Manual

For The Application Of

Cold Milling Machines

Edition: January 2004

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Preamble

The well-known statement that "the road network of the Federal Republic of Germany has been
completed to a large extent" applies to new construction only. This sentence is not true with regard
to the performance and maintenance condition of the existing road network as, due to stress, the
road network is subject to constant wear and tear, which increases disproportionately with a growing
percentage of trucks in the total traffic load. In the future, more and more new construction work will,
therefore, be replaced by maintenance work. Gradually, this also becomes known to wider sections
of the public.

The changes resulting from the above mentioned shifting of funds in road construction will affect not
only construction engineering but also the construction machines used, and powerful and
economical cold milling machines equipped with options tailored to the requirements of maintenance
projects will be the focus of interest more than ever.

Windhagen (Germany), January 2004

Feedback to:
Dieter Simons
Wirtgen GmbH
Hohner Straße 2
D-53578 Windhagen
Germany

E-mail: engineering@wirtgen.de
Phone: +49 (0) 26 45 /131-147
Fax: +49 (0) 26 45 /131-313
Internet: www.wirtgen.de

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Table of Contents
Introduction 6-7
1

Goals of road maintenance 8-13

2 Traffic safety, riding quality, environmental protection, protection of assets, objective

Methods 14-19
3 Cold milling, standard milling, fine milling, features

Principles and requirements of milling 20-27

4 Base, milling depth, surface structure and structural depth, evenness, etc.

Benefits of cold milling 28-33

5 The benefits of small and large milling machines with regard to application technology and profitability

Selection and use of equipment 34-43

6 Small milling machines, large milling machines, features of the different milling machine types
with regard to application technology

Applications of small milling machines 44-73

7 Patching, repairing small areas, replacing pavements, milling around manhole covers, etc.

Applications of large milling machines 74-95

8 Large-scale removal of road pavements, milling surface courses, complete road structures

Calculating the milling performance 96-103

9 Large and small milling machines

Flexible Cutter System (FCS) 104-111

10 The versatile quick-change system for milling drums

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 Fine milling 112-123
11 An economical method for the rehabilitation of road pavements

Cutting tools and tool systems 124-137

12 Toolholders, wear and tear patterns, recommendations for use

Levelling systems 138-151

13 An overview of the different levelling systems

Special applications 152-163

14 Surface mining, cold recycling

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Introduction

The significance of cold milling for road pavement rehabilita

Many objectives of modern road maintenance, such as the preservation of traffic safety, riding quality
and environmental protection, can be achieved by the use of modern milling technologies.
Besides reinforcing the upper pavement structure, maintenance construction is often specially aimed
at improving the surface condition of the road pavement in question.

Some examples:

• Improving the skid resistance.

• Levelling longitudinal as well as transverse irregularities in evenness.
• Removing bitumen oxidation and cracking of the surface course.

In recent years, the "Forschungsgesellschaft für Straßen- und Verkehrswesen" (Research Institute for
Roads and Traffic) has published additional technical contract conditions and specifications for the
structural maintenance of traffic areas, which are to be included in the construction contracts. These
new additional technical contract conditions and specifications present a good overview of the main
construction methods in road maintenance.

These new additional technical contract conditions and specifications for the maintenance of traffic
areas concern the partial or complete production of new pavement layers. Although milling off
pavement layers does not produce new pavements, the milling procedure itself is of great significance
for the quality of a new, thin pavement layer and has therefore been categorised as an "auxiliary
construction method", regulated in a special information leaflet published in the year 2000.

Many maintenance construction methods require the specific removal of the existing surface and
binder courses. The previously common method of reclaiming the complete asphalt package in the
form of slabs must be ruled out, since it results in a mix of different kinds and types of asphalt, thus
standing in the way of a re-use of the reclaimed material at a high construction engineering standard.
The asphalt layers should, therefore, always be reclaimed by milling.

Nevertheless, it could not be prevented in the past that damages occurred in the upper pavement
structure due to extreme traffic loads, which in asphalt construction showed as deformations, wear
and tear or cracking. Especially deformations in the form of ruts or transverse corrugations impair the
riding quality and are a traffic hazard in wet conditions. Cracking of the surface course leads to a
reduced service life of the entire upper pavement structure.

The upper layers of the pavement structure are particularly affected by stress due to climatic
influences or effects from the traffic load. Wheel loads and their resulting compressive, tensile and
shear stresses are deflected via the surface and binder courses into the base course of the road
structure without causing any damage.
In the medium term, however, damages in the uppermost layer are frequently the cause of serious
damage patterns in the entire road structure. Cracks in the surface course can, for instance, promote
the penetration of water, which will then expand when freezing and lead to cracking in the subgrade.

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Maintaining the surface course is, therefore, very important when it comes to maintaining the quality
of the road structure as a whole.

If the old base is too uneven, too smooth or excessively oxidised, milling is often a prerequisite for
placing thin pavement layers in hot or cold application. It is, for example, recommended to order
additional measures, such as fine milling, in case the unevenness of the base exceeds 10 mm. Only
then will it be possible to make demands with regard to the evenness of the completed layer.

Surface courses with an insufficient load-bearing capacity must be milled off prior to placing an
overlay in order to prevent them from being exposed to increased shear stresses.
Layers of road construction materials containing tar can also be specifically reclaimed by milling for
separate stockpiling and re-use.

Influences Type of Damage

Results Action
from: damage characteristics

Deformations Poor
resulting from Aquaplaning
evenness
Deformations shear stresses
Poor riding
Deformations quality
Construction resulting from
technology settlements Ruts Noise emission

Bitumen Rehabilitation
Ravelling Aquaplaning
oxidation
Polished Poor skid
Wear and tear surface resistance
Traffic
Abrasion Potholes Noise emission

Damaged seams
/ Open joints Penetration of
dirt and water
Individual
Cracks
Environment cracks Potholes
Alligator
Frost heave
cracking

An overview of damage characteristics and their effects

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8
2. Goals of road maintenance

2.1 Traffic safety 10

2.2 Riding quality 10

2.3 Environmental protection 11

2.4 Protection of assets 11

2.5 Objective 11-12

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2. Goals of road maintenance

The primary goal of road maintenance is to ensure an optimum road condition for the road user,
allowing safe and comfortable driving and a smooth flow of traffic under all weather conditions.

Regular road maintenance results in:

• High traffic safety

• Good riding quality
• Environmental protection
• Protection of assets

2.1 Traffic safety

The highest priority must be placed on the traffic safety. It is primarily influenced by road damages
occurring in the form of deformations or wear and tear. Wear and tear affects the evenness and skid
resistance of a road surface.

Deformations occur in the form of shear or settlement deformations. They impede a swift drainage of
the surface water, which leads to aquaplaning with an increased risk of skidding and to longer
braking distances. Shock loads of the car and the road pavement lead to additional noise emissions.

Rutting

2.2 Riding quality

The riding quality influences the driving behaviour of the road users, the flow of traffic and the traffic
safety. Decisive factors are the quality of the longitudinal and transverse evenness as well as the
properties of the pavement (roughness, potholes, optical properties). A poor riding quality has adverse
effects on the traffic safety, the driving behaviour and the flow of traffic.

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2.3 Environmental protection

Increasing significance is attached to the protection of the environment with respect to rolling noise
emissions and the formation of wheel spray. Typical disruptive factors are roughness, transverse
unevenness and potholes.

Cracks in a surface course

2.4 Protection of assets

Considerable assets are tied up in the road network, making it very important from an economical
viewpoint to maintain these assets as long as possible. Pavement damages, such as cracks and
potholes, ravelling or flaws resulting from the construction technology, will invariably lead to larger
damages or even to the destruction of the entire road structure.

The effects:
• Considerably higher rehabilitation costs when compared to a "preventive" repair of the
damage.
• High indirect costs (from an economical viewpoint) due to a poor flow of traffic, accidents
and increased fuel consumption.

2.5 Objective

The goals set for road maintenance can be fully achieved by way of suitable rehabilitation measures,
either by restoring the properties of the upper pavement structure, such as stability, evenness, level
profile and skid resistance, or by improving them in accordance with the new requirements.

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The choice of the method being most beneficial from a technological and economical point of view de-
pends upon the type of damage, its cause and also the requirements that will be placed on the new
layers.

In case of deformations, it must be established as to whether these are limited to the surface course,
or whether underlying layers have already been affected. If the damage extends into these deeper
layers, the rehabilitation measures must include a strengthening of the damaged layers, i.e. their load-
bearing capacity must be increased. If only the surface course is affected, a rehabilitation of this layer
will be sufficient.

Wear and tear in the form of abrasion and ravelling is limited to the surface. In this case, a treatment or
an improvement of the surface area (surface course) will be sufficient.

Cracks occur in the form of alligator cracking, transverse or longitudinal cracks. Whilst alligator
cracking and transverse cracks are mostly limited to the surface course, longitudinal cracks often
extend into deeper layers. Cracks allow the penetration of water and dirt, thus inevitably leading to the
destruction of these layers. A timely treatment of cracked layers is, therefore, absolutely essential.

Economical construction methods have been developed for these problems in asphalt road
construction. Milling is one of these methods, whereby damaged asphalt layers are removed using the
appropriate machines. One or more new layers are then placed on top of these bases produced by
milling.

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14
3. Methods

3.1 The cold milling method 16

3.2 Standard milling 17

3.3 Fine milling 17

3.4 Features 18-19

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3. Methods

3.1 The cold milling method

Cold milling has generally been accepted as being the state of the art. Other methods are of minor
importance and are typically only used as a supplementary method to milling.

Cold milling can be carried out on both, asphalt and concrete surfaces. The surface to be milled must
not contain steel inlays. Surfaces containing plastic or fibre inlays can only be milled at higher costs.
The process is almost independent of weather conditions.

A large milling machine milling an asphalt pavement

Cold milling machines are very compact, mobile machines. They are easily manoeuvred even on
narrow or winding surfaces. The design of the milling machine itself and the casing of the individual
aggregates ensure that the inevitable noise emission during the milling operation is reduced to an
absolute minimum.

The machine travels over the pavement to be milled, whereby the rotating milling drum is lowered in
accordance with the required milling depth, scarifying the material. The milling drum can be lowered
either parallel or in a specific incline to the pavement surface. The machine travels on either wheels or
crawler track units and has an infinitely variable drive system. During the milling operation, a milling
depth control unit regulates the pre-set milling depth in relation to the reference height.

The achievable milling performance (speed x milling width x milling depth) basically depends upon the
capacity of the milling machine used and upon the road construction material to be milled. Depending
upon the construction method or requirement, the material recovered by cold milling (reclaimed
asphalt pavement) can be loaded on trucks using the machines' own conveyor system, discharged to
the side of the machine or left behind on the milled surface. It may sometimes be necessary to work
without a conveyor system when small milling machines are used to mill off small-sized areas, tapered
junctions or areas inaccessible to large machines.

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3.2 Standard milling

Standard milling involves the removal of asphalt pavements or parts thereof by milling off individual
layers or the entire pavement structure. The tool spacing of a standard milling drum, which is the
distance between one cutting tool tip and the next, is approx. 15 mm.
Depending upon the type of machine used, milling depths of up to 35 cm and milling widths between
30 cm and 4.30 m can be achieved.

Standard milling drums with a tool spacing of 15 mm are ideally suited for the removal of entire
pavement structures.

A large milling machine milling a surface course

3.3 Fine milling

Fine milling involves the milling of traffic surfaces to restore the skid resistance or the evenness of the
pavement. Typically, only a few millimetres of the surface course are removed. The maximum milling
depth is 4 cm.

Special fine milling drums with a tool spacing of approx. 8 mm are used for fine milling. Depending
upon the requirements placed on the fine milled area, the spacing may sometimes be even smaller
(e.g. 5 mm). Milling widths of up to 2.20 m are standard, and widths of up to 4.30 m are possible.

A country road, fine milled with a machine of the 2 m class

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3.4 Features

Milling machines (road milling machines)

Small milling machines are mostly wheel-mounted machines. Their milling is drum positioned at the
rear of the machine. For this reason, they are also called "rear loaders".

Large milling machines are typically equipped with crawler track units.

These machines are intended for use in large-scale rehabilitation projects and have, therefore, been
designed for a high area performance.

Their features include a standard conveyor system and a milling drum positioned at the centre of the
machine, between the front and rear axles.

Working direction

Working direction of a small milling machine

Working direction

Working direction of a large milling machine

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The most important tool of the machine is a rotating milling drum, which works in an up-milling
direction (Picture 1). It is equipped with rotating point-attack cutting tools (Picture 2) and scarifies the
existing asphalt material. Typically, the milling drum is firmly connected to the machine frame. Its
height is adjusted via the travel drive units of the machine.

The advance speeds range from 1 m/min to approx. 30 m/min. Road milling machines are capable of
collecting the milled material and loading it on transport vehicles by way of their conveyor system.
Small milling machines are mostly equipped with a conveyor located at the rear of the machine (rear
loaders), whereas large milling machines are typically designed as front loaders. The conveyors can
usually be adjusted in height and slewed to either side.

Milling drum

Working direction

(Picture 1)

Carbide tip

Base material

Pre-tensioned sleeve

Wearing plate

(Picture 2)

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4. Principles and requirements of milling

4.1 The road base 22

4.2 Milling depth 22

4.3 Surface structure and structural depth 22-23

4.4 Evenness 23

4.5 Level profile 23-24

4.6 Forming the milling edge 24

4.7 Condition of the reclaimed asphalt pavement 25

4.8 Notes to requirements, testing, acceptance, billing 26-27

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4. Principles and requirements of milling

4.1 The road base

The road base is the area underlying the pavement to be milled. It must possess a sufficient degree
of stability and load-bearing capacity for the equipment being used.

This means that the client must indicate possible problems relating to the condition of the road base
in the specification of works. The milling contractor can then account for such problems in his
calculation.

4.2 Milling depth

The milling depth depends upon the pavement condition, the objective of the construction project and
the type and thickness of the existing pavement.

This means that the client must determine the required milling depth in the specification of works in
accordance with his knowledge of the type and condition of the layer. The milling contractor must
adhere to the milling depth, and the tolerances for the paving thicknesses established in accordance
with the road construction and additional technical contract conditions and specifications for country
road pavements likewise apply to the milling depth.

When milling on bridges, the client must indicate the milling depth in the specification of works in such
a manner that, taking into account the permissible tolerances and the structural depth, no damage of
the existing insulation or the structural body occurs.

4.3 Surface structure and structural depth

The surface structure of the separating layer is influenced during the milling operation by the type of
machine used, the arrangement and shape of the tools, the working speed and the type of material to
be removed.

A regular structure or uniform condition of the milled surface is imperative for a good adhesion with the
new asphalt layer to be placed. This includes cleaning the milled area and removing loose remnants of
material from the road base or the separating layer.

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Regular surface structure of a milled surface

4.4 Evenness

The attainable evenness of the road base produced by milling depends upon the following factors:

• Evenness of the surface to be processed

• Homogeneity and condition of the material to be removed
• Adhesion between the individual layers
• Condition of the external tools used to determine the level (grade line, Multiplex, laser,
or similar)

Several machine passes may be required in case one or more of these prerequisites cannot be met,
since the evenness of the milled surface is decisive for the subsequent placing of the new asphalt layer
and for its attainable evenness.

4.5 Level profile

Carriageways are built with a transverse slope in order to enable the drainage of water. If a layer of uni-
form thickness is to be placed across the milling width at a constant transverse slope, the milling
depth must be stipulated in such a manner that the lowest point of the transverse profile is included
(ruts, deformations, etc.).

It may be necessary to mill at varying depths in relation to the transverse profile if an intermediate layer
is to be placed to improve the cross-section.

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Uniform layer thickness across the entire pavement width

4.6 Forming the milling edge

The milling operation usually produces vertically shaped longitudinal milling edges.

It is, however, not possible to produce a vertically shaped transverse milling edge in one machine
pass. The rounded transverse edge of the milled track is due to the machine configuration and must
be reworked using a small milling machine or another suitable piece of equipment.

If there is a risk of ravelling of the milling edges due to the condition of the surface to be milled
(bitumen oxidation, cracking, insufficient adhesion between the layer and the road base, etc.), the
remaining surface must be cut off by a straight crosscut prior to milling. Such additional work must,
however, be stipulated in the specification of works in an own, separate item.

Forming the connecting edge of a milled surface

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4.7 Condition of the reclaimed asphalt pavement

The condition and the particle size of the reclaimed asphalt pavement depend upon the following
influencing factors:

• Condition of the layer to be milled

• Type of mixture of the layer to be milled
• Weather conditions
• Advance speed
• Gradation control beam (reduces the formation of slabs)

There is also the risk of slabs forming in the milled material if the milling operation takes place near
the seam separating two asphalt layers and there is insufficient adhesion between the individual
layers.

The particles of gravel or chippings may be crushed due to the milling operation. The properties of
the bitumen contained in the reclaimed asphalt pavement will remain unchanged. The bitumen
properties must, however, be examined if the asphalt granulate is to be re-used.

Cold milling is the only method where surface course, binder course and base course can be
removed in separate, individual layers. Therefore, cold milling meets the requirements for an
economical re-use of the reclaimed asphalt pavement.

Removal of a surface course

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4.8 Notes to requirements, testing, acceptance, billing

The requirements and the acceptance and billing modalities of the following additional technical
contract conditions and specifications apply: additional technical contract conditions and
specifications for the construction of road surfaces with asphalt, additional technical contract
conditions and specifications for base courses in road construction, additional technical contract
conditions and specifications for the constructional maintenance of road surfaces with the asphalt
construction method, and additional technical contract conditions and specifications for country road
pavements.
It is recommended to specify the following requirements with regard to the milling performance:

• Level profile
If the road base is produced by way of milling, the tolerance of the required transverse slope must
not exceed ± 0.4 %.

• Evenness
The following threshold values for any longitudinal and transverse unevenness of the milled area
must not be exceeded on a 4 m long measured section:

On a free road section with no level requirements:

• Milling of a surface course: < 6 mm
• Milling of binder and surface course: < 10 mm

On road sections with constructional constraints, for example road junctions, tram or railway tracks,
bridge superstructures or other fixtures, such as sliding covers, manhole covers, edge stones or
kerbstones:
• Milling of a surface course or of surface and binder course: < 10 mm

When fine milling an asphalt pavement intended for immediate trafficking, the longitudinal and
transverse unevenness on a 4 m long measured section must not exceed:
• 4 mm for the road categories SV and I to III
• 6 mm for all remaining road categories

• Milling depth
When milling asphalt pavements, the structure displayed in the following illustration is produced
transverse to the direction of milling.
The structure is characterised by the cutting tool spacing and the cutting angle. Due to the surface
structure of the milled surface, two different milling depths can be measured. The upper milling depth
is determined when measuring at the highest point, and the lower milling depth is determined when
measuring at the lowest point of the milling pattern. The decisive value for billing purposes is the
mean milling depth. The mean milling depth is the arithmetic mean value established from an
identical number of upper and lower milling depth measurements, and the milling depth is billed
accordingly.

The client and the contractor must mutually agree upon the number of individual measurements per
area unit required to calculate the mean milling depth.

26
 Mean milling depth
Upper edge of the
Upper milling depth
original surface
Lower milling depth

Cutting angle (")

Cutting tool spacing

Milling structure, section transverse to the milling direction

In case of a required uniform thickness of the subsequently placed asphalt layer, the tolerance for the
paving thickness as specified in the corresponding additional technical contract conditions and
specifications likewise applies to the mean milling depth.

The upper milling depth is established if the layer thickness of the overlay is determined by means of
an electromagnetic thickness measurement.

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28
5. Benefits of cold milling

5.1 Benefits with regard to application technology 30-32

- Small milling machines
- Large milling machines

5.2 Benefits with regard to profitability 33

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5. Benefits of cold milling

5.1 Benefits with regard to application technology

• Cold milling makes it possible to limit the removal of the damaged or dependent traffic area to the
actual extent of the damage.

The removal is limited to the damaged area.

30
 Surface course
Binder course

Base course

Subgrade

The removal can be limited to the layer thickness or to the depth of the damage.

• Allows the removal of individual layers of the damaged area.

• Is the only method allowing the selective removal and separation of different types of mix. This is
an important aspect in view of the existing regulations for the re-use of reclaimed asphalt
pavements.
• Allows the production of an even, profiled new road base, providing a favourable surface structure
as a prerequisite for a good adhesion between the individual layers.
• Produces vertical and clean milling edges for good connecting joints and a good adhesion between
the individual layers.

Small milling machines

Small milling machines with working widths of up to 50 cm are particularly well suited for partial
pavement repairs. Electrically driven, emission-free cold milling machines are now available for
operation in factories or other indoor areas. The "small ones" have a particularly compact machine
design, making transport to the site fast and easy.
Small milling machines distinguish themselves by a number of technical features, which make them
exceptionally flexible. Small milling machines do, for example, have an extremely small turning radius,
making them exceedingly versatile. The conveyor of small milling machines can be uncoupled very
easily, allowing the machine to be driven close to any obstacle when removing larger surfaces. Their
slewable support wheels enable milling close to building walls or kerbstones. These features are
particularly important on job sites where large milling machines are in operation and additional work
must be carried out, a task that small milling machines are frequently used for.

• Milling around obstacles

A typical application of small milling machines is milling around manhole covers. Settlements of the
manhole covers make it necessary to correct their height from time to time, since they would otherwise
jeopardise the traffic safety. In contrast to a jackhammer, a small milling machine with a small turning
radius can remove the pavement around the damaged manhole cover quickly and cleanly down to the
desired depth. The height of the manhole cover is then corrected, for example by inserting
intermediate rings. After that, the area around the manhole cover is either filled with new asphalt mate-
rial or paved with cobblestones.

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• Partial rehabilitation of road pavements

Pavements, for example on heavily frequented access roads, are often excessively stressed, and the
rehabilitation of partial areas becomes necessary. Small milling machines are ideally suited for this
task. After the pavement of the area in need of repair has been milled off, a tack coat is applied,
ensuring a good adhesion with the new asphalt layer. The vertical milling edge, which offers a good
interlocking structure for the new material, is additionally provided with a bitumen-impregnated strip.
The new asphalt can then be placed true to line and level - either with a small paver or manually. The
partial repair is completed after compaction.

• Small milling machines with working widths of up to 1.0 m

Small milling machines with working widths of up to 1.0 m are often equipped with an additional
automatic levelling system, allowing the precise removal of the material true to line and level. In this
machine class, it is generally also possible to choose between wheel-mounted or track-mounted
machines. The latter have proved particularly suitable when used on soft subsoil where, in contrast to
wheel-mounted machines, the crawler tracks do not sink in, thus ensuring a constant and accurate
forward advance movement.

Large milling machines

The large milling machine class includes machines with standard milling widths of up to 2.20 m.
Milling widths of up to 4.30 m are possible with special milling drum units. Typically, all large milling
machines are front loaders, i.e. the truck to be loaded drives in front of the machine. As with all
milling machines, the conveyor can be slewed to either side, so that a truck running alongside and to
the front of the cold milling machine can be loaded in a continuous operation.

• Application examples for large milling machines

Large milling machines with working widths of up to 2.20 m are an economical solution when it
comes to the removal of complete asphalt packages down to a depth of 35 cm, for example in
connection with rehabilitation projects on motorways or federal roads. Large milling machines are
also well suited for levelling large, continuous surfaces. For this purpose, the machines are equipped
with a fine milling drum.

The use of large milling machines is made exceptionally profitable by their powerful travel drive and
high milling performance.

Large milling machines of a more recent type have a number of special technical features ensuring a
high degree of efficiency and user friendliness.

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5.2 Benefits with regard to profitability

Cold milling:
• is the fastest and most powerful method for removing damaged layers of the upper
pavement structure.
• allows a cost-efficient rehabilitation of traffic areas, limited to the actual extent of the
damage.
• is cost-efficient due to short construction periods with only minor traffic disruptions.

Important factors for a machine's profitability are its user-friendliness and acceptance by its operator.
Only then can a thorough servicing and maintenance of the machine be guaranteed. Hence, the user-
friendliness of a machine is an essential aspect also with regard to its availability.

In this respect, the machines of the new generation differ from their predecessor models by small,
but distinct features: Wirtgen GmbH does, for example, offer machines with wide opening doors,
easy access to all servicing and inspection points, clearly laid-out control panels and self-explanatory
symbols.

33
34
6. Selection and use of equipment

6.1 Small milling machines 36

6.2 Large milling machines 37

6.3 Features of the different milling machine types with 38-41

regard to application technology

6.4 Fields of application 42

35
6. Selection and use of equipment

A suitable machine must be selected in accordance with the specific characteristics of the work to be
carried out. Aspects like working width, machine size, milling depth and performance must be taken
into account. Basically, cold milling machines are divided into small and large milling machines.

6.1 Small milling machines

Small milling machine

The working widths of these machines range from 300 mm to 1000 mm. Depending upon the
machine type, they have a maximum milling depth of up to 300 mm. Due to their many application
possibilities, machines of this size are in continuous operation on road rehabilitation projects.
Remarkable features of these machines are their compact design and high manoeuvrability.

One design feature is the position of the milling drum between the rear wheels, allowing flush milling
close to rear obstacles or in a transverse direction to the pavement. The rear right-hand wheel can be
slewed in front of the milling drum to allow flush milling alongside edge stones or kerbstones. Due to
their high versatility and good manoeuvrability, the machines can also operate on narrow job sites or
small areas. Depending upon the physical conditions, manual rework is mostly not required.

Most of these machines are either equipped with or suitable to be equipped with a conveyor system
to load the milled material.

36
6.2 Large milling machines

These machines have working widths of 1300 mm or larger. Depending upon the machine type, they
have a maximum milling depth of up to 350 mm. The machines are intended for use in large-scale
rehabilitation projects and have, therefore, been designed for a high area performance. Their features
include a standard conveyor system and a milling drum positioned at the centre of the machine,
between the front and rear axles.

Large milling machine

37
6.3 Features of the different milling machine types with regard to
application technology

W 350: Milling around manhole covers

The W 350 shown on this picture is a compact

small milling machine suitable for partial pavement
repairs or for the removal of indoor pavements. Its
operating weight can be reduced by one third,
which means that it can also be used on floors
with a lower load-bearing capacity, such as multi-
storey car parks. In addition, the machine is
equipped with a slewable support wheel.

W 350 milling around a manhole cover

W 350 E: Removal of factory floors

The W 350 E is an electrically driven cold milling

machine. It is mostly used to mill off factory floors
in the food production industry.

W 350 E removing a factory floor

W 500

The W 500 is an all-round machine used by both,

construction companies as well as contractors.

W 500 with a milling width of 500 mm

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 W 600 DC

The deep milling machine W 600 DC is a universal

machine meeting both, the requirements of trench
cutting as well as the highest demands of surface
rehabilitation. A standard application is milling off
the complete pavement package at a working
width of 600 mm and a working depth of 300 mm,
and then loading it on trucks. Drums with working
widths of 500 mm or 400 mm can also be
mounted, using a simple and user-friendly quick-
W 600 DC change system.

W 1000 L

The cold milling machine W 1000 L from Wirtgen

has made a name for itself in many countries of
the world. Its reliable engineering, high milling per-
formance and resulting high profitability have
stood the test in all applications. Its strength lies
in the removal of entire road pavement layers.
This can either be the large-scale removal of
entire pavement layers or access work for which
the use of a large milling machine is not
W 1000 L worthwhile.

W 1000

The W 1000 is a powerful cold milling machine for

modern pavement rehabilitation with high daily
performances. The machine is also equipped with
a slewable support wheel and a removable
conveyor system to load large transport vehicles.
Both, the W 600 DC and the W 1000 can be
equipped with a standard milling drum and a
milling ring to produce groove-shaped cuts.

W 1000

39
 Front loader W 1000 F

Front loading, manoeuvrability and a high degree

of user-friendliness are characteristic for the
practical relevance and modern design of the W
1000 F. The machine's crucial advantage is its
ability to front-load the milled material, allowing a
perfect coordination between the truck driver and
the machine operator. With a milling depth of up
to 30 cm, the machine is suitable for both, the
removal of entire pavements as well as trench
W 1000 F cutting.

W 1000 F/ W 1200 F / W 1300 F

Optional wheel or crawler track unit

The user of a W 1000 F can equip his machine

with either wheels or crawler track units. The rear
right drive unit can be folded inwards, irrespective
of whether the machine is mounted on wheels or
on crawler tracks.Milling drums of 1200 mm or
1300 mm working width are also available.

W 1300 F

W 1500 - W 1900

The well-established cold milling machines of the

1300 DC to 2000 DC series have made an
excellent name for themselves over the past 10
years. They were redesigned and have now been
in operation on construction sites under the name
W 1500 / W 1900 since the beginning of 2001.
The new model range offers a maximum degree
of flexibility with regard to its working width,
combined with reliable, practical features.
W 1900

40
 W 2000

The cold milling machine W 2000 is a powerful

and compact machine. The W 2000 stands for the
swift completion of construction projects in
pavement rehabilitation.

W 2000

W 2100

The W 2100 is the power package of the 2 m

machine class. This high-performance cold milling
machine with a milling width of 2.0 m has been
designed for the large-scale removal of
pavements on roads and airports. The milled
material is loaded to the front via a two-stage
conveyor system.

W 2100

W 2200

The W 2200 is a machine of the new upper class.

Large construction sites, like the removal of entire
carriageway structures over a length of many
miles, are in the domain of the W 2200. The
machine works its way through the pavement with
an incredibly fast forward advance speed, thus
ensuring the swift completion even of very large
construction sites.

W 2200

41
6.4 Fields of application

The selection of the appropriate machine depends upon the conditions prevailing on the job site, for
example the type of surface to be milled and the traffic situation.

The following must be considered with regard to the surfaces to be milled:

• Size of the total construction project

• Large-scale removal
• Small rehabilitation project
• Stipulated construction period
• Obstructions, such as manhole covers or fixtures
• Stipulated milling widths and milling depths

The following must be considered with regard to the traffic situation:

• Partial or complete road closure, travelling job site

• Construction measures on road crossings or junctions
• Rail-bound traffic
• Job site procedures, such as transport routes of the milled material, etc.

Typical working widths in cm 30 50 100 130 150 190 200

Application
Asphalt milling
Milling surfaces of up to 500 m2
Milling surfaces of up to 1,000 m2
Milling surfaces of up to 3,000 m2
Milling surfaces of up to 7,000 m2
Milling surfaces exceeding 7,000 m2
Milling depths of 0 to 100 mm in one machine pass
Milling depths of 0 to 300 mm in one machine pass
Removing and shaping deformed asphalt pavements
Rehabilitation of ruts
Removing damaged pavements on bridges
Removing deformed marginal surfaces
Improving the lateral incline
Wedge-shaped joints in transverse direction
Milling on road crossings
Milling on road junctions
Milling in corners

Applications of road milling machines in accordance with their working width and the task at hand

42
43
44
7. Applications of small milling machines

7.1 The various applications of milling machines 46

7.1.1 The milling principle 46-48

7.2 Patching 48

7.3 Small-scale repairs of surface courses 49-51

7.4 Overlapping surface overlays in road construction 52-54

7.5 Replacing a pavement with a rear loader 54-55

7.6 Replacing a pavement with a 1 m front loader 56-57

7.7 Milling flush to kerb 58

7.8 Small and large milling machines complementing one 58-59

another
7.9 Overlaying damaged pavement sections 59-61

7.10 Levelling elevations 61-62

7.11 Correcting manhole covers 62-63

7.12 Pavement removal at full depth 64-66

7.13 Building traffic islands 67

7.14 Cutting grooves 68-69

7.15 Rehabilitating industrial surfaces 70-72

45
7. Applications of small milling machines

7.1. The various applications of milling machines

The theoretical part, which has explained the objectives of road maintenance and their requirements,
is now followed by a short explanation of the cold milling method and of the milling principle.

A large portion of this chapter will concern the various applications of cold milling machines in
practical operation.

7.1.1 The milling principle

A milling drum rotating in an up-milling direction is installed in the machine transverse to the direction
of travel. It is equipped with cutting tools, scarifying the existing pavement material. The machine
moves forward on either wheels or crawler tracks, and its advance speed is continuously adjustable.
During the milling operation, the pre-selected milling depth is regulated by a milling depth control unit,
which senses a reference height.

Detail: Milling in an up-milling direction

The layer to be removed is milled off, whilst the usable layers remain intact. The conveyor system loads the milling
granulate on a truck driving in front of the milling machine.

Milling and loading

A sufficient number of vehicles is needed for the transport of the milled material to ensure a swift job
site completion. On this photo, the pavement is milled off and the milling granulate is loaded in one
machine pass.

46
The damaged pavement

Rehabilitation measures for roads and surfaces include milling of traffic or parking areas consisting of asphalt or
concrete, thus maintaining or adjusting them to changing traffic loads.

The milled surface

Milling is the customary construction method used to remove damaged layers while at the same time maintaining the
usable layers of the upper pavement structure.

The new pavement

The damaged layer can then be replaced by a new layer complying with the latest technical rules and regulations.

47
n addition to the large-scale rehabilitation of motorways and airports, an adequate maintenance of
the traffic infrastructure requires an increasing amount of smaller repairs, which are carried out
efficiently and economically using small milling machines.

7.2 Patching

Apparently simple methods, which can only be regarded as repairs offering an extremely short serv-
ice life, are frequently used for the repair of partial pavement damages. This includes, for example,
filling up potholes without prior treatment, even if the damaged area has been excavated with a
jackhammer. This method results in jagged edges, loosened pavement slabs and uneven subsoil,
leading to an inadequate adhesion with the existing pavement. An even surface cannot be produced
due to the different paving thicknesses.

When a milling machine is used, the machine operator can, on the other hand, precisely regulate the
working depth and the longitudinal and transverse slope of the milled area. The rotating drum
removes the existing pavement without any shocks or vibrations, which results in a clean, smooth
milling edge and avoids ravelling. The structure of the milled surface ensures a good material
bonding between the base and the new, filled-in material. This results in an interlocking effect which,
in the future, will reliably transfer any shear stresses.

Incorrect: This kind of patching is insufficient.

48
7.3 Small-scale repairs of surface courses

Milling off the damaged pavement area

First, the damaged pavement is milled off to the desired depth and in adjacent milling cuts.

Transverse milling at the end of the milled track

Transverse milling at both ends of the milled track ensures that a vertical milling edge is produced here, too.

49
Insertion of the bitumen-impregnated strip

A bitumen-impregnated strip is inserted along the milling edges.

Placing the new surface course material

The new surface course material can be placed. In this case, it is mastic asphalt.

50
Completed pavement repair

The completed repair is characterised by a good evenness and a long service life of the pavement.

51
7.4 Overlapping surface overlays in road construction
Some time after filling up a trench, sporadic sagging tends to occur as the result of a post-
compaction of the materials used. This leads to traffic hazards and to the necessity of prematurely
repairing the new surface course in the area of the trench.

The use of milling machines can solve this problem. The binder course is initially placed up to the top
edge of the pavement surface. After an adequate post-compaction has been achieved, the area of
the trench is milled off at a depth of 4 cm, overlapping approx. 20 cm to both sides of the trench.
This area is then filled with asphalt material.

52
Milling off the surface course

The surface course is milled off over an area exceeding the width of the trench itself, thus producing strong shoulders
for the new pavement on both sides of the trench.

Overlapping surface

The milled surface, on top of which the new pavement strip is to be laid, overlaps with the trench on both sides.

53
Compacting the newly laid pavement strip

The new pavement strip is compacted. This construction method offers the advantage that the seam does not extend
vertically through the entire asphalt pavement structure, which could easily result in an opening of the seam. Because of
the offset, the seam is outside the area of the trench where settlements can occur, and is thus not exposed to
gravitational forces. A good interlock between the existing and the new material is also ensured.

7.5 Replacing a pavement with a rear loader

Removal of large pavement sections

The 4 cm thick surface course is usually removed at full depth when rehabilitating entire pavement sections by replacing
the pavement. Small milling machines can be used very economically for this type of work as their performance has
been consistently improved through suitable design measures. The W 1000, for example, can achieve a performance of
up to 400 m2 per hour.

54
Inadequate drainage of water

This photo shows the inadequate drainage of water on a parking lot, the surface course of which has been damaged by
rutting. Replacing the entire surface course is the most sensible way to deal with such a problem.

Removing the surface course

The deformed surface course has been milled off, and the new asphalt pavement can now be laid on top of the levelled
surface.

55
7.6 Replacing a pavement with a 1 m front loader

The W 1000 F and W 1200 F have proved to be highly suitable for the removal of entire pavement structures in one
machine pass. With the crawler-mounted model, the machine operator can also rely on the machine's good traction,
track accuracy and high stability when working on unconsolidated subsoil with a limited load-bearing capacity.

The wheel-mounted model of the W 1000 F is ideally suited for the removal of individual asphalt layers, e.g. when
working on an urban rehabilitation project.

56
The variable milling machine of the 1 m class: Wheels or tracks

The conversion from tracks to wheels or vice versa can be carried out within an extremely short period of time.

Quiet in spite of their high engine power: The cold milling machine models W 1000 F to W 1300 F are equipped with a
sound deadening package, which enables them to work without any problems even in residential areas.

57
7.7 Milling flush to kerb

With the support wheel folded inwards, the old pavement is removed flush to gutter or kerb.

7.8 Small and large milling machines complementing one another

A team for a complete job:

Large milling machines are used to rehabilitate entire carriageways. As the milling drum must always
be lifted when there are fixtures in the road, remnants of the old pavement are left behind, which
must then be removed separately. Such work is ideally carried out using small milling machines, and
is best completed before the large milling machine starts off on its job.

The Wirtgen milling machines are powerful not

only when it comes to removing large pavement
sections. They do a complete job: The surface
courses are completely milled off, even around
manhole covers.

58
W 350 complementing the operation of a large milling machine

A W 350 complements the operation of a large milling machine in rehabilitating an urban through road.

7.9 Overlaying damaged pavement sections

A team for overlaying damaged pavement sections

Cold milling machines are successfully employed not only in replacing entire pavements, but also when it comes to
overlaying individual pavement sections. When the section of a road is overlaid with a new surface course, tie-ins
between the existing and the new pavement result at the beginning and at the end of the overlaid section.

59
Typical damage

This photo shows the typical damage of an overlay carried out without milling a tie-in. The connecting edge crumbles
away.

Wedge-shaped milling of tie-ins

The problem of tie-ins to existing pavements, fixtures or water gutters is solved by wedge-shaped milling. The milled
wedge is normally 4 cm deep, corresponding to the thickness of the surface course, at the point where the new
pavement ties in with the existing pavement or fixture, and it decreases to zero in the direction of the pavement to be
overlaid. This allows the new surface course to be laid with the full thickness right up to the vertical milling edge or the
gutter.

60
Overlaid tie-in of the repaired pavement section

This photo shows the completed repair of the road section with a smooth transition between the different pavement
sections and a flush transition to the water gutter. A consistent compaction is assured.

7.10 Levelling elevations

Ruts endanger the traffic safety of high-speed vehicles, increasing the risk of skidding or aquaplaning. Milling machines
can repair these damages very quickly. Such a measure is sensible if the damages consist of lateral displacements and
there is no additional damage, such as cracks, to the heavily stressed troughs of the ruts.

61
After milling

The elevations are milled off very quickly. New aggregate is not required, and the water drainage is restored.

7.11 Correcting manhole covers

Conventional methods of correcting manhole covers use a jackhammer to excavate the pavement around the manhole
cover. This is a noisy, time-consuming task, which does not produce a level surface on top of which the new overlay can
be placed.

62
Milling around a manhole cover

With a small milling machine, on the other hand, the depth to which the surrounding pavement is to be removed can be
adjusted very precisely. Depending upon the type of machine used, the manhole can be laid open to a depth of 28 cm.
For this purpose, the machine simply drives around the manhole cover once. Its height can then be corrected using
different methods, such as inserting intermediate rings. After that, the area surrounding the manhole cover is either
refilled with new asphalt material or paved with cobblestones.

Corrected manhole cover

The manhole cover after correction and cobbling.

63
7.12 Pavement removal at full depth

Changes in the layout of crossings or junctions, for instance to handle the increasing traffic load by means of a new
traffic management, often require the removal of the entire asphalt pavement structure of certain road sections. Small
milling machines can either remove the various courses (i.e. surface, binder and base course) individually for the purpose
of separate re-use, or - as shown on this photo - the entire asphalt structure can be removed in adjacent cuts at full
depth and in a single pass.

Removing pavement strips in trench cutting

The use of cold milling machines to remove pavements at full depth is an increasingly accepted method in trench
cutting, too.

64
Breaking the pavement with a hydraulic hammer

Simply out-of-date: Breaking the pavement into slabs with a hydraulic hammer.

Milling and loading the granulated milled material

A milling machine can directly crush the bound asphalt during milling, the resulting granulate being loaded on trucks via
the machine's integrated conveyor system. In case of larger trench widths, the strips are milled off in adjacent cuts. This
photo shows the asphalt package being removed and granulated for subsequent re-use in one machine pass.

65
Temporarily trafficable

Unlike the material broken with a hydraulic hammer, the milled material can, for the moment, remain in the trench to be
temporarily trafficked after compaction. This photo shows a granulated pavement strip prior to excavating the trench.

Trench excavation after milling

After the asphalt package has been milled off in individual strips, the trench is excavated without damaging the straight
milling edges.

66
7.13 Building traffic islands

Milling the outline of a traffic island

Preparing the installation of traffic islands is a further application of small milling machines. For this purpose, pavement
sections can be removed to the determined depth and in the specified outline. The three-wheeled milling machines are
particularly well suited for the production of interesting geometrical shapes.
Here, the pavement strips have been removed for laying the cobbled pavement.

Completed traffic island

This photo shows the completed island as a means of restraining the traffic.

67
7.14 Cutting grooves

Small milling machines are used for the excavation of trenches, where entire pavement strips are removed by milling. As
an alternative, milling rings can be installed in lieu of the milling drum, cutting the slots along the trench to be excavated.

Cutting the pavement

Grooves are cut into the pavement on both sides. The asphalt package can then be excavated without damaging the
edges, and the construction work in the trench can be carried out.

68
A typical damage: Chunking

This photo shows a typical damage: Chunking results if the trench is excavated without the prior cutting of grooves.
Slots are often cut where cables must be laid into asphalt or concrete surfaces, for example for airport lighting.

Milling out the inserted wood material

An economical application in the new construction of concrete pavements is milling out expansion joints prior to sealing.

69
7.15 Rehabilitating industrial surfaces

It is not necessary to remove or to renew the entire surface of workshop floors showing extensive depressions, if milling
machines are used to carry out the necessary repairs. It is sufficient to prepare the edges of the surface to be overlaid by
appropriate milling so that they tie in with the existing pavement.

Milling off the floor coating

On this photo, a W 500 is milling off the floor coating of an assembly workshop within the scope of a rebuilding project.
The milled material is loaded manually.

70
Levelling concrete surfaces

Small milling machines can also be used to correct the level of concrete surfaces which have been paved at an incorrect
height. Such reworking measures may sometimes be impeded by the fact that there is no access to these areas, for
instance to the bottom of a storage tank or to the floor of an underground basement.

Lifting the machine in with a crane

In such cases, the compact small milling machine is lowered into the building by a crane

71
Milling off contaminated layers

In the course of demolishing industrial plants, huge amounts of debris accumulate due to the removal of their concrete
flooring. As this material has often been polluted by various substances over a period of many years, it is classified as
being contaminated and must be disposed of at great expense. Milling machines have proved to be the ideal solution to
this problem. The first few millimetres or 1 - 2 cm of the contaminated layers are milled off, thus reducing the amount of
material requiring special disposal to only a fraction of the entire debris.

72
73
74
8. Applications of large milling machines

8.1 The various applications of large milling machines 76

8.1.1 Removing entire pavements 77

8.1.2 Levelling 77
8.1.3 Verge milling 78
8.1.4 Pavement removal 78
8.1.5 Removing the surface course 79
8.1.6 Milling off the surface course (3.8 m wide drum unit) 79
8.1.7 Milling off pavement layers 80
8.1.8 Milling flush to kerb 80

8.2 The operator station 81

8.3 Effective loading of the milled material 82

8.4 Conveyor belt speed and discharge width 83-84

8.5 The multi-functional scraper blade 85-86

8.6 Four-track steering 87

8.7 Hydraulically lifting side plates 88-90

8.8 Automatic advance speed control 91

8.9 Engineering for increased profit 92

8.10 The lighting system 93

8.11 Safety for the machine and its operator 94

75
8. Applications of large milling machines

8.1 The various applications of large milling machines

From a working width of 1500 mm or larger, the machines are categorised as medium-class or large
milling machines. Depending upon the machine type, they have a maximum milling depth of up to
350 mm. The machines are intended for use in large-scale rehabilitation projects and have, therefore,
been designed for a high area performance. Their features include a standard conveyor system and a
milling drum positioned at the centre of the machine, between the front and rear axles.

Applications of large milling machines:

Large-scale removal of road and airport pavements
Milling off surface courses
Removing entire pavement structures

The machine models

W 1900 W 2000 W 2100 W 2200

This type of machines offers the following advantages with regard to

application technology:
Fast job site completion

High area performance

Direct loading of the milled material on trucks

Good levelling properties

Large milling depth

76
8.1.1 Removing entire pavements / W 1900

Milling off asphalt layers at full depth with a standard milling drum.
On this photo: a milling drum unit with a milling width of 2 m.

8.1.2 Levelling / W 1900

Levelling a deformed pavement stretch to prepare it for the application of a thin layer of cold asphalt.
A fine milling drum with a milling width of 2 m is used.

77
8.1.3 Verge milling / W 1900

The carriageway is widened by milling out a strip using the flexible cutter system.

8.1.4 Pavement removal / W 2000

Wirtgen large milling machines are capable of milling off the complete pavement package (surface, binder and base
course) in a single machine pass, thus saving the machine user time and money.
Approx. 2,000 - 2,800 t of material per day can be removed at full depth.

78
8.1.5 Removing the surface course / W 2200

With their optional milling width of 2200 mm, Wirtgen large milling machines are ideally suited for the removal of large
surfaces (particularly in motorway and airport construction). They are capable of milling off carriageways of up to 4.30 m
width in two adjacent machine passes only. Example: motorway lane plus medium lane and hard shoulder.

8.1.6 Milling off the surface course (3.8 m wide drum unit) / W 2200

The use of the 3.80 m wide milling drum unit increases the milling width by more than 70% when compared to the stan-
dard unit. The number of machine passes is considerably reduced, and less turning manoeuvres are required that would
interrupt the work flow every time.

79
8.1.7 Milling off pavement layers / W 2000

Due to its powerful transmission and automatic power control, the W 2000 is capable of a high milling performance
when milling off pavement layers.

8.1.8 Milling flush to kerb

Even difficult operations, such as removing a marginal strip at a motorway service area, are easily mastered with the
individually height-adjustable crawler tracks.

80
8.2 The operator station / W 1900
Simple operation
The control elements of the walk-
through operator station of the W
1500 / W 1900 are arranged within
easy reach of the operator. They are
combined into functional groups, and
each of them is clearly labelled.

The operator station / W 2100

Clear and ergonomic
arrangement
The machine operator works at a con-
venient control panel with clear
labelling. The walk-through operator
station is equipped with two driver
seats, which can both be shifted
beyond the edge of the machine.

The operator station / W 2200

Convenient working for
optimum results
Simple operation: The machine has a
proportional steering system, which is
effected via joysticks. The control
elements are clearly arranged and
labelled. A cover protects the panels
from unauthorised access and
vandalism.

81
8.3 Effective loading of the milled material

All in good view: The driver can shift the seat and the control panel sideways
beyond the edge of the machine while working, which gives him a good
overall view on the surface to be milled as well as on the truck driving in front
of the machine, enabling him to ensure an optimum filling of the truck.

Effective loading:
The discharge conveyor can be
continuously slewed at an angle of 90°.

Flexible: The front-loading conveyor can be continuously slewed at an angle of 90° (45° to the left, 45° to the right).
Easy loading offers advantages: in narrow bends, when driving around traffic obstacles or on road crossings and
junctions.

82
8.4 Conveyor belt speed and discharge width

Adjustable: conveyor belt speed and discharge width of the milled material.
A variable conveyor belt speed offers advantages: optimum loading even of long tractor-trailers.

High conveyor belt speed

Low conveyor belt speed

Long tractor-trailers can be fully loaded due to the adjustable conveyor belt speed.

83
The W 2200 operating on a partially closed road

The tremendous stream of milled material demonstrates that the W 2200 is built for the large-scale projects. Due to its
compact design, it is almost always possible to let the traffic flow alongside the construction site.

Diagram demonstrating the exchange of trucks

The trucks are smoothly pulling in and out of the flowing traffic. This offers a number of advantages: Considerable
amounts of time and money are saved, and the risk of traffic congestions is reduced.

84
8.5 The multi-functional scraper blade

Loading the milled material on trucks by way of the two-stage conveyor system.

Windrowing the milled material at the side of the pavement by way of the two-stage conveyor system.

Windrowing the milled material in the milled track (drum door open).

Depositing the granulated pavement material at the side of the road.

85
 Scraper blade
in floating
position

Thorough cleaning of the milled area

When milling off the top layers of bituminous road pavements, the scraper blade is pressed downwards with a certain
pressure so that the scraper blade edge slides on the milling surface as if spring-loaded, sealing the drum housing off to
the rear.

Scraper blade
in locked
position

Milling down to the top edge of the subbase layer

If the complete asphalt layer is milled off down to the top edge of the subbase layer, the scraper blade is hydraulically
locked in the required position. As a result, the scraper blade cannot dig into the loose gravel or sand layer and pick up
material from there.

Scraper
blade in
locked
position

Trench milling with partial loading

When milling off pavement layers for trench construction, it may be useful to leave a part of the milled material in the
trench prior to the trench being excavated at a later date. For this purpose, the scraper blade is locked at the required
height, so that a part of the milled material is loaded and the remainder is profiled and left in the trench.

86
8.6 Four-track steering

1 2 3 4

1: Approaching the milling track in the crab steering mode.

2: Milling along a bend by steering the front crawler tracks.
3: Four-track steering allows manoeuvring and milling even in a very confined space.
4: Correcting the direction with the rear crawler tracks while driving onto a low-loader.

Due to the good manoeuvrability of the milling machine, the pavement can be removed flush to kerb even in bends
without the necessity of setting in several times.

87
8.7 Hydraulically lifting side plates

The side plates, which have a Brinell hardness of HB 400, neatly seal the drum housing off to the side. The wear-resist-
ant skids fitted to the lower edge of the side plates can be replaced individually.

The side plates can be lifted by means of the hydraulic cylinders, making it easy to replace the outer cutting tools on the
job site.

88
Milling flush to kerb

The side plate slides on the top edge of the kerbstone when milling flush to kerb, which means that it
must be lifted accordingly. With hydraulically lifting side plates, this is possible at the touch of a
button. Bodily effort or an interruption of the milling operation is not required.
An additional benefit of this feature takes effect when milling several adjacent cuts: When the machine
approaches the end of the first cut while milling the second, lifting the side plate will prevent it from
jamming.

Complete removal of a surface course flush to kerb. The right-hand side plate slides on the higher edge of the kerb.

89
 Milling the second cut: The right-hand side plate slides on the milled surface of the first cut.

When approaching the end of the cut, the right-hand side plate is lifted without having to interrupt milling.

The machine can work to the end of the cut without having to interrupt milling. Jamming of the side plate is prevent-
ed.

90
8.8 Automatic advance speed control

Soft asphalt

Engine speed
m/min

Advance speed

1.Soft asphalt: The engine operates within the optimum speed range.

Hard asphalt

2.
3.
3.
Engine speed
m/min

Advance speed

2. The asphalt gets harder, and the engine speed decreases.

3. The power control unit reduces the advance speed, causing the engine speed to increase again to the optimum value.

91
8.9 Engineering for increased profit

Wirtgen – Engineering for increased profit!

Make headway by means of considerable time savings, forward-oriented working and high
engine power!

Optimum flow of work:

Simpler, faster and better by purposefully working with the flowing traffic. All in good view -
always: milled edge, side of the milling drum, loading operation and flowing traffic. Good overall
view and control prevent operating errors!

Smooth transport of the milled material: The trucks can pull in and out with and in the direction
of the flowing traffic, thus avoiding hazardous turning manoeuvres on the road.

Economical transport due to the use of cost-saving tractor-trailers.

Less traffic obstructions. It is not necessary to close the second traffic lane when front loading,
which would otherwise be required for the turning manoeuvres of the loading trucks. This saves
time, money and a full closure of the road:
One lane of a two-lane motorway can remain open to traffic, since only the lane to be milled
must be closed.

Spilling milled material during loading: This is no problem, since the material will be picked up
by the subsequent pass of the machine.

92
8.10 The lighting system

A "shining example": Their efficient lighting system makes the machines independent of the time of the day.

Safe and accurate working even at night: The working lights sufficiently illuminate the important spots of the machine
and the road. Reflecting safety beacons on the machine additionally ensure that the W 2000 is clearly discernible.

93
8.11 Safety for the machine and its operator

Wirtgen – Engineering for increased safety!

Active safety protects the operating personnel from accidents on the job site:

Engine kill switches ensure an immediate shutdown of the machine in any critical
operating situation.

The automatic locking device of the scraper blade allows safe working on the milling drum,
for example when replacing cutting tools. What is more: Height adjustment, drum drive and
travel drive are automatically shut down as soon as the scraper blade is opened.

All hazardous machine components, such as conveyor and milling drum drive, are
completely enclosed to prevent unintentional contact during operation.

Passive safety protects the machine from operating errors and technical defects:

Automatic shutdown in case of engine overheating protects the machine from costly
operating errors.

An independent power control for an optimum advance speed prevents costly operating
errors.

Permanent monitoring and display of hydraulic oil pressure and engine temperature.

94
95
96
9. Calculating the milling performance

9.1 Milling performance and influencing factors 98-99

9.2 Calculated differently: milling of concrete surfaces 99

9.3 Calculating the milling performance of 100-102

W 500 / W 1000 F / W 2100

97
9. Calculating the milling performance

9.1 Milling performance and influencing factors

The practical performance of cold milling machines depends upon many influencing factors, namely
machine and material parameters, job site conditions, traffic situation, transport capacity and logistics
as well as the experience of the operating personnel.

Wirtgen supplies idealised performance curves for their machines, from which the theoretical area per-
formance can be read. The practical area performance is then calculated taking into account a deduct
factor, which can result from influences lessening the productivity, for example long idle times waiting
for trucks, or disconnected milling surfaces. This factor amounts to between 0.3 and 0.5 when milling
in urban areas, and between 0.5 and 0.7 when milling on free road sections. A factor of 0.5 has proved
to be suitable for approximate calculations. The temperature of the pavement to be milled must also
be taken into account. As a general rule, it can be said that higher ambient temperatures increase the
area performance, whilst it is reduced if the temperature falls below 15°C.

Three theoretical performance curves of a small milling machine and a milling machine of the 2 m
class, which can be used for a rough calculation of the milling performance, are illustrated below. First,
the milling performance is read from the diagram, using the desired milling depth and the advance
speed. The reduced, practical area performance is then calculated by multiplying this figure by the
appropriate deduct factor.

Machine Material Job site Traffic Transport

parameters parameters conditions control capacity

Condition
Working width Milling depth Type of closure Number of trucks
of asphalt

Type of Size of unobstructed

Engine output Obstructions Organisation
aggregate surface

Type of grain
Weight Partial repairs Traffic situation
round/crushed

Type of binding
Cutting speed Disruptive factors
agent

Cutting tool type,

Temperature
tool spacing

Travel drive
tracks / wheels

Area performance = advance speed x milling width

Factors influencing the area performance

98
 The practical performance of milling machines depends upon numerous
influencing factors.

The most important factors are:

• Machine parameters
• Material parameters
• Job site conditions
• Traffic situation
• Transport capacity for the milled material
• Experience of the operating personnel

W 1900

W 2000

W 2100

W 2200

50 100 150 200 [t/h]

9.2 Calculated differently: milling of concrete surfaces

All calculations and examples presented in this manual apply to the milling of asphalt surfaces. The
use of the curves is limited to making a rough estimate when milling concrete. For this purpose, the
value of the theoretical area performance when milling hard asphalt must be multiplied by a factor of
0.3. This will give an approximate estimate of the practical performance to be expected when milling
concrete.

It should also be borne in mind that, when milling concrete surfaces, the theoretically possible milling
depth of the machine type involved cannot be utilised to the same extent as when milling asphalt.

99
9.3 Theoretical performance data: cold milling machine W 500

Technical data: • Milling depth: 9 cm

Engine output: 79 kW / 105 HP / 107 PS • Total area to be milled: 300 m2
Milling width: 50 cm • Pavement: asphalt, medium hard
Milling depth: 0-16 cm • Required working time: 4 - 5 working hours

Milling depth
(T) cm
20

18

16
Hard asphalt
14

12 Soft asphalt
10

8
Most common working range
6

0 Advance speed
0 2 4 6 8 10 12 14 16 18 20 22
V (m/min)
Theoretical area
0 100 200 300 400 500 600 performance
140 m2/h FT (m2/h)

Sample calculation: Milling a 300 m2 section of an urban through road with rainwater inlets.

Despite the good applicability of the diagrams depicted in this manual, Wirtgen GmbH cannot accept any liability in relation to the calculation methods.
All details are without obligation.

100
Theoretical performance data: cold milling machine W 1000 F

Technical data: • Milling depth: 4 cm

Engine output: 190 kW / 255 HP / 258 PS • Total area to be milled: 2,000 m2
Milling width: 1.0 m • Pavement: asphalt, medium hard
Milling depth: 0-31.5 cm • Required working time: approx. 3 working
hours

Milling depth
(T) cm
32
30
28 Hard asphalt
26
24
22 Soft asphalt
20
18
16 Most common working range
14
12
10
8
6
4
2 Advance speed
0 V (m/min)
0 2 4 6 8 10 12 14 16 18 20 22 24 26 28
Theoretical area
0 200 400 600 800 1000 1400 1600 performance
1,160 m2/h FT (m2/h)

Sample calculation: Milling off the surface course of a motorway section.

Despite the good applicability of the diagrams depicted in this manual, Wirtgen GmbH cannot accept any liability in relation to the calculation methods.
All details are without obligation.

101
Theoretical performance data: cold milling machine W 2100

Technical data: • Milling depth: 30 cm

Engine output: 470 kW / 630 HP / 640 PS • Total area to be milled: 30,000 m2
Milling width: 2.0 m • Pavement: asphalt, hard
Milling depth: 0-32 cm • Required working time: 34 - 35 hours

Milling depth
(T) cm
34
32
30
28
26
Hard asphalt
24
22
20 Soft asphalt
18
16
14 Most common working range
12
10
8
6
4
2 Advance speed
0 V (m/min)
Theoretical area
0 500 1000 1500 2000 2500 3000 performance
280 m2/h FT (m2/h)

Sample calculation: Removing the entire pavement structure on a motorway.

Despite the good applicability of the diagrams depicted in this manual, Wirtgen GmbH cannot accept any liability in relation to the calculation methods.
All details are without obligation.

102
103
104
10. Flexible Cutter System (FCS)

10.1 The modular system with the large variety of 106-107

milling drums

10.2 Field experiences with the FCS from all parts 108-111
of the world

105
10. Flexible Cutter System (FCS)

10.1 The modular system with the large variety of milling drums
The unique quick-change system for milling drums.
One drum for several machines - one machine with several drums.

W 1200 F W 1900

W 1000 F W 2000

106
The FCS with the cold milling machines W 1000 F and W 1200 F

Quick exchange:
The system has been designed so that the drums of the W 1000 F and the W 1200 F can be
exchanged by skilled personnel within a period of 2 - 3 hours, using ordinary tools.

The drum change is as simple as that: Open the Once the drum has been pulled off the shaft, it can be
hinged side plate and remove the drum. Only the outer conveniently deposited on the FCS mounting trolley.
drum ring is changed.

Milling drums for use in different machine types

All milling drums depicted on this photo can be used in the 2 m machine models W 1900 or W 2000 equipped for the
use of the FCS system. Additional benefit: The three drums on the left can also be used in the FCS machines W 1000 F,
W 1200 F and W 1300 F.

107
10.2 Field experiences with the FCS from all parts of the world

Milling at an airport: This W 1000 F is equipped with a 50 cm wide FCS drum.

A W 1900 milling off the road pavement.

108
The FCS makes it happen:

The milled material can always be loaded, irrespective of the working width of the machine: partial loading of the milled
material with a W 600 DC.

Fine milling on a country road: W 2000.

This W 1000 F with FCS is equipped with crawler tracks, which make it ideally suited for work on soft soil - even at small
working widths.

109
Typical application: a country avenue with a soft shoulder and a heavy drop-off between the pavement and the shoulder,
representing an increased accident risk.
The pavement layer, which has an insufficient load-bearing capacity, must be removed.

The W 1000 F with FCS in operation: The pavement material, which has lost its load-bearing capacity, is removed at a
depth of 300 mm and a width of 600 mm.
An advantage of the crawler-mounted W 1000 F with FCS is the machine's stability when running on the soft shoulder,
which is due to the crawler tracks.

110
Once the material has been removed, the trench is filled with asphalt and compacted.
The photo on the right shows the completed paved shoulder or, respectively, widened pavement. The result: The
accident risk is reduced.

111
112
11. Fine milling

11.1 The fine milling method 114-118

11.2 Improving the skid resistance 119-121

11.3 The benefits of fine milling at a glance 122

113
11. Fine milling

11.1 The fine milling method

Fine milling: an economical method for the rehabilitation of road pavements

Servicing and maintaining the existing road pavements becomes ever more important in times of an
increasing traffic load. The traffic safety, which is often jeopardised because of corrugating, rutting or
slippery pavements, must be ensured even in times of limited budget funds. Here, the Wirtgen road
milling machines make an important contribution. Fine milling, in particular, is an economical and
efficient method to maintain existing road pavements and to increase the traffic safety.

What is "fine milling"?

In contrast to milling with a standard milling drum, drums with a tool spacing of only 8 mm are used
when fine milling. Due to the smaller spacing between the individual cutting tools, a much more finely
textured surface results from this kind of pavement treatment. The maximum milling depth is 4 cm,
but typically only a few millimetres are milled off, thus allowing the machines to achieve very high
daily performances. To facilitate the execution of fine milling projects for the machine user, Wirtgen
offers additional fine milling drums for both, their large and small milling machines. These can be
exchanged very easily - flexibility that pays off.

The benefits: Cost saving and environmentally friendly

The benefits of this method lie in the reduction of costs and in saving valuable resources, since a
costly removal and subsequent reconstruction of the complete surface course is not required.
An important point for contractors and authorities is the simple on-site procedure. One traffic lane
only must be closed, and the milled surface can be re-opened to traffic immediately after completion
of the treatment. Traffic obstructions are thus reduced to a minimum. Fine milling with the Wirtgen
milling machines is an economical alternative for the following applications.

114
Restoring the skid resistance of the pavement

An excessively smooth pavement is often due to the excessive accumulation of binder at the surface
of the road. The mineral aggregate responsible for the skid resistance is embedded as a result of
heavy traffic loads, and the bitumen rises to the surface. To solve this problem, the Wirtgen machine
precisely mills off that portion of the surface course in which the excessive binder accumulation has
occurred. The required skid resistance of the pavement is restored in just one machine pass, quickly
and without the necessity of a costly removal and replacement.

Levelling deformed pavement stretches

Ruts, bulges and lateral deformations also have a negative effect on the traffic safety. The riding
quality is considerably reduced. They also prevent the surface water from draining off, which results
in longer braking distances or aquaplaning. A new construction of the surface course would be costly
and time-consuming. Therefore, the ecological and economical alternative is:
Fine milling with the Wirtgen machines. Rutted pavements are levelled by milling off the raised parts
of the road. Contrary to other methods, such as shot-blasting or high-pressure removal, a well-
defined, even surface is produced.

Specific corrections of the transverse slope of a road

Roads are deliberately paved with a certain transverse slope in order to improve the drainage of
water or to increase the cant of a bend. The profile of an inadequate transverse slope can be
corrected by a Wirtgen milling machine, too. After fine milling, the road displays the desired profile
and a uniform skid resistance at the same time.

Preparing to apply thin pavement layers

Fine milling is the ideal method for preparing the application of thin layers, since the entire surface
can be evenly coated, ensuring a better adhesion between the existing asphalt and the new
pavement layer. The evenness of the fine milled surface also ensures a uniform layer thickness of the
entire cold asphalt pavement, which results not only in an increased service life, but also in a
reduction of the amount of cold asphalt required. Reducing costs and saving valuable resources are,
therefore, the most essential aspects of this kind of application.

115
 Fine milling

Improving the skid resist- Restoring Preparing to apply thin

ance of the pavement the evenness pavement layers

Standard milling drum for a road milling machine model Fine milling drum for the same machine
W 2000

116
 15 mm 15 mm 15 mm 8 mm 8 mm 8 mm 8 mm

The standard milling drums with a tool spacing of The fine milling drums with a tool spacing of 8 mm
15 mm are highly suitable for the removal of entire are ideally suited for the treatment of surface
road pavements. courses.

Milling pattern obtained when using a standard milling drum with a tool spacing of 15 mm.

Milling pattern obtained when using a fine milling drum with a tool spacing of 8 mm.

117
Standard milling with a tool spacing of 15 mm produces a Fine milling with a tool spacing of 8 mm produces a very
roughly textured milling pattern. finely textured milling pattern.

Entire road pavements can be removed in a single Fine milling drums remove a few millimetres or centimetres
machine pass when using standard milling drums (milling of the surface course, as required.
depths of up to 30 cm).

118
11.2 Improving the skid resistance

Fine milling can be carried out in flowing traffic, and the milled surface can immediately be trafficked again after
sweeping or vacuum cleaning.

This surface course has been milled off using a fine milling drum with a working width of 2000 mm and a tool spacing of
4x2. The surface is clean and even like a newly constructed road.

119
Surface structure

This close-up view shows the surface structure of the fine milled and of the non-milled surface.

Concrete surface at an airport

This method is suitable for both, asphalt pavements and concrete

surfaces.

Close-up view of the milled surface.

120
Fine milled concrete surface

A fine milled concrete surface at an airport.

The surface structure of a concrete surface

This close-up view shows the good surface structure of the fine milled concrete surface. Evenness and skid resistance
are ensured.

121
11.3 The benefits of fine milling at a glance!
Possible applications

• Fine milling can be undertaken in almost all weather conditions.

• Fine milling is the ideal method for a durable restoration of the traffic safety of damaged
road pavements (e.g. in case of ruts, poor skid resistance and unevenness, or if the road
is not true to cross-section, line and level)
• Fine milling is the ideal method for the removal of road markings.
• Fine milling can be undertaken with large and small milling machines from Wirtgen,
as fine milling drums are available from Wirtgen in different versions for both large and
small milling machines.

Profitability

• No special equipment other than the fine milling drum is required on the machine
for fine milling.
• Fine milling enlarges the portfolio of services offered by contractors, thus improving
their competitiveness.
• Fine milling is also an efficient method from an economical point of view, since the
overall costs per rehabilitated square metre are marginal for a high-quality road.
• Fine milling considerably reduces the amount of infill material required when
preparing to apply thin pavement layers.
• Fine milling is accurate and fast.
• Fine milling drums can be installed and removed easily.

Environmental protection

• Fine milling is economically friendly, since the number of truck journeys is considerably
less than when removing complete pavement layers.
• Fine milling is economically friendly because it saves valuable resources, which would
otherwise be required when replacing a complete surface course.
• Fine milling can, under certain circumstances, considerably reduce rolling noise emissions.

Improving traffic safety and riding quality

• Fine milling minimises the nuisance to traffic during road works.

• Fine milled roads can immediately be reopened to traffic.

122
123
124
12. Cutting tools and tool systems

12.1 Cutting tools: Theoretical principles 126-127

12.2 Wear patterns of road cutting tools 128-130

12.3 Recommendations for the use of cutting tools 131-132

with road milling machines

12.4 Advantages of the Wirtgen toolholders 133

12.5 Toolholder HT 3 Plus 134-135

12.6 Toolholder HT 01 136

12.7 Drum turning device, additional seat for 137

cutting tool replacement

125
12. Cutting tools and tool systems
12.1 Cutting tools: Theoretical principles

Carbide tip

High-grade brazing joint

Extra-hard tool head

Extractor groove

Pre-tensioned sleeve

Long sleeve
Wear plate

Binding agent Mineral aggregate Weather

Properties Properties Properties
Viscosity Strength Temperature
Adhesion Particle properties Weather conditions
Hardness Abrasiveness
Bitumen content Density
Quartz content
Examples Examples Examples
Cement Gravel Cold
Water Chippings Warm
Lime Sand Rain
Bitumen Grit Snow

Penetration resistance / Wear and tear / Rotation

Advance speed / Cutting tool costs / Machine downtime

Wear and tear / Volume unit

Factors influencing cutting tool wear and tear

126
Optimum milling performance at low cutting tool costs

Wear distance of holder: 16 mm

Wear distance of tool: 9 mm

approx. 15 mm
16
+
9
=
25
m
m

The cutting depth changes due to the different stages of wear and tear.

127
12.2 Wear patterns of road cutting tools
Optimum wear
Wear patterns of road cutting tools
Carbide fracture
Causes:
• Hard asphalt or concrete
pavement
• Steel reinforcement
• Poor brazing joint
• Thermal or mechanical stress
• Water sprinkling
128
Poor rotation Steel erosion
Causes: Causes:
• High percentage of bitumen in • Soft asphalt
the asphalt • Carbide tip is too small
• Poor condition of holder • High advance speed
• Tool sticks to the sleeve due to
high temperatures
Carbide drop-out Optimum wear of a
concrete cutting tool
Causes:
• Hard asphalt or concrete
pavement
• Cobbled pavement
• Poor carbide quality
• Thermal or mechanical overload
• Water sprinkling
Characteristics of an optimum wear of the cutting tool:

• Symmetrical shape of the remaining carbide tip

• Evenly tapered shape of the base material
• Sufficient base material to support the carbide core

Characteristics of an
optimum wear of the
cutting tool
As soon as the base material begins to show distinct notches (right), it is more economical
to replace the cutting tools than to continue working with them.

Example 1: Example 2: Example 3:

Cutting tool W5, used in Cutting tool W1-13, used in Cutting tool did not rotate in the
excessively soft material excessively soft material toolholder shaft

Recommendation: Recommendation: Recommendation:

Choose a cutting tool with
a larger carbide tip, e.g. W6
or W7
Choose a cutting tool with a
mushroom-shaped carbide
tip, e.g. W6 (better protection
of the base material)
• Check toolholder for signs of
wear
• Check water spray system in
the drum chamber or water
level in the tank

129
Defect upper part of a quick-change toolholder

• The toolholder shows heavy abrasion due to a broken cutting tool.

• The toolholder must be replaced, or else the cutting tools will continue to break.

Normal wear and tear of the upper part of a toolholder after approx. 600 operating
hours
• The toolholder must be replaced, since the rotation of the cutting tools with a collar diameter of
38 mm is greatly impaired by the burr.

130
12.3 Recommendations for the use of cutting tools with road milling
machines

131
132
12.4 Advantages of the Wirtgen toolholders

High-quality steel grades

for low wear and tear

Optimum shape for

easy processing
during production

Toolholders made from

weldable hardened and
tempered steel are
welded onto the drum
body with a welding wire

Pressure-resistant clamping
screw for a pre-tensioning Wear-resistant head with a
force of up to 200 kN hardness of 48 - 54 HRC
Upper part
reliably
supported by
Free rotation at a diameter of 44
bottom part
mm for reduced longitudinal wear
and optimum cutting tool rotation

Easily removed, fracture-

proof pentagonal shaft

Three-layered welding
seams, wear-resistant and
fracture-proof

High-grade forged steel,

hardened and tempered

Screw without limiting stopTorque of the

screw = 500 Nm

133
12.5 Toolholder HT 3 Plus

Wear and tear

Large wear surface, Ø 44 mm

Large wear volume

Wirtgen logo

Upper part reliably supported Optimised head shape for Large contact surface with
by bottom part better wear values a diameter of 44 mm, for
low wear and tear
Plug of theretaining
Status indicator for easy wear
screw
and tear monitoring

Pentagonal shaft for

accurate positioning
Identical upper part
Screw without limiting stop, with
for all milling drums
self-locking thread

134
 Ø
44
16

M 24 x 2
,7
61

47,4
Example: Wear and tear after approx. 800 operating Retaining screw HT 3
hours with a W 2200

Ø
44
,7
61

Ø
44
,7
61

Ø
22
Dummy upper part

Ø
20

Point-attack toolholder
HT 3 D22 (optional)

Point-attack toolholder
HT 3 - 44

Quick-change toolholder system HT 3 Plus

135
12.6 Toolholder HT 01

Ø
42
Ø
25
,4
46

Ø
20

Toolholder HT 01
Application: For all road milling machines and for special machines
Features: Wear-resistant toolholder
• Welded connection to the milling drum
• Can be repositioned
• Hardness 44 - 52 HRC
Machines: Suitable for all milling machines with the most diverse applications

136
12.7 Drum turning device

Additional seat for convenient cutting tool replacement

137
138
13. Levelling systems

13.1 The different levelling systems 140-141

13.1.1 Height sensing with the wire-rope sensor 142

13.1.2 Sensing with the ultrasonic sensor 142

13.1.3 Sensing along a wire with the transducing sensor 143

13.1.4 Sensing with the sonic ski sensor 143

13.1.5 Sensing in front of the drum with the wire-rope 144

sensor

13.1.6 Sensing in front of the drum with the ultrasonic 144

sensor

13.1.7 The slope control sensor 145

13.1.8 The Multiplex system 146-147

13.1.9 Working with the laser sensor 148

13.1.10 Levelling by means of a 3D control 149-151

139
13.1 The different levelling systems for road milling machines
Wirtgen offers the highest standards not only for the cutting tools, but also for the levelling systems.

The automatic levelling system consists of two control loops operating independently of one another:
one for the right-hand and one for the left-hand side of the machine, irrespective of which sensors
are connected.

Ultrasonic sensor Wire-rope sensor Transducing sensor Slope control sen- Laser sensor for Sonic ski sensor for wire-
for contact-free for sensing at the for sensing along a sor for milling a milling a physically rope or contact-free sens-
sensing side panel wire pre-selected defined area ing of a reference surface
transverse slope

Operator station: All in good view

The control units with integrated digital controller include both, the corresponding function keys and
the easily readable displays for the pre-selected target value and the momentary actual value of the
milling depth (in cm or inches). They can either be mounted at the operator station for both, the right
and left sides of the machine, or on the corresponding side of the machine for operation from the
ground.

The target values of the automatic levelling system can be entered either from the operator station or from the ground.

140
 Sensing

Side panel Reference wire

Transducing
Wire-rope Ultrasonic Sonic ski
sensor

In front of the drum

Wire-rope Ultrasonic

all compatible with:

Slope control
sensor

Levelling

Multiplex Laser 3D control

141
13.1.1 Mechanical height sensing with the wire-rope sensor

For this type of levelling, the wire-rope sensor is hooked onto the drum panels, which glide over the
reference surface. The long skid of the side panel compensates any unevenness in its length. When
milling the second cut, the panel on one side glides over the milled surface, serving as a reference
height.

Wire-rope sensors are used for mechanical sensing at the side panel next to the milling drum.

13.1.2 Sensing with the ultrasonic sensor

This sensor operates contact-free and is therefore not subject to any mechanical wear and tear. It is
called an ultrasonic sensor because of its operating principle. A major advantage lies not only in its
accuracy, but also in the variety of ways in which it can be used for sensing: at the drum panel, at
the side of the drum and also in front of the drum (milling flush to the unpaved shoulder). Instead of
complex mechanics or a hydraulic installation, the ultrasonic sensor is simply plugged into its holder,
the plug inserted into the socket and the sensing plate swung out.

The ultrasonic waves, … where they are reflected

which are emitted at high
frequency, hit the reference
surface...
and detected by the sensor.
The time between
transmission and reception
serves as an indicator for
the distance between sen-
sor and surface.

The ultrasonic sensor with its non-contact principle of operation can sense both, the height of the side panel and the
reference surface at the side of or in front of the milling drum.

142
13.1.3 Sensing along a wire with the transducing sensor
In case of extensive rehabilitation work involving the replacement of several pavement layers, a grade
line is drawn for the surfacing work carried out by a road finisher. This grade line can also be used as
a reference line for the milling depth. For this purpose, the grade line is sensed by the arm of a
transducing sensor. A slope control sensor or an appropriate height sensor is used to control the
milling depth on the other side of the machine.

Transducing sensors are used for sensing along a pre-drawn wire.

13.1.4 Sensing with the sonic ski sensor

The sonic ski is a multiple ultrasonic sensor allowing an even more convenient adjustment of the
milling depth. It can be used for sensing a grade line as well as for sensing a reference surface. The
five sensors (one additional sensor for temperature compensation) make it easier to drive along the
grade line and compensate any unevenness in the pavement to be removed.

The sonic ski is an ultrasonic sensor suitable for both, sensing along a wire and sensing the height along a reference line.

143
13.1.5 Sensing in front of the drum with the wire-rope sensor
This additional feature makes it possible to sense the height in front of the drum if there is no paved
shoulder for sensing the height at the side of the machine.

Sensing in
front of the
drum

Sensing shoe in front of the milling drum

13.1.6 Sensing in front of the drum with the ultrasonic sensor

The ultrasonic sensor with its non-contact principle of operation can sense both, the height of the
side panel as well as the reference surface at the side of or in front of the milling drum.

Swivelling the bracket allows sensing in front of the drum.

144
13.1.7 The slope control sensor

The main applications of this type of sensor include a specific change of the transverse slope by
milling off the pavement, for instance when changing the gradient to ensure an effective water
drainage, or if a height sensor cannot be used when milling flush to the unpaved shoulder of a road.

Milling depth Milling depth

control sensing control with a
the height (e.g. slope control sen-
wire-rope sensor) sor

The slope control sensor functions in the same way as an electronic pendulum. It is firmly attached to the chassis and
operates in combination with a height sensor.

145
13.1.8 The Multiplex system

When working with the Multiplex system, three sensors each are fitted on both sides of the machine
to sense the reference surfaces. The controller then calculates a mean value from the three measured
values in order to compensate any unevenness.

Control unit
3 sensors
left

Slope control sensor

3 sensors
right
Control unit

Ideally suited for fine milling: the Multiplex system

When working with the Multiplex system, three sensors each are fitted on both sides of the machine
to sense the reference surfaces. The controller then calculates a mean value from the three measured
values in order to compensate any unevenness. The system basically functions in the same way as a
very long averaging ski. The sensors at the front and rear of the machine, usually ultrasonic sensors,
can be ideally positioned with the aid of swivel arms. The sensor next to the drum may be either an
ultrasonic or a wire-rope sensor.

146
Changing the gradient over several milling cut
When changing the gradient over several milling cuts, the best results are achieved with the use of
slope control sensors in combination with the Multiplex system.

The applications of this system include fine milling to level slightly deformed surface courses or to
ensure proper water drainage and skid resistance. It can also be used to mill off a few millimetres
prior to applying a thin-layer pavement.

Sensing at three points

The system basically functions in the same way as a very long averaging ski. The sensors at the front
and rear of the machine, usually ultrasonic sensors, can be ideally positioned with the aid of swivel
arms. The sensor next to the drum may be either an ultrasonic or a wire-rope sensor.

147
13.1.9 Levelling surfaces with the laser sensor
Adjustment of the milling depth via lasers is a special application: In this case, the reference surface
is defined by a rotating laser beam given off by a transmitter. The milling depth on the right and left
sides is adjusted by two receivers on the milling machine, irrespective of the actual pavement
geometry. This method is used, for example, in large halls or on large traffic areas, such as airports.

148
13.1.10 Levelling by means of 3D
With a 3D system, which determines an absolute position of the machine and automatically regulates
height and slope, a high degree of milling accuracy is achieved even in case of several milling
passes.

Position of the machine

is determined via a prism

Angle correction
Total station

Mast slope sensor

Height difference, which is

compensated (calculated) by
the mast slope sensor

Total station

149
Machine control by means of a 3D system.

Machine control unit for pavers and milling machines. Controller for 3D system, receiver modem, screen (PC),
controller 3D system.

150
The asphalt pavement is removed by a cold milling machine controlled via a 3D system.

Lowering a tunnel floor

151
152
14. Special applications

14.1 Surface Miner 2200 SM 154-158

14.2 Cold Recycler 2200 CR 159-163

153
14.1 Surface Miner 2200 SM

Cutting width: 2,200 mm

Cutting depth: 0 - 350 mm
Engine output: 596.5 kW / 811 PS
Operating weight: 47,730 daN (kg)
Cutting drum drive: mechanical
Number of crawler tracks: 4
Travel drive: hydraulic four-track drive

The machine user can order modern large milling machines with an additional machine setup, which
considerably broadens the range of possible applications of the machine and ensures an increased
machine utilisation. Equipped with a "surface mining package", the Wirtgen cold milling machine
W 2200 can, for example, operate as a mining machine in open-cast mining.
The most important element of the machine's conversion is the milling drum: The standard road
milling drum is replaced by a drum that is equipped with cutting tools specially adapted to the mining
operation. The machine's conveyor system, operator station canopy or crawler tracks can also be
easily modified or replaced, depending upon the intended use in the quarry.
Once the components have been exchanged, the degree of utilisation is increased and idle times are
reduced, thus improving the efficiency of the machine.

Advantages:

• No blasting required.
• Cutting of steep, stable surfaces and embankments (better utilisation).
• Accurate cutting of defined profiles (embankments, surfaces).
• Production of small-sized aggregate during the cutting procedure. Due to its gradation,
the cut material is suitable for use as gravel.

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Accurate cutting of trenches, surfaces and embankments
Contractors benefit from the technical features of the Wirtgen Surface Miners when it comes to the
accurate cutting of

• trenches
• tunnel floors
• embankments
• surface profiles

consisting of limestone or other medium hard to hard materials.

Possible with a Wirtgen Surface Miner: Cutting limestone for the inlet of a water reservoir

Possible with a Wirtgen Surface Miner: Lowering a For modern railway systems with increased capacity
tunnel floor

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Direct loading
Direct loading on trucks

One of the most important features of the Wirtgen Surface Miners is their capability of directly
loading the cut material on trucks. The Wirtgen Surface Miners are designed as either front or rear
loaders, depending upon the machine model.

Front loading

The 2200 SM is a front loader. Its discharge conveyor is mounted at the front of the machine. The
conveyor can be slewed to either side, and its discharge height can be adjusted. Depending upon
the size of the truck, these machines load the trucks either from the rear (left) or from the side (right).
The operator of the Surface Miner has an unobstructed view of the truck.

Front loading: loading from the rear Front loading: loading from the side

Indirect loading
Tipping the material to the side means that a
stockpile is produced by depositing the material
of several cuts on the stockpile by means of the
conveyor. Depending upon the slewing angle of
the conveyor, the material of 3 to 5 adjacent cuts
can be tipped on top of each other. Depending
upon the height of the stockpile thus produced,
the material can then be easily loaded again by a
front loader.

2200 SM: tipping the material to the side of the

machine

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Windrowing
With the windrowing method, the cut material is deposited directly behind the machine without using
the conveyor system. The cutting operation can thus be carried out independent of truck loading.
The material must, however, be loaded at a later date using a front loader.

Wirtgen Surface Miner: the windrowing method Wirtgen Surface Miner: the windrowing method

Picking up the windrowed material Loading the windrowed material

With many applications, the higher productivity of the windrowing method when compared to direct
loading offsets the additional costs incurred by the subsequent loading of the material (e.g. with
wheel-loaders). Moreover, the conveyor belt is not subjected to wear and tear, and operating costs
for the conveyor system are not incurred.

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 Wirtgen Surface Miners cut, crush and load rock in one single operation
without blasting. The fields of application of the 2200 SM include:

• Highly selective mining of thin seams of useful minerals (e.g. coal or phosphate).
• Mining of rock wherever blasting is difficult or not possible at all (e.g. in the
vicinity of railway installations, residential areas and industrial buildings).
• Mining of rock with different degrees of hardness that can no longer be
excavated by conventional equipment.
• Production of exact, neat and stable surfaces, carriageways and embankments.
• Production of small-sized material without the need for crushing.
• Expansion of existing carriageway structures (when equipped with a road milling
drum).
• In-situ processing of road construction materials (when equipped with a cold
recycling system).

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14.2 Cold recycler 2200 CR
A technology with ecological as well as economical benefits earned itself worldwide renown when the
cost-efficient cold recycling process was introduced at the beginning of the eighties.
Cold recycling in-situ, i.e. directly on the job site, involves milling and granulating the damaged road
pavement by the recycler in adjacent working cuts, resulting in a graded mixture of asphalt granulate
and gravel from the old underlying base course layer. New binder and water to achieve the optimum
water content are added at the same time. The result: a processed construction material mixture with
a high load-bearing capacity.
The processed base course material is then directly placed - for example in case of the 2200 CR - by
the machine's integrated paving screed or by a motor grader following behind. In both cases, the
new pavement is compacted by heavy vibratory rollers. The recycled layer is typically overlaid with a
thin asphalt surface course, serving as a wearing course.

Working width: 2,200 mm

Working depth: 0 - 250 mm
Engine output: 597 kW / 811 PS
Operating weight, CE: 49,720 daN (kg)
Milling drum drive: mechanical
Number of crawler tracks: 4
Travel drive: hydraulic four-track drive

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The metered binding agents are injected into the milling and mixing chamber and mixed with the scarified asphalt
pavement. The construction material mixture is then evenly spread over the full working width by the spreading auger
and pre-compacted by the paving screed.

Can be used with different binding agents

The cold recycler 2200 CR can process the reclaimed road construction materials with various
binding agents. For this purpose, the 2200 CR is specially equipped with different spraying systems.
These systems deliver the required fluid via hose lines to the spraying bar above the milling and
mixing chamber. The quantities to be injected are controlled via a microprocessor, which ensures a
constant quality of the processed mixture. The variety of possible additives is particularly large, since
two spraying systems can be used simultaneously. As a result, the scarified material can, for
example, be processed with bitumen emulsion and water or with a combination of water-cement
slurry and bitumen emulsion.

Processing with foamed bitumen

It goes without saying that hot bitumen can also be added to the processed material. The hot
bitumen passes through heated lines with filters to the individual expansion chambers in the spraying
bar. Here, foamed bitumen is produced by adding compressed air and water from the machine's
water tank. As a rule, water is added via the second spraying bar when recycling with foamed
bitumen in order to ensure that the optimum moisture content is achieved in the mixture. Water-
cement slurry can also be added via this spraying bar.
Construction material mixtures processed with foamed bitumen have a particularly high load-bearing
capacity. Foamed bitumen is also an exceedingly cost-efficient binding agent for the production of
cold mixes, since only small amounts of binding agent are required.

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Cold recycling of road pavements with bitumen emulsion

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In-situ processing of road pavements

The surface course of this road showed alligator cracking and lateral displacements, which indicated that the underlying
base course layer had been damaged.

The spreading auger and paving screed are controlled via two control panels mounted at the left and right sides of the
machine.

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The new base course was open to traffic during the cold recycling operation. The entire carriageway was overlaid with a
new surface course upon completion of the recycling work.

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 Fax:
Internet: www.wirtgen.com
53578 Windhagen · Germany
Phone: +49 (0) 26 45 / 131- 0
+49 (0) 26 45 / 131- 242
Wirtgen GmbH · Hohner Straße 2
Illustrations are without obligation. Subject to technical changes. Performance data depend upon operational conditions. – Nr.19-10 EN- 01/04 © by Wirtgen GmbH 2004 Printed in Germany