Wirtgen’s KMA 240(i) Cold Recycling Plant Economically & Ecologically Handles German Airport Project

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The Wirtgen KMA 240(i) cold recycling asphalt mixing plant can fill a 22-ton truckload every five minutes. (Photo courtesy of Wirtgen Group.)

Recently a Wirtgen KMA 240(i) portable cold recycling mixing plant helped resurface a sizable area of pavement at the Paderborn-Lippstadt Airport in Büren, North Rhine-Westphalia, Germany. Set up near the worksite, the KMA 240(i) processed 6,062 tons (5,500 metric tons) of material in just seven days and produced 22 tons (20 metric tons) of cold recycled mix every five minutes.

The KMA 240(i)’s location near the jobsite lowered construction time and cost by up to 50%, according to Wirtgen. The plant also reduced carbon dioxide emissions by up to 60% with its cold processing technology.

Recycling To Requirements

Construction contractor Oevermann was in charge of rehabilitating the apron of the Paderborn Airport, along with its refueling and deicing area. The company’s workers removed about 18,000 square yards (15,000 square meters) of tarred surface using a Wirtgen W 220(i) cold milling machine. They fed the reclaimed asphalt into the KMA 240(i) using wheel loaders, along with a crushed limestone additive.

The Airport had specific requirements for the compressive strength of the new pavement, so the operator of the mixing plant selected a ratio of 80% milled granulate material to 20% limestone along with water. The operator also chose to add 10% of a cement binding agent to the cold mix in order to form cement-treated base layers (CTBs) with a compressive strength rating of 1,813 to 2,176 pounds per square inch (12.5 to 15 megapascals), as opposed to a traditional 5% to 6% cement mix rated at 725 to 1,015 psi (5 to 7 MPa).

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Using precise microprocessor control, the Wirtgen plant can produce cement-treated base layers (CTBs), roller-compacted concrete (RCC), and bituminous-bound base layers with cement, bitumen emulsion, or foamed bitumen. (Photo courtesy of Wirtgen Group.)

Precise Production

The portable KMA 240(i) builds on the features of Wirtgen’s earlier KMA 220(i) model, with better mixing performance and a cement metering system that self-calibrates automatically through static weighing. Using precise microprocessor control, the Wirtgen plant can produce CTBs, roller-compacted concrete (RCC), and bituminous-bound base layers with either emulsion or foamed bitumen.

Wirtgen says that the KMA 240(i) conserves natural resources in several ways, claiming that it reuses 100% of the existing material (and thus wastes 100% less of it), requires 90% less material to be hauled to the jobsite, and uses 90% fewer resources and 50% fewer binding agents.

The KMA 240(i)’s twin-shaft pugmill is powered by a Tier 4 Final/EU Stage V, 173-horsepower (129-kilowatt), six-cylinder diesel engine in a sound-insulated enclosure. The plant can be run by a single operator in an air-conditioned, ergonomic cab. An LED light pole and other work lights support operation before dawn, after dusk, or around the clock.

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Source: Wirtgen Group