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1 Cold planers Prestudy Jan 2009 / Jrgen Seemann Slide 2 2 Introduction questions What is cold milling? What is needed for a cold milling operation ? What are the key factors to compare cold planers? What are the key components of a milling drum? What are the four recycling methods? What are typical cold milling jobs ? Slide 3 3 What is cold milling? Cold milling is the controlled removal of an existing pavement to a desired depth or slope. The cold planer is therefore equipped with a rotary cutting drum. The drum has specially designed and replaceable tungsten carbide cutting teeth/tools/picks that remove or mill the existing pavement. The cutting drum rotates in an up-cut direction, means, the rotation is opposite to the moving direction of the cold planer. The reclaimed asphalt pavement (RAP) is loaded into a truck by a conveyor system on the milling machine and typically removed from the site. The RAP is than recycled in a central asphalt mixing plant and reused as mixture for new asphalt pavements. Slide 4 4 What is needed for a cold milling operation ? A cold planer, adapted in size, power and system for the desired milling operation Haul trucks to remove the RAP from the site Water trucks to refill the water tank of the cold planer, which is needed to control the dust and cool the tools Sweeper or power broom to clean the surface Slide 5 5 What are the key factors to compare cold planers? Milling drum (width and max. cutting depth; drum layout) Operating weight (drum load = kg/ mm cutting width) Horse power (power load = hp/ mm cutting width) Loading system (front/rear loading) Track or wheeled traction system Slide 6 6 What are the key components/factors of a milling drum? 1.Cutting width and max cutting depth 2.Drum layout 1.number of tools (spacing) and 2.number of tools per cutting lane 3.Tool holder system 1.welded or 2.replaceable system (quick change system) 4.Tungsten carbide tools Slide 7 7 What are the four recycling methods ? Cold Planing (CP) Hot In-Place Recycling (HIR) Cold In-place Recycling (CIR) Full Depth Reclamation (FDR) Slide 8 8 What are typical cold milling jobs ? Repair and maintenance work (potholes, cracks, wheel ruts etc. etc.) Removal of the total asphalt structure for roadway reconstruction Mill to a desired depth to prepare road surface for an overlay Texturing the surface to increase road safety Correct slope for a better drainage Removal of road markings (with micro milling drums) Trenching jobs (for cable or pipe laying) Special jobs like milling of safety lanes (rumble strips) Slide 9 9 The components of a large cold planer back side 1) Operator dashboard 6) Tracks 2) Panels for ground man 3) Cutter housing with milling drum 5) Moldboard 4) Side shields Slide 10 10 The components of a large cold planer front side 8) Water tank 10) Height adjustable legs 9) Discharge conveyor 12) Downholder 7) Drum drive 11) Primary conveyor Slide 11 11 The components of a drum 1) Barrel 2) Flange 5) Edge cutter3) Spirals / Vanes 6) Kicker 7) Cutter tool4) Toolholder Slide 12 12 Parameters which influence the milling performance Machine parameters Material parameters Traffic control Transport capacity Operating staff Working width Engine power Weight Cutting speed Type of bit / Line spacing Asphalt condition Type of rock Grain shape round/broken Binder type Temperature Travel drive tracked / wheeled Area capacity = advancing speed x cutting width Cutting depth Unobstructed area Partial repair work Obstructing factors Type of barricading Obstacles Number of lorries Organization Traffic situation Qualification Site conditions Slide 13 13 PL XYZ XY Planer Cutting width in mm L = Light version (PL2000LS) R = Rear conveyor (PL1000RS) D = Deep cut (PL 500TD) S = 2 nd generation T = 3 rd generation Denomination of Dynapac cold planers Slide 14 14 Four platforms / 8 models PL 350T PL 500T PL 500TD PL 600/30S PL 1000RS PL 2000LS PL 2000S PL 2100S (two control systems) Slide 15 15 PL 350T technical data Cutting width 350 mm Cutting depth 100 mm Engine Cummins B3.3 45 kW / 60 hp / 61 PS @ 2200 rpm Weight Transport weight2,45 to Op. weight (CE)2,8 to Ballast weight 1,1 to Max weight (CE)4,25 to Dimensions w/o conveyor 2.973 x 1.332 x 1.925 mm Slide 16 16 Compact planer PL 350T Main applications Working in conjunction with bigger planers to cut leftovers Cutting around man hole covers Cutting of joints Repair and maintenance work Demarcation of road marking. Daily output ~ 250 m ~ 20 m Slide 17 17 PL 500T and PL 500TD technical data PL 500TPL 500TD Cutting width 500 mm500 mm Cutting depth 160 mm200 mm Engine Cummins QSB4.5-C110QSB4.5-C130 82kW / 110hp97kW / 130hp @ 2200 rpm@ 2200 rpm Weight Transport weight6,9 to7,2 to Op. weight (CE)7,2 to7,5 to Long conveyor 0,6 to0,6 to Max weight (CE)8,3 to8,6 to Dimensions w/o conveyor of both models 2.973 x 1.332 x 1.925 mm Long conveyor5.900 x 900 x 900 mm Slide 18 18 Compact planers PL 500T and PL 500TD Daily output ~ 400 - 500 m ~ 40 - 60 m Main applications (as of PL 350T) Working in conjunction with bigger planers to cut leftovers Cutting of joints Repair and maintenance work Cutting of trenches (PL 500TD) Slide 19 19 PL 600/30S and PL 1000RS technical data PL 600/30SPL 1000RS Cutting width 600 mm1000 mm Cutting depth300 mm250 mm Engine Cummins QSB5.9QSB5.9 129kW / 173hp129kW / 173hp @ 2100 rpm@ 2100 rpm Weight Transport weight12,2 to12,4 to Op. weight (CE)13,0 to13,2 to Max weight (CE)13,7 to13,9 to Dimensions w/o conveyor of both models 4.300 x 2.250 x 2.600 mm Conveyor5.900 x 900 x 900 mm Slide 20 20 Compact planers PL 600/30 and PL 1000RS Daily output ~ 600 2.000 m ~ 75 m - 120 m Main applications: Larger milling jobs (PL 1000RS) Cutting of street junctions Repair and maintenance work Cutting of trenches (PL 600/30S) Slide 21 21 PL 2000LS/S and PL 2100S technichal data PL 2000LS/SPL 2100S Cutting width 2010 mm2100 mm Cutting depth320 mm320 mm Engine Cummins QSX15QSX 15 447kW / 600hp447kW / 600hp @ 2100 rpm@ 2100 rpm Weight Transport weight28,2/31 to31,4 to Op. weight (CE)30,7/33,5 to33,9 to Max weight (CE)33,4/36,2 to36,6 to Dimensions w/o conveyor of both models 8.100 x 2.550 x 3.100 mm Conveyor8.150 x 1.350 x 1.050 mm Slide 22 22 Large planers PL 2000LS/S and PL 2100S Daily output ~ 10.000m ~ 600m Main applications Highways, airports, country roads Slide 23 23 Driven by innovation committed to customer performance