Sapa Group - Shape Magazine 2003 # 2 - Aluminium / Aluminum

Shape A magazine from the Sapa Group • # 2 2003

ALUMINIUM THE HOT CHOICE FOR THE MOTOR INDUSTRY A VISIT TO THE NEW FACTORY IN BELGIUM ALUQUEEN READY TO SET SAIL AROUND THE WORLD AGAIN

8

MYTHS ABOUT ALUMINIUM

The super bike SHAPE PUT A PROFESSIONAL CYCLIST IN THE SADDLE – HE GAVE IT TOP MARKS

CONTENTS

IN BRIEF

A business concept with added value

A hammock for angels creates a secret place in the park

autious signs of optimism are starting to emerge in both American and European economies after two or three years of fairly weak economic activity. In most industrial sectors we are still a long way from the record levels seen during 1999/2000, but we can now see the proverbial light at the end of the tunnel! During the past two years we have been working hard to rationalise costs, improve productivity and reduce tied-up capital, so that we are in a stronger position to face the market. In close collaboration with professional, demanding customers, we have continued to develop our ability to create significant added value for our customers. We have invested and structured our efforts in important sectors, and formed three strategic business segments – Building Systems, Automotive and Mass Transportation.

A hammock for you to rest your tired thoughts at the end of the day. That was textile artist Anita Graffman’s vision with “Hammock for angels”. “As it hangs between the trees, it forms a secret place in the park,” she says. The piece of art is sponsored by Sapa, and is a part of the “Culture Park Project” exhibition at Djurgården in Stockholm. Since August this year seven artists have each displayed their own work, all on the theme of evening time. “I’ve used materials that withstand wind and rain. I took a double-strength fishing net and embroidered it using aluminium foil in various

C

4-6 10-11

Sony orders loudspeaker stand

Staffan Bohman President and CEO of Sapa 2 SHAPE • No 2 2003

10-11

16

8-9

14-15 A visit to the new factory in Belgium

New seats attract attention

Where profiles and welded tubes are manufactured . . . . . . 4-6

Why Sting and The Tube from Denmark are successes . . . . . . . 13

Eight myths about aluminium

Aluminium the right choice for the motor industry

…but the truth is quite different . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

More profiles in new cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15

“It’s like sitting in an armchair”

Sapa’s first female Factory Manager

The pro gives marks to the new bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9

“Take your chance when it comes” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17

“Have faith in the employees”

The seven seas await Aluqueen

Sapa’s founder in a major interview . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-11

The aluminium boat will soon be casting off again . . . . . . . . . . . . . . . 19

Shaping the future

Shape is a magazine from the Sapa Group, published twice a year in eight languages for customers, shareholders, analysts, journalists, employees and other interested parties. Shape is also available on the Internet: www.sapagroup.com

The angels’ hammock can withstand all kinds of weather.

Fantastic views in south-east London

13

WE HAVE CONTINUED to invest in the markets in the

USA, China and Eastern Europe, and we have also set up new production facilities in markets that are new for us, such as Lithuania and China. We have completed several important acquisitions, the most recent of which is Remi Claeys Aluminium in Belgium, see page 4. We are proud of having been able to develop Sapa through a combination of excellent growth and profitability over a long period of time. The fact is that the annual rate of growth has been 10 per cent a year since 1990, which means that our turnover has increased by a factor of three. The biggest challenge is to always surpass previous successes. We are aware of what it means to work continuously to refine our business model, so that our most demanding customers continue to perceive us to be competent, efficient and competitive business partners. As we approach the Christmas period, I would like to thank our customers for the faith that you have shown in Sapa as a business partner. I would also like to thank all employees in the company for your loyalty and excellent work during 2003, and finally I would like to wish us all a prosperous, successful 2004.

colours and thin wires that light up with the aid of electricity. The hammock was then suspended from silver-coloured aluminium profiles,” says Anita Graffman. The hammock measures sixteen metres by four metres, and took almost four months to create. The idea for the piece came from a poem that the artist herself wrote. The opening lines are: “People walk in the park. Their thoughts drift up between the trees, over the meadows and water.” “People come here to the park to reflect. Now their thoughts can also have a place to rest,” says Anita Graffman.

Editor in Chief: Eva Ekselius. Production: OTW Publishing. Changes of address: Customers should inform

their contact person at Sapa, shareholders the institution that manages their account, employ-

Sapa has won another important order from Sony. The aluminium profiles are to be used as components in a new generation of speaker casings and speaker stands. Once more, the profiles will be manufactured and processed by Sapa Aluminium in Poland, the only manufacturer of aluminium profiles in Europe to hold the Sony Green Partner Certificate. “Sony is a leading player in the fast-moving consumer goods segment, and they have strict demands in terms of design, surface finish and logistics,” says Lothar Kanowski, manager of Sapa Vertrieb in Germany. “We’re competitive because we’re involved in our customers’ product development, and we can deliver specially adapted, cost-efficient, logistically smart solutions.” The profiles are being delivered over the course of one year, starting in August/September 2003.

ees their salary department and others the Communications and Investor Relations Department. Tel. +46 (0) 8 459 59 00. Sapa is an international industrial group of companies that develops, manufactures and markets

Residential area with a clean, modern design.

The first phase in a new building project in Deptford in south-east London has been completed. Sapa Building Systems supplied a number of products, including windows, doors and inner walls. The buildings have been given a clean, modern design. The penthouse apartments are fitted with Glostal 325 walls, giving residents an outstanding view over London. The apartments on the lower levels have Monaframe sliding doors and Proframe 325 windows in a dark grey shade. The building contractor is St James Homes, and Sapa’s products were fitted by Wynda Components in collaboration with SBD.

Sales right on track Sapa Mass Transportation has won another order for FSW panels for Alstom LHB, who are building 240 carriages for local trains for DB (Deutsche Bahn). The order is for complete floor and side panels for these carriage frames, and will be delivered over a period of 1.5 years, starting Q2 2004. “Deliveries have already been under way for nearly two years,” says Sven Lundin, Sales Manager for Mass Transportation. “Initially the order was limited to side panels (the walls of the carriage frame). But the results of Friction Stir Welding (FSW) were so impressive that Alstom extended the job to include complete floor panels.” Deliveries to the rail industry are a significant area for Sapa, and since last year have become a separate business segment within Sapa.

value-added aluminium profiles, profile-based components and systems, and aluminium heat exchanger strips. Following divestments and restructuring in 2003, today’s Sapa has sales of approximately SEK 12 billion, and has approx.

7,600 employees in companies in Europe, the USA and China. The company is one of Europe’s leading manufacturers in its field. Major customer segments include the construction and engineering industries.

Sapa supplies panels for local trains.

Economic information: Sapa AB is listed on the Stockholm Stock Exchange’s O-list. Q4 2003 February 6th 2003, Q1 2004 April 15th (AGM), Q2 2004 July 15th, Q3 2004 October 18th, Q4 2005 February

No 2 2003 • SHAPE 3

BUSINESS

*

Welkom!

Shape welcomes the latest addition to the Sapa family Ladders, yacht masts and ski sticks. Bike frames, turbo coolers and window frames. Sapa’s latest acquisition, Belgian company Remi Claeys Aluminium (RCA), manufactures aluminium profiles and welded aluminium tubing for lots of different products. The acquisition is one part of Sapa’s strategy of growing in the European market, and in particular strengthening its position in the Benelux countries.

A How the acquisition took place The first serious discussions with management at Remi Claeys Aluminium took place in 2000 without any agreement being reached. Sapa maintains good relations with RCA. Contact was re-established with management at the beginning of 2003, and the response was positive. An initial meeting was held shortly thereafter, and in early April agreement was reached to buy the main owner’s (the Desimpel family) holding, which amounted to 54 per cent of share capital. During the summer Sapa received the go-ahead from the competition authorities, and in October Sapa took over 100 per cent of the shares.

4 SHAPE • No. 2 2003

n aluminium sculpture created by the world-famous Tony Cragg towers up alongside the entrance to the Remi Claey factory and head office in the small town of Lichtervelde in the northwest of Belgium. This was an initiative by the company’s previous owner, Aimé Desimpel, who died last year. The sculpture is big, but then so were Aimé Desimpel’s ambitions in 1991 when his family took over a centralised, state-owned and neglected RCA. During the 1990s he built up an efficient company based on the core values of specialisation and focus on three activities. The company is characterised by a strong entrepreneurial spirit, which also corresponds with Sapa’s philosophy and is an important strategic value. “RCA is one of the major players on the European market, and is a very interesting complement to Sapa. On the profile side, Sapa can add expertise that we believe will give the business a boost,” says Staffan Bohman, President and CEO of Sapa, continuing: * “Welkom” means “welcome” in Dutch and Flemish.

RCA can complement Sapa’s product portfolio in terms of pressing large, complex profiles. The largest press 1999 Intexalu in France. Manufactures aluminium profiles. can handle profiles that are 620 milli1999 Aluvar in France. Manufactures building systems. metres wide and 26 metres long. 2000 Anodil in Portugal. Manufactures aluminium profiles. “When the large press was bought 2000 Anodizing in the USA. Manufactures aluminium in the early 1990s, it was one phase in RCA’s ambition to be a specialist. profiles. We had the technical expertise in 2002 Pressweld in Great Britain. Manufactures aluminium house, and the ambition to make realprofiles. ly complicated profiles,” explains 2003 RCA in Belgium. Chris Depreeuw, RCA’s current MD. He is backed up by Staffan Bohman: “RCA has extremely good technical » We had the technical expertise in capacity for extruded profiles, as well house and the ambition to make as good market penetration, especially in the really complicated profiles « Benelux countries.”

Sapa’s acquisitions in recent years

“As far as aluminium profile-based construction systems are concerned, RCA will increase Sapa’s existing business by 50 per cent. This is an important addition, which gives us a strong position in the market.” has a well-developed business in terms of aluminium profiles. Despite this,

SAPA CURRENTLY

of the 1990s the company was divided into three business areas so that it could focus on the individual markets. The business areas for profiles, construction systems (RC System) and Alutubes (welded aluminium tubes) are still there today. During the last decade RCA has made a number of investments in several areas. One

AT THE BEGINNING

No. 2 2003 • SHAPE 5

»

BUSINESS

»

was the extension of production capacity through the acquisition of Aleurope’s pressing plant in Ghlin, Belgium. Chris Depreeuw explains that RCA also targeted the construction industry: “It’s difficult to grow organically in the construction sector. So we decided to grow through acquisitions.” RCA completed a number of acquisitions and expanded rapidly in the field of building systems. RCA now has a market presence in large parts of Europe, including Benelux, France, Germany and several countries in Eastern Europe. The head office of Building System is in Landen, near Brussels. What happened with the third business area, welded aluminium tubes (Alutubes), during this period?

“Alutubes is a special niche for RCA, where we’ve got stronger and stronger. The business grew slowly, from 10,000 tonnes to a current level of 25,000 tonnes. The business area accounts for around 30 per cent of RCA’s turnover,” says Chris Depreeuw. The manufacture of welded tubes is a speciality for RCA. The tubes are formed from rolled aluminium bands. This means that » Welded aluminiextremely thin pieces can be proum tubes will duced, as little as always be there, 0.3 millimetres, but it’s a small with fine toleranmarket with little ces. The tubes are also given a surgrowth « face finish. “Welded aluminium tubes will always be there, but it’s a small market with little growth, a niche market with few competitors,” says Chris Depreeuw. “We hope that the collaboration with Sapa can give us the opportunity to move into new markets. It’ll also be interesting to see how the partnership between Sapa Heat Transfer and RC Automotive in Germany will develop, bearing in mind RC Automotive’s production of aluminium tubes for various kinds of heat exchangers. “Remi Claeys Aluminium’s core business used to be welded aluminium tubes. Sapa’s core business is profiles, which means that the focus will now be on that part,” explains Chris Depreeuw. 6 SHAPE • No. 2 2003

Facts • Remi Claeys Aluminium Head office: Lichtervelde. Turnover 2002: 293 million euros Number of employees: 1070. Number of business units: 3. Great Britain ALUTUBES Divided into two parts: Lichtervelde, supplying consumers and industry, and RC Automotive in Remscheid (Germany), manufacturing tubes for various kinds of heat exchangers. Minority holding in the Alabama Tube Corporation (Fort Payne, USA) Capacity (annual): Foundry: 27,000 tonnes, cold-rolling plant: 30,000 tonnes, cutting: 30,000 tonnes, four seam welding machines: 25,000 tonnes. PROFILER Manufactures profiles for industry, the construction sector and the transport sector. Two presses in Lichtervelde and two presses in Ghlin. Capacity (annual): Lichtervelde 20,000 tonnes, Ghlin 18,000 tonnes. Ghlin (RC Aleurope) also has a foundry with a capacity of 35,000 tonnes. RC SYSTEM The Belgian business is based in Landen (head office), Gent and Lichtervelde. In France there are operations in Strasbourg, Bordeaux, Lyon, Lille and Angers. Germany (Velbert), Poland (Wroclaw), Czech Republic (Kladno), Turkey (Istanbul) and Holland (Breda).

The Netherlands Lichtervelde • Brussels • Belgium

Germany

Luxembourg France

Questionnaire • What do you know about Sapa?

Name: Thierry Devos, 32. Position: Supervisor, profile manufacturing. Number of years at RCA: 12. “I know that Sapa has great expertise in and experience of extruding aluminium profiles. I hope that we can learn from Sapa, and also that we can pass our knowledge of products such as large profiles on to Sapa.”

Name: Eric Decoster, 38. Position: Supervisor in packing. Number of years at RCA: 18 “There have been regular changes at RCA. Now that Sapa’s taken over, there will be a number of benefits.”

Name: Jan Verslyppe, 41. Position: Sales manager, Alutubes business unit. Number of years at RCA: 20. “We believe that the deal is positive for RCA. Of course, it’ll take some time to adapt the companies. Sapa will give us opportunities to expand into markets where we currently have no presence within Alutubes.”

GENERAL

h t u r t e and th

8 myths about aluminium Aluminium does not cause Alzheimer’s Disease. Aluminium saucepans are not hazardous. Aluminium does not burn. There are lots of myths about aluminium. Here is the truth. Lage Knutsson from Sapa Technology in Finspång responds to the statements. Statement: 1. Aluminium packaging is harmful to the environment. Truth: Packaging made of aluminium is light, which reduces the energy requirements in both manufacturing and transport. A 33 cl drinks can only weighs 5 per cent of the packed drink, while a returnable bottle made of glass weighs about the same as the content. About 90 per cent of a can is recyclable. 2. Saucepans emit aluminium during cooking, which is said to be dangerous. Saucepans do emit a little aluminium during cooking, but this is not harmful, as only small amounts are involved. Every day we ingest about 12 mg aluminium through the food we eat, such as vegetables or tea. The proportion of aluminium that comes from packaging and saucepans only amounts to 3 per cent of this weight. 3. Aluminium wastes energy. Aluminium saves both energy and the environment. The metal is used in light constructions, which save energy because they are light to carry, lift, move and handle. Vehicles made partly of aluminium thus save fuel. Every 100 kilos saved in weight represents a fuel saving of 1,000 litres during a vehicle’s normal life cycle. This represents a reduction in carbon dioxide emissions of 2,500 kilos. As aluminium does not corrode, constructions made of this metal require a minimum of maintenance and surface treatment. 4. Aluminium should not be used as a building material, as it is highly

Facts: Aluminium • Aluminium is the 13th element in the periodic system, chemical symbol Al. • The surface of the Earth contains on average approx. seven per cent aluminium. • Over millions of years, plants, animals and humans have been adapted to this environment. • Aluminium, like iron, can be considered non-toxic.

inflammable. Aluminium powder, used in such products as fireworks, will burn, but solid aluminium does not burn – it melts. 5. Aluminium can cause Alzheimer’s Disease. In older studies, researchers found higher contents of aluminium in the brain tissue of patients with Alzheimer’s Disease than in healthy people. It was therefore believed that aluminium was a contributory factor to the disease, but at the global conference on Alzheimer’s in 2000 this risk factor was dismissed by medical experts. 6. You should not use aluminium foil when cooking, as it spoils the taste

of food. Aluminium does not emit any flavour, and it is a material that provides a tight seal by creating a hundred per cent barrier against light, oxygen, moisture, odour and taste. 7. The aluminium in the ground is harmful. This is not true. If that were so, plants would die and people and animals that eat grain that is grown in the earth would be harmed. 8. You should not use aluminium trays when baking. Aluminium is 100 per cent recyclable. Many bakers prefer aluminium trays, as they produce better baked products, partly because the trays can better withstand high temperatures. No. 2 2003 • SHAPE 7

ENGINEERING

Lean back and enjoy! The Bigha aluminium bike is no ordinary bike. Professional cyclist Andreas Lindqvist can confirm that. “It’s so comfortable. It’s like sitting in an armchair.” ndreas is a member of the Swedish national action sports team, and BMX cycling is his job. BMX bikes are small bicycles that can be used to perform routines, but when this professional “freestyle rider” gets to try out the Bigha, he waxes lyrical. “This bike’s a real pleasure in terms of comfort. It’s ideal for cycling long distances, for example on country roads.” And that’s probably what the American entrepreneur and open-air enthusiast John Acres had in mind when he started the Bigha project. He holds more than 25 patents, and used to work in the games industry, producing new technical solutions for computer games. Then John Acres decided to create a product that actually served the user, and settled on bicycles. Why should cyclists have to sit awkwardly and stare down at the asphalt, when they can sit up straight and enjoy a better view? The bike was designed after experts had examined the human body and ways in which a bicycle could be better integrated with it.

A

IT WAS ON THIS BASIS that features such as the saddle were developed, but the special feature of the Bigha bike is that it is made from aluminium profiles. This has given the bike its positive properties such as reduced weight and durability, which Andreas Lindqvist really likes. 8 SHAPE • No. 2 2003

Cycling pro gives the new aluminium bike top marks Name: Andreas Lindqvist Age: 29 Profession: Professional BMX Freestyle cyclist for ten years. Member of the Swedish national action sports team.

»Why should cyclists have to sit awkwardly and stare down at the asphalt, when they can sit up straight and enjoy a better view? « “It’s an advantage that they made the bike in aluminium, as the material’s ideal for this kind of vehicle. Easy to carry and to fold up. This makes it easy to take the bike along in the car or on the train. “I don’t think it’ll take much time to learn to ride it, that’ll be no problem at all. But it’s less stable than a normal bike, as the centre of gravity is so far back,” he says. One of the biggest differences between the Bigha and a traditional bike is its saddle and

pedal design. Instead of sitting up straight, on the Bigha you sit on a seat with the pedals in front of the handlebar. This means less of a strain on the back and shoulders, and more comfort when cycling. The handles are designed to reduce the stain on arms and hands, meaning that you hold your hands below rather than above the handlebar. THE BIKE IS ALSO FITTED with a travel computer that shows information such as speed, temperature, wind speed and compass direction, as well as a built-in alarm, which is set off if someone tries to move the bike. In contrast to a traditional bike, you cannot relax and recover your strength. To recover your strength you rest against the back support. “There’s just as much strength in this design, but I still think you’ll ride faster on a normal bike, as they have bigger wheels. On the other hand, this bike’s more comfortable if you’re riding a long way,” says Andreas Lindqvist. “The fact that the front wheel’s small doesn’t really affect the power, as the bike is driven by the rear wheel. So you don’t need to pedal more to build up the same speed as on a traditional bike.” According to the designer, the Bigha is a bike that is built for adventure and discovery, but it can also be used in a city environment. The bike was developed and manufactured in Oregon, USA by a team of 20 experts in the fields of industrial design and engineering, as well as professional cyclists. Bigha means “just because” in the Apache Indian language, and this was the starting point when the bike was developed.

Cycling doesn’t get any better. Imagine pedalling along at a gentle pace in beautiful natural surroundings, looking straight ahead (and not down at the asphalt). Andreas Lindqvist was more than satisfied after his test ride.

Facts • Bigha • Bigha is a bike for excursions and adventures, for day trips out into the woods. Put it in your car boot and drive out to a park. • Originator John Acres explained Bigha in the San Francisco Chronicle daily newspaper as a bike for those “who want outdoor entertainment, who want to

Facts • Sapa Inc. switch off the TV, get out and explore the real world”. • A Bigha bike costs around 3,000 dollars, including freight. The bike is sold direct from the manufacturer via the Internet, which reduces all kinds of intermediaries. • website: www.bigha.com

• Sapa is currently the USA’s major supplier of specially manufactured bike frames. • The concept is called “Billet to bike”, and involves pressing specially adapted hollow profiles, which then undergo several stages of processing. • The process is completed by environment-friendly powder coating. • The end product offers both superior strength and rigidity. • Sapa has pressed and processed both the main frame and the mounted seat for the Bigha bike.

No. 2 2003 • SHAPE 9

INTERVIEW Name: Nils Bouveng Age: 74 Family: Wife and four children, plus grandchildren Lives: Outside Vetlanda. Leisure interests: Hunting elk, deer and hare. And my wife takes me on trips all over the world.

’’The Sapa spirit is the key to success’’ Entrepreneurial flair. Leadership. Innovation. Customer orientation. These were some of the principles when Sapa was founded in 1963. 40 years later, the company has a turnover of almost SEK 13 billion. Despite this, the principles remain the same.

Nils on … … life in retirement “Enjoyable, but can be boring sometimes. That’s when my wife takes me off on various trips, most recently to Morocco.” … entrepreneurial flair “That’s when energetic people who believe in something get things done.” … entrepreneurs of the future “Put figures on everything! It’s important to have a feel for money and to be able to count. And everyone’s welcome to ask us for tips!”

Still on top form. Many important decisions down the years have been made around the billiard table in Sapa’s cellar.

and back-slapping. As we apa is still a company stroll around the area, we that looks after its have the chance to take a customers through look at production and also thick and thin, a company play a game of billiards. that has included entreWhen Lars Bergenhem preneurial flair in its and Nils Bouveng started mission statement, a the company four decades company that believes in ago, very quickly something the ability of its employees. developed that later came to As Shape meets Sapa’s be called the Sapa spirit. founders, Lars Bergenhem Nils and Lars have just started up the press. It is 1963. and Nils Bouveng, on the So what is the Sapa spirit? occasion of the 40th anniversary, it is in “Whoever’s closest, does it,” says Nils a classical setting. We are back where Bouveng. it all started, in Vetlanda in Southern And that’s the Sapa spirit in a nut3 0 0 Sweden. We’re sitting in the staff shell, it appears. It is actually the only -2 3 6 19 canteen during the lunch break. Fried thing that appeared on the organisation plaice and potatoes are on the menu. chart when Sapa was being built up. Nothing complicated, straight to the point. THE TWO FOUNDERS, now in their seventies, What has the Sapa spirit meant for the still feel at home at Sapa. Although they sold company? their company in the 1970s, they still know “The Sapa spirit is and always has been the many of the employees. There is much greeting key to our success. Without it, Sapa would be

S

SAPA

AT 40!

just another average company,” says Nils Bouveng and continues: “The Sapa spirit was born out of the two objectives that Lars and I set up when we founded the company: we wanted to enjoy ourselves and to get rich. The spirit is based on kinship, healthy rivalry within the company, respect for the individual, security and faith in the company”. Sapa has grown to become a large group of companies. What is most important if we’re to retain the Sapa spirit?

“Strong leadership. Both Lars and I were strong leaders, and we dared to surround ourselves with strong people. We had tremendous faith in our employees and close contact with them, we had an openness that created mutual trust, and we could instil our belief in Sapa’s business concept into them,” says Nils Bouveng. If you ask Sapa’s current President and CEO Staffan Bohman to define strong leadership, he immediately refers to the two founders. “As a leader you must be clear, you must dare to make demands and be able to motivate the

England reaches 35, Poland 10 It’s not only Sapa as a whole that is celebrating this year. Poland is celebrating its tenth anniversary, Sapa’s British business its thirty-fifth. The story in Britain began in 1968 with a sales office, then in 1973 the company started to produce profiles on a press at the plant in Tibshelf. Down the years the presses have been developed in terms of both technology and productivity. Sapa is now one of the leading profile manufacturers in Great Britain, producing more than 40,000 tonnes of high-quality products.

organisation so that you get extraordinary efforts from ordinary people. Just as it has been ever since Nils Bouveng and Lars Bergenhem founded Sapa. Of course, all of this means that you must like the people who make up Sapa.” DOWN THE YEARS the Sapa spirit has been developed, but never losing sight of the basic values. Just

as important is the focus on profitability and cost control. From the very outset, Sapa was one of the industry’s most profitable companies. The secret is to put figures on everything, as Lars Bergenhem explains. “For example, we counted and evaluated ten profiles, and only accepted the six that we knew we could make money on. Our competitors were welcome to the other four!” says Lars Bergenhem with a laugh. “For the first ten years I authorised every single invoice!” interjects Nils Bouveng. Good profitability has been maintained long after the founders left Sapa. To find out how this has been achieved, we ask Staffan Bohman: “Easy, it’s down to the four core values and to our employees. Their efforts are the reason why, year after year, we’ve succeeded in growing faster and with higher returns than many of our competitors. The fact that we achieve this is because 98 per cent of decisions are made by the operational companies, not by those of us at group management level.”

Name: Lars Bergenhem Age: 73 Family: Wife and two children, plus grandchildren Lives: On the Bjäre peninsula and in London Leisure interests: Golf, travel and a 1935 Dodge.

Lars on … … life in retirement “It’s a golden age, even if it’s sad to get old. When I’m in London I work at an asset management company where I’m a part-owner. It’s really great to work with young people.” … tips for politicians to improve the entrepreneurial climate nowadays “Politicians shouldn’t get involved in everything. Remove unnecessary bureaucracy and leave entrepreneurs in peace. Then we’d have a good climate for entrepreneurs.”

SAPA AT 40 - THE LANDMARK DATES 1963 Lars Bergenhem and Nils Bouveng forms the company. The first profile is pressed on April 16th. Informal atmosphere, with everyone on first-name terms! 1965 Anodisation plant opened. 1967 Sapa starts to sell processing. 1968 New factory in Sjunnen (Sweden) with one press (1,650 tonnes) and anodisation.

10 SHAPE • No. 2 2003

1969 Sales office opens in London. 1970 Own construction system: Sapa Spont. Sapa and Nokia create the Nordalex company. 1971 Anodisation of boat masts in Vetlanda. Remelting plant in Sjunnen. 1972 In-house tool manufacturing. 1973 Press plant in England.

1974 Sales office opens in Norway. 1975 Processing starts up in Torsby. 1976 Gränges acquires Sapa. One month’s salary for all. Sapa is a sponsor of the America’s Cup. 1977 New press, England. 1978 Remelting plant opens in England. 1980 Electrolux acquires Gränges.

Anodisation in England. 1981 New factory in Denmark. Third press in England. Acquires Thronville Industrial Group. 1983 Sales office in Finland. Turnover SEK one billion, profit SEK 100 million. 1984 Aluminiumwerk Offenburg whollyowned subsidiary. Biggest order so far –

850 tonnes cooler floor profiles for shipyard in South Korea. 1985 Processing in Finspång. 1986 Sapa accounts for 56 per cent of all aluminium profile consumption in Sweden (45,000 tonnes). Consumption per person per year is 5.6 kg. 1988 Sapa celebrates its 25th anniversary.

1992 New press plant in Poland. 1993 Press plant in Vetlanda opened by King Carl Gustaf XVI. Acquisition of press plant and lacquering company in France. 1995 New press plant in Poland. 1996 New welding method for aluminium (Friction Stir Welding). Acquisition of the Bredon Group.

1997 Carl Gustaf XVI opens a new press in Finspång. Sales office in Lithuania. Gränges on the Stock Exchange. 1999 Acquisition of Intexalu and Aluvar. Heat Transfer starts operations in China. Painting and fabrication in Poland 2000 Gränges renamed Sapa. Acquisition of Anodil in Portugal and Anodizing in the USA.

2001 Eurofoil and Autoplastics sold. Norska Elkem acquires shares in Sapa. 2002 New vertical lacquering plant opened. Acquisition of Pressweld in England. Sales offices opened in Spain, the Czech Republic and China. 2003 Processing operations start up in Shanghai. Remi-Claeys acquired.

No. 2 2003 • SHAPE 11

PRODUCT

DESIGN

Fly the flag with Sapa

New profile with a sting

Simple to put up, will not break and virtually maintenancefree. Sapa’s flagpole made from aluminium profile has many benefits. In conjunction with Sapa’s 40th anniversary the pole is available at a reduced price to all customers.

The Sting aluminium chair is a success. The piece has been produced by furniture manufacturer Blå Station together with designers Fredrik Mattson and Stefan Borselius.

I

withstand the English weatt all began back her conditions, the in 1969. The Englishman placed the first trade association’s order. AGM in Jönköping, The flagpole is now Sweden, toured the Sapa’s only pure consumer county together product. And since 1969 with five County more than 100,000 flagGovernors. One of poles have been sold. the stop-offs was at Styrbjörn Lüning. “Flags have become popular Sapa in Vetlanda. in recent years. Many companies display Before the visit, Sapa’s sales their hospitality by raising a visiting engineer at the time, Gunnar customer’s national flag. Marketing Burmann, ran down to the stan3 0 0 your company by flying a flag is also dard profile warehouse, grabbed -2 3 6 9 1 a cheap, simple way of getting your three tubes of various dimenmessage across,” says Styrbjörn sions and sent a message to one Lüning, Product Manager at Sapa. of Sapa’s subcontractors: “Now we’re going to make flagpoles!” AS THE FLAGPOLE is delivered in A few days later the sections, the package is only three flagpoles were five metres long, ready. Weights, flags, which reduces both ropes and rope holders transport and storage were all bought, and on costs significantly. the day of the visit the The customer can County Governors were easily assemble the given the honour of being flagpole on site. the first to see Sapa’s “You don’t need newly- manufactured aluscrews or glue, as a minium flagpoles in use. rubber ring helps the parts to grip tightly to one another,” says Styrbjörn Lüning. SHORTLY AFTER the County The advantage of an aluminiGovernors’ visit, on um pole compared to the traditioSeptember 26th 1969, nal ones made of wood or plastic Gunnar Burmann visited a is that it will neither become disbusiness contact in coloured nor break off. England, who was very “The flagpole is delivered cominterested when he heard plete with rope and everything. about Sapa’s flagpoles. All you need to provide is the Having worked out that actual flag.” the tube dimensions were more than sufficient to

SAPA

AT 40!

Do you want to buy a flagpole at a special price? Contact and order: www.sapagroup.com/flagpoles 12 SHAPE • No. 2 2003

Taking along a few bikes is no problem.

Close collaboration Thule and Sapa have been collaborating for a long time. Now this partnership is being further intensified, as Thule, which develops and produces rack systems for cars, has opened a factory only 20 minutes away from Sapa’s plant in Trzianka, Poland. Sapa and Thule enjoy a successful partnership in Poland, which has been given an extra boost precisely because the companies are so close to one another. But it’s not only in Poland that the companies have ended up close together. In Sweden, it takes about an hour to drive between Thule’s plant in Hillerstorp and Vetlanda, while in Britain it only takes half an hour, and with Thule opening a factory in Poland a short while ago, the plants are only 20 minutes’ drive apart. “Thule is an important customer for Sapa. The proximity between the plants in Sweden, Britain and Poland makes collaboration easier and means more efficient logistics,” explains Anders Thålin, Account Manager for Thule at Sapa. Johan Wilhelmsson, buyer at Thule, emphasises that the short distances mean that deliveries of aluminium profiles are reliable, and that the risk of damage to the profiles during transport is minimised.

A look at Danish innovation.

Bold designs

S

ting received its premiere at a furniture fair at Stockholm in February this year, and then at the furniture fair in Milan. Since then, the chair has attracted tremendous interest. Both designers have a bright future ahead of them. The design is innovative, and nothing has been done to hide the chair’s origin. “No, quite the reverse, we really want to show that it’s aluminium profiles that support the construction,” says Fredrik Mattson. “Extrusion is an extremely productionfriendly, cost-efficient method. The material means that the furniture can be used both indoors and outdoors.” AS ALUMINIUM can be produced in such thin dimensions, the metal is suitable for the manufacture of stacking furniture. One of the criteria was that the chair should take up a minimum of space when stacked. At present the chair adds a total of 13 millimetres in height when stacked, which means that a stack of ten chairs is no higher than 13 centimetres plus the legs. The special feature of the Sting chair, which has aroused so much attention, is the fact that the whole seat is extruded in one piece. It is one of the broadest tools that Sapa has manufactured.

“Aluminium is corrosion-resistant and can withstand all kinds of weather, it’s also an incredibly robust material. It gives a piece of furniture an extremely long service life,” says Fredrik Mattson. The chair’s underframe is made of stainless steel, and the soft upholstery, on models that have it, is made of polyurethane, a kind of rubber. The legs act as a peg, locking the whole construction into place, which is why no glue or screws are needed for assembly.

Facts • Thule

Facts • Exciting aluminium chairs down the years

• Thule develops and manufactures cycle racks, roof racks, roof boxes and ski racks. • Thule develops, manufactures and markets complete, functional luggage systems for cars. • Thule’s aim is to make it easy to take with you whatever you need for an active life, from bikes and canoes to skis and surfboards, etc. • Thule has a presence in all the major markets, and is the world leader in its segment.

In 1938 the Italian designer Gio Ponti developed a chair for the Montecatini company. Even though the chair contained standardised parts, this didn’t stop Gio Ponti from creating a unique chair.

In 1988 the Argentinean designer Jorge Pensi created the Toledo, a chair that has won many prizes. With the Toledo, Pensi succeeded in making use of the special qualities of aluminium.

In 1999 the American designer and architect Frank Gehry developed an alternative to Pensi’s Toledo. The chair is extremely light, but still has a solid appearance.

Sapa has supplied profiles for The Tube, drawn and designed by Karsten Eriksen. The chair was displayed at the Scandinavian Furniture Fair in Copenhagen. With his company, Klapstuhl, Karsten Eriksen has a vision of innovation in the choice of materials, design profile and production methods. The chair is part of a range of furniture called Tubed Furniture, which has been produced by C-Frisk. The prototype was developed in collaboration with Sapa Profiler in Grenå, Denmark. Product development was quick. The first profile came out of the press after only 3–4 weeks, ready to be made into a chair. The design is entirely down to Karsten Eriksen, but Sapa was able to offer support in the form of good advice and adapting the profiles to facilitate production, in terms of such matters as the choice of alloy, anodisation and lacquering. “Now, together with Karsten, we’ve shown that there is innovation in the Danish furniture industry,” says Flemming Larsen at Sapa Profiler. The full range of furniture can be seen at the C-Frisk website www.c-frisk.com

In 2000 the British designer Ross Lovegrove created the Go Chair. With its simplicity and elegance, Lovergrove’s chair is one of the most innovative chair designs of recent years.

No. 2 2003 • SHAPE 13

ENGINEERING

Sapa supplies aluminium components to Volvo, for items including engine brackets, roof racks and seat rails.

An easy choice A heavier car means higher fuel consumption and a poorer environment. But replacing steel parts with aluminium ones reduces the weight considerably. Niclas Hagert at Sapa Automotive highlights the important parts that go to make up the whole.

tions using aluminium than, for example, steel. Aluminium also combines the major benefits of high material strength and low weight at a low cost. “Cars are getting heavier. They have become safer and more comfortable, which is why parts such as engines, brakes, beams, bodywork and wheel mounts are also getting bigger and stronger, to maintain the same level of

this weight trend, and in a performance. This creates positive way. If we develop a secondary weight increase something in aluminium effect, and vehicles are getthat makes a car lighter, ting heavier,” says Niclas you can use smaller Hagert. “Just look at the engines, smaller beams, Golf. It’s been around for and so on. We’ve not yet nearly 30 years, and they’re Niclas achieved our objective, but now into version 5 of the Hagert. car manufacturers are model. The car’s become starting to open their eyes to soluabout 30 per cent heavier than tions using aluminium profiles. the original model, partly due to “At present we supply aluthe increased number of comfortminium parts for items such as related parts.” seat rails, instrument beams, At the same time, fuel conroof racks, engine parts, and so sumption has been reduced. on.” “We advocate trying to reverse

3

4

6

1) Fuel distribution pipe in the engine This pipe distributes fuel to the various cylinders in the engine. Sapa has developed a totally new production method, leading to a cheaper, simpler end product. The fuel distribution pipe made from aluminium profile has been used in all Volvos since 1991, representing 300400,000 parts a year. 2) Engine bracket This is a part that secures the engine to the chassis. Here use is made of aluminium’s excellent impact properties to perform duplicate functions: to secure the engine in place and also to absorb force in the event of a collision. These brackets are currently supplied to the Volvo Car Corporation.

» At the moment the Audi A2 is the car with the highest aluminium content, 37 per cent « 14 SHAPE • No. 2 2003

2

8 7

Why the motor industry is increasingly turning to aluminium

T

1

5

By using a developed ASK aluminium body, the Audi A2 is about 43 per cent lighter than had a conventional method been used. The A2 is now coming off the assembly line in Neckarsulm, Southern Germany.

he advantage of aluminium profiles is that several different functions can be built into one single part. So you can solve several problems simultaneously, according to Niclas Hagert, Sales Co-ordinator at Sapa Automotive. The use of aluminium in the motor industry has increased significantly in recent years. It is often easier to find smart solu-

Here are some of the car parts for which Sapa’s profiles are used

of aluminium contained in a car at present is 120 kilos. Within three years this figure is expected to rise to 150 kilos. In the USA they are even expecting the increase to be as much as 50 per cent in the next five years. Aluminium was first used in cars during the 1920s. It actually all began with aluminium being used in the aviation industry, where they could draw the maximum benefit from the material’s properties. It is light and strong, and is ideal as a construction material for aeroplanes. The con-

THE AVERAGE AMOUNT

cept was developed by the same people, who were also interested in developing the car. Initially a lot of bodywork parts and aluminium panels were also used. After the Second World War extrusion technology started to develop quickly. Aluminium parts from Sapa are used mainly in models produced by BMW, Volvo, Saab, Mercedes, Jaguar and Audi. “Audi leads the way in terms of aluminium. At the moment the Audi A2 is the car with the highest aluminium content, 37 per cent. That’s a lot,” says Niclas Hagert.

3) Roof racks The light weight and design properties of aluminium make it ideal for the manufacture of roof racks. Aluminium can be used to create shapes that would be impossible in steel, for example. The racks are used on cars such as the Volvo Combi and on Scania trucks. 4) Instrument panel beams An instrument panel beam forms the frame from which the whole instrument panel hangs. Aluminium is used here because it is light and easy to shape. Sapa supplies panel beams to

Plastal, who in turn manufacture instrument panels for cars. This product can be found in the Iveco Daily. 5) Seat rails These rails enable you to slide the seats forwards and backwards. Sapa manufactures the rails for exclusive cars, such as Mercedes, Volvo and Saab. 6) Airbag casing The airbag on the passenger side is contained in a casing together with an explosive charge. In the event of a collision, the charge is detonated and the airbag is inflated. The airbag casing is Sapa’s single biggest product, and is supplied to Autoliv, who manufacture the actual airbag. 7) Charge air pipe This part is contained in Volvo’s prestige R-line cars. These have a 300 hp engine in which the charge air pipe transports the air from the turbo to the engine. This part is hydroformed, a technique that enables you to create complex geometries and change the cross-section along the length of the profile. 8) Rear seat backrest The backrest is contained in Volvo’s V70 Cross Country model. The strength requirements for the product are extremely strict, as the passengers’ seat belts are attached to the back frame.

No. 2 2003 • SHAPE 15

CAREER

ARCHITECTURE

Sapa is working to attract more female managers

Ulrika Molander is Sapa’s first female Factory Manager. She is very happy in her role, and hopes for more challenges in the company in the longer term. “It’s a shame that more women don’t get technical qualifications and move into heavy industry,” she says.

“Industry should do more to attract women. Throughout entire organisations, not just in managerial roles. Even when they’re at university, girls have to be told that heavy industry is an option,” says Ulrika Molander.

Sapa is taking part in a project that aims to increase the proportion of women in managerial roles in business. It is being run by the Swedish Center for Business and Policy Studies (SNS). By sponsoring the project, Sapa is showing that this issue is being prioritised within the group. “We believe that it’s an important issue in the sector where Sapa operates, with the preconceptions about the industry being dirty and heavy. This just isn’t the case any more,” says Gabriella Pihl, Information Manager at Sapa. A careers survey has been conducted at Sapa in Sweden to investigate the breakdown between genders. “The result shows that we have a lot of work to do. We’ve now taken the same survey to other companies in the group.” The project will end in February 2004, after which Sapa will continue to work on the matter internally. The glass roof that slides up from the flat roof covered with natural grass has panels that open automatically to provide ventilation.

”Take your chance when it comes’’ T

he chill wind bites on a cold autumn day outside factory unit P4 at Sapa in Vetlanda, but inside the great press hall the warmth is tangible. The lunch break has just finished, and Ulrika is walking out on the floor between the machines. Everywhere, people greet one another – Ulrika knows all of the 90 people for whom she is responsible by their first name. The atmosphere is cheerful. “A lot of people thought it was wonderful when I got the job, especially the women in the organisation. But even the guys think it’s great to be the first to have a female boss. The ones who aren’t so sure just wait and see – and then it’s up to me to prove that I can do the job,” says Ulrika Molander, aged 37. Factory Manager since April this year. Previously she worked as Planning Manager at Sapa in Vetlanda, Logistics

SHE HAS BEEN

Manager in Finspång, and before that in the textile industry. “I’ve always wanted to work in heavy industry. Actually seeing a product take shape is the best thing about it. And I also find engineering really exciting.” “I enjoy being involved and having a say in decisions that are made. And I can do that as a manager. I also think it’s really great to work with people and to see them develop.” AT THE MOMENT Sapa has 56 managers, six of whom are women, equivalent to 11 per cent. The proportion of women among employees is 24 per cent. “It’s a problem within heavy industry at the moment to attract women as employees. I think there are more preconceptions outside the industry than inside: that it’s a male environment, dirty and heavy. Which is a shame, because it’s mostly untrue.”

Is there any advantage in being a woman in this job?

“I wouldn’t say it’s an advantage or a disadvantage, the main thing is who you are as a person and that you’re suitable for the job,” says Ulrika Molander. As for Ulrika, she’s had both male and female bosses, and did not find anything specific to either of their management styles. “I think it’s going too far to talk about male and female. It reinforces preconceived notions. Of course there are differences, but I believe that sometimes people dwell on them more than is really necessary. “The main thing is having the right person in the right place. Having female quotas for top jobs doesn’t help anyone. Then it doesn’t matter how good you are, everyone will just assume you got the job because you’re a woman,” says Ulrika Molander. SWEDEN much has happened in this field in recent years, and here people no longer raise their eyebrows when they see a female manager in an industrial company. But Ulrika does attract more attention when travelling on business.

IN

» It’s going too far to talk about male and female. It reinforces preconceived notions « 16 SHAPE • No. 2 2003

“Further south it’s different. There you can find the person you’re due to meet standing and looking for a man, not even considering that I might be the one they’re due to meet. But I think that’s down to local customs rather than simple bad manners.” Is it a problem that there are often no women at board level?

“Yes, I think it’d help if there were more women on the board. But at the same time I believe you must start at the bottom and work upwards.” in engineering, it is above all the camaraderie at the workplace and the sense of team spirit that Ulrika appreciates. “Sapa has an open attitude to people, and not just in terms of gender. There is a wide range of different ethnic backgrounds, levels of education and ages here. I think that a good mix is valuable, it make the workplace much more enjoyable. “I hope to stay in the company, and in time to have the chance to face more challenges. More people should dare to seize the opportunity,” says Ulrika Molander. DESPITE A GREAT INTEREST

Nice work! An architectonic masterpiece. This is how Lindorff’s new head office in Lahell, half an hour’s drive from Oslo, has been described. “The building’s inviting and attractive, and makes a positive first impression,” says Vegar Andersen, the group’s Information Manager. Lindorff works on the selection, care and development of customers. In sectors such as banking, finance, telecommunications and the public sector, Lindorff provides clients

with one-stop solutions for payment followup and customer development. The architects, Didrik Hvoslef-Eide AS, satisfied the demand for a first-class client entertainment centre by making maximum use of light, space and the beautiful surroundings.

About Lindorff Object: Lindorff office and client entertainment centre. Year built: 2002. City/region: Lahell/Hyggen, Norway Building proprietor: Lindorff Holding A/S Architect: Ark. Didrik Hvoslef-Eide A/S, Oslo Contractor: Ole K. Karlsen Entreprenør A/S Producer: FasadeConsult Aluminium A/S Sapa supplied the following products: façades (SFB 4050), doors (SFB 2050, 2074), glass roof: SFB 5050. Surface treatment: natural anodisation. Glass in roof: clear glass, 6-16-6 laminated on the inside.

Lindorff’s office is in a modern Norwegian residential area, on a hillside with an excellent view down over the fjord.

No. 2 2003 • SHAPE 17

ENGINEERING

THE WORLD The Aluminium Queen

The small car that’s a big help The Access Shopper is a vehicle for people with restricted mobility, adapted for the Nordic climate. Comfort, functionality and design have been brought to the fore in a quite different way than is usual for this kind of vehicle.

T

here should no longer be any obstacle to anyone being able to move around their local area,” says Rasmus Leiro, industrial designer at Labyrint Development AS in Norway. He has worked with a team of six designers to produce the form of the Access Shopper. In development work it was important to give the vehicle a friendly profile, so that it would not appear intrusive to other road users. “We placed great emphasis on giving the vehicle a high-quality profile, both inside and out. We used high-quality materials, hardened glass in the windscreen, which is less vulnerable to scratching than plastic windscreens, eco-labelled ABS plastic and aluminium profiles in the bodywork,” says Rasmus Leiro.

I N THE SUMMERTIME the doors can be removed, and for rainy days the vehicle has both windscreen wipers and a car heater. In winter you can even switch to studded tyres. Isn’t there a risk of being blown over?

“No, the vehicle has a low centre of gravity, and the bodywork is also extremely light. The total weight is 140 kilos.” Why did you decide to use aluminium?

“Aluminium profiles provide a light material with an excellent structure. In this case this was important for the appearance. The design requires tremendous precision when assembling the parts of the bodywork, which is made easier by the use of profiles.” Can the vehicle be used to go into shops?

“Yes, it will fit through regular doors, then it’s up to the shop whether they want to allow the vehicle in.”

The Access Shopper is small, attractive and extremely practical.

Facts: No licence required • Requires no driving licence, nor is there an age limit for driving it. • The vehicle is powered by a battery that will last for up to 40 km. • The maximum speed is 10 km/hour, which is the requirement for it to be permitted on pedestrian areas and pavements. • Since its launch in July, 25 Access Shoppers have been sold in Norway. The next launch will be in Germany, to be followed by the Nordic countries. From start to finished product, the development process lasted only seven months. An Access Shopper costs around SEK 125,000.

Profile School/ The many benefits in screwing edge joints Have you always wondered how to fit a screw joint in a corner? Stay with Shape’s profile school and you’ll find the answer. There are several benefits in screwing an edge joint, such as: – simple processing of holes by drilling, stamping or milling – easy to dismantle when replacing or repairing – assembly in factory or at user’s premises – low machine cost Here you can see three different principles used with frames for windows and doors. Each of these principles will give you a compression force against the straight surface of the section. In the examples in figures 1 and 2, this is achieved with an eccentricity between the holes in the profile and the corner angle. A recessed screw is used for assembly. Recessing the

18 SHAPE • No. 2 2003

assembly holes in the profile is a relatively expensive process, and you can achieve the same result using a separate flange plate or a special screw. The corner angles can be made using an extruded aluminium profile or in a

compression-moulded version. Figure 1. The separate steel flange plate has a recess for the screw. This joint has a tremendous capacity, as the flange plate with its larger diameter can withstand a greater pressure on the edge of the hole in the profile than a screw alone can. In constructions that are subject to extreme force, the profile thickness can be reduced. Figure 2. The screw has been specially manufactured with a thin flange and a recess. There is a corresponding recess in the corner angle. Figure 3. A compression-moulded corner angle is fitted in an open groove in the outer part of the profile in a window frame. The corner angle is fitted with two oblique clamping screws, which provide the compression force. No processing of holes is required here. The application of the design may need to be completed with filler or glue to achieve the necessary seal and durability.

The world is waiting just around the corner. Wim Dijksterhuis is getting ready for yet another voyage around the world, even if his dog Purdy is less enthusiastic about it all.

Aluqueen was built by Sapa in 1983, based on drawings by boat designer Pelle Pettersson. It was used as a promotional yacht to market aluminium as a material. With ten sleeping berths, a conference room, microwave oven, fridge, freezer and ice machine, the yacht was incredibly advanced and luxurious for its time. “We produced Aluqueen in connection with the 50th anniversary of aluminium in Sweden, as the first motor yacht with aluminium profiles in the shell plating. The design actually means that instead of shaping the plate to form a hull, the shell plating is welded using special aluminium profiles,” explains Anders Norlin, project manager at Sapa. “Our intention was to show what can be achieved with aluminium. Fine, curved shapes and a surface that looks just as smooth as a plastic boat, without the angular shapes that are common in boats with a hull made from panels.”

Around the world – again! Easy to look after, easy to sail and with an enchanting design. “Aluqueen” is the only sailing yacht in the world with aluminium profiles in the shell plating. In a few days her owner Wim Dijksterhuis sets off on yet another journey around the world. nents or the use of unsuitable combinations quite simply easier to sail in an aluminium ince 1990, when Dutchman Wim of other metals. boat. The only problem with aluminium is Dijksterhuis bought the aluminium that the metal conducts electricity. If the curyacht, it has sailed around the world a Exactly which parts of Aluqueen are made of rent passes out into the water, galvanic corfew times. He has taken his wife Marianne, aluminium? daughter Susanne and the Jack Russell terrier rosion can occur in the hull. “The hull, deck and cabin.” But galvanic corrosion can be avoided by Purdy along on these journeys. In the last 20 years it has become increafitting sacrificial anodes and painting the “Aluqueen really attracts attention when singly popular to use aluminium to build outside of the hull so that the metal doesn’t she arrives, with her special design, form boats. The material is mainly used for the hull. come into contact with the water. This has to and character. Aluminium’s ideal for During the summer months Wim be done every ten years.” creating attractive shapes,” says Wim Dijksterhuis organises sailing competitions. Galvanic corrosion occurs due to the Dijksterhuis. During the winter months Aluqueen is on “Aluminium’s a strong metal in relation to incorrect installation of electrical compodry land – unless the family’s out on a voyage its weight, which is why it’s mostly around the world. Between 1997 and replaced steel in the yachting world. If 2001 he and his family went on a really “ Aluqueen really long voyage. Purdy the dog is actually Aluqueen had been built in steel, its total weight would have been 20 tonnes attracts attention frightened of sailing, and spends most of rather than 15 tonnes, as it is now. the time hiding in the machine room. when she Aluminium is also a corrosion-resistant What’s your next project? metal, so it doesn’t need as much main“In 2004 I’ll be organising two more arrives, with her tenance as a steel boat. sailing trips.” special design “In general Aluqueen needs much Will Purdy be coming along? Wim and Marianne Dijksterhuis. and form ” less maintenance than other boats. It’s “Yes, of course.”

S

No. 2 2003 • SHAPE 19

FINALLY… Telephone box suitable for people with disabilities

Now the wait for the tram doesn’t feel as long.

Passengers in Nottingham can find shelter The wait for a tram will now be more comfortable thanks to Sapa, who delivered 19 tonnes of aluminium profiles to be used for shelters in a new tram system built by NET, Nottingham Express Transit. NET designed the shelters together with a company called Metalfast and the design company Woodhouse. The design of the shelter was refined and adapted for production by Sapa’s designers. This means that only five different profiles are required, including one used for seats in the shelter. The first phase in the project involves shelters for a tram route between the northern and southern parts of Nottingham. It will be officially opened at the end of 2003. Nottingham plans to further extend the tram system in the next few years. The tram project as a whole has created much interest in the British media, and is a continuation of similar projects in Manchester and Sheffield. Several tram systems are being planned in other major cities in the UK.

Award-winning school furniture The British furniture manufacturer Varitech has produced an awardwinning furniture system for schools and universities. Prize-winning furniture. The furniture had to be easy to dismantle and move, while at the same time still being strong and durable. Sapa in England developed the concept in collaboration with Varitech. Four of the profiles are manufactured at Sapa in Tibshelf, while the fifth and largest profile is manufactured in Sapa’s French facility in Albi. “System 24/15” has attracted a lot of interest in education circles, and has also won the “Special recognition award for innovation”, a competition held by the East Lancashire Chamber of Commerce. 20 SHAPE • No. 2 2003

Sapa has delivered profiles for a new kind of telephone box, which will be installed in Sweden by TeliaSonera and Outstanding Media. The phone boxes are suitable for people with disabilities, which means above all that they are larger and thus easier to enter in a wheelchair. The new phone 1,000 phone boxes boxes also have space for suitable for disabled advertising in the form of users are to be an illuminated panel. In one produced. year 400 phone boxes have been installed in over 40 municipalities.

Collaboration for greater crash safety The Crash Zone development project is a collaboration between Volvo Trucks, Scania’s suggestion for a Scania, the truck with greater crash University of safety. Linköping and four suppliers (Sapa, Finnveden, Accra Teknik and Prirox) to improve crash safety in both private cars and trucks. Crash Zone involves several projects running in parallel for a period of six months, and all tests are conducted in theoretical models. Each participant presents their own proposal. Scania has presented a proposal for how it should look, fitted to a truck.

Sapa expands in Lithuania Sapa is continuing to expand in Lithuania by opening a factory to manufacture components based on aluminium profiles. Lars Forsberg. The business will open at the beginning of 2004, and the company will initially employ 20 or so people. “We’re now stepping up our efforts in an attractive growth market,” says Lars Forsberg, manufacturing manager at Sapa Profiler AB. “Many of our customers are setting up production facilities in Lithuania, so we’ve decided to follow suit by starting our own manufacturing unit.” Sapa has had a sales office in Lithuania since 1998.

Autoliv buys deflectors Sapa has won a new order from Autoliv Sweden for deflectors for the passenger airbag for platform 2 (P2X). The platform includes Volvo models Volvo V70, S80, S60, XC90 and C70.

Customised IKEA training At the beginning of October a customised training course was held for IKEA’s purchasing strategists, buyers and product developers from all over the world. The course was held on an intensive day in Interested IKEA employees Finspång, Sweden, from Germany, Bulgaria, Turkey, Vietnam and where Sapa has Thailand. A new group will two manufacturing be trained in the spring. units. “The training programme has been developed specifically for IKEA. The concept has been drawn up together with IKEA’s training co-ordinator,” explains Tor Zetterström from Swedish company Sapa Profiler AB. “The aim is to provide key people in IKEA with good training about aluminium as a material and to shatter the myth that aluminium is an expensive metal.” The participants also paid a study visit to Sapa’s pressing plant in Finspång. “It was a rewarding day,” says Ulf Svensson, Sapa’s contact person for Ikea. “We showed the benefits of aluminium, and we had the chance to make contacts with key people at IKEA.”

Pool fence protects children The French company Distral has developed a fence for swimming pools made of laminated glass and aluminium profiles. The fence is used to keep children safe from falling in the pool. The fence also has an alarm device, in case anyone tries to climb the fence and enter the area around the pool. Another benefit of the fence is that it provides total cover, meaning that it protects the pool from litter and other airborne dirt. “We chose alu- The pool fence also has an minium profiles for alarm.. aesthetic and practical reasons. The profiles fit in well in all environments, and are easy to manage,” says Mr Manenc at Distral.