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. As both plants have a fairly long service record – even the youngest is 14 years old – there are now plans to modernize them. The aim is to upgrade both 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 is creating a more productive and efficient production facility.

Systematic dismantling begins in Nenzing.

Plant in Nenzing – this will be dismantled here and re-installed in Götzis with the addition of new components.

Finished! 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 parts of the asphalt mixing plant in Nenzing are dismantled using 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 components of two of its existing asphalt mixing plants. This will involve dismantling the TBA plant located in the Austrian town of Nenzing and then combining its components with the bitumen tanks in the plant 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 transportable asphalt mixing plant from Nenzing, the company has chosen a future-oriented solution.

Götzis town sign with tagline: “an energy-efficient community”

Aspects Relating to Resource-Efficiency and Energy Utilization

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

3D graphic of the planned asphalt mixing plant
A Look Into the Future
A Fascinating Look at the Installation Process at the Asphalt Mixing Plant

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 fluctuating bitumen prices. This makes it possible to efficiently manage the volume as well as the variety of bitumens.

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 created by the production of asphalt mixes are kept as low as possible.

Premium Usability

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

Strategic Location Offers Logistical Advantages

The location of the newly installed plant was a clever strategic choice: it is situated at the southern tip of Lake Constance, close to Germany, Lichtenstein, and Switzerland. This means that asphalt mixtures can quickly be delivered between these countries. 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 were optimized 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 complete, installation can begin.

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

Increased 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, and 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 neighboring 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 center” 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 liter less heating oil or the equivalent energy source required to heat the aggregate.

Done – the yard and logistics roadways have been surfaced with asphalt and asphalt production can be resumed.

An area prepared for the erection of the new asphalt mixing plant, seen here in the foreground of a wintry alpine panorama.
A construction site in deep snow, with only the foundation for the asphalt mixing plant cleared.
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/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. Now, a crane is used to position the cylindrical, horizontal dryer drum.
The mixed material storage silo, dryer drum, and bitumen tanks are in place on the foundations. Construction work is well underway.
View from the back of the construction site: the bitumen tanks are seen on the left while a roofed storage area for various mineral aggregate types can be seen on the right.
Other containers have been positioned on the prepared foundations.
The containers for the mixed material storage silo’s first and second secondary tower are positioned at the construction site.
A total of three times three containers have been set up as towers on stilts for the mixed material storage silos.
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 nearing completion 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 center 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 against a backdrop of a wintry landscape.
Two fitters install the roofing of 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 construction concept also makes it possible to upgrade existing plants to the latest technologies.

TBA Plants

TBA asphalt mixing plants are characterized by their modular construction concept and high storage capacities of the hot bin section and the mixed material storage silo. These characteristics, combined with long-term retrofit options for components, guarantee outstanding plant performance.

TBA asphalt mixing plants are an ideal choice for both semi-mobile and stationary use. Their outstanding 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 Strong and Highly-Skilled Team

A project as large and complex as the one in Austria can only be successfully realized with a strong and highly-skilled 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.

Defining interfaces, understanding and taking process technology into account and control system integration – it is about so much more than simply swapping out a few chunks of stee.

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

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Media & Press

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