FORUM 43 EN

DOMINICAN REPUBLIC: Wirtgen Group expands highway network. SO PAULO: Environmentally-friendly road rehabilitation thanks to cold recycling.CIBER: An indispensable part of the Wirtgen Group.

ROAD AND MINERAL TECHNOLOGIESwww.wirtgen-group.com

FORUMThe magazine for customers, staff and friends of the Wirtgen Group

nUMbeR 43 issUe 1/12

Strong in Latin America

Forum 43_en.indb 1 08.06.12 14:23

FoUR stRonG bRanDs FoR the MininG anD ConstRUCtion inDUstRies FRoM a sinGle soURCe

ROAD AND MINERAL TECHNOLOGIES www.wirtgen-group.com

Forum 43_en.indb 2 08.06.12 14:24

eDitoRial | FoRUM 43 3

it is at times of economic turbulence, such as those currently

being witnessed around the world, that our far-sighted strate-

gies prove their worth, not only for us as manufacturers, but

also and particularly for our customers.

OUR LONG-STANDING WORKFORCE: AN INVALUABLE RESOURCEIt is well known that nothing can replace experience. We are now

benefitting from the fact that our repeatedly reestablished market

leadership in Road Technologies and our continually expanding

position in the field of Mineral Technologies are assured by a com-

petent workforce who are of great service to our customers in their

daily work; a workforce of exceptionally enthusiastic employees

from all around the world who work towards our joint success,

acting as once big family, regardless of their cultural backgrounds;

a team which operates with the customers in mind, which under-

stands their concerns, problems and challenges in daily working

life and offers the best possible support whenever it is needed.

With their in-depth knowledge of the market, the experts

at our headquarters develop products, focussing on quality and

economic efficiency. The result is a portfolio that fits the bill, not

only in terms of processes, but also in terms of regional condi-

tions, catering to project- or customer-related requirements. Our

customers have frequently inspired us to develop innovative

construction, cutting, processing and rehabilitation technologies,

consistently focussing on performance, costs and resource con-

servation. These processes have become a standard part of the

rules and regulations imposed by authorities issuing invitations

to tender.

BASIS FOR THE FUTURE: A CLOSE PARTNERSHIP WITH OUR CUSTOMERSTo ensure that we would always be close to our customers, we

began organizing and qualifying our sales and service companies

accordingly at an early stage. As a result, highly experienced ex-

perts are now also available there as partners for our customers.

This applies both to our own subsidiaries and to the authorized

dealers with whom we have been collaborating for many years

indeed, some have been partners so long, they are now in their

second generation. The range of services encompasses everything

from applications consulting and training to workshop or job site

services and the availability of original spare parts supported by Jrgen Wirtgen Stefan Wirtgen

practice-oriented maintenance and diagnosis systems. The sales

and service companies receive back-up from the headquarters,

creating a common competence which benefits Wirtgen Group

customers and provides them with added value.

THINK GLOBAL ACT LOCAL:OUR COURSE IN LATIN AMERICAIn this issue of the Wirtgen Group FORUM, we will mainly be fo-

cussing on the Latin American market. We will be looking at local

product development and production as well as our sales or-

ganization, including the dealers with whom we have long-stand-

ing partnerships. The modern factories in Germany are another

focal topic in this issue. We will be taking a peek over the shoul-

ders of the employees who advanced the latest innovations in

product development and production.

Having gained a lead thanks to the services of our trusty

employees around the world, our overall position is solid and we

will remain a reliable business partner at the service of our cus-

tomers.

Our warmest wishes

Dear customers, dear staff and friends

Forum 43_en.indb 3 08.06.12 14:24

4

PROJECTS + PARTNERS 08 The blessing of the Caribbean

Wirtgen Group companies sustainably improve the traffic

infrastructure of the Dominican Republic.

14 Recycling in the megacity

The Avenida Sapopemba in So Paulo is rehabilitated by

cold recycling, making economical use of resources.

SALES + SERVICE 18 A strong partner

Ciber is an indispensable part of the Wirtgen Group.

EXHIBITIONS + EVENTS 22 Global presence

Review and outlook: The Wirtgen Group at international

trade fairs.

24 Premieres in Paris

The Wirtgen Group presented four world premieres at this

years Intermat, captivating trade visitors.

SPECIAL FEATURE: DEVELOPMENT28 We are the recyclers

Customer feedback is often the initial inspiration for

Wirtgens innovations including the new WR 240.

30 A new generation

Good cooperation and far-sighted planning ensured the

successful production launch of the Vgele dash 3-zero

series.

32 A strong team for strong compactors

Customers the world over rave about the new H-series from

Hamm. Many of the advantages were developed during

construction of the prototype.

34 Never stop moving

The quality of the EVO plants is the result of decades of

experience and continual development work.

08

24 Highlights from the Wirtgen Group were eye-catchers at Intermat 2012.

Children from the slums of Rio are looked after at the Bom Samartiano day care centre.

In the Dominican Re-public, Wirtgen Group technologies expand a section of the islands most important highway.

44

Forum 43_en.indb 4 08.06.12 14:24

5

FORUM The magazine for customers, staff and friends of the Wirtgen Group

PUBLISHED By Wirtgen Beteiligungsgesellschaft mbH, Reinhard-Wirtgen-Strae 2, 53578 Windhagen, Germany, E-Mail: [email protected], www.wirtgen-group.com Commercial Register Montabaur HRB 10492, VAT No.: DE 149 525 751

BOARD OF MANAGEMENT Jrgen Wirtgen, Stefan Wirtgen, Rainer Otto

RESPONSIBLE FOR CONTENT Michaela Adams, Tel.: +49 2645-131 128, Fax: +49 2645-131 499, E-Mail: [email protected]

EDITORIAL STAFF Michaela Adams, Mario Linnemann. All rights reserved. Reproduction only with written permission by the editorial staff.

PRODUCTION muehlhausmoers corporate communications gmbh, Cologne, Germany; Project management: Jrgen Jehle, Jessika Knauer; Editorial staff: Christian Fuchs, Jessika Knauer; Layout: Tobias Heinrich, Pascal Schning, Britta Siebert

TRANSLATION interteam bersetzungsbro, Grnwald, Germany

PRINT Gebr. Kopp GmbH & Co.KG, Cologne, Germany

PHOTOS Forum 43: Dawin Meckel/OSTKREUZ (cover), Florian Kopp (p. 6-7), Jens Lyncker (p. 34 top, 43); Amendment Forum 42: HOCH ZWEI/picture alliance (cover, p. 11 bottom left), Roemers/laif (p. 6-7), Jens Lyncker (p. 42-45)

PUBLISHERS DETAILS

DIGITAL FORUMSimply download the current issue as

a pdf or send Forum 43 to a friend using

the QR code.

www.wirtgen-group.com/forum-mobil

PLANTS + KNOW-HOW36 In full swing

Wirtgen was able to sustainably optimize basic production

conditions with its new plant for special-purpose machinery.

38 High in-plant production

Vgele converted a large portion of its production facili ties

to in-house manufacturing.

40 Quality concerns us all

The Hamm QA team assures the quality of purchased

parts, processes and final products.

42 Investment in the future

A new investment has enabled Kleemann to further

extend its position as a series manufacturer in 2011.

CHILDREN IN NEED CHARITy44 Hope for children in need

The children of Rio de Janeiro get a chance for a better

life in the Bom Samaritano childrens day care centre.

30A strong team: the people behind the dash 3 generation.

Contents | FoRUM 43

Forum 43_en.indb 5 08.06.12 14:24

Roads of the futurePage 8 Motorway extension in the Dominican RepublicPage 14 Environmental protection in So PauloPage 18 Ciber: The Wirtgen Groups partner in Latin America

THE WIRTGEN GROUP IN LATIN AMERICA

6

Forum 43_en.indb 6 08.06.12 14:24

Roads of the future

toPiC | FoRUM 43 7

Forum 43_en.indb 7 08.06.12 14:24

88

The blessing of the CaribbeanWirtgen, Vgele, Hamm, Kleemann and Ciber technologies are sustainably improving the traffic infrastructure in the island state.

DOMINICAN REPUBLIC

Forum 43_en.indb 8 08.06.12 14:24

PRojeCts + PaRtneRs | FoRUM 43 9

he 223-km-long highway Corredor Vial del Este is the

main traffic route in the east of the Dominican Republic.

The project involved the extension of the 70-km section

known as the Autopista Del Coral to four lanes, each

with a width of 3.65 m, the aim being to connect the two tourist

centres La Romana and Punta Cana with their respective airports

La Romana Airport and Punta Cana International Airport. As many

as 20,000 vehicles use this important stretch of road each day.

TWENTy WIRTGEN GROUP CONSTRUCTION MACHINES IN OPERATION ON SITEFaced with complex technical requirements and an ambitious

schedule, the project management organization, the consortium

Consorcio Autopista del Coral, elected to use the reliable world

market leading machines from the Wirtgen Group, explained Jos

Luis Matallana from Resansil RD S.A., the Wirtgen Group dealer in

the Dominican Republic. A total of 20 Wirtgen Group machines got

to work in December 2010. Eighteen months later, the new Auto-

pista Del Coral section was completed as planned.

STRONG WIRTGEN SURFACE MINERS AND KLEEMANN IMPACT CRUSHERS The first construction phase involved eight surface miners and

two impact crushers. Thanks to their flexible all-terrain mobility,

the surface miners were able to make maximum use of their

capacity. The four 2100 SMs and the four 2200 SMs milled off

limestone in a single pass, producing the grain size of 0 to 4

required for its reuse for the road extension an economical

process. For the 2200 SM mines between 150 and 200 m of

limestone per hour while the thickness of the cutters only drops

by 0.01 mm per cubic metre. Not only did using the surface

miner enable us to dispense with the expensive and time-con-

suming drilling and blasting of larger lumps of rock, it levelled

the surface of the ground perfectly, preparing it for the following

steps, and saved resources, too, said Matallana.

The Mobile Impact Crusher MR 130 Z EVO processed

more of the limestone, also crushing it down to the required

T

Dominican Republic

Area: 48,700 km

Capital: Santo Domingo

Population: 10,088,600 (estimate for 2012)

GDP: US$ 51.6 billion (2010)

Road network: 19,705 km, asphalted portion: approx. 50%

Highways: 12,600 km, asphalted portion: approx. 50%

FACTS AND FIGURES

The blessing of the Caribbean

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10

1. The 3414 VIO Compactor with Vibration and Oscillation was used for the earthworks. Being able to compact in vibratory or oscillating mode, the VIO drums offer the ultimate in versatility.

2. The high-performance Super 1900-2 Paver with Extending Screed AB 500 TP2 ensures ex-tremely high-quality paving, right from the ma-terial feed stage: large, oscillating push-rollers ensure residue-free feeding by the truck a cru-cial factor in ensuring maximum evenness dur-ing paving.

3. The Batch Asphalt Plant UAB 18 E is used, in particular, in large-scale projects requiring an uninterrupted production of high-quality asphalt mixes. It can be used as a stationary or semi-mobile plant and has impressive environmental features, too.

4. Oscillating drums such as the HD O 90 V do not waste power producing unwanted vibrations in the vicinity, but guide it directly into the ma-terial to be compacted exactly where it is needed. Low vibrations guarantee a long ma-chine service life and optimum driver comfort.

10

2

1

3

4

Forum 43_en.indb 10 08.06.12 14:24

PRojeCts + PaRtneRs | FoRUM 43 11PRojeCts + PaRtneRs | FoRUM 43 11

grain sizes directly on site. Crushing 450 m of limestone per

hour, it ensured that the new base material for the further

expansion of the highway section was available in next to no time.

As a result, there was no need to procure the required material

from a mine located 40 km away, avoiding high transport costs.

TECHNOLOGIES FROM VGELE AND CIBER ENSURE A PERFECT PAVED RESULTThe excellent preparation of the soil meant that the three Vgele

pavers could start paving the lower base course immediately.

They were supported by the Ciber Cold Mix Plant USC 50 P and

the Batch Asphalt Plant UAB 18 E. Producing between 100 and

140 t of mix per hour, the UAB 18 E, for instance, supplied the

high-quality paving material without delays. The Vgele SUPER

1900-2 then got to work, performing excellently. The resultant

pavement had a remarkable evenness of below 2 m/km according

to the International Roughness Index (IRI) and a very high degree

of compaction of 88% on a 25-cm-thick asphalt pavement. As a

result, the work progressed swiftly, as no further compaction

measures were required.

The 20-cm-thick lower base course and the 17-cm-thick

upper base course were thus quickly paved, each with a width

of 6.5 m. A 4-cm binder course and a 3.5-cm wearing course

rounded off the pavement of the new traffic route.

DATA AND FACTS

Using innovative EVO technology, the MR 130 Z EVO ensures an optimum material flow, easily achieving feed capacities of 450 m of limestone per hour.

Machines used

1 x Wirtgen Soil Stabilizer WR 2400

4 x Wirtgen Surface Miners 2200 SM

4 x Wirtgen Surface Miners 2100 SM

3 x Vgele Pavers SUPER 1900-2 AB 500 TP2

2 x Hamm Tandem Rollers HD 90 and HD O 90 V

1 x Hamm Vibratory Compactor 3414 VIO

1 x Hamm Vibratory Compactor 3520

2 x Kleemann Impact Crusher MR 130 Z EVO

1 x Ciber Cold Mix Plant USC 50 P

1 x Ciber Batch Asphalt Plant UAB 18 E

Wirtgen soil stabilizers and Hamm earthwork rollers had already

ensured a perfectly cohesive foundation before the asphalt paving

work commenced. In the process, the Vibratory Compactor 3520

took on the work of two ordinary 11-t rollers, being able to com-

pact as much as 1200 m of uncompacted 25-cm-thick base

course. With their wide range of applications, the earthworks

rollers 3520 and 3414 VIO with vibration and oscillation also

Forum 43_en.indb 11 08.06.12 14:24

12

Surface miners such as the 2200 SM cut routes through native rock. This route provides an ideal sub-base for the courses of the road.

Forum 43_en.indb 12 08.06.12 14:24


greatly reduced the amount of rollers required for the project.

Hamm Tandem Rollers HD 90 put the finishing touches to the

roadway surface and, needless to say, they achieved ideal com-

paction values.

PIONEERING: WIRTGEN GROUP EXCELS IN ALL AREASBy constructing the Autopista Del Coral section and extending

the entire Corredor Vial del Este highway, the local authorities

achieved an important milestone in the improvement of their

national traffic infrastructure. Traffic safety has been greatly

improved, important centres have been linked and travelling

times slashed by up to 50%. This will not only benefit locals,

but also the tourism trade, the Dominican Republics most im-

portant industry.

FACTS AND FIGURES

Monte Plata

San Pedro de Macors

San CristbalBan

San Francisco de Macors

Venezuela

Trinidad &Tobago

St Vincent &The Grenadines

St Lucia

St Kitts & Nevis

Puerto Rico

Panama

Nicaragua

Martinique

Jamaica

Grenada

DOMINICAN REPUBLIC

HAITI

Dominica

C u b a

U.S.A.

Costa Rica

Barbados

B a h a m a s

Antigua &Barbuda

CaracasPort-of-Spain

KingstownCastries

Basseterre

SanJuan

Panama City

Fort-de-France

Kingston

PORT-AU-PRINCE

St. George's

SANTODOMINGO

Roseau

Havana

SanJose

Nassau

Bridgetown

St. John's

Kissimmee

Key West

Bartow

Oranjestad

George Town

Plymouth

The Valley

San Carlos

Bluefields

Sapzurro

Wani

San Carlos

Karawala

Karata

Auastara

Tocamacho

Kaski

Barra Patuca

Tortuguero

Drake Tucupita

West Palm Beach

Fort Pierce

Fort Myers

Santiago

Juigalpa

Puerto Limon

UpataLa FriaAyapel

Willemstad

Basse-Terre

Guanare

Coro

Ciudad Bolivar

BarcelonaValledupar

Sincelejo

Santa Marta

Monteria

Fort Lauderdale

Montego Bay

CAP-HAITIEN

Barahona

Valera

Puerto Ordaz

Calabozo

Cabimas

Anaco

El Tigre

Aguachica

Saint Petersburg

Merida

Maturin

Cumana

Barquisimeto Valencia MaracayCartagena

Barranquilla

Tampa

Miami

David

Colon

Santiago de Los Caballeros

Santa Clara

Bayamo

Ponce

Santiago De Cuba

Pinar Del Rio

Matanzas

Holguin

Guantanamo

Cienfuegos

Camaguey

Maracaibo

El Seibo

Guanare

Coro

Ciudad Bolivar

BarcelonaValledupar

Sincelejo

Santa Marta

Monteria

Fort Lauderdale

Montego Bay

SantaCruzDe Barahona

La Romana

Valera

Puerto Ordaz

Calabozo

Cabimas

Anaco

El Tigre

Aguachica

Saint Petersburg

SamanSabana de la Mar

PuntaCana

Nagua

La Romana

Data on the project

Project management organization: the consortuim Consorcio

Autopista del Coral comprising the companies

Constructora Norberto Odebrecht (CNO)

and Moya Supervisiones y Construcciones S.A

Tender issued by: Ministry of Public Works and

Communications of the

Dominican Republic SEUPC

Total project volume: 338.000 m of base course and

287,000 m of wearing course

Investment volume: US$ 255 million

Personnel during the construction phase: approx. 2,500

construction workers

Machine operators during operation: approx. 30

Autovia del Este y S. Pedro La Romana

Autopista del Coral

Boulevard del Este

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Recycling in the megacityThe Avenida Sapopemba is the busiest road in So Paulo and one of the countrys main traffic routes. It has now been rehabilitated, making economical use of resources. In operation: the KMA 220 and the MR 110 Z EVO.

ENVIRONMENTAL PROTECTION IN SO PAULO

14

Forum 43_en.indb 14 08.06.12 14:24

he Avenida Sapopemba is the busiest road in So

Paulo and one of the countrys main traffic routes. It

has now been rehabilitated, making economical

use of resources. In operation: the KMA 220

and the MR 110 Z EVO.

As in every large metropolis, extensive urbani-

zation processes are under way in So Paulo, creating

up to 16,000 t of rubble daily. The road rehabilitation

programme for the 17,000-km-long road network cre-

ates an additional 20,000 m3 of asphalt material each

month, which has been stored in refuse dumps up to

now. The municipal authorities decided to take action

and created a legal basis for the reuse of reclaimed

asphalt pavement and construction rubble in the con-

struction of new roads.

The cold recycling process is a particularly attractive op-

tion here, featuring the complete recycling of the reclaimed mate-

rial and its cost-effective processing while saving a great deal of

time, too. The municipal administration of So Paulo also opted

to use reclaimed asphalt pavement (RAP) with foamed bitumen for

the current project to rehabilitate the 5-km stretch between the

Avenida dos Sertanistas and the Rua Bento Guelfi. This

T The project has raised the benchmark for road construction

in Brazil. Antonio Monfrinatti, Managing Director (Reciclotec)


The mobility and flexibility of the plant facilitate job processing considerably. Equipped with its own energy-saving diesel engine, the KMA 220 requires no external power supply.

Forum 43_en.indb 15 08.06.12 14:24

16

marked a new departure in urban road rehabilitation in Brazil,

where RAP had only ever been used to construct new periph-

eral roads outside of cities, explained Antonio Monfrinatti,

Managing Director of Reciclotec, the Wirtgen Groups author-

ized dealer in So Paulo.

THE WIRTGEN KMA 220 AND KLEE-MANN MR 110 Z EVO LAy THE BASISThe local road construction contractor Fremix (ANE

Group) set up a recycling point in the direct vicinity of

the job site for the processing of the construction and

recycling materials as well as the RAP. This was where

the Wirtgen Group machines really came into their own.

The mobile impact crusher MR 110 Z EVO from Kleemann

crushed rubble, some of which originated from demolished build-

ings, into the specified grain sizes. The new material flow concept

enabled the impact crusher to process the material quickly and

reliably for further use. Fremix elected to use in-plant cold recy-

cling to produce the RAP. In other words, the asphalt removed by

a Wirtgen Cold Milling Machine W 1000 F was processed in a mo-

bile plant the Wirtgen KMA 220 along with foamed bitumen and

then repaved on the roadway. The plant performed impressively,

producing high-quality cold mix from recycled construction mate-

rials CDW (civil demolition waste) and achieving a high mixing

capacity of up to 220 t/h, concluded Valmir Bonfim, Engineer at

Fremix. The KMA 220 was economical in every respect: time-

consuming trips by trucks between the mix production site and

the job site were minimized. With an output of 200 t/h, a complete

truck load of 20 t of cold recycling mix was produced every six

minutes while simultaneously reducing CO2 emissions.

The KMA 220 achieved a perfect mixing

capacity and mix quality

Valmir Bonfim, Engineer (Fremix)

A PIONEERING PROJECT IN LATIN AMERICA Thanks to the efficient cold recycling process and the perfect in-

teraction of the Wirtgen Group machines, the project in So Pau-

lo was concluded swiftly and successfully and the Avenida Sap-

opemba reopened for urban traffic. The municipal administration

of the Brazilian metropolis has raised the bar in urban road reha-

bilitation with this construction project, setting a shining example

to other Latin American city centres.

The final grain quality was outstand-ing: with an output of up to 350 t/h, the MR 110 Z EVO processes quantities that can normally only be matched by much larger plants. A high-perfor-mance final screen creates the speci-fied final product.

Forum 43_en.indb 16 08.06.12 14:24


Wheeled loaders tip unbound input materials into the batching unit via vibrating grates. Precise dosing is monitored by a microprocessor-based plant control system.

Clear, user-friendly function keys facilitate the work. The machine operator adjusts the pivoting discharge belt with millimetre precision so that the finished mix can be loaded onto trucks without a hitch.

The composition of the mix is regularly checked by means of the Wirtgen Laborato-ry-Scale Foamed Bitumen Plant WLB 10 S. Mix processed with foamed bitumen is particularly durable and retains its high quality even when stockpiled for months.

Forum 43_en.indb 17 08.06.12 14:25

18

A strong partnerBesides the four strong brands Wirtgen, Vgele, Hamm and Kleemann Ciber is an indispensable part of the Wirtgen Group in the Latin American market.

CIBER EQUIPAMENTOS RODOVIRIOS

Forum 43_en.indb 18 08.06.12 14:25

19sales + seRviCe | FoRUM 43

Ciber Equipamentos Rodovirios is Wirtgen Groups lo-

cal production facility for Latin America and completes

the comprehensive product range with its own brand.

The headquarters is located in the southern state of Rio

Grande do Sul in Brazil, in the city of Porto Alegre, and extends

over 48,000 square meters. Ciber manufactures its own brand of

hot mix asphalt plants and pavers on five production lines. Oper-

ating under licence, it also produces a model from the Wirtgen cold

milling machine line and a Hamm roller in Porto Alegre, each of

which are adapted to the requirements of the local market.

CERTIFIED MANUFACTURERS OF HOT MIX ASPHALT PLANTSAlong with a logistics centre, a central warehouse, and an admin-

istrative building, the Ciber plant also boasts a training centre and

a testing ground. Last year, a special test track was created

especially for the Hamm rollers.

A strong partner

Ciber manufactures the Hamm 3411 under licence using the flow assembly process.

Spick and span assembly lines: new crane systems were one of the in-vestments made for the production of the Ciber hot mix asphalt plants.

Everything has its place in the large warehouse, with its 8-metre-high shelf system.

We have invested in the optimi-zation of our processes, enhanced our product quality, trained our dealers and forged ahead with innovations. Luiz Marcelo Tegon, Ciber Vice President

Forum 43_en.indb 19 08.06.12 14:25

MEXIKO

VENEZUELA

URUGUAY

PERU

PARAGUAY

PANAMA

NICARAGUA

HONDURAS CARIBBEAN

PUERTO RICO

ECUADOR

COSTA RICA

COLUMBIA

CHILE

BRAZIL

BOLIVIA

ARGENTINA

CUBA

DOMINICAN REPUBLIC

GUATEMALAEL SALVADOR

HAITIMEXICO

THE WIRTGEN GROUP IN LATIN AMERICA

20

Ciber has been certified in accordance with ISO 9001 (Interna-

tional Organization for Standardization) since 2011 and thus

belongs to the select group of certified hot mix asphalt plant

manufacturers.

The Wirtgens central office in Brazil (Wirtgen Brasil Sul) is

also located in the Ciber headquarters. Two further subsidiaries of

Wirtgen Brasil are located in the country: Wirtgen Brasil Centro

Oeste, located in Goinia (in the state of Gois) and Wirtgen Bra-

sil Nordeste, located in Recife (in the state of Pernambuco).

A total of 322 people work for Ciber and Wirtgen Brasil.

Nine additional authorized dealers provide excellent sales and

service support for Wirtgen Group customers in Brazil. Fifteen

further dealers in Latin America act as a point of contact for cus-

tomers from Argentina to Mexico.

www.ciber.com.br

We can count on the

excellent sup-porting team in

the manufacturing plants. With their back-up, we can dedicate ourselves to pro-viding an optimum customer service. Francisco Isaza Quintero Fiza (Columbia)

Our team is always up to date thanks to regular training and service meet-ings at the German headquarters. Diego Lopez Fizamaq (Ecuador)

We invest in the structure of our com-pany to keep

pace with our market success

and to develop additional business segments. Felix Vezjak Vezla (Bolivia)

Brazil

Ciber Equipamentos Rodovirios

Wirtgen Brasil

Vianmaq Equipamentos

Decker Brasil Equipamentos

Nicamaqui Equipamentos

Reciclotec Comercial

Motriz Equipamentos e Mquinas

Requimaq Equipamentos e Mquinas

Tratorcenter Peas e Servios

Delta Mquinas

Deltamaq Equipamentos da Amaznia

Latin America

Argentina: Covema S.A.C.I.F.

Bolivia: Vezla

Chile: Salinas y Fabres

Costa Rica: Corporacin ven Resansil de Costa Rica

Ecuador: Fizamaq

El Salvador, Guatemala and Honduras: Rensansil Guatemala

Columbia: Fiza

Nicaragua: Resansil

Mexico: Construmac

Panama: Panam Rensansil

Paraguay: Cimasa

Peru: Intermaq

Puerto Rico, Dominican Republic and Haiti: Resansil RD

Uruguay: Tradinter

Venezuela: Inversiones Resansil

ROAD AND MINERAL TECHNOLOGIES

Forum 43_en.indb 20 08.06.12 14:25

MEXIKO

VENEZUELA

URUGUAY

PERU

PARAGUAY

PANAMA

NICARAGUA

HONDURAS CARIBBEAN

PUERTO RICO

ECUADOR

COSTA RICA

COLUMBIA

CHILE

BRAZIL

BOLIVIA

ARGENTINA

CUBA

DOMINICAN REPUBLIC

GUATEMALAEL SALVADOR

HAITIMEXICO

21sales + seRviCe | FoRUM 43

Thanks to our technical service, our warranties, and our applica-tions expertise, our customers see us as an extension of the Wirtgen Group. That makes me feel proud. Manfred Baumgartner Inversiones Resansil, (Venezuela)

I am proud to be repre-senting the market leader and feel sure I am offering

customers the best machines.

Fernando Ferme Tradinter (Uruguay)

Our customers are familiar with the tradi-tion and the quality of Wirtgen Group products. That inspires confidence in us as dealers. Christian Gianakis Coverna (Argentina)

Forum 43_en.indb 21 08.06.12 14:25

LAS VEGAS

CHARLOTTE

BERCHTES-GADEN

global presenceThe Wirtgen Group is there for its customers not only on site but also at trade fairs throughout the world, where it presents the latest innovations in road and mineral technologies.

REVIEW, FIRST HALF OF 2012

World of Concrete

2327 Jan 2012

Exhibitor: Wirtgen America

Visitors: 52,088

M & T Expo

29 May 2 Jun 2012

Exhibitor: Ciber

Visitors: 45,000

Deutsche Asphalttage

810 Feb 2012

Exhibitor: Wirtgen Group

Visitors: 1,000

World of Asphalt

1315 Feb 2012

Exhibitor: Wirtgen America

Visitors: 6,500

LAS VEGAS, USA

SO PAULO, BRAZIL BERCHTESGADEN, GERMANYCHARLOTTE, USA

22

SO PAULO

Forum 43_en.indb 22 08.06.12 14:25

JunE

610 Jun 2012

ANKOMAK 2012, Istanbul, Turkey

1921 Jun 2012

Hillhead 2012, Buxton Quarry, Derbyshire,

UK

AuguST

2325 Aug 2012

Turkmenconstruction, Ashgabat,

Turkmenistan

SEPTEMBER

1621 Sep 2012

Capac Expo Habitat 2012, Panama City,

Panama

2022 Sep 2012

Entreprenad Expo 2012, Knutstorp,

Sweden

2429 Sep 2012

International Technical Fair, Plovdiv,

Bulgaria

OCTOBER

1518 Oct 2012

ROAD 2012, Moscow, Russian Federation

1617 Oct 2012

Deutsche Straen- und Verkehrskongress

2012, Leipzig, Germany

1720 Oct 2012

Baku Build 2012, AZ 1128 Baku,

Azerbaijan

2426 Oct 2012

DorTransExpo 2012, Kazan, Russian

Federation

nOvEMBER

2123 nov 2012

Asphaltica 2012, Padua, Italy

2730 nov 2012

bauma China 2012, Shanghai, China

www.wirtgen-group.com/fairs

PREVIEW, SECOND HALF OF 2012

The Wirtgen Group will also be represented at trade fairs throughout the world in the second half of 2012. Its well worth looking in! Here is a selection of events until the end of the year:

MAKE A NOTE!

intermat

1621 Apr 2012

Exhibitor: Wirgen France

Visitors: 200,000

CTT

29 May 2 Jun 2012

Exhibitor: Wirtgen International

Visitors: 30,000

PARIS, FRANCE MOSCOW, RUSSIAN FEDERATION

exhibitions + events | FoRUM 43 23

PARIS

MOSCOW

Forum 43_en.indb 23 08.06.12 14:25

24

Premieres in ParisThey were the stars of the Intermat 2012: the Wirtgen Groups four world premieres. Trade visitors were truly captivated and enthused about the technical highlights of the top exhibits.

INTERMAT 2012

Forum 43_en.indb 24 08.06.12 14:25

exhibitions + events | FoRUM 43

Once again, this years international trade fair for con-

struction machinery, construction materials machin-

ery and construction technology proved extremely

popular, attracting some 200,000 visitors. Presenting

31 road construction machines in Paris on an area of about

2,000 m2, the Wirtgen Group showcased a cross-section of its well

established product range in the road and mineral technologies

25

sector. Drawn by the four world premieres, the Wirtgen Cold Re-

cycler and Soil Stabilizer WR 240i, the Vgele Paver

SUPER 2100-3i, the Hamm compactor H 20i and the mobile im-

pact crusher MR 130 ZS EVO from Kleemann, trade fair visitors

were given a comprehensive overview of the machines from a

total of ten product lines. Experts from the four strong brands

were available to offer advice and answer any questions on

WiRTgEn AnD REPROAD maintain excellent rela-

tions and this also extends to our technical collabora-

tion. The company offers a sensational range and qual-

ity of products in the milling and soil stabilization segments. In

matters of service, Wirtgen is absolutely close to its customers.

Michel Ltscher, Managing Director of the REPROAD Group (left) with his son Benedikt Ltscher

WE PuRChASED our first Vgele paver back in 1987

and have appreciated the quality, the price-perfor-

mance ratio and the after-sales service in Tunisia ever

since. We have extended our fleet with the purchase of an

MT 3000-2, the Super 3000-2 as well as 36 Hamm rollers.

Noureddine Hachicha, President of the Tunisian SOROUBAT Group

iT WAS ExCiTing to see the reactions of the trade

visitors to our products. The feedback from our cus-

tomers was very positive, confirming that we address

their needs and requirements on the job site and translate them

into targeted solutions in our new developments.

Benot Etienne, President of Wirtgen Francee

WE hAvE gREAT TRuST in the products, the service

and the personnel of Wirtgen France. We ordered 16

Wirtgen milling machines at the Intermat and our fleet

now comprises 176 of these units. Some of the new machines will

also go to our new subsidiary Fraisavia.

Michel Chauvet, Managing Director of von Soloc

Forum 43_en.indb 25 08.06.12 14:25

26

the various technological segments. Experienced applica-

tions engineers provided interested trade visitors with exten-

sive first hand information on current new developments, as is

usual in the Wirtgen Group.

Visitors to the Wirtgen Group pavilion were unanimous

about one thing: bursting with innovative features which cater

precisely to customer requirements, the new product develop-

ments are certainly impressive. They offer real added value

which will mainly benefit the operators who work with the ma-

chines each day on the job site. In this respect, the four world

premieres fit in perfectly with the Wirtgen Groups portfolio of

tried-and-tested solutions.

www.wirtgen-group.com/intermat

OnCE AgAin, the Wirtgen Groups trade fair presen-

tation was impressive. I enjoy visiting the pavilion and

finding out about the latest developments. We cooper-

ate with Vgele on a partnership basis. The SUPER 800 and the

SUPER 1600-2 are successful machines in our range.

Reinhard Roth (right), North Rhine-Westphalia Branch Manager for HKL Baumaschinen

ThE innOvATivE STREngTh of the Wirtgen Group

constantly amazes me. Often, it is the supposedly mi-

nor optimizations which prove most effective in terms

of user-friendliness or economic efficiency. In the case of the EVO,

I am particularly taken with the new material flow concept.

Damien Masson (right), TPDM

i BOughT My fiRST milling machine in the mid-1970s,

back in the early days of Wirtgen. I held many construc-

tive conversations with the company founder Reinhard

Wirtgen and this was important for both parties. Wirtgen has al-

ways forged ahead with the further development of its machines.

Gnter Meyer, founder and former Managing Director of GMS Fahrbahnsanierungen

WE hAvE BEEn WORking very economically with

Ciber, Wirtgen and Vgele products for many years now.

I would now like to introduce the cold recycling process

to Algeria, with the help of experts from Wirtgen. Thus we can ad-

vance environmentally friendly road construction in the country.

Dr. Kamel Mehsas (left), President of Rotahem and Chairman of the Civil Engineering Association in Algeria

Forum 43_en.indb 26 08.06.12 14:25

Be it standard or special-purpose milling drums cutting technology is Wirtgens core competence.

exhibitions + events | FoRUM 43 27

The four world premieres from Wirtgen, Vgele, Hamm and Kleemann were the main attraction for visitors, alongside machines which have been successful on the market for many years.

The principle of oscillation demonstrated in a tangible form in the special presentation.

Forum 43_en.indb 27 08.06.12 14:25

five very different job sites, but the story always the same:

the Wirtgen Soil Stabilizer and Cold Recycler WR 240i

glides effortlessly over the substrate, whether it is stabi-

lizing heavy swampy soil or cold recycling a motorway.

This machine is the product of a technical development which

began with the customer before being implemented by Wirtgen

product managers, applications engineers, design engineers and

production workers.

For product managers, regular exchanges with customers

are a key source of ideas from practical applications. Which fea-

tures help operators in their day-to-day work? Which technical

details could further enhance economic efficiency? Supplemented

by experience and the well-founded test results of Wirtgens ap-

plications engineers, this information is pooled, sorted and vetted

for viability. An initial picture emerges at this stage. This is when

the design engineers at Wirtgen GmbH come into play, collaborat-

ing with the product management and applications engineering

teams on a development project to design the new machine, tak-

We are the recyclersIt sets new standards in terms of performance, user-friendliness and end prod-uct quality as field tests have proven. But which factors shaped the develop-ment of the WR 240i? And who are the people behind it?

MAKING OF: WIRTGEN WR 240i

ing applications and sales aspects into account. And the develop-

ment of the WR 240i was no exception

COMMUNICATION IS A CRUCIAL PART OF THE CONCEPTUAL DESIGN Continuous communication between all parties is decisive during

this phase. If the development objectives are to be met, our de-

sign engineers must be provided with transparent, detailed infor-

mation, explained Christoph Menzenbach, Applications Engineer

at Wirtgen. Once all interfaces and work sections such as steel

construction and electrical design had been involved and the

conceptual design work completed, we could then begin with the

construction of a prototype, added his colleague Heiko Bhme,

who has overall project responsibility.

Whether the machine meets Wirtgens high quality stand-

ards in practice and can thus go into series production becomes

clear during the test phase. The WR 240i was hence subjected to

28

Forum 43_en.indb 28 08.06.12 14:25

site. And Wirtgen does its utmost to transfer its know-how to its

customers. For instance, not only are the sales and service person-

nel at the headquarters familiarized with all the details, but also

the teams at Wirtgens 55 sales and service companies and even

the staff of the 100 authorized dealers worldwide. This enables

them to pass on the expertise they have gained on applications

and servicing to the customers. This knowledge transfer marks the

end of the long development process for the WR 240i, from con-

ception to market maturity.

www.wirtgen.de

The team who designed and constructed the brand newWR 240i.

WR 240/WR 240iWorking width 2,400 mmWorking depth 0-510 mmEngine output 447 kW/433 kW

prolonged and exacting tests in a wide variety of applications.

External feedback is also important here, particularly responses

from machine operators. This soon reveals any aspects that need

further tweaking and indicates which features work and are well

received, said Menzenbach. The WR 240i passed muster on the

job site and was approved for series production. The multi-func-

tional joystick is a particularly big hit with machine operators, mak-

ing their work much easier, said Christoph Menzenbach, who is

overjoyed with the positive feedback.

AFTER-SALES SERVICE ROUNDS OFF THE NEW DEVELOPMENTAs always, Wirtgens contact with its customers does not end with

the sale of a machine. Indeed, this is just the beginning of a lasting

service partnership. Training courses are an important factor, en-

suring that customers learn all the details of the machines so that

they can harness all of the advantages of the WR 240i on the job

sPeCial FeatURe: DeveloPMent | FoRUM 43 29

APPROVED

Forum 43_en.indb 29 08.06.12 14:26

The new dash 3 paver generation from Vgele is a

product series bursting with innovative features. The

development of the new SUPER 1900-3 and 2100-3

machines demanded exacting work from Project Man-

ager Thomas Schmidt and his team. It all starts with a project

study. We set out our development aims and target costs for the

new product and prepare ideas for technical solutions, collaborat-

ing closely with Production Management, Sales, Service and Mar-

keting, explained Schmidt. If a conceptual design fulfils the

specifications, the project group then develops a 3D model of all

the individual parts using a CAD program. The entire machine is

created in this way, bit by bit. The highest quality at optimized

costs: that is the prime objective, said Thomas Schmidt. We

scrutinized the main assemblies over and over, thinking of ways

to further improve the drive units, traction and the conveyance of

A new generationCross-departmental collaboration, a definition of measures and far-sighted planning: this was the recipe that ensured the successful production launch of the dash 3 zero series. A peek behind the scenes.

MAKING OF: VGELE DASH 3

mix. But financial aspects arent the only factor, of course: the

development aims take priority.

WORKING HAND IN HAND TO CREATE THE MOST ECOLOGICAL PAVER IN THE WORLDWhen designing new machines, the team must always take ac-

count of the European exhaust gas emissions standard COM 4 and

the US standard EPA TIER 4f, too. One of the great challenges of

the dash 3 project was the task of uniting engine variants in a

single machine by means of a modular design in order to avoid a

duplication of the different model series. Another aim was to use

the smallest possible range of parts for the dash 3 series to

simplify parts management in the factory. This makes for stream-

lined procurement, storage and supply processes in assembly.

30

Forum 43_en.indb 30 08.06.12 14:26

poses. We often pass on suggestions for improvements to the

Engineering department.

Thomas Mette completes the triumvirate. He is responsible

for all tests on the prototypes. The high temperature test is above

all extremely important to us, as Vgele pavers are supposed to

function perfectly at the highest temperatures and at full load,

said Mette. We aim to guarantee optimum cooling while avoiding

excessive fan speeds which would increase fuel consumption un-

necessarily and make the machine louder. These tests led to the

development of a new feature in the dash 3 paver generation

the variable-speed fan.

www.voegele.info

A strong team (from the left): Hermann Vetter, Thomas Mette and Dieter Kolba in front of theSUPER 2100-3i displayed at the Intermat 2012.

A prototype is created once the 3D drawings and parts lists are

complete. Three Vgele employees play a pivotal role here: Her-

mann Vetter, Prototype Construction Manager, Dieter Kolba, De-

signer in the Final Assembly department and Thomas Mette, Ex-

perimental Technician. Our department collaborates closely with

the Engineering department. We discuss new features together

and test their feasibility and suitability for series production, said

Hermann Vetter. The development team involves Dieter Kolba, too,

at an early stage, as he is responsible for the smooth start of

series production. In the beginning, the SUPER 2100-3 and SU-

PER 1900-3 will be produced alongside the dash 2 generation,

which is due for discontinuation. We have to ensure that the

assembly equipment is suitable for all the models and that the

tools required are available on site, explained Kolba. Parts are

frequently installed and then dismantled again for testing pur-

SUPER 2100-3iNominal output 186 kW at 2.000 rpmMaximum pave width 13 mMaximum laydown rate 1.100 t/h


APPROVED

Forum 43_en.indb 31 08.06.12 14:26

32

The mechanical components for the H-series had long been

designed with 3D-CAD and welded or bolted together vir-

tually. What were missing were the electrical cables and

hydraulic hoses. Project Manager Thomas Bletscher ex-

plains why: Computer-aided design has its limitations. Prototype

builders are needed for the fine-tuning and exact positioning of these

components.

HANDS-ON MACHINE DEVELOPMENT WITH PROTOTyPINGTechnicians breathe life into the CAD designs. No easy task, consid-

ering that the H 20i consists of some 2,500 different parts in various

quantities, as well as numerous hydraulic hoses and cable har-

A strong team for strong compactorsCustomers the world over rave about the new H-series due to its ergonomic design, ease of operation and high traction and compaction performance. Many of these application advantages are developed as early as during the prototype phase.

MAKING OF: HAMM H 20i VIBRATORY COMPACTOR

nesses. Determining their optimum position and length was no mean

feat with the H-series, as many assemblies had been completely

redesigned to provide the Tier 4 technology with the additional space

it requires without increasing the size of the compactors. Markus

Pilz, an industrial mechanic on the prototyping team, sheds light on

another challenge: We aim to ensure that no hydraulic hoses collide

with other components, even during extreme manoeuvring. That was

tricky with the H-series, but we succeeded nonetheless.

The prototype development process corresponds to the sub-

sequent series production process, with the chassis, engine and front

tractor unit coming first in line, followed by the hydraulic systems and

the electrical cables. As usual, most components fitted perfectly right

from the start when constructing the first H-series prototype. And if

something didnt fit, then a creative solution was called for. The

Forum 43_en.indb 32 08.06.12 14:26


A strong team for strong compactors

The core team behind the H-series from the development and design department: designers, control engineers and prototype builders

prototype builders are familiar with the production processes and

they know what is required for simple and safe assembly. They dont

give up until theyve explored every avenue. Thats how innovation

works, explains Thomas Bletscher, a mechanical engineer, about

his team, which always cooperates closely with colleagues from the

series production and job preparation teams.

CLOCKING UP THE OPERATING HOURS AND LONG-TERM TESTINGAs soon as the prototype was ready, it was Karl Schleichers turn to

step in: Im the fi rst person to try all new compactor models. With

the H-series, I was amazed at the clarity of my colleagues design for

the 25t heavy H 25i. And he should know, as its his job to test the

H 20i VIBRATORy COMPACTOROperating width 2,140 mmOperating weight with operators cab 19.7 tStatic linear load, front 60.3 kg/cm

H 20i VIBRATORy

compactors in all situations, i.e. driving, compacting, steering, turning,

fuelling, heating and cooling, even testing the horn and cleaning the

machine. He tested the H 20i for well over 1,000 hours in standard and

extreme situations on the factory grounds, on different surfaces and

on countless job sites. Karl provides us with valuable feedback on

the handling of the machine. Sometimes there are unusual noises,

other times he has an idea that could improve the ergonomics, ex-

plains Thomas Bletscher. A positive customer response is our re-

ward. However, the team is far from fi nished after building the H 20i

and its sister models the H 18i and H 25i. The creative engineers and

technicians are now completing additional models with a lower oper-

ating weight, with ideas, know-how and unparalleled commitment.

www.hamm.eu

APPROVED

Forum 43_en.indb 33 08.06.12 14:26

34

A typical job site situation: a derelict industrial facility is

knocked down and a track-mounted impact crusher pro-

cesses the demolition waste. If the material includes not

just the usual steel reinforcements but larger steel struc-

tures, too for instance a section of a double-T beam an ordinary

plant can soon get damaged, but not an EVO plant from Kleemann!

Indeed, the company, based in Gppingen, Baden-Wrt-

temberg, has decades of experience in the development of crush-

ing plants and works continually to improve them. Our work is a

challenge for every engineer, said Thomas Khnle, Head of the

Development department. We give new ideas plenty of space and

tread new paths each day. Kleemanns engineers have come up

with countless innovations in the relatively young domain of track-

mounted impact crushers. For instance, a system that protects the

crusher from overloads: if a steel girder gets into a crusher in the

Mobirex MR 110 EVO series, the crushing rocker automatically

moves back to prevent damage to the rotor.

never stop movingKleemanns Mobirex EVO plants process a vast range of materials reliably and efficiently. This quality is the result of decades of experience and continual development work.

MAKING OF: MOBIREX EVO PLANTS

And thats not all by a long shot: a high-performance screening

unit with two screen decks ensures the effective primary screening

and a steady material flow. The optimized crusher infeed geometry

ensures that the material is guided perfectly into the impact range

of the rotor. The width of the conveyor system increases progres-

sively in the direction of material flow, making material blockages

a thing of the past. Further winning features of the plants include

wear-optimized baffle plates, an economical drive concept and a

high safety factor.

KLEEMANNS CUSTOMERS ARE A KEy DRIVER OF INNOVATIONSInnovations are frequently inspired by individual customer require-

ments. For the Bernegger Group, Kleemanns engineers developed

a track-mounted plant which can crush limestone without the clay

deposited on the machine impeding the material flow. The team is

Forum 43_en.indb 34 08.06.12 14:26


painters later on in the process. It generally takes three years for

a machine to progress from the drawing board to the finished plant.

Thomas Khnle sees a great deal of potential for further

optimization of the mobile EVO plants in future. His team is set on

further improving the control and material flow while cutting pow-

er consumption.

For us, its not about achieving the highest maximum short-

term plant output, emphasizes Khnle: The ideal EVO plant is not

a sprinter but a marathon runner. It runs at a consistently high

level, but it never stops moving.

www.kleemann.info

Thomas Mssner (far left), Thomas Khnle (far right) and the Development department team work continually to optimize the EVO plants.

MOBIREX 130 ZS EVOOutput 450 t/hCrusher inlet 1,300 x 900 mmEngine output 384 kW

currently working for an Australian company, developing a machine

set comprising several interlinked plants for the processing of iron

ore. Thomas Mssner, Head of the Mobile Technology department,

recently paid a visit to the site to get an idea of the progress being

made. Field work on customers premises is what makes my work

exciting, he says. This is where I get to combine theory and prac-

tice perfectly.

CROSS-DEPARTMENTAL TEAMWORK FROM THE IDEA TO THE IMPLEMENTATIONApart from custom-built products, Kleemann naturally develops

series models, too. The needs of the market are the central aspect

here: how heavy can a plant be? What can it cost? At the start of

a project, Thomas Khnle and his team hold in depth discussions

with their colleagues from Purchasing, Production and Assembly.

After all, the design has to be feasible for welders, electricians and

MOBIREX 130 ZS EVO

APPROVED

Forum 43_en.indb 35 08.06.12 14:26

36

in full swingSince going into operation at the start of the year, production has been in full swing in the new plant for special-purpose machinery. Countless improvements have sustainably improved basic conditions.

e reported on the factory extension in

Windhagen and the extension of the

plant for special-purpose machinery in

Issue 42. Some six months down the

line, the first results speak for themselves: improved

quality, optimally coordinated processes and shorter

production times for cold recyclers, slipform pavers and

surface miners.

SURFACE MINER 4200 SM PRODUCTION TIME CUT The Surface Miner 4200 SM is a prime example of the increase in

productivity: its production time has been cut by a week. The

additional space available is a valuable resource for production.

Then theres the fact that we have almost doubled the number of

employees in our division, explained Norbert Lenzenbach, Fore-

man in the Special-Purpose Machinery division, which includes

the Wirtgen surface miners. The success of the special-purpose

machines on the market means that the production plan remains

demanding, despite the increase in personnel, said Lenzenbach,

who is looking forward to the upcoming challenges for himself and

his motivated team.

NEW CRANE AND PRE-ASSEMBLy FACILITATE RECyCLER PRODUCTIONKlaus-Peter Brabender, Foreman in the Recycler Series Production

division, reports on optimizations in recycler assembly: Thanks

to the new 2 x 10-t crane with two trolleys, we can move our mill-

ing drums and engines without stressing the materials and position

them absolutely precisely for installation. We used to need two

cranes for this job. The additional room has also created more

storage space, improving the flow assembly process. According

to Brabender, This means that we can also combine the pre-as-

sembly of various series on site, further boosting efficiency.

The logistics systems also benefited from important pro-

cess optimizations. Order picking is now a great deal easier for

the entire production hall and is no longer confined to the respec-

WIRTGEN: NEW PLANT FOR SPECIAL-PURPOSE MACHINERY

W The extended production halls provide us with

the space we need to process

orders more flexi-bly and respond more

quickly. Norbert Lenzenbach, Foreman in the Surface Miner division

With the new, flexible crane, we can transport assemblies which used to be impossi-ble or extremely difficult to move.Klaus-Peter Brabender, Foreman in the Recycler Series Production division

Forum 43_en.indb 36 08.06.12 14:26

Plants + Know-how | FoRUM 43 37

tive hall nave, explained Thomas Buchholz, Foreman

in the Slipform Paver division. Preassembly and the

small parts store for slipform pavers have now also

been geared to the various assemblies, enabling us to

reduce transport routes, too. Planning is even more

flexible as response times have also been reduced.

The aim of the hall extension was to equip Wirt-

gens special-purpose machinery production facilities to

meet the challenges of the future. The first six months in the

new plant for special-purpose machinery have shown that Wirtgen

is on the right track.

The optimized process steps help us to as-sure and even

boost quality within shorter pro-

duction times.Thomas Buchholz, Foreman in the Slipform Paver division

More than twice the space: the final assembly hall for special-purpose machines has seven new hall naves, extending the total area from 11,000 to 25,000 m2. Surface miner production is one of the areas to benefit.

Forum 43_en.indb 37 08.06.12 14:26

When relocating its headquarters, Joseph Vgele AG converted various sections of its production facilities to in-house manufacturing, by investing additionally some 4.5 million in new processing machines in 2012.

38

high in-plant production

VGELE: INVESTMENTS IN PRODUCTION

Compared with the 3-KW system used hitherto, the two Trumpf L3030 laser cutting systems reduce the cutting time by about 35% in each case.

Forum 43_en.indb 38 08.06.12 14:26

Modern machines, short routes and

economical work processes: the

new factory of Joseph Vgele AG

in Ludwigshafen, Rhineland-Palat-

inate has all of these features to offer. In the past

year, the traditional brand in the Wirtgen Group

invested around 4.5 million in the improvement of

its production facilities. A Heckert HEC 1000 type

processing centre was added to each of the flexible

manufacturing systems (FFS) for the machining of welded com-

ponents for screeds. Meanwhile, the optimized travelling routes

minimize the processing time per workpiece by 30%.

Two new laser cutting systems simplify the cutting of sheet

metal in the production of screed components. The machine is

loaded via an integrated turntable while the laser in the interior

cuts sheets up to 25 mm thick. The sheets are transported di-

rectly from the raw materials warehouse to the machine by a chain

conveyor. Short routes like this are typical of the Vgele plant with

its ingenious layout.

WELDING ROBOTS GUARANTEE A PERFECT PRODUCTION CyCLEVgele invested in two large stand-alone robot cells, each

equipped with four or five welding devices, in order to weld the

basic frame of the extending screeds AB 500 and AB 600 and their

extension frames even more economically. The special feature of

the system is that it sets up and machines simultaneously. The

pallets are automatically conveyed to the robot and then welded.

At the same time, more pallets are being loaded in the upstream

area so that there are no robot downtimes in the cycle. A small

robot cell was also procured for welding the bottom component

assemblies of the screed frame and for producing smaller welded

screed components.

Two new CNC turning machines make for simpler handling

and two-fold time savings. Firstly, there is a 20% reduction in the

processing time thanks to the higher rapid feed speed. Secondly,

over 10% of the non-productive machine time is saved by the out

of round turning function, as the workpiece needs to be clamped

less frequently, improving material flow.

IMPROVED WORKING CONDITIONS FOR THE LUDWIGSHAFEN TEAMVgele considered the welfare of its employees, too: many se-

quences are now much simpler and the workplaces are more er-

gonomic. The large welding robot cells bring nothing but benefits

for the workers who operate them: height-adjustable loading sta-

tions mean that they can adapt their working environment to suit

their statures. Vgele has also enhanced health and safety by in-

stalling an efficient smoke extractor at the rewelding station.

And where does it go from here for the worlds most ad-

vanced paver factory? We were primarily concerned with ways to

boost capacity in 2011. We are currently planning various replace-

ment investments and will be phasing out old, less effective ma-

chines to make way for modern ones, said Siegried Khler, Pro-

duction Manager.

We have already ordered a new straightening press for as-

semblies and a CNC turning machine for tubes. The new systems

will be up and running by the end of 2012.

www.voegele.info

39Plants + Know-how | FoRUM 43

We currently are planning various replacement

investments and will be phasing out

old, less effective machines to make way for modern ones.Siegfried Khler, Production Manager

Shift Supervisor Jaganjac Zicrija loading a large robot cell with frames for the Extending Screed AB 600.

Forum 43_en.indb 39 08.06.12 14:26

4040

Quality check right behind the factory gate: random checks are performed on in-dividual products in accordance with SAP requirements.

Sum quid quiatque sunt ut harum earum disqui dolupit a porit doloreped mo magnam quibus quam ducimus ea derum qui si nullabo. Testions

The final check at the testing stands is the responsibility of long-standing employees with a wealth of knowledge and experience of production.

From the engine temperature to the vibration drive: a roller has to pass some 50 individual tests before it is given a quality test seal.

Forum 43_en.indb 40 08.06.12 14:26


Quality begins with the development, is the motto of

Wendelin Geiler, Head of Quality at Hamm, but all

the other sections of the company make a major con-

tribution to quality, too. An internal quality assurance

process covers everything, including external suppliers. This is

why Hamm has been concluding new QA contracts with strategi-

cally important suppliers since 2010.

The supplier must know how its products are going to be

used if it is to produce in the appropriate quality, explained the

QA Manager Geiler. A team formulates the intended use and the

requirements of every part for this purpose. Colleagues from

the Quality, Purchasing and possibly Production depart-

ments conduct an audit to check that suppliers pro-

cesses are suitable for producing the required qual-

ity and quantity. Once theyve overcome this hurdle,

initial samples and pre-production series are

manufactured before series production starts.

Not only do individual incoming parts un-

dergo stringent random inspections, but the qual-

ity awareness of the assembly workers is also in

demand. Supported by the QA team, all members

of staff are sensitized to specific quality features in

their working environment and trained.

TARGETED QUALITy MANAGEMENT IN THE PRODUCTION PROCESSThe quality deviation report (QAB) is an effective QA tool. This is

where employees note down any defects they notice, for instance

during assembly or the final check. Collaborating with the workers,

the QA team investigates causes, scrutinizes parts, processes and

specifications and works out measures to prevent the same de-

fects from reoccurring in the future. At the same time, the quality

assurance staff analyse data from the SAP QM module, to pinpoint

trends and identify optimization potential.

Quality concerns us allEnsuring the quality of purchased parts, processes and final products is the main task of the QA team at Hamm. The staff are involved in the entire production process, from the supervision of suppliers right up to shipment.

HAMM: QUALITY MANAGEMENT

Each roller is rigorously examined during the final check in the

testing hall before its status is changed to ready for dispatch.

The shipping audit, a final inspection, was introduced in 2011 to

test the machines directly before shipment. QA staff conduct ran-

dom inspections on the function and appearance of the rollers. It

is gratifying to see that the number of defects registered at this

stage is falling continually. Wendelin Geiler knows why: QA

measures are now firmly established in production. The work we

have done over past few years is bearing fruit.

We conduct our inspections with customers interests in mind.

Michael Schedl, Shipping Audit Quality Inspector

Quality can only be produced if every-one involved is committed to achieving it.Wendelin Geiler, Head of Quality

www.hamm.eu

Forum 43_en.indb 41 08.06.12 14:26

investment in the futureEffective flow assembly, flexible assembly lines, and short throughput times. Following its plant expansion, Kleemann has greatly increased its production since 2009. The company has thus extended its position as a series manufacturer, thanks to new investments over the past year.

KLEEMANN: SUCCESSFUL SERIES PRODUCTION

kleemanns investments are paying off. Alongside the

four new welding booths in which Kleemann trains its

next generation of skilled specialists, a new welding

robot has also joined the team in Gppingen. Since

last year, Kleemann has been using the robot to manufacture rotors

for its mobile crushing and screening plants, vastly increasing its

internal rotor production. Helge Borsody, the Head of Steel Con-

struction, is enthusiastic about the new acquisition: The old robot

needed 26 hours to weld a rotor. We have been able to shorten

that time to 17 hours, using our newest robot. Its all a question of

the right programming and the right know-how! The Kleemann

team is still tweaking the programming. Only when the robot is

optimally programmed will it be able to work reliably and essen-

tially unsupervised, said Oliver Khlkopf, Borsodys deputy and

Kleemans welding expert. The advantage is already obvious: by

speeding up internal production of its core components, Kleemann

can produce in higher quantities, without needing to depend on

suppliers.

Kleemann, located in Gppingen, produces almost all of

the core components for its plants itself a strategy that offers

many advantages, as Helge Borsody explains: Our employees

know best what is important for components in assembly. The

dimensions fit virtually one hundred percent. And if, on rare occa-

sions, this is not the case, there is no need to go through official

channels, as the teams can discuss the matter directly. Klee-

manns great in-house production depth allows it to respond

quickly to new situations. Borsody can swiftly expand a production

team if there is a run on chutes, rotors, or screens.

TEAM MEMBERS ENSURE PROSPEROUS SERIES PRODUCTIONHowever, the success of the investments depends upon the ded-

ication of the teams on the factory floor. And this is why motivating

team members and involving them in the optimization processes

is a top priority at Kleemann. Once a month, we get together as

a team and think about how we can improve the work process. It

is often team members who work on the same assemblies day

after day that come up with the best ideas, said Borsody. The

successful optimizations of the past few years have proven him

correct.

www.kleemann.info

42

Forum 43_en.indb 42 08.06.12 14:26

Oliver Khlkopf knows that good welders are hard to find and puts a lot of time into training young talents.

Working under supervi-sion, the apprentices learn their craft in the welding booths.

The use of a welding robot shortens the time it takes to weld a rotor by more than nine hours.

Helge Borsody wants to boost production quantities this year, too.


Forum 43_en.indb 43 08.06.12 14:26

44

hope for children in needA chance for the kids of Rio de Janeiro: around 100 boys and girls are currently benefi ting from the care and education offered by the Bom Samaritano childrens day care centre in the Ipanema district.

BRAZIL

Forum 43_en.indb 44 08.06.12 14:26

ChilDRen in neeD ChaRitY | FoRUM 43 45

Forum 43_en.indb 45 08.06.12 14:27

46

io de Janeiro is a beautiful city, with enchanting beach-

es, imposing mountains and modern shopping centres.

But Rio is not just Sugar Loaf Mountain; the favelas are

also just as much a part of the city. The word favela

originally referred to a hill in Rio on which former mercenaries built

an illegal shanty town in 1879. In the middle of the last century,

the city became increasingly attractive for the impoverished rural

population and more and more people were forced to take up

quarters in the makeshift dwellings of one of the over 1,000 fave-

las that exist today. Poor education, high unemployment and low

income affect the majority of the people who live there. Sometimes

their meagre income is not even sufficient to pay for the staple rice

and black beans, not to mention milk, fruit or medical care.

Most of the families in the favelas live in shacks made from

wooden boards or bare brick walls. They often have to share their

one or two rooms with their extended families. The power and

water supply are poor and the sanitary conditions catastrophic. In

addition, the favelas are ruled by drug gangs, and violence and

shootings are commonplace.

The men try to escape the harsh realities of daily life with

drugs and alcohol. Violence directed at women and children is an

everyday occurrence. Many women supplement their income

through prostitution. Struggling with these hardships, families of-

ten lack direction and the strength to devote themselves to their

childrens upbringing.

ACHIEVING MORE TOGETHER

These were the issues addressed by Father Braun when he found-

ed Bom Samaritano in 1979. He set himself the task of alleviating

the indescribable misery of the children as much as he could. As

he came up against difficulties with the funding of his project, he

asked Kinder in Not e.V. to provide ongoing support. The day care

centre is in Ipanema, next to the deprived Cantalego district.

Juliana and Luane are lovingly cared for in the safety of the day care centre.

R

In the deprived areas, families live in shanties, often without electricity or water.

Preschool attendance increases the childrens chances of graduating from school.

Health care is a top priority at Bom Samaratino.

Forum 43_en.indb 46 08.06.12 14:27

ChilDRen in neeD ChaRitY | FoRUM 43 47

Vilma and her staff were horrified and visited the family immedi-

ately with a food package. Together they sought solutions and

ensured that at least the most urgent bills were paid. The team did

not rest until the mother had found a permanent job. She is now

also receiving psychological therapy, and Kauan and Miguel can

smile again.

ALLEVIATE MISERy AND OFFER A FUTURE

What prospects do the children in Bom Samaratino have today?

The children from the favelas have no social skills and many are

traumatized by the violence that surrounds them. As a result, most

of them already come to grief at primary school. The newspaper

O Globo reported on 29 February 2012 that of the 171,000 children

who started school in 2010, 34,000 stopped going, and many had

to repeat the year. Children who attend preschool have been

shown to fare much better in primary school and are much less

likely to drop out. Thanks to the work of Bom Samaratino and the

support of Kinder in Not e.V. these children have better prospects

for successful schooling and hence a more responsible, self-reliant

life later on.

Without the support of Kinder in Not e.V. the day care cen-

tre would have to close. What would become of these children?

Donation accounts

Sparkasse Neuwied

Account No. 012 022 752

Bank code 574 501 20

Raiffeisenbank Asbach-Neustadt

Account No. 100 052 724

Bank code 570 692 38

The charity

Founded in 1983 on the initiative of Gisela Wirtgen

Provides help and relief education on a voluntary, altruistic basis

Maintains and supports relief projects in the Philippines, India, Chile,

Argentina and Brazil

further information

www.kinder-in-not.de

CHILDREN IN NEED CHARITY

Children in Need Charity

Gisela Wirtgen, Chairwoman

Yours sincerely,

Around 100 boys and girls from age two to six are looked after

there every day from 8 am to 5 pm. The smallest ones attend a

kindergarten group, and the older children one of the three pre-

school groups to prepare them for primary school. At least while

they are in the centre, they are safe from the violence and terror

of the drug gangs and are provided with a decent shelter. They

receive some of the things that are missing in the misery of their

own homes: fresh drinking water and nutritious meals. A paediatri-

cian carries out regular examinations, vaccinations and weight

checks, and a dentist checks and treats the childrens teeth and

instructs them in daily oral hygiene.

The importance of involving the mothers in the centres

work can be seen by the case of the brothers Kauan and Miguel.

They have been attending the centre for three years. Early this year

they started to become increasingly solemn and introverted. Vilma,

the director of Bom Samaratino, finally received the following let-

ter from the mother: I am writing this letter in desperation. I can

see no other option than to take my life. Apart from the two boys

I have an eight-month-old baby. My husband has been convicted

for drug dealing and is in prison. As his wife I am branded, and no

one will employ me. The house where I live with my children is not

only a health risk but also full of rats. Sometimes we have no food,

electricity, water or soap to wash our clothes.

We require donations for our aid project in Ipanema to give the children a chance of a better future.

Forum 43_en.indb 47 08.06.12 14:27

ROAD AND MINERAL TECHNOLOGIES www.wirtgen-group.com

The Wirtgen Group stands for leading, innovative road and

mineral technology products. All of the four Wirtgen Group

brands have had a marked impact on the development of

machines and processes. Our passion for road construction

and mineral extraction and processing drives us to continue

to perfect our portfolio. Customers have always been the

central focus, which is why the Wirtgen Group not only offers

customized product solutions, but a first-class worldwide

service as well. Close to our customers is our pledge one

that we not only proclaim but also put into practice.

CLOSE TO OUR CUSTOMERS

Forum 43_en.indb 48 08.06.12 14:27

P. 1: TITLEP. 3: EDITORIALP. 4: CONTENTSP. 8: PROJECTS + PARTNERSP. 8: The blessing of the CaribbeanP. 14: Recycling in the megacity

P. 18: SALES + SERVICEP. 18: A strong partner

P. 22: EXHIBITIONS + EVENTSP. 22: Global presenceP. 24: Premieres in Paris

P. 28: SPECIAL FEATURE: DEVELOPMENTP. 28: We are the recyclersP. 30: A new generationP. 32: A strong team for strong compactorsP. 34: Never stop moving

P. 36: PLANTS + KNOW-HOWP. 36: In full swingP. 38: High in-plant productionP. 40: Quality concerns us allP. 42: Investment in the future

P. 44: CHILDREN IN NEED CHARITYP. 44: Hope for children in need

Documents

FORUM 43 EN