Limitless applications in economically efficient concrete...
Transcript of Limitless applications in economically efficient concrete...
Limitless applications in economically efficient concrete paving
The World ofWirtgen Slipform Pavers
Introduction 4 -5
History 6 -7
Offset slipform pavers in detail 8 -11
Inset slipform pavers in detail 12 -17
Leadership in technology 18 -29
Product portfolio 30 -31
Manufacturing technology 32 -33
Reliable customer service 34 - 35
In operation around the globe 36 - 37
Environmental sustainability 38 - 39
contents
2 //3
InTroducTIon
Slipform pavers get concrete into shape
Motorways and airport runways
are exposed to ever higher stress-
es caused by heavy-vehicle traffic
on the one hand and air traffic on
the other. Concrete pavements
are capable of withstanding these
tremendous loads for many years
to come. Slipform pavers have
become indispensable in concrete
paving because of their unsur-
passed efficiency in the highly
automated production of concrete
road pavements. The track-mount-
ed multipurpose machines are
also masters in the production of
a countless range of poured-in-
place profiles.
Major process innovations have
gained Wirtgen an excellent
reputation, and our slipform paver
range is occupying a leading po-
sition in the world market. We are
strongly driven by our firm com-
mitment to expand this position
further and to keep treading new
paths in the future.
Wirtgen is synonymous with efficiency in concrete paving
4 //5
hISTory
many product innovations paved theway to becoming a global player
The history of Wirtgen’s slip-
form paver division is impressive
proof that it is possible to take
up an existing technology and to
successfully develop it to per-
fection with innovative spirit and
creativity. Following the integra-
tion of a business that enjoyed
an excellent repu tation in the
industry, Wirtgen is now setting
many ground-breaking milestones,
one after the other, which are all
contributing signifi cantly to the
renewed success of the entire
technology. Our many pioneering
innovations include, for example,
a high degree of process automa-
tion, the development of machin-
ery for offset paving and dual-layer
concrete paving applications.
In 1989, Wirtgen became actively
involved in the technology by
acquiring Belgian slipform paver
manufacturer SGME and their
technologies. Slipform pavers from
Wirtgen have meanwhile gained
an excellent reputation in the
market and are the prime choice
for perfect concrete paving.
Wirtgen is setting important milestones
1989Following the acquisi-tion of a slipform paver manufacturer, Wirtgen
begins engineering and marketing slipform
pavers.
1991The SP 1600 is the
world’s first slipform paver capable of direct
dual-layer concrete paving.
1998The SP 850 Vario
features a hydraulically telescoping mould for working widths
ranging from 3.0 m to 6.0 m.
2006The SP 1200 features
a self-loading unit which comprises
dowel bar inserter, tie bar inserter, oscillat-ing beam and super
smoother.
1990As the first machine
developed by Wirtgen, the SP 500 is launched
on the market.
1994The SP 250 is a multi-purpose machine used mainly for offset pav-
ing applications.
1999Featuring two track units per machine
only, the SP 1500 L paving train is suitable for two-layer concrete
paving.
2010The multipurpose SP 15 and SP 25
slipform pavers set new standards in the efficiency of inset and
offset applications.
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1990The SP 850 offers a
variable working width ranging from 2.5 m to
9.0 m.
1997The TCM 850 enables freshly paved concrete
slabs to be cured in order to optimize their
surface finish.
2000The SP 1500 used on motorways and air-
ports can be equipped with dowel bar insert-er, tie bar inserter and finishing equipment.
2013AutoPilot and Field Rover enable most
diverse profile config-urations to be paved in a precise, automated process without using
stringlines.
offSeT SLIPform PaverS In deTaIL
Quick-change artists in concrete paving
8 //9
Slipforming poured-in-place pro-
files is usually more economically
efficient than using pre-fabricated
parts. Compact offset pavers are
generally used for slipforming the
profiles on the left or right side of
the machine. Our slipform pavers
offer a broad range of different
paving moulds in both stand-
ardized or customized designs.
Whether road boundaries, con-
crete safety barriers, canals, water
gutters or narrow paths: profiles
of any conceivable design are
produced quickly and at low cost.
Wirtgen supplies just the right
paving mould for any specified
poured-in-place profile. Continu-
ous, compact and – if required –
reinforced concrete structures are
thus produced, cast into a homo-
geneous whole.
The completed concrete pro-
files are distinctive for their high
stability, extremely low tolerances,
smooth surface and ease of main-
tenance.
The right paving mould for any given profile
offSeT SLIPform PaverS In deTaIL
operating principle and components
Concrete mixers are typically used
to deliver concrete into the slipform
paver’s receiving hopper when
paving in offset application. The
concrete is transported to the offset
mould in a continuous operation
either via a slew able belt conveyor
or via a slewable feeding auger.
Electrically or hydraulically driven
vibrators are installed in the paving
mould in accordance with customer
specifi cations. They are capable of
compacting most diverse grades
of concrete uniformly by means of
high-frequency vibrations. They are
capable of compacting concrete
material of many different grades
uniformly by means of high-fre-
quency vibrations. The paving
mould produces the poured-in-
place profi le while the slipform
paver keeps moving forward at a
continuous advance rate, producing
a concrete structure of uniform,
superior quality and excellent fi nish.
Paving poured-in-place profi les in
narrow bends is no problem at all
thanks to highly accurate levelling
technology and a precise steering
system. In addition, previously laid
steel reinforcement can be directly
included in the paving process
while the paver keeps moving
forward.
from the concrete mixer into the paving mould
TRACK UNITS, FRONTHydraulically driven, separately height-adjustable and steerable track units for precise driving be-haviour and high-precision concrete paving
CONCRETE FEEDING Concrete feeding system in either belt conveyor or auger conveyor design offering various adjustment options for transport of the freshly delivered concrete into the mould
TELESCOPING MACHINE FRAMEMachine frame telescoping in longitudinal and transverse direction to allow full adjust-ment to site conditions
PIVOTING LEGPivoting legs left and right for adjustment of the track units to site conditions
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OPERATOR’S PLATFORMErgonomically designed, walk-through
operator’s platform for non-tiring, productive working
TRIMMERTrimmer offering various
adjustment options for perfect preparation of the base
POWER UNITHigh-powered, fuel-effi cient diesel
engine for concrete paving in the optimal performance and torque ranges
CROSS-FEEDING AUGERCross-feeding auger to ensure reliable
concrete feeding in diffi cult site conditions
VIBRATORSElectrically or hydraulically driven vibrators to
ensure reliable concrete compaction
OFFSET PAVING MOULDOffset mould suitable for mounting on the left or right side of the paver
and telescoping to both sides
TRACK UNITS, REAROne or two hydraulically driven,
side-moving and height-adjustable track units for optimum adjustment to site
conditions
InSeT SLIPform PaverS In deTaIL
mobile road construction plants
Concrete pavements fully comply
with all expectations in terms of
bearing capacity, robustness and
service life. Inset slipform pavers
are the ideal candidates for an
economically efficient production
of concrete pavements on a large
scale. These mobile concrete
plants are capable of paving
concrete slabs at paving widths of
up to 16.0 m between their track
units. Different, highly effective
curing methods are additionally
available to give the completed
pavement surface the specified
properties. High-quality con-
crete pavements are not prone to
developing wheel ruts or surface
irregularities even after many years
of extensive use.
Slipform pavers are masters in
particular in the economically effi-
cient production of traffic arteries
subject to a high percentage of
heavy traffic, airport runways,
tracks for rail traffic, car parks or
highly stressed industrial surfaces.
Producing durable pavements economically
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InSeT SLIPform PaverS In deTaIL
operating principle and components
When paving in inset applica-
tion, the concrete is delivered by
trucks and dumped ahead of the
slipform paver. Depending on the
paver model used, the material is
then distributed evenly across the
full paving width by a spreading
auger or spreading plough. The
robust paving mould slipforms the
concrete pavement while travelling
over the previously distributed
concrete material. Electrically
driven vibrators emitting high-fre-
quency vibrations ensure optimum
compaction of the concrete during
the paving process.
The automated dowel bar inserter
places dowel bars into the con-
crete at specifi able intervals and
parallel to the direction of travel.
The automated tie bar inserter
places central tie bars and side tie
bars into the concrete at speci-
fi able intervals and transverse to
the direction of travel. The inte-
grated oscillating beam and super
smoother then produce an even
concrete surface across the full
width. In a fi nal step, texture cur-
ing machines give the surface the
texture specifi ed in the relevant
tender.
Paving between the track units
SUPER SMOOTHERSuper smoother for a perfectly smooth surface fi nish
TRACK UNITSHydraulically driven, separately height-adjustable and steerable track units for precise driving be-haviour and high-precision concrete paving
TELESCOPING MACHINE FRAMEMachine frame telescoping in longitudi-nal and transverse direction to allow full adjustment to site conditions
PIVOTING LEGPivoting leg for adjustment of the track unit to site conditions
OSCILLATING BEAMEccentrically driven oscillating beam to remove any irregulari-ties in the concrete surface
LONGITUDINAL JOINT TIE BAR INSERTERAutomated insertion of longitudinal joint tie bars to prevent the slabs from drifting apart
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OPERATOR’S PLATFORMErgonomically designed, walk-through
operator’s platform for non-tiring, produc-tive working
CONCRETE SPREADING Spreading plough or spreading auger to ensure even distribution of the concrete
delivered in front of the inset paving mould
POWER UNITHigh-powered, fuel-effi cient diesel engine for
concrete paving in the optimal performance and torque ranges
VIBRATORSElectrically or
hydraulically driven vibrators to ensure
reliable concrete compaction
INSET PAVING MOULDInset paving mould suitable for
mounting between the track units, underneath the machine
DOWEL BAR INSERTERAutomated insertion of dowel bars to maintain the surface levels of adjacent concrete slabs
SIDE TIE BAR INSERTERAutomated insertion of side
tie bars to enable the paving of adjacent concrete slabs
InSeT SLIPform PaverS In deTaIL
dual-layer concrete paving with a single paver or paving train
In a fi rst step of the operation, the
SP 1600, which has been equipped
with a supplementary module,
paves a standard concrete slab,
the bottom-layer concrete. An
excavator or other type of con-
crete delivery equipment feeds the
top-layer concrete into the receiv-
ing hopper in front of the SP 1600.
From here it is transported to the
rear of the machine via feeding
conveyors and deposited on top of
the freshly paved bottom layer. The
top concrete layer is then paved
while travelling over the bottom-
layer concrete.
If a paving train – comprising two
each pavers SP 1500 or SP 1500 L
– is used, the fi rst paver paves a
standard concrete slab, the bot-
tom-layer concrete. An excavator
or other type of concrete delivery
equipment feeds the top-layer
concrete into a receiving hopper.
From here it is passed onto a trans-
port conveyor which conveys the
top-layer concrete over and across
the bottom-layer paver to depos-
it it on the freshly paved bottom
layer ahead of the second paver.
The top-layer paver then paves the
material right on top of the bottom
concrete layer.
dual-layer paving in a single pass
Slipform paver fortop concrete layer
Topconcrete layer
Dumpedmaterial for topconcrete layer
Bottomconcrete layer
Bottomconcrete layer
Delivery hopper fortop-layer concrete
Bottomconcrete layer
Topconcrete layer
Inset pavingmould for top-layer concrete
Working direction
Working direction
Two-layer concrete paving with one single slipform paver
Two-layer concrete paving with two slipform pavers
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Slipform paver forbottom concrete layer
Beltconveyor
Beltconveyor
Receiving hopperfor top-layer concrete
Receiving hopperfor top-layer concrete
Inset pavingmould for bottom-layer
concrete
The continuous delivery of homo-
geneous concrete material is of vi-
tal importance for paving all kinds
of concrete profiles. Belt con-
veyors are ideal for offset paving
because they are easily cleaned
and impress with low wear and
tear, whereas auger conveyors mix
the concrete once again during
transport to the paving mould. The
auger conveyor can additionally
be adjusted to a steeper incline.
The cross-feeding auger is useful,
for instance, when the mould is
mounted far to one side of the
machine frame and the concrete
mixer and paver must travel in one
lane. In this case, the concrete is
delivered to the belt conveyor or
auger conveyor, forwarded to the
cross-feeding auger and trans-
ported into the offset mould.
Users can choose between a
spreading auger or spreading
plough to ensure even distribution
of the concrete across the paver’s
full working width when paving in
inset application.
Tried-and-tested solutions
LeaderShIP In TechnoLogy
concrete feeding to perfection
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LeaderShIP In TechnoLogy
fully automatic insertion of steel reinforcement
concrete armoured with high-tech
An exceptionally high degree of
intelligent engineering has gone
into our integrated high-tech com-
ponents for the insertion of steel
reinforcement. The fully automated
units insert dowel bars and tie
bars of any length into the freshly
paved, pre-compacted concrete
at specifiable intervals. Insertion of
the dowel bars parallel to the ma-
chine’s direction of travel is char-
acterized by an exceptionally high
degree of efficiency: to ensure
the slipform paver’s continuous
forward movement, the dowel bar
inserter is movable and stays in
place during insertion of the dowel
bars until the operation has been
completed. Dowel bars ensure
both the surface levels of adjacent
concrete slabs and the transmis-
sion of shear forces from one slab
to the next. The longitudinal joint
tie bar inserter inserts tie bars as
reinforcement transverse to the
paving direction. Tie bars prevent
the slabs from moving apart. The
side tie bar inserter inserts tie bars
in the side of the concrete slab.
They allow the paving of adjacent
concrete slabs.
20 //21
LeaderShIP In TechnoLogy
Perfectly smooth surface finish
We rely on a whole series of
technical refinements to give the
surface of concrete pavements a
perfect surface finish.
The eccentrically driven heavy-
duty oscillating beam is moved
back and forth transverse to
the direction of travel, removing
surface irregularities caused by,
for instance, the insertion of dowel
bars. It is followed by the super
smoother which is manufactured
from high-quality material and car-
ries out an oscillating, combined
longitudinal and transverse move-
ment to level out all remaining
irregularities in the upper portion
of the concrete slab.
The combination of dual, hydrau-
lically adjustable sideplates and
dual trailing and deep paving
mould provides clean finished
edges while at the same time
guaranteeing a smooth work
process.
evenness improves riding quality
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LeaderShIP In TechnoLogy
effective curing
anti-skid surface,optimal hardening
Concrete needs to be protected
against premature drying during
the hydration process to prevent
stresses from occurring that can
lead to excessive cracking. The
texture curing machine is therefore
equipped with an automatic spray-
ing and brooming unit, following
right behind the slipform paver
during the paving operation.
The concrete slab is given the
specified texture by moving a
broom across the entire concrete
surface. The spraying unit sub-
sequently applies a thin film of
curing compound on the freshly
paved concrete surface to prevent
premature evaporation.
Depending on tender specifica-
tions, the texture curing machine
can guide a broom, burlap or artifi-
cial turf across the moist concrete
surface to produce the specified
skid resistance. Washed concrete
is increasingly applied as an alter-
native technology.
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LeaderShIP In TechnoLogy
Intelligent machine control
26 //27
Wirtgen offers a range of different
machine control systems to cater
to different user needs. High-pre-
cision sensors can be installed at
the slipform paver, for example, to
scan previously tensioned string-
lines. The stringless 3D levelling
system offered by Wirtgen oper-
ates in an even higher efficiency
class. In this process, a total
station uses a laser beam to con-
tinuously track a prism mounted
on the slipform paver, reconciling
the measured data with a geodetic
terrain model to ensure concrete
paving to pinpoint accuracy.
The ultimate solution is offered by
the proprietary, low-cost AutoPilot:
time-consuming surveying, instal-
lation and removal of stringlines or
the preparation of a geodetic data
model are not required. Instead,
the innovative “Field Rover” prism
pole and special software are
used to calculate a precise virtual
stringline right on site which is
imported into the control system.
Precision in paving guaranteed
LeaderShIP In TechnoLogy
Professional expertise for complex concrete paving operations
Slab track and tunnel construction
Wirtgen has played a key role in
developing the so-called “slab
track” construction method. In
this process, the slipform paver
produces a concrete slab with
a specified cross-section that
needs to adhere to requirements
with pinpoint accuracy. The “slab
track” can be produced in any
given shape, serving as a stable
foundation for high-speed trains
– a means of transport that is
becoming increasingly important.
High-speed trains generate ex-
tremely high forces acting on the
rail system, which is why the rails
are embedded in concrete rather
than in “loose” ballast. Compelling
marks in favour of the non-bal-
lasted type of construction are
durability, strength, precise rail po-
sitions, reduced noise emissions
and ease of maintenance.
Wirtgen has many years of ex-
perience also in paving concrete
floors in tunnels where space is
extremely limited. In such projects,
the machine setup is customized
to precisely fit these specific, chal-
lenging application requirements.
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ProducT PorTfoLIo
Strong paving team covering all working widths
catering to all standard and special applications
Wirtgen’s comprehensive prod-
uct portfolio comprises twelve
slipform paver models across
all performance classes and for
all applications in high-precision
concrete paving. Standard paving
widths range from 1.0 m to 16.0 m
at standard paving thicknesses
of up to 450 mm. Concrete safety
barriers for impact protection on
motorways can be produced at
standard heights of up to 2.2 m.
Larger paving parameters can be
realized in accordance with cus-
tomer requirements.
In addition to the comprehensive
array of concrete pavers, Wirtgen
offers two texture curing machines
and one side feeder model to
guarantee perfect paving results.
Metric and imperial paving moulds
in standard design or built to cus-
tomer specifications are available,
enabling customers to comply
with specific national standards
and guaranteeing an extensive
range of applications.
30 //31
SP 15 SP 15 i SP 25 SP 25 i SP 500 SP 82 i
SP 84 i SP 850
TCM 950
SP 1200
TCM 1800
SP 1500 SP 1500 L SP 1600
ISF 850
manufacTurIng TechnoLogy
State-of-the-art manufacturingprocesses for highly durable machines
Mature manufacturing processes,
manufacturing-related know-how,
customized products, extensive
quality testing and employees
working on their own initiative
– these are the cornerstones of
Wirtgen’s slipform paver produc-
tion hub in Windhagen, Germany.
Our high standards are reflected
in the modern, computer-con-
trolled production equipment,
high degree of vertical integration
and highly qualified workforce.
In-house production of a large
number of equipment features
and special components allows
many different, customer-specific
equipment combinations. The use
of high-quality materials ensures
the smooth functioning and long
life of our machines.
Our success proves us right:
each single machine leaving our
production facilities is of superior
technical quality.
We putquality first
32 //33
reLIabLe cuSTomer ServIce
Worldwide service networkmakes the difference
experts appreciate ourcustomer focus
Wirtgen combines mature,
innovative technology with an
extensive, global service network
of highly competent subsidiaries,
sales partners and dealers. This
combination guarantees that our
customers get real added value
– around the globe, around the
clock. For our customers, opti-
mum service reads: short delivery
times for machines, spare parts
and wearing parts, as well as
comprehensive parts inventories,
qualified technial support, demon-
strations by qualified local person-
nel, and trainings at the custom-
er’s location.
Experienced service technicians
from Wirtgen accompany the pro-
ject, providing support as required.
Our service engineers are experts,
fully equipped with modern tools
and fully familiar with Wirtgen’s
entire product portfolio. They can
be contacted around the clock,
guaranteeing that parts on order
can be delivered immediately.
34 //35
In oPeraTIon around The gLobe
Wirtgen slipform paversare conquering the world
Following acquisition by Wirtgen, it doesn’t take long for the
technology to be bearing the hallmarks of a world-leading
construction equipment manufacturer. For the concrete slip-
form paver business is quick in conquering the world market:
a large customer base is established not only in Central Eu-
rope, but also in Eastern Europe and many countries across
Asia. In recent years, our machines have found a market in
North America as well. Wirtgen slipform pavers are in opera-
tion around the globe, having earned their merits in particular
on account of their extremely long service life: quality “made
in Germany” has become the hallmark of our machines.
Successful market expansionin all parts of the world
36 //37
Stat
e-of
-th
e-art e
ngine technology
Sta
te-o
f-th
e-ar
t mac
hine
co
ntro
l
Anti-vibration engine support
Sound
proofi ng
redu
ces
ex
haust
and noise emissions
redu
ces
exha
ust a
nd n
oise
em
issi
ons
reduces vibration and noise emissions
r educes noise em
issions
envIronmenTaL SuSTaInabILITy
We face up to the challengeof environmental protection
environmentallyfriendly machinetechnology
Wirtgen expressly commits to
protecting the environment, to
manufacturing safe and environ-
mentally compatible machinery,
and to developing more ecologi-
cally sustainable technologies and
products.
Slipform pavers are energy-ef-
fi cient machines with low fuel
consumption and simultaneously
low exhaust emissions. Slip-
form pavers are, in turn, used to
produce highly durable concrete
pavements and profi les. The long
period between new construction
and reconstruction or rehabilitation
respectively greatly benefi ts our
environment from an ecological
viewpoint: its positive results are
lower emission levels, reduced
energy requirements, and the non-
use of valuable natural resources.
Slipform paving minimizes dis-
ruptions to traffi c, which reduces
strain on the environment. Con-
crete pavements offer reduced
rolling resistance, which in turn
reduces the fuel consumption of
vehicles.
Wirtgen concrete paving
saves natural resources
Stat
e-of
-th
e-art e
ngine technology
Sta
te-o
f-th
e-ar
t mac
hine
co
ntro
l
Anti-vibration engine support
Sound
proofi ng
redu
ces
ex
haust
and noise emissions
redu
ces
exha
ust a
nd n
oise
em
issi
ons
reduces vibration and noise emissions
r educes noise em
issions
38 //39
Wirtgen concrete paving
saves natural resources
Wirtgen GmbHReinhard-Wirtgen-Str. 2 · 53578 Windhagen · Germany
Phone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-392Internet: www.wirtgen.com · E-Mail: [email protected]
Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes.Performance data depend on operational conditions. No. 2176308 01-73 en-10/14 © by Wirtgen gmbh 2014. Printed in germany