Alcoa in Russia: Figures and Facts


February 1, 2005
- Alcoa completed the acquisition of the Samara Metallurgical Plant (currently - ZAO Alcoa SMZ) and Belaya Kalitva Metallurgical Manufacturing Association (currently - ZAO Alcoa Metallurg Rus) from Russky Aluminy (RUSAL) for $257.5  million.

In order to improve the product quality and raise the production efficiency to the international standards required by large customers in Russia and abroad, Alcoa upgrades the production and implements new technologies at Alcoa SMZ and Alcoa Metallurg Rus.

In addition to equipment purchases and upgrades, substantial funds are invested in Environment, Health and Safety System improvement, Alcoa Business System implementation, and employee training and development.

In 2005 - 2014 Alcoa investments in aligning the Russian production facilities with Alcoa’s best global standards reached nearly $587 million:

  • 2005 - $3 million 
  • 2006 - $96 million 
  • 2007 - $169 million 
  • 2008 - $200 million
  • 2009 - $22 million
  • 2010 - $12 million
  • 2011 - $27 million
  • 2012 - $14 million
  • 2013 - $24 million
  • 2014 - $20 million


Since 2005 total investments in Alcoa Russia (including the acquisition) exceeded $844 million.

PRODUCTION FACILITIES IN RUSSIA


ZAO Alcoa SMZ is Russia’s largest producer of fabricated aluminum. 

 

The share of Alcoa SMZ in the Russian mill products market is nearly 40%.

 

ZAO Alcoa SMZ plant is:

  • 1,380,000  square meters of land
  • 680,000 square meters under roof

 

ZAO Alcoa SMZ has 3 business units:

  • Casthouse
  • Mill products
  • Extrusions (includes forgings production)

- the largest extrusion press in Russia
- the largest forging press in Russia

 

ZAO Alcoa Metallurg Rus is one of the largest producers of fabricated aluminum in southern Russia.

 

The share of ZAO AMR in the mill products market is nearly 10%.

 

ZAO Alcoa Metallurg Rus plant is:

  • 861 500 square meters of land
  • 277 550 square meters under roof

 

ZAO AMR has 4 business units:

  • Casthouse
  • Mill products
  • Extrusions (includes a forgings-extrusions shop)
  • Cookware (former OOO Zavod Kalitva)


MANUFACTURED PRODUCTS

ZAO Alcoa SMZ
manufactures a wide variety of flat-rolled, extruded and forged products:

  • coils, including beverage can stock (body, end and tab), food can stock, lacquered strip;
  • profiles, panels, pipes, forgings, incl. large-scale ones

 

ZAO AMR manufactures a wide variety of flat-rolled, extruded and forged products:

  • coils, plate;
  • panels, profiles, pipes, forgings;
  • aluminum cookware with antistick coating, aluminum matt cookware, special cookware (churns, canisters, etc.) under Kalitva trademark using the most recent technologies and antistick coatings of world leading producers - Du Pont  и Akzo Nobel.

 

The plants serve customers in many markets, including aerospace, packaging shipbuilding, automotive, building and construction, oil and gas, transportation and other industries.

 

INVESTMENT PROGRAM

Based on the outlook for the Russian and global aluminum markets, Alcoa invests in the casthouse, mill  and forging capacities in order to meet the demand of the most rapidly developing sectors of the Russian economy.

 

The investment program at  ZAO Alcoa SMZ includes:

 

  • Casthouse: development of high-quality ingot production for can stock and fabricated aluminum in aerospace, building and construction, food industry.
  • Extrusions: development of fabricated aluminum production for oil and gas, building and construction.
  • Forgings: development of large-scale forgings production for aerospace, oil and gas.
  • Mill Products: development of can stock production, tin stock and lacquered stock for aerospace, building and construction, food industry.


The investment program at  ZAO AMR includes:

 

  • Casthouse: development of high-quality ingot production for aerospace, automotive.
  • Forgings: development of forged wheel production
  • Mill products: development of plate and sheet production for aerospace

 

QUALITY CERTIFICATES:

 

Alcoa SMZ: 

 

  • BSI certificate on quality management system ISO 9001 and AS 9100;
  • BSI certificate on quality management system ISO/TS 16949;
  • BSI certificate on environmental management ISO 14001;
  • Certificate of Aviation Register of Interstate Aviation Committee on aerospace materials production;
  • Certificate of Russian Maritime industry of Shipping on recognition of shipbuilding materials manufacturer;
  • TUV Certificate for production according to European Directive on pressure equipment PED 97/23/EC;
  • Certificate of Federal Accreditation Service Rosaccreditatsiya for the metrological department granting the right to check the measuring equipment;
  • Accreditation certificate of Federal Agency on Technical Regulation and Metrology (Rosstandart) for the plant’s Testing Laboratory;
  • Accreditation certificate of Certifying Center “Material” for the plant’s Testing Laboratory.

 

Alcoa Metallurg Rus:

 

  • Registration certificate on quality management system AS 9100 REV C/BS EN 9100:2009, ISO 9001:2008;
  • Certificate of Aviation Register of Interstate Aviation Committee on aerospace materials production;
  • NADCAP certificate on ultrasound control;
  • Certificate of Certification Center “Material” for the plant’s Testing Laboratory;
  • Accreditation Certificate of Federal Agency for Technical regulation and metrology the Testing Laboratory of Duralumin Center;
  • Accreditation Certificate of Federal Agency for Technical regulation and metrology on calibration of measuring units;
  • BSI certificate on environmental management system ISO 14001
  • Declarations, Sanitary-Epidemiological Conclusion Certificates for cookware production.  

 

CORPORATE SOCIAL RESPONSIBILITY ACTIVITY

In 2005-2014 Alcoa Russia and Alcoa Foundation have invested in the communities $11 million (Samara region – $5.5 million, Rostov region – $4 million, Moscow region – about $1.5 million).

 

Alcoa Russia corporate social activity is aligned with the global focus areas of the Alcoa Foundation – Environment, Education and Community Enhancement. As part of this commitment Alcoa Russia and the Alcoa Foundation implement long-term technical and economical education support programs, educational programs in conservation, sustainability and healthy lifestyle for youth, cardiac care program for children.

 

In addition, ZAO Alcoa SMZ and ZAO AMR implement community programs to address the local  community needs. These projects include support of socially vulnerable groups of population (elderly people, orphans, people with disabilities), environmental events. As part of Alcoa program Ten Million Trees, Alcoa employees planted about 65 000 trees.

The combined community investments in the Samara region in 2005-2014 amount to $5.5 million

 

Initiatives:

  • Alcoa Foundation Technical Education Support Program in Samara State Aerospace University (SGAU): scholarships to best students at engineering faculties, stipends for young faculty members, technical upgrades of lecture rooms and laboratories 
  • Alcoa Foundation Technical Education Support Program in Samara Metallurgical College: scholarships to best students
  • Technical modeling for secondary schools
  • Alcoa Foundation Program “Healthy Youth – healthy future of Russia” (equipping middle schools of the Kirovsky district in Samara with free-access fitness areas and organizing events to promote healthy lifestyle among young people, prevention of AIDS and other diseases among young people)
  • Reforestation in the Samara Region
  • Projects of Alcoa SMZ for local community: community enhancement, assistance to children with disabilities, orphans, veterans, employee volunteering events to clean up, refurbish and landscape the Metallurg district, environmental events in natural reserves and other projects.

 

The combined community investments in Belaya Kalitva and the Rostov region in 2005-2014 amount to more than $4 million

Initiatives :

  • Alcoa Foundation Technical Education Support Program in Donskoy State Technical University (DGTU): 50 scholarships to best students at engineering faculties, 5 development stipends for young faculty members, technical upgrades of lecture rooms

  • Alcoa Foundation Technical Education Support Program in Belaya Kalitva Polytechnic College: scholarships to best students

  • Alcoa Foundation program “Club of Nature’s Friends”  for secondary schools

  • Alcoa Foundation program “Youth votes for health” – equipping middle schools of Belaya Kalitva district with free-access fitness areas and organizing events to promote healthy lifestyle among young people

  • Children’s cardiac care program “Heart to Heart” through support of Alcoa Foundation

  • Local community projects in Belaya Kalitva: assistance to veterans, people with special needs, orphans and children from socially vulnerable groups, Alcoa employee volunteering events to clean up, refurbish and landscape the city.

 

 

ALCOA IN RUSSIA: FIGURES AND FACTS [57KB]

 

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Alcoa Russia Locations

Alcoa SMZ, ZAO
Fabricating facility in Samara

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Alcoa Metallurg Rus, ZAO 
Fabricating facility in Belaya Kalitva

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Alcoa SMZ, ZAO, Separate entity
Administrative office in Moscow

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DOCUMENTS

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ALCOA IN RUSSIA: FIGURES AND FACTS 

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