Foam Bitumen Recycling

DPU DKI
Jakarta, 19 Nopember 2007
Welcome
 Technologies
from the market leader
Strong brands, innovative products and applications know-how
 The Wirtgen Group

High-capacity and highly modern headquarters in Germany

Hamburg

Berlin

Cologne

Windhagen

Tirschenreuth
Mannheim

Göppingen
Munich
 Product line:
Cold milling machines
Unique portfolio and broadest product range worldwide
15 machine models
650 options
Milling widths:
14 mm to 4.40 m
Milling depths:
up to 350 mm
330 standard and
special milling drums
9 new small milling
machines
 Product line:
Slipform pavers
Mature and comprehensive product portfolio
9 concrete paver
models
Over 11,000
combinations
Paving widths:
1 m to 16 m
Paving thicknesses:
up to 450 mm
Side feeder
Texture curing
machines
 Product line:
Hot recyclers
Wirtgen as the technological driving force with applications expertise

Working width:
3,00 m to 4,50 m
Working depth:
up to 60 mm
Preheater with
infrared technology
Remix Plus process
 Product line:
Cold recyclers / Stabilizers
Market leader and market trendsetter with broadest portfolio in the market

11 machine models
Wheel-mounted and
track-mounted
machines
Working widths:
2.00 m to 4.20 m
Working depths: up to
500 mm
Foamed bitumen
technology
 The German headquarters

Joseph Vögele AG: Largest manufacturer of road pavers worldwide

Mannheim

Engineering, manufacturing and marketing of road pavers.

 Product line:
Mini and small pavers
The latest generation: compact and very powerful
2 machine models
Track widths: 1.1 m
Drive-through
widths: 1.2 m
Paving widths:
0.5 m to 3.2 m
Paving capacities:
up to 250 t/h
AB 200
 Product line:
Tracked pavers
“Dash-2” generation: all performance classes, all paving situations
7 machine models
Paving widths: up to
16 m
Paving thicknesses:
up to 40 cm
Paving capacities:
up to 1,500 t/h
Simple operating
concept ErgoPlus
 Product line:
Wheeled pavers
High performance, compact dimensions, innovative technology
4 machine models
Paving widths:
up to 8 m
Paving thicknesses:
up to 30 cm
Paving capacities:
up to 700 t/h
Simple operating
concept ErgoPlus
 The German headquarters

Hamm AG: Second-largest roller manufacturer in Germany

Tirschenreuth

Engineering, manufacturing and marketing of rollers

for road and earthwork construction.
 Product line:
HD-Tandem rollers
Complete range of articulated tandem vibrating rollers and combination rollers

Weight classes:
from 1.4 to 14 tons
Optimum range of
vision
Ergonomical
operator’s platform
High compaction
performance
New Compact Line
with 10 roller models
 The German headquarters

Kleemann GmbH: Headquarters in Göppingen

Göppingen

Engineering, manufacturing and marketing of mobile and stationary processing

technology for natural rock and for the recycling of construction materials.
 The Wirtgen Group

Present at all major international platforms

bauma
bauma China
Conexpo
Intermat
Regional trade fairs
 BAUMA 2007

Sold machines:

833 units
Turn over Wirtgen Group (Bauma):

75 Mio. €
Foam bitumen technology
•Foam bitumen
•In plant/ place in situ
•Technology in other countries

Job site Cirebon

•Pre investigation
•Mix design
•Foam Bitumen Recycling Processing / Cirebon
•Final
•Test results
Foam bitumen technology

Cold recycling in place

Distressed pavement Structural rehabilitation
Asphalt wearing course
Asphalt wearing course Recycled
Binder course
layer
Base

Sub Base Sub base

 Benefit of recycled layer

Un-laminated Laminated
(un-stabilised) (recycled)
Foam bitumen technology
Foam bitumen technology

Cold Recycling in situ

Binding Agent

cement water

+ =
Asphalt course emulsion water
with granular base

foamed bitumen water

Bound granular
base course
cement emulsion water

Milled material
cement foamed bitumen water
Foam bitumen technology
Foam bitumen technology

+ BITUMEN =

ASPHALT TECHNOLOGY
Bitumen coating (thin films)
Contact adhesive

STABILISATION TECHNOLOGY
Bitumen dispersion selective
Bound granular material
Foam bitumen technology

Width cm

Depth

cm
Speed

m/min
Density

kg/m³
Binding agent

% =

Binder addition
Foam bitumen technology
Foam bitumen technology
Foam bitumen technology

in plant

in situ
Foam bitumen technology

WR 2500 S
Cold recycling in Germany
Foam bitumen technology

WR 2000 Cold Recycling in Japan

Foam bitumen technology

Cold recycling in situ in Malaysia

Cold Recycling in situ Indonesia

Cold Recycling the asphalt and granular base layers by adding pre-spread cement
Cold Recycling in situ Highway in Italy

Injection Injection
width width

Mixing
drum width

Injection width can be seperately controled by switching off certain nozzles

Cold Recycling in situ Highway in Italy

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

Foam bitumen technology

Cold Recycling in plant

Foam bitumen technology

Cold Recycling in plant Jinghu Expressway,

Tianjing China
Foam bitumen technology

Cold recycling with foam bitumen

Mix Design Test for
Foamed Bitumen

Tests done on the milled sample:

•Grading analysis
•Water content
•Bitumen content
•Modified Proctor to determine the optimum water
content (OMC) and maximum dry density (MDD)

Tests done on the bitumen sample:

•Optimisation of foaming properties – variation of
bitumen, temperature and bitumen water quantity
Mix Design Test for
Foamed Bitumen

Mix design and manufacturing briquettes:

• Addition of cement (1.5 M.-%)

• Addition of water (80 - 90% of OMC)

• Addition of Foamed Bitumen (2; 2,5; 3,0; 3,5 M.-%): with

WLB 10 directly into the laboratory mixer

• Production of briquettes by Marshall compaction – modified

to

75 blows / briquette-side

• Storing for 72 hours at 40 °C (simulating 28 days)

Mix Design Test for
Foamed Bitumen
Mix Design Test for
Foamed Bitumen
Mix Design Test for
Foamed Bitumen
Mix Design Test for
Foamed Bitumen
Mix Design Test for
Foamed Bitumen
Mix Design Test for
Foamed Bitumen
Plant for the production of
foamed bitumen in laboratory
conditions
Test of bitumen foaming
properties and optimisation of
bitumen water
Production of foamed bitumen
mix design for optimisation of
the foamed bitumen content

More than175 plants:

Customers are commercial
laboratories, consultants,
research institutes, universities
and construction contractors
Mix Design Test for
Foamed Bitumen
Mix Design Test for
Foamed Bitumen

Mix Design Test for Foamed Bitumen

Dry ITS
Indirect Tensile Strength [kPa]

80
0
Soaked ITS

60
0
40
0
20
0

Foamed Bitumen content [% by mass]

Optimisation of Foamed Bitumen content
Mix Design Test for
Foamed Bitumen
Project Indonesia - Cirebon

Existing pavement

400 - 500 mm
old asphalt

granular base
Project Indonesia - Cirebon

1. Mill off asphalt

20 cm

old asphalt

granular base
Project Indonesia - Cirebon

2. Cement stablizing

old asphalt
25 cm CTRB

granular base
Project Indonesia - Cirebon

3. Bring back RAP and

foamed bitumen recycling

20 cm Foam Bitumen

old asphalt
25 cm CTRB

granular base
Project Indonesia - Cirebon

4. Wearing course 4cm,

and 6cm Binder course

4 cm WC
6 cm Binder
20 cm Foam Bitumen
old asphalt
25 cm CTRB

granular base
Project Indonesia - Cirebon

Before 05.08.2007 After 23.08.2007

Cirebon 2006

Recycling

Mill & Overlay

Busway
Busway

Concrete overlay with

levelling

2,5% 15-17cm

• Concrete layer 27cm

• Concrete levelling (Asphalt)
Busway

Recycling Proposal:

Existing pavement

50 – 100 cm
old asphalt

granular base
Busway

1. Mill off asphalt

25 cm

old asphalt

granular base
Busway

2. Cement stablizing

old asphalt
25 cm CTRB

granular base
Busway

3. Bring back RAP and

foamed bitumen recycling

25 cm Foam Bitumen

old asphalt
25 cm CTRB

granular base
Busway

4. Wearing course 4cm,

and 6cm Binder course

4 cm WC
6 cm Binder
20 cm Foam Bitumen
old asphalt
25 cm CTRB

granular base
Advantage of foam bitumen recycling:
• economical
• no heating energy necessary
• re-use of asphalt material
• no waste disposal of old asphalt
• enviroment friendly
• quick , short construction time , short traffic closing
• reduce transportation (>90%)
• reduce life time cost, too (longer life time for overlay)
Thank you