A Wirtgen recycler mills off the top pavement layer.

Cold recycling – from dusk to dawn

A cold recycling train from the Wirtgen Group completes the rehabilitation of two sections of an important motorway in Greece in the shortest possible time

Greek motorway operator Nea Odos SA, chose the in-situ cold recycling method with a cold recycling train from the Wirtgen Group for the rehabilitation of two sections of an important motorway, close to the city of Lamia and the town of Kamena Vourla. The sustainable, fast and cost-efficient method is ideal for the rehabilitation of busy motorways. On the E 75 motorway, the Wirtgen cold recycler W 380 CRi at the heart of the chain was accompanied by a latest generation SUPER 2100-5i Highway Class road paver, a SUPER 1800-3 Universal Class paver from Vögele and a team of Hamm rollers comprising of two HD+ 140i tandem rollers and a HP 280i pneumatic-tyre roller. Due to high daytime temperatures, the contractor scheduled all construction activities after midnight and finished before the early morning.

Lamia and Kamena Vourla

The sections of the motorway to be reconstructed, were located close to the city of Lamia and the town of Kamena Vourla are extremely busy and important traffic intersections. In all, the project involved the rehabilitation of an area of more than 50,000 m² / 540,000 sq ft of asphalt roadway in locations where complete closure would have led to absolute traffic chaos. The most efficient solution here was the use of a cold recycling train from the Wirtgen Group. Thanks to in-situ cold recycling, it was possible to reduce the construction time otherwise expected when using conventional methods by around 50% and direct the traffic flow around the rolling construction site without any problems.

Tolles Produkt

In-situ cold recycling: the sustainable choice

In-situ cold recycling enables significant savings when it comes to costs for materials and transportation. The cold recycler from Wirtgen is the backbone of the rehabilitation project The W 380 CRi deployed on this project is capable of recycling the damaged road pavement in a single pass. In the course of this, cement, water and foamed bitumen are added to the existing material in-place (in-situ) to produce a bitumen stabilised material (BSM). This freshly produced, high-quality construction material can then be laid down on the spot. In Lamia, this eliminated the need for around 24,000 tons of virgin material – which not only conserved valuable resources, but also reduced CO₂ emissions on and around the construction site.

Facts & figures

Project: Rehabilitation of two sections of a motorway

  • Locations:E 75km 212 to 214 near Lamia and km 179 to 185 near Kamena Vourla
  • Overall length: ~8 kilometres / ~5 miles
  • Total area: 50,000 m² / 540,000 sq ft
  • Construction method: In-situ cold recycling with a Wirtgen Group Production System
  • Working width: 3.80 m / 10.2 ft
  • Project completion time: 15 days
  • Up to 90% reduction of resources required:Elimination of the need for 24,000 t of fresh asphalt mix
  • Up to 90% fewer transport movements:2,400 truck tours saved
  • Up to 100% reduction of waste for disposal
  • Up to 60% reduction of CO₂ emissions
  • Up to 60% reduction of overall costs

Graphic representation of a cold recycling train

Turning night into day

The LED floodlights of the W 380 CRi and the new Light Package Plus on the SUPER 2100-5i provided excellent lighting during the rehabilitation project. The integrated lighting systems provide even illumination of the entire working area. This not only ensured the safety of traffic driving past the site, but also of the crew on and around the cold recycling train.

Tolles Produkt

Step-by-step to a new road surface

The mix produced in this way was transferred directly to a Vögele SUPER 2100-5i paver following behind the recycler. With an extra material hopper, the latest-generation Highway Class paver can take up to 20 tons of mix on-board and pave it at a laydown rate of up to 1,100 tons per hour.

Tolles Produkt

Press/media kit

Click here to download a ZIP file containing the press release in the available languages in Microsoft Word format and the images in 300 dpi resolution.

Download