15.10.2024 | Aluminium Association

Russian-made solutions aimed at saving regional budgets and compensating for talent shortage are being showcased at the 'Road 2024' International Specialised Exhibition in Yekaterinburg, taking place on October 15-17 at Yekaterinburg EXPO. The leading manufacturers of aluminium products in their respective fields are represented at the collective booth (1A-47) organised by the Aluminium Association. The booth features KraMZ LLC (Krasnoyarsk Territory), DiMedia LLC (Tyumen Region), Alums LLC (Moscow Region), MKM Consult LLC (Moscow), and Alumpark LLC (Republic of Udmurtia).

Today, companies in the aluminium industry are ready to implement complex projects, from transport infrastructure to urban and park development. The ease and adaptability of aluminium solutions mean a much smaller team needed to install and dismantle structures. Plus, the ongoing costs of operating these ready-made solutions are significantly lower compared to their alternatives. This is due, among other things, to the strength of aluminium alloys and their high resistance to corrosion. This allows for minimal maintenance of objects even in aggressive environments.

Therefore, the advantages of bridges made of aluminium alloy have already been tested in various Russian regions. Since 2017, more than 20 pedestrian crossings have been installed in our country, including in the Nizhny Novgorod, Tula, Ryazan regions, Krasnoyarsk Territory, Moscow, etc. The first aluminium pedestrian bridges will be installed in the Altai Territory and Bratsk (Irkutsk region) by the end of the year. In late 2023, the first road bridge in Russia made with innovative alloys and technologies never used in bridge construction before was installed in the Nizhny Novgorod Region. The construction of a road bridge made of aluminium alloys is the result of several years of research and development by research institutes. They conducted numerous studies and tests to evaluate various aspects of the bridge, including its dynamics, tensile strength, fire resistance, wear resistance, weld quality, and other factors. The research was conducted by leading Russian scientific hubs, such as the Institute of Light Materials and Alloys (ILMiT), the Moscow State University of Civil Engineering (MSU), and the Mosty Centre for Scientific Research of Artificial Structures (TSADI). The project received scientific and technical support at the design stage from Central Research Institute of Transport Construction JSC. The developer of special technical conditions for design was Small Innovative Enterprise 'Scientific and Engineering Centre of Bridges and Structures' LLC. The experience gained from implementing this pilot project in the Nizhny Novgorod region will serve as the basis for the Russian Ministry of Construction to approve Amendment No. 1 to SP 443.1325800.2019 regarding road bridges.

The project not only allowed to create new regulatory documents and improved technologies, but also served as a driving force for the development of new competencies within the participating companies. The Krasnoyarsk Metallurgical Plant (KraMZ) is showcasing a unique product at the exhibition: an orthotropic plate used in the construction of road bridge spans. The plates are made up of hollow elements connected using an innovative method called friction stir welding. This method provides a better joint quality compared to traditional argon arc welding.

The leading companies in the market for transport infrastructure structures are also showing interest in aluminium solutions for bridge construction. The PIK company of Nizhny Novgorod, which is showcasing its products at booth A1-38, has named the manufacturing of aluminium structures a separate area of focus. The company has already been directly involved in the construction of various facilities in the Nizhny Novgorod region. This region is a leader in terms of the number and types of bridges made from aluminium alloys.

One of the main advantages of aluminium solutions is their quick construction. These structures can be installed and dismantled within a few hours, causing minimal inconvenience for pedestrians, passengers, and motorists. The pre-fabricated standard bridge kits presented by KraMZ can be installed on site in just two hours. The design of the bridge kit dictates the quickness of installation. The parts are delivered from the factory with high readiness, so the bridge can be assembled like a construction toy without any additional machining. This project will help solve the pressing issue of bridge structures in the state of disrepair as soon as possible. It is important to note that the new structures will have a service life of at least 50 years. The first bridge kits have already been deployed in Nizhny Novgorod and the Kaliningrad region.

Pre-fabricated structures have the potential to be a key driver for the successful implementation of the 'Tourism and Hospitality Industry' National Project which has been extended by decision of President Vladimir Putin until 2030. One of the main goals of the project is to increase the share of tourism in our country's GDP to 5%, to boost the export of travel services and to increase the number of tourist trips to 140 million per year. Most tourists want to feel comfortable and safe, even in the most remote places. Modular aluminium structures can help promptly solve this problem. The systems developed by Alums are specifically designed to suit the landscape, seismic activity, and other dynamic conditions in a particular region. They can withstand temperature changes, high humidity, and sea air without losing their original appearance for decades. Thanks to their light weight and easy installation, they can be easily moved from one site to another. This means the investor can start making a profit from the very start of the project. The system is unique in that it can be adapted to create a bus station, a temporary passenger terminal at the airport, a building for equipment repair and parking, a production shop or warehouse, a mobile tourist complex, and many more. The construction period for a fully finished structure, including exterior and interior finishes and electrical work, is only 1-3 months, depending on the pavilion's size.

The reaisation of tourist potential is impossible to imagine without creating a fully-developed berthing infrastructure. Our compatriots' interest in recreation on water continues to grow rapidly, and this has already had a positive impact on the aluminium shipbuilding industry. In recent years, Russian shipyards have launched a variety of modern boats, catamarans, cruise liners, and hovercraft. The trend of expanding production will continue thanks to the development of a groundbreaking aluminium-scandium alloy 1581. This alloy has allowed to improve the hull strength and reduce the overall weight of vessels. The alloy was created by a member of the Aluminium Association, the Institute of Light Materials and Technologies (ILMiT). It is a lightly doped alloy with a scandium content of 0.03%. This allowed to improve the strength of the material while still making it readily available on the market. Tests conducted by the Aluminium Association and BRO Boats, a manufacturer of boats from Rostov-on-Don, have shown that it is possible to reduce the weight of a boat by more than 10% compared to an analogue made of alloy 5083. In the case of high-speed vessels, the difference is even more significant.

However, in order to grow the fleet, there is also the need to update the existing transport and berthing infrastructure, an essential part of any water area. Currently, there are next to no available guest berths in hotels and restaurants. Urban pier infrastructure either does not exist at all or is poorly developed. There are not enough modern berthing complexes, and owners of small vessels complain about a lack of berths. In a bid to address this issue, the booth of the Aluminium Association showcased a groundbreaking development by KMK-Consult: load-bearing ventilated flooring made from aluminum alloys 6005A, AD33, and AD35. This solution stands out for its environmentally friendly and aesthetically pleasing features. The extruded aluminium parts do not require any additional processing and can be painted in any colour. The decking is made from natural wood without any chemical treatment. It emits zero harmful substances into the environment. With a spacing of 3 metres, the supports can withstand an additional load of up to 200 kilograms per square metre. The distinctive feature of this solution is that it can be configured in any way. This allows to use the decking for various purposes, such as building floating berths, swimming pools, and promenades, as well as creating eco-trails, recreational areas, and terraces, and landscaping coastal zones.

Improving the comfort and safety of citizens is directly connected to another aluminium product on display at the 'Road 2024' exhibition–bus stops. Modern bus stops are equipped with advanced technologies. These include wireless internet access, gadget charging ports, information systems, and video surveillance systems. These features make waiting for the bus much more comfortable and safe for passengers. DiMedia, a manufacturer based in Tyumen, has also developed a technology for installing bus stops that accounts for the climatic conditions of the specific region. For the northern areas, they can offer indoor or heated pavilions. Already today, the company's products are successfully used in various regions of our country. The number of aluminium pavilions installed exceeds 5,000.

Road safety is a crucial requirement of the 'Safe Quality Roads' federal programme. The aluminium poles presented by Alumpark do not absorb the collision energy, preventing severe injuries to passengers and the driver. This fully meets the requirements of the programme. Besides the lighting pole, the participant of the Aluminium Association is also presenting a traffic light pole, a road sign pole, and an EV charging station at the exhibition. The company's products are already well-known in various places such as Adler, Novorossiysk, Irkutsk, Ufa, Tuapse, Mineralnye Vody, the Kaliningrad region, and Udmurtia. The company offers a range of products that provide end-to-end solutions for parks, squares, and other public spaces. The housings for luminaires and street lighting kits are made of high-quality extruded and sheet aluminium. These materials have high thermal properties, with a thermal conductivity of more than 200 V/mK. The aluminium luminaire housing is protected from corrosion and exposure to harsh environmental conditions such as sea water, ultraviolet radiation, and salt by an anodised coating. One of the biggest automated anodising lines in Russia offers a wide range of products in twelve unique colours, including matte versions for each colour option. The warranty for anodising treatment is 20 years, regardless of the region where the product is used.

'When it comes to the aluminium industry, we can confidently talk about our technological independence. Our exhibition at 'Road 2024' is entirely dedicated to Russian-made technologies, metal, and materials. Using aluminium products for the construction or modernisation of infrastructure projects helps create new jobs in the regions. It also increases tax revenues for the local budgets and reduces the cost of operating these facilities in the future. The environmental soundness of aluminium structures and their recyclability also allow to recoup some of the initial investment after the product is used,' says Evgeny Vasiliev, Deputy Chair of the Aluminium Association and Director of Market Development at RUSAL.