Turning two into one
View over the Rhine Valley to Lake Constance, as seen from the Hilti & Jehle GmbH site.

Implementation and expansion of an asphalt mixing plant in the Alpine Rhine Valley

Hilti & Jehle GmbH operates two asphalt mixing plants in Austria at its sites in Götzis and Nenzing. Both plants have been in operation for several years – even the youngest is 14 years old – there are now plans to modernise them. The aim is to upgrade the existing plants to meet the latest technical standards and combine them at the Götzis site. The following approach is being taken: the re-use of individual components of the existing plants and the addition of new and innovative Retrofit solutions. This is all possible thanks to the modular construction concept of Benninghoven asphalt mixing plants. In this way, Hilti & Jehle will be able to realise a more productive and efficient production facility.

Systematic dismantling begins in Nenzing.

The plant in Nenzing – this will be dismantled here and reconstructed in Götzis with the addition of new components.

Finished! The installation of the components in Götzis can now begin.

An aging asphalt mixing plant seen in the foreground of a snowy alpine panorama.
The individual components of the asphalt mixing plant in Nenzing are dismantled and removed with the aid of cranes and lifting platforms.
The dismantling phase in Nenzing is complete. Only a few parts remain standing.

Asphalt mixing plant dismantling, relocation and installation

To create a mixing plant fit for the future, Hilti & Jehle GmbH is combining two of its existing asphalt mixing plants. This will involve dismantling the TBA plant located in the Austrian town of Nenzing and then combining it with the bitumen tanks in the plant located in Götzis, about 21 km to the north. Additional Retrofit components will be used to upgrade the production facility to the latest technical standards. By re-using the components of the transportable asphalt mixing plant from Nenzing, the company has chosen a forward-looking solution.

Götzis town sign with motto: ‘an energy-efficient community’

Resource-Efficiency and Energy Utilisation

  • Maximum re-use of plant components
  • Cost-efficient asphalt production, thanks to cold and hot recycling
  • Reduction of CO₂ emissions
  • Noise reduction
  • Improved energy-efficiency

3D graphic of the planned asphalt mixing plant
A look into the future
A fascinating look at the asphalt mixing plant construction process

New technologies for a wider variety of asphalt mixes

Hot bin section

To offer potential customers a wide choice of recipes, the company needs to make sure that the range of mineral aggregate types and sizes kept in stock is as large as possible. With an overall capacity of 14 bins, including a rotary chute and a total capacity of 150 t, hot storage is now possible for various aggregate types.

Flexibility in the bitumen supply system

By combining the bitumen supply systems of both plants and integrating a smart bitumen control system, the customer can now react flexibly even when faced with energy bottlenecks and volatile bitumen market prices. This enables efficiently management of the volume and varieties of bitumen.

For asphalt mixes with a high proportion of RAP

Alongside the existing cold recycling system, a recycling drum with hot gas generator was also pre-configured for hot recycling. This new and forward-looking technology will be used in the future to further increase the proportion of RAP material in the final product. The aim here is to ensure that the emissions generated by the production of asphal mixes are kept as low as possible.

Usability

Thanks to the new BLS4 control system, plant operation is now simpler and more straightforward for employees.

Expanding storage capacities

Eight bins are now available to ensure larger storage capacities and a wider range of types of finished asphalt, and for stockpiling mastic asphalt.

A strategic location with logistical advantages

The location of the newly erected plant was a strategically smart choice: it is situated at the southern tip of Lake Constance, close to the borders with Germany, Lichtenstein and Switzerland. This means that these countries can be quickly supplied with asphalt mixes . Multiple countries mean different requirements for the asphalt mixes or a wider range of recipes – both of which are easy to achieve with the ‘rebooted’ plant. All procedures and paths have been optimised not only for the installation phase but also for the future, with the aim of creating a future-proof mixing plant.


Installation and expansion of the plant at the Götzis site

Start of plant installation and Retrofitting in Götzis.

The weather does not always play along!

Work on the foundations is well underway.

The foundations are laid, installation can begin.

The centerpiece of the plant, the new weighing and mixing section (Retrofit), is being delivered simultaneously from the factory in Wittlich.

Improved flexibility and cost-efficiency

The bitumen tanks from Nenzing are positioned and installed next to the existing bitumen tanks.

The first containers for the mixed material storage silo are now in place, as the dryer drum is moved into position …

… and the plant starts to take shape.

View of the plant from the rear.

The tower is complete up to the skip track.

Containers for the mixed material storage silo’s first and second secondary towers are moved into position.

The neighbouring mixed material storage silo is taking shape.

Containers for the mixed material storage silo’s second secondary tower are moved into position.

The filler tower is being erected.

The weighing and mixing section has been expanded to include an enclosure with trapezoidal metal wall cladding for protection against noise, dust, and steam emissions, and to reduce radiant heat loss.

The first containers for the new hot bin section are being positioned on the mixing tower.

The ‘command centre’ is being set up in parallel.

The 150-tonne hot bin section continues to grow.

The screen is flown in.

… almost done …

Positioning of the cold feed unit and installation of the roofing. This is an important step: a 1% reduction in moisture in the aggregate is equivalent to 1 litre less heating oil or the equivalent energy source required to heat the mineral aggregate.

Done – the yard and logistics roadways have been surfaced with asphalt and asphalt production can start again.

An open area prepared for the erection of the new asphalt mixing plant, seen here against a backdrop of a wintry alpine panorama.
A construction site with heavy snowfall, with only the foundation for the asphalt mixing plant cleared of snow.
A late stage in the foundation work, seen here at dawn in the foreground of a wintry landscape.
Completed foundations, including integrated supports for later parts of the asphalt mixing plant, seen here in the foreground of a wintry alpine panorama.
A crane is used to place the weighing and mixing section onto the supports provided in the foundation.
Positioning of bitumen tanks from Nenzing next to the existing bitumen tanks: The seventh of a total of eight cylindrical bitumen tanks is erected with the help of a crane.
Three containers have been set up on the first part of the mixed material storage silo. A crane is now being used to horizontally position the cylindrical dryer drum.
The mixed material storage silo, the dryer drum and the bitumen tanks are in place on the foundations. Construction work is well underway.
View of the construction site from the back: the bitumen tanks are seen on the left, while a roofed storage area for various types of mineral aggregates can be seen on the right.
Other containers have been positioned on the prepared foundations.
The containers for the first and second secondary towers of the mixed material storage silo are positioned on the construction site.
A total of three times three containers for the mixed material storage silos have been set up as towers on stilts.
The last containers for the mixed material storage silo’s second secondary tower are moved into position.
On a foggy day, a cylindrical filler tower is erected with the help of a crane.
View of the construction site: The weighing and mixing section is being completed behind the dryer drum.
Containers for the hot bin section are moved into position on the mixing tower. The Hilti & Jehle logo is applied to a container.
Alongside the mixing tower and mixed material storage silo unit, a new control centre is being constructed from wood.
View of the construction site from the back. Other containers with attached stairs are stacked onto the hot bin section.
The screen is suspended from a crane.
Now almost complete, the asphalt mixing plant is seen here in against a backdrop of a wintry landscape.
Two fitters install the roofing for the cold feed unit with the help of a lifting platform.
The completed asphalt mixing plant on a paved site, seen against a backdrop of a spring landscape – the yard and access roadways have been paved with asphalt.

Modular design – Plug & Work

Transportable asphalt mixing plants from Benninghoven are not only designed to be easily moved from one site to another – their modular design also makes it possible to upgrade existing plants to the state of the art.

TBA plants

TBA asphalt mixing plants are characterised by a modular construction concept and large storage capacities for the hot bin section and the mixed material storage silo. These characteristics, combined with long-term retrofitting options for components, guarantee outstanding plant performance.

TBA asphalt mixing plants are an ideal choice for both semi-mobile and stationary use. Their enormous flexibility, wide range of available options, and impressive specifications make TBA plants true specialists in the asphalt mixing plant market.

The innovative plant construction concept enables seamless integration of the plant throughout its entire lifecycle.

Learn more about asphalt mixing plants

A seasoned team

A project as large and complex as the one in Austria can only be successful with a strong team. While the requirements for each Retrofit project will differ, Benninghoven is very familiar with the key steps in the process, thanks to its vast experience in the field.

Interface definitions, understanding and accounting for process technology, control system integration – it is about so much more than simply swapping out a few steel parts.

A panoramic view of Lake Constance on a sunny day, with light mist cloaking the surrounding landscape.

Details and further information can be found on our product pages.

Retrofit

Retrofit

TBA 4000

TBA

Media & press

Click here to download a ZIP file containing the press release in the available languages in Microsoft Word format and the images in 300 dpi resolution.

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