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How cold in-situ recycling works

Cold in-situ recycling with CR series machines

Cold recycling with the integrated paving screed

If required, cement is pre-spread by a STREUMASTER binding agent spreader which is followed by water and binder tanker trucks. The milling and mixing rotor of the W 240 CR / W 240 CRi granulates the asphalt pavement layers. At the same time, the cement is mixed in and the water and bitumen emulsion or foamed bitumen are sprayed into the mixing chamber via injection bars. The processed construction material is conveyed to the rear of the machine by the primary conveyor and paved true to grade and slope by the integrated VÖGELE paving screed with a spreading auger. HAMM rollers then carry out the final compaction.

Material processing with the W 240 CR / W 240 CRi (downcut)

The heavy-duty milling and mixing rotor granulates the damaged asphalt pavement. The granulated material is homogeneously mixed with a binding agent and water sprayed into the mixing chamber to produce the new mix on the spot.

The helical design of the milling and mixing rotor transports the mix to the centre and then to the paving unit via the primary conveyor. The spreading auger distributes it evenly in front of the variable paving screed, which ensures that the mix is paved true to line and level.

Cold recycling with built-in rear loading

If required, cement is pre-spread by a STREUMASTER binding agent spreader which is followed by water and binder tanker trucks. The milling and mixing rotor granulates the asphalt pavement layers. At the same time, the cement is mixed in and the water and bitumen emulsion or foamed bitumen are sprayed into the mixing chamber via injection bars. The conveyor unit transfers the processed construction material directly into the material hopper of the VÖGELE asphalt paver, which then paves it. HAMM rollers then carry out the final compaction.

Material processing with the W 380 CR / W 380 CRi (downcut)

The heavy-duty milling and mixing rotor granulates the damaged asphalt pavement. The granulated material is mixed with injected binding agent and water in the mixing chamber, thus creating a new homogeneous mix in an in-situ process.

The helical design of the milling and mixing rotor transports the mix to the centre and then to the asphalt paver’s material hopper via the primary conveyor and discharge conveyor. The paver then paves the surface true to line and level.

Further potential applications

Lateral pre-milling and recycling with discharge conveyor and paver

Cold milling with discharge conveyor and truck

The advantages of high-performance cold recyclers

As a pioneer in cold recycling, WIRTGEN has a burning passion for the creation of efficient processes. The technological leadership we have acquired in this complex field enables us to maintain the functional properties of roads over the long term.

Recyclers achieve high production rates that significantly reduce construction times compared to most alternative rehabilitation methods.

During working hours, traffic is routed in a single lane on the other side of the road past the building site.

State-of-the-art recyclers produce a uniform, high-quality mixture of the existing materials with water and binding agents.

Our recyclers in action around the globe

Structural rehabilitation of rural road ER 361 through the village of Monsanto, about 100 km north of Lisbon.

W 380 CR cold recycling train in Pragosa

The Wirtgen W 380 CRi recycler is capable of recycling the road surface to a full depth of up to 30 cm, which means it is also perfect for full-depth reclamation (FDR).

Full depth, high quality

W 380 CRi: the World’s Most Powerful Cold Recycler

Cold Recycler W 380 CRi

North American Premiere of the W 380 CRi from Wirtgen: the World’s Most Powerful Cold Recycler

North American Premiere W 380 CRi

At the heart of this recycling train are tracked cold recyclers such as the new W 380 CRi from Wirtgen.

In San José/USA, in-situ cold recycling with a Wirtgen 3800 CR recycler proves to be the most economical solution.

100 miles – day and night

By supplying the 3800 CR as a rear loader, Wirtgen offers an efficient and flexible solution for in-situ cold recycling. However as a front loader the 3800 CR also excels as a high-performance cold milling machine.

Unbeatably versatile

By supplying the 3800 CR as a rear loader, Wirtgen not only offers an efficient and flexible solution for in-situ cold recycling: the 3800 CR also excels as a high-performance cold milling machine.

In-place cold recycling of bituminous materials was carried out during a project in Illinois. For this purpose, the contractor selected the 2200 CR recycler with a working width of 3.80 m.

Cold recycling at Highway 15