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Wirtgen Green Mix Technology On Xitong Expressway Improvement Project Saves CNY28 Million

Wirtgen China — Tue, 03 Aug 2010 09:33:23 +0000

Economical efficient and environmentally friendly use of Wirtgen Green Mix cold recycling technology with foamed bitumen cuts costs, reduces emissions and saves on material.

Beijing, China (August 03, 2010) /ChinaNewswire.com/ — On June 28th, 2010, after being closed for 53 days, the southern half of the Tongguan to Xian section of the Lianhuo Expressway improvement and widening project was reopened with four lanes in two directions. This is the first expressway in China which has been improved and widened on large scale using Green Mix foamed bitumen cold recycling technology from Wirtgen. As the existing pavement material was reused as efficiently as possible, the cost saving was around CNY 28,000,000. This provides a reference example for highway overhaul, improvement and widening in Shanxi province with clear economic efficiency and environment benefits from this project.

A traditional pavement overhaul focuses mainly on substitution and strengthening. Substitution results in higher costs, longer time duration, and a more complex project. A large quantity of milled material would not be reused properly, resulting in waste and pollution. Strengthening has the drawbacks that pavement bearing capacity can not be meaningfully increased and pavement defects can not be effectively eliminated. With the advent of the 21st century, many high-class roads need to be maintained and repaired or improved — around 12% of pavement needs to be overhauled every year – and this requires a total quantity of around 2,200,000 tons of existing pavement material. Recycling of this material and reusing it in new construction and repair of pavement, will be not only be environmentally friendly, but will also result in major cost savings. Especially in western area of the country, reusing large quantity of existing pavement material, will reduce pollution, conserve water and soil, and allow the building of more roads with less investment. So, it has very important effect.

Recently Wirtgen's Green Mix foamed bitumen technology has become more and more popular, both in China and abroad. It provides a new method for modernized cost effective repair and maintenance of roads. "Individual study of foamed bitumen cold recycling" was supported by technology finance from Ministry of Finance, and was declared to be a technology development project for Shaanxi province. When this study is finished, the annual cost saving on material through recycling will be CNY1.500 billion.

In foamed bitumen technology water is injected into hot bitumen, making it expand and become bitumen foam. The foam will settle down after a short time. The foam bitumen becomes millions of tiny particles spread over fine material and forms a slurry. After mixing and compaction, it will bind the coarse particles and make the pavement course stable. Compared to traditional methods, the advantages of foamed bitumen technology include: long time storage of mix, higher shear strength, and less sensitivity of the mix to water.

With regard to energy saving, Green Mix foamed bitumen has a number of very strong points. According to Mr. Li Jingde, in traditional design, bitumen content of the asphalt base course is 3.4%, and for the binder course it is 4.4%. When using foamed bitumen, existing material will be reused extensively, saving crushed stone. When paving on hard shoulders, it replaces binder and base courses with a bitumen content of only 2.1%. This equates to saving half of the bitumen. He says the detailed calculations are as follows: "The cost of 12 cm base course is CNY 98/m², the cost of 6 cm binder course is CNY 61/m², resulting in a total cost of both courses together of CNY159/m². The cost of 18 cm foamed bitumen course is only CNY76/m². So, replacing the base and binder courses with foamed bitumen mix gives a cost saving of CNY 83/m². That is CNY 259,790 cost saving per kilometer. The total foamed bitumen recycled material in Xsitong expressway project is about 61,800 m³, and gives a total cost saving of around CNY28,000,000. It really makes waste profitable." Further more, foamed bitumen recycling requires less labor and investment in machines. It cures naturally and this can be finished within two days in thesummer time. In comparison the traditional water spreading curing method needs seven days.

As a new road technology, foamed bitumen recycling has been tested and applied throughout the country. But, for expressway improvement and widening like Xitong expressway project, there is no experience or reference data. Xitong expressway improvement and widening is the first project in China to use this design and construction and to benefit from major savings in cost material and emissions.

About the Wirtgen Group
The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating four traditional brands: Wirtgen, Vogele, Hamm, and Kleemann. As a technological leader, they offer their customers mobile machine solutions for road construction and road rehabilitation, as well as for mining and processing minerals.

The Wirtgen Group has been present in China for more than 20 years and, since 2004, has operated an assembly factory in Langfang, Hebei Province. With more than nine branches and 250 employees, Wirtgen China are always close to their customers.

For more information: www.wirtgen-china.com.cn

Wirtgen Recycling Technology Saves Cost And Energy In China's Xi'an

Wirtgen China — Wed, 14 Oct 2009 06:27:17 +0000

Wirtgen's high precision recycling and spreading technology reduces the amount of material required and yields a faster project completion on Xi'an's major axial road reconstruction.

Beijing, China (October 14, 2009) /ChinaNewswire.com/ — By using Wirtgen's Streumaster high precision spreading technology for cold recycling of the road surface, together with a Wirtgen WR 2500S Recycler, a Hamm 3625HT single drum compactor, and a Voegele S-1803-2 wheel paver, the Xi'an Management Bureau was able to make major savings in energy and costs when widening and resurfacing Chang'An Nan Lu, the main north-south axial road in the historic city.

China has been using cold recycling of road surfaces for some time and traditionally the stabilizing agents are spread manually. The recycling of the surface of Chang'An Nan Lu required around 11,100 tons of cement. Using the manual spreading method, a total of 444,000 25 kilogram bags of cement would be required. Since it takes around three hours to load and unload a truck load of 800 bags the total time just to load and unload cement bags for this project would be 167 days, or seven months.

For the Chang'an Nan Lu project the Xi'an Management Bureau used a Wirtgen Streumaster SW16 MC mounted on a SX3255DR385 truck from Shaanxi Automobile Group. The tank for the stabilizing agent in the SW16MC has a capacity equal to approximately 20 tons of cement. Since the cement is pumped directly from a silo truck into the Streumaster's tank, and it takes just 30 minutes to fill the tank, this reduced the total time required to load the 11,100 tons of cement on the Chang'An Nan Lu job to around 28 days. With a spreading width of 2.46 meters and spreading the stabilizing agent at a speed of 1.5 kilometers an hour the Streumaster took approximately 10 days to spread the cement on the total area of 370,000 square meters. Thus the total duration of the project was reduced to around 38 days compared to an estimated 137 days using manual methods.

Besides this huge saving in time and costs, the Streumaster improved efficiency on the job since the stabilizing agent could be spread just when it was needed and there was no need to consider weather changes such as rain, which would have forced the jobsite team to cover all the bags if they had been placed manually.

Another very important cost saving advantage of using the Streumaster was that – in accordance with regulations from the Chinese authorities on recycling jobs – when using bagged cement (in this case a 5% mix), the contractor has to add an additional 1% of cement to the mix to compensate for stabilization agents that are lost by being blown away by the wind, or are wasted by poor accuracy of spreading on the road. When spreading the cement using the Wirtgen Streumaster this additional 1% was not required, which made it possible to save a total quantity of 1,850 tons of cement with a cost saving of CNY740,000 and concomitant savings in fuel and energy costs resulting from the reduction in the number of truck journeys required.

Speaking about the project, Mr. Gang, the managing director of the Xi'an Municipal Management Bureau, said: "Our government strongly emphasizes environmentally friendly recycling projects with construction waste reduction and sustainability. Sustainability and reuse are our targets. The recycling market has just begun. As more and more companies consider recycling in their future projects, the recycling market will become bigger and bigger."

"The characteristics of municipal road repair and maintenance are busy traffic, many job sites, limited working time, and the need for high quality. It follows that the requirements for machines include reliability, less breakdowns, easy operation, and simple service and maintenance. In essence, machines from the Wirtgen Group meet our construction requirements." Mr. Gang added.

The Wirtgen Group is an internationally operating group of companies in the construction machinery sector incorporating four traditional brands: Wirtgen, Vogele, Hamm, and Kleemann. As a technological leader, they offer their customers mobile machine solutions for road construction and road rehabilitation, as well as for mining and processing minerals. In 2008, with its workforce of more than 4,500 men and women, the Wirtgen Group generated consolidated sales of 1.5 billion Euros.

The Wirtgen Group has been present in China for more than 20 years and since 2004 has operated an assembly factory in Langfang, Hebei Province. With more than nine branches and 200 employees, Wirtgen China are always close to their customers.

www.wirtgen-china.com.cn

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