Production of aluminium columns

Material
Column cones are rolled from aluminium alloy pipes EN AW-6060. The base of the columns is extruded from aluminium alloy plates EN AW-5754. Materials used guarantee the correct process of robotized welding, polishing and production of anodic oxide coatings on manufactured articles.

Technology of production of standard columns
The new automatic production line features six technologically advanced workstations that can work simultaneously or as separate components, depending on their needs. Full automation of the aluminium column manufacturing process greatly increases productivity. It takes just one minute to produce 1 meter of aluminium column. As a result, the production of a 10-meter ROSA column takes only 10 minutes. The innovative aluminium column production line from ROSA is the only such investment in the world, and solution is protected by a patent. Each stage of the production process is closely monitored and controlled, which makes the final product stand out for its high quality.

Technology of production of nonstandard columns
Apart from catalogue projects, we execute individual orders, compliant with author projects. We have practically unlimited production possibilities which allows for custom design of columns or extension arms. We offer both minor modifications, based on typical cataloged products as well as completely new designs, completely different from our standard offer. Experienced engineering staff in the design and engineering department can execute the design and calculate a price for each customer request. We have a highly developed and modern machine park. Such devices as water cutting machine, laser cutting station, CNC machines, bending machines for pylons, sheets and tubes allow us to make various details of complex shapes, cut various decorative elements for columns and extension arms and bend the columns, extension arms to the specified radius.

Combination of two-element columns
The durable combination of two-piece aluminium columns is ensured by the use of a specially constructed connector made of stainless steel.

The connecting element is blocked by:
 • 3 M10 bolts – for two-piece SAL columns,
 • 4 M10 bolts - for two-piece MAL columns.

Resistance calculations
The resistance calculations of the columns we make in the author's calculation program in accordance with the requirements of EN 40 and EN 1991-1-4. The resistance  is calculated for columns without chamber door fitted.

Permissible load on columns
The basis for the design of lighting columns is the EN 40 standard group.

 1. EN 40-1 - Lighting columns - Terms and definitions.
 2.EN 40-2 - Lighting columns - General requirements and dimensions.
 3. EN 40-3-1 - Lighting columns - Design and verification - Specification of characteristic loading and referred to EN 1991-1-4. Basics of design and impact on structures.2-4 Wind loads.
 4. EN 40-3-2 - Lighting columns - Design and verification
- Verification by testing.
 5. EN 40-3-3 - Lighting columns - Design and verification
- Verification by calculations.
 6. EN 40-6 - Aluminum lighting columns - requirements.
 7. . EN 40-5 - Steel lighting columns - requirements.

The above listed standards, apart from a number of recommendations, specify the method of determining the permissible load on the structure of the column. Calculating the permissible load on the columns takes into account a number of characteristic parameters such as average wind speed, location category, horizontal deviation, shape factor.

Cleaning and maintenance

What is the cleaning and maintenance of aluminum lighting columns?

In general, anodised surfaces are highly resistant to contamination, but maintenance of high decorative surfaces of the columns may require periodic cleaning. Why? Some types of pollutants, due to their properties, can permanently fall on the surface of the column, thus impairing the decorative qualities. In case of columns, these are often pollutants typical of highly industrialized areas: substances used in the operation of roads, industrial plants, etc. The frequency of cleaning and maintenance depends mainly on the user's decision. The vast majority of external factors are unable to negatively affect the quality and durability of the anodised surface.

Important! For cleaning and maintenance of anodised columns only cleaning products with neutral pH (5-9) should be used. What is more, do not use materials and objects that can scratch and damage the anodic coating. After removing the impurities, the surface must be rinsed thoroughly with clean water to completely remove the residue of cleaning substances.

Example of cleaning and maintenance of anodised columns using traditional cleaning and maintenance products for aluminum anodised surfaces.

In  case of extremely difficult to remove solid, permanent precipitates often formed by the crystallization of salt compounds, it is recommended to use specially dedicated products, for example, for removal of heating stones from an installation made of aluminum. These products effectively dissolve all types of sediments without damaging the top anodic layer. An example of such an application could be the removal of salt sediment from the seawater-fed water system after the desalination process from the surface of an anodised column installed in Saudi Arabia. This kind of water in its composition contains lots of mineral compounds. Because of high ambient temperatures, water rapidly evaporates, leaving a solid sediment on the column surface. The picture below shows the anodised column construction before and after cleaning with Calnex C.

For removing all types of paints, adhesives, graffiti and other residues of this type of substances, it is best to use products  for paint coatings removal.  A wide range of solvents such as acetone, nitro or alcohol based solvents are available on the market, which effectively dissolve these impurities while remaining safe for the surface of the column.

Above example of column cleaning from graffiti and glue leftovers from stickers. By using generally available products for removing such contaminants, any dirt has been effectively removed without interfering with the anodic coating. After cleaning there is no any difference on the surface of the column.

Anodising is second to none.Benefits of using anodised aluminium columns.

Among the various ways to protect aluminium, anodising is second to none. In addition to the superior protection against weather conditions, anodised aluminium also features exceptional decorative qualities. Among the many advantages of using anodised aluminium columns, we distinguish:

  • high aesthetics of the column throughout its life;
  • anodised coatings are integrally connected with the surface, so there is no possibility of peeling, spalling or delamination;
  • full protection throughout the life of the service;
  • high resistance to UV radiation,
  • high abrasion resistance due to greater hardness of the coating,
  • anode surfaces are free from corrosion,
  • availability of a wide range of colours dyed with electrochemical and interferential methods;
  • possibility to recycle the material (100% recyclable);
  • decorative surface function.

We take care of the environment

Moreover, our line is equipped with modern devices that significantly reduces the negative impact on the environment. This is a waste water neutralizer, air purification system, or a number of devices that limit energy and water consumption. Thanks to our modern laboratory we constantly control the parameters of the bath, the composition of waste water discharged and the consumption of chemicals.