Morton Group and RUSNANO Open Showcase Plant for the Manufacture of Modular Housing

27 February 2015

The company DSK-Grad officially opened its new plant for the manufacture of high-tech prefabricated building units near the town of Naro-Fominsk in Moscow Region. The company and plant are a joint project of RUSNANO and the Russian residential developer, Morton Group. Total investments in the project are 9 billion rubles, of which RUSNANO contributed 2 billion. The opening ceremony was attended by the Russian Minister of Construction and Housing Services, Mikhail Men, the Governor of Moscow Region, Andrei Vorobyev, the Executive Board Chairman of RUSNANO Anatoly Chubais and the President of Morton Group, Alexander Ruchyev.

DSK Grad is the largest national-scale manufacturer of building units to have entered the Russian market in the last 30 years. The company will be a full-cycle producer, making all of the pre-fabricated units that are required for construction of residential and public buildings with enhanced levels of comfort and energy efficiency. When operating at capacity, output of the Naro-Fominsk plant will be sufficient for the construction 525,000 sqm of new floor space each year, of which 450,000 sqm for ​​apartments and 75,000 sqm for community facilities.

Production by DSK Grad will use a number of innovative nanotechnology materials developed by RUSNANO portfolio companies. These companies include SP Glass (window glass that prevents heat loss by means of nano-coatings), Akrilan (concrete plasticizers, nano-dispersion paints and  fillers) and Galen (fiberglass window profiles, basalt-plastic rebar and other composite materials to improve the thermal efficiency of walls). The plant also uses advanced foreign technologies, which have not previously been present on the Russian market. Equipment suppliers to DSK Grad include leading international manufacturers (Sommer, Elematic, AWM, Teko, Weckenmann).

DSK Grad is the first Russian modular housing manufacturer to bring together the whole range of modular production capacities (frame and large-panel construction, colored and textured concrete) at a single site. The capacities are integrated by the latest IT-technologies and an automated control system, which significantly reduce costs and make the production process as efficient as possible.

Unlike earlier modular housing plants, DSK Grad is not limited to any specific residential construction  series. Modern equipment enables the plant to produce modules for any type of housing, offering a huge variety of architectural and planning solutions to achieve industrial production of high-quality, individually designed buildings. The company has already developed its own designs for apartment buildings, Grad-1M and Grad-2M, as well as exclusive layouts for schools and kindergartens.

In 2014 DSK Grad was accorded status as a priority investment project by the Government of Moscow Region. DSK Grad has created more than a thousand highly-qualified jobs and is one of the largest enterprises in Naro-Fominsk District.

Some Innovative Solutions from RUSNANO Portfolio Companies, Used by DSK Grad

  • Fiberglass profiles for windows made by Galen. The profiles are stronger, cheaper and more environmentally friendly than aluminum analogues and can be used for windows of any size, unlike PVC profiles. The composite material can withstand temperatures from -50°C to +90°C, does not rot, does not absorb water and is completely non-toxic.
  • Galen will also deliver composite building materials to DSK Grad, including basalt-plastic rebar, flexible wall connections and wall plugs that can increase thermal efficiency of building walls by 25%. These products are comparable in strength to steel, but much less vulnerable to wear and corrosion. Their quality is confirmed by success on export markets: Galen products will be used for the construction of a metro system to serve the FIFA World Cup 2018 in Doha, the capital of Qatar, where specifics of climate and soil cause rapid deterioration of concrete reinforcements made from steel.
  • Window glass with energy-efficient nano-coatings made by SP Glass. These windows can reduce loss of heat during the winter by up to 70% compared with conventional glass and also help to prevent overheating inside buildings during the summer.
  • Concrete plasticizers from Akrilan, which increase the strength of concrete by 10-15% and give elasticity gains of 15-20%. Akrilan also supplies DSK Grad with nano-dispersion paint, fillers and primers. Akrilan coatings offer durability that is much superior to that of analogues, without using the harmful substances that traditional analogues often contain.

Additional information

Reference

RUSNANO Joint-Stock Company was founded in March 2011 through reorganization of state corporation Russian Corporation of Nanotechnologies. JSC RUSNANO contributes to implementation of the state policy on the development of the nanotechnology industry by investing directly and through investment funds of nanotechnology in financially effective high-technology projects providing the development of new production facilities in the Russian Federation. Its primary investment focus is in electronics, optoelectronics and telecommunications, healthcare and biotechnology, metallurgy and metalwork, energy, mechanical engineering and instrument making, construction and industrial materials, chemicals and petrochemicals. 100 percent of RUSNANO’s shares are state owned. Thanks to RUSNANO’s investments, there are currently 95 factories and R&D Centers opened in 37 regions in Russia. JSC RUSNANO has profit for the last 4 years.

Management of assets of RUSNANO JSC is carried out by Limited Liability Company established in December 2013, RUSNANO Management Company. Anatoly Chubais is the Chairman of its Executive Board.

Work to establish nanotechnology infrastructure and carry out educational programs is fulfilled by RUSNANO’s Fund for Infrastructure and Educational Programs, which was also established during the reorganization of the Russian Corporation of Nanotechnologies.

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Morton Group of companies is a leading Russian developer with a business history of 21 years. The company specializes in the construction of new residential districts in Moscow and Moscow Region, complete with utilities and social infrastructure (education and recreation) to ensure a high quality of life for local people.

Morton consistently ranks among the top three Russian developers by construction volumes and is the largest developer in the Moscow metropolitan area. The company commissioned 1.03 million sqm of new housing in 2014, when new records were set for sales (up by 16% from 2013 in volume terms, while the average price per square meter rose by 14.5%). Revenue in 2014 was 17% higher year-on-year at 60 billion rubles.

The total current project portfolio of Morton Group at the beginning of 2015 was in excess of 7.6 million sqm and the Group was developing 38 construction projects. The Company is also planning a number of major new projects in Moscow and Moscow Region with total area of ​​about 3 million sqm. At present every fourth apartment on the new-build market in and around Moscow is sold by Morton.

Strong growth rates and a secure financial position have justified consistent rise of Morton’s credit rating over the past three years. In December 2014, the National Rating Agency lifted the Group’s rating to A+.

The Group’s strategic goal is to strengthen its manufacturing base, creating a strong industrial and technology core of plants producing modular units, concrete and other specialized outputs.

Morton is pursuing joint projects with leading Asian and Western European companies in high-tech construction and manufacturing, bringing to Russia the latest international developments in transport, energy efficiency and energy saving for residential and office complexes. The Group is implementing new solutions in the construction materials industry and installing innovative life-support systems as a part of its residential developments.