Milling and mixing rotors for cold recyclers and soil stabilizers

DURAFORCE - A single rotor catering to all requirements

Challenging operating conditions such as the powerful cold recy-cling, granulation or stabilization of coarse-grained soils make ex-treme demands on the cutting tools. This calls for perfectly matched components designed to meet the highest performance requirements. They can be relied on to provide high milling and mixing performance while ensuring maximum resistance and durability at the same time.

The original WIRTGEN DURAFORCE milling and mixing rotor im-presses with extreme wear resistance, impact strength and frac-ture strength for all applications in soil stabilization and cold recycling: a single rotor catering to all requirements.

Outstanding features of the DURAFORCE milling and mixing rotor
Multipurpose milling and mixing rotor
High performance and perfect mixing results
Extended service life and maintenance intervals
Powerful mixing process
Robust design
Extended service life of bottom part
Easy replacement of the heavy-duty edge ring segments
High-performance soil stabilization

Soil stabilization, which is in use around the globe, represents the ideal solution for converting subsoils of insufficient bearing capacity into soils suitable for placing and compacting. In the process, a wide variety of different types of soils need to be processed which may be highly cohesive, abrasive or even interspersed with coarse-grained rock.

Requirements on the milling and mixing rotor:
  • Effective splitting and crushing of the soil to optimize binder effectiveness
  • Uniform distribution and homogeneous mixing of binders and, where appropriate, water to produce a mixture of high strength
  • Maximum cutting performance even in tough, hard soil to ensure high productivity and low fuel consumption
  • High fracture strength when operating in soils interspersed with coarse-grained rock to ensure extended uptimes
  • High wear resistance in abrasive, cohesive soils to ensure maximum economic efficiency
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The tried-and-tested WIRTGEN DURAFORCE milling and mixing rotor meets every challenge in soil stabilization and is the ideal candidate to convert even the most difficult soils into construction materials of superior quality.

Environmentally friendly cold recycling

Cold recycling and granulation are also internationally established construction processes. Distressed asphalt pavements comprising the most diverse types of rock and the underlying gravel layer are milled, usually mixed with added binders to produce a homogeneous material and then placed again in an in-situ process.

Requirements on the milling and mixing rotor:
  • Steady milling process to prevent oversized particles and to ensure high-quality results
  • High milling performance and low wear even in hard, abrasive material to ensure high economic efficiency
  • Compliance with the specified grading curve to ensure the permanent structural integrity of the new base layer
  • Homogeneous mixing of the binders to ensure high adhesion (bonding strength) between the individual particles and thus maximum bearing capacity
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The DURAFORCE milling and mixing rotor also handles the specific requirements of cold recycling. Users benefit from maximum performance, an extended service life and highest quality of the new base layers.

Unrivalled expertise from a single source

WIRTGEN offers high-performance cutting systems from a single source. From a single source means perfectly matched components and consistently impeccable quality. The DURAFORCE milling and mixing rotors combine expertise gained in many decades with mature manufacturing methods and forward-thinking technologies. Field experience and customer feedback are important factors feeding directly into the process.

Solution-driven engineering

State-of-the-art work equipment – such as professional simulation tools – is an essential ingredient of WIRTGEN’s standard tools of the trade. It forms an integral part of the highly complex engineering process to determine the ideal solution. A prime example of this is the holder base. In combination with the selected alloy, its defined geometry results in high wear resistance, the best possible weldability and even load distribution, thus offering reliable protection against excessive loading of the holder base. High shear forces, in particular, are deflected most efficiently in this way.

Tried-and-tested forging process

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

Automated welding processes

Final welding of the quick-change toolholders and holder bases on the DURAFORCE milling and mixing rotor is effected using welding robots. Our welding robots provide a maximum degree of process reliability, precision and quality of the welding seams, guaranteeing fast and efficient production processes.

Precise balancing

The milling and mixing rotors, which can weigh up to 4,500 kg, operate at significantly higher milling speeds than the milling drums installed in cold milling machines. That is why each single rotor produced at the WIRTGEN plant is balanced with meticulous care. The resulting perfect concentricity of the rotor not only considerably extends the useful life of the entire machine but also protects the machine operator from vibration.

Brochure

Click here to download the brochure on the DURAFORCE milling and mixing rotor.

English (PDF 5 MB)
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