composites for environmental friendly infrastructure ... · 105066 moscow, 6, spartakovskaya str.,...

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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.”

www.apatech.ru


• 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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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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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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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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105066 Moscow, 6, Spartakovskaya str., Tel./fax. +7 (499) 261-7076, [email protected]

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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• 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

composites for environmental friendly infrastructure ... · 105066 moscow, 6, spartakovskaya str.,...

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