, Wirtgen recently conducted a number of large-scale field tests on material degradation. The company found that its surface miners offer significant advantages when it comes to minimizing contamination by selectively mining coal seams to separate the ore from the waste.

Wirtgen surface miners

A Wirtgen surface miner is a crawler-mounted mining machine with a rotating cutting drum for rock penetration mounted at the centre of gravity, a configuration that ensures that the full weight of the miner machine can be transformed into rock penetration force. The cutting drum transfers the material onto a conveyor belt from which it is directly loaded onto a dump truck.

The machine mines layer by layer down to the required depth and the cutting depth can vary according to seam thickness. “Even thin seams of just 10 cm thick can be mined and precisely separated from the layers above and below. This level of precision makes for a cost-effective and more environmentally sensitive approach to mining of mineral deposits without any drilling or blasting,” Fennell notes.

PSD field tests

In its many field tests over the years on PSD and material degradation, coal and sedimentary ore from eight different pits were analysed to obtain their PSD. Close to 8000 tons of material was screened to compare the material produced by surface miners versus conventional mining methods.

In one coal mine, Wirtgen surface miners operated alongside dozers that employed the conventional rip-and-stack method and in view of the coal prices at the time, the mine was optimising every step of the operation. This included optimising the process for target size material, enabling most of the material to be processed in the cheaper coarse circuit of the processing plant. Reducing crushing costs was also an objective.

“Once again, the test proved the suitability of the Wirtgen surface miner for this type of operation,” says Fennell, explaining, “The machine delivered coal with a lower fines level and more target size material than the conventional dozer rip-and-stack method. In fact, out of the 1500 t/h of coal delivered from the dozer to the processing plant, 225 t/h were fines smaller than 2 mm, but with the surface miner, this figure is closer to 185 t/h. This means that 22% less coal had to be washed in the fines circuit and could be washed in the cheaper coarse circuit. In terms of fines smaller than 1 mm, by using the Wirtgen surface miner, the plant could process 33% less fine material.”

The Wirtgen surface miner delivers more than 70% target size coal (2-40 mm), while the dozer ranges at less than 58%. Savings are also enjoyed in the crushing stage, where only 17% of the material from the surface miner has to be crushed, as opposed to more than 26% when processing dozer coal, resulting in more fines that have to be processed.

In another trial location with sedimentary ore deposit mined using surface miners as well as the conventional drill-and-blast method, the surface miner was able to continually feed material with a < 1 mm fines level as low as 15% to the processing plant. The normal plant feed (includes material of drill-and-blast and surface miner operation) contained 25% and more fines < 1 mm.

Impact of rehandling

Rehandling contributes significantly to material degradation occurring during the mining process. Simulating this process, Wirtgen conducted a study to establish the amount of material degradation that occurs during rehandling.

For simulation purposes, 80 tons of material was loaded by a wheel loader and run through a screening plant several times. With every throughput, the amount of fine material increased significantly and during five test cycles in coal, the amount of material < 4 mm increased from 19% to 26%, representing an increase of 34%. A similar result was found with sedimentary ore in that the fine fraction increased by 24% during five test cycles. “None of the steps in the simulation (loading, transport to the screen deck, sizing on the screen deck itself) involved the high material stress levels that would be induced, for example, by a dozer moving on stockpiled material,” comments Fennell. “Nevertheless, significant material degradation was measured during the simulation, leaving one to assume that the material degradation that takes place during stockpiling results in an even higher increase of the fine fractions,” he adds. Keeping in mind that even this level of ‘soft’ rehandling causes significant material degradation, it is important to minimise the number of rehandling steps, each of which contribute to processing costs. "This is where Wirtgen surface miners offer a two-fold advantage: Material mined with a surface miner has not been blasted, but cut out of the ground by the rotating cutting drum, which means that the level of fines is already low; and as the material is loaded for transport, rehandling is kept to a minimum, contributing further to a low level of fines. With a view of the complete mining operation, it is clear that a surface miner simplifies mining operations and reduces the number of process steps tremendously, resulting in immediate cost savings,” Fennell says. The Wirtgen surface mining concept is no longer an unknown in the southern African mining sector. Surface mining has proven to be a viable alternative in South African open-cast mines, most especially in coal mines, where these machines really prove their worth. “Wirtgen SA is engaged in extensive talks with various mining companies about solutions for their greenfields and existing mines,” remarks, Fennell, concluding, “Wirtgen surface miners are set to revolutionise the open-cast mining industry in southern Africa, as it has done across the world, by addressing the need for safer, more environmentally friendly, effective and efficient mining by improving yields.” [ENDS]

About Wirtgen SA

Wirtgen SA is the local partner for the Wirtgen Group’s sales and service offering in South Africa. Wirtgen Group offers a broad range of services tailored to individual requirements for all areas of road construction as well as the mining and processing of pay minerals. With passion and know-how, our experienced team ensures your success every single day.

More than just a machine supplier, for Wirtgen Group, the delivery of a machine marks the beginning of a long-standing service partnership. Our team of service experts is always on hand to answer any questions concerning the machine and its operation. Short response times and fast solutions are guaranteed by our experienced service specialists. In addition, we remain in close contact with the Wirtgen Group’s headquarters to ensure comprehensive support whenever it is needed.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating the traditional brands, Wirtgen, Vögele, Hamm, Kleemann and Benninghoven. As a technological leader, the company offers its customers mobile machine solutions for road construction and rehabilitation as well as for mining and processing minerals.

Wirtgen SA contact:

Calvin Fennell
Business Development Manager
Tel: 011 452 1838
Cell: 072 721 3951
Email: Calvin.Fennell@wirtgen-group.com
Web: http://www.wirtgen-group.com/southafrica/en/about-us/wirtgen-south-africa/

Media contact:

Bridgette Macheke
MoonDawn Media & Communications
Cell: +27 (0)73 400 1549
Email: bridgette@moondawnmedia.co.za
Web: www.moondawnmedia.co.za