The Wirtgen Rock Crusher in Dresden

The Wirtgen Rock Crusher at the Dresden-Friedrichsstadt port

The WRC 240i Speeds up the Recycling Project for the New TrailerPort

Coarse Material from the Demolition Project is Processed Particularly Cost-Effectively in-situ

Dresden | Germany

The port operator, Sächsische Binnenhäfen Oberelbe GmbH, has demolished and rebuilt parts of the port in Dresden-Friedrichstadt. Currently under construction on the site is a state-of-the art TrailerPort for rail-road-transshipment requiring a particularly stable, high-quality cement-treated base layer. A WRC 240i Rock Crusher carried out the in situ preparation of the site.

The port has been rebuilt many times in its 130-year history, so the soil contained large amounts of stone and the remains of foundations with edge lengths of up to 250 mm left behind after the demolition of the old buildings and infrastructure.

In Situ Preparation of the Ground

Heber Terramix, the contractor commissioned to carry out the work, decided to use in-situ preparation of the soil. A new Wirtgen WRC 240i Rock Crusher was brought to the 12,000 m² site to carry out the in-situ granulation and homogenization of the soil. This offered the particularly resource-friendly advantages of being able to re-use the existing material and eliminate the need for transportation of material to and from the site. All told, this resulted in a calculated reduction of overall material logistics activities by more than 1,000 truck movements.

in situ preparation of the soil with a Rock Crusher

granulation and homogenization of the soil material

A view over the construction site of the TrailerPort Dresden-Friedrichsstadt

Robust Crushing and Mixing Rotor

The Rock Crusher processed the soil on the site to a depth of 50 cm with its crushing and mixing rotor. At an advance rate of around 8 m/min, it achieved an average productivity of approximately 450 t per hour. The HT18 cutting tools broke up the material on the crusher bars and the screen kept it in the crushing and mixing chamber until it fulfilled the specified material requirements (grain size 0/32) and could pass through the 45 mm screen mesh. The homogeneously mixed material remaining behind the WRC was then treated by the addition of NovoCrete ST98 cement in preparation for the subsequent stabilization.

HT18 crushing tools for impact crushing:

HT18 crushing tools for impact crushing: long service life and easy to exchange.

45 mm screens

45 mm screens ensured compliance with the required material grain size.

Homogeneously mixed material for the subsequent stabilization

Homogeneously mixed over the entire working width and depth.

Quality assurance behind the WRC. All requirements were fulfilled.

Base Layer Production after the Crushing and Mixing Process

A dozer spread the material evenly with the desired grade. 80 kg/m² of cement mix was spread by a Streumaster SW 16 MC in two passes and subsequently mixed in homogeneously by a WR 250i soil stabilizer. The Wirtgen WR was followed by an soil compactor for pre-compaction, a Grader for fine grading, and, after this, a smooth drum compactor for final compaction.

Overview of the port construction site in Dresden

The Wirtgen Rock Crusher on the port construction site in Dresden

Significant Reduction of Transport Costs

The advantages of this approach lay in the reduction of transport costs and the time and resources required. The in-situ recycling of the existing pavement and the soil material enabled the realization of a sustainable and resource-friendly construction method. The base layer with a thickness of 48 cm was completed within 2 weeks. Removal and replacement of the soil would have taken 8 to 14 weeks. The WRC 240i considerably shortened the construction time and enabled a substantial reduction of the transport costs.

Project Details