{"data":{"news":{"items":[{"title":"Wirtgen’s next generation of WR series cold recyclers and soil stabilisers","date":"2025-08-29 07:59:43","id":5977,"author":"","blurb":"","blurb_image_uid":"https://dxfpracgmlczp.cloudfront.net/2025/08/1755955502900_W_pic_Jobsite_Euskirchen_WR240X_0001_HI copy.jpg","blurb_expanded_image_uid":null,"article":"\n\t\n\n\n

Wirtgen’s new WR series can be used for various applications, from cold recycling to the stabilisation of a wide range of construction materials, in processes such as soil stabilisation or consolidation in road construction. This new series will be available around the world from mid 2025.

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The compact dimensions and low machine weight of the WR 200 X make it easy to transport from place to place. The WR 240 X strikes a perfect balance between machine performance and weight to assure high daily productivity. The WR 250 X is the most powerful machine of the WR series and delivers the highest productivity.

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The three models have working widths of up to 2,400 mm, with engine power outputs of between 305 and 571 kW (depending on the model). The improved Duraforce milling and mixing rotor enables consistently high mixing quality and productivity under all working conditions and contributes to the minimisation of fuel consumption, CO2 emissions and wear.

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Improved operating concept

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The most important aspect of these new cold recyclers and stabilisers is their revised and enhanced operating concept. A new multifunction joystick, fingertip control and ergonomic height adjustment via the multifunction armrest ensure maximum ease of use. In addition to digital process monitoring, the large machine control panel features application-relevant displays and the Wirtgen Group CoPilot. This digital assistance system helps operators to exploit the full potential of their machine, provides suggested courses of action during the work in progress and offers interactive tutorials.

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The tutorials help operators to familiarise themselves with the machine and its functions. Explanations of the steering modes, the features of the multifunction joystick as well as transport and safety instructions are also provided. Operators are offered visualised recommendations for action and their effect while interacting directly with the machine. The system guides operators step by step through each scenario, detects their input commands and the machine status and then automatically proceeds to the next process step.

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Digital solutions for higher efficiency

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The AutoTrac steering assistance system steers the machine accurately on the basis of a previously calculated reference strip and a specified overlap of adjacent strips. The Automatic Reverse function enables rapid reversal of the travel direction at the press of a button.

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With the Mix Assist digital assistance system, various automated functions can be individually configured and conveniently initiated simply by pressing a button. It also allows operators to set up and save a sequence of working steps as an automated process for later use when needed. When using this, the system rearranges the camera images displayed to set a focus on the currently relevant working area. This reduces the operator’s workload and simultaneously improves machine productivity.

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The Wirtgen Group Performance Tracker Recycling (WPT Recycling) generates seamless documentation of every project. It records all relevant, location-specific construction site parameters and documents them in a detailed field report.

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WRC 240 X and WRS 240 X

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Apart from the WR series, Wirtgen also introduces the WRC 240 X rock crusher. This machine crushes coarse rocks and stones as found in hard packed stone pavement layers and stony ground, and homogeneously mixes the resulting material in a single pass. With a working width of 2,320 mm and a working depth of up to 510 mm, the WRC 240 X can achieve output rates of up to 600 t/hr.

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The heavy-duty crushing and mixing rotor with HT18 toolholders and tools developed especially for the crushing process delivers ideal results in stony ground. The crushing tools have extra-large, impact-resistant carbide cutting edges and holder bases with high-tensile steel wear protection. This guarantees high utilisation rates and process reliability, even in demanding applications.

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In addition to crushing rocks and stones with edge-lengths of up to 300 mm and a uniaxial compressive strength of up to 200 MPa, the machine can add and mix water and binding agents into the crushed material during the same pass, e.g. to produce base layers.

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Meanwhile, the operator’s platform of the WR 240 X has been chosen for the new WRS 240 X model, and a binding agent spreading unit with a container capacity of 5.5 cu m has been integrated in the machine for dust-reduced spreading of binding agents such as lime or cement.

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The WRS 240 X is suitable for deployment on motorways, industrial estates and in nature reserves with strict emission regulations. Thanks to its excellent all-terrain mobility, binding agents can be spread reliably and precisely, especially on soils with poor load-bearing properties in challenging terrain. The WRS 240 X offers the further option of pushing a binding agent silo ahead of the machine. This binding agent silo can be kept permanently filled on load bearing ground.

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To ensure that roads remain functional over the long term, they are increasingly in need of structural rehabilitation. To meet this requirement, Wirtgen has developed the high-performance W 380 CRi cold recycler.

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The cold recycling process – which at a minimum recycles the surface and base course material – has been used globally, and demand for this solution is expected to continue to grow in the future. In the in-place cold recycling process, the asphalt surface is removed either in full or in layers, depending on the level of damage, by a recycling train operating across the entire width of the pavement in a single pass, mixed with binding agents on site, and then paved again immediately. At the heart of this recycling train are tracked cold recyclers, such as the Wirtgen W 380 CRi.

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Providing working widths of 3,200, 3,500 and 3,800 mm, the W 380 CRi cold recycler can mill roads between 100- and 300-mm-deep in most applications. At the same time, it granulates the material and transforms it into a new, homogeneous material mixture by adding binding agents such as cement, bitumen emulsion or foamed bitumen.

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The W 380 CRi features a mixing capacity of up to 800 t/hr. It can feed enormous quantities of recycled material to a Vögele paver via its swivel-mounted and height-adjustable discharge conveyor at the rear. This makes it possible to complete extremely long stretches of road in a single day of work. Final compaction is carried out by Hamm tandem and tyre rollers.

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Wirtgen’s tracked cold recyclers use the down-cut process when recycling, in which the milling and mixing rotor rotates in sync. This method is believed to have become an essential part of day-to-day recycling operations, as it allows to selectively vary the particle size of the material being processed – especially in the case of fragile, thin, old asphalt roads.

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Durable foamed bitumen mixture

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Wirtgen pointed out that roads rehabilitated using the cold recycling process have to meet the same durability requirements as roads designed and built using conventional methods. For this reason, the company has created solutions to guarantee that the rehabilitation measures will be cost-effective and sustainable even before they are carried out. As a result, the recycler offers the capability to define the ideal composition of the RAP, and also to directly analyse its quality and properties using samples in triaxial and splitting tensile strength tests. The quality of the foamed bitumen can also be precisely defined in the materials laboratory prior to starting the rehabilitation project.

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Cold recycling, particularly with foamed bitumen, is gaining popularity with road authorities and construction companies, said Wirtgen. With this method, the foamed bitumen is processed in-place with the existing building material. The newly produced bituminous mix is known as BSM (bitumen-stabilised material). After final compaction, it shows a long-term and extremely high load-bearing capacity.

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Viewed from a long-term perspective, BSM has another advantage, added Wirtgen. The foamed bitumen mixed in leads to selective adhesion within the cold recycling layer and thus prevents cracking. The permanent layers prepared in this way form the perfect foundation for the final asphalt layer with considerably reduced thickness.

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Cost-effective design ‘with less binders’

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The significant potential for energy savings during material processing is also a highlight of the cold recycling process. The raw materials do not have to be dried or heated, so 10-12 l of fuel can be saved per ton in comparison to conventional rehabilitation methods, explained Wirtgen. By almost completely reusing the surface course, the need to transport building materials can be reduced by up to 90%. At the same time, companies can cut resource consumption by 90% and completely eliminate the need to dispose of materials. This results in substantially reduced fuel consumption and lower CO2 emissions.

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Most importantly, the cold recycling design minimises the use of binders by up to 50% – the area with the greatest potential savings, since binders are still the biggest cost factor in road rehabilitation, revealed Wirtgen. Thanks to the special properties of BSM, the cold recycling technology allows for very low costs over the entire life of the roads.

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As the RAP is immediately recycled and the associated logistics are extremely lean, in-place cold recycling means that projects can be completed much quicker than with conventional rehabilitation methods.

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According to Wirtgen, the entire series of machines required for the rehabilitation process can fit in the width of just one lane. On two-lane roads, for example, the work can be performed across the width of a single lane, while traffic can be routed along the other side of the roadway past the construction site in one lane. Beyond normal working hours, the entire road width is usually available, as the freshly recycled pavement can temporarily be used immediately after compaction has been completed.

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In addition to the W 380 CRi (775 kW; EU Stage 5 / US Tier 4f) and W 380 CR (708 kW; EU not regulated / US Tier 2) models, the new generation of Wirtgen recyclers includes the W 240 CRi (775 KW; EU Stage 5 / US Tier 4f) and W 240 CR (708 KW; EU not regulated / US Tier 2).

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The W 240 CRi and W 240 CR cold recyclers can be equipped with integrated Vögele AB 375 T variable screeds and have a maximum working width of 2,350 mm.

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The four cold recyclers can also be used as efficient, high-performance milling machines employing the traditional up-cut process. Thanks to powerful engines and an impressive conveyor belt capacity, they achieve high removal rates at a maximum milling depth of up to 350 mm – for instance, when removing complete asphalt packages or for large-scale rehabilitation measures such as on motorways or airport runways.

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www.wirtgen-group.com/singapore

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