The WIRTGEN Brand Headquarters in Windhagen

Prefabrication — Prefabrication is the first step of production for over 90 different road construction machine models from five product lines.

Continuous Powder Coating System — The components are first blasted or chemically pretreated in the continuous powder coating system, then the powder is applied and finally fired in the furnace.

Machining and turn/mill centers – All of the CNC lathes can also be used for drilling and milling with power tools. When machining large components that take a long time to complete, employees operate several machines simultaneously.

Heavy-duty lathes — Our largest lathes can machine workpieces up to 1,200 mm in diameter and 6,000 mm in length. These machines have a drive power of 100 kW.

Horizontal boring mill — Workpieces up to 12 meters long, 5 meters wide, and 3 meters high can be processed here.

Flexible manufacturing systems — The two systems consist of two or three identical four-axis and five-axis machining centers as well as an automated racking system with 30 or 56 locations for machine pallets and up to 82 locations for standard euro pallets.

Robot systems — State-of-the-art welding robots process the components that are produced in large quantities. Assembly is carried out directly by the robot in a constant welding sequence and thus with constant welding distortion.

Steel construction for mass-produced components — This is where mass-produced steel components and parts that are subsequently processed in the mechanical department are assembled.

Training workshop — The training workshop for industrial and technical professions is equipped with state-of-the-art, real-world equipment. WIRTGEN currently has vocational trainees in twelve different occupations.

Sheet metal workshop — A total of 7,500 of the 14,000 different assemblies are manufactured in the sheet metal workshop alone.

Bending center — Press brakes with pressing capacities between 125 t and 400 t are available; approx. 30% of the different individual parts are formed here.

Edge rounding machines — In order to meet the highest requirements with regard to surface quality, the systems round off the extremely sharp-edged sheet metal edges produced by the laser process.

Cutting — The sequence of operations in all areas – sawing, lasering, flame-cutting, and blasting – is determined via digital worklists.

Roll bending center — Two drum bending machines are needed to form the 15 to 30 mm thick and up to 2,500 mm wide two-dimensional metal sheets into tubes. After machining, the blanks have an outside diameter of 450 to 1,000 mm.

Final assembly facility for mass-produced milling machines — The entire final assembly facility is equipped with approx. 50 overhead traveling and slewing cranes.

Power & Free tunnel/Suspension station — From the coating plant, the powder-coated parts are transported to the final assembly plant immediately for further processing.

Electric workshop for mass-produced components — More than 50 electrical cabinets leave the electric workshop every week for our mass-produced products. The operator’s platform and control panels of a large milling machine consist of some 7,500 components.

Central pre-fabrication — Around 20 different discharge conveyors and hoods are manufactured for mass-produced machines.

Paced large milling machine assembly — All of the large milling machines with a working width of 1,500 to 4,400 mm are finally assembled on three paced lines. The large milling machines are assembled from more than 4,000 individual parts.

Information booths — The latest information is always saved online for the employee at an information booth. This includes hydraulic diagrams, electrical diagrams, assembly instructions, parts specifications, drawings, torque tables, quality assurance information, standards, instructions, etc.

Paced assembly of compact milling machines with 1,000 to 1,800 mm working width — The individual steps of the assembly process on a paced assembly line are synchronized with each other. Our machines are not sold off the rack, i.e. each machine is specially manufactured for its specific later use.

Paced Assembly of Small Milling Machines with up to 1,000 mm Working Width — Five different cold milling machine models with working widths ranging from 350 mm to 1,000 mm are assembled in this area of the factory. The individual prefabricated components are located right next to the installation positions on the paced assembly line.

Mass-produced component finishing — In the finishing department, the completed machines receive their final visual touches. The machines are washed and then stickers as well as hazard and safety warnings are affixed to them.

Final quality control and acceptance, mass-produced machines — Final quality control and acceptance is the last step of production in the final assembly facility. Using state-of-the-art measurement technology, we can uncover quality defects here.

Main warehouse/incoming goods — There are three storage zones in the main warehouse where the different items are stored.

Shipping — When an order is placed, the order is received online at the central warehouse. All of the delivered parts are labeled with information about the number of articles, weight, etc. in the customer’s native language – in a computer-controlled process.

Assembly facility for special machines — The new building has been specially designed to accommodate the large machines, enabling full assembly even of the largest surface miner model – the 4200 SM.

Coating system for large components — This system can be used to coat hanging parts up to 30 t weight, 9 m length, 3 m height, and 3 m width.

Conveyor construction — The complex production of the extremely lightweight, yet stable truss structure is one of WIRTGEN’s core competencies.

Steel construction for large components — The production of heavy chassis as well as heavy individual parts up to 40 tons etc. is part of the daily routine here. Weld seams up to a = 20 mm thickness, welded in up to 17 layers, can be produced here.

Production sequence in roller manufacturing — With the aid of setting devices, the toolholders are riveted to the prefabricated, mechanically machined milling drum tubes with extreme precision.

Highlights of drum production — WIRTGEN’s standard range includes more than 500 different milling drum types, and numerous special designs complement the variety of applications – no other company in the world can offer this. The range of milling widths extends from 14 mm to 4.40 m.

Final assembly of slipform pavers — Due to stringent customer-specific and project-related requirements, slipform pavers are assembled on a stand-alone basis.

Production Warehouse for Special Machines — The numerous options and special components for special machines are order-picked in a separate, highly flexible warehouse.

Final assembly of special machines, surface miners — Surface miners are also built in the special machine division in accordance with individual customer requirements. A capable team of approx. 70 specialists is exclusively responsible for the assembly of these machines.

Final assembly of special machines, recyclers — The recyclers built her include the tractor-towed stabilizer, W 240 CRi and 380 CRi cold recyclers, the KMA 220i mobile mixing plant, and hot recyclers. Due to the large number of different versions of these machines, stand-alone assembly is the most economical solution.

Paced Assembly of WR Series — We assemble up to six different series on the 100 m long paced assembly line specially designed for the wheel-mounted recyclers and soil stabilizers.

Electrical workshop for special machines — In this workshop, qualified employees manufacture all of the electrical components for special machines, such as electrical cabinets, terminal boxes, cable harnesses, etc.