Structural Applications of Aluminum

Source: https://www.tandfonline.com/doi/pdf/10.2749/101686606778995128?
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Structural Applications of Aluminium in Civil Engineering
Summary
The Aluminium (Al) element was discovered 200 years ago. After an initial period of technological
development, aluminium alloys were used in many structural applications, including the civil
engineering field. The last decades have been devoted to analyse the structural behaviour of
extruded and welded members by means of theoretical and experimental research. The achieved
knowledge represents today the solid basis for modern codification. The present paper gives an
overview of the contemporary developments in the design of aluminium alloy structures.
Basic Prerequisites
The success of aluminium alloys as constructional material and the possibility of a competition with
steel are based on some prerequisites, which are connected to the physical properties, the
production process, and the technological features.
In particular, it is commonly recognised that aluminium alloys can be economical, and therefore
competitive in those applications where full advantage is taken of the following prerequisites [1, 2,
3]:
Lightness
Low specific weight of aluminium alloys which is one third of steel, makes it possible to:
– simplify the erection phases;
– transport fully prefabricated components;
– reduce the loads transmitted to foundations;
– economize energy either during erection and/or in service;
– reduce the physical labour.
Corrosion Resistance
Formation of a protective oxide film on the surface makes it possible to:
– reduce the maintenance expenses;
– provide good performance in corrosive environments.
Functionality of Structural Shape
Extrusion process makes it possible to:
– improve the geometrical properties of the cross-section by designing a shape which simultaneously
gives the minimum weight, and the highest structural efficiency;
– obtain stiffened shapes without using built-up sections, thus avoiding welding or bolting;
– simplify connecting systems among different component, thus improving joint details;
– combine different functions of the structural component, thus achieving a more economical and
rational profile.
Fields of Application
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Competitiveness
The best application can be obtained in some typical cases, which are characterised in getting profit
at least of one of the main basic properties: lightness, corrosion resistance and functionality [4, 5, 6].
The structural applications which best fit these properties in the field of civil engineering are the
following:
– Long-span roof systems in which live loads are small compared with dead loads, as in the case of
reticular space structures and geodetic domes covering large span areas, like halls and auditoriums.
– Structures located in inaccessible places far from the fabrication shop, for which transport
economy and ease of erection are of extreme importance, like for instance electrical transmission
towers, which can be carried by helicopter.
– Structures situated in corrosive or humid environments such as swimming pool roofs, river bridges,
hydraulic structures, and offshore super-structures.
– Structures having moving parts, such as sewage plant crane bridges and moving bridges, where
lightness means economy of power under service.
– Structures for special purposes, for which maintenance operations are particularly difficult and
must be limited, as in the case of masts, lighting towers, antenna
– towers, sign motorway portals, and so on. The above groups mainly belong to the range of ‘civil
engineering’, but a wider field of potential applications is the more general one of ‘structural
engineering’.
Lightweight Structures
When structural weight is a fundamental issue, the utilization of aluminium can represent a valid
alternative to steel. In addition, the complete absence of maintenance increases the advantages in
particular for those structures situated in humid environments.
Several applications of reticular space structures can be found in South America (Brazil, Colombia,
Ecuador). The historical background in this field is represented by a very spectacular space structure
which has been erected for the Interamerican Exhibition Centre of Sao Paulo in Brazil in 1969 (Fig. 1),
covering an area of about 67600 m2 with a mesh 60 × 60 m. The depth of the reticular layer is 2,36
m. It was entirely site-bolted on the ground, and later it was lifted at the final level of 14 m by means
of 25 cranes located in the corners of the mesh, in the position of the actual supports. The weight of
the reticular structure was 16 kg/m2 ; the number of bars was 56820 and their total length one after
another was 300 km. The erection time was extraordinarily quick (27 hours), by using a number of
550000 bolts in 13724 nodes. The materials were: aluminium alloys of 6063 and 6351 series T6 for
cylindrical bars, Al 99,5 for trapezoidal sheeting and, galvanized steel bolts for connections. Very
similar is the case of the International Congress Centre in Rio de Janeiro, where the same mesh 60 ×
60 m has been used, covering a total area of 33000 m2 (Fig. 2).
(...)
A field where the properties of aluminium play a determinant role is – the hydraulic applications
(pipelines, reservoir). The case of the rotating crane bridges for large settling circular pools in water
sewage treatment plants is a typical case (Fig. 10). In particular, the ‘corrosion resistance’ allows to
eliminate any protection also in the presence of a corrosive environment, while the ‘lightness’
corresponds to energy saving – during the operating phases of the plant [10].
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It seems important to underline that nowadays offshore applications can be considered the main –
future – trend for aluminium alloys. In fact, they offer to this industry enormous benefits in the form
of cost savings, ease of fabrication, and proven performance in difficult and hostile environments.
Stair towers, mezzanine flooring, access platforms, walkways, gangways, bridges, towers and cable
ladder systems can all be constructed in pre-fabricated units for simple assembly offshore, or at the
fabrication yard.
Mobility and ease of installation are maintained even for large structural elements, such as link
bridges and telescopic bridges.
Helidecks, have been made by using aluminium alloy since the early seventies, so they are now fully
tried in heavy duty situations (Fig. 11).
Moreover, they are designed to be modular and have bolted connections, allowing quick erection
and easy shipping, and handling. In addition, they offer weight reduction of up to 70% over steel,
meeting the highest safety standards; and providing up to 12% cost saving [11].

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Source: https://www.tandfonline.com/doi/pdf/10.2749/101686606778995128?

– simplify the erection phases;

– transport fully prefabricated components;

– reduce the loads transmitted to foundations;

– economize energy either during erection and/or in service;

– reduce the physical labour.

Formation of a protective oxide film on the surface makes it possible to:

– reduce the maintenance expenses;

– provide good performance in corrosive environments.

Functionality of Structural Shape

Extrusion process makes it possible to:

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