Turning two into one
View over the Rhine Valley to Lake Constance, as seen from the premises of Hilti & Jehle GmbH.

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

Hilti & Jehle GmbH operates two asphalt mixing plants in Austria at its sites in Götzis and Nenzing. As both plants have a fairly long service record – even the youngest is 14 years old – there are now plans to modernize them. The aim is to upgrade both plants to meet the latest technical standards and consolidate them at the Götzis site. A sustainable strategy is also being followed here by reusing individual components of the existing plants while adding new and innovative Retrofit solutions. This is all possible thanks to the modular design of Benninghoven asphalt mixing plants. This allows Hilti & Jehle to achieve a more productive and efficient facility while actively contributing to environmental protection.

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Careful dismantling work starts in Nenzing.

Plant in Nenzing – this will be dismantled here and reconstructed in Götzis with the addition of new components.

Finished! Assembly in Götzis can now begin.

An outdated asphalt mixing plant seen in the foreground of a snowy alpine panorama.
The individual parts of the asphalt mixing plant in Nenzing are dismantled using cranes and access platforms.
The dismantling phase in Nenzing is complete. Only a few parts remain standing.
An outdated asphalt mixing plant seen in the foreground of a snowy alpine panorama.
The individual parts of the asphalt mixing plant in Nenzing are dismantled using cranes and access platforms.
The dismantling phase in Nenzing is complete. Only a few parts remain standing.
An outdated asphalt mixing plant seen in the foreground of a snowy alpine panorama.
The individual parts of the asphalt mixing plant in Nenzing are dismantled using cranes and access platforms.
The dismantling phase in Nenzing is complete. Only a few parts remain standing.

Asphalt mixing plant dismantling, relocation, and assembly

To create a mixing plant fit for the future, Hilti & Jehle GmbH is consolidating two of its existing asphalt mixing plants. This will involve dismantling the type TBA plant located in the Austrian town of Nenzing and then combining it with the bitumen tanks in the plant located in Götzis, about 21 km to the north. Additional Retrofit components will be used to upgrade the production facility to the latest technical standards. By reusing the transportable mixing plant from Nenzing, the company has opted for a sustainable solution.

Götzis town sign with tagline: “an energy-efficient community”

Sustainability aspects

  • Optimum reuse of plant components
  • Economic and ecological asphalt production thanks to cold and hot recycling
  • Lower levels of CO₂ emissions
  • Noise reduction
  • Energy savings

3D mock-up of the planned asphalt mixing plant
A look into the future
A fascinating look
at the assembly process
for the asphalt mixing plant

New technologies for a wider range of asphaltic mixtures

Hot bin section

To offer potential customers a wide choice of recipes, the company needs to make sure that the range of aggregate types and sizes kept in stock is as large as possible. With a capacity of 14 bins overall, including a rotary chute and a total capacity of 150 t, hot storage is now possible for various aggregate types.

Flexibility in the bitumen supply system

By combining the bitumen supply systems of both plants and integrating an intelligent bitumen control system, the customer can now act flexibly even when faced with energy bottlenecks and fluctuating bitumen prices. This enables the efficient management of both the quantity and quality of bitumen.

For a more sustainable asphalt

Alongside the existing cold recycling system, a recycling drum with hot gas generator was also pre-configured for hot recycling. This new and forward-looking technology will be used in the future to further increase the proportion of recycled materials in the final product. The aim here is to ensure that the emissions created by the production of asphaltic mixtures are kept as low as possible.

Premium usability

Thanks to the new BLS4 control system, plant operation is now simpler and more streamlined for employees.

Expanding storage capacities

Eight bins are now available to ensure larger storage capacities and a wider range of types of finished asphalt, and for stockpiling mastic asphalt.

Strategic location offers logistical advantages

The location for the newly installed plant has been strategically selected: near to the southern tributary of Lake Constance, in direct proximity to Germany, Liechtenstein, and Switzerland. This ensures fast cross-border deliveries of asphaltic mixtures. Multiple countries mean different requirements for the asphaltic mixture or a wider range of recipes – both of which are easy to achieve with the “rebooted” plant. All processes and access routes were optimized not only for the installation phase but also for the future, with the aim of creating a future-proof mixing plant.


Installation and expansion of the plant at the Götzis site

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Start of plant installation and Retrofit in Götzis.

The weather does not always play ball!

Work on the foundations is well underway.

The footing is finished, installation can begin.

The centerpiece of the plant, the new weighing/mixing section (Retrofit), is being shipped simultaneously from the plant in Wittlich.

Improvements to flexibility and cost-effectiveness

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

The first containers for the loading silo are now in place, as the dryer drum is moved into position …

… and the plant starts to take shape.

View of the plant from the rear.

The tower is complete up to the skip track.

Containers for the loading silo’s first and second secondary towers are moved into position.

The neighboring loading silo is taking shape.

Containers for the loading silo’s second secondary tower are moved into position.

The filler tower is being erected.

The weighing/mixing section has been expanded to include an enclosure with corrugated sheeting for protection against noise, dust, and steam emissions, and to reduce radiant heat loss.

The first containers for the new hot bin section are being positioned on the mixing tower.

The “command center” is being set up in parallel.

The 150-tonne hot bin section continues to grow.

The screen is flown in.

… almost done …

Positioning of the cold feed unit, plus assembly of the roofing. This is an important step: A 1% reduction in moisture in the aggregate is equivalent to 1 l less heating oil or the equivalent energy source required to heat the aggregate.

Done! The yard and access routes have been paved with asphalt and asphalt production can now be restarted.

A total of three times three containers have been set up as towers on stilts for the loading silos.
The last containers for the loading silo’s second secondary tower are moved into position.
On a foggy day, a cylindrical filler tower is erected with the help of a crane.
View of the construction site: The weighing/mixing section is being completed behind the dryer drum.
Containers for the hot bin section are moved into position on the mixing tower. The Hilti & Jehle logo is applied to a container.
Alongside the mixing tower and loading silo unit, a new control center is being constructed from wood.
View of the construction site from the rear. Other containers with attached stairs are stacked onto the hot bin section.
The screen is suspended from a crane.
Now almost complete, the asphalt mixing plant is seen here in the foreground of a wintry landscape.
Two fitters install the roofing for the cold feed unit with the help of an access platform.
The completed asphalt mixing plant on a paved site, seen in the foreground of a spring landscape – yard and access routes have been paved with asphalt.
A site prepared for the new asphalt mixing plant, seen here in the foreground of a wintry alpine panorama.
A construction site with heavy snowfall, with only the foundation for the asphalt mixing plant cleared of snow.
A late stage in the foundation work, seen here at dawn in the foreground of a wintry landscape.
Completed foundations, including integrated supports for later parts of the asphalt mixing plant, seen here in the foreground of a wintry alpine panorama.
A crane is used to place the weighing/mixing section onto the supports provided in the foundation.
Positioning of bitumen tanks from Nenzing next to the existing bitumen tanks: The seventh of a total of eight cylindrical bitumen tanks is erected with the help of a crane.
Three containers have been set up on the first part of the loading silo. A crane is now being used to position the cylindrical dryer drum lying on its side.
The loading silo, dryer drum, and bitumen tanks are in place on the foundations. Construction work is well underway.
The construction site from the rear: the bitumen tanks are seen on the left while a roofed storage area for various types of aggregate can be seen on the right.
Other containers have been positioned on the prepared foundations.
The containers for the loading silo’s first and second secondary tower are positioned at the construction site.
A total of three times three containers have been set up as towers on stilts for the loading silos.
The last containers for the loading silo’s second secondary tower are moved into position.
On a foggy day, a cylindrical filler tower is erected with the help of a crane.
View of the construction site: The weighing/mixing section is being completed behind the dryer drum.
Containers for the hot bin section are moved into position on the mixing tower. The Hilti & Jehle logo is applied to a container.
Alongside the mixing tower and loading silo unit, a new control center is being constructed from wood.
View of the construction site from the rear. Other containers with attached stairs are stacked onto the hot bin section.
The screen is suspended from a crane.
Now almost complete, the asphalt mixing plant is seen here in the foreground of a wintry landscape.
Two fitters install the roofing for the cold feed unit with the help of an access platform.
The completed asphalt mixing plant on a paved site, seen in the foreground of a spring landscape – yard and access routes have been paved with asphalt.
A site prepared for the new asphalt mixing plant, seen here in the foreground of a wintry alpine panorama.
A construction site with heavy snowfall, with only the foundation for the asphalt mixing plant cleared of snow.
A late stage in the foundation work, seen here at dawn in the foreground of a wintry landscape.
Completed foundations, including integrated supports for later parts of the asphalt mixing plant, seen here in the foreground of a wintry alpine panorama.
A crane is used to place the weighing/mixing section onto the supports provided in the foundation.
Positioning of bitumen tanks from Nenzing next to the existing bitumen tanks: The seventh of a total of eight cylindrical bitumen tanks is erected with the help of a crane.
Three containers have been set up on the first part of the loading silo. A crane is now being used to position the cylindrical dryer drum lying on its side.
The loading silo, dryer drum, and bitumen tanks are in place on the foundations. Construction work is well underway.
The construction site from the rear: the bitumen tanks are seen on the left while a roofed storage area for various types of aggregate can be seen on the right.
Other containers have been positioned on the prepared foundations.
The containers for the loading silo’s first and second secondary tower are positioned at the construction site.

Modular design – Plug & Work

Transportable asphalt mixing plants from Benninghoven are not only designed to be easily moved from one site to another – their modular design also makes it possible to upgrade existing plants to the state of the art.

TBA plants

TBA asphalt mixing plants feature a modular design plus large storage capacities for the hot bin section and the asphaltic mixture loading silo. These characteristics, combined with long-term retrofit options for the components, guarantee outstanding plant performance.

The TBA asphalt mixing plant is ideally suited to both semi-mobile and stationary use. Its high degree of flexibility, wide range of available options, and impressive specifications make the TBA a true specialist in the asphalt mixing plant market.

The innovative plant design enables seamless integration of the plant throughout its entire lifecycle.

Go to asphalt mixing plants

A seasoned team

A project as large and complex as the one in Austria can only be successful with a strong team. While the requirements for each Retrofit project will differ, Benninghoven is very familiar with the key steps in the process, thanks to its long experience in the field.

Interface definitions, understanding and accounting for process technology, control system integration – it is about so much more than simply swapping out a few steel parts.

A panoramic view of Lake Constance on a sunny day, with light mist cloaking the surrounding landscape.

You can find details and more information on our product pages.

Retrofit

Retrofit

TBA 4000

TBA