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105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected] 1
COMPOSITES FOR ENVIRONMENTAL FRIENDLY INFRASTRUCTURE –
CHOICE FOR FUTURE GENERATIONS
Prof. Andrey Ushakov, General Director“ApATeCh Co. Ltd.”
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105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected] 2
• Traditional materials: explosion of construction market as a hazard to environment
• Criteria for mass introduction of composites into new infrastructure markets
• Today and future markets for composite materials: view from Russia
• Environmental friendly composites today and in future infrastructure (ApATeCh experience)
Composites for environmental friendly infrastructure – choice for future generations
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105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected] 3
Traditional materials: environmental impact caused by pollution during construction and maintenance
Concrete dust
Corrosive failure
Protective chemicals
Deicing chemicals
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Traditional materials: explosion of construction market in developing countries
Foreseen in next few years explosion of house & road construction in developing countries will cause the mass uncontrolled
environmental pollution
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Traditional materials: economic impact
In 2002 Federal Highway Administration of USA released a study “Corrosion Costs and Preventive Strategies in the United States”.This study showed that in 1998 the total annual estimated direct cost of metallic corrosion in nearly every U.S. industry sector was approximately $276 billion(3.2% of the US gross domestic product)”The corrosive failure of Silver Bridge, USA,
1967. Bridge collapsed in less than a minute, killing 46 drivers and passengers
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The environmental impact of infrastructure objects (houses, bridges, buildings, poles, e.t.c.) in contrast to traditional composite products (aircrafts, boats, sporting goods) is critical issue for world ecology and economy
Traditional materials: environmental impact
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• Traditional materials: explosion of construction market as a hazard to environment
• Criteria for mass introduction of composites into new infrastructure markets
• Today and future markets for composite materials: view from Russia
• Environmental friendly composites today and in future infrastructure (ApATeCh experience)
Composites for environmental friendly infrastructure – choice for future generations
www.apatech.ru
105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected] 8
passive chemical behaviour reusability & recyclability high specific propertiesmobility & transportability flexibility in properties high energy capacity
Composite structures for infrastructure produced and maintained in high volumes should satisfy the following criteria to provide true environmental safety:
Criteria for composites mass introduction into infrastructure
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0 5000 10000 15000 20000 25000
CO2
CO
CH4
N2O
PM Fe/Al
PM Si/Ca
SO2
NOx
Styrene
Struct. steel
Composite
Aluminum
Reinf. concrete
in 103 m3 of air
0 100 200 300 400 500 600 700
Aluminum
Amonia
Cadmium
Copper
Cyanide
Fluoride
Manganese
Mercury
Zinc
Cobalt
Struct. steel
Composite
Aluminum
Reinf. concrete
in m3 of water
Air pollution as result of bridge construction in various materials
Water pollution as result of bridge construction in various materials
7090
41100
310407920
*«In Search of Optimal Shapes for Composite Bridges», Ryszard A. Daniel, Ministry of Transport & Water
Management, Utrecht, The Netherlands, «COBRAE CONFERENCE 2007», Stuttgart, Germany, March 28-30, 2007
697.4
85.8
565.3
341.9
Composite materials: reduction of air and water pollution during construction and maintenance*
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105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected] 10
• Traditional materials: explosion of construction market as a hazard to environment
• Criteria for mass introduction of composites into new infrastructure markets
• Today and future markets for composite materials: view from Russia
• Environmental friendly composites today and in future infrastructure (ApATeCh experience)
Composites for environmental friendly infrastructure – choice for future generations
www.apatech.ru
105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected] 11
Primary & secondary structures for aircrafts and spaceships
Wind turbine bladesand nacelles
On several markets for recent 50 years composites turned from “advanced” and “premium” to quite conventional materials comparable with aluminum and steel
Composites: from “advanced” to “conventional” structural material
Hulls and decks for boats & sailing yachts
Sports goods: parts for racing cars and bikes, helmets, hockey sticks, fishing rods
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Research centres of competence
Scientific and technical management
Local production facilities
THE WAY TO ACHIEVE - MASS PRODUCTION FOR MARKETS:
•Infrastructure of railways and highways
•Bridge building•Sport arenas•Energy systems•Avia- and automotive transport
GOAL:Annual turnover of composites
production & sales
1 billion $ in 6 years
2011 2017
billion $ 1000
100
State support of
innovations and
modernization in
Russia
Technical policy:• Legislation basis
• Innovation tools
• Scientific & technical
background
VISION OF RUSSIAN ENVIRONMENTAL FRIENDLY COMPOSITES INDUSTRY PROGRESS
JOINT PROJECT: “Extension of nanostructured carbon- and glasscarbon polymer composite materials manufacturing for mass production of large dimensional primary structures for infrastructure”
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Project of Zenith Stadium in Saint-Petersburg
Bridges, buildings, transport and electrical infrastructure: capacity for composites is 10…50 times greater compare to level achieved by 2010
The key advantage: environmental friendly
Girders and decks for vehicular bridges
Today and future growing markets
Seawalls, infrastructure of railways
Hybrid glasscarbon vacuum infused 100 m beams
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State investment corporation “Rusnano” –main driver of new Russian composite industry
HC “Composite”Local production of raw materials: carbon fiber, textiles and prepregs
“TsAGI”Development of standards and guidelines for designing and production of composites
“ApATeCh”Local production of
high-performance
structures for civil
markets
“Aerocomposit”Local production of high-performance aerospace composite structures
State support of innovations and modernization in Russia
Technical policy
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HC “Composite”: new Russian producer of raw materials for high performance structures
PAN fiber production facility
Carbon fiber production facilitiesCapacity: 3000 tons
Textiles & prepregs production facilitiesCapacity: 4500 tons
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• Traditional materials: explosion of construction market as a hazard to environment
• Criteria for mass introduction of composites into new infrastructure markets
• Today and future markets for composite materials: view from Russia
• Environmental friendly composites today and in future infrastructure (ApATeCh experience)
Composites for environmental friendly infrastructure – choice for future generations
www.apatech.ru
105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected] 17
• Long service life and minimum maintenance/repair on the life cycle of 100 years
• No air and water pollution during installation and in service
• Design based on combination of natural and manufactured materials
100 % reusable composite seawalls
Reusability
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Innovative strategy of Russian Railways
Oleg Toni, Vice President of Russian Railways:“The new composite seawall installed along Tuapse-Adler railroad is stronger than concrete structure, has lower weight and gives possibility to perform installation 1.5-2 times faster without heavy machinery. Life cycle of composite seawall is 70 years compare to just 15 years of reinforced concrete. Thus the goal of Russian Railways is to introduce more innovative materials and technologies with minimum cost and maximum efficiency” – Russian newspaper “Gudok”, 05/04/2011
Composite environmental friendly infrastructure for Olympic Sochi
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• Possibility to transport and install large size preassembled and half-assembled structural parts
• Mobility and minimum use of transport polluting atmosphere
• Reusability: possibility to use the structure again without destroying it and additional processing
Mobility & fast installation
Mobile, temporary & reusable footbridges
Moscow 2006
Garden ring,
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№ Property Value
1 Life cycle 50 years
1 Fatigue strength up to 1 billion cycles of gross load
2 Train speed up to 200 km/hour
3 Joint minimum insulation 1 kОm
4 Operating temperature -60ºС…+80ºС
Long service life: corrosion and fatigue free composite high loaded fishplates for railway isolating joints
Winner of JEC Award 2002By 2010 on the railroads of Russia, Kazakhstan, Lithuania and other countries more than 1 200 000 fishplates are being in service. The lightweight design together with excellent electrical isolation properties resulted in significant energy saving compare to traditional metal fishplates.
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Life cycle 50 years
Width 0.5…0.8 m
Length 2…6 m
Weight 6…23 kg / linear m
Depth 0.4…1 m
Saving of labour and transport costs:composite water removal channels
The installation of composite water removal channels doesn’t require application of heavy machinery and thus allow to save energy and
preserve environment from additional pollution. In service channels also require no maintenance
providing environmental friendly life cycle.
Composite channelsConcrete channels
Winner of JEC Award
2007
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Bridge for Ulan-Ude
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Comparison of maintenance costs for standard composite, concrete and metal bridges (painting, waterproofing, repair of coverings, filling of cracks, etc.)
CompositeReinforced concrete
Metal
Energy consumption for one-year maintenance of 1 m2 of the bridge structure
1058 kW/h
101 200 €
6282 kW/h
667 500 €
2870 kW/h
305 000 €
Energy saving during composite application in comparison withother materials on the life cycle of 50 years
261.2 MW/h 90.6 MW/h
Average cost of 1 m2 of the bridge (data provided by“ApATeCh”)
1 775 € 525 € 850 €
Payback of composite material compared with steel concrete and metal due to energy saving
2.25 years 4.8 years
Energy efficiencyApATeCh bridges experience 2004-2011
Over railways, stations and yardsOver highways for people
safety in small towns
Over small rivers in parks and
recreation areas
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ApATeCh developed technology which allow to produce, transport and assemble in the field large buildings (hangars) with area 500m x 500m using vacuum infused beams 100m long
The developed technology is highly demanded in the regions with underground thermal waters (North Caucuses in Russia). Composite materials allow to use underground vapor as heating agent for those buildings and also preserve
structure from corrosion and failure in severe hot wet conditions which are not sustainable for concrete and steel
The standard vacuum infused beam
Use of geothermal energy sourcesof North Caucuses
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•New Mayor of Moscow started program to reduce traffic jams in the city
•Moscow crossroads require hundreds of lightweight modular fast-to-install viaducts
• Fast installation with minimum impact on the traffic on the first level
• No air and water pollution and in service• Easy to remove and install at new place with
minimum efforts on demounting
Moscow traffic problems:lightweight composite viaducts and bridges
ApATeCh composite bridge over Moscow Garden Ring, 2006
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Testing of ApATeCh heated deck in conditions of hard snowfall
Heated ramp for physically challenged people, Moscow,
Petrovsko-Razumovskaya station
Witness plate with natural level of snow
•Lightweight design•Easy replacement of any single panel
•Energy efficient solution •Energy saving control system
Size: 1100 x 500 х 40Power: 200…300 W/m2
Min surface temp. +2°С
Composite ramps with smart heating system instead of deicing chemicals
Environmental friendly solutions chemicals free deicing system
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Smart nanocomposite bridge structures
Illuminated bridge in Sochi, “ApATeCh” gift to the city
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Let’s make life of future generations more safe and easy!
Thank you very much for your attention