Astec’s warm mix system on its portable plant is ready to handle the increased RAP usage in HMA production.

One of the largest road construction enterprises in the Orenburg Region of Russia is GPDS Construction Company. Founded in 1992 and working successfully ever since, the main business activities include construction, reconstruction, and road repair; construction of airport runway surfaces and turn-off strips; production of concrete products and paving slabs using new technologies; and performing main works contractor functions.


GPDS Construction Company expects that a significant increase in RAP usage worldwide, along with the benefits of RAP usage, will positively impact its long-term plans.

For more than 20 years, GPDS Construction Company has produced and paved more than 2 million tonnes (2.2 million tons) of high-quality asphalt. The total estimated area of pavement built and paved by GPDS Construction Company is 20 million m2 (215 million ft2). The company performed general maintenance and construction of more than 160 km (100 mi) of federal highways, development of inhabited areas, industrial facilities, and the Gazprom Dobycha Orenburg road network.

To accomplish the work, the company's equipment fleet includes more than 150 machines and 130 units of road construction equipment.


Due to the growth in the Orenburg Region and in the Republic of Bashkortostan, GPDS Construction Company needed reliable up-to-date equipment for asphalt production with maximum performance. In 2014, the company bought an Astec portable 270 MTPH (300 TPH) Double Barrel® plant.

An observer control center is positioned near the 181-tonne (200 ton) New Generation storage system and two, 90-tonne (100 ton) silos.
The Astec plant features a portable 10 ft x 12 ft (3.05 m x 3.66 m) five-bin cold feed system and a portable 51,955 ACFM Pulse Jet baghouse.

Alexey Krikovtsov, GPDS Construction Company asphalt production manager, remarked: "In choosing the plant, we considered many key factors. First, we needed a mobile plant with actual production not less than 240 MTPH (265 TPH). Second, we planned production of large volumes of SMA (stone matrix asphalt) so we needed a plant that would not lose performance while producing mixes requiring extended mixing time. Third, we needed to store the mix within a couple of days. Astec technology satisfied all our needs. Moreover, being a company which is determined to use new technologies, we took into account two more important factors: the ability to add RAP (reclaimed asphalt pavement) and produce WMA (warm-mix asphalt)."


The plant was commissioned in autumn 2014 and produced only 10,000 tonnes (11,023 tons). The production consisted of five mix designs, including SMA and Novachip, before operations ended in winter. In 2015, GPDS Construction Company plans to increase its production to 240,000 to 250,000 tonnes (266,000 to 276,000 tons) of mix.

"In USA and Europe, all large companies are working with RAP. In Russia, we are only beginning to consider recycle; we're also seeing the first standards for RAP usage being issued here. We believe the timing for consistent RAP usage in HMA (hot-mix asphalt) production in this part of the world is close at hand. If RAP is used properly, it will minimize the cost of mix and improve its performance. That's why we bought an Astec warm mix system with the plant," said Krikovtsov.