# 1 2009 SHAPE • 1

A magazine from the Sapa Group • # 1 2009

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BRIGHT FUTURE FOR LIGHTING DESIGN

THE ARTIST WHO SWITCHED FROM PAINT TO ALUMINIUM

NEW SURFACE FINISH STOPS CORROSION

SOLAR-POWERED BILLBOARD SAVES ENERGY

Shape

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windS OF CHANGESAPA ON CONTRACT FOR WORLD’S BIGGEST WIND FARM

Aluminium profiles are becoming increasingly popular in the furniture and lighting industry. Optimised design using aluminium profiles can deliver savings of up to 50 percent in manufacturing costs, according to Sapa in Spain.

Shaping the future

Sapa is expanding into new markets. We are recruiting tal-ents of all nationalities and growing stronger internationally to help our global customers even more with their specific

needs.Our presence in 29 countries enables us to work more closely

with customers during every stage of development. Together, we can solve the challenges of making products designed specifically for your market.

Making customised products can be a complicated business. We are well aware of the efforts that are required to create clever solutions. A close working relationship between suppliers and customers helps achieve this. That is why, wherever you are, we aim to be there too, for instance through Sapa’s three global busi-ness segments – Mass Transportation, Thermal Management and Automotive.

Finding ways to reduce CO² emissions is one of the automo-tive industry’s greatest challenges. Pressure is on the industry to produce vehicles that consume less fuel and emit less CO². One solution is to build lighter, aluminium vehicles, since they use less fuel and release fewer CO² emissions than heavier, steel vehicles. Sapa’s contribution is to increase the share of aluminium parts.

One of our customers, Audi, was one of the first car manufac-turer to produce an aluminium car. Today we have the technology to serial produce aluminium cars and most vehicle manufacturers are moving towards using more and more light-weight aluminium in their vehicles.

At Sapa, we are working hard to not only facilitate the manufac-turing of aluminium cars, but to find ways to do so at a reasonable cost. Investing in such activities is especially worthwhile when the world is looking for solutions to environmental problems.

Our goal is to develop an aluminium solution suitable for your business, no matter what industry you are in, or where you are located in the world.

Let Sapa add value to your business by making it our business.

Ole Enger, President and CEO

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18Sapa is an international indus-trial group that develops, manufactures and markets value-added aluminium profiles, profile-based components and systems, and heat exchanger strips in aluminium. Sapa has annual sales of approximately SEK 35 billion and roughly 15,000 employees in compa-nies throughout Europe, and in North America, Central America and China. Shape is the Sapa Group’s customer magazine, and is issued twice annually in 14 languages. Shape is also avail-able at www.sapagroup.com

Editor-in-Chief: Eva EkseliusEditor: Anna-Lena AhlbergGraphic design: Karin LöwencrantzProduction: OTW PublishingPrinting: Strokirk-Landströms, Lidköping, SwedenChanges of address: Customers should inform their contact person at Sapa, employees their sal-ary department and others the Communications Department on +46 (0) 8 459 59 00.

CONTENTS #1

Sapa’s business segment managers talk about globalisation and the benefits of working closely with customers. Early involvement right from the design stage can be the key to a successful solution.

Geometric art works created from aluminium profiles have become the signature of Lars Erik Falk.

“I didn’t want to use a beautiful material … it detracts from the impact of the composition,” he says.

A new surface treatment for the car industry from Sapa Components gives aluminium parts better protection from corrosion due to alkaline chemicals.

The world’s largest ocean-based wind farm is being built in the North Sea. The wind farm consists of 80 turbines that will start generating electricity in autumn 2009.

2 SHAPE • # 1 2009

Closer to you

BRIGHT FUTURE for aluminium

Aluminium has many properties that make it suitable for furniture and lighting. it is strong, practical, weather-resistant – as well as aesthetically attractive.

Sapa Profiles in Spain has chosen to invest in the furniture and lighting industry by working closely with customers right from the design stage.

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DESIGN

4 SHAPE • # 1 2009

DESIGN

It may seem remarkable today, but in the early 20th century, before aluminium began to be used industrially, it was regarded as an expen-

sive and exclusive material, and was often used by designers and artists of that period.

Today, this once exclusive material has become a utility material thanks to improve-ments in technology. As a result of growing general interest in interior design, aluminium has also become more relevant in high-quality applications where design, innovation and aesthetics are important factors. Nowadays alu-minium is more often associated with futuristic concepts and high-tech design, which makes it a prime candidate for the manufacture of furni-ture and lighting.

SAPA IN SPAIN has seen increased use of aluminium profiles in the furniture and lighting industry, and is strongly committed to the industry and its cus-tomers. In Spain alone, production in the furniture and lighting industry rose by 10 percent in 2007, compared with the previous year, and exports climbed by 22 percent between 2006 and 2007.

The combination of good design with the vari-ous advantages of aluminium can create numerous benefits.

“Good design should not make the end prod-uct more expensive – just the opposite. A well-designed product can instead be cheaper to make,” says Raquel Fernández Campaya from the market-ing and communication department, adding that optimised design can cut manufacturing costs by as much as 50 percent.

BECAUSE ALUMINIUM is recyclable it enables practi-cal design to be combined with ethical values. It is also possible to integrate several functions in a single profile, making production more efficient, which can ultimately lead to a product that is even more innovative and attractive, explains Raquel Fernández Campaya.

“Designers today cannot focus solely on the elegance of the finished product and ignore the

industrial aspects; they have to combine aesthetic, production and technical requirements.”

Sapa Profiles in Spain offers a collaborative part-nership with customers in order to develop practi-cal solutions together. The plant in La Selva has specialist expertise in this area, and Sapa has recent-ly opened a new application centre for research and development in Navarra, where customers can get advice from experts and engineers during the prod-uct development phase. One of the companies with which Sapa has entered such a partnership is the lighting company Ornalux, which among other products, makes advanced lighting for hospi-tals, trade fairs and exhibitions.

“Working with our customers right from the design stage is important, as it means we can contribute our experience from the outset,” says Matteo Luppi, managing director of Sapa in Spain.

“In future we aim to become an integral element in the client’s value chain, in order to provide a glo-bal service. We offer collaboration in the design of profiles, mechanical solutions and surface finishes, so that customers can concentrate on their core business – design.”

TEXT JESSICA JOHANSSON

“Good design should not make the end product more expensive – just the opposite. A well-designed product can instead be cheaper to make”

SHAPE ASKED A FEW OF SAPA’S CUSTOMERS IN THE LIGHTING

INDUSTRY WHY THEY USE ALUMINIUM PROFILES.

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Ataro, made from a con-tinuous aluminium profile.

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The Waldmann Group is one of the leading lighting companies in Germany, and designs lighting for offices and the workplace, as well as medical lighting. We talked to

Wolfgang Auber, marketing manager.

which products do you use aluminium profiles for, and why?

“For desk lamps, floor lamps and industrial lighting. Aluminium profiles are high-quality materials with a long life and excellent thermal conductivity, which is especially important when lamps are fitted with LEDs.”what are the advantages of this material?

“We buy in semi-fabricated profiles and it’s relatively easy to add other components, using screw fasteners or by bonding, for example.”what quality requirements do you impose when choosing materials for a new prod-uct?

“Long life, the right material properties for each application, the ability to apply surface finishes in different colours, manufacturing requirements, the ability to recycle the material, and materials handling requirements for production.”what was the main challenge with your new Ataro lamp?

“The challenge lay in bending the long alu-minium profile and thus creating a one-piece aluminium frame without joints.”

Hoffmeister Leuchten GmbH in Germany manufactures, among other things, utility lighting products for architect-designed indoor and outdoor settings. Frank Lesch, purchasing manager, replies.

why do you use aluminium profiles in your products?

“It’s the best solution for creating lamp hous-ings with the same cross-section but in different lengths. Aluminium profiles are also light, and with an anodised finish you also get good corrosion protection. We use aluminium profiles for indoor and outdoor lighting, and for lighting tracks.”what are the benefits?

“Aluminium profiles are light, they’re easy to machine and they have good thermal conductivity.”

Have you encountered any challenges in pro-ducing furniture and lighting in aluminium?

“The main challenges in the design of new lamp housings lie in meeting the designer’s requirements for thin walls and creating new, contemporary shapes in the manufacturing process.”

1SHAPE ASKED A FEW OF SAPA’S CUSTOMERS IN THE LIGHTING

INDUSTRY WHY THEY USE ALUMINIUM PROFILES.

Modular Lightning Instruments in the Netherlands produces inno-vative lighting designs for concert halls, private homes

and offices. Tom Samyn, marketing manager, answered as follows.

why do you use aluminium profiles?“Aluminium profiles are incredibly versa-

tile, which is essential for products that are ordered by length. Modular uses 15 different aluminium profiles, each with a unique design. It’s not just the visible shape of the profile that is important, but also the internal channels, which are part of the design of the profile and help to make installation easier.”what do you use the material for?

“Aluminium profiles are used in our light pro-files business area. This division specialises in products that are ordered by length. We start with aluminium profiles with a maximum length of six metres. We cut the profile to the desired length and make holes for mounting different types of light sources. Each order is unique, with different designs, lengths and configura-tions.”what are the benefits of this material?

Aluminium is an incredibly flexible material. It can also be 95 percent recycled, which is an increasingly important factor due to concerns over the environment and sustainability.”what do you see as the biggest trend in lighting products at the moment?

“Right now it is fashionable to use coloured aluminium profiles. White and black profiles are very trendy, whether they are anodised or lacquered.”

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Bibox spotlight.

Lighting profiles for offices.

6 SHAPE • # 1 2009

DESIGN

Products from Ornalux in Spain include high-tech lamps for hospitals, official buildings, exhibitions and office environ-ments. We spoke to Isabel González de los Reyes, co-ordinator.

why do you use aluminium profiles?“The main characteristic of the material

is its flexibility – it’s possible to shape alu-minium in so many different ways. You can produce a great variety of finishes to suit the image you want the product to convey and its intended purpose. The material also enhances designs; it is hard-wearing and completely recyclable.”which components do you use alu-minium for?

“For any components that have a regular cross-section, where we can exploit the mechanical properties of aluminium, such as its thermal conductivity, light weight and ability to take an anodised finish.”what are the design benefits of extrud-ed aluminium?

“It’s a material that stands for elegance, practicality, quality and concern for the environment.”How have you benefited from Sapa’s services?

“Sapa have made constructive sugges-tions that have improved our design.”

Imperial is a lighting manufacturer that has a market lead in Poland and sells a product range that extends to over 2,000 different lighting products. Export man-ager Bartłomiej Družba replied as follows.

For which products do you use aluminium profiles? “We’ve designed our own aluminium profiles and we use them to

produce the lamp housings for our Profi range of products.”what are the current trends in lighting in the Polish market?

“The Polish lighting market has grown in recent years. Poland fol-lows all the European trends in lighting. Suspended and recessed light fittings for T5 light sources with housings made from aluminium profiles are very popular. LED lighting is also popular.”what are the benefits of aluminium?

“The most important benefits are reductions in product weight, bet-ter cooling for electronic components and all the design possibilities.”

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Etherea office lighting.

# 1 2009 SHAPE • 7

BRIEF NOTICES

A letterbox in each door – rather than mailboxes at the entrance – has been the norm for apartment blocks in Sweden for some time. But

this is about to change as a new company, Blockbox, aims to offer a totally new alternative to the basic solutions that have been available so far.

“We want residents to feel that home begins at the entrance to their apart-ment block,” says Markus Berglund from Blockbox. “In an age when interior design is so important, it’s only natural to expect a touch of elegance in the stairway.”

Blockbox mailboxes are available in a choice of styles, with replaceable components. The company has given a lot of attention to the design of the boxes, even ensuring that the sound they make is muted when opened and closed.

The Swedish post office’s requirement for central locking and architects’ requests for a modular design were naturally taken into account at the design stage.

Blockbox developed the range using aluminium profiles, in order to keep the investment and tooling costs to a reasonable level.

“Sapa have been a valuable sounding board throughout the devel-opment process,” says Markus Berglund. “Aluminium profiles make it easy to develop modular solutions. We can extend the width and height as required. And of course Sapa can supply an enormous variety of surface finishes, so we can create a wide choice of variants based on just a few components.”

Did you know that ... … if the weight of aluminium cans were reduced by five percent it would cut carbon dioxide emissions by 78,000 tonnes in the European market alone.

Partnership delivers the mail

In the hotel and outdoor restaurant business they’re known as “jumbrellas” – those ultra-sized umbrellas or parasols that offer shelter from sun and rain.

Take the Bahama Largo by the German manufacturer Becher Textil- & Stahlbau GmbH. A single unit provides up to 64 square metres of outdoor roofing. Unfolded, it can withstand wind gusts of up to 130 kilometres per hour. It looks like a stylish tulip, with built-in lighting and manoeuvring gear drive, and it can collect rainwater inside, draining it directly into the sewage system through the centre pole.

Becher Textil- & Stahlbau has more than 30 years of experience in processing and even welding aluminium. The company appreciates Sapa’s reliable deliveries, readiness and flexibility to meet technical requirements and its ability to under-stand a customer’s particular needs.

Designer shade and shelter

Source: Aluminiumriket (A Swedish aluminium business association)

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Finland’s aluminium boom

For decades, wooden interior wall systems and partitioning systems

were the rule in Finland. But when things started to change, Finnish interior build-ing and construction specialist Muotolevy Oy didn’t want to be left behind.

“Architects love aluminium,” says Mika Kujanpää, sales manager for interior wall systems. “Aluminium systems have been growing for years and are now at least as popular as wood.”

Muotolevy soon realised that a tailor-made design was needed to meet the requirements of sound isolation and flexibility.

“Our cooperation with Sapa has been successful and we got a lot of valuable advice when developing our product,” says Kujanpää.

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ENVIRONMENT

SAPA COOLSNORTH SEA WIND FARM

8 SHAPE • # 1 2009

The biggest ocean-based wind farm is currently being constructed in the North Sea. ABB has the task of linking the new wind farm to the German grid – a task that requires effective water cooling.

“Continuous improvements are being made in the water-cooling system and Sapa have an active role in this,” says Pontus Mellung, who handles purchasing from Sapa at ABB’s HVDC division in Ludvika, Sweden.

German energy company eon is responsible for constructing the wind farm that will supply power to the German grid. The

output from the wind farm is equivalent to that of the average coal-fired power plant, or half a Swedish nuclear plant.

abb’s role in the project is to transfer power from the wind farm. This is one of the biggest single contracts for abb in 2007, with a value of sek 2.7 billion. The contract is for an hvdc Light system, a transmission technology in which abb has a strong lead.

“It is proven technology, but this is the first time we are using it on our own offshore plat-form with an unmanned operating centre,” explains Tommy Lövehagen, overall project manager at abb.

“This requires other solutions, since offshore installations increase the need for automation and communications. The platform is 128 kilometres offshore. We have to be able to carry out most of the inspection and maintenance without travelling out to the platform. Information on

status and any faults is sent to a manned centre onshore by fibre optic communication links.”

On the platform, electricity from the wind farm is converted from alternative current to direct current and then fed by cable to an onshore receiving station, where it is converted back to ac.

ELECTRICITY IS CONVERTED at either end of the cable by converters known as valves. This process gen-erates heat, which has to be carried away by cool-ing profiles made by Sapa in Finspång, Sweden.

“The high precision that is required for effi-cient cooling is achieved using profiles that are joined by friction stir welding (fsw),” says Rolf Pettersson, sales representative for cooling pro-files at Sapa.

A large number of water coolers of different types are needed to keep temperatures down. Sapa therefore maintains close contact with abb so that products can be continuously developed. Numerous other aluminium products are also being supplied for the project.

“We’re working together to develop new prod-ucts and to refine existing ones. A team from abb meets up regularly with representatives of Sapa,” says Pontus Mellung.

According to Tommy Lövehagen there is a great deal of optimism about offshore wind farms:

“It’s the first time such a big installation has been built offshore and it’s important that it is successful. This is a growing market and we’re working very hard to establish a strong position in this field. We also have a unique technology for this type of project.”

TEXT MATS LUNDSTRöM

Tommy Lövehagen

The wind farm in brief

• The project is called NordE.ON 1 and the instal-lation is located 128 kilometres off the North Sea coast of Germany.

• The wind farm is made up of 80 wind turbines that will be brought into operation in autumn 2009 and will have a combined output of 400 MW.

• There are plans to build further large clusters of wind farms, with each cluster consisting of sev-en to eight wind farms. The clusters are called Borkum 1, Borkum 2, Helgoland and Sylt.

• Germany is investing heavily in offshore wind power. By 2020 the total output is expected to be 12,000 MW.

# 1 2009 SHAPE • 9

SAPA COOLSNORTH SEA WIND FARM

GERMANY

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BORKUM 2

Cuxhaven

BremerhavenWilhelms-haven

Emden

NORDEN

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128 km

10 SHAPE • # 1 2009

A pneumatic elevator – sometimes called a pneu-

matic vacuum elevator – is like a crystal tube containing a cabin that travels up or down to the desired level through no visible means of propulsion. Air, or rather the absence of air pressure, silently lifts the elevator to an upper floor, and atmospheric pressure gently pushes it back down to the ground floor. A pneumatic elevator uses a small amount of regular-voltage electricity on the way up and none at all on the way down.

This new kind of elevator, which was initially developed about 10 years ago, is rapidly gaining market share in single-family houses. The installation takes up no more than a square meter of space and doesn’t require a pit or a machine room. The devices are easy to install and you can even take them with you when you move.

Elevadores Neumáticos Ibéricos S.L. is a manufacturer building up a solid position in Spain and Portugal after just two years in business. Sapa supplies the aluminium profiles – bent, machined and finished according to Elevadores Neumáticos’ own design and specifications – which are used for the tube’s frame, including rings and clasps.

Pneumatic elevators break new ground

BRIEF NOTICES

Switzerland-based Montech is a world leader in the automation of complex production and intralogistic processes. Its successful Montrac modular

transport system, widely used across the world and industrial fields, relies on a monorail track made of clear anodised extruded aluminium supplied by Sapa. A wide range of standardised components, such as curves, shuttles, lifts, crossings and switches, allow a variety of layouts and configurations according to the customer’s needs.

Since the length of these rail systems can amount to hundreds of metres of track, supporting an intense traffic of moving parts, extreme precision and a high resistance to torsion are required. “Aluminium profiles with a perfect and sustained quality level and a positive visual impact contribute a lot to the success of our prod-ucts,” says Marco dal Maso, purchasing manager at Montech.

On the right track

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First project for unitised curtain wall

Sapa Building System has won a project for new offices at the Polish Academy of Sciences in Warsaw. It is the first application for

the new unitised curtain wall.A unitised curtain wall is a facade of panels – made of aluminium pro-

files – and glass that is put together in the factory and then installed on the building at the site. With the unitised system, the lead times at the site can be reduced substantially.

“The first order is the ultimate test of all features of the unitised curtain wall,” says Hans Johansson, business area president, Sapa Building System.

15,000cans were used to build a 12-metre tall model of the Eiffel tower, which was exhibited at the Aluminium 2008 trade fair in Essen in September.

Source: Aluminiumriket (A Swedish aluminium business association)

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# 1 2009 SHAPE • 11

PROFILE

LARS ERIkFALkIt was when his name appeared in Sweden’s National Encyclopaedia that Lars Erik Falk realised he had become a part of Swedish art history. Now he has written a book about life and art, and a little about aluminium.

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12 SHAPE • # 1 2009

His creations are geometric, often constructed using the same equal-sided, L-shaped aluminium profiles from Sapa. The racks in his attic studio support metre after metre of the raw material.

“My work isn’t based on real life. Instead I use the aluminium profiles to build my own reality. My sculptures are called modular sculptures and modular reliefs. The modules are identical all the way, so I can build whatever I want,” says Lars Erik Falk.

His studio is simply the top floor of the house that he and his wife Margit have shared for dec-ades. The walls are covered with drawings signed by his children and grandchildren. Lars Erik has at least three work benches. When one becomes too cluttered he simply moves to another. A bookshelf houses a personal library of books on constructiv-ists such as Olle Baertling, who always instructed taxi drivers to take an extra turn around Lars Erik Falk’s sculpture at Hornsplan in Stockholm.

hIS STUDIO IS FILLED WITh machinery and tools, since he builds his sculptures himself.

“Obviously some of them won’t fit in here, as they can be twelve metres high. So I build them at a boatyard,” he says.

There are books and paintings on the stairs lead-ing to the top floor. He has just completed two exhibitions, one in Stockholm and another in his hometown of Sigtuna.

“It’s hard work, you have to meet people and sign books and hold an opening exhibition. I may also have an order for a public artwork, but I can’t talk about that yet; it’s too early. You often get enquiries, but then there’s so much bureaucracy that it can sometimes fall apart. So I’ll probably get to grips with that once I’ve had a little time off.”

His new book Life/Art Lars Erik Falk is mostly self-biographical. Many unsuccessful artists passed through the doors of the cut-price hotel that Lars Erik’s father owned in Uppsala. Sometimes his father had to accept paint in lieu of payment for hotel bills that never were paid. His parents were sceptical of his artistic ambitions, and as a result his debut came later than usual. His first independent exhibition was in 1952. Lars Erik Falk is one of few artists who has not followed trends and fashions.

He calls himself a constructivist, since he does not portray what he sees around him, but creates his own worlds.

He has remained loyal to constructivism since he first encountered it. In the 1940s he studied painting under the Swedish artist Isaac Grünewald, who was infuriated by his student’s interest in the abstract.

“SO, YOU’RE CREATING a new reality – is this one not good enough for you?”

“The answer is that I want the freedom to do what I want; I don’t need to spend my time paint-ing people. That doesn’t mean that I set myself above those who paint figuratively. A friend and I often sit and philosophise about the difference. We’ve come to the conclusion that it doesn’t matter how it looks, as long as the art is good,” he says.

ALThOUGh hE DESCRIBES

contemporary art in his book as “young women with figurative period pains”, he is more diplo-matic in real life.

“My approach isn’t at all intellectual or about work-ing with installations. You know, the idea of setting a tiger trap and creating an interior. That’s not the way

I work at all. But I feel there is room for differ-ent lines of attack.”

He always makes meticulous drawings first. And he recommends younger artists to burn everything they are not happy with, as he has done himself.

“If I don’t use paint, I use wax to create a slight sheen. I rub in car wax, and it turns out that Sapa does the same when they want a slight gloss”

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Lars Erik Falk’s distinctive leaning profiles, seen here on Karlavägen in Stockholm.

# 1 2009 SHAPE • 13

The artist in close-up

Born: 1922 in Uppsala, Sweden.Trained: By Otte Sköld and Isaac Grünewald. Studied graphic design at Beckmans College of Design. It took until the 1980s to make a liv-ing from his art.Family: Sons Hans, Johan and Gunnar, with his former wife Kerstin, and son Mikael with his present wife Margit. Home: Sigtuna in Sweden.Other interests: Enjoys reading proletar-ian authors; the books he has most enjoyed recently are those of Elsie Johansson.Favourite work of art: A cardboard guitar by Picasso.

“I’m glad I did. It’s no fun to see work that’s not good. And it’s immoral if people buy it for good money.”

Lars Erik grew up in an environment that was social democrat in every respect. His sons were active in the radical student movement of the late 1960s, and Lars Erik designed posters in protest against the commercialisation of Christmas, among other things.

hOWEVER, hIS OWN art carries no political or emo-tional message.

“It’s easier to write about that than to paint it. I also feel that art takes place in the eye of the beholder,” he says.

The constructivists are a small group, with a not entirely fashionable perspective towards art, in an age when controversial photo-art and dia-mond-studded skulls are in the media spotlight.

“There’s so little left when you distil a theme as I do, so what remains can sometimes be per-ceived as cold. But we have a passion like any other artist.”

From painting the Uppsala plains in the 1940s, he progressed into cubism and geomet-ric cardboard figures, when painting became too two-dimensional. Then he turned to alu-

minium, the material that has since become his signature.

“I didn’t want to use a beautiful material, which is not to say that aluminium is ugly. If you use copper, it is beautiful in its own right. It detracts from the impact of the composition.”

You can also paint aluminium. Lars Erik’s sculptures are often painted in bold, primary colours. It’s a time-consuming job to get the finish just right, which he does himself.

“If I don’t use paint, I use wax to create a slight sheen. I rub in car wax, and it turns out that Sapa does the same when they want a slight gloss,” he says.

ALUMINIUM IS ALSO IDEAL in another respect. It works well on a large scale.

“It’s part of my approach to art, that I see and express the full extent of the images I work with. I’ve naturally pictured in my head how it would look if it were full size. But there’s still an element of uncertainty. Will it be good? Will it appear as I hope? How will it be received? It’s hard work, and it keeps me awake at night. I’ve never been disappointed yet, but it’s still just as difficult every time.”

TEXT EMMA OLSSON

These 16-metre tall aluminium profiles reach for the sky from the platform at Kista underground station in Stockholm. Lars Erik Falk also chose the colour scheme for the entire station.

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14 SHAPE • # 1 2009

SAPA PROFILES’ BUSINESS SEGMENTS have been estab-lished to harness the Group’s global resources in order to meet the specific requirements of cus-tomers in the automotive, rail and marine, and telecoms and electronics industries. Although quite different markets, they share certain charac-teristics that have enabled Sapa to develop a single

philosophy that drives the business forward.All three are challenging markets, and to

become part of them, Sapa has recognised the need to become much more than simply a sup-plier of aluminium profiles. One of Sapa’s key strategic pillars is customer intimacy: each busi-ness segment has set itself the task of immersing

teams of sales, marketing and technical experts in the markets, developing specialised knowledge and a close understanding of how the key players work and exactly what they want from their sup-ply partners. The key objective that the business segments share is to add value and move from sup-plying profiles to delivering solutions.

Sapa Profiles’ three strategic business segments serve three different markets but share one philosophy: to move the operation from the supply of profiles to the delivery of solutions.

INSIGHT: BUSINESS SEGMENTS

THrEE mArkETS – ONE PHILOSOPHY

Tolga Egrilmezer Lars-Inge ArwidsonVictor Schneider Lars Forsberg

14 SHAPE • # 1 2009

# 1 2009 SHAPE • 15

THrEE mArkETS – ONE PHILOSOPHY “OUR BUSINESS SEGMENTS build one-to-one rela-

tionships with customers and identify design and supply solutions, then operate across all Sapa territories to ensure a seamless supply operation when and where in the world the cus-tomer wants it,” Forsberg says.

Forsberg has overall responsibility for two business segments, Sapa Thermal Management and Sapa Mass Transportation.

Sapa Thermal Management, with its roots in the telecoms industry, began by working with Ericsson on enclosures. When a push from the market drove production towards Asia, Sapa set up a manufacturing facility in Shanghai.

Sapa Profiles business segments work as part of the customer’s design and development team, which they describe as engineering in partner-ship. “As an integral part of the customer’s design team, we can help produce better solu-tions,” says Lars-Inge Arwidson, Sapa Thermal Management’s manager.

“If we’re working with our customers from the outset, we can carry out the necessary thermal calculations to arrive at the optimum design,” Arwidson says. “Take heat sink devel-opment: with involvement at an early stage, we can advise the customer how best to design for maximum efficiency to extend component life.

“OUR MARKET CAN encompass any application where you need to get heat away from elec-tronic components. We’re looking to build on our established base in telecoms where we’ve developed expertise alongside market leaders like Ericsson and Nokia, into applications such as power, consumer products, windmills and hybrid drives.”

Sapa Mass Transportation is the smallest segment with the biggest global ambition, segment manager Tolga Egrilmezer says. “One week our team can be working on a high-speed passenger train project in Europe,

and the next we might be visiting an Asia-Pacific shipyard.

“In rolling stock there is growing emphasis on public transportation, and we’re seeing major developments in everything from trans-continental high-speed trains to tram and metro networks.

“Some significant high-speed train projects are coming up in North America in the next 10 to 15 years, and aluminium is still in its infancy in this market,” Egrilmezer says. “We need to be able to talk to our customers’ customers to encourage the specification of aluminium.”

A jOINT VENTURE with Alcoa has had a major impact on the size and structure of Sapa Profiles’ business. “Shortly after the formation of the joint venture there was a major strategic review, and we committed to growing our business by 150 percent,” Forsberg says. “To meet this target, it is essential that we bring the right people on board – people who have direct industry experience and technical experts who can help us build close relationships with our customers by combining their specific industry knowledge with Sapa Group’s wider compe-tence. This will enhance our value offering to customers across the globe.”

Matching global footprintsA key feature in the business segments’ markets is globalisation. “The major players in each segment operate globally and look for supply partners that can match their global footprint,” says Lars Forsberg, head of business segments.

16 SHAPE • # 1 2009

INSIGHT: BUSINESS SEGMENTS

the automotive language

VICTOR SChNEIDER, vice president Sapa Auto-motive, has joined the business with a 25-year track record in the automotive industry. A mechanical engineer by profession, he has worked in the automotive industry in the United States and Europe, spending the last 10 years with a Tier 1 supplier in France. “Light weight design is a major driver towards the reduction of fuel consumption for lower co2 emissions,” he says. “Aluminium is an ideal material for both cars and trucks because of its excellent weight-to-strength ratio, good corro-sion resistance and ease of processing. With our technological know-how and manufacturing capabilities we are confident that we will be able to offer more and more innovative solutions for a wide range of automotive applications.”

Sapa Automotive’s approach to the market is based on customer value management, work-ing closely with customers from an early design stage to ensure that the optimum solutions are identified. Key account managers are supported by dedicated engineering experts. “Our mission is a total focus on the automotive industry, and we have developed an engineering competence dedicated to that market,” Schneider says.

FROM ITS STRONG position in the Nordic market, Sapa Automotive is now embarked on a strategy to extend its automotive business model globally. “To achieve this we have to adapt ourselves and develop our organisation to reach new customers in other regions,” Schneider says. “A key to our success is to

build a strong automotive network inside Sapa’s operating companies around the world to enable them to relate to the industry in their regions. We are developing people who know the automotive business, who speak the customer’s language and know the customer’s expectations.”

ThE AUTOMOTIVE INDUSTRY is not only globalised but also very standardised. “To be a key supplier to the automotive industry it is not enough to simply offer good technology or product inno-vation,” Schneider says. “We must also under-stand the way in which the industry as a whole works. It is an industry that expects all the play-ers to work to the same sophisticated manage-ment procedures and standards. These systems are the baseline of good business development and are part of the automotive ‘language’ – the language that Sapa Automotive is committed to speak.”

TEXTS LINDA TROTMAN

PHOTO ED SHAW

The automotive industry plays an important part in Sapa’s growth strategy, and changes in the market offer major opportunities for Sapa Automotive. Environmental issues call for a new approach to design, and extruded aluminium is an ideal materials choice.

SPEAkinG

16 SHAPE • # 1 2009

GIANT TENTS ENABLE FLEXIBLE CONSTRUCTION

# 1 2009 SHAPE • 17

ITS hEADQUARTERS ARE located in Norway, but OB Wiik sells its products all over the world – at the South Pole, in Siberia, Malmö, Oslo and Hamburg – wherever there is a need for tempo-rary storage or to protect building projects from the wind and weather.

“Moisture during the building stage is one of the biggest problems for the building industry today. That’s why we build more and more under cover. Demand from building contrac-tors and developers is growing,” says Lars Dalgaard, managing director of OB Wiik.

The product that makes this possible is weather protection, which basically consists of a tent that is erected over the building. It can be used for new builds and for roof replacement or extensive renovation projects. As well as elimi-nating damp problems this solution also creates

a better working environment for the builders.“The weather protection is designed to meet

the market’s high demands for flexibility. The framing system for the walls and roof is built using an aluminium beam that Sapa machines and assembles according to our specifications,” says Lars Dalgaard.

hE EXPLAINS ThAT steel was the first choice of material for this type of structure for a long time, but in the last five years OB Wiik has increasingly been using aluminium. Reduced weight is naturally one of the benefits, but Lars Dalgaard also points out that aluminium is easier to form to precisely the shape you desire.

“That’s important for us, as we’ve come up with a special design that makes it easier to attach the tent material to the frame.”

Aluminium profiles are also used as the sup-porting structure for some of OB Wiik’s storage tents – a flexible alternative for those who need to be able to erect and dismantle storage facili-ties quickly.

“We’re seeing growing demand for this type of warehouse facility. In many cases it’s a better solution than a traditional building, especially if you’re unsure how long you’ll need storage for, or if you don’t have the resources to buy a per-manent warehouse,” says Lars Dalgaard.

Once again aluminium is increasingly replac-ing traditional steel-framed solutions for this type of product.

“The biggest advantage is speed of erection. If a structure has to be erected and dismantled several times, aluminium is the best choice.”

TEXT SUSANNA LIDSTRöM

A lightweight material that is easy to erect and easy to form – these were the main criteria that made aluminium profiles the choice of Norwegian company OB Wiik, for its storage tents and weather protection.

A tent protects workers and the bridge structure during repairs.

18 SHAPE • # 1 2009

The new coating from Sapa has been tested on roof rails, window surrounds and grilles, with good results.

›TODAy’S TECHNOLOGy

# 1 2009 SHAPE • 19

TODAy’S TECHNOLOGy

CORROSION

IT’S AN INCREASINGLY tough world for cars. Even at the car wash, more aggressive clean-ing fluids are taking the shine off aluminium components faster than ever before. To counter this attack, Sapa Components Ltd in Gloucester, United Kingdom, has developed an enhanced anodising process that offers a much-improved resistance to corrosive chemicals on the market.

Anodising is a widely used surface treat-ment for aluminium alloys that provides a protective coating by oxidising the metal by electrolysis in sulphuric acid. The benefits are increased resistance to corrosion and wear, and anodising provides better adhesion for paint primers and adhesives than bare metal.

“The new anodising process consists of a new type of corrosive-resistant coating that has the ability to inhibit the attack of alkalis on the surface of the anodised aluminium,” says Richard Shaw, anodising manager at Sapa Components (Pressweld).

ThE NEW PROCESS has been developed in response to the automotive industry’s need for more corrosion-resistant car components, particularly as aggressive alkali chemicals are used increasingly in high-pressure car

cleaning. Strong alkalis degrade anodised aluminium coatings quickly, and the growing use of aluminium by vehicle manufacturers has prompted intense development activity to address this issue. To give some idea of the improvement, Shaw says: “Standard alumin-ium oxide films are usually stable between a pH range of 4 to 8. The coating that we intend to offer is in excess of 12.5 pH.” As the pH scale is logarithmic with a maximum value of 14 for the strongest alkalis, the actual increase from 8.5 to 12.5 represents an improvement of a factor of 10,000.

Details of the process are a closely guarded secret, says Tony Wall, sales director at Sapa Components. “We had to overcome consid-erable technical hurdles,” he says “to achieve a coating with the right physical characteris-tics to deal with increasingly corrosive alkali exposure. The two-year development project adds an extra step to the anodising process, and Sapa has worked with its main chemical suppliers to develop the new coating. “The make-up of the chemicals is key to the proc-ess,” Wall says.

ThE COMPANY hAS invested around £500,000 in the development of the new process and associated equipment and production facili-ties that have given Sapa “a two- to three-year lead over key competitors in the market-place,” Wall says. Though a small number of companies across Europe claim to offer a higher level of resistance, Wall says, “We believe we are the only company capable of offering 12.5 pH resistance anodised finishes in a variety of colours.” In addition, the com-pany’s development activities are aimed at pushing this pH resistance towards the magic figure of 13.5, which has been requested by

automotive companies but not yet achieved practically. Experimentally, Sapa has dem-onstrated that 13.0 pH resistant coatings are possible.

As well as benefiting existing exterior alu-minium car components, the new coating offers vehicle manufacturers the ability to use this lightweight and recyclable material more widely. Cutting the overall weight of a vehicle saves fuel consumption and reduces carbon dioxide emissions. In addition, the resistant aluminium coating also offers the attractive finish that is used increasingly in trim com-ponents.

The new coating has been tested on a number of automotive components such as roof rails, window surrounds and grilles with major car companies including General Motors, Ford, Jaguar and Aston Martin. And following the success of these trials, the com-pany had its first volume product order with a major original-equipment manufacturer for finishing of a new exterior trim, Wall says.

Sapa has also set its sights on exploring the wider application potential of its new coating which it believes has great potential within all aspects of aluminium anodising sectors. One promising area is in the architectural market for window frames. In the United States, one aluminium window manufacturer is inter-ested in the extra protection the coating can give to products installed in coastal regions where sea salt is a corrosion issue.

The kitchen appliance market is another sector where the new anodising process could be of benefit for products such as dishwashers, cookers and washing machines where alkaline cleaning products are commonly used, Wall says.

TEXT ELAINE MCCLARENCE

Growing use of aluminium by car makers has increased the vulnerability of vehicles to corrosive chemicals. But a new anodising process can boost the metal’s resist-ance by a factor of 10,000.

WAR ON

20 SHAPE • # 1 2009

A SUITABLE ALLOY

“CREATING AN ALLOY mix is like tailoring a suit,” says Sergio Sannicolo, location manag-er for Sapa Profili s.r.l. in Bolzano, Italy. Just as custom suits are designed for the wearer, the hard alloys used in the aluminium pro-files produced by the Bolzano plant have to be suited to specific client needs. Since the Bolzano plant specialises in profiles for auto-motive and industrial applications (largely hard alloy screw machine stock for mechani-cal, electrical and electronic equipment), the alloys it uses need to fit the requirements of those industries.

Until recently, Sapa had used lead in its alloy mixes, because the addition of up to two percent lead helped enhance productivity in the manufacturing process. Lead reduced

excess metal shaving and increased speed and accuracy. But two European Union regula-tions passed by the European Parliament in 2002 and 2003, coming into effect in 2006 and this year, essentially prohibited lead as an additive in aluminium alloys. (Up to 0.4 percent lead is still acceptable, but only if it’s already present in recycled aluminium.)

“These edicts created significant problems for our industry,” Sannicolo recalls. Sapa would have preferred that the eu specifies a substitute alloy, but Brussels left it up to the market. So for the past several years Sapa has focused on developing a lead-free alloy that would retain lead’s desirable properties. After many months of research, the company developed an alloy of aluminium mixed with magnesium, silicon, copper, tin and bismuth. The additives, notably the tin and bismuth, mimic lead in that they enhance the charac-teristics of the alloy.

“The initial results were very good, just about as good as alloys with a lead additive, and the shaving problem was handled well,” says Sapa marketing analyst Claudio Del

Furia. “Of course it’s not quite like lead, but it is rather satisfactory and much healthier.”

Once Sapa had an alloy mix it thought might work, it began testing the mix with a German client in the automotive industry to see how it actually performed. The client was so pleased that he has ordered 600 tonnes of the new alloy for 2009, notes Sannicolo. “We would say that we have reached the 80 percent mark in terms of a solution to the lead-free issue.”

NEVERThELESS, SAPA CONTINUES to work on the alloy to refine it. Research is ongoing at the company’s research centre in Sweden to reduce the waste from metal shavings, as well as improve quality control. Automotive proc-esses are high speed and highly automated. If a metal is of inferior quality, it threatens both the speed of output and the quality of the final product.

“We should always be striving for perfec-tion, no?” says Sannicolo.

TEXT CLAUDIA B. FLISI

When the EU banned lead as an additive in aluminium alloys, a plant in Italy set out to find a substitute.

TODAy’S TECHNOLOGy

# 1 2009 SHAPE • 21

A SUITABLE ALLOYBRIEF NOTICES

“Thirteen years ago, Hällde had three suppliers of aluminium profiles, but now we have just one: Sapa,” says Rami Riihimäki, purchasing manager for Hällde.

Hällde is a Swedish manufacturer of catering appliances. With a number of key patents, the company has achieved a global lead in the development and manufacture of vegetable slicers and other food processors. Its products are sold in over 80 countries around the world.

These professional appliances are in a class apart from everyday household appliances. Hällde appliances have a reputation for efficiency, safety, ergonomics and performance.

“The Hällde range of appliances is built around housings made from aluminium profiles sup-plied entirely by Sapa, and thanks to the high volumes, Sapa have been able to offer us a com-plete, cost-effective solution,” reports Rami Riihimäki.

One-stop supplier provides better terms

Two important commercial projects in Portland, Oregon, have won third place in the 2008 “Daily

Journal of Commerce” Top Projects Awards.The Atwater Place condominium in Portland boasts a

custom glass railing system and aluminium privacy screens by Sapa, which provided in-house paint, engineering, draft-ing and project management.

The Casey, another award-winning Portland condominium, has a highly customised Sapa railing system combining three types of infill (glass, panels and interior panels) and a three-coat commercial-grade charcoal paint. All designs, drawings, die creations, extrusions, etcetera were done in-house.

Two at the top>

Aluminium is a material of choice for the solar industry. Its strength, ductility, corrosion

resistance and low weight make it ideal for this kind of application. Aluminium profiles can integrate functionality, are highly durable and practically maintenance-free and can be finished according to customer needs. And – a must for green applica-tions – they are 100 percent recyclable.

Sapa has launched a new organisation for the

solar industry offering total solutions, whether for solar panel frames or installation systems. Over the years, the company has built a huge bank of knowledge covering almost all industrial fields, and every day it sees examples of ideas and solutions feeding into each other. All this experience is now at the disposal of the solar industry.

For more information, see www.sapagroup.com/solar

Solar solutions at Sapa>

>

22 SHAPE • # 1 2009

WORLD’S SMARTEST BILLBOARD

TRADITIONAL BILLBOARDS hAVE been around for a long time, and normally have a frame of wood or steel and a poster that is pasted on. This often takes more than one person and requires very careful positioning, since the posters are pasted up in sec-tions.

The approach that Bannergear takes is differ-ent. The poster is hooked to a frame made from aluminium profiles and then simply winched into place.

“It means that one person can replace a poster measuring several square metres in the space of just five minutes. The posters can be supplied in a variety of materials – paper, polythene, airtex or pvc – depending on the customer’s wishes,” says

Kari Karesola, product man-ager at Bannergear.

The size of the billboard can also be tailored to the customer’s requirements, along with a choice of lighting, by spotlights above the billboard or led lighting behind semi-transparent posters.

The frame profiles for the billboards are always made from the same mate-rial, however, and Kari Karesola explains his com-pany’s choice.

“The profiles have an extremely long life, they are easy to machine and a variety of features can be built into the profiles themselves. The fact that aluminium is an attractive material is obviously an added benefit. Sapa are very good to work with.

They quickly understood what we were looking for and can supply profiles in different lengths.”

The billboards can also be made even more environmentally friendly by attaching solar cells to the frame. This allows the lighting to be powered without a mains supply.

“This means the customer can effectively place the billboard anywhere that receives daylight. All the customer needs to do is change the poster

occasionally. We’re also looking at a variant that is wind-powered, which will be ideal for windy loca-tions,” says Kari Karesola.

Current customers include the German food giant Lidl, and the building company K-Rauta.

“There is a lot of interest, so there is a good likelihood that Bannergear will grow over the next few years.”

TEXT DAG ENANDER

It can cope with any weather. It does not require a mains supply for illumination. And a single person can change a poster in less than five minutes. Bannergear in Finland has developed the billboard of the future – in aluminium of course.

Replacing billboard posters is now both quicker and easier.

Kari Karesola

# 1 2009 SHAPE • 23

Motorsport enthusiasts are used to seeing Öhlins’ service vans at racetracks around the world. But it is not just competition motorbikes, cars, snowmobiles and ATVs that use suspension com-

ponents from Öhlins Racing. A growing number of private users are ordering Öhlins dampers made in Sweden for their two-wheel, four-wheel or tracked vehicles.

Sapa, which has been a supplier to Öhlins for 25 years, has followed the company all the way, from local manufacturer to world contender in the highest division. Continuous research and product development lie behind Öhlins’ success, and have been key elements in the part-nership with Sapa as a supplier of increasingly complex and refined components.

“We set high standards of quality, performance, function and appearance,” says Lars Macklin, purchasing manager at Öhlins Racing. “Picture a newly washed motorcycle standing in the sun … the owner is obviously not going to be satis-fied with a shock absorber that is simply the best – it has to look like the best as well.”

Good suspension takes the lead>

Riverside pearlsPicture a neighbourhood with miles of riverfront for walking, running or cycling. Think of a district featuring art galleries, bookshops, new res-

taurants and cafés. Then put the two together.Downtown culture and the great outdoors are the backdrop for the

Waterfront Pearl, two 10-storey towers on the banks of the Willamette River in Portland, Oregon. The architects behind the project contacted Sapa Railing Systems to provide residents with an unobstructed view.

The final design used Sapa’s series 200 flat top aluminum railing with 1/4" tempered glass infill and decorative horizontal midrails. The residents of the Waterfront Pearl can maximise their pano-ramic views while feeling safe and secure on their balconies.

Many cities in the world may soon benefit from a modern touch of “la belle époque,” as changing styles of urban

architecture transform the shape of aluminium lighting columns, influenced by fashion, design and technical developments.

Today modern extrusion techniques allow Sapa Pole Products to supply affordable and innovative aluminium columns, such as the square columns that fit the Philips Urban Line lanterns shining in Düsseldorf, Tilburg, Eindhoven and Amsterdam. The one-stop-shop Sapa plant in Drunen, the Netherlands, can deliver not only round and square aluminium lighting columns but a large variety of different shapes. Through a combination of an extensive knowledge of aluminium, extrusion technology, procedure, design and fabrication, Sapa Pole Products are able to fulfil the needs of customers.

Urbanenlightenment

BRIEF NOTICES

>>

24 SHAPE • # 1 2009

Most of us use aluminium foil for wrapping a packed lunch or covering leftovers in the fridge. But Israeli choreographer ilan Azriel saw a slightly different application for this material than you would normally expect, and turned it into the key element in his dance performance: the Aluminum Show.

S ince its premiere in Israel in 2003 the show has toured the world and drawn capacity audiences. Accompanied by modern dance

music, audiences have seen aluminium in the form of gigantic cushions that hover over their heads, giants controlled by the dancers, an opera-singing ball gown, and in the form of enormous Slinkys, those spiral toys that were able to walk down stairs. The performance is a mix of dance, music and special effects, topped with a generous serving of imagination and creativity.

At the press conference prior to the European tour in 2008, Ilan Azriel explained how he hit upon the idea:

“I was looking for inspiration for my next show and happened to find a piece of aluminium duct from an air conditioning system. I stuck my hand in the duct and realised how flexible it was, and my imagination took over from there. Once I’d decided to use aluminium I discovered that you can do almost anything with this material.”

He received assistance with the technical details from Yuval Keden, a special effects designer, who made the most of all the crazy ideas the choreo-grapher had. The performance can be interpreted as questioning whether man controls technology, or technology controls man, but can also be seen purely as light entertainment.

For the dancers, however, this is no light task, as they frequently have to dance wearing outfits made from aluminium.

“Rehearsing for the performance wasn’t easy,” reports Ilan Azriel.

“Dancers like to show themselves off, but here they are mostly hidden inside a variety of alumin-ium shapes. It takes time getting used to dancing in aluminium, but because they are all profession-als it eventually becomes as natural as any other costume.”

And yes, of course, all the aluminium that is used in the performance is recycled.

TEXT HENRIK EMILSON

DANCING IN ALUMINIUM