VOL 19 ISSUE #2
Russian contractor uses Astec Portable Double Barrel® plant on highway project

Russian company Technostroy is a local contractor in the region of Karelia, situated next to the border of Finland in Northwestern Russia. The company started operations in 2000 with the acquisition of a 200 MTPH (220 TPH) Astec 6 ft (1.83 m) Portable Double Barrel® plant. Over the past 10 years, the company has grown into one of the largest paving contractors in Russia, working mostly with the Federal Highway administration across the territory of seven regions with the combined population of 20 million. 

In 2013, the company reached the level of producing almost 1 million tons (907,184 tonnes) of HMA (hot-mix asphalt) and embarked on paving jobs in various regions requiring high capacity, high mobility of equipment, and use of the most recent HMA technologies available. 

NEW PLANT COMMISSIONED

Facing the challenges, the company turned to its long-term partner—Astec,Inc.—and commissioned the delivery of the latest version of the Six Pack® Portable Double Barrel® plant incorporating the latest developments over the last 10 years. Among the specific features requested by Technostroy were full compliance with Russian and European regulations, high portability and fast erection times, plus documentation and the control system in Russian. 

The new plant started operations in July 2013. 

“The machine does a very good and accurate job,” says Dmitry Rebrikov, Technostroy plant operator, who’s been working with Astec HMA plants since 2003. “You just need to power it on in the morning and power it off in the evening. It took us as little as three days to have it up and running.”

The maximum performance of the Six Pack asphalt plant is 200 MTPH (220 TPH) with nominal capacity of 180 MTPH (198 TPH). Currently, it runs on average 170 MTPH (187 TPH) using two to three mix designs per day.

ASTEC WARM MIX SYSTEM

The Astec Six Pack is delivered complete with Double Barrel® drum mixer and the Astec warm mix system, which can produce both conventional hot-mix asphalt and environmentally friendly warm-mix asphalt. The production of the plant in 2013, after four months of operation, was approximately 250,000 m3 (326,987 yd3). The company has been using the Astec Double Barrel® and warm mix system for producing warm-mix asphalt (WMA) for virtually for all highway projects and all mix types. 

Smalkov Andrey, manager of Technostroy, believes WMA is a very efficient technology. “Autumn is a cold season here in Russia. With WMA, we benefit in terms of quality by having very little temperature drop despite long hauling stretches. The mix hauled to the site is consistent and of good quality,” he said.

M10 PROJECT

The Six Pack asphalt plant was set up in Veliky Novgorod (Novgorod the Great)—one of the oldest Russian cities. Veliky Novgorod is located on M10, a federal highway in Russia connecting Moscow and Saint Petersburg. The major federal highway is not the longest in the country at 664 km (412.5 mi), but one of the most important ones. It runs through numerous cities and settlements and is always in high demand. High traffic loads (approximately five times more than expected) caused severe damage to the pavement, and by 2013, many sections of M10 needed repair. The reconstruction of M10 became the first project where the Six Pack asphalt plant was used. 

According to Rebikov, the Astec Six Pack is ideal for large highways. “Portability and the compact size of equipment are extremely important for Technostroy, which constructs and repairs roads in different parts of Northwestern Russia and has to move from site to site. The transportation of the Six Pack is easy and convenient, and can be set up close to the jobsite. It reduces transportation time and fuel consumption and provides good quality of asphalt.” 

Rebikov continued: “High serviceability is the best feature of the Six Pack; it has no vertical members typical of batch plants and requires no working at height.”

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