Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 1 of 83 PageID #:
`14206
`
`Exhibit T
`Part 1 of 2
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 2 of 83 PageID #:
`14207
`
`/~
`WIRTGEN
`GROUP
`\~
`
`Manual
`For The Application Of
`Cold Milling Machines
`
`Edition: January 2004
`
`Wirtgen EX2009 - Part 1 of 2
`Caterpillar v. Wirtgen
`IPR2018-01091
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 3 of 83 PageID #:
`14208
`
`~
`WIRTGEN
`GROUP
`~
`
`2
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 4 of 83 PageID #:
`14209
`
`Preamble
`
`The well-known statement that "the road network of the Federal Republic of Germany has been
`completed to a large extent " applies to new construction only. This sentence is not true with regard
`to the performance and maintenance condition of the existing road network as, due to stress, the
`road network is subject to constant wear and tear, which increases disproportionately with a growing
`percentage of trucks in the total traffic load. In the future, more and more new construction work will,
`therefore, be replaced by maintenance work. Gradually, this also becomes known to wider sections
`of the public.
`
`The changes resulting from the above mentioned shifting of funds in road construction will affect not
`only construction engineering but also the construction machines used, and powerful and
`economical cold milling machines equipped with options tailored to the requirements of maintenance
`projects will be the focus of interest more than ever.
`
`Windhagen (Germany), January 2004
`
`Feedback to:
`Dieter Simons
`Wirtgen GmbH
`Hohner StraBe 2
`D-53578 Windhagen
`Germany
`
`E-mail: engineering@wirtgen.de
`Phone: +49 (0) 26 45/131-147
`Fax: +49 (0) 26 45 /131-313
`Internet: www.wlrtgen.de
`
`3
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 5 of 83 PageID #:
`14210
`
`~
`WIRTGEN
`GROUP
`~
`
`Table of Contents
`II Introduction
`
`Goals of road maintenance
`Traffic safety, riding quality, environmental protection, protection of assets, objective
`
`El
`II
`
`Methods
`Cold milling, standard milling, fine milling, features
`
`Principles and requirements of milling
`Base, milling depth, surface structure and structural depth, evenness, etc.
`
`6-7
`
`8-13
`
`14-1 9
`
`20-27
`
`Benefits of cold milling
`The benefits of small and large milling machines with regard to application technology and profitability
`
`28-33
`
`Selection and use of equipment
`Small milling machines, large milling machines, features of the different milling machine types
`with regard to application technology
`
`II
`
`Applications of small milling machines
`Patching, repairing small areas, replacing pavements, milling around manhole covers, etc.
`
`Applioations of large milling machines
`Large-scale removal of road pavements, milling surface courses, complete road structures
`
`Calculating the milling performance
`Large and small milling machines
`
`Flexible Cutter System (FCS)
`The versatile quick-change system for milling drums
`
`4
`
`34-43
`
`44-73
`
`7 4-95
`
`96-103
`
`104-111
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 6 of 83 PageID #:
`14211
`
`~
`WIRTGEN
`G R OUP
`~
`
`An economical method for the rehabilitation of road pavements
`
`Toolholders, wear and tear patterns, recommendations for use
`
`m Fine milling
`m Cutting tools and tool systems
`Dl Levelling systems
`
`An overview of the different levelling systems
`
`Special applications
`Surface mining, cold recycling
`
`112-123
`
`124-1 37
`
`138-151
`
`152-163
`
`5
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 7 of 83 PageID #:
`14212
`
`~
`WIRTGEN
`G ROUP
`~
`
`4 w jrtgen
`
`Introduction
`
`The significance of cold milling for road pavement rehabilita
`
`Many objectives of modern road maintenance, such as the preservation of traffic safety, riding quality
`and environmental protection, can be achieved by the use of modern milling technologies.
`Besides reinforcing the upper pavement structure, maintenance construction is often specially aimed
`at improving the surface condition of the road pavement in question.
`
`Some examples:
`
`• Improving the skid resistance.
`• Levelling longitudinal as well as transverse irregularities in evenness.
`• Removing bitumen oxidation and cracking of the surface course.
`
`In recent years, the "Forschungsgesellschaft fUr StraBen- und Verkehrswesen" (Research Institute for
`Roads and Traffic) has published additional technical contract conditions and specifications for the
`structural maintenance of traffic areas, which are to be included in the construction contracts. These
`new additional technical contract conditions and specifications present a good overview of the main
`construction methods in road maintenance.
`
`These new additional technical contract conditions and specifications for the maintenance of traffic
`areas concern the partial or complete production of new pavement layers. Although milling off
`pavement layers does not produce new pavements, the milling procedure itself is of great significance
`for the quality of a new, thin pavement layer and has therefore been categorised as an "auxiliary
`construction method", regulated in a special information leaflet published in the year 2000.
`
`Many maintenance construction methods require the specific removal of the existing surface and
`binder courses. The previously common method of reclaiming the complete asphalt package in the
`form of slabs must be ruled out, since it results in a mix of different kinds and types of asphalt, thus
`standing in the way of a re-use of the reclaimed material at a high construction engineering standard.
`The asphalt layers should, therefore, always be reclaimed by milling.
`
`Nevertheless, it could not be prevented in the past that damages occurred in the upper pavement
`structure due to extreme traffic loads, which in asphalt construction showed as deformations, wear
`and tear or cracking. Especially deformations in the form of ruts or transverse corrugations impair the
`riding quality and are a traffic hazard in wet conditions. Cracking of the surface course leads to a
`reduced service life of the entire upper pavement structure.
`
`The upper layers of the pavement structure are particularly affected by stress due to climatic
`influences or effects from the traffic load. Wheel loads and their resulting compressive, tensile and
`shear stresses are deflected via the surface and binder courses into the base course of the road
`structure without causing any damage.
`In the medium term, however, damages in the uppermost layer are frequently the cause of serious
`damage patterns in the entire road structure. Cracks in the surface course can, for instance, promote
`the penetration of water, which will then expand when freezing and lead to cracking in the subgrade.
`
`6
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 8 of 83 PageID #:
`14213
`
`~
`WIRTGEN
`GROUP
`~
`
`# wirtgen
`
`Maintaining the surface course is, therefore, very important when it comes to maintaining the quality
`of the road structure as a whole.
`
`If the old base is too uneven, too smooth or excessively oxidised, milling is often a prerequ isite for
`placing thin pavement layers in hot or cold application. It is, for example, recommended to order
`additional measures, such as fine milling, in case the unevenness of the base exceeds 10 mm. Only
`then will it be possible to make demands with regard to the evenness of the completed layer.
`
`Surface courses with an insufficient load-bearing capacity must be milled oft prior to placing an
`overlay in order to prevent them from being exposed to increased shear stresses.
`Layers of road construction materials containing tar can also be specifically reclaimed by milling for
`separate stockpiling and re-use.
`
`An overview of damage characteristics and their effects
`
`Action
`
`Rehabilitation
`
`7
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 9 of 83 PageID #:
`14214
`
`~
`WIRTGEN
`G R OUP
`~
`
`8
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 10 of 83 PageID #:
`14215
`
`~
`W IRTGEN
`G R OUP
`~
`
`2. Goals of road maintenance
`
`2.1 Traffic safety
`
`2.2 Riding quality
`
`2.3 Environmental protection
`
`2.4 Protection of assets
`
`2.5 Objective
`
`10
`
`10
`
`11
`
`11
`
`11-12
`
`9
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 11 of 83 PageID #:
`14216
`
`~
`WIRTGEN
`GROUP
`~
`
`2. Goals of road maintenance
`
`The primary goal of road maintenance is to ensure an optimum road condition for the road user,
`allowing safe and comfortable driving and a smooth flow of traffic under all weather conditions.
`
`Regular road maintenance results in:
`
`• High traffic safety
`• Good riding quality
`• Environmental protection
`• Protection of assets
`
`2.1 Traffic safety
`
`The highest priority must be placed on the traffic safety. It is primarily influenced by road damages
`occurring in the form of deformations or wear and tear. Wear and tear affects the evenness and skid
`resistance of a road surface.
`
`Deformations occur in the form of shear or settlement deformations. They impede a swift drainage of
`the surface water, which leads to aquaplaning with an increased risk of skidding and to longer
`braking distances. Shock loads of the car and the road pavement lead to additional noise emissions.
`
`Rutting
`
`2.2 Riding quality
`
`The riding quality influences the driving behaviour of the road users, the flow of traffic and the traffic
`safety. Decisive factors are the quality of the longitudinal and transverse evenness as well as the
`properties of the pavement (roughness, potholes, optical properties). A poor riding quality has adverse
`effects on the traffi c safety, the driving behaviour and the flow of traffic.
`
`10
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 12 of 83 PageID #:
`14217
`
`~
`W IRTGEN
`GRO UP
`~
`
`Jiwjrtgen
`
`2.3 Environmental protection
`
`Increasing significance is attached to the protection of the environment with respect to rolling noise
`emissions and the formation of wheel spray. Typical disruptive factors are roughness, transverse
`unevenness and potholes.
`
`Cracks in a surface course
`
`2.4 Protection of assets
`
`Considerable assets are tied up in the road network, making it very important from an economical
`viewpoint to maintain these assets as long as possible. Pavement damages, such as cracks and
`potholes, ravelling or flaws resulting from the construction technology, will invariably lead to larger
`damages or even to the destruction of the entire road structure.
`
`The effects:
`• Considerably higher rehabilitation costs when compared to a "preventive" repair of the
`damage.
`• High indirect costs (from an economical viewpoint) due to a poor flow of traffic, accidents
`and increased fuel consumption.
`
`2.5 Objective
`
`The goals set for road maintenance can be fully achieved by way of suitable rehabilitation measures,
`either by restoring the properties of the upper pavement structure, such as stability, evenness, level
`profile and skid resistance, or by improving them in accordance with the new requirements.
`
`11
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 13 of 83 PageID #:
`14218
`
`~
`WIRTGEN
`GROUP
`~
`
`The choice of the method being most beneficial from a technological and economical point of view de(cid:173)
`pends upon the type of damage, its cause and also the requirements that will be placed on the new
`layers.
`
`In case of deformations, it must be established as to whether these are limited to the surface course,
`or whether underlying layers have already been affected. If the damage extends into these deeper
`layers, the rehabilitation measures must include a strengthening of the damaged layers, i.e. their load(cid:173)
`bearing capacity must be increased. If only the surface course is affected, a rehabilitation of this layer
`will be sufficient.
`
`Wear and tear in the form of abrasion and ravelling is limited to the surface. In this case, a treatment or
`an improvement of the surface area (surface course) will be sufficient.
`
`Cracks occur in the form of alligator cracking, transverse or longitudinal cracks. Whilst alligator
`cracking and transverse cracks are mostly limited to the surface course, longitudinal cracks often
`extend into deeper layers. Cracks allow the penetration of water and dirt, thus inevitably leading to t he
`destruction of these layers. A timely treatment of cracked layers is, therefore, absolutely essential.
`
`Economical construction methods have been developed for these problems in asphalt road
`construction. Milling is one of these methods, whereby damaged asphalt layers are removed using the
`appropriate machines. One or more new layers are then placed on top of these bases produced by
`milling.
`
`12
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 14 of 83 PageID #:
`14219
`
`~
`WJRTGEN
`GROUP
`~
`
`13
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 15 of 83 PageID #:
`14220
`
`~
`W IRTGEN
`GROUP
`~
`
`14
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 16 of 83 PageID #:
`14221
`
`~
`WIRTGEN
`GROUP
`~
`
`3. Methods
`
`3.1 The cold milling method
`
`3.2 Standard milling
`
`3.3 Fine milling
`
`3.4 Features
`
`16
`
`17
`
`17
`
`18-1 9
`
`15
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 17 of 83 PageID #:
`14222
`
`~
`W IRTGEN
`GROUP
`~
`
`3. Methods
`
`3.1 The cold milling method
`
`Cold milling has generally been accepted as being the state of the art. Other methods are of minor
`importance and are typically only used as a supplementary method to milling.
`
`Cold milling can be carried out on both, asphalt and concrete surfaces. The surface to be milled must
`not contain steel inlays. Surfaces containing plastic or fibre inlays can only be milled at higher costs.
`The process is almost independent of weather conditions.
`
`A large milling machine milling an asphalt pavement
`
`Cold milling machines are very compact, mobile machines. They are easily manoeuvred even on
`narrow or w inding surfaces. The design of the milling machine itself and the casing of the individual
`aggregates ensure that the inevitable noise emission during the milling operation is reduced to an
`absolute minimum.
`
`The machine travels over the pavement to be milled, whereby the rotating milling drum is lowered in
`accordance with the required milling depth, scarifying the material. The milling drum can be lowered
`either parallel or in a specific incline to the pavement surface. The machine travels on either wheels or
`crawler track units and has an infinitely variable drive system. During the milling operation, a milling
`depth control unit regulates the pre-set milling depth in relation to the reference height.
`
`The achievable milling performance (speed x milling width x milling depth) basically depends upon the
`capacity of the milling machine used and upon the road construction material to be milled. Depending
`upon the construction method or requirement, the material recovered by cold milling (reclaimed
`asphalt pavement) can be loaded on trucks using the machines' own conveyor system, discharged to
`the side of the machine or left behind on the milled surface. It may sometimes be necessary to work
`w ithout a conveyor system when small milling machines are used to mill off small-sized areas, tapered
`junctions or areas inaccessible to large machines.
`
`16
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 18 of 83 PageID #:
`14223
`
`~
`WIRTGEN
`GROUP
`~
`
`3.2 Standard milling
`
`Standard milling involves the removal of asphalt pavements or parts thereof by milling off individual
`layers or the entire pavement structure. The tool spacing of a standard milling drum, which is the
`distance between one cutting tool tip and the next, is approx. 15 mm.
`Depending upon the type of machine used, milling depths of up to 35 em and milling widths between
`30 em and 4.30 m can be achieved.
`
`Standard milling drums with a tool spacing of 15 mm are ideally suited for the removal of entire
`pavement structures.
`
`A large milling machine milling a surface course
`
`3.3 Fine milling
`
`Fine milling involves the milling of traffic surfaces to restore the skid resistance or the evenness of the
`pavement. Typically, only a few millimetres of the surface course are removed. The maximum milling
`depth is 4 em.
`
`Special fine milling drums with a tool spacing of approx. 8 mm are used for fine milling. Depending
`upon the requirements placed on the fine milled area, the spacing may sometimes be even smaller
`(e.g . 5 mm). Milling widths of up to 2.20 m are standard, and widths of up to 4.30 m are possible.
`
`A country road, fine milled with a machine of the 2 m class
`
`17
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 19 of 83 PageID #:
`14224
`
`~
`WIRTGEN
`G ROUP
`~
`
`Al;wirtgen
`
`3.4 Features
`
`Milling machines (road milling machines)
`
`Small milling machines are mostly wheel-mounted machines. Their milling is drum positioned at the
`rear of the machine. For this reason, they are also called "rear loaders".
`
`Large milling machines are typically equipped with crawler track units.
`
`These machines are intended for use in large-scale rehabilitation projects and have, therefore, been
`designed for a high area performance.
`
`Their features include a standard conveyor system and a milling drum positioned at the centre of the
`machine, between the front and rear axles.
`
`Working direction
`
`Working direction of a small milling machine
`
`Working direction
`
`Working direction of a large milling machine
`
`18
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 20 of 83 PageID #:
`14225
`
`~
`W IRTGEN
`GROUP
`~
`
`The most important tool of the machine is a rotating milling drum, which works in an up-milling
`direction (Picture 1). It is equipped with rotating point-attack cutting tools (Picture 2) and scarifies the
`existing asphalt material. Typically, the milling drum is firmly connected to the machine frame. Its
`height is adjusted via the travel drive units of the machine.
`
`The advance speeds range from 1 m/min to approx. 30 m/min. Road milling machines are capable of
`collecting the milled material and loading it on transport vehicles by way of their conveyor system.
`Small milling machines are mostly equipped w ith a conveyor located at the rear of the machine (rear
`loaders), whereas large milling machines are typically designed as front loaders. The conveyors can
`usually be adjusted in height and slewed to either side.
`
`Milling drum
`
`Working direction
`
`(Picture 1)
`
`Carbide
`
`Base material
`
`Pre-tensioned sleeve
`
`(Picture 2)
`
`19
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 21 of 83 PageID #:
`14226
`
`~
`WIRTGEN
`GROUP
`~
`
`20
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 22 of 83 PageID #:
`14227
`
`~
`WIRTGEN
`GROUP
`~
`
`4. Principles and requirements of milling
`
`4.1 The road base
`
`4.2 Milling depth
`
`4.3 Surface structure and structural depth
`
`4.4 Evenness
`
`4.5 Level profile
`
`4.6 Forming the milling edge
`
`4.7 Condition of the reclaimed asphalt pavement
`
`22
`
`22
`
`22-23
`
`23
`
`23-24
`
`24
`
`25
`
`4.8 Notes to requirements, testing, acceptance, billing
`
`26-27
`
`21
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 23 of 83 PageID #:
`14228
`
`~
`WIRTGEN
`GROUP
`~
`
`4. Principles and requirements of milling
`
`4.1 The road base
`
`The road base is the area underlying the pavement to be milled. It must possess a sufficient degree
`of stability and load-bearing capacity for the equipment being used.
`
`This means that the client must indicate possible problems relating to the condition of the road base
`in the specification of works. The milling contractor can then account for such problems in his
`calculation.
`
`4.2 Milling depth
`
`The milling depth depends upon the pavement condition, the objective of the construction project and
`the type and thickness of the existing pavement.
`
`This means that the client must determine the required milling depth in the specification of works in
`accordance with his knowledge of the type and condition of the layer. The milling contractor must
`adhere to the milling depth, and the tolerances for the paving thicknesses established in accordance
`with the road construction and additional technical contract conditions and specifications for country
`road pavements likewise apply to the milling depth.
`
`When milling on bridges, the client must indicate the milling depth in the specification of works in such
`a manner that, taking into account the permissible tolerances and the structural depth, no damage of
`the existing insulation or the structural body occurs.
`
`4.3 Surface structure and structural depth
`
`The surface structure of the separating layer is influenced during the milling operation by the type of
`machine used, the arrangement and shape of the tools, the working speed and the type of material to
`be removed.
`
`A regular structure or uniform condition of the milled surface is imperative for a good adhesion with the
`new asphalt layer to be placed. This includes cleaning the milled area and removing loose remnants of
`material from the road base or the separating layer.
`
`22
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 24 of 83 PageID #:
`14229
`
`~
`WIRTGEN
`GR O UP
`~
`
`Regular surface structure of a milled surface
`
`4.4 Evenness
`
`The attainable evenness of the road base produced by milling depends upon the following factors:
`
`• Evenness of the surface to be processed
`• Homogeneity and condition of the material to be removed
`• Adhesion between the individual layers ·
`• Condition of the external tools used to determine the level (grade line, Multiplex, laser,
`or similar)
`
`Several machine passes may be required in case one or more of these prerequisites cannot be met,
`since the evenness of the milled surface is decisive for the subsequent placing of the new asphalt layer
`and for its attainable evenness.
`
`4.5 Level profile
`
`Carriageways are built with a transverse slope in order to enable the drainage of water. If a layer of uni(cid:173)
`form thickness is to be placed across the milling width at a constant transverse slope, the milling
`depth must be stipulated in such a manner that the lowest point of the transverse profile is included
`(ruts, deformations, etc.).
`
`It may be necessary to mill at varying depths in relation to the transverse profile if an intermediate layer
`is to be placed to improve the cross-section.
`
`23
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 25 of 83 PageID #:
`14230
`
`~
`W IRTGEN
`GROUP
`~
`
`Uniform layer thickness across the entire pavement width
`
`4.6 Forming the milling edge
`
`The milling operation usually produces vertically shaped longitudinal milling edges.
`
`It is, however, not possible to produce a vertically shaped transverse milling edge in one machine
`pass. The rounded transverse edge of the milled track is due to the machine configuration and must
`be reworked using a small milling machine or another suitable piece of equipment.
`
`If there is a risk of ravelling of the milling edges due to the condition of the surface to be milled
`(bitumen oxidation, cracking, insufficient adhesion between the layer and the road base, etc.), the
`remaining surface must be cut off by a straight crosscut prior to milling. Such additional work must,
`however, be stipulated in the specification of works in an own, separate item.
`
`Forming the connecting edge of a milled surface
`
`24
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 26 of 83 PageID #:
`14231
`
`~
`WIRTGEN
`GROUP
`~
`
`4. 7 Condition of the reclaimed asphalt pavement
`
`The condition and the particle size of the reclaimed asphalt pavement depend upon the following
`influencing factors:
`
`• Condition of the layer to be milled
`• Type of mixture of the layer to be milled
`• Weather conditions
`• Advance speed
`• Gradation control beam (reduces the formation of slabs)
`
`There is also the risk of slabs forming in the milled material if the milling operation takes place near
`the seam separating two asphalt layers and there is insufficient adhesion between the individual
`layers.
`
`The particles of gravel or chippings may be crushed due to the milling operation. The properties of
`the bitumen contained in the reclaimed asphalt pavement will remain unchanged. The bitumen
`properties must, however, be examined if the asphalt granulate is to be re-used.
`
`Cold milling is the only method where surface course, binder course and base course can be
`removed in separate, individual layers. Therefore, cold milling meets the requirements for an
`economical re-use of the reclaimed asphalt pavement.
`
`Removal of a swface course
`
`25
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 27 of 83 PageID #:
`14232
`
`~
`WJRTG EN
`GROUP
`~
`
`4.8 Notes to requirements, testing, acceptance, billing
`
`The requirements and the acceptance and billing modalities of the following additional technical
`contract conditions and specifications apply: additional technical contract conditions and
`specifications for the construction of road surfaces with asphalt, additional technical contract
`conditions and specifications for base courses in road construction, additional technical contract
`conditions and specifications for the constructional maintenance of road surfaces with the asphalt
`construction method, and additional technical contract conditions and specifications for country road
`pavements.
`It is recommended to specify the following requirements with regard to the milling performance:
`
`• Level profile
`If the road base is produced by way of milling, the tolerance of the required transverse slope must
`not exceed± 0.4 %.
`
`• Evenness
`The following threshold values for any longitudinal and transverse unevenness of the milled area
`must not be exceeded on a 4 m long measured section:
`
`On a free road section with no level requirements:
`• Milling of a surface course:
`~ 6 mm
`s:. 1 0 mm
`• Milling of binder and surface course:
`
`On road sections with constructional constraints, for example road ju nctions, tram or railway tracks,
`bridge superstructures or other fixtures, such as sliding covers, manhole covers, edge stones or
`kerbstones:
`• Milling of a surface course or of surface and binder course: < 10 mm
`
`When fine milling an asphalt pavement intended for immediate trafficking, the longitudinal and
`transverse unevenness on a 4 m long measured section must not exceed:
`• 4 mm for the road categories SV and I to Ill
`• 6 mm for all remaining road categories
`
`• Milling depth
`When milling asphalt pavements, the structure displayed in the following illustration is produced
`transverse to the direction of milling.
`The structure is characterised by the cutting tool spacing and the cutting angle. Due to the surface
`structure of the milled surface, two different milling depths can be measured. The upper milling depth
`is determined when measuring at the highest point, and the lower milling depth is determined when
`measuring at the lowest point of the milling pattern. The decisive value for billing purposes is the
`mean milling depth. The mean milling depth is the arithmetic mean valu~ established from an
`identical number of upper and lower milling depth measurements, and the milling depth is billed
`accordingly.
`
`The client and the contractor must mutually agree upon the number of individual measurements per
`area unit required to calculate the mean milling depth.
`
`26
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 28 of 83 PageID #:
`14233
`
`Mean milling depth
`
`Upper milling depth
`
`Lower milling depth
`
`~
`W IRTGEN
`GROUP
`~
`
`Upper edge of the
`original surface
`
`Cutting angle ( 1
`
`Milling structure, section transverse to the milling direction
`
`Cutting tool spacing
`
`In case of a required uniform thickness of the subsequently placed asphalt layer, the tolerance for the
`paving thickness as specified in the corresponding additional technical contract conditions and
`specifications likewise applies to the mean milling depth.
`
`The upper milling depth is established if the layer thickness of the overlay is determined by means of
`an electromagnetic thickness measurement.
`
`27
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 29 of 83 PageID #:
`14234
`
`~
`WJRTGEN
`GROUP
`~
`
`28
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 30 of 83 PageID #:
`14235
`
`~
`WIRTGEN
`GR O U P
`~
`
`5. Benefits of cold milling
`
`5.1
`
`Benefits with regard to application technology
`- Small milling machines
`- Large milling machines
`
`5.2
`
`Benefits with regard to profitability
`
`30-32
`
`33
`
`29
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 31 of 83 PageID #:
`14236
`
`~
`WIRTGEN
`GROUP
`~
`
`5. Benefits of cold milling
`
`5.1 Benefits with regard to application technology
`
`• Cold milling makes it possible to limit the removal of the damaged or dependent traffic area to the
`actual extent of the damage.
`
`The removal is limited to the damaged area.
`
`30
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 32 of 83 PageID #:
`14237
`
`~
`WIRTGEN
`G ROU P
`~
`
`@1:w jrtgen
`
`Surface course
`
`Binder course
`
`Base course
`
`Subgrade
`
`The removal can be limited to the layer thickness or to the depth of the damage.
`
`• Allows the removal of individual layers of the damaged area.
`• Is the only method allowing the selective removal and separation of different types of mix. This is
`an important aspect in view of the existing regulations for the re-use of reclaimed asphalt
`pavements.
`• Allows the production of an even, profiled new road base, providing a favourable surface structure
`as a prerequisite for a good adhesion between the individual layers.
`• Produces vertical and clean milling edges for good connecting joints and a good adhesion between
`the individual layers.
`
`Small milling machines
`
`Small milling machines w ith working widths of up to 50 em are particularly well suited for partial
`pavement repairs. Electrically driven, emission-free cold milling machines are now available for
`operation in factories or other indoor areas. The "small ones" have a particularly compact machine
`design, making transport to the site fast and easy.
`Small mill ing machines distinguish themselves by a number of technical features, which make them
`exceptionally flexible. Small milling machines do, for example, have an extremely small turning radius,
`making them exceedingly versatile. The conveyor of small milling machines can be uncoupled very
`easily, allowing the machine to be driven close to any obstacle when removing larger surfaces. Their
`slewable support wheels enable milling close to building walls or kerbstones. These features are
`particularly important on job sites where large milling machines are in operation and additional work
`must be carried out, a task that small milling machines are frequently used for.
`
`• Milling around obstacles
`
`A typical application of small milling machines is milling around manhole covers. Settlements of the
`manhole covers make it necessary to correct their height from time to time, since they would otherwise
`jeopardise the traffic safety. In contrast to a jackhammer, a small milling machine with a small turning
`radius can remove the pavement around the damaged manhole cover quickly and cleanly down to the
`desired depth. The height of the manhole cover is then corrected, for example by inserting
`intermediate rings. After that, the area around the manhole cover is either filled with new asphalt mate(cid:173)
`rial or paved with cobblestones.
`
`31
`
`

`

`Case 1:17-cv-00770-JDW-MPT Document 121-7 Filed 11/17/22 Page 33 of 83 PageID #:
`14238
`
`~
`WIRTGEN
`GROUP
`~
`
`• Partial rehabilitation of road pavements
`
`Pavements, for example on heavily frequented access roads, are often excessively stressed, and the
`rehabilitation of partial areas becomes necessary. Small milling machines are ideally suited for this
`task. After the pavement of the area in need of repair has been milled off, a tack coat is applied,
`ensuring a good adhesion with the new asphalt layer. The vertical milling edge, which offers a good
`interlocking structure for the new material, is additionally provided with a bitumen-impregnated strip.
`The new asphalt can then be placed true to li