Wirtgen Rock Crusher in Dresden

Wirtgen Rock Crusher in the port of Dresden-Friedrichstadt

WRC 240i accelerates recycling project for new trailer port

Coarse material from reinstallation project is processed in situ with great cost efficiency.

Dresden | Germany

The transhipment and logistics company, Sächsische Binnenhäfen Oberelbe GmbH, has rebuilt parts of the port in Dresden-Friedrichstadt. A modern trailer port is being built on the site for road-rail transhipment, which requires a particularly stable, high-quality hydraulically bound base layer. A WRC 240i Rock Crusher carried out the in-situ processing of the terrain.

The port has been rebuilt many times in its 130-year history, so after the old halls and infrastructure had been dismantled, the ground was full of foundation remains and stones with an edge length of up to 250 mm.

In-situ processing of the ground

The contracted construction company, Heber Terramix, opted in favour of in-situ processing of the ground. A new Wirtgen WRC 240i Rock Crusher was used on the 12,000 m² area to crush and homogenise the ground material. This meant that the existing material could be used in a particularly resource-friendly way and had the added benefit of eliminating the need to transport materials. In terms of figures, this saved more than 1,000 truck journeys for the entire material logistics process.

Crushing and homogenisation of the ground material.

View of the construction site for the Dresden-Friedrichstadt trailer port

Robust crushing and mixing rotor

The Rock Crusher processed the ground material with its crushing and mixing rotor to a depth of 50 cm. With an advance rate of around 8 m/min, it achieved an average productivity of approximately 450 t per hour. The HT18 crushing tools shattered the material on the crushing bars and the screens retained this material in the crushing and mixing chamber until it passed through the 45 mm mesh size, thereby meeting the material requirements (grain size: 0/32). The homogeneously mixed material that remained behind the WRC was prepared for subsequent stabilisation with NovoCrete ST98 cement.

HT18 crushing tools for impact crushing:

HT18 crushing tools for impact crushing: Durable and easy to change

45 mm screens

45 mm screens ensured the desired particle size was maintained.

Homogeneously mixed material used for subsequent stabilisation process

Homogeneously mixed, across the entire working width and depth.

Quality check behind the WRC. All requirements were fulfilled.

Base layer production following the crushing and mixing process

A crawler dozer distributed the material evenly to the desired grading. A Streumaster SW 16 MC spread 80 kg/m² of cement mixture in two passes. The cement was then mixed in homogeneously by a WR 250i soil stabiliser. The Wirtgen WR was followed by a soil compactor for pre-compaction, a Grader for producing the fine subgrade and then a smooth drum roller for final compaction.

Top view of the construction site at Dresden port

Wirtgen Rock Crusher at the Dresden port construction site

Significant transport cost savings

The chosen approach had the advantage of saving transport costs, time and resources. By recycling the existing surface reinforcement and ground material on site, a sustainable and resource-conserving construction method was implemented. The 48-centimetre thick base layer was completed within 2 weeks. Soil replacement would have taken 8 to 14 weeks. The use of the WRC 240i significantly reduced the construction time and led to huge transport cost savings.

Project details