Irkutsk
Ulan-Ude

Blagoveshchensk
Chita
Yakutsk

Birobidzhan
Vladivostok
Khabarovsk

Magadan
Yuzhno-Sakhalinsk

Anadyr
Petropavlovsk-
Kamchatsky
Moscow

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Yakut materials of the future

The Yakut production of basalt materials will include in the list of territories for the outstripping development of the Far East

Yakut materials of the future

The high-tech production of Basalt Materials Technologies is of great importance both for the construction industry of the Far East and for entering the Asia-Pacific countries market.

The significance of the TBM project is confirmed by the level of support from the federal development institutions. Director of New Business Artem Avetisyan believes that "the implementation of the Yakut project and its scaling in the Far East will contribute to consolidating Russia's leading role in the development of technology and the production of basalt-composite materials, structures and products from them."

The appearance of the Pokrovsk plant and the further development of the company's capacities are due to the strong market demand. More than half of the territory of the Far East is in the permafrost zone, which in fact means requiring a special approach to construction technologies and materials capable of withstanding northern climatic conditions. The range of materials produced in Yakutia has already found its application in road and infrastructure construction. And the demand will increase, as only in the republic it is supposed to reach the volume of housing construction of one million square meters per year. With reaching the projected capacity, the company has every chance to become a major player in the market of innovative materials in South-East Asia.

"The important point of the Yakut project is that the raw materials are in the same place as the production, which has a major impact on the cost price. And first of all we must understand that these are materials for civil construction that help create decent conditions for life in the north, "said Andrey Nikitin, Director General of the Agency for Strategic Initiatives.

How it all began

The LLC Basalt Technologies Company was established in 2008 with the support of RUSNANO. 16 February 2009 of the year Vyacheslav Shtyrov, then the President of the Republic, held a working meeting, during which he launched the factory of basalt materials. Then 2 March on the board of directors of JSC "RIC", which was chaired by Egor Borisov, was unanimously adopted a positive decision. The authorized capital was 400 million rubles. The share of TBM LLC is 37,4%, the remaining 62,6% was invested by OJSC RIK. The first funds were received by the end of March, by that time the equipment was already selected, negotiations were held with suppliers, and real work began.

The plant began to produce basalt insulation, which quickly gained respect in the building materials market: they are inexpensive, have a long service life - up to 75 years, while being fire resistant and have a high level of sound insulation and noise reduction.

The head of Sakhabasalt, Yegor Zhirkov, decided to go further - so there was an innovative project "Basalt - New Technologies" in the direction "Basalt-plastic composites for the North of Russia". In July 2012, Pokrovsk launched the 1 line for the production of basalt continuous fiber (BNV), by the end of the year there were already two technological lines.

The essence of the project is the creation of a complex of production facilities for the production of basalt continuous fiber up to 2 260 tons per year and nanostructured basalt plastic materials based on it (basalt plastic reinforcement and concrete structures and products for the North of Russia).

“The project aims to create a new generation of high-tech products for use in the residential, industrial and road construction sectors, the main feature of the project is an integrated approach from the extraction of raw materials to the production of final products,” shared E.Zhirkov.

The basis of the Yakut innovations are unique domestic technologies for the production of basalt continuous fiber. According to E. Zhirkov, these technologies come from Soviet times and only recently they were declassified.

Today we can say with certainty that the plant has taken place. Production has been adjusted, all personnel issues have been solved, complex equipment has been mastered and even technical modernization has been carried out. Total investment in the project amounted to 960 million rubles.

Eternal piles

Zhirkov's dream is to create piles of a new generation, with a basalt-composite reinforcement instead of steel, suitable for a climate with sharp temperature changes and resistant to an aggressive environment.

As E.Zhirkov explained, to create such a technology, one simply needs to change the composition to basalt concrete and make a framework of basalt composite materials, and it has the same coefficient of thermal expansion as concrete, and does not expand from temperature drops, therefore, microcracks do not appear - the main reasons The beginning of the processes of corrosion and cracking. Unlike reinforced concrete products, such piles do not threaten corrosion either through 30 or through 50. Plus, when using such a frame, the weight of the piles will decrease by 8-9 times. Basalt composite fabrics can be used not only for piles, but also for many other responsible positions.

In Yakutia, basalt-composite reinforcement is already being used in practice. A recognized leader in the diamond mining industry of the world, ALROSA uses basalt-composite materials in deep mines.

As for the environmental friendliness of production and the finished product, here, according to Zhirkov, everything is in order: there is no more damage from the plant of basalt materials than from the quarter boiler house. Basalt insulation, which is a success with Yakutians, contrary to leisurely speculation, are completely safe for health. In the production of insulation used phenol-formaldehyde resins, which do not emit dangerous volatile substances. Yes, and used resins even below the permissible limits: from 0,5 to 2%.

Problems and prospects

As you know, everything new is in doubt and even fear. At first, the local authorities looked at the project with caution: “Will we overpower it?”. However, E. Zhirkov proved: we can, we cope. The basalt fiber plant was modernized by the workers themselves and in the second year was able to exceed its design capacity by one and a half times: instead of the declared 64 thousand cubic meters of fiber, it produced 102 thousands.

The inclusion of the project in the list of priority development areas is fully justified. The importance of enterprises engaged in the production of basalt fiber and basalt composite materials and structures is difficult to overestimate.

"Reducing the cost of final products will reduce the cost per square meter of housing in Yakutsk, if developers will use basalt reinforcement as piles for multi-apartment buildings"- sure E. Zhirkov.

The production of building materials for use in housing, industrial and road construction in the North of Russia will reduce the cost of northern imports from the budget of the Russian Federation, reduce the cost of transporting construction materials from the central part of Russia. The economic effect when replacing the steel reinforcement with basalt plastic is about 220 million rubles a year.

The TBM company is not going to stop there and aims to reach a large level of production of valves - more than 2 thousand tons per year. Already this year, private developers will have an alternative - basalt rebar as a foundation.

This year it is planned to launch the Combined Basalt Concrete Plant with a design capacity of up to 32 thousand cubic meters of products. The plant will produce piles, prestressed road slabs, floor slabs and hollow core slabs. The plans - the promotion of our products outside the country.

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