3800cr October 09 Version

Edn:Oct 09

Cold In Place Recycling – Wirtgen 3800CR

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Cold Recycler 3800 CR - Machine overview

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Technical Specification – 3800CR Cold Recycler 3800CR Working width

12ft 6ins

Recycling Depth

0 – 6ins

Milling Depth Up cutting

13.75 ins

Tool Spacing HT11

5/8 ins

Number of tools

294

Cutting Direction

Up cut or down cut Requires drum to be removed and turned through 180 deg and fit either upcut or down cut planetary drives

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Technical Specification – 3800CR Cold Recycler 3800CR Engine Type Cooling No Cylinders Output

Caterpillar C27 ATAAC Water 12 708kW/950HP/963PS

Engine Speed

2100 rpm

Fuel consumption full load

49 gal/hr

Fuel consumption 2/3 load

32 gal/hr

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Technical Specification – 3800CR Cold Recycler 3800CR Fuel Tank Capacity

395 gal

Hydraulic fluid tank

132 gal

Water tank

1315 gal

Milling Mode Belt width primary conveyor

43.3 ins

Belt width discharge conveyor

43.3 ins

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Technical Specification – 3800CR Cold Recycler 3800CR Paving Screed

Vogele AB425T

Screed width

Up to 14ft

Auger width

9 ft 8 ins

Screed compaction

Tamper bar Variable frequency

Spray Systems Water Spray system

12 nozzles, 105 gal/min

Foam / Emulsion Spray system

18 nozzles, 1100 lbs/min

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Technical Specification – 3800CR Cold Recycler 3800CR Weights Own weight, complete

124,890 lbs (c/w screed & auger)

Operating weight, complete

138,310 lbs (c/w screed & auger)

Breakdown weights Base tractor weight Conveyor weight discharge Drum housing & cutter weight

75,680 lbs 4,440 lbs 35,420 lbs

Screed & Auger weight

8,800 lbs

Counter weight

4,000 lbs

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Cold Recycler 2200 CR Injections systems

Double pump, 2 Spray bars -Water - Foamed Bitumen or Emulsion

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Cold Recycler 3800 CR Double pump for Water and Foamed Bitumen or Emulsion

Water

Foam or Emulsion

supply of Water (out of 3800 CR tank)

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Cold Recycler 3800 CR Foamed Bitumen or Emulsion with Water injection system 2 Spray bars Bitumen filter

Bitumen or Emulsion

Bitumen pump

Flow meter

Test nozzle

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Cold Recycler 3800 CR Foamed Bitumen or Emulsion with Water injection system 2 Spray bars

Water

Bitumen filter

Flow meter

Hot Bitumen or Emulsion Foamed Bitumentest nozzle ROAD AND MINERAL

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Cold Recycler 2200 CR Foamed Bitumen or Emulsion with Water injection system 2 Spray bars Metered injection of foamed bitumen or emulsionand water via the 3800 CR

3800CR

ROAD AND MINERAL

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Scraper blade Thorough cleaning of the milled area 1. The top layers of bituminous road pavements are milled off 2. The scraper blade is pressed down with the pre-selected downward pressure 3. The scraper blade edge slides on the milled surface as if spring-loaded 4. The drum housing is sealed off to the rear

Milling down to the top edge of the subbase layer 1. The asphalt is milled off down to the subbase layer 2. The scraper blade is locked hydraulically 3. The scraper blade does not dig into the subbase layer 4. Material is picked up

Recycling Mode 1. Possibility to leave recycled material in a windrow 2. For this purpose, scraper blade is locked at the required height

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Conveyor Shoe / Gradation Beam

A horizontal connection bar connects the side walls of the conveyor shoe Slanting or jamming is prevented Fully sealed conveyor shoe with torsionproof connection to primary conveyor No relative movement between conveyor shoe and conveyor due to rigid cross strut No jamming of material Optimum belt protection

Equaliser joint

Lifting cylinder for conveyor shoe

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Torsion-proof connection between conveyor and conveyor shoe

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Gradation beam Robust design, torsion-proof connection between left and right side Effectively prevents slabs from breaking loose in front of the milling drum Material has a convenient piece size Protects the conveyor (large slabs would damage the conveyor belt)

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Gradation beam / Operating positions Floating position

Typical of urban milling operations: Obstacles, such as rainwater inlets or gully holes

When approaching the obstacle, the primary conveyor is lifted hydraulically without interrupting the milling operation.

Thus it is possible to mill close to the gully lid. Manual removal of remaining asphalt material is reduced to a minimum.

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3800CR Concept Views

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Screed 14´ width

Auger 11´ width Cutter 12´6“ width

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Cold Recycler 3800 CR Vario screed and Distrubution auger Vögele Vario screed with Tamper AB425T

Working width: up to 14ft

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• Bevelled screed plate for

Tamper Bars Made of HARDOX 400 for Long Service Life

perfectly packing the mix under the screed. • Direct hydraulic tamper drive maintenance-free) • Infinitely variable speed. Smooth running from 500 (minimum) to 1800 (maximum) revs/min. • Long lasting tamper bar shape. HARDOX 400)

Tamper Shaft with Coupling for Bolt-On Extension

Tamper Stroke 7mm (fixed)

α 30 Tamper Bar

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Screed end plates open/close hydraulically for material management www.wirtgenamerica.com ROAD AND MINERAL

Drum & Speed

Down cut mode fit down cut planetary Up cut mode swing drum through 180 deg and fit up cut planetary

drum for up / down cut

12´8”

Bearing adaption

upcut 93 rpm downcut 104 rpm

upcut 73 rpm www.wirtgenamerica.com downcut 82 rpm ROAD AND MINERAL

Spraybars

Foam bar 18 nozzles Bitumen nozzle 3,5mm

Water bar 12 nozzles

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Cutter Drum with Spray Bars

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Foamed bitumen spraybar – 12ft 6ins Model 2 1

4 3

Nine switches

5

7 6

8 9

18 nozzles

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Water spraybar – 12ft 6ins Model

2 1

six switches

4

3

6 5

12 nozzles

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Rear door

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Track Drives at outside position

Tracks offset 8 inch

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Auger

Two spacers

Auger 11´ width www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Mason County Illinois

Upper Pavement Layers

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38000CR CIR Project Example – Mason County Illinois

Project View – 35 year Pavement, 5ins to 6ins Asphalt www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Pavement highly oxidized, major cracking with localised cold mix repair areas www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Lane 1 pass 3 ½ ins depth, 2.5% Emulsion www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Lane 1 View after Recycling CIR www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Recycled Material Surface Finish / Mix www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Recycled material at Auger before screed, well mixed and well graded material www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Emulsion Inlet

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38000CR CIR Project Example – Mason County Illinois

Gradation Beam www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Screed end plate in closed position www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Screed end plate in open position

Excess material run out for shoulder backing

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38000CR CIR Project Example – Mason County Illinois

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38000CR CIR Project Example – Mason County Illinois

3800CR Compact Design features allow for traffic accommodation, even on narrow lane widths www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Recycling width 12ft 6ins, depth 4ins, average speed 28ft/min www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

Speed 8.5 m/min (28ft/min) Compaction water 2.6% Emulsion content 2.7%

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38000CR CIR Project Example – Mason County Illinois

Compaction immediately behind recycler with HAMM Model HD120 Compactor www.wirtgenamerica.com ROAD AND MINERAL

38000CR CIR Project Example – Mason County Illinois

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38000CR CIR Project Example – Mason County Illinois

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38000CR CIR Project Example – Mason County Illinois

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CIR Project Example – 3800CR Urban Recycling, Toronto

Upper Pavement Layers

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CIR Project Example – 3800CR Urban Recycling, Toronto

Busy 4 lane through way Kerb & gutter Manholes & Side drains Centre traffic islands Turning lanes Traffic Accommodation

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CIR Project Example – 3800CR Urban Recycling, Toronto

Pre-Mill 4ins with Wirtgen Model W2100 Milling Machine www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto – Foamed Bitumen

The CIR Train comprises 2 units, Wirtgen Model 3800CR & Bitumen Tanker www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Recycle flush to Kerb as approaching Side drains www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Steer recycler just to clear drain, creating short taper www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Recycle flush with drain www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Steer recycler back to flush with kerb www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Screed end plates in closed position www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Hydraulically open screed end plate to allow sufficient recycled material to flow around drain and fill taper both sides www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Continue recycle pass flush to kerb www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

6 ins overlap at longitudinal joint

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CIR Project Example – 3800CR Urban Recycling, Toronto

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CIR Project Example – 3800CR Urban Recycling, Toronto

Centre traffic Island www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

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CIR Project Example – 3800CR Urban Recycling, Toronto

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CIR Project Example – 3800CR Urban Recycling, Toronto

Hydraulically open screed end plate and allow recycled material to flow flush to Island kerb www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

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CIR Project Example – 3800CR Urban Recycling, Toronto

Traffic Accommodation -During the recycling operation it is possible to keep the traffic flowing, in this case either side of the 3800CR as the centre pass is being made www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Average recycling speed for the project 27.5 ft/min. This average speed at a depth of 6 ins and a width of 12.5ft equates to an hourly recycling tonnage of 610 tons per hours.

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CIR Project Example – 3800CR Urban Recycling, Toronto

Finished foamed bitumen recycled material at screed www.wirtgenamerica.com ROAD AND MINERAL

CIR Project Example – 3800CR Urban Recycling, Toronto

Pavement Recycled & Paved back to 2% slope, stabilized with 2.5% foamed bitumen using the 3800CR www.wirtgenamerica.com ROAD AND MINERAL

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