A WIRTGEN GROUP COMPANY

TECHNOLOGIES & COMPLETE SOLUTIONS

MASTIC ASPHALT
> Production Page 04 > Storage Page 06
> Transport Page 08 > Customer support Page 18
COMPLETE SOLUTIONS FOR MANUFACTURING, STORING AND TRANSPORTING
HIGH-QUALITY MASTIC ASPHALT.
As a material, mastic asphalt has become increasingly important because of its diverse
range of potential applications. It has a long service life, is extremely cost-effective and
has low operating costs. It is also eco-friendly and 100% recyclable.
BENNINGHOVEN GMBH & CO. KG
THE NEW MIXING CULTURE –
MADE IN GERMANY.
We have been specialising in the construction of asphalt mixing plants from as long ago
as the 1960s. A company that started with gear wheels and machine tools in 1909 now
supplies the leading technology for asphalt mixing plants. With more than 600 employees
in Germany and abroad, you can come to us directly for everything – from planning and
assembly through to commissioning.
BENNINGHOVEN GmbH & Co. KG is a member of the Wirtgen Group, an expanding,
international group of companies in the construction equipment industry.
 MASTIC ASPHALT | 05

PRODUCTION OF MASTIC ASPHALT

MIXING TO PERFECTION.

Mastic asphalt is produced in fully automatic asphalt

mixing plants. The mixture, made up of aggregates
and a high proportion of bitumen and filler, enters
the storage silos after the mixing procedure or is
loaded directly into mastic asphalt mixers.

// ASPHALT MIXING PLANT

// ASPHALT MIXING PLANT LAYOUT

1 Cold feed system
2 Dryer drum/burner
4
3 Dust collection system
4 Screen and mixing tower
5
5 Mixing and weighing section/mixer
6 Mixed material storage silo
7 Filler silo
8 Bitumen system
9 Command cabin
7
6
3
// ASPHALT MIXING PLANTS // FILLER HEATER
1
Whether standard or customised, the range of equip- The filler heater developed by Benninghoven was 8
ment for Benninghoven asphalt mixing plants is huge. designed with the objective of maximising efficiency 2
We can supply the right plant to suit any requirement on in the mastic asphalt production process. The filler is
9
the market: from mobile to stationary, and at capacities heated to the required temperature even before it is fed
from 80 to 400 t/hour – but one thing doesn’t change: to the mixer to optimise the performance capacity of
Benninghoven plants are recognised around the world the mixing plant. Heating is provided by the filler heater
for the quality of their asphaltic mixtures. (FEH), which lowers energy costs and keeps the material
in great condition.

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 MASTIC ASPHALT | 07

// VERLADESILO

Storage silos are designed to further increase

the homogeneity of the mastic asphalt.
They are integrated into an asphalt mixing
plant, but can also be operated as stand-alone
units or retrofitted to existing Benninghoven
or third-party plants.

The extremely robust silos are manufactured using

the latest technology and can be used for white, black
and recycled material. They can also be retrofitted to
existing plants at any time. The Benninghoven range
includes agitators with content of up to 70 t.

Special wear- and heat-resistant materials maximise the

long life of the units and minimise maintenance costs.
Careful heating is provided optionally by oil, gas or
combi burner. The volume-controlled agitator drive with
variable speeds minimises wear, with a direct hydraulic
or electric drive available.

Optimum mixing and homogenisation of the mastic

asphalt are guaranteed thanks to a high-performance
drive and the unique arrangement of mixing arms.
Continuous temperature monitoring also makes sure
that the quality of the asphaltic mixture is consistently
good. Flue gas sensors are installed to protect the
periphery of the plant. Heating-up time is short and
achieved with low heat loss thanks to high-quality
MASTIC ASPHALT STORAGE insulation and the small number of thermal bridges.

PROPER STORAGE DOES HALF // STORAGE SILO

THE WORK OF LAYING.

TECHNICAL DATA MASTIC ASPHALT STORAGE SILOS (GAV)

10.4 m³ 12.5 m³ 16.5 m³ 20.8 m³ 25 m³ 29 m³

Capacity (t) 1) 25 30 40 50 60 70

Dimensions (L×W×H, mm) 5,200×2,500×2,780 5,000×2,600×3,200 5,000×2,890×3,380 5,000×2,890×3,900 5,780×3,270×3,680 6,400×3,300×3,700 4

Total weight from (kg) 12,000 13,000 14,000 16,000 18,000 20,000

Torque (Nm) 42,000 64,000 64,000 120,000 120,000 120,000

Electric motor output (kW) 30 30 45 55 75 75

Agitator motors (quantity) 1 1 1 2 2 2 1

Burner Fully automatic oil or natural gas burner Fully automatic oil, natural gas or combi burner
// STORAGE SILO CROSS-SECTION
Burner output (kW) 2x75 2x85 2x100 2x120 2x180 2x240
1 Drive – hydraulic or electric
Cauldron wall/end wall (mm) 2) 15 15 15 15 15 15 2 2 Burner
Outlet opening (mm) 600×400 600×400 600×400 600×400 600×400 600×400 3 Flue
Panels Side walls = metal decking, RAL colour as requested by customer, end walls = plain sheet in black 4 Agitator
3
1)
At a density of 2.4 kg/m³, set up at 3° 2)
Made of Brinar > Special sizes on request

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 MASTIC ASPHALT | 09

// KOCHER GKL

// GKL SILENT
Noises can be inconvenient or can even make you ill – in
particular when you are trying to sleep or in sensitive areas
such as pedestrian zones, residential areas and hospitals.

The GKL Silent is a new product from Benninghoven and

makes it possible to carry out work outside of normal working
hours. The direct electric drive produces no inconvenient
noise emissions.

Process-relevant parameters and operating states can also

be visualised via a tablet, making it possible to monitor
permanently from the cab.
// TRANSPORT MIXER GKL
HORIZONTAL TRANSPORT TECHNOLOGIES

ALWAYS TURNING, BUT NEVER TECHNICAL DATA MASTIC ASPHALT TRANSPORT MIXER (GKL)

OVERHEATING. 5 m³ 7.5 m³ 10 m³
Capacity (t) 1) 12 18 24

Exterior dimensions (L×W, mm) 2)

4,650×2,500 5,600×2,550 6,900×2,550
GKL mixers with horizontal mixing shaft and hydraulic or electric direct drive Exterior height (mm) 3) 2,115/2,235 2,200 2,200
are perfectly designed for homogenisation and mixing during transport. Total weight from (kg) 4,100 4,900 6,100

Torque (Nm) 30,000 38,000 38,000

The compact unit is ideal for mobile and stationary Continuous temperature monitoring also makes sure Generator for Silent design (kW) 33.85 35.18 35.18

applications. There is also a wide variety of possible that the quality of the asphaltic mixture is consistently Diesel engine output (kW/PS) 4)
20.9/28.4 31.2/42.4 31.2/42.4
setups (lorry/trailer/fifth wheel/hook). The highest good. Flue gas sensors are installed to protect the Mixing arms (quantity) 6 8 11
quality materials and maintenance-free components periphery.
Burner output (kW) 2×35 2×55 2×75
guarantee excellent wear protection.
There is also an integrated multifunction display with Cauldron wall/end wall (mm) 5) 8 (Option 10/12/15) 8 (Option 10/12/15) 8 (Option 10/12/15)

The weight-optimised mixers come with fully automatic all process-relevant parameters for control. Live data Filling opening (L×W, mm) 1,300×800 1,300×800 1,300×800
gas- or oil-heated firing. The volume-controlled, variable can be retrieved at all times with a receipt printer or Outlet opening (L×W, mm) 600×400 600×400 600×400
drive minimises wear and helps to reduce the consump- our Webfleet technology. A clearly visible flashing lamp Insulation (mm) 60 mm for cauldron, 60 mm for end walls, 100 mm for floor
tion of resources. indicates if any fault has occurred.
Exterior panels Aluminium or stainless steel

1)
At a density of 2.4 kg/m³ 2)
Including chute 3)
For gas/oil firing, including frame 4)
At 2000 min-1 5)
Made of Brinar > Special sizes on request

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 MASTIC ASPHALT | 11

IMPRESSIONS

COMPLETE DEDICATION.
// WEBFLEET TECHNOLOGY
The Webfleet technology from Benninghoven transfers data
relevant to transport, such as agitator rotation speed, agitator
pressure, temperature, location etc. via satellite to the relevant
control stations. Optimum product quality is guaranteed thanks
to seamless transport tracking, from the asphalt mixing plant to
the laying site.
// GKL 10 LAYING SITE
The mastic asphalt is unloaded directly in front of the paving
screed and spread to the required width. The paving screed
guarantees the required coating thickness and the evenness
of the mastic asphalt layer.

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 MASTIC ASPHALT | 13

// TRANSPORT MIXER GKS VERTICAL TRANSPORT TECHNOLOGIES

ALWAYS THERE, EVEN WHEN IT’S

A BIT OF A SQUEEZE.
TECHNICAL DATA MASTIC ASPHALT TRANSPORT MIXER (GKS)

3.5 m³ 5 m³ 5.5 m³
Capacity (t) 1) 8 12 13

Exterior dimensions including chute (L×W, mm) 4,150×2,300 4,350×2,500 7,050×2,500

Exterior height (mm) 1,750 2,100 2,200

Total weight from (kg) 4,300 4,700 4,800

GKS mixers are produced with a content of up to 5.5 m³, depending
Torque (Nm) 30,000 33,000 33,000
on customer requirements. The short design of the mixer means that
Diesel engine output (kW/PS) 2)
20.9/28.4 31.2/42.4 31.2/42.4
you can access hard-to-reach areas of your site easily.
Mixing arms (quantity) 6 6 6

Ring or lance burner output (kW) 60 75 80 The compact unit is ideal for mobile applications and Simple operation and high reliability underscore
Cauldron floor/wall (mm) 3)
12/6 12/6 12/6 can be used in a wide variety of possible setups (lorry/ the quality of the mixer.
Filling opening (L×W, mm) 1,300×800 1,300×800 1,300×800
trailer/fifth wheel/hook).
Continuous temperature monitoring and limitation
Outlet opening (L×W, mm) 600×400 600×400 600×400
Firing is with gas and is either semi- or fully automatic. also ensure that the quality of the asphaltic mixture
Insulation (mm) 50 50 50 The highest quality materials and maintenance-free is consistently good and the periphery is protected.
Exterior panels Aluminium or stainless steel components guarantee excellent wear protection.

1)
At a density of 2.4 kg/m³ 2)
At 2000 min-1 3) Made of Brinar > Special sizes on request

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 MASTIC ASPHALT | 15

// DUMPER DU 500

// DU 500 DUMPER/DU BURNER UNIT

VERTICAL TRANSPORT TECHNOLOGIES

A FAVOURITE: SMALL BUT BEAUTIFUL.

TECHNICAL DATA MASTIC ASPHALT DUMPER (DU)

350 500 600

Capacity (t) 1) 0.8 1.2 1.4

Exterior dimensions (L×W, mm) 2)

3,220×1,950 3,220×1,950 3,220×1,950

Exterior height max. (mm) 2,200 2,200 2,200

The DU dumper is an extremely useful vehicle due to its rear axle steering,
3)

and is particularly suited to building car parks and industrial buildings and Total weight from (kg) 1,500 1,500 1,500

ideal for hard-to-reach laying sites. Torque (Nm) 1,400 1,400 1,400

Diesel engine output (kW) 4)

17.2/23.4 17.2/23.4 17.2/23.4

Mixing arms (quantity) 2 2 2

The mastic asphalt dumper with direct hydraulic agitator The mixer can be tipped hydraulically. A scissor lift can Ring burner output (kW) 20 20 20

drive and tipping mechanism is ideal for mobile appli- also be integrated into the system. Firing is semi-auto- Cauldron floor/wall (mm) 5)
8/6 8/6 8/6
cations. matic with gas. Filling height (mm) 1,150 1,150 1,150

Tilting/lifting capacity 300 mm with tilting cylinder

The standard lighting and integrated trailer coupling The mixer lifting mechanism can be operated with one
Filling opening (L×W, mm) 300×500 300×500 300×500
are also an advantage, allowing the dumper to be used hand while driving. BENNINGHOVEN dumpers are also
as a tractor. The design includes hydrostatic drive and fitted with operating hour, tank and engine temperature Outlet opening (L×W, mm) 300×200 300×200 300×200
hydraulic brake system. A four-wheel drive is also indicators as standard. Gradeability (%) 15 15 15
available for rough terrain. Insulation (mm) 50 50 50

Fully hydraulic steering Rear axle

Other Brakes: fully hydraulic/Exterior panels: aluminium or stainless steel

1)
At a density of 2.4 kg/m³ 2)
Including chute 3)
With standard safety bar 4)
At 2800 min-1 5)
Made of Brinar > Special sizes on request

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 MASTIC ASPHALT | 17

JOINT-SEALING MIXER

NEVER AGAIN WILL YOUR WORK

COME APART AT THE SEAMS.
If you need to seal gaps between two asphalt layers or between asphalt layers and built-in
fixtures, then you require a joint-sealing mixer. Precision is really important here, because joints
that have been processed incorrectly are usually responsible for initiating damage to roads.

// INNOVATIVE DUOMATIC HEATING SYSTEM
The new BENNINGHOVEN joint-sealing mixer (FUG)
guarantees gentle heating of the joint-sealing material.
The newly developed DUOMATIC heating system heats
up the material indirectly. The first step, which involves
heating up the thermal oil heating medium, is carried
out based on fuel oil. The second step involves main-
taining the temperature level electrically. The advanta-
ges of this innovative heating system are obvious – the
specific characteristics of the various bituminous masses
remain unaltered and are not changed or destroyed
through overheating or flame contact.
The system is resource-saving and environmentally
friendly. Application of the joint-sealing material mostly
involves simply maintaining it at a certain temperature
which, at BENNINGHOVEN, is achieved purely using
electricity. This requires less fuel oil and prevents
additional exhaust gases.
// IMPRESSIVE DOWN TO THE VERY LAST DETAIL
The agitator features a direct electric drive, so the FUG
can also be used in underground car parks without
generating any annoying exhaust gases or noise.
The filter, which is freely accessible from the outside,
can be cleaned at any time without emptying the mixer.
The electrically heated sealing hose can be emptied
without a compressor, via a bitumen pump. A gantry
girder also makes for ergonomic work and provides
physical relief.
// FURTHER OPTIONS
> LED light Rear with large, hydraulically controlled, maintenance-free
> Tandem chassis
outlet opening to empty the mixer quickly.
> Self-propulsion

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 MASTIC ASPHALT | 19

M O R E T H A N

CUSTOMER SUPPORT

RIGHT NEXT TO OUR CUSTOMERS.

107
Y E A R S O F C U S TO M E R F O C U S

M O R E T H A N

600
Our local contacts in sales and service
companies provide comprehensive support for
all issues and queries relating to our products.
This includes diagnosis and technical support,
ordering original spare parts and advice on
using our products.

M OT I VAT E D S P E C I A L I S TS
Rapid technical support is our top priority. We guarantee
a short response time and rapid solutions thanks to a
close-knit network of offices, their experienced service
technicians and the additional support of our home
factory.

Knowing exactly how to operate our plants is the key to

using them successfully. To provide your employees with
the specialist knowledge they need, BENNINGHOVEN
offers a wide range of training courses at our main fac-
tory in Mülheim – or we can come to you.

We develop training courses specifically adapted to

our customers’ needs, which are then delivered by
competent employees from our specialist departments.

// ASPHALT MIXING PLANT

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 BENNINGHOVEN_Gussasphalt_042016_EN_R0

BENNINGHOVEN GmbH & Co. KG

Germany
Industriegelände
54486 Mülheim an der Mosel
Phone: +49 6534 1890
Fax: +49 6534 8970
E-Mail: info@benninghoven.com
www.benninghoven.com