OAO “Aeroportstroy” Metal Structures Plant as a part of IBC “Pulkovo” is a large-scale enterprise specializing in metal structures production.
The plant yearly increases its total output volume, develops more composite structures and expands the geography of its deliveries throughout Russia and CIS countries.
Thus at the end of 2006 Metal Structures Plant started production of the new innovative type of structures – corrugated beams (Sin-beams). The picture shows a fragment of the building frame made of our Sin-beams.
Corrugated Sin-beam is light welded metal structure made from black cold-rolled shaped sheet that is welded to hot-rolled steel flanges. Long ago engineers realized that profield sheet is much more rigid and stable and so is more effective. Adoption of this concept into metal structures producing and erecting process gives a number of competitive advantages.
So Sin-beam allows to get rid of several defects of standard I-beam that require additional works to increase rigidity. More over the usage of more thin sin-beams requires fewer raw materials – the saving is 10-30 per cent in comparison with standard metal structures and up to 40 per cent in comparison with hot rolled beams.
Sin-beams provide high ratio of strength and weight, decrease the height of the beam in comparison with standard purling and simultaneously reduce cost and increase the width of unsupported aisles. All this significantly reduce the cost of erection. Corrugated web provides greater rigidity at bending and rotation so there is no need in extra lifting equipment for sin –beams unloading and erection. The same resistance to rotation forces allows avoiding additional angles and other connections that also reduce costs and erection time.
Production of corrugated beams at the own plant allows IBC “Pulkovo” to use them widely in design and construction of different purpose buildings – from simple single-storey buildings to bearing frames of large logistic centers.
Metal Structures Plant’s producing capacity is more than 20 000 ton of metal structures a year.
EQUIPMENT
Metal Structures Plant is equipped with high-precision European machinery and production lines which have no match in any other factory in Russia.
The Plant has all the necessary equipment for metal structures production, including welding, thermal and painting machinery. We make metal structures from various steel grades: plain carbon steel, low-alloyed structural steel and tool steel. The production is equipped with computer controlled automated measuring devices that monitor the production process in automatic mode.
KALTENBACH AUTOMATIC MACHINERY
Kaltenbach machinery is used for drilling structural steel, I-beams, channel bars (U-beams), angel steel, square and rectangular profiles, as well as for edge sawing at any angle using laser marking. СNС allows a single operator to carry out all necessary cutting.
TERMIT UNIT
The Termit Unit is used for plasma cutting of metal sheets. СТС allows a single operator to carry out the entire process.
GIETART AUTOMATIC SYSTEM
Gietart System is used for metal shotblasting without human intervention.
The basis of IBC “Pulkovo” prefabricated buildings is skillfully designed metal frame which is calculated to withstand big loadings. For metal structures production (girders, trusses, columns, connection elements, etc.) we use high-quality metal of British Steel, SSAB and Ruuki (Rautaruuki). All used metal goes the obligatory shotblasting to remove extraneous dirties.
Anticorrosion protection
OAO “Aeroportstroy” Metal Structures Plant has successfully decided the main problem of Russian metal structures manufactures – low quality of anticorrosion protection.
The competitive advantage is obtained by using modern European automated shotblasting and painting lines with special paint spraying chambers for welded metal structures.
Competitive advantages:
- Are cleaned all surfaces of metal structures, including welded joints and heat-affected zone
- The time from cleaning to painting is not hours (according to GOST not more than 24 hours)
but minutes (about 12-15)
- The cleaning is done by 10 powerful turbines located at different angles that ensures a high
quality cleaning of all surfaces and high efficiency of process
- The coloring is done automatically by several paint spraying guns located at different angles
that ensures a high quality and efficiency of coloring process
- It is possible to carry out both priming and painting with a guaranteed dry level thickness from
40 to 120 microns
- The production line ensures ecologically clean shotblasting and painting of structures. The
emissions correspond to strict European and Russian standards
- The work force is reduced to a minimum and is not directly involved in the cleaning and
painting process (1 or 2 workers operate the line and 2 people load and unload the structures)
- Removing dust and solvents is completely automated
- It is possible to use almost any types of paint and primer
- It is possible to change quickly in automatic mode the color and even type (paint) of coating
- High quality of anticorrosion coating
The manufacturing capacity of Metal Structures Plant is more that 20 thousand ton of metal structures a year.
The enterprise has the experience of metal structures manufacturing in accordance to European design standards or codes adapted to Russian standards.
The Metal Structures Plant has its own railway siding and specialized trucks for shipping products to the customers.
Besides production and shipment IBC “Pulkovo” performs erection of metal structures.
