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Meet the Wirtgen W 380 CRi Cold Asphalt Recycler, a machine that removes, crushes, mixes, and prepares old asphalt for reapplication in a single operation, recycling 100% of the material on-site.
The Wirtgen W 380 CRi Cold Asphalt Recycler represents a cutting-edge solution for pavement rehabilitation, combining high performance with sustainability. This equipment is designed for a complete in situ process: it removes the existing asphalt, crushes it, mixes it with new binding agents, and prepares it for reapplication, all in one operational pass, allowing for total recycling of the material.
With a mixing capacity of up to 800 tons per hour, the W 380 CRi is a breakthrough in efficiency and productivity, offering significant economic and environmental benefits for road infrastructure maintenance.
Wirtgen W 380 CRi and the Revolution in Sustainable Road Rehabilitation
The growing demand for sustainable and economically viable road maintenance solutions has driven the Cold In-Place Recycling (CIR) technology. The Wirtgen W 380 CRi is a prominent example of this advanced machinery, capable of fully reusing the materials of the existing pavement. This process minimizes environmental impact and associated costs, positioning itself as a strategic response to global pressures for greener and more economical infrastructure development.
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Inside the Giant: Specifications and Technology of the Wirtgen W 380 CRi
The Wirtgen W 380 CRi Cold Asphalt Recycler integrates power with sophisticated control. Its length is approximately 18.5 meters, and the often-mentioned “30-meter length” refers to the complete operational recycling train (recycler, binder/water trucks, paver, and rollers). The machine features a Caterpillar C27 ATAAC engine with 1038 HP (775 kW), meeting EU Stage 5 / US EPA Tier 4f emission standards. It offers working widths of up to 3.8 meters and depths of up to 350 mm.
Innovative technologies are crucial to its performance. The robust milling and mixing rotor features the MCS EXTEND system for variable working widths. High-precision injection systems for water, bituminous emulsion, or asphalt foam (with VARIO bar) ensure mixture quality. The renowned LEVEL PRO leveling system automatically adjusts height, depth, and slope for precise results. The operator platform is ergonomic, with excellent visibility and a camera system.
The Cold In-Place Recycling (CIR) Process with the Wirtgen W 380 CRi
The Wirtgen W 380 CRi Cold Asphalt Recycler executes the core recycling steps in a coordinated flow. The process begins with the milling and mixing rotor disaggregating the damaged pavement. Immediately afterward, the milled material (RAP) is transported to the mixing chamber, where it is homogeneously mixed with selected binders (cement, bituminous emulsion, or asphalt foam) and water.
After mixing, the recycled material is generally discharged via conveyor belts into the silo of a paver (e.g., Vögele SUPER 2000-3i) that follows the recycler. Maximum efficiency is achieved with a synchronized “recycling train,” which includes water and binder trucks, the W 380 CRi, the paver, and compactors (e.g., Hamm HD+ 140 VV-HF). The “single pass” refers to the continuous transformation of the old pavement into a new recycled base layer.
Economic and Environmental Advantages of the Wirtgen W 380 CRi Cold Asphalt Recycler
The CIR technology facilitated by the Wirtgen W 380 CRi Cold Asphalt Recycler offers multiple benefits. The CIR improves pavement longevity by eliminating existing defects and creating a stable base layer, mitigating crack reflection. Economically, the reuse of 100% of the material on-site drastically reduces costs for virgin aggregates and transportation, with potential savings of 20% to 50% compared to conventional methods.
The speed of the single pass process accelerates project timelines, minimizing traffic disruption and associated social costs. Environmentally, cold recycling conserves natural resources and significantly reduces energy consumption (up to 63% less) as it does not require heating materials. Consequently, the carbon footprint and atmospheric pollutant emissions are substantially lower.
Global Applications and the Relevance of the Wirtgen W 380 CRi for Brazil
The versatility of the Wirtgen W 380 CRi Cold Asphalt Recycler has been demonstrated in various global projects. A notable example was in the Full Depth Reclamation (FDR) of Highway 123 in South Carolina, USA. The machine recycled the pavement to a depth of 20 cm, mixing it with asphalt foam and cement, achieving a production rate of 427 metric tons per hour. The W 380 CRi can also be converted and used as a high-performance cold planer, maximizing its utilization.
Considering Brazil’s extensive road network and the need for sustainable rehabilitation, CIR technology and machines like the W 380 CRi have great potential in Brazil. The Wirtgen Group has an established presence in the country through CIBER Rodoviary Equipment in Porto Alegre (RS), which offers equipment, technical support, and training, facilitating the adoption of these advanced technologies.
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