WIRTGEN milling and mixing rotors for cold recyclers and soil stabilizers

DURAFORCE – A rotor for all situations

Under challenging duty conditions – such as high-performance cold recycling, granulation or stabilization of soils with larger stones – everything is demanded of the cutting tools. Components that are designed for extreme performance and are perfectly tuned to one another are needed here. They permit reliable high performance in milling and mixing while offering maximum strength and long life.

The original WIRTGEN DURAFORCE milling and mixing rotor is appealing with its extreme wear resistance, impact resistance, and fracture stability for all applications in soil stabilization and cold recycling: a rotor for all cases.

Highlights of the DURAFORCE milling and mixing rotor
Universal milling and mixing rotor
High performance and perfect mixing results
Long component life and maintenance intervals
High-performance mixing
Rugged design
Increased life of the bottom part
Easy to replace the rugged square-profile ring segments
High-performance soil stabilization

The soil stabilization process that is used worldwide is the ideal solution for taking soil that has insufficient bearing capacity and generating construction-capable, compressible soil. In this process, a broad range of soil types must be processed, ranging from "very cohesive" to "filled with rough stone" to "abrasive."

Requirements of the milling and mixing rotors:
  • Effective splitting and size reduction of the soil material for optimal effects of the binder
  • Uniform distribution and homogeneous mixing of binders and possibly water for high mixture strength
  • Greatest possible cutting friendliness, even in the case of tough, hard soil for productivity and low diesel consumption
  • High degree of impact resistance for soils in which large stones are dispersed for long productive time periods
  • High wear resistance with abrasive, cohesive soils for a high level of economy
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The practice-proven WIRTGEN DURAFORCE milling and mixing rotor masters all of the requirements of soil stabilization and is ideally designed to transform even the most challenging soils into high-quality construction material.

Eco-friendly cold recycling

Cold recycling and granulation are also internationally established methods. Damaged asphalt compositions with a wide variety of stone types and the underlying gravel layer are milled up, are generally mixed homogeneously with the addition of binder, and are reconstructed on-site.

Requirements of the milling and mixing rotors:
  • Uniform milling process to avoid excessive grain size and to achieve high-quality work results
  • High level of cutting performance with low wear, even with hard, abrasive stone, for exceptional economy
  • Conformance to desired screen line for constant stability of the new base layer
  • Homogeneous mixing of the binder for high level of adhesion (binding force) between the individual grains and thereby for optimal bearing capacity
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The DURAFORCE milling and mixing rotor even masters the special requirements of cold recycling. Users benefit from maximum performance, long life of components and optimal quality of the new base layers.

Unique know-how from a single source

WIRTGEN offers high-performance cutting systems from a single source. From a single source means components that are ideally tuned to one another and consistently good quality. In its DURAFORCE milling and mixing rotors, the company brings together its expertise acquired over decades, mature production engineering, and future-oriented technologies. It is informed, in particular, by experience in practice and feedback from our customers.

Solution-oriented engineering

State-of-the-art tools are part of our daily work at WIRTGEN – these include professional simulation tools. They are a fixed component of the highly complex engineering process that is used to find the optimal solution. The best example of this is the holder web. Its defined geometry, in combination with the selected alloy leads to excellent wear resistance, the best possible weldability and uniform load distribution – all of which leads to reliable protection against overload of the holder web. In this way, it optimally redirects high lateral forces in particular.

Proven forging process

The holder webs of the DURAFORCE milling and mixing rotors are given an ingenious 3D geometry in a proven forging process. In addition to uniform load distribution and thereby maximum component life, this also provides for optimal material flow and homogeneous mixtures of the construction materials.

Automatic welding process

The final welds of the quick-change holders and holder webs on the DURAFORCE milling and mixing rotors are made by a welding robot. Our welding robots not only guarantee a high degree of process assurance, precision and weld quality. They also guarantee quick, economical manufacturing.

Precisely balanced

The milling and mixing rotors, which can weigh up to 9,920 lbs (4,500 kg), operate at substantially higher cutting speeds than the milling drums used for cold milling. That is why WIRTGEN balances each rotor meticulously. The resulting perfect true running of the rotor not only extends the life of the entire machine tremendously, but also relieves the operator of vibrations.

Brochure

You can download the brochure for DURAFORCE milling and mixing rotors here.

English (PDF 5 MB) American (PDF 4 MB)
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