Wirtgen Group is redefining small-scale road repairs with precision, efficiency, and sustainability. This report explores how its compact machines deliver seamless, zero-emission results
Small milling machines, MINI class pavers, and compact rollers work seamlessly together for small-scale repair projects, delivering high-quality results with zero operating emissions. These machines are ideal for working in confined spaces, ensuring long-term structural integrity in various applications.
On small project sites, whether dealing with minor repairs or addressing localised surface damage, maintaining top-tier quality remains essential. The Wirtgen Group provides a range of machines designed for application-specific efficiency and cost-effectiveness. Alongside Wirtgen’s small milling machines, this lineup includes Vögele’s MINI class pavers and Hamm’s compact rollers.
Permanent repair solutions
Common applications include small-scale maintenance in road construction, such as removing markings, working around road fixtures, milling gutters and slots, and repairing surfaces in active traffic areas. These machines also support the construction of cycleways, footpaths, farm tracks, car parks, and sports facilities. Their versatility extends to filling sewer trenches, paving industrial floors, and working in underground parking structures, as well as gardening and landscaping projects. Compact machines are particularly effective for time-sensitive repair and maintenance work, delivering durable results.
High-performance machines
Wirtgen’s small milling machines range from the compact W 35 Ri to the half-metre class W 50 Ri and the 1-metre class models. Despite their size, these machines offer impressive daily productivity, efficiently removing surface layers or milling multiple layers at once. The W 120 Ri rear loader, for instance, can remove complete asphalt packages up to 30 cm deep and 1.2 m wide.
Their efficiency is enhanced by single-handed operation, high travel speeds of up to 12 km/h, and the FCS quick-change system, which allows for rapid drum replacement with different widths and tool spacings. This enables both standard and fine-milling applications. Exceptional maneuverability allows precise milling around manhole covers and other tight spaces.
Compact paving solutions
For sites with restricted space or low headroom, Vögele’s smallest pavers—MINI 500, MINI 502, SUPER 700i, and SUPER 800i—provide paving widths from 0.25 m to 3.5 m, reducing manual labour while increasing efficiency. These machines enable contractors to execute small projects with greater convenience, precision, and cost-effectiveness.
Vögele’s Compact Class pavers are also suitable for small to medium-sized projects. Depending on the model, machines such as the SUPER 1000i, SUPER 1003i, SUPER 1300-3i, and SUPER 1303-3i can achieve paving widths ranging from 0.75 m to 5.00 m.
Versatile compaction machines
Hamm’s HD CompactLine tandem rollers, with operating weights between 1.5 t and 4.5 t, are highly adaptable for road and pathway construction, as well as landscaping. These rollers efficiently compact crushed stone, frost protection layers, base materials, and asphalt surfaces. Depending on the material and required compaction depth, contractors can select vibration, oscillation, or combination rollers for optimal results.
Hamm also offers electric rollers for zero-emission operation. The HD 10e and HD 12e models (drum widths: 1 m and 1.2 m, respectively, with operating weights of 2.5 t and 2.7 t) match the compaction performance of traditional combustion-engine models. Their operating system mirrors that of other HD CompactLine rollers, ensuring ease of use.
Innovative asphalt options
Using coloured asphalt enhances sustainability and aesthetics. Colourless bitumen, a mineral oil-based synthetic binder, allows for the integration of pigments. This approach enables urban planners, landscape designers, and construction firms to create unique paving effects for intersections, traffic guidance, and decorative landscaping. Small machines facilitate the efficient and precise application of colored asphalt.
Zero-emission construction
Municipal construction projects increasingly require sustainable solutions, and investors demand environmentally friendly execution. Contractors, too, are setting their own sustainability targets. The Wirtgen Group now offers a modular, end-to-end system that enables road construction projects to be completed with zero operating emissions. This fully integrated solution ensures operational reliability and seamless machine-to-machine coordination.
At the core of this system is a battery-electric drive concept, which can be expanded with additional modules. In road construction, this technology is exemplified by the Wirtgen W 50 Re milling machine, the Vögele SUPER 1300-5e paver, and the Hamm HX 70e tandem roller. These machines allow road rehabilitation projects to be completed with zero emissions.
This production system is designed for scalability. The Benninghoven MULTI JET burner, powered entirely by green hydrogen, is the first of its kind to achieve asphalt production without CO₂ emissions. Additionally, the Kleemann MR 100i NEOe mobile impact crusher enables the sustainable processing of milled material, allowing it to be reused in new asphalt mixes. The system can run exclusively on electric power from an external grid. If grid power is insufficient, it can also operate using a low-emission diesel-electric system powered by HVO100.
Wirtgen's compact machines redefine road repairs
Wirtgen Group advances zero-emission road repairs with efficient, high-performance milling, paving, and compaction solutions. (Image source: Wirtgen Group)
