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Foam Bitumen Recycling DPU DKI Jakarta, 19 Nopember 2007

5. Foam Bitumen Recycling

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Page 1: 5. Foam Bitumen Recycling

Foam Bitumen Recycling

DPU DKI

Jakarta, 19 Nopember 2007

Page 2: 5. Foam Bitumen Recycling

Welcome

Page 3: 5. Foam Bitumen Recycling

Strong brands, innovative products and applications know-how

Technologies from the market leader

Page 4: 5. Foam Bitumen Recycling

High-capacity and highly modern headquarters in Germany

Hamburg

Munich

Berlin

Cologne

Windhagen

Mannheim

Göppingen

Tirschenreuth

The Wirtgen Group

Page 5: 5. Foam Bitumen Recycling

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

Page 6: 5. Foam Bitumen Recycling

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

Page 7: 5. Foam Bitumen Recycling

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

Page 8: 5. Foam Bitumen Recycling

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

Page 9: 5. Foam Bitumen Recycling

The German headquarters

Joseph Vögele AG: Largest manufacturer of road pavers worldwide

Mannheim

Engineering, manufacturing and marketing of road pavers.

Page 10: 5. Foam Bitumen Recycling

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

Page 11: 5. Foam Bitumen Recycling

“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

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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

Page 13: 5. Foam Bitumen Recycling

Engineering, manufacturing and marketing of rollers for road and earthwork construction.

The German headquarters

Hamm AG: Second-largest roller manufacturer in Germany

Tirschenreuth

Page 14: 5. Foam Bitumen Recycling

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

Page 15: 5. Foam Bitumen Recycling

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

Page 16: 5. Foam Bitumen Recycling

bauma

bauma China

Conexpo

Intermat

Regional trade fairs

The Wirtgen Group

Present at all major international platforms

Page 17: 5. Foam Bitumen Recycling

BAUMA 2007

Sold machines:

833 units833 unitsTurn over Wirtgen Group (Bauma):

75 Mio. €75 Mio. €

Page 18: 5. Foam Bitumen Recycling

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

Page 19: 5. Foam Bitumen Recycling

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

Page 20: 5. Foam Bitumen Recycling

Benefit of recycled layer

Un-laminated

(un-stabilised)

Laminated

(recycled)

Page 21: 5. Foam Bitumen Recycling

Foam bitumen technology

Page 22: 5. Foam Bitumen Recycling

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

Page 23: 5. Foam Bitumen Recycling

Foam bitumen technology

Page 24: 5. Foam Bitumen Recycling

ASPHALT TECHNOLOGY

Bitumen coating (thin films)

Contact adhesive

STABILISATION TECHNOLOGY

Bitumen dispersion selective

Bound granular material

+ BITUMEN =

Foam bitumen technology

Page 25: 5. Foam Bitumen Recycling

Width cm

Depth

cmSpeed

m/minDensity

kg/m³Binding agent

%

Binder addition

in l/min

=

Foam bitumen technology

Page 26: 5. Foam Bitumen Recycling

Foam bitumen technology

Page 27: 5. Foam Bitumen Recycling

Foam bitumen technology

Page 28: 5. Foam Bitumen Recycling

in plantin plant

in situin situ

Foam bitumen technology

Page 29: 5. Foam Bitumen Recycling

WR 2500 SWR 2500 S

Cold recycling in Germany

Foam bitumen technology

Page 30: 5. Foam Bitumen Recycling

WR 2000 Cold Recycling in Japan

Foam bitumen technology

Page 31: 5. Foam Bitumen Recycling

Cold recycling in situ in Malaysia

Foam bitumen technology

Page 32: 5. Foam Bitumen Recycling

Cold Recycling in situ Indonesia

Cold Recycling the asphalt and granular base layers by adding pre-spread cement

Page 33: 5. Foam Bitumen Recycling

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

Page 34: 5. Foam Bitumen Recycling

Cold Recycling in situ Highway in Italy

Milling off 28 cm of existing Asphalt in the right hand lane

Page 35: 5. Foam Bitumen Recycling

Cold Recycling in plant

Foam bitumen technology

Page 36: 5. Foam Bitumen Recycling

Cold Recycling in plant Jinghu Expressway, Tianjing China

Foam bitumen technology

Page 37: 5. Foam Bitumen Recycling

Cold recycling with foam bitumen

Foam bitumen technology

Page 38: 5. Foam Bitumen Recycling

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

Page 39: 5. Foam Bitumen Recycling

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

Page 40: 5. Foam Bitumen Recycling

Mix Design Test for Foamed Bitumen

Page 41: 5. Foam Bitumen Recycling

Mix Design Test for Foamed Bitumen

Page 42: 5. Foam Bitumen Recycling

Mix Design Test for Foamed Bitumen

Page 43: 5. Foam Bitumen Recycling

Mix Design Test for Foamed Bitumen

Page 44: 5. Foam Bitumen Recycling
Page 45: 5. Foam Bitumen Recycling

Mix Design Test for Foamed Bitumen

Page 46: 5. Foam Bitumen Recycling

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

Page 47: 5. Foam Bitumen Recycling

Mix Design Test for Foamed Bitumen

Page 48: 5. Foam Bitumen Recycling

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

Page 49: 5. Foam Bitumen Recycling

Mix Design Test for Foamed Bitumen

Page 50: 5. Foam Bitumen Recycling

granular base

400 - 500 mmold asphalt

Existing pavement

Project Indonesia - Cirebon

Page 51: 5. Foam Bitumen Recycling

granular base

old asphalt

1. Mill off asphalt

20 cm

Project Indonesia - Cirebon

Page 52: 5. Foam Bitumen Recycling

granular base

old asphalt

2. Cement stablizing

25 cm CTRB

Project Indonesia - Cirebon

Page 53: 5. Foam Bitumen Recycling

granular base

old asphalt

3. Bring back RAP and

foamed bitumen recycling

20 cm Foam Bitumen

25 cm CTRB

Project Indonesia - Cirebon

Page 54: 5. Foam Bitumen Recycling

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

Page 55: 5. Foam Bitumen Recycling

Project Indonesia - Cirebon

Before 05.08.2007 After 23.08.2007

Page 56: 5. Foam Bitumen Recycling

Recycling

Mill & Overlay

Cirebon 2006

Page 57: 5. Foam Bitumen Recycling

Busway

Page 58: 5. Foam Bitumen Recycling

2,5% 15-17cm

Concrete overlay with levelling

• Concrete layer 27cm

• Concrete levelling (Asphalt)

Busway

Page 59: 5. Foam Bitumen Recycling

granular base

50 – 100 cmold asphalt

Existing pavement

Busway

Recycling Proposal:

Page 60: 5. Foam Bitumen Recycling

granular base

old asphalt

1. Mill off asphalt

25 cm

Busway

Page 61: 5. Foam Bitumen Recycling

granular base

old asphalt

2. Cement stablizing

25 cm CTRB

Busway

Page 62: 5. Foam Bitumen Recycling

granular base

old asphalt

3. Bring back RAP and

foamed bitumen recycling

25 cm Foam Bitumen

25 cm CTRB

Busway

Page 63: 5. Foam Bitumen Recycling

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

Page 64: 5. Foam Bitumen Recycling

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)

Page 65: 5. Foam Bitumen Recycling

Thank you