limitless applications in economically efficient concrete...

Limitless applications in economically efficient concrete paving

The World ofWirtgen Slipform Pavers

Introduction 4 -5

History 6 -7

Offset slipform pavers in detail 8 -11

Inset slipform pavers in detail 12 -17

Leadership in technology 18 -29

Product portfolio 30 -31

Manufacturing technology 32 -33

Reliable customer service 34 - 35

In operation around the globe 36 - 37

Environmental sustainability 38 - 39

contents

InTroducTIon

Slipform pavers get concrete into shape

Motorways and airport runways

are exposed to ever higher stress-

es caused by heavy-vehicle traffic

on the one hand and air traffic on

the other. Concrete pavements

are capable of withstanding these

tremendous loads for many years

to come. Slipform pavers have

become indispensable in concrete

paving because of their unsur-

passed efficiency in the highly

automated production of concrete

road pavements. The track-mount-

ed multipurpose machines are

also masters in the production of

a countless range of poured-in-

place profiles.

Major process innovations have

gained Wirtgen an excellent

reputation, and our slipform paver

range is occupying a leading po-

sition in the world market. We are

strongly driven by our firm com-

mitment to expand this position

further and to keep treading new

paths in the future.

Wirtgen is synonymous with efficiency in concrete paving

4 //5

hISTory

many product innovations paved theway to becoming a global player

The history of Wirtgen’s slip-

form paver division is impressive

proof that it is possible to take

up an existing technology and to

successfully develop it to per-

fection with innovative spirit and

creativity. Following the integra-

tion of a business that enjoyed

an excellent repu tation in the

industry, Wirtgen is now setting

many ground-breaking milestones,

one after the other, which are all

contributing signifi cantly to the

renewed success of the entire

technology. Our many pioneering

innovations include, for example,

a high degree of process automa-

tion, the development of machin-

ery for offset paving and dual-layer

concrete paving applications.

In 1989, Wirtgen became actively

involved in the technology by

acquiring Belgian slipform paver

manufacturer SGME and their

technologies. Slipform pavers from

Wirtgen have meanwhile gained

an excellent reputation in the

market and are the prime choice

for perfect concrete paving.

Wirtgen is setting important milestones

1989Following the acquisi-tion of a slipform paver manufacturer, Wirtgen

begins engineering and marketing slipform

pavers.

1991The SP 1600 is the

world’s first slipform paver capable of direct

dual-layer concrete paving.

1998The SP 850 Vario

features a hydraulically telescoping mould for working widths

ranging from 3.0 m to 6.0 m.

2006The SP 1200 features

a self-loading unit which comprises

dowel bar inserter, tie bar inserter, oscillat-ing beam and super

smoother.

1990As the first machine

developed by Wirtgen, the SP 500 is launched

on the market.

1994The SP 250 is a multi-purpose machine used mainly for offset pav-

ing applications.

1999Featuring two track units per machine

only, the SP 1500 L paving train is suitable for two-layer concrete

paving.

2010The multipurpose SP 15 and SP 25

slipform pavers set new standards in the efficiency of inset and

offset applications.

6 //7

1990The SP 850 offers a

variable working width ranging from 2.5 m to

9.0 m.

1997The TCM 850 enables freshly paved concrete

slabs to be cured in order to optimize their

surface finish.

2000The SP 1500 used on motorways and air-

ports can be equipped with dowel bar insert-er, tie bar inserter and finishing equipment.

2013AutoPilot and Field Rover enable most

diverse profile config-urations to be paved in a precise, automated process without using

stringlines.

offSeT SLIPform PaverS In deTaIL

Quick-change artists in concrete paving

8 //9

Slipforming poured-in-place pro-

files is usually more economically

efficient than using pre-fabricated

parts. Compact offset pavers are

generally used for slipforming the

profiles on the left or right side of

the machine. Our slipform pavers

offer a broad range of different

paving moulds in both stand-

ardized or customized designs.

Whether road boundaries, con-

crete safety barriers, canals, water

gutters or narrow paths: profiles

of any conceivable design are

produced quickly and at low cost.

Wirtgen supplies just the right

paving mould for any specified

poured-in-place profile. Continu-

ous, compact and – if required –

reinforced concrete structures are

thus produced, cast into a homo-

geneous whole.

The completed concrete pro-

files are distinctive for their high

stability, extremely low tolerances,

smooth surface and ease of main-

tenance.

The right paving mould for any given profile

offSeT SLIPform PaverS In deTaIL

operating principle and components

Concrete mixers are typically used

to deliver concrete into the slipform

paver’s receiving hopper when

paving in offset application. The

concrete is transported to the offset

mould in a continuous operation

either via a slew able belt conveyor

or via a slewable feeding auger.

Electrically or hydraulically driven

vibrators are installed in the paving

mould in accordance with customer

specifi cations. They are capable of

compacting most diverse grades

of concrete uniformly by means of

high-frequency vibrations. They are

capable of compacting concrete

material of many different grades

uniformly by means of high-fre-

quency vibrations. The paving

mould produces the poured-in-

place profi le while the slipform

paver keeps moving forward at a

continuous advance rate, producing

a concrete structure of uniform,

superior quality and excellent fi nish.

Paving poured-in-place profi les in

narrow bends is no problem at all

thanks to highly accurate levelling

technology and a precise steering

system. In addition, previously laid

steel reinforcement can be directly

included in the paving process

while the paver keeps moving

forward.

from the concrete mixer into the paving mould

TRACK UNITS, FRONTHydraulically driven, separately height-adjustable and steerable track units for precise driving be-haviour and high-precision concrete paving

CONCRETE FEEDING Concrete feeding system in either belt conveyor or auger conveyor design offering various adjustment options for transport of the freshly delivered concrete into the mould

TELESCOPING MACHINE FRAMEMachine frame telescoping in longitudinal and transverse direction to allow full adjust-ment to site conditions

PIVOTING LEGPivoting legs left and right for adjustment of the track units to site conditions

10 //11

OPERATOR’S PLATFORMErgonomically designed, walk-through

operator’s platform for non-tiring, productive working

TRIMMERTrimmer offering various

adjustment options for perfect preparation of the base

POWER UNITHigh-powered, fuel-effi cient diesel

engine for concrete paving in the optimal performance and torque ranges

CROSS-FEEDING AUGERCross-feeding auger to ensure reliable

concrete feeding in diffi cult site conditions

VIBRATORSElectrically or hydraulically driven vibrators to

ensure reliable concrete compaction

OFFSET PAVING MOULDOffset mould suitable for mounting on the left or right side of the paver

and telescoping to both sides

TRACK UNITS, REAROne or two hydraulically driven,

side-moving and height-adjustable track units for optimum adjustment to site

conditions

InSeT SLIPform PaverS In deTaIL

mobile road construction plants

Concrete pavements fully comply

with all expectations in terms of

bearing capacity, robustness and

service life. Inset slipform pavers

are the ideal candidates for an

economically efficient production

of concrete pavements on a large

scale. These mobile concrete

plants are capable of paving

concrete slabs at paving widths of

up to 16.0 m between their track

units. Different, highly effective

curing methods are additionally

available to give the completed

pavement surface the specified

properties. High-quality con-

crete pavements are not prone to

developing wheel ruts or surface

irregularities even after many years

of extensive use.

Slipform pavers are masters in

particular in the economically effi-

cient production of traffic arteries

subject to a high percentage of

heavy traffic, airport runways,

tracks for rail traffic, car parks or

highly stressed industrial surfaces.

Producing durable pavements economically

12 //13


operating principle and components

When paving in inset applica-

tion, the concrete is delivered by

trucks and dumped ahead of the

slipform paver. Depending on the

paver model used, the material is

then distributed evenly across the

full paving width by a spreading

auger or spreading plough. The

robust paving mould slipforms the

concrete pavement while travelling

over the previously distributed

concrete material. Electrically

driven vibrators emitting high-fre-

quency vibrations ensure optimum

compaction of the concrete during

the paving process.

The automated dowel bar inserter

places dowel bars into the con-

crete at specifi able intervals and

parallel to the direction of travel.

The automated tie bar inserter

places central tie bars and side tie

bars into the concrete at speci-

fi able intervals and transverse to

the direction of travel. The inte-

grated oscillating beam and super

smoother then produce an even

concrete surface across the full

width. In a fi nal step, texture cur-

ing machines give the surface the

texture specifi ed in the relevant

tender.

Paving between the track units

SUPER SMOOTHERSuper smoother for a perfectly smooth surface fi nish

TRACK UNITSHydraulically driven, separately height-adjustable and steerable track units for precise driving be-haviour and high-precision concrete paving

TELESCOPING MACHINE FRAMEMachine frame telescoping in longitudi-nal and transverse direction to allow full adjustment to site conditions

PIVOTING LEGPivoting leg for adjustment of the track unit to site conditions

OSCILLATING BEAMEccentrically driven oscillating beam to remove any irregulari-ties in the concrete surface

LONGITUDINAL JOINT TIE BAR INSERTERAutomated insertion of longitudinal joint tie bars to prevent the slabs from drifting apart

14 //15

OPERATOR’S PLATFORMErgonomically designed, walk-through

operator’s platform for non-tiring, produc-tive working

CONCRETE SPREADING Spreading plough or spreading auger to ensure even distribution of the concrete

delivered in front of the inset paving mould

POWER UNITHigh-powered, fuel-effi cient diesel engine for

concrete paving in the optimal performance and torque ranges

VIBRATORSElectrically or

hydraulically driven vibrators to ensure

reliable concrete compaction

INSET PAVING MOULDInset paving mould suitable for

mounting between the track units, underneath the machine

DOWEL BAR INSERTERAutomated insertion of dowel bars to maintain the surface levels of adjacent concrete slabs

SIDE TIE BAR INSERTERAutomated insertion of side

tie bars to enable the paving of adjacent concrete slabs


dual-layer concrete paving with a single paver or paving train

In a fi rst step of the operation, the

SP 1600, which has been equipped

with a supplementary module,

paves a standard concrete slab,

the bottom-layer concrete. An

excavator or other type of con-

crete delivery equipment feeds the

top-layer concrete into the receiv-

ing hopper in front of the SP 1600.

From here it is transported to the

rear of the machine via feeding

conveyors and deposited on top of

the freshly paved bottom layer. The

top concrete layer is then paved

while travelling over the bottom-

layer concrete.

If a paving train – comprising two

each pavers SP 1500 or SP 1500 L

– is used, the fi rst paver paves a

standard concrete slab, the bot-

tom-layer concrete. An excavator

or other type of concrete delivery

equipment feeds the top-layer

concrete into a receiving hopper.

From here it is passed onto a trans-

port conveyor which conveys the

top-layer concrete over and across

the bottom-layer paver to depos-

it it on the freshly paved bottom

layer ahead of the second paver.

The top-layer paver then paves the

material right on top of the bottom

concrete layer.

dual-layer paving in a single pass

Slipform paver fortop concrete layer

Topconcrete layer

Dumpedmaterial for topconcrete layer

Bottomconcrete layer


Delivery hopper fortop-layer concrete


Topconcrete layer

Inset pavingmould for top-layer concrete

Working direction

Working direction

Two-layer concrete paving with one single slipform paver

Two-layer concrete paving with two slipform pavers

16 //17

Slipform paver forbottom concrete layer

Beltconveyor

Beltconveyor

Receiving hopperfor top-layer concrete

Receiving hopperfor top-layer concrete

Inset pavingmould for bottom-layer

concrete

The continuous delivery of homo-

geneous concrete material is of vi-

tal importance for paving all kinds

of concrete profiles. Belt con-

veyors are ideal for offset paving

because they are easily cleaned

and impress with low wear and

tear, whereas auger conveyors mix

the concrete once again during

transport to the paving mould. The

auger conveyor can additionally

be adjusted to a steeper incline.

The cross-feeding auger is useful,

for instance, when the mould is

mounted far to one side of the

machine frame and the concrete

mixer and paver must travel in one

lane. In this case, the concrete is

delivered to the belt conveyor or

auger conveyor, forwarded to the

cross-feeding auger and trans-

ported into the offset mould.

Users can choose between a

spreading auger or spreading

plough to ensure even distribution

of the concrete across the paver’s

full working width when paving in

inset application.

Tried-and-tested solutions

LeaderShIP In TechnoLogy

concrete feeding to perfection

18 //19


fully automatic insertion of steel reinforcement

concrete armoured with high-tech

An exceptionally high degree of

intelligent engineering has gone

into our integrated high-tech com-

ponents for the insertion of steel

reinforcement. The fully automated

units insert dowel bars and tie

bars of any length into the freshly

paved, pre-compacted concrete

at specifiable intervals. Insertion of

the dowel bars parallel to the ma-

chine’s direction of travel is char-

acterized by an exceptionally high

degree of efficiency: to ensure

the slipform paver’s continuous

forward movement, the dowel bar

inserter is movable and stays in

place during insertion of the dowel

bars until the operation has been

completed. Dowel bars ensure

both the surface levels of adjacent

concrete slabs and the transmis-

sion of shear forces from one slab

to the next. The longitudinal joint

tie bar inserter inserts tie bars as

reinforcement transverse to the

paving direction. Tie bars prevent

the slabs from moving apart. The

side tie bar inserter inserts tie bars

in the side of the concrete slab.

They allow the paving of adjacent

concrete slabs.

20 //21


Perfectly smooth surface finish

We rely on a whole series of

technical refinements to give the

surface of concrete pavements a

perfect surface finish.

The eccentrically driven heavy-

duty oscillating beam is moved

back and forth transverse to

the direction of travel, removing

surface irregularities caused by,

for instance, the insertion of dowel

bars. It is followed by the super

smoother which is manufactured

from high-quality material and car-

ries out an oscillating, combined

longitudinal and transverse move-

ment to level out all remaining

irregularities in the upper portion

of the concrete slab.

The combination of dual, hydrau-

lically adjustable sideplates and

dual trailing and deep paving

mould provides clean finished

edges while at the same time

guaranteeing a smooth work

process.

evenness improves riding quality

22 //23


effective curing

anti-skid surface,optimal hardening

Concrete needs to be protected

against premature drying during

the hydration process to prevent

stresses from occurring that can

lead to excessive cracking. The

texture curing machine is therefore

equipped with an automatic spray-

ing and brooming unit, following

right behind the slipform paver

during the paving operation.

The concrete slab is given the

specified texture by moving a

broom across the entire concrete

surface. The spraying unit sub-

sequently applies a thin film of

curing compound on the freshly

paved concrete surface to prevent

premature evaporation.

Depending on tender specifica-

tions, the texture curing machine

can guide a broom, burlap or artifi-

cial turf across the moist concrete

surface to produce the specified

skid resistance. Washed concrete

is increasingly applied as an alter-

native technology.

24 //25


Intelligent machine control

26 //27

Wirtgen offers a range of different

machine control systems to cater

to different user needs. High-pre-

cision sensors can be installed at

the slipform paver, for example, to

scan previously tensioned string-

lines. The stringless 3D levelling

system offered by Wirtgen oper-

ates in an even higher efficiency

class. In this process, a total

station uses a laser beam to con-

tinuously track a prism mounted

on the slipform paver, reconciling

the measured data with a geodetic

terrain model to ensure concrete

paving to pinpoint accuracy.

The ultimate solution is offered by

the proprietary, low-cost AutoPilot:

time-consuming surveying, instal-

lation and removal of stringlines or

the preparation of a geodetic data

model are not required. Instead,

the innovative “Field Rover” prism

pole and special software are

used to calculate a precise virtual

stringline right on site which is

imported into the control system.

Precision in paving guaranteed


Professional expertise for complex concrete paving operations

Slab track and tunnel construction

Wirtgen has played a key role in

developing the so-called “slab

track” construction method. In

this process, the slipform paver

produces a concrete slab with

a specified cross-section that

needs to adhere to requirements

with pinpoint accuracy. The “slab

track” can be produced in any

given shape, serving as a stable

foundation for high-speed trains

– a means of transport that is

becoming increasingly important.

High-speed trains generate ex-

tremely high forces acting on the

rail system, which is why the rails

are embedded in concrete rather

than in “loose” ballast. Compelling

marks in favour of the non-bal-

lasted type of construction are

durability, strength, precise rail po-

sitions, reduced noise emissions

and ease of maintenance.

Wirtgen has many years of ex-

perience also in paving concrete

floors in tunnels where space is

extremely limited. In such projects,

the machine setup is customized

to precisely fit these specific, chal-

lenging application requirements.

28 //29

ProducT PorTfoLIo

Strong paving team covering all working widths

catering to all standard and special applications

Wirtgen’s comprehensive prod-

uct portfolio comprises twelve

slipform paver models across

all performance classes and for

all applications in high-precision

concrete paving. Standard paving

widths range from 1.0 m to 16.0 m

at standard paving thicknesses

of up to 450 mm. Concrete safety

barriers for impact protection on

motorways can be produced at

standard heights of up to 2.2 m.

Larger paving parameters can be

realized in accordance with cus-

tomer requirements.

In addition to the comprehensive

array of concrete pavers, Wirtgen

offers two texture curing machines

and one side feeder model to

guarantee perfect paving results.

Metric and imperial paving moulds

in standard design or built to cus-

tomer specifications are available,

enabling customers to comply

with specific national standards

and guaranteeing an extensive

range of applications.

30 //31

SP 15 SP 15 i SP 25 SP 25 i SP 500 SP 82 i

SP 84 i SP 850

TCM 950

SP 1200

TCM 1800

SP 1500 SP 1500 L SP 1600

ISF 850

manufacTurIng TechnoLogy

State-of-the-art manufacturingprocesses for highly durable machines

Mature manufacturing processes,

manufacturing-related know-how,

customized products, extensive

quality testing and employees

working on their own initiative

– these are the cornerstones of

Wirtgen’s slipform paver produc-

tion hub in Windhagen, Germany.

Our high standards are reflected

in the modern, computer-con-

trolled production equipment,

high degree of vertical integration

and highly qualified workforce.

In-house production of a large

number of equipment features

and special components allows

many different, customer-specific

equipment combinations. The use

of high-quality materials ensures

the smooth functioning and long

life of our machines.

Our success proves us right:

each single machine leaving our

production facilities is of superior

technical quality.

We putquality first

32 //33

reLIabLe cuSTomer ServIce

Worldwide service networkmakes the difference

experts appreciate ourcustomer focus

Wirtgen combines mature,

innovative technology with an

extensive, global service network

of highly competent subsidiaries,

sales partners and dealers. This

combination guarantees that our

customers get real added value

– around the globe, around the

clock. For our customers, opti-

mum service reads: short delivery

times for machines, spare parts

and wearing parts, as well as

comprehensive parts inventories,

qualified technial support, demon-

strations by qualified local person-

nel, and trainings at the custom-

er’s location.

Experienced service technicians

from Wirtgen accompany the pro-

ject, providing support as required.

Our service engineers are experts,

fully equipped with modern tools

and fully familiar with Wirtgen’s

entire product portfolio. They can

be contacted around the clock,

guaranteeing that parts on order

can be delivered immediately.

34 //35

In oPeraTIon around The gLobe

Wirtgen slipform paversare conquering the world

Following acquisition by Wirtgen, it doesn’t take long for the

technology to be bearing the hallmarks of a world-leading

construction equipment manufacturer. For the concrete slip-

form paver business is quick in conquering the world market:

a large customer base is established not only in Central Eu-

rope, but also in Eastern Europe and many countries across

Asia. In recent years, our machines have found a market in

North America as well. Wirtgen slipform pavers are in opera-

tion around the globe, having earned their merits in particular

on account of their extremely long service life: quality “made

in Germany” has become the hallmark of our machines.

Successful market expansionin all parts of the world

36 //37

Stat

e-of

-th

e-art e

ngine technology

Sta

te-o

f-th

e-ar

t mac

hine

co

ntro

l

Anti-vibration engine support

Sound

proofi ng

redu

ces

ex

haust

and noise emissions

redu

ces

exha

ust a

nd n

oise

em

issi

ons

reduces vibration and noise emissions

r educes noise em

issions

envIronmenTaL SuSTaInabILITy

We face up to the challengeof environmental protection

environmentallyfriendly machinetechnology

Wirtgen expressly commits to

protecting the environment, to

manufacturing safe and environ-

mentally compatible machinery,

and to developing more ecologi-

cally sustainable technologies and

products.

Slipform pavers are energy-ef-

fi cient machines with low fuel

consumption and simultaneously

low exhaust emissions. Slip-

form pavers are, in turn, used to

produce highly durable concrete

pavements and profi les. The long

period between new construction

and reconstruction or rehabilitation

respectively greatly benefi ts our

environment from an ecological

viewpoint: its positive results are

lower emission levels, reduced

energy requirements, and the non-

use of valuable natural resources.

Slipform paving minimizes dis-

ruptions to traffi c, which reduces

strain on the environment. Con-

crete pavements offer reduced

rolling resistance, which in turn

reduces the fuel consumption of

vehicles.

Wirtgen concrete paving

saves natural resources

Stat

e-of

-th

e-art e

ngine technology

Sta

te-o

f-th

e-ar

t mac

hine

co

ntro

l

Anti-vibration engine support

Sound

proofi ng

redu

ces

ex

haust

and noise emissions

redu

ces

exha

ust a

nd n

oise

em

issi

ons

reduces vibration and noise emissions

r educes noise em

issions

38 //39

Wirtgen concrete paving

saves natural resources

Wirtgen GmbHReinhard-Wirtgen-Str. 2 · 53578 Windhagen · Germany

Phone: +49 (0) 26 45 / 131-0 · Fax: +49 (0) 26 45 / 131-392Internet: www.wirtgen.com · E-Mail: [email protected]

Illustrations and texts are non-binding and may include customized fittings. Subject to technical changes.Performance data depend on operational conditions. No. 2176308 01-73 en-10/14 © by Wirtgen gmbh 2014. Printed in germany

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