TECHNOLOGIES & COMPLETE SOLUTIONS

MASTIC ASPHALT

A WIRTGEN GROUP COMPANY

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 agoas the 1960s. A company that started with gear wheels and machine tools in 1909 nowsupplies the leading technology for asphalt mixing plants. With more than 600 employeesin Germany and abroad, you can come to us directly for everything – from planning andassembly 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.

COMPLETE SOLUTIONS FOR MANUFACTURING, STORING AND TRANSPORTINGHIGH-QUALITY MASTIC ASPHALT.

As a material, mastic asphalt has become increasingly important because of its diverserange of potential applications. It has a long service life, is extremely cost-effective andhas low operating costs. It is also eco-friendly and 100% recyclable.

> Production Page 04 > Storage Page 06 > Transport Page 08 > Customer support Page 18

// ASPHALT MIXING PLANT LAYOUT

1 Cold feed system

2 Dryer drum/burner

3 Dust collection system

4 Screen and mixing tower

5 Mixing and weighing section/mixer

6 Mixed material storage silo

7 Filler silo

8 Bitumen system

9 Command cabin

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// ASPHALT MIXING PLANT

Mastic asphalt is produced in fully automatic asphaltmixing plants. The mixture, made up of aggregatesand a high proportion of bitumen and filler, entersthe storage silos after the mixing procedure or isloaded directly into mastic asphalt mixers.

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// ASPHALT MIXING PLANTSWhether standard or customised, the range of equip-ment for Benninghoven asphalt mixing plants is huge.We can supply the right plant to suit any requirement onthe market: from mobile to stationary, and at capacitiesfrom 80 to 400 t/hour – but one thing doesn’t change:Benninghoven plants are recognised around the worldfor the quality of their asphaltic mixtures.

// FILLER HEATERThe filler heater developed by Benninghoven was designed with the objective of maximising efficiency in the mastic asphalt production process. The filler is heated to the required temperature even before it is fed to the mixer to optimise the performance capacity of the mixing plant. Heating is provided by the filler heater (FEH), which lowers energy costs and keeps the material in great condition.

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PRODUCTION OF MASTIC ASPHALT

MIXING TO PERFECTION.

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The extremely robust silos are manufactured usingthe latest technology and can be used for white, blackand recycled material. They can also be retrofitted toexisting plants at any time. The Benninghoven rangeincludes agitators with content of up to 70 t.

Special wear- and heat-resistant materials maximise thelong life of the units and minimise maintenance costs.Careful heating is provided optionally by oil, gas orcombi burner. The volume-controlled agitator drive withvariable speeds minimises wear, with a direct hydraulicor electric drive available.

Optimum mixing and homogenisation of the masticasphalt are guaranteed thanks to a high-performancedrive and the unique arrangement of mixing arms.Continuous temperature monitoring also makes surethat the quality of the asphaltic mixture is consistentlygood. Flue gas sensors are installed to protect theperiphery of the plant. Heating-up time is short andachieved with low heat loss thanks to high-qualityinsulation and the small number of thermal bridges.

// VERLADESILO

// STORAGE SILO CROSS-SECTION

1 Drive – hydraulic or electric

2 Burner

3 Flue

4 Agitator

Storage silos are designed to further increase the homogeneity of the mastic asphalt.They are integrated into an asphalt mixingplant, but can also be operated as stand-alone units or retrofitted to existing Benninghoven or third-party plants.

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MASTIC ASPHALT STORAGE

PROPER STORAGE DOES HALF 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

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

Burner Fully automatic oil or natural gas burner Fully automatic oil, natural gas or combi burner

Burner output (kW) 2x75 2x85 2x100 2x120 2x180 2x240

Cauldron wall/end wall (mm) 2) 15 15 15 15 15 15

Outlet opening (mm) 600×400 600×400 600×400 600×400 600×400 600×400

Panels Side walls = metal decking, RAL colour as requested by customer, end walls = plain sheet in black

1) At a density of 2.4 kg/m³, set up at 3° 2) Made of Brinar > Special sizes on request

// STORAGE SILO

// KOCHER GKL

// GKL SILENT

Noises can be inconvenient or can even make you ill – inparticular when you are trying to sleep or in sensitive areassuch as pedestrian zones, residential areas and hospitals.

The GKL Silent is a new product from Benninghoven andmakes 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 alsobe visualised via a tablet, making it possible to monitorpermanently from the cab.

The compact unit is ideal for mobile and stationaryapplications. There is also a wide variety of possiblesetups (lorry/trailer/fifth wheel/hook). The highestquality materials and maintenance-free componentsguarantee excellent wear protection.

The weight-optimised mixers come with fully automaticgas- or oil-heated firing. The volume-controlled, variabledrive minimises wear and helps to reduce the consump-tion of resources.

Continuous temperature monitoring also makes surethat the quality of the asphaltic mixture is consistentlygood. Flue gas sensors are installed to protect theperiphery.

There is also an integrated multifunction display withall process-relevant parameters for control. Live datacan be retrieved at all times with a receipt printer orour Webfleet technology. A clearly visible flashing lamp indicates if any fault has occurred.

GKL mixers with horizontal mixing shaft and hydraulic or electric direct driveare perfectly designed for homogenisation and mixing during transport.

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HORIZONTAL TRANSPORT TECHNOLOGIES

ALWAYS TURNING, BUT NEVER OVERHEATING.

TECHNICAL DATA MASTIC ASPHALT TRANSPORT MIXER (GKL)

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

Exterior height (mm) 3) 2,115/2,235 2,200 2,200

Total weight from (kg) 4,100 4,900 6,100

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

Generator for Silent design (kW) 33.85 35.18 35.18

Diesel engine output (kW/PS) 4) 20.9/28.4 31.2/42.4 31.2/42.4

Mixing arms (quantity) 6 8 11

Burner output (kW) 2×35 2×55 2×75

Cauldron wall/end wall (mm) 5) 8 (Option 10/12/15) 8 (Option 10/12/15) 8 (Option 10/12/15)

Filling opening (L×W, mm) 1,300×800 1,300×800 1,300×800

Outlet opening (L×W, mm) 600×400 600×400 600×400

Insulation (mm) 60 mm for cauldron, 60 mm for end walls, 100 mm for floor

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

// TRANSPORT MIXER GKL

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// 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 pavingscreed 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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IMPRESSIONS

COMPLETE DEDICATION.

The compact unit is ideal for mobile applications andcan be used in a wide variety of possible setups (lorry/trailer/fifth wheel/hook).

Firing is with gas and is either semi- or fully automatic.The highest quality materials and maintenance-freecomponents guarantee excellent wear protection.

Simple operation and high reliability underscore the quality of the mixer.

Continuous temperature monitoring and limitationalso ensure that the quality of the asphaltic mixture is consistently good and the periphery is protected.

GKS mixers are produced with a content of up to 5.5 m³, dependingon customer requirements. The short design of the mixer means thatyou can access hard-to-reach areas of your site easily.

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VERTICAL TRANSPORT TECHNOLOGIES

ALWAYS THERE, EVEN WHEN IT’SA 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

Torque (Nm) 30,000 33,000 33,000

Diesel engine output (kW/PS) 2) 20.9/28.4 31.2/42.4 31.2/42.4

Mixing arms (quantity) 6 6 6

Ring or lance burner output (kW) 60 75 80

Cauldron floor/wall (mm) 3) 12/6 12/6 12/6

Filling opening (L×W, mm) 1,300×800 1,300×800 1,300×800

Outlet opening (L×W, mm) 600×400 600×400 600×400

Insulation (mm) 50 50 50

Exterior panels Aluminium or stainless steel

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

// TRANSPORT MIXER GKS

// DUMPER DU 500

The mastic asphalt dumper with direct hydraulic agitator drive and tipping mechanism is ideal for mobile appli- cations.

The standard lighting and integrated trailer couplingare also an advantage, allowing the dumper to be used as a tractor. The design includes hydrostatic drive and hydraulic brake system. A four-wheel drive is alsoavailable for rough terrain.

The mixer can be tipped hydraulically. A scissor lift can also be integrated into the system. Firing is semi-auto-matic with gas.

The mixer lifting mechanism can be operated with one hand while driving. BENNINGHOVEN dumpers are also fitted with operating hour, tank and engine temperature indicators as standard.

// DU 500 DUMPER/DU BURNER UNIT

The DU dumper is an extremely useful vehicle due to its rear axle steering, and is particularly suited to building car parks and industrial buildings and ideal for hard-to-reach laying sites.

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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) 3) 2,200 2,200 2,200

Total weight from (kg) 1,500 1,500 1,500

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

Ring burner output (kW) 20 20 20

Cauldron floor/wall (mm) 5) 8/6 8/6 8/6

Filling height (mm) 1,150 1,150 1,150

Tilting/lifting capacity 300 mm with tilting cylinder

Filling opening (L×W, mm) 300×500 300×500 300×500

Outlet opening (L×W, mm) 300×200 300×200 300×200

Gradeability (%) 15 15 15

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

// INNOVATIVE DUOMATIC HEATING SYSTEMThe new BENNINGHOVEN joint-sealing mixer (FUG)guarantees gentle heating of the joint-sealing material.

The newly developed DUOMATIC heating system heatsup the material indirectly. The first step, which involvesheating 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 environmentallyfriendly. Application of the joint-sealing material mostlyinvolves simply maintaining it at a certain temperaturewhich, at BENNINGHOVEN, is achieved purely usingelectricity. This requires less fuel oil and preventsadditional exhaust gases.

// IMPRESSIVE DOWN TO THE VERY LAST DETAILThe agitator features a direct electric drive, so the FUGcan also be used in underground car parks withoutgenerating 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 emptiedwithout a compressor, via a bitumen pump. A gantrygirder also makes for ergonomic work and providesphysical relief.

// FURTHER OPTIONS> LED light> Tandem chassis> Self-propulsion

If you need to seal gaps between two asphalt layers or between asphalt layers and built-infixtures, 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.

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Rear with large, hydraulically controlled, maintenance-freeoutlet opening to empty the mixer quickly.

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JOINT-SEALING MIXER

NEVER AGAIN WILL YOUR WORKCOME APART AT THE SEAMS.

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Our local contacts in sales and servicecompanies provide comprehensive support forall issues and queries relating to our products.This includes diagnosis and technical support,ordering original spare parts and advice onusing our products.

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 toour customers’ needs, which are then delivered bycompetent employees from our specialist departments.

// ASPHALT MIXING PLANT

107YEARS OF CUSTOMER FOCUS

M O R E T H A N

600M O T I V A T E D S P E C I A L I S T S

M O R E T H A N

CUSTOMER SUPPORT

RIGHT NEXT TO OUR CUSTOMERS.

BENNINGHOVEN GmbH & Co. KGGermany

Industriegelände54486 Mülheim an der Mosel

Phone: +49 6534 1890Fax: +49 6534 8970E-Mail: info@benninghoven.comwww.benninghoven.com B

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