Cold recycler 3800 CR
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High-quality in-place recycling of asphalt layers

Recycling of traffic lanes at full width in a single pass Flexible concept to ensure optimum machine utilization It is quite obvious that the 3800 CR is capable of recycling 3.8 m wide traffic lanes seamlessly in a single pass: the powerful recycler mixes damaged asphalt layers with binders to convert them into high-quality, pre-compacted base layers quickly and with economic efficiency while at the same time minimizing disruptions to traffic. Different injection systems give the cold recycler superior flexibility. In addition, it offers an unparalleled range of equipment features enabling...

Two cold recycling options using a single machine Recycling train including the 3800 CR (up-cut / down-cut): Where specified, cement is pre-spread by a Streumaster binder spreader which is followed by a water tanker and binder tanker truck. The milling and mixing rotor granulates the asphalt layers to a depth of up to 15 cm. The pre-spread cement is mixed in at the same time while water and bitumen emulsion or foamed bitumen are injected into the mixing chamber via injection bars. The recycled material is spread across the entire working width by a spreading auger and placed true to line...

Compact recycling train ideally suited for working in urban environments. Short material handling times for ease of operation and full control of the work process. Simple modification allows recycling in up-cut or down-cut mode. The 3800 CR can also be used as a cold milling machine (with conveyor system). Reduced labour requirements. Working direction Optimum material management thanks to flexible loading concept enables paving true to line and level. State-of-the-art Vögele paving technology for highest quality standards. High compaction thanks to the paver’s tamper and pressure bar. The...

Perfectly engineered milling and m ­ ixing rotor for the tough jobs Recycling in or against the direction of travel The 3.8 m wide, robust milling and mixing rotor is based on the many decades of experience Wirtgen has gained in milling technology. Whether working in the conventional up-cut mode with the rotor revolving against the direction of travel, or in down-cut mode with the rotor revolving in the direction of travel: the powerful rotor mixes the different materials to produce a homogeneous construction material. The state-of-the-art down-cut process enables precise particle size...

Up-cut process The milling and mixing rotor works against the recycler’s direction of travel. Down-cut process The milling and mixing rotor works in the recycler’s direction of travel. This process optimizes particle size and prevents the material from breaking into larger chunks.

Innovative injection systems for highly precise binder addition A great variety of mixing options As binders need to be added in precise quantities to produce perfect mixes and base layers of high quality, the 3800 CR is equipped with state-of-the-art injection systems. Tanker trucks pushed by the 3800 CR deliver water and bitumen emulsion or hot bitumen to the recycler’s injection systems via coupled hose connections. Hot b ­ itumen is foamed prior to injection. Foamed bitumen is produced by adding precisely metered quantities of water and compressed air to hot bitumen which has a...

Foamed bitumen production Air Expansion chamber with foam nozzle Foamed bitumen The binder quantities to be added are keyed in at the control panel – the system is governed by microprocessors. All high-tech: electrically heated bitumen-carrying components, non-contact flow meters and self-cleaning injection nozzles.

State-of-the-art cold recycling – here’s how it works Material processing with the 3800 CR (up-cut / down-cut) Damaged asphalt layer Pre-spread cement Injection bars for water and binding agents Milling and mixing rotor Material guide plate system Spreading auger Paving screed Paving by means of an integrated paving screed The heavy-duty milling and mixing rotor – the heart of the 3800 CR – granulates the existing damaged asphalt pavement to a depth of up to 15 cm. The granulated material is then mixed with injected binding agents and water in the machine’s mixing chamber, thus creating a...

Material processing with the 3800 CR “Rear Load” (down-cut) Damaged asphalt layer Pre-spread cement Injection bars for water and binding agents Milling and mixing rotor Conveyor for material transfer to asphalt paver Paving by means of a separate asphalt paver The heavy-duty milling and mixing rotor granulates the existing damaged asphalt pavement to a depth of up to 18 cm. The granulated material is then mixed with injected binding agents and water in the machine’s mixing chamber, thus creating a new homogeneous mix in an in-situ process. Ejectors on the milling and mixing rotor then...

State-of-the-art screed for high-quality paving 3.8 m wide paving unit with h ­ igh-compaction Vögele paving screed and spreading auger. Paving true to line and level The 3800 CR relies on tried-andtested Vögele technology to guarantee perfect paving of the mix true to line and level. The continuously adjustable AB 375 T screed makes paving easy even in bends or when having to navigate permanent fixtures. A sensor-controlled spreading auger installed in front of the screed distributes the mix evenly across the entire working width. The centrally divided auger is operated in clockwise or...

Reliable material loading even under full load In rear-loading mode, the powerful conveyor transfers the mix to an asphalt paver. The discharge conveyor fills the paver’s material hopper at adjustable belt speeds. Flexibility comes as a standard feature The 3800 CR has been designed for maximum performance and is therefore equipped with a powerful conveyor system offering exceptionally high conveying capacities. The slewing and height-adjustable discharge conveyor enables huge amounts of material to be moved quickly and with maximum flexibility. When cold recycling in rear-loading mode, the...