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Foam Bitumen Recycling
DPU DKI
Jakarta, 19 Nopember 2007
Welcome
Strong brands, innovative products and applications know-how
Technologies from the market leader
High-capacity and highly modern headquarters in Germany
Hamburg
Munich
Berlin
Cologne
Windhagen
Mannheim
Göppingen
Tirschenreuth
The Wirtgen Group
Unique portfolio and broadest product range worldwide
15 machine models
650 options
Milling widths: 14 mm to 4.40 m
Milling depths: up to 350 mm
330 standard and special milling drums
9 new small milling machines
Product line: Cold milling machines
Mature and comprehensive product portfolio
9 concrete paver models
Over 11,000 combinations
Paving widths: 1 m to 16 m
Paving thicknesses: up to 450 mm
Side feeder
Texture curing machines
Product line: Slipform pavers
Wirtgen as the technological driving force with applications expertise
Working width: 3,00 m to 4,50 m
Working depth: up to 60 mm
Preheater with infrared technology
Remix Plus process
Product line: Hot recyclers
Market leader and market trendsetter with broadest portfolio in the market
11 machine models
Wheel-mounted and track-mounted machines
Working widths: 2.00 m to 4.20 m
Working depths: up to 500 mm
Foamed bitumen technology
Product line: Cold recyclers / Stabilizers
The German headquarters
Joseph Vögele AG: Largest manufacturer of road pavers worldwide
Mannheim
Engineering, manufacturing and marketing of road pavers.
The latest generation: compact and very powerful
2 machine models
Track widths: 1.1 m
Drive-through widths: 1.2 m
Paving widths: 0.5 m to 3.2 m
Paving capacities: up to 250 t/h
AB 200
Product line: Mini and small pavers
“Dash-2” generation: all performance classes, all paving situations
7 machine models
Paving widths: up to 16 m
Paving thicknesses: up to 40 cm
Paving capacities: up to 1,500 t/h
Simple operating concept ErgoPlus
Product line: Tracked pavers
High performance, compact dimensions, innovative technology
4 machine models
Paving widths: up to 8 m
Paving thicknesses: up to 30 cm
Paving capacities: up to 700 t/h
Simple operating concept ErgoPlus
Product line: Wheeled pavers
Engineering, manufacturing and marketing of rollers for road and earthwork construction.
The German headquarters
Hamm AG: Second-largest roller manufacturer in Germany
Tirschenreuth
Complete range of articulated tandem vibrating rollers and combination rollers
Weight classes:from 1.4 to 14 tons
Optimum range of vision
Ergonomical operator’s platform
High compaction performance
New Compact Line with 10 roller models
Product line: HD-Tandem rollers
Engineering, manufacturing and marketing of mobile and stationary processing technology for natural rock and for the recycling of construction materials.
The German headquarters
Kleemann GmbH: Headquarters in Göppingen
Göppingen
bauma
bauma China
Conexpo
Intermat
Regional trade fairs
The Wirtgen Group
Present at all major international platforms
BAUMA 2007
Sold machines:
833 units833 unitsTurn over Wirtgen Group (Bauma):
75 Mio. €75 Mio. €
Foam bitumen technology
•Foam bitumen
•In plant/ place in situ
•Technology in other countries
Job site Cirebon
•Pre investigation
•Mix design
•Foam Bitumen Recycling Processing / Cirebon
•Final
•Test results
Cold recycling in place
Distressed pavement Structural rehabilitation
Asphalt wearing course
Base
Sub Base
Recycled layer
Sub base
Binder course
Asphalt wearing courseAsphalt wearing course
Foam bitumen technology
Benefit of recycled layer
Un-laminated
(un-stabilised)
Laminated
(recycled)
Foam bitumen technology
Cold Recycling in situ
+ =emulsion water
foamed bitumen water
cement wateremulsion
watercement foamed bitumen
watercement
Binding Agent
Bound granularbase course
Asphalt coursewith granular base
Milled material
Foam bitumen technology
Foam bitumen technology
ASPHALT TECHNOLOGY
Bitumen coating (thin films)
Contact adhesive
STABILISATION TECHNOLOGY
Bitumen dispersion selective
Bound granular material
+ BITUMEN =
Foam bitumen technology
Width cm
Depth
cmSpeed
m/minDensity
kg/m³Binding agent
%
Binder addition
in l/min
=
Foam bitumen technology
Foam bitumen technology
Foam bitumen technology
in plantin plant
in situin situ
Foam bitumen technology
WR 2500 SWR 2500 S
Cold recycling in Germany
Foam bitumen technology
WR 2000 Cold Recycling in Japan
Foam bitumen technology
Cold recycling in situ in Malaysia
Foam bitumen technology
Cold Recycling in situ Indonesia
Cold Recycling the asphalt and granular base layers by adding pre-spread cement
Cold Recycling in situ Highway in Italy
Mixing drum width
Injection width
Injection width can be seperately controled by switching off certain nozzles
Injection width
Cold Recycling in situ Highway in Italy
Milling off 28 cm of existing Asphalt in the right hand lane
Cold Recycling in plant
Foam bitumen technology
Cold Recycling in plant Jinghu Expressway, Tianjing China
Foam bitumen technology
Cold recycling with foam bitumen
Foam bitumen technology
Tests done on the milled sample:
•Grading analysis
•Water content
•Bitumen content
•Modified Proctor to determine the optimum water content (OMC) and maximum dry density (MDD)
Tests done on the bitumen sample:
•Optimisation of foaming properties – variation of bitumen, temperature and bitumen water quantity
Mix Design Test for Foamed Bitumen
Mix design and manufacturing briquettes:
•Addition of cement (1.5 M.-%)
•Addition of water (80 - 90% of OMC)
•Addition of Foamed Bitumen (2; 2,5; 3,0; 3,5 M.-%): with
WLB 10 directly into the laboratory mixer
•Production of briquettes by Marshall compaction – modified
to
75 blows / briquette-side
•Storing for 72 hours at 40 °C (simulating 28 days)
•Indirect tensile strength on dry and soaked briquettes at 25
°C
Mix Design Test for Foamed Bitumen
Mix Design Test for Foamed Bitumen
Mix Design Test for Foamed Bitumen
Mix Design Test for Foamed Bitumen
Mix Design Test for Foamed Bitumen
Mix Design Test for Foamed Bitumen
Plant for the production of foamed bitumen in laboratory conditions
Test of bitumen foaming properties and optimisation of bitumen water
Production of foamed bitumen mix design for optimisation of the foamed bitumen content
More than plants: Customers are commercial laboratories, consultants, research institutes, universities and construction contractors
175
Mix Design Test for Foamed Bitumen
Mix Design Test for Foamed Bitumen
Foamed Bitumen content [% by mass]
400
800
600
200
Soaked ITS
Dry ITS
Mix Design Test for Foamed Bitumen
Optimisation of Foamed Bitumen content
Indi
rect
Ten
sile
Str
engt
h [k
Pa]
Mix Design Test for Foamed Bitumen
Mix Design Test for Foamed Bitumen
granular base
400 - 500 mmold asphalt
Existing pavement
Project Indonesia - Cirebon
granular base
old asphalt
1. Mill off asphalt
20 cm
Project Indonesia - Cirebon
granular base
old asphalt
2. Cement stablizing
25 cm CTRB
Project Indonesia - Cirebon
granular base
old asphalt
3. Bring back RAP and
foamed bitumen recycling
20 cm Foam Bitumen
25 cm CTRB
Project Indonesia - Cirebon
granular base
old asphalt
4. Wearing course 4cm,
and 6cm Binder course
4 cm WC
20 cm Foam Bitumen
25 cm CTRB
6 cm Binder
Project Indonesia - Cirebon
Project Indonesia - Cirebon
Before 05.08.2007 After 23.08.2007
Recycling
Mill & Overlay
Cirebon 2006
Busway
2,5% 15-17cm
Concrete overlay with levelling
• Concrete layer 27cm
• Concrete levelling (Asphalt)
Busway
granular base
50 – 100 cmold asphalt
Existing pavement
Busway
Recycling Proposal:
granular base
old asphalt
1. Mill off asphalt
25 cm
Busway
granular base
old asphalt
2. Cement stablizing
25 cm CTRB
Busway
granular base
old asphalt
3. Bring back RAP and
foamed bitumen recycling
25 cm Foam Bitumen
25 cm CTRB
Busway
granular base
old asphalt
4. Wearing course 4cm,
and 6cm Binder course
4 cm WC
20 cm Foam Bitumen
25 cm CTRB
6 cm Binder
Busway
Advantage of foam bitumen recycling:
• economical
• no heating energy necessary
• re-use of asphalt material
• no waste disposal of old asphalt
• enviroment friendly
• quick , short construction time , short traffic closing
• reduce transportation (>90%)
• reduce life time cost, too (longer life time for overlay)
Thank you