Turning two into one
View across the Rhine Valley towards Lake Constance, as seen from the Hilti & Jehle GmbH site.

Implementation and expansion of an asphalt mixing plant in the Alpine Rhine Valley

Hilti & Jehle GmbH run two asphalt mixing plants at the Götzis and Nenzing sites in Austria. Both plants have been around for quite a while – the youngest is 14 years old – and are now ready for modernisation. The objective is to update the existing plants to the state of the art and combine them at the Götzis site. The project is based on a sustainable approach: individual components of the existing plants are reused while new, innovative Retrofit solutions are added. This is made possible by the modular design of Benninghoven asphalt mixing plants. It allows Hilti & Jehle to not only create a more efficient production site but also to make an active contribution to environmental protection.

Structured dismantling starts in Nenzing.

Plant in Nenzing – the plant is dismantled here and re-installed in Götzis with new components added.

Finished! Installation in Götzis can start.

An outdated asphalt mixing plant against the backdrop of a snowy mountain panorama.
The individual parts of the asphalt mixing plant are dismantled in Nenzing with a crane and lifting platform.
Dismantling in Nenzing has been completed. Only a few parts remain.

Dismantling, relocation and installation of the asphalt mixing plant

To create a mixing site ready for the future, Hilti & Jehle GmbH are combining two of their existing asphalt mixing plants. To do this, the TBA plant in Nenzing/Austria is being dismantled, so it can be combined with the bitumen tanks at the plant in Götzis, some 21 km away. Additional Retrofit components will update the production site to the state of the art. By re-using the transportable asphalt mixing plant from Nenzing, the company has chosen a sustainable solution.

Town sign for Götzis with information: energy-efficient community.

Sustainability aspects

  • Maximum re-use of plant components
  • Economical and ecological asphalt production, thanks to cold and hot recycling
  • Reduction of carbon emissions
  • Noise reduction
  • Lower energy consumption

3D diagram of the planned asphalt mixing plant
A look ahead
Exciting insights
into the installation process
at the asphalt mixing plant

New technologies for a wider variety of asphalt mixtures

Hot bin section

In order to offer customers a large variety of recipes, the greatest possible number of different aggregate types and sizes has to be kept in stock. A capacity of
in total, including a rotary chute, and a volume of 150 t now enable the hot storage of different types of aggregate.

Flexibility for the bitumen supply

By combining the bitumen supply systems from both plants and integrating an intelligent bitumen control system, the customer can act flexibly in times of energy bottlenecks and fluctuating bitumen prices. This makes it possible to efficiently manage the volume as well as the variety of bitumen.

For more sustainable asphalt

In addition to the existing cold recycling system, a recycling drum with a hot gas generator has been prepared for hot recycling. This new, forward-thinking technology is to be used in the future to increase the recycled materials content in the end product. The objective is to keep the emissions generated during the production of asphalt mixtures as low as possible.

Usability

The new BLS4 control system gives the plant a clearer structure and makes it easier to use.

Expanding storage capacities

There are now eight bins available for larger storage capacities and more varieties of finished asphalt as well as for storing mastic asphalt.

Strategic location offers logistical advantages

The location of the newly installed plant was a clever strategic choice: it is situated at the southern tip of Lake Constance, in direct proximity to Germany, Liechtenstein and Switzerland. This means that asphalt mixtures can quickly be delivered across various borders. Multiple countries mean different requirements for the mixtures and a greater variety of recipes, which can easily be achieved with the updated plant. During the installation period but also for the time afterwards, all processes and routes were optimised to create a mixing site for the future.


Installation and expansion of the plant at the Götzis site

Start of plant installation including Retrofit in Götzis

We cannot always choose the weather.

Work on the foundations in full swing.

The base is finished, ready for the next phase.

The heart of the plant, the new weighing and mixing section (Retrofit), is delivered from the factory in Wittlich at the same time.

Increased flexibility and economic efficiency

The bitumen tanks from Nenzing are positioned and installed next to the existing bitumen tanks.

The first containers for the loading silo have been set up. The dryer drum is positioned at the same time …

… and the plant is starting to grow.

View of the plant from the rear.

The tower up to the skip track is in place.

Containers for the loading silo’s first two secondary towers are positioned.

The neighbouring loading silo is taking shape.

Positioning of the containers for the loading silo’s second secondary tower.

The filler tower is erected.

The weighing and mixing section has been expanded, including an enclosure for the section with corrugated sheeting to protect against noise, dust and vapour emissions, and to reduce heat loss.

Positioning of the first container for the new hot bin section on the mixing tower.

The ‘command centre’ is set up at the same time.

The 150-t hot bin section continues to grow.

The screen unit is airlifted in.

… almost finished …

Installation of the cold feed unit, including the roof. The roof is crucial because 1% less moisture in the aggregate saves 1 l of heating oil or the energy equivalent during heating of the aggregate.

Done – the yard and logistics paths have been surfaced with asphalt and asphalt production can start again.

A prepared area for the new asphalt mixing plant against a winter mountain panorama.
A snow-covered construction site where only the foundation for the asphalt mixing plant has been cleared of snow.
Foundation work is well underway, seen at sunrise against a winter panorama.
Finished foundations, including integrated supports for the components of the asphalt mixing plant, against a winter panorama.
The weighing and mixing section is placed on the prepared support structure in the foundation with a crane.
Positioning of the bitumen tanks from Nenzing next to the existing bitumen tanks: the seventh of a total of eight cylindrical bitumen tanks is installed with a crane.
Three containers have been placed on the first part of the loading silo. Now the horizontal cylindrical dryer drum is positioned with a crane.
Loading silo, dryer drum and bitumen tanks are on their foundations. Construction work in full swing.
The construction site viewed from the rear, with the bitumen tanks on the left and a covered storage area for different aggregates on the right.
Additional containers have been placed on the prepared foundation.
Containers for the loading silo’s first two secondary towers are positioned at the site.
Overall, three times three containers have been installed as towers on stilts for the loading silos.
Positioning of the last containers for the loading silo’s second secondary tower.
Installation of the cylindrical filler tower with a crane in the fog.
A view of the construction site: completion of the weighing and mixing section behind the dryer drum.
Positioning of containers for the hot bin section on the mixing tower. Marking of a container with the Hilti & Jehle logo.
Made from wood, a new control centre is constructed next to the mixing tower and loading silo unit.
Rear view of the construction site. Additional containers with attached steps are stacked onto the hot bin section.
The screen unit suspended from a crane.
Almost finished, the asphalt mixing plant is seen against a winter panorama.
Two people installing the cover for the cold feed unit with a lifting platform.
Finished asphalt mixing plant on the asphalt-surfaced site against a spring panorama; the yard and logistics paths have been surfaced with asphalt.

Modular design – Plug & Work

The transportable asphalt mixing plants from Benninghoven are not only designed to be transferred from one location to the next – the modular design also makes it possible to upgrade existing plants to the state of the art.

The TBA

TBA asphalt mixing plants feature a modular design and large storage capacities for the hot bin section and the mixed material loading silo. These properties, combined with the continuous retrofit options for the components, ensure outstanding plant performance.

TBA asphalt mixing plants are ideally suited for both semi-mobile and stationary use. The TBA is a true specialist in the field of asphalt mixing plants, thanks to its high level of flexibility, the number of available options and the impressive specifications.

The innovative plant concept enables seamless integration of the plant throughout its life cycle.

To the asphalt mixing plants

Strength in numbers

A project as large and complex as the one in Austria can succeed only with a strong team. While the requirements differ for each Retrofit project, Benninghoven have the experience to know what counts – the essential process steps.

Defining interfaces, understanding and considering process technology, and integrating the control system – it is all about so much more than just replacing steel.

Panoramic view across Lake Constance with a slightly misty landscape but bright sunshine.