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 divisions.

Continuous powder coating system — The components are first blasted or chemically pre-treated in the continuous powder coating system, then the powder is applied and finally fired in the furnace.

Heavy-duty turning lathes — All CNC turning lathes additionally allow boring and drilling, as well as milling using driven tools. Employees operate several machines simultaneously when machining large components that require long machining times.

Heavy-duty turning lathes — Our largest turning lathes allow workpieces to be machined which measure up to 1,200 mm in diameter and up to 6,000 mm in length. These machines offer a drive power of 100 kW.

Floor-type boring and drilling machines — Workpieces up to 12 metres long, 5 metres wide and 3 metres high can be processed here.

Flexible manufacturing systems — The two systems consist of two or three identical four- and five-axis machining centres 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 — Components manufactured in large numbers are machined by state-of-the-art welding robots. The components are assembled directly at the robot in a constant welding sequence and therefore with constant welding distortion.

Steel construction for series components — Series steel components are assembled here, as well as components intended for further processing in the mechanical division.

Training workshop — The training workshop for technical professions is furnished with state-of-the-art equipment and in line with practical requirements. WIRTGEN is currently training apprentices in twelve different professions.

Metalworking shop — Of the 14,000 different subassemblies altogether, as many as 7,500 are manufactured in the metalworking shop alone.

Bending centre — Press brakes offer pressing forces ranging from 125 tons to 140 tons, forming around 30% of the different parts.

Edge-rounding machines — To meet the highest requirements in terms of surface quality, the plants very efficiently round the edges of steel plates which are extremely sharp as a result of the laser-cutting process.

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

Drum bending centre — 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 between 450 mm and 1,000 mm.

Final assembly plant, series milling machines — There are roughly 50 travelling and slewing cranes installed throughout the final assembly plant.

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

Electrical shop, series machines — More than 50 control cabinets leave the electrical shop each week to be installed in our series machines. The operator’s platform and control panels of a large milling machine consist of some 7,500 components.

Central preassembly — Around 20 different discharge conveyors and covers are produced for the series range.

Cyclic assembly of large milling machines — All large milling machines with working widths from 2,000 mm to 4,400 mm are assembled here on three cyclic assembly lines. The large milling machines are assembled from more than 4,000 individual parts.

Information desks — All current information is stored online at the information desks, ready to be retrieved by the employee. It comprises hydraulic diagrams, electrical diagrams, assembly instructions, drawings, parts specifications, torque tables, quality assurance details, standards, instructions etc.

Cyclic assembly of compact milling machines, working width 1,000 to 1,800 mm — Cyclic assembly proceeds in precisely coordinated, individual work steps. Our machines are not sold off the shelf – every single machine is produced specifically for its intended use.

Paced assembly of small milling machines with a working width of up to 1,000 mm — 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 pre-fabricated components are located right next to the installation positions on the paced assembly line.

Finishing, series machines — This is where the completed machines are given their finishing touches. They are washed and provided with general labels as well as hazard and safety symbols.

Final quality control and acceptance, series machines — Final quality control and acceptance is the last step of production in the final assembly plant. Quality defects are revealed here using state-of-the-art measuring technology.

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

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

Assembly plant, special-purposemachines — The building has been specially dimensioned to accommodate the large machines, enabling full assembly even of the largest surface miner model - the 4200 SM.

Coating line for large components — Suspended parts weighing up to 30 tonnes and measuring up to 3 metres in height and 3 metres in width can be coated here.

Conveyor construction — The complex production of the extremely lightweight, yet stable truss structure is a WIRTGEN core expertise.

Steel construction for large components — The production of heavy machine frames and heavy individual components weighing up to 40 tonnes is on the daily agenda in this division. Welds measuring up to 20 mm in thickness are produced here in up to 17 layers.

Production sequence in drum production — With the aid of positioning devices, the toolholders are tack-welded on the prefabricated, machined milling drum tubes with pinpoint accuracy.

Highlights of drum production — WIRTGEN’s standard range comprises in excess of 500 different types of milling drums, the broad range of applications being complemented by several specialized designs – this is unique in the world. The range of milling widths extends from 14 mm to 4.40 metres.

Final assembly of slipform pavers — Slipform pavers are produced in stationary assembly as they need to meet high customer-specific and project-related requirements.

Production warehouse for special machines — The numerous options and special components for the special-purpose machines are order-picked in a separate, highly variable warehouse.

Final assembly of surface miners — Surface miners are also built in the special-purpose machinery division in accordance with individual customer requirements. A strong team comprising around 70 specialists is dedicated solely to the assembly of the machines.

Final assembly of special-purpose machines, recyclers — The recyclers built in this division include the tractor-towed stabilizer, W 240 CRi and W 380 CRi cold recyclers, KMA 220i mobile mixing plant and hot recyclers. Stationary assembly is the most economical solution here as these machines are offered in many different variants.

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 stabilisers.

Electrical shop, special-purpose machines — All the electrical components needed for the special-purpose machines, such as control cabinets, terminal boxes, cable harnesses etc. are produced in the workshop by highly qualified workers.