Wirtgen Group Spreaders and Technology

www.wirtgen-group.
com
Edition: April 2013
INNOVATIVE CONSTRUCTION
TECHNOLOGIES OUR PASSION.
ROAD AND MINERAL TECHNOLOGIES
CONTENTS
PREFACE PAGE 4
WIRTGEN GROUP PAGE 6
History Page 8
Company structure Page 10
BRANDS AND TECHNOLOGIES PAGE 12
Wirtgen Page 14
Vgele Page 22
Hamm Page 26
Kleemann Page 30
PRODUCTION PLANTS AND KNOW-HOW PAGE 32
Main plant of Wirtgen Page 34
Main plant of Vgele Page 36
Main plant of Hamm Page 38
Main plant of Kleemann Page 40
Local production plants Page 42
CUSTOMER SERVICE WORLDWIDE PAGE 44
Sales and service companies Page 46
Service and more Page 50
Consulting from A to Z Page 52
2 I 3
SERVING THE WORLDS CONSTRUCTION INDUSTRY.
Stefan Wirtgen Jrgen Wirtgen
These technologies, which are used on an
international scale, are served by the German
headquarters of the Wirtgen Group: Wirtgen,
Vgele, Hamm and Kleemann. With their
modern plants that we keep investing in on an
ongoing and long-term basis. In addition to
further plants located in Brazil, China and India,
which manufacture a selected range of prod-
ucts. And with their worldwide subsidiaries
the sales and service companies and a large
number of authorized dealers.
This fervour, the passion for genuine progress,
will continue to be our motivation in the future.
Because passion seems to us to be the best
driving force on the road of success.
Welcome to the world of the Wirtgen Group.
4 I 5
Fully committed to genuine progress
Any invention, any forward-thinking innovation
in the production of exciting machines which
complete jobs today that nobody would have
dared to think about in earlier times they are
all made possible solely by the people standing
behind them. Visionaries, engineers, techni-
cians and users. Individuals who join forces in
a combined effort when the maxim is: Lets
gather ideas, lets get started.
Because it is only from the fascination and res -
ponsibility for products and services epitomizing
genuine progress that the enthusiasm arises
which opens up new horizons. As a company
operating on a global scale, the Wirtgen Group
has therefore fully dedicated its services to the
construction industry in all parts of the world.
Technologies for road construction that is how
we perceive our core business. The underlying
philosophy reads: being a service provider. And
being a pacesetter and innovator for the
development of construction methods which
offer a high degree of economic efciency and
environmental sustainability. Also being an
investor in environmentally friendly technologies
for the mining and processing of mineral raw
materials in the Mineral Technologies line of
business.
GROUP TECHNOLOGIES PLANTS SERVICE
A GROUP OF COMPANIES AT HOME IN THE WORLD.
6 I 7
The power of the Wirtgen Group comes from the strength of
its four core brands with their distinctive wealth of experience.
State-of-the-art production plants in Germany and a global
sales and service network are the hallmarks today of the
Groups successful business model.
As a global player, the Wirtgen Group focuses on two areas
of business in which it has established a successful market
position. Wirtgen Road Technologies comprises the technologies
for the new construction and rehabilitation of roads. Wirtgen
Mineral Technologies encompasses the technologies for the
mining of mineral deposits and for the processing of mineral
raw materials and recycling materials.
1971:
Built and operated by Wirtgen one of
over 100 Wirtgen hot milling machines
for surface course removal.
Four strong brands a major chapter of mechanical engineering in Germany
Each of the four brands of the Wirtgen Group Wirtgen, Vgele, Hamm and Kleemann
contributes a wealth of experience in machinery and plant construction. Altogether, this adds
up to 520 years. The employees of the specialized brands have played a vital part
at all times in the ongoing development of the processes in their core businesses.
1938:
Self-propelled spreader from Vgele for even
asphalt paving.
1940:
The rst blacktop paver model from Vgele
with pre-compaction.
An innovator since 1836:
Joseph Vgele AG
Vgele has contributed numerous milestones to
the development of the road paver technology.
These include the innitely variable hydraulic
drive, automated grade and slope control,
combined tamping and vibrating screed,
single-tube system for paving width control,
electric screed heating, and pressure bars for
high compaction driven by pulsed ow hydrau-
lics. The latest development is a paving process
that enables two asphalt layers to be paved in
hot-on-hot application.
Over 50 years of pioneering technologies
for the world: Wirtgen GmbH
The company history of Wirtgen GmbH is
marked by numerous innovations for the new
construction and rehabilitation of roads. With
tremendous pioneering spirit, the company
worked its way up to become the world market
leader in road milling machines, set milestones
in the in-situ recycling of construction materials,
and perfected the automatic paving of concrete
slabs. The range of technologies is completed
by large machines for the mining of mineral
deposits.
PROGRESS IS TRADITION WITH US.
1911:
Hamm builds the rst road roller worldwide
equipped with a diesel engine.
1950:
Hand-fed, wheeled mobile jaw crusher
with drum screen.
The Wirtgen Group and its
leading companies have
always played a major role
in the development and
maintenance of trafc
infrastructure on a global
scale.
Technology leader for over 150 years:
Kleemann GmbH
Kleemann began to get actively involved in
minerals processing as early as the 1920s,
developing and manufacturing the rst mobile
crushing and screening plants. From the 1960s,
the company focused to an ever-increasing
extent on the production of stationary plants,
and was among the pioneers in manufacturing
mobile tracked plants for the natural stone and
recycling industry in the mid 1980s.
Progress has been a hallmark
for over 130 years: Hamm AG
Being a trendsetter and pioneer, Hamm has
launched numerous innovations, thus setting
the standard in compaction technology.
Examples include the rst road roller equipped
with a diesel engine, the rst tandem roller
with all-wheel drive and all-wheel steering, or
dynamic compaction using oscillation. These
and many other pioneering technologies are the
milestones in Hamms company history, which
goes back more than 130 years.
8 I 9 GROUP TECHNOLOGIES PLANTS SERVICE
Wirtgen Road Technologies:
Number 1 worldwide
Wherever roads are concerned, the Wirtgen
Group impresses with innovative solutions,
internationally recognized processes and a
comprehensive, state-of-the-art product
portfolio which meets the highest demands.
Whether new construction or rehabilitation,
asphalt or concrete roads, from narrow bicycle
paths to airport runways capable of taking
extremely high loads the Wirtgen Group offers
its customers a compelling range of machines
and services, which have enabled it to success-
fully acquire the market leadership in mobile
road construction equipment.
SUCCESS IS ALSO A MATTER OF STRUCTURE.
ROAD TECHNOLOGIES MINERAL TECHNOLOGIES
Wirtgen Mineral Technologies:
On track for success
Wherever the mining of mineral deposits and
the processing of mineral raw materials are
concerned, the Wirtgen Group impresses with
innovative technologies designed for real-world
application and for meeting even the most
challenging operating conditions. Whether
mining hard rock or coal in 24/7 operation or
operating interlinked crushing and screening
plants in a quarry: highest reliability and low
operating costs are the hallmarks that ever
more frequently speak in favour of using
technologies from the Wirtgen Group.
10 I 11
Wirtgen Group
One company, at home in the world
Wirtgen Beteiligungsgesellschaft is the holding
company of the Wirtgen Group. It comprises four
main plants in Germany, three local production
facilities outside of Germany, and 55 own sales
and service companies located in all parts of the
world. This successful business model includes
the cooperation with system partners, and
additional customer service through authorized
dealers. The clear structure of the Wirtgen Group
is characterized by family tradition and highly
decentralized responsibility.
HOLDING COMPANY:
WIRTGEN BETEILIGUNGSGESELLSCHAFT
Main plants
in Germany
International
production facilities
Sales and service
companies
SALES
AND SERVICE
COMPANIES
55 own
companies worldwide
CIBER LTDA.
Porto Alegre, Brazil
WIRTGEN GMBH
Windhagen
JOSEPH VGELE AG
Ludwigshafen
HAMM AG
Tirschenreuth
KLEEMANN GMBH
Gppingen
WIRTGEN CHINA
Langfang, China
WIRTGEN INDIA
Pune, India
OUR HALLMARKS:
INNOVATIVE TECHNOLOGIES.
Innovator market leader pacesetter pioneer trailblazer.
There are many names for the strong position of the four
German brands united under the umbrella of the Wirtgen
Group. For Wirtgen, Vgele, Hamm and Kleemann have
shaped numerous tried-and-tested technologies for the
construction industry and opencast mining industry worldwide.
This strength will continue to be a hallmark of the Wirtgen Group.
For innovative construction, mining and processing methods
made in Germany are more in demand than ever before, and are
appreciated by
investors and
users around
the globe.
12 I 13 GROUP TECHNOLOGIES PLANTS SERVICE
MILLING MACHINES FROM THE WORLD MARKET LEADER:
THE BENCHMARK FOR HIGH PERFORMANCE.
1
WIRTGEN COLD MILLING MACHINES
1 The W 250i is ideal for
fast work on large milling
job sites.
2 Wirtgen W 35 DC
small milling machine
removing the markings
on a country road.
3 This W 100 F cold mill-
ing machine from Wirtgen
is milling off the complete
asphalt pavement in re-
stricted space conditions.
4 A Wirtgen W 200 cold
milling machine in the
process of rehabilitating
a surface course.
14 I 15
2 3 4
Unmatched customer focus through core
competency in cutting technology
Wirtgens leading position is based in no small
part on its core competency in cutting technol-
ogy. It comprises everything, from low-wear
cutting tools and the various toolholder sys-
tems all the way to complete milling drums of
most diverse design. All components are
specically tailored to t the milling machine
they are used in. The Flexible Cutter System,
for example, permits milling drums to be
changed quickly and easily, thus enabling dif-
ferent types of jobs to be carried out by one
single machine. An unbeatable advantage when
it comes to using the machines in different
applications. The range extends from ne mill-
ing used to prepare surfaces for the application
of thin pavement layers all the way to the eco
cutters. These are milling drums with a wide
tool spacing, allowing large areas to be milled
at high production rates. In addition to the
comprehensive delivery range of standard
and optional milling drums, Wirtgen offers its
customers the design and manufacture of
special, customized milling drums.
Roads, motorways, airports, industrial
estates: rehabilitation using Wirtgen cold
milling machines
Wirtgen road milling machines remove individual
pavement layers on a large scale or complete
pavement packages at full depth. The reclaimed,
granulated material is a high-quality construction
material suitable for recycling which is directly
loaded into trucks for removal from site.
Typical of a rehabilitation project involving pave-
ment replacement: the new pavement is placed
immediately following the removal of the dam-
aged layer, thus permitting short construction
times for this type of rehabilitation project.
Wirtgen offers the broadest machine portfolio
worldwide of currently 26 models. Standard mill-
ing widths range from 30 cm to 2.20 m. The
worlds largest milling drum, manufactured by
Wirtgen, has a working width of 4.40 m. The
milled material is loaded via a detachable rear
loading conveyor in the small milling machines,
and via a two-stage conveyor system with front
loading conveyor in the large milling machines.
WIRTGEN RECYCLERS
INNOVATIVE MACHINE CONCEPTS:
BENEFICIAL TO ENVIRONMENT AND RESOURCES.
1 Wirtgen Remixer reha-
bilitating a bituminous
surface course by hot
recycling.
2 This Wirtgen 3800 CR
cold recycler with inte-
grated paving screed is
recycling a carriageway
lane across the full width.
3 Wirtgen KMA 220 cold
recycling mixing plant pro-
cessing milled material
near the paving site.
4 Soil stabilization with a
limestone/cement mixture
for the construction of an
industrial site using the
WR 250.
1 2 3
Recycling pavements and entire carriageways
Different technologies are used, which depend
on whether the damage is limited to the roads
surface course or has been caused by struc-
tural defects.
Hot recycling involves the rehabilitation of
bituminous surface courses a job that the
Wirtgen Remixer completes in a single pass.
In the process, the asphalt pavement is
softened, recycled with binding agents and
supplementary mix, and then placed again
immediately true to grade and slope.
In the cold recycling process, the bound and
unbound layers of the pavement structure are
milled at full depth and recycled by adding new
binding agents and additives to produce a
stable layer capable of withstanding trafc
loads. Using the innovative foamed bitumen
technology ensures superior performance
characteristics of the recycled layers and
additionally reduces the cost for binding
agents in the recycling operation.
Resource-saving technologies for
pavement rehabilitation
The time eventually comes for every road that
its service life is at an end, and rehabilitation
measures are required to preserve the pave-
ment substance. The worlds largest eet of
recyclers from Wirtgen offers the cutting-edge
technologies to do just that. For an environmen-
tally gentle rehabilitation of road pavements, the
existing construction materials are fully reused,
which signicantly reduces material costs. In
that way, the recyclers from Wirtgen are making
a major contribution to the future in all parts of
the world as environmental protection and the
considerate treatment of natural resources play
an ever-increasing role also in the domain of
road construction.
16 I 17
4
Stabilizing soil: for an extended lifespan
Offering a working depth of up to 56 cm and
tremendous area performance, the Wirtgen
stabilizers mill soil that lacks bearing capacity.
While evenly mixing in pre-spread binding
agents at the same time. Aiming to stabilize and
improve the subgrade of roads, car parks,
industrial facilities, airports, harbour facilities or
track beds. For an extended lifespan.
WIRTGEN SLIPFORM PAVERS
THE BENCHMARK IN CONCRETE PAVING:
PERFECTION.
1
using stringlines or wireless 3D systems, all the
way to the automatic insertion of dowel bars
and side tie bars. Whatever the job at hand is:
the Wirtgen slipform pavers can be relied on to
produce precise concrete proles and made-to-
measure concrete pavements of high bearing
capacity.
Across all widths:
Automated concrete paving
Wirtgen slipform pavers do a precision job
wherever concrete slabs or monolithic proles
need to be paved. In road construction, on
airports or in special applications. Numerous
intelligent systems work hand in hand in the
fully automated machines: from the charging
equipment ensuring uniform and continuous
concrete feeding, and precise levelling systems
18 I 19
2 3
Tremendous performance:
Paving high-quality concrete slabs
Concrete roads are extremely durable. Their
tremendous compressive strength prevents the
formation of wheel ruts even when used by a
high percentage of heavy vehicle trafc. Such
concrete pavements, which need to withstand
exceptional loads each and every day, are paved
and smoothed by the Wirtgen slipform pavers at
working widths of up to 16 m. The dual-layer
paving method is particularly economical. In
this process, the slipform paver places both the
stable bottom-layer concrete and the wear-
resistant top-layer concrete in one single
operation. This not only minimizes labour
requirements and reduces construction times
but additionally permits tremendous savings in
construction material.

Truly versatile:
Monolithic proles in offset application
The smaller slipform paver models work in off-
set application, which permits the production of
a nearly limitless variety of concrete proles.
The slipform can be mounted either on the left
or on the right side of the machine to adapt to
the specic paving situation, such as accom-
modation of trafc in the area of the construc-
tion site. Fitted with an intelligent quick-change
system, the pavers are capable of completing
various different jobs on a single day, which
enhances both their exibility and degree of
utilization.
1 Fully automatic paving
of a high-quality concrete
slab with the Wirtgen
SP 1600 slipform paver.
2 Paving a concrete
safety barrier with the
Wirtgen SP 15.
3 Paving a concrete
safety barrier with the
Wirtgen SP 25.
4 Paving a concrete slab
at an airport with the
Wirtgen SP 500.
4
WIRTGEN SURFACE MINERS
AROUND THE CLOCK:
HEAVY-DUTY MACHINES FOR TOUGH APPLICATIONS.
1 Mining and direct load-
ing of iron ore with the
2500 SM surface miner.
2 Mining and windrowing
of coal in an opencast
mining operation.
3 Mining lignite coal with
the 4200 SM surface
miner. The cut material
is loaded directly into
dumpers.
1 2
Economical mining of mineral deposits
Surface mining is a method for the mining of
mineral deposits that is well established on an
international scale and dispenses with conven-
tional drilling, blasting and primary crushing.
Surface miners cut, crush and load the material
in one single machine pass meaning that one
single machine completes the job of many
different pieces of equipment. The mining
operation thus becomes simple and econo m-
ically efcient because there is no need to
co-ordinate different sub-processes. The
surface miners produce small-sized material in
the mining operation, so that crushing of the
material in a separate work step is dispensed
with.
Selective mining of thin seams
ensures high quality
The machines adjustable cutting depth allows
even thin seams to be mined selectively and
with high purity, thus contributing to a better
exploitation of the mineral deposit. While mate-
rials of different qualities are mixed when using
conventional methods involving blasting, and
need to be separated again afterwards in a
highly complex process, selective mining using
Wirtgen surface miners results in an improved
quality of the useful mineral mined, which also
entails lower processing costs.
20 I 21
3
Maximum machine availability
Surface miners are used as the principal mining
technology and are typically operated on a
24-hour basis. To ensure maximum machine
availability, Wirtgen offers a unique customer-
specic service for large-scale projects: in close
cooperation between the German main plant
and the Wirtgen Groups local subsidiary,
Wirtgen sets up additional service facilities in
the immediate vicinity of the customers site.
Service centres ensure the professional repair
or overhaul of surface miners while enabling a
comprehensive parts inventory to be stocked at
the same time. It goes without saying that, as
part of the efcient service concept, highly
qualied Wirtgen Group specialist staff is
present at the service centre and mine all the
time to ensure optimal machine support.
BUILDING ROADS FASTER.
TRACKED AND WHEELED ROAD PAVERS
1
1 Vgele Super 2100-3i
maximum comfort and
high performance with
minimum fuel consump-
tion.
2 Paving a surface course
in special asphalt to en-
sure the durable perfect
grip of a Formula-1 race
track in Texas, USA, with
the Super 2100-2.
3 The SUPER 800 is idea
for small to medium-sized
jobs.
4 The VISION Paver 5103-2
was specially designed for
the US market.
A comprehensive road paver portfolio
Vgele offers a nely tiered product portfolio
of both tracked and wheeled road pavers.
Customers can choose from a range of state-
of-the-art, highly reliable machines extending
from mini and footpath pavers all the way to
large pavers capable of working at paving
widths of up to 16 m.
Vgele pavers are distinctive for their innovative
and reliable engineering. All machines feature
state-of-the-art control technology and heavy-
duty, reliable components for conveying the
material to be paved.
The drive concept of all tracked pavers from
Vgele offers maximum precision and traction,
enabling them to work at powerful advance
speeds all the time. Wheeled pavers are
distinctive for their excellent manoeuvrability
and ease of transport on their own wheels.

22 I 23
2 3 4
Pioneering development:
The ErgoPlus operating concept
All machines in the dash 3 generation are
equipped with the highly ergonomic and readily
comprehensible ErgoPlus 3 operating concept.
The innovative operating concept offers the
machine operator a perfect working environment
to ensure no-fatigue working. It gives the operator
excellent all-round visibility on the paver, enabling
him to monitor and control all processes on the
construction site at all times.
The ErgoPlus operators consoles have been
arranged with functionality and clarity in mind,
enabling the machine operator and the screed
operator to perform all paving functions safely
and easily.
The InLine Pave method
The new InLine Pave concept offered by Vgele
is a highly innovative paving method that is
particularly suitable for the hot-on-hot paving
of compact asphalt structures. InLine Pave
enables the binder course and the surface
course to be paved in a single operation,
which not only results in a perfect bond but
also in an excellent interlock between layers,
both of which are essential prerequisites for
the durability of roads.
The SprayJet process
SprayJet technology from Vgele offers an
economical and clean alternative wherever
pre-spraying and subsequent paving are
required.
Paving screeds
The range of paving screeds offered by Vgele
caters to a broad variety of most diverse
applications. Standard and extending screeds
from Vgele enable paving operations to be
carried out at widths ranging from 0.5 m to
16 m. In addition to asphalt, Vgeles high-
precision screeds are also ideally suited to
paving other materials, such as concrete,
gravel or special mixes.
Whether footpaths, bicycle paths, landlls or
squares, the construction of country roads and
motorways, or the high-precision paving of rac-
ing circuits or airport runways placing highest
demands on evenness road builders and civil
engineering companies can depend on the
Vgele paving screeds to perform any job with
maximum precision and reliability.
PAVING TECHNOLOGY MEETING HIGHEST DEMANDS.
PAVING SCREEDS AND SPECIAL MACHINERY
1 2
3
24 I 25
1 Technology leadership
in action: a screed paving
asphalt at a working width
of 16 m.
2 The spray paver Super
1800-2 SprayJet applies
emulsion which is then
immediately paved over
with asphalt.
3 InLine Pave enables two
asphalt layers to be paved
in a single machine pass.
MAXIMUM QUALITY IN ASPHALT COMPACTION.
1
26 I 27
2 3
Just the right roller for any application
User-friendly, extremely productive, built to eld
requirements, easy to service, economical
these are the hallmarks of the tandem rollers
from Hamm. Not for nothing have nearly all
machines in the current product portfolio been
awarded major international prizes for their
user-friendly and innovative design. The well-
balanced design of the small rollers in the
CompactLine, or of the tandem rollers in the
HD+ or HD series with operating weights of up
to 14 tons, provides operators with a perfect
view of the roller drums and the working envi-
ronment on site. The tandem rollers with all-
wheel steering in the DV series impress with
their panorama concept and innovative driving
and steering system allowing the operator to
drive forward all the time. The product portfolio
is complemented by pneumatic-tyred rollers
and static three-wheeled rollers.
Oscillation:
Higher strength in fewer roller passes
Achieve higher density in fewer roller passes,
and compact dynamically where other rollers
can work in static mode only these are the
main highlights of oscillation compaction from
Hamm. The principle: the roller drum is made to
vibrate horizontally instead of vertically while
maintaining contact with the ground all the
time. The technology thus increases the perfor-
mance in standard applications, such as the
construction of base or binder courses. But
thats not all because it permits dynamic com-
paction also when paving asphalt on bridges,
compacting surface courses, producing thin
pavement layers or compacting in the vicinity of
vibration-sensitive structures.
1 The oscillation technol-
ogy of the HD+ rollers de-
veloped in Tirschenreuth
has proven an excellent
choice for compacting
surface courses on Grand
Prix race tracks.
2 The articulated tandem
rollers and combination
rollers of the award-win-
ning CompactLine offer
a perfect view of the
drum edge.
3 The DV 90 tandem roller
with all-wheel steering
offers roller drivers an
ergonomically optimized,
fully equipped workplace.
OFFERING ECONOMICAL STRENGTH:
SINGLE-DRUM COMPACTORS FROM HAMM.
1 The high-climbing H 20i
the Hammtronic intel-
ligent microprocessor
control permits a grade-
ability of up to 70%.
2 The three-point articu-
lated swivel joint guaran-
tees unsurpassed direc-
tional stability and highest
driving comfort.
3 Area-wide compaction
monitoring via HCQ
ensures the quality and
durability of the road.
1
equipped with either smooth drums or padfoot
drums. Single-drum compactors in VIO design
are even capable of compacting with vibration
or oscillation. Their wide variety of possible
applications makes these single-drum compac-
tors versatile and highly economical multi-
purpose machines.
Creating the foundation
Earth compaction rollers need to produce
ground of high bearing capacity. Single-drum
compactors from Hamm guarantee maximum
productivity and quality in performing this job
while offering low consumption rates and ease
of operation at the same time. The broad prod-
uct range comprises machines from 5 to 25 tons
HCQ Hamm Compaction Quality:
The modular measuring and documentation
system for compaction
Measure compaction parameters, such as asphalt
temperature or stiffness, evaluate any changes,
and document compaction results HCQ is capa-
ble of all that. The HCQ GPS Navigator, for exam-
ple, permits continuous compaction control in
earthmoving operations, which produces ground
of uniform bearing capacity even when compact-
ing large areas with different types of subsoils. In
asphalt compaction, HCQ is synonymous with
complete process evaluation. It supports the roller
drivers in compacting asphalt surfaces systemati-
cally and homogeneously, thus preventing insuf-
cient or excess compaction while increasing
compaction quality at the same time.
Hammtronic
the intelligent co-pilot of the roller driver
HAMMTRONIC is an electronic machine
management system which ensures optimum
performance of the rollers in any working
situation. HAMMTRONIC monitors all engine
and machine functions, in particular travel drive,
vibration, oscillation and engine speed. The
system adjusts both vibration and travel speed
to the operating conditions prevailing on site,
prevents spinning of the roller drums or wheels,
and enables compaction even on gradients of
up to 70%. In addition, HAMMTRONIC ensures
low fuel consumption rates and low noise
emissions.
28 I 29
2 3
FOR FINEST AGGREGATE FRACTIONS:
HEAVY-DUTY CRUSHING AND SCREENING PLANTS.
1 This three-stage crush-
ing plant from Kleemann
with screening of nes
produces up to seven
different nal aggregate
fractions.
2 The high performance
offered by crushers from
Kleemann is crucial for
the economic efciency
of a quarry.
3 The new mobile jaw
crushers in the Mobicat
EVO series set standards
in terms of performance,
economic efciency and
consumption.
1
30 I 31
3 2
Impressive: up to 1000 t/h, 6 sizes, approx.
150 different congurations
Kleemann offers leading technologies for the
processing of mineral raw materials and for the
recycling of construction materials. The compa-
nys range of products comprises six jaw crusher
models of various sizes, a variety of impact
crushers of different sizes, as well as gyratory
crushers and screening plants. For a broad
performance range extending from 100 t/h to
1000 t/h. The delivery range includes tracked
mobile plants suitable for low-loader transport
with 150 different customer-specic plant
congurations.
Economic efciency through mobility
The operation of tracked mobile crushing and
screening plants right on the production site
offers a high degree of economic efciency.
In quarries or in the recycling of concrete,
asphalt or other construction materials. The
economical performance of a plant is enhanced
even further by tailoring it to accurately t the
customers specic requirements. The major
parameters include: prevailing local conditions,
the processing operation, and requirements on
the quality of the nal product. Experience
gained in many decades plays an important role
when Kleemann offers turnkey processing
plants for all sectors of the primary industry.
In planning, production, assembly and initial
operation.

FROM WINDHAGEN TO LANGFANG:
WHERE OUR PROS ARE AT WORK.

32 I 33
Wirtgen, Vgele, Hamm and Kleemann these four highly
specialized main plants are united under the umbrella of the
Wirtgen Group. Each of the four plants contributes its own,
specic technological know-how. The entire process chain,
from engineering all the way to manufacture and assembly
of the machines, is precisely tailored to the brand-specic
product ranges.
State-of-the-art manufacturing processes and sophisticated
systems for quality assurance are in place not only in the
German main plants but also in the local production facilities
in Brazil, China and India. A global strategy implemented to
last.
WIRTGEN MADE IN WINDHAGEN.
1
66 machine models produced in one location
Windhagen is home to the biggest main plant of
the Wirtgen Group. Milling machines, hot recyclers,
cold recyclers, slipform pavers and surface miners
are built here in the main plant of Wirtgen GmbH.
Parts production is highly versatile as a result,
comprising in particular those parts that are essen-
tial components of Wirtgens core competencies.
It includes the entire sphere of cutting technology,
that is, the production of milling drums for road
milling machines, recyclers, soil stabilizers and
surface miners. The high-quality construction
machines with their practical equipment features
are then produced on the various assembly lines.
Targeted plant expansion in 2012
Doubling the production space for its range of
special-purpose machinery, Wirtgen responds to
their exceptional market success. The new ca-
pacities guarantee an even faster and more ef-
cient assembly of the complex large machines.
In addition to that, processes are optimized sig-
nicantly by moving the Steel Construction divi-
sion to the immediate neighbourhood of the nal
assembly plant for special-purpose machines. Al-
together, the concept of minimizing distances is a
key theme across the entire production plant as
the assembly lines at the nal assembly plant for
the series machines have also been consistently
optimized with a view to short lead times.
34 I 35
3 2
1 The high-quality con-
struction machines from
Wirtgen are manufactured
at this plant. The Wirtgen
Groups head ofce is
also located here in
Windhagen.
2 Cutting technology is a
core competency: high-
precision manufacture of
milling drums.
3 Flow assembly of cold
recyclers and soil stabiliz-
ers for consistently high
quality and short through-
put times.
VGELE MADE IN LUDWIGSHAFEN.
1 2
In-house production for
highest component quality
Vgeles experienced core workforce produces
the complete range of market-leading tracked
and wheeled road pavers at the companys lo-
cation in Ludwigshafen. The production of indi-
vidual parts and assembly groups in pre-fabri-
cation is distinctive for specialized
manufacturing methods and a high degree of
automation. Welding robots and highly exible
machining centres with computer-controlled
workpiece and tool control are used, for exam-
ple, guaranteeing the production of high-quality
products. Material ow is controlled by state-
of-the-art methods, thus ensuring short lead
times and enabling fast adjustment to the parts
demand resulting from customer requirements.
The new Vgel plant
manufacturing facility of superlatives
Since 2010, the machines of the world market
leader have been built at and shipped from the
worlds most modern plant for road pavers in
Ludwigshafen on the Rhine. It ranks among the
most signicant decisions to invest throughout
Europes machine construction industry. Build-
ing the new production plant on a green belt
site enabled the entire workow to be designed
and implemented in line with process optimiza-
tion principles so as to ideally match Vgeles
requirements. For example, all model ranges
have been restructured to ow production. In
addition, the cycle times of the individual as-
sembly lines have been optimized further to im-
prove synchronization of the different model
ranges on one line. Machines with customized
equipment features are thus continuously pro-
duced to highest quality standards and in ex-
tremely short lead times. After attaching the
screed to the tractor unit, each paver is sub-
jected to extensive quality testing prior to leav-
ing the plant.
1 Assembly is organized
in accordance with ow
production principles,
thus enabling optimum
material ow.
2 Vgele experts use
state-of-the-art measur-
ing technology, such as
the coordinate measure-
ment machine, to detect
any deviations in quality.
3 The production of road
pavers is in full swing at
the new main production
plant of Joseph Vgele AG.
36 I 37
3
A new dimension in instruction and training
In addition to the new production facilities, spe-
cial emphasis is placed on the new Centre for
Training and Technology, short CTT. Ongoing
training of the operators of Vgele road pavers
takes place in the nearly 3,000-m large training
centre. Training courses at Vgele take place in
an environment that is ideal in terms of both
space and functionality.
A separate training ground is available, for ex-
ample, which allows the training participants
from all parts of the world to simulate the pro-
cess of road construction and to learn how to
perfectly control the Vgele technology.
The birthplace of state-of-the-art
compaction technology
Hamms employees produce the world-
renowned rollers of highest quality at the
companys location in Tirschenreuth. In two
large assembly plants, the single-drum com-
pactors, tandem rollers and static rollers are
produced on cyclic assembly lines. Highly
qualied expert staff assembles the rollers from
individual parts and pre-assembled component
groups, customizing them in accordance with
customer requirements. Following assembly,
each machine must pass stringent quality
checks prior to being shipped to customers
in all parts of the world. The smart logistics,
intelligent warehouse systems and organization
of the assembly lines have earned the location
its name it is called the plant of short
distances.
HAMM MADE IN TIRSCHENREUTH.
1 2
1 The drums for the
world-renowned Hamm
rollers are manufactured
from thin steel sheets on
state-of-the-art produc-
tion lines.
2 Cyclic assembly lines
ensure efcient manufac-
turing and high quality in
series production.
3 Everything to do with
compaction is produced
at the Tirschenreuth loca-
tion.
38 I 39
3
of both the markets and the products, enabling
Hamm to respond to enquiries exibly and in an
extremely short period of time.
Maximum exibility
at consistently high quality
Hamm AG has expanded its capacities yet
again in 2008 by building the worlds most
modern plant for drum production. Processes
in the new section of the plant are essentially
tailored to series production but permit an
efcient assembly of very small lot sizes as
well. This aspect is becoming increasingly
important in times of an ongoing diversication
KLEEMANN MADE IN GPPINGEN.
1
Flexibility in plant assembly,
efciency in parts shipping
Optimized supply of production materials is
ensured by the large warehouse covering a total
area of 2,600 square metres, which enables
exible adjustment to the assembly process.
Plants from different product lines can be
manufactured in the assembly division quite
easily to fully adapt to current order levels.
Yet another mark in favour of the new produc-
tion facility: combined with the large ware-
house, state-of-the-art logistics systems enable
highly efcient shipping of original parts to any
destination around the globe.
Series production with maximum
productivity and product quality
From prefabrication all the way to nal
assembly at Kleemanns new main plant in
Gppingen, all production processes have now
been brought together under one roof. Short
distances and state-of-the-art manufacturing
processes enable Kleemanns staff to produce
their leading-edge crushing and screening
equipment under optimal conditions.
Process innovations, such as the environmen-
tally friendly powder coating plant, improve the
quality of the core components manufactured
at the new production facility. Assembly of the
crushing and screening plants in cyclic assem-
bly at four production lines increases productiv-
ity while minimizing delivery times, with a con-
sistent quality assurance system guaranteeing
adherence to the high quality standards.
40 I 41
1 Short distances and
optimal manufacturing
processes are the hall-
marks of Kleemanns new
main production facility at
the Stauferpark industrial
estate in Gppingen.
2 Qualied technicians
and a high vertical inte-
gration make for premium
end products.
3 Cyclic assembly at four
production lines reduces
the lead times in the as-
sembly of the crushing
and screening plants.
3 2
LOCAL PRODUCTION FACILITIES:
WORLD CLASS LOCAL PRESENCE.
1 The headquarters near
Pune offer sufcient
production capacities to
supply large unit numbers
to the Indian market.
2 The production plant of
Vgele America is located
in the heartland of the
American market.
3 Construction machinery
for the Latin American
markets is produced at
Ciber in Porto Alegre.
1
42 I 43
3 2
The Wirtgen Group operates local production facilities in Brazil, China and India which ensure
optimum coverage of country-specic demands by producing close to the market and with a local
procurement share. In doing so, their focus is always on one common goal: fully satisfying the
requirements of our customers.
Ciber:
Products for Latin America
Ciber, a company of the Wirtgen Group head-
quartered in the Brazilian city of Porto Alegre,
produces mixing plants for road construction in
Latin America. The plants are also exported to
Africa. Wirtgen road milling machines and Hamm
single-drum compactors for the Latin American
market also roll off the assembly line.
Wirtgen China:
Machine assembly and more
In Langfang, close to the Chinese capital of
Beijing, the Wirtgen Group has set up a base
that not only accommodates an assembly plant
but also includes a sales and service centre
with workshop and parts warehouse. The local
product range includes selected models of
Wirtgen cold milling machines, Vgele road
pavers and Hamm rollers. The percentage of
parts and assembly groups procured locally is
increasing continuously, with the same strict
quality standards being applied as in the
German main production plants.
Wirtgen India: Single-drum compactors
made for India
The Indian subsidiary of the Wirtgen Group is
based near the industrial centre of Pune in the
northwest of the country. The new sales and
service centre also houses a nal assembly
plant, workshop, blasting facility, painting facil-
ity and spare parts depot. Licence production
of the 311 single-drum compactor a Hamm
model specically developed for the Indian
market has begun in 2011. A new chain of lo-
cal suppliers has been established in Pune that
ensures the reliable supply of high-quality
components.
THE SALES AND SERVICE COMPANIES:
DYNAMIC PARTNERS AT YOUR DOORSTEP.
44 I 45
Our sales and service network is distinctive for professional local
presence, always offering solutions that focus on customer
requirements. These high-level services are ensured not only
by the Groups own sales and service companies but also by
authorized dealers.
The local experts can rely on additional support by the
main production plants at any time in order to always offer
customers a maximum degree of professional expertise.
Own sales and service companies
Countries where Wirtgen Group brands
are represented by dealers
EXPERTISE KNOWS NO FRONTIERS.
BRAZIL
BELGIUM
DENMARK
IRELAND
NETHERLANDS
NORWAY
ITALY
GERMANY
GREAT BRITAIN
FRANCE
USA
CZECH REPUBLIC
AUSTRIA
46 I 47
NEW ZEALAND
MALAYSIA
INDIA
THAILAND
CHINA
JAPAN
TAIWAN
PHILIPPINES
SINGAPORE
AUSTRALIA
IRAN
TURKEY
UZBEKISTAN
KAZAKHSTAN
SERBIA
BULGARIA
ROMANIA
RUSSIA
NETHERLANDS
SWEDEN
FINLAND
ESTONIA
LATVIA
LITHUANIA
SOUTH AFRICA
LIBYA
POLAND
UKRAINE
SLOVAKIA
Present in all parts of the world: sales and service companies of the Wirtgen Group.
From left to right: USA, Australia, Italy, Netherlands, Turkey, Taiwan.
THE OBVIOUS CHOICE:
ALL BRANDS, ONE WORKSHOP.
Workshop services from A to Z
Fully equipped workshops with an excellent
service infrastructure ensure that our custom-
ers can count on reliable local support on all
continents. Covering the full range of services
that a dependable workshop located at the
customers doorstep has to offer: from
inspection, servicing and maintenance of the
machines all the way to repair and general
overhaul. Special facilities are additionally
available, for example, for the repair of paving
screeds or milling drums.
1 Excellent availability at
all times in the parts
warehouse.
2 Professional repair of
assembly groups in the
workshops.
3 Replacement of worn
parts with original spare
parts professionally
installed by specialist
personnel.
4 Wirtgen Zwickau: a
typical Wirtgen Group
workshop, committed to
high performance in their
customer service offer.
1 2
Parts warehouse ensuring fast availability
Large, well-stocked parts warehouses close
to the customers location ensure that their
machines can resume operation without any
undue delay. At the subsidiaries and service
companies around the world, our customers
benet from readily available Wirtgen Group
Original Parts of superior quality and high
durability.
Parts and More
the help system for parts ordering
Parts and More, the Wirtgen Group expert
system for spare parts, offers both clarity and
safety when ordering Wirtgen Group Original
Parts. Catalogue, DVD and Internet offer cus-
tomers and users the necessary support on
everything to do with spare parts, information on
servicing or aspects of application technology.
3
48 I 49
4
1 We are wherever you
need us: reliable support,
however remote the
construction site.
2 Always reaching the
customer fast: Wirtgen
Group spare parts
service.
3 Trust is built on local
expertise.
4 Expert help conveys
safety in everyday
operation on the job site.
1
MOBILITY IS OUR STRENGTH:
SERVICE ON THE CONSTRUCTION SITE.
helpers are always there when it counts.
The range of working tools of our highly quali-
ed service technicians includes WIDOS, the
electronic documentation system that contains,
in great detail, all relevant technical information
on the machine type in question. From operat-
ing manual and hydraulic, electric and hosing
diagrams all the way to machine specications,
safety manual and spare parts catalogue.
Mobile service kits containing measuring in-
struments for electric and hydraulic compo-
nents guarantee that any malfunctions are
diagnosed quickly and reliably. The mobile
workshops in our fully equipped service vans
also provide rst-class support. For on-site
service that caters to any and all needs.
Troubleshooting on site
Quick support is needed in the event of mal-
functions on the construction site that cannot
be remedied unaided. The same is true also
when spare parts are needed in order to get a
construction machine up and running again as
quickly as possible. It is therefore an integral
part of the Wirtgen Groups service philosophy
to be fully present for quick troubleshooting
and support on the construction site whenever
needed.
Experienced service technicians provide
direct support
Specially trained mobile service technicians of
the Wirtgen Group provide technical support
worldwide when it comes to getting machines
up and running again quickly. Whether in the
customers yard or on the machines job
location. Whether on remote job locations or
at unusual working hours our experienced
50 I 51
3 2 4
TALK TO US YOULL BE WELL ADVISED:
WHEREVER, WHENEVER.
1
Protability increases with knowledge
Whether in the preliminary stages of a sched-
uled construction project or relating to the
implementation of a particular application the
highly qualied engineers and application
experts of the Wirtgen Group offer professional
consulting services to customers around the
globe. For Wirtgen, Vgele, Hamm and Klee-
mann machines. On the optimum use of control
and levelling systems. On special processes
and methods, such as oscillation compaction,
pre-spraying of emulsion with the SprayJet
module, the rehabilitation of road pavements
using InLine Pave, ne milling or cold recycling
with foamed bitumen. To enable customers to
gain the knowledge that will optimize their
applications, ensure optimum work results
and open up new business opportunities.
52 I 53
Training knowledge is the key to success
Well-trained employees work more efciently.
The main plants and subsidiaries of the Wirtgen
Group support them in doing just that by offer-
ing broadly based training programs for all rel-
evant target groups. Because qualied operator
training is the key to using the machines from
the Wirtgen Group efciently in all applications.
Training offers are tailored, for example, to roller
drivers, screed operators, service technicians,
site managers or maintenance staff. The Wirtgen
Groups highly qualied training experts ensure
optimum learning results by keeping the learn-
ing groups small and providing state-of-the-art
learning equipment. So that customers in all
parts of the world can count on employees
who are top-qualied for their particular jobs.
1 Applications support at
your doorstep custom-
ers benet from our rich
experience.
2 To ensure perfect work-
ing results, Wirtgen Group
experts are on hand to
explain the advantages of
our machine technology.
3 Professional operator
training increases produc-
tivity in operation.
3 2
SATISFACTION GUARANTEED.
54 I 55
Satisfaction right from day one: it is the be-
ginning of a long-term partnership for all those
who decide in favour of a machine from the
Wirtgen Group eet. Because it does a top job
every day on construction sites around the
globe and with tremendous efciency, too.
Whether in opencast mining, in quarries, or in
the construction of roads and motorways
around the world. Operators join in the chorus: satisfaction
guaranteed thanks to unique comfort and ease of operation.
The service philosophy has earned itself top marks as well.
The employees of the Wirtgen Group are right there when-
ever they are needed. Fast, reliable, professional. And that
holds true for a whole machine lifetime. We of the Wirtgen
Group call it: Close to our customers. Our customers call it:
Satisfaction all round.

KLEEMANN GMBH
Manfred-Wrner-Str. 160
73037 Gppingen Germany
Phone: +49 (0) 7161/206-0
Fax: +49 (0) 7161/206-100
www.kleemann.info
HAMM AG
Hammstr. 1
95643 Tirschenreuth Germany
Phone: +49 (0) 9631/80-0
Fax: +49 (0) 9631/80-120
www.hamm.eu
JOSEPH VGELE AG
Joseph-Vgele-Str. 1
67075 Ludwigshafen Germany
Phone: +49 (0) 621/8105-0
Fax: +49 (0) 621/8105-461
www.voegele.info
WIRTGEN GMBH
Reinhard-Wirtgen-Str. 2
53578 Windhagen Germany
Phone: +49 (0) 26 45/131-0
Fax: +49 (0) 26 45/131-242
www.wirtgen.de
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www.wirtgen-group.com
INNOVATIVE CONSTRUCTION
TECHNOLOGIES OUR PASSION.
ROAD AND MINERAL TECHNOLOGIES
Edition: April 2013

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