Wirtgen enables sustainable recycling closer to the jobsite


Wirtgen is enabling sustainable recycling close to the jobsite with its new KMA 240(i) mobile cold recycling mixing plant.

The KMA 240(i) is capable of processing 240 tons of mix per hour from a variety of construction materials in an environmentally friendly manner. 

The machine, according to Wirtgen, makes  a major contribution to ensuring that recycled construction materials are returned to the road construction cycle in the form of high quality mix. The new roads and industrial areas built with recycled material stand out for their high bearing capacity, resistance to deformation and long service life.

The KMA 240(i) cold recycling mixing plant produces mix/cold mix that can be paved immediately and is ideally suited to producing different types of bound base layers.

Alongside cement-treated base layers (CTB) and roller-compacted concrete (RCC), the machine can also be used to produce bituminous bound base layers (with emulsion or foamed bitumen). The different mixes can be used for a wide range of applications, including highway construction, road and path construction and the construction of parking lots or industrial areas. 

The cold recycling mixing plant is mounted on a flatbed semitrailer and has its own engine. The mobile design allows the system to be moved to different locations and set up rapidly. 

With the new cold recycling mixing plant, Wirtgen has combined the advantages of its earlier model, the KMA 220(i), with improved mixing performance and an innovative cement metering system with automatic self-calibration via static weighing. 

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The powerful six-cylinder diesel engine is designed for the machine’s high mixing capacity of up to 240 tons per hour. Thanks to an efficiently insulated housing, it also emits minimal noise. The engine can be operated extremely economically for up to two days on one tank, and its low emission values also allow it to be used in urban areas.

With a capacity of 240 tons per hour, the machine produces a full truckload of 20 tons of mix every five minutes. As a result, sections of a cement-treated or bituminous bound base layer — with a working width of 4 metres and a paving thickness of 15 cm — can be completed over a length of 1,400 metres daily.

The KMA 240(i) is able to process a large variety of non-cohesive base materials, which wheel loaders feed to the plant’s hopper via vibrating grids. This makes it possible to produce mixes from a wide variety of new granular mixtures or various milled materials and binding agents. 

Asphalt milled material, all other non-cohesive materials reclaimed from old road surfaces, and materials from RC processing can all be used to build new road surfaces in an environmentally friendly manner. The ability to completely reuse the material results in high carbon dioxide and energy savings with minimal construction costs and project periods.

Faster mix prep   

Silos or tank trucks supply the cold recycling mixing plant with binding agents, such as hot bitumen, bitumen emulsion and cement. The precise metering of the input materials and binding agents, the ratio of which is determined in advance by preliminary tests in the road construction laboratory, is monitored by a proven microprocessor control system. The KMA 240(i) ideally loads the new, homogeneous mix directly onto trucks or deposits it continuously on a stockpile. Loading or depositing can be carried out in a flexible manner thanks to the discharge conveyor that can swing 55 degrees to either side.

Cold recycling technology from Wirtgen is environmentally friendly and cost-effective. The rehabilitation method can be carried out either in place – in which case the damaged pavement is removed by a mobile recycling train, processed on site and immediately repaved. 

If the mixing plant is located too far away or the jobsite doesn’t meet the logistical requirements needed to complete the entire recycling process in one pass, cold in-plant recycling is often the ideal solution. 

The method involves setting up the KMA mobile cold recycling mixing plant in the immediate vicinity of the jobsite. 

This saves time, truck capacity and is also extremely environmentally friendly, making it possible to achieve up to 70 per cent fewer carbon dioxide emissions through cold processing, a 90 per cent reduction in transport volumes, and up to 40 per cent lower construction costs. As well, the high-quality building materials are completely reused.