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
A business concept
with added value
autious signs of optimism are starting to
C emerge in both American and European eco-
nomies 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 pro-
verbial light at the end of the tunnel!
During the past two years we have been wor-
king 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, deman-
ding 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.
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 acquisi-
tions, 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 pre-
vious 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, effi-
cient and competitive business part-
ners.
As we approach the
Christmas period, I would like
to thank our customers for
the faith that you have
shown in Sapa as a busi-
ness 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.
Staffan Bohman
President and CEO of Sapa
2 SHAPE • No 2 2003
IN BRIEF
A hammock for angels creates a secret place in the park
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
4-6 embroidered it using aluminium foil in various
10-11
13
Sony orders
loudspeaker stand
Sapa has won another important order
from Sony. The aluminium profiles are to
be used as components in a new gene-
ration of speaker casings and speaker
stands. Once more, the profiles will be
manufactured and processed by Sapa
10-11 16 Aluminium in Poland, the only manufactu-
rer of aluminium profiles in
8-9
Europe to hold the Sony
Green Partner Certificate.
“Sony is a leading play-
er in the fast-moving con-
sumer goods segment,
and they have strict de-
mands in terms of design,
surface finish and logis-
tics,” says Lothar Kano-
wski, manager of Sapa
Vertrieb in Germany.
“We’re competitive
14-15
because we’re involved in
our customers’ product
development, and we can
A visit to the new factory in Belgium New seats attract attention deliver specially adapted,
Where profiles and welded tubes are manufactured . . . . . . 4-6 Why Sting and The Tube from Denmark are successes . . . . . . . 13 cost-efficient, logistically
smart solutions.”
Eight myths about aluminium Aluminium the right choice for the motor industry The profiles are being
…but the truth is quite different . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 More profiles in new cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
delivered over the course
of one year, starting in
“It’s like sitting in an armchair” Sapa’s first female Factory Manager
August/September
The pro gives marks to the new bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-9 “Take your chance when it comes” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16-17
2003.
“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
Shape is a magazine from the Sapa Group, Editor in Chief: Eva Ekselius. ees their salary department and others the
published twice a year in eight languages for cus- Production: OTW Publishing. Communications and Investor Relations
tomers, shareholders, analysts, journalists, emp- Changes of address: Customers should inform Department. Tel. +46 (0) 8 459 59 00.
loyees and other interested parties. Shape is also their contact person at Sapa, shareholders the Sapa is an international industrial group of com-
Shaping the future available on the Internet: www.sapagroup.com institution that manages their account, employ- panies that develops, manufactures and markets
colours and thin wires that light up with the aid
of electricity. The hammock was then suspen-
ded 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. The angels’ hammock can withstand all kinds of weather.
Fantastic views in south-east London
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 apart-
ments on the lower levels have Monaframe sliding
doors and Proframe 325 windows in a dark grey
shade. The building contractor is St James Homes,
Residential area with a clean,
and Sapa’s products were fitted by Wynda
modern design.
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 deli-
vered 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
Sapa supplies
for Mass Transportation. panels for local
“Initially the order was limited to side panels trains.
(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 sepa-
rate business segment within Sapa.
Economic information:
value-added aluminium profiles, profile-based 7,600 employees in companies in Europe, the Sapa AB is listed on the Stockholm Stock
components and systems, and aluminium heat USA and China. The company is one of Europe’s Exchange’s O-list.
exchanger strips. Following divestments and leading manufacturers in its field. Major customer Q4 2003 February 6th 2003, Q1 2004 April 15th
restructuring in 2003, today’s Sapa has sales of segments include the construction and enginee- (AGM), Q2 2004 July 15th, Q3 2004 October
approximately SEK 12 billion, and has approx. ring industries. 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.

How the acquisition took place
The first serious discussions with manage-
ment at Remi Claeys Aluminium took place
in 2000 without any agreement being
reached. Sapa maintains good relations
with RCA.
Contact was re-established with manage-
ment 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 competi-
tion authorities, and in October Sapa took
over 100 per cent of the shares.
4 SHAPE • No. 2 2003
A
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 initi-
ative 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 cen-
tralised, 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 corres-
ponds 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
Sapa’s acquisitions in recent years portfolio in terms of pressing large,
complex profiles. The largest press
1999 Intexalu in France. Manufactures aluminium profiles.
can handle profiles that are 620 milli-
1999 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
profiles. in RCA’s ambition to be a specialist.
2002 Pressweld in Great Britain. Manufactures aluminium We had the technical expertise in
house, and the ambition to make real-
profiles.
ly complicated profiles,” explains
2003 RCA in Belgium. Chris Depreeuw, RCA’s current MD.
He is backed up by Staffan Bohman:
» We had the technical expertise in “RCA has extremely good technical
capacity for extruded profiles, as well
house and the ambition to make as good market penetration, especially in the
really complicated profiles « Benelux countries.”
“As far as aluminium profile-based con- AT THE BEGINNINGof the 1990s the company
struction systems are concerned, RCA will was divided into three business areas so that
increase Sapa’s existing business by 50 per it could focus on the individual markets. The
cent. This is an important addition, which business areas for profiles, construction sys-
gives us a strong position in the market.” tems (RC System) and Alutubes (welded alu-
minium tubes) are still there today.
has a well-developed business in
SAPA CURRENTLY During the last decade RCA has made a
terms of aluminium profiles. Despite this, number of investments in several areas. One »
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 acquisi-
tions 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 busi-
ness 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 for-
med from rolled aluminium bands.
This means that
extremely thin » Welded alumini-
pieces can be pro- um tubes will
duced, as little as always be there,
0.3 millimetres,
with fine toleran- but it’s a small
ces. The tubes are market with little
also given a sur- growth «
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:
The
293 million euros Netherlands
Number of employees: 1070.
Number of business units: 3. Lichtervelde Germany
ALUTUBES Great Britain • • Brussels
Belgium
Divided into two parts:
Lichtervelde, supplying consu- Luxembourg
France
mers 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 construc-
tion sector and the transport sector. Two pres-
ses 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).
Questionnaire • What do you know about Sapa?
Name: Thierry Devos, 32. Name: Eric Decoster, 38. Name: Jan Verslyppe, 41.
Position: Supervisor, profile Position: Supervisor in Position: Sales manager,
manufacturing. packing. Alutubes business unit.
Number of years at RCA: 12. Number of years at RCA: 18 Number of years at RCA: 20.
“I know that Sapa has great “There have been regular “We believe that the deal is
expertise in and experience changes at RCA. Now that positive for RCA. Of course,
of extruding aluminium profi- Sapa’s taken over, there will it’ll take some time to adapt
les. I hope that we can learn be a number of benefits.” the companies. Sapa will
from Sapa, and also that we give us opportunities to
can pass our knowledge of expand into markets where
products such as large we currently have no presence
profiles on to Sapa.” within Alutubes.”
GENERAL
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 con-
tent. 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 envi-
ronment. The metal is used in light construc-
tions, 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, construc-
tions 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
e truth
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. of food.
Aluminium powder, used in such products Aluminium does not emit any flavour, and it
as fireworks, will burn, but solid aluminium is a material that provides a tight seal by cre-
does not burn – it melts. ating a hundred per cent barrier against
light, oxygen, moisture, odour and taste.
5. Aluminium can cause Alzheimer’s
Disease. 7. The aluminium in the ground is
In older studies, researchers found higher harmful.
contents of aluminium in the brain tissue of This is not true. If that were so, plants would
patients with Alzheimer’s Disease than in die and people and animals that eat grain
healthy people. It was therefore believed that that is grown in the earth would be harmed.
aluminium was a contributory factor to the
disease, but at the global conference on 8. You should not use aluminium trays
Alzheimer’s in 2000 this risk factor was dis- when baking.
missed by medical experts. Aluminium is 100 per cent recyclable. Many
bakers prefer aluminium trays, as they produce
6. You should not use aluminium foil better baked products, partly because the
when cooking, as it spoils the taste 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
A 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 com-
fort. 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 pro-
duct 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.
IT WAS ON THIS BASIS that features such as the
saddle were developed, but the special featu-
re 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, tem-
perature, 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. Cycling doesn’t get any better. Imagine pedalling
“There’s just as much strength in this along at a gentle pace in beautiful natural
design, but I still think you’ll ride faster on a surroundings, looking straight ahead (and not
normal bike, as they have bigger wheels. On down at the asphalt). Andreas Lindqvist was
more than satisfied after his test ride.
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 Facts • Bigha Facts • Sapa Inc.
driven by the rear wheel. So you don’t need • Bigha is a bike for excursions and switch off the TV, get out and • Sapa is currently the USA’s major supplier of specially manufac-
to pedal more to build up the same speed as adventures, for day trips out into explore the real world”. tured bike frames.
on a traditional bike.” the woods. Put it in your car boot • A Bigha bike costs around 3,000 • The concept is called “Billet to bike”, and involves pressing
According to the designer, the Bigha is a and drive out to a park. dollars, including freight. The specially adapted hollow profiles, which then undergo several
bike that is built for adventure and discovery, • Originator John Acres bike is sold direct from the stages of processing.
but it can also be used in a city environment. explained Bigha in the San manufacturer via the • The process is completed by environment-friendly powder
The bike was developed and manufactured Francisco Chronicle Internet, which redu- coating.
in Oregon, USA by a team of 20 experts in daily newspaper as ces all kinds of inter- • The end product offers both superior strength and rigidity.
the fields of industrial design and enginee- a bike for those mediaries. • Sapa has pressed and processed both the main frame and the
ring, as well as professional cyclists. Bigha “who want out- • website: mounted seat for the Bigha bike.
means “just because” in the Apache Indian door entertain- www.bigha.com
language, and this was the starting point ment, who want to
when the bike was developed.
No. 2 2003 • SHAPE 9
INTERVIEW
Name: Nils
Bouveng
Age: 74

’’The Sapa spirit Family: Wife and

four children,
plus grandchildren
Lives: Outside Vetlanda.
Leisure interests: Hunting elk, deer and hare.

is the key to And my wife takes me on trips all over the

world.

Nils on …

success’’
… 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.”
Entrepreneurial flair. Leadership. Innovation. … entrepreneurs of the future
Customer orientation. “Put figures on everything! It’s important to
have a feel for money and to be able to count.
These were some of the principles when Sapa was founded And everyone’s welcome to ask us for tips!”

in 1963. 40 years later, the company has a turnover of almost

SEK 13 billion. Despite this, the principles remain the same. Still on top form. Many important decisions down the years have been made around the billiard table in Sapa’s cellar. Name: Lars
Bergenhem
Age: 73
apa is still a company and back-slapping. As we just another average company,” says Nils as important is the focus on profitability and

S
that looks after its
customers through
thick and thin, a company
that has included entre-
preneurial flair in its
mission statement, a
company that believes in
the ability of its employees.
As Shape meets Sapa’s
founders, Lars Bergenhem Nils and Lars have just started up the
press. It is 1963.
and Nils Bouveng, on the
occasion of the 40th anniversary, it is in
a classical setting. We are back where
it all started, in Vetlanda in Southern
Sweden. We’re sitting in the staff
canteen during the lunch break. Fried
plaice and potatoes are on the menu.
THE TWO FOUNDERS, now in their seventies,
still feel at home at Sapa. Although they sold
their company in the 1970s, they still know
many of the employees. There is much greeting key to our success. Without it, Sapa would be
Family: Wife and
stroll around the area, we Bouveng and continues: England reaches 35, Poland 10 cost control. From the very outset, Sapa was two children,
have the chance to take a “The Sapa spirit was born out of the two It’s not only Sapa as a whole that is celebrating one of the industry’s most profitable companies. plus grand-
look at production and also objectives that Lars and I set up when we founded this year. Poland is celebrating its tenth anniver- The secret is to put figures on everything, as children
play a game of billiards. the company: we wanted to enjoy ourselves and sary, Sapa’s British business its thirty-fifth. Lars Bergenhem explains. Lives: On the Bjäre peninsula and in London
Leisure interests: Golf, travel and a 1935
When Lars Bergenhem to get rich. The spirit is based on kinship, healthy The story in Britain began in 1968 with a “For example, we counted and evaluated ten
Dodge.
and Nils Bouveng started rivalry within the company, respect for the sales office, then in 1973 the company started profiles, and only accepted the six that we knew
the company four decades individual, security and faith in the company”. to produce profiles on a press at the plant in we could make money on. Our competitors we- Lars on …
ago, very quickly something Sapa has grown to become a large group of Tibshelf. Down the years the presses have been re welcome to the other four!” says Lars … life in retirement
developed that later came to companies. What is most important if we’re to developed in terms of both technology and pro- Bergenhem with a laugh. “It’s a golden age, even if it’s sad to get old.
be called the Sapa spirit. retain the Sapa spirit? ductivity. Sapa is now one of the leading profile “For the first ten years I authorised every When I’m in London I work at an asset mana-
So what is the Sapa spirit? “Strong leadership. Both Lars and I were manufacturers in Great Britain, producing more single invoice!” interjects Nils Bouveng. gement company where I’m a part-owner. It’s
“Whoever’s closest, does it,” says Nils strong leaders, and we dared to surround our- than 40,000 tonnes of high-quality products. Good profitability has been maintained long really great to work with young people.”
Bouveng. selves with strong people. We had tremendous after the founders left Sapa. To find out how
SAPA
0 3
And that’s the Sapa spirit in a nut- faith in our employees and close contact with this has been achieved, we ask Staffan Bohman:
… tips for politicians to improve the
entrepreneurial climate nowadays
19 63-20 shell, it appears. It is actually the only them, we had an openness that created mutual organisation so that you get extraordinary “Easy, it’s down to the four core values and “Politicians shouldn’t get involved in every-
thing that appeared on the organisation trust, and we could instil our belief in Sapa’s efforts from ordinary people. Just as it has been to our employees. Their efforts are the reason
AT 40!
thing. Remove unnecessary bureaucracy and
chart when Sapa was being built up. business concept into them,” says Nils Bouveng. ever since Nils Bouveng and Lars Bergenhem why, year after year, we’ve succeeded in gro- leave entrepreneurs in peace. Then we’d have
Nothing complicated, straight to the point. If you ask Sapa’s current President and CEO founded Sapa. Of course, all of this means that wing faster and with higher returns than many a good climate for entrepreneurs.”
What has the Sapa spirit meant for the Staffan Bohman to define strong leadership, he you must like the people who make up Sapa.” of our competitors. The fact that we achieve
company? immediately refers to the two founders. this is because 98 per cent of decisions are ma-
“The Sapa spirit is and always has been the “As a leader you must be clear, you must dare DOWN THE YEARS the Sapa spirit has been developed, de by the operational companies, not by those
to make demands and be able to motivate the but never losing sight of the basic values. Just of us at group management level.”

SAPA AT 40 - THE LANDMARK DATES

1963 Lars Bergenhem and Nils Bouveng
forms the company. The first profile is pres-
sed 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.
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 wholly-
owned 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.

10 SHAPE • No. 2 2003 No. 2 2003 • SHAPE 11

PRODUCT
Fly the flag with Sapa
Simple to put up, will not break and virtually maintenance-
free. 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.
I t all began back
in 1969. The
trade association’s
AGM in Jönköping,
Sweden, toured the
county together
with five County
Governors. One of
the stop-offs was at
Styrbjörn Lüning.
Sapa in Vetlanda.
Before the visit, Sapa’s sales
engineer at the time, Gunnar
Burmann, ran down to the stan-
dard profile warehouse, grabbed
three tubes of various dimen-
sions and sent a message to one
of Sapa’s subcontractors:
“Now we’re going to make
flagpoles!”
A few days later the
three flagpoles were
ready. Weights, flags,
ropes and rope holders
were all bought, and on
the day of the visit the
County Governors were
given the honour of being
the first to see Sapa’s
newly- manufactured alu-
minium flagpoles in use.
SHORTLY AFTER the County
Governors’ visit, on
September 26th 1969,
Gunnar Burmann visited a
business contact in
England, who was very
interested when he heard
about Sapa’s flagpoles.
Having worked out that
the tube dimensions were
more than sufficient to
Do you want to buy a flagpole at a special price?
Contact and order: www.sapagroup.com/flagpoles
12 SHAPE • No. 2 2003
withstand the English weat-
her conditions, the
Englishman placed the first
order.
The flagpole is now
Sapa’s only pure consumer
product. And since 1969
more than 100,000 flag-
poles have been sold.
“Flags have become popular
in recent years. Many companies display
their hospitality by raising a visiting
SAPA 03
customer’s national flag. Marketing
19 63-20 your company by flying a flag is also
a cheap, simple way of getting your
AT 40! message across,” says Styrbjörn
Lüning, Product Manager at Sapa.
AS THE FLAGPOLE is delivered in
sections, the package is only
five metres long,
which reduces both
transport and storage
costs significantly.
The customer can
easily assemble the
flagpole on site.
“You don’t need
screws or glue, as a
rubber ring helps the
parts to grip tightly to one anot-
her,” says Styrbjörn Lüning.
The advantage of an alumini-
um pole compared to the traditio-
nal ones made of wood or plastic
is that it will neither become dis-
coloured nor break off.
“The flagpole is delivered com-
plete with rope and everything.
All you need to provide is the
actual flag.”
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, empha-
sises that the short distances mean that de-
liveries of aluminium profiles are reliable, and
that the risk of damage to the profiles during
transport is minimised.
Facts • Thule
• 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.
DESIGN
New profile with a sting
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.
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
Sapa has supplied profiles for The
Tube, drawn and designed by
tremendous interest. Karsten Eriksen. The chair was dis-
Both designers have a bright future ahead played at the Scandinavian Furniture
of them. The design is innovative, and no- Fair in Copenhagen.
thing has been done to hide the chair’s origin. With his company, Klapstuhl, Karsten
“No, quite the reverse, we really want to Eriksen has a vision of innovation in the
show that it’s aluminium profiles that sup- choice of materials, design profile and
port the construction,” says Fredrik Mattson. production methods. The chair is part of a
“Extrusion is an extremely production- range of furniture called Tubed Furniture,
friendly, cost-efficient method. The material which has been produced by C-Frisk. The
means that the furniture can be used both prototype was developed in collaboration
indoors and outdoors.” with Sapa Profiler in Grenå, Denmark.
Product development was quick. The first
AS ALUMINIUM can be produced in such thin profile came out of the press after only
dimensions, the metal is suitable for the 3–4 weeks, ready to be made into a chair.
manufacture of stacking furniture. One of The design is entirely down to Karsten
the criteria was that the chair should take up “Aluminium is corrosion-resistant and can Eriksen, but Sapa was able to offer support
a minimum of space when stacked. At pre- withstand all kinds of weather, it’s also an in the form of good advice and adapting
sent the chair adds a total of 13 millimetres incredibly robust material. It gives a piece of the profiles to facilitate production, in
in height when stacked, which means that a furniture an extremely long service life,” says terms of such matters as the choice of
stack of ten chairs is no higher than 13 centi- Fredrik Mattson. alloy, anodisation and lacquering.
metres plus the legs. The chair’s underframe is made of stain- “Now, together with Karsten, we’ve
The special feature of the Sting chair, less steel, and the soft upholstery, on models shown that there is innovation in the
which has aroused so much attention, is the that have it, is made of polyurethane, a kind Danish furniture industry,” says Flemming
fact that the whole seat is extruded in one of rubber. The legs act as a peg, locking the Larsen at Sapa Profiler.
piece. It is one of the broadest tools that whole construction into place, which is why The full range of furniture can be seen
Sapa has manufactured. no glue or screws are needed for assembly. at the C-Frisk website www.c-frisk.com
Facts • Exciting aluminium chairs down the years
In 1938 the Italian designer Gio In 1988 the Argentinean designer In 1999 the American designer In 2000 the British designer
Ponti developed a chair for the Jorge Pensi created the Toledo, and architect Frank Gehry Ross Lovegrove created the
Montecatini company. Even though a chair that has won many prizes. developed an alternative to Go Chair. With its simplicity and
the chair contained standardised With the Toledo, Pensi succeeded Pensi’s Toledo. The chair is elegance, Lovergrove’s chair is
parts, this didn’t stop Gio Ponti in making use of the special extremely light, but still has a one of the most innovative chair
from creating a unique chair. qualities of aluminium. solid appearance. designs of recent years.
No. 2 2003 • SHAPE 13
ENGINEERING
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.
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.
Why the motor industry is increasingly turning to aluminium
T
he advantage of aluminium
profiles is that several diffe-
rent functions can be built
into one single part. So you can
solve several problems simul-
taneously, 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-
» At the moment the Audi A2 is the car with
the highest aluminium content, 37 per cent «
14 SHAPE • No. 2 2003
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
performance. This creates
a secondary weight increase
effect, and vehicles are get-
ting heavier,” says Niclas
Hagert. “Just look at the
Golf. It’s been around for
nearly 30 years, and they’re Niclas
now into version 5 of the Hagert.
model. The car’s become
about 30 per cent heavier than
the original model, partly due to
the increased number of comfort-
related parts.”
At the same time, fuel con-
sumption has been reduced.
“We advocate trying to reverse
this weight trend, and in a
positive way. If we develop
something in aluminium
that makes a car lighter,
you can use smaller
engines, smaller beams,
and so on. We’ve not yet
achieved our objective, but
car manufacturers are
starting to open their eyes to solu-
tions using aluminium profiles.
“At present we supply alu-
minium parts for items such as
seat rails, instrument beams,
roof racks, engine parts, and so
on.”
THE AVERAGE AMOUNT 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 maxi-
mum benefit from the material’s
properties. It is light and strong,
and is ideal as a construction
material for aeroplanes. The con-
Sapa supplies alu-
minium components
to Volvo, for items
including engine
brackets, roof racks
and seat rails.
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 tech-
nology 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.
Here are some of the car parts for
which Sapa’s profiles are used
1 2
6
5 8
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, lea-
ding to a cheaper, simpler end
product. The fuel distribution
pipe made from aluminium pro-
file has been used in all Volvos
since 1991, representing 300-
400,000 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.
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
3 4
7
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 back-
wards. 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 colli-
sion, the charge is detonated
and the airbag is inflated. The
airbag casing is Sapa’s single
biggest product, and is suppli-
ed 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 require-
ments 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
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
Ulrika Molander is Sapa’s and Policy Studies (SNS). By sponsoring
the project, Sapa is showing that this
first female Factory issue is being prioritised within the group.
“We believe that it’s an important issue
Manager. in the sector where Sapa operates, with
the preconceptions about the industry
She is very happy in her being dirty and heavy. This just isn’t the
case any more,” says Gabriella Pihl,
role, and hopes for more Information Manager at Sapa.
A careers survey has been conducted
challenges in the company at Sapa in Sweden to investigate the
in the longer term. breakdown between genders. “The result
shows that we have a lot of work to do.
“It’s a shame that more We’ve now taken the same survey to
other companies in the group.”
women don’t get technical The project will end in February 2004,
after which Sapa will continue to work on
qualifications and move into “Industry should do more to attract women. Throughout entire organisations, not just in the matter internally.
managerial roles. Even when they’re at university, girls have to be told that heavy industry is
heavy industry,” she says. an option,” says Ulrika Molander. 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’’ Nice work!

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.
SHE HAS BEENFactory Manager since April this
year. Previously she worked as Planning
Manager at Sapa in Vetlanda, Logistics
» It’s going too far to talk about male and female. It
reinforces preconceived notions «
Manager in Finspång, and before that in the
textile industry.
“I’ve always wanted to work in heavy indus-
try. 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 outsi-
de 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 dis-
advantage, 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.
INSWEDEN 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 tra-
velling on business.
“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
DESPITE A GREAT INTEREST
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 back-
grounds, 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 chal-
lenges. More people should dare to seize
the opportunity,” says Ulrika Molander.
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 with one-stop solutions for payment follow-
makes a positive first impression,” says Vegar up and customer development.
Andersen, the group’s Information Manager. The architects, Didrik Hvoslef-Eide AS,
Lindorff works on the selection, care and satisfied the demand for a first-class client
development of customers. In sectors such as entertainment centre by making maximum
banking, finance, telecommunications and use of light, space and the beautiful
the public sector, Lindorff provides clients 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
Lindorff’s office is in a modern Norwegian
anodisation. Glass in roof: clear glass, 6-16-6
residential area, on a hillside with an
laminated on the inside.
excellent view down over the fjord.

16 SHAPE • No. 2 2003 No. 2 2003 • SHAPE 17

ENGINEERING
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, functiona-
lity 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 desig-
ners to produce the form of the Access
Shopper. In development work it was impor-
tant 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, harde-
ned glass in the windscreen, which is less
vulnerable to scratching than plastic wind-
screens, eco-labelled ABS plastic and alumi-
nium profiles in the bodywork,” says
Rasmus Leiro.
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 repai-
ring
– 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 achi-
eved 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
I N THE SUMMERTIME the doors can be removed,
and for rainy days the vehicle has both wind-
screen 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 gravi-
ty, 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 mate-
rial 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.”
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
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 pro-
duct, the development process lasted only
seven months. An Access Shopper costs
around SEK 125,000.
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 dia-
meter 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 manu-
factured 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 cor-
ner 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
The Aluminium Queen
Aluqueen was built by
Sapa in 1983, based on
drawings by boat designer
Pelle Pettersson.
It was used as a promo-
tional yacht to market alu-
minium as a material. With
ten sleeping berths, a con-
ference 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.”
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.
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.
ince 1990, when Dutchman Wim quite simply easier to sail in an aluminium nents or the use of unsuitable combinations
S Dijksterhuis bought the aluminium
yacht, it has sailed around the world a
few times. He has taken his wife Marianne,
boat. The only problem with aluminium is
that the metal conducts electricity. If the cur-
rent passes out into the water, galvanic cor-
of other metals.
Exactly which parts of Aluqueen are made of
aluminium?
daughter Susanne and the Jack Russell terrier rosion can occur in the hull. “The hull, deck and cabin.”
Purdy along on these journeys. But galvanic corrosion can be avoided by In the last 20 years it has become increa-
“Aluqueen really attracts attention when fitting sacrificial anodes and painting the singly popular to use aluminium to build
she arrives, with her special design, form outside of the hull so that the metal doesn’t boats. The material is mainly used for the hull.
and character. Aluminium’s ideal for come into contact with the water. This has to During the summer months Wim
creating attractive shapes,” says Wim be done every ten years.” Dijksterhuis organises sailing competitions.
Dijksterhuis. Galvanic corrosion occurs due to the During the winter months Aluqueen is on
“Aluminium’s a strong metal in relation to incorrect installation of electrical compo- dry 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 had been built in steel, its “ Aluqueen really long voyage. Purdy the dog is actually
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.
Aluminium is also a corrosion-resistant
when she What’s your next project?
metal, so it doesn’t need as much main- arrives, with her “In 2004 I’ll be organising two more
tenance as a steel boat. sailing trips.”
“In general Aluqueen needs much
special design Will Purdy be coming along?
Wim and Marianne Dijksterhuis.
less maintenance than other boats. It’s and form ” “Yes, of course.”
No. 2 2003 • SHAPE 19
FINALLY…
Telephone box suitable for people Autoliv buys deflectors
with disabilities Sapa has won a new order from Autoliv Sweden
Sapa has delivered profiles for deflectors for the passenger airbag for plat-
for a new kind of telephone form 2 (P2X). The platform includes Volvo models
box, which will be installed Volvo V70, S80, S60, XC90 and C70.
in Sweden by TeliaSonera
and Outstanding Media. Customised IKEA training
The phone boxes are suit- At the beginning of October a customised training
able for people with dis- course was held
abilities, which means for IKEA’s purcha-
Now the wait for the tram doesn’t feel as long.
above all that they are larger sing strategists,
Passengers in Nottingham can find and thus easier to enter in a buyers and product
shelter wheelchair. The new phone
1,000 phone boxes developers from all
The wait for a tram will now be more comfortable boxes also have space for suitable for disabled over the world. The
thanks to Sapa, who delivered 19 tonnes of alumini- advertising in the form of users are to be course was held on
um profiles to be used for shelters in a new tram an illuminated panel. In one produced. an intensive day in Interested IKEA employees
system built by NET, Nottingham Express Transit. year 400 phone boxes Finspång, Sweden, from Germany, Bulgaria,
NET designed the shelters together with a company have been installed in over 40 municipalities. where Sapa has Turkey, Vietnam and
Thailand. A new group will
called Metalfast and the design company Woodhouse. two manufacturing be trained in the spring.
The design of the shelter was refined and adap- Collaboration units.
ted for production by Sapa’s designers. This for greater “The training programme has been developed
means that only five different profiles are required, crash safety specifically for IKEA. The concept has been drawn
including one used for seats in the shelter. The The Crash Zone up together with IKEA’s training co-ordinator,”
first phase in the project involves shelters for a development pro- explains Tor Zetterström from Swedish company
tram route between the northern and southern ject is a collabora- Sapa Profiler AB.
parts of Nottingham. It will be officially opened at tion between “The aim is to provide key people in IKEA with
the end of 2003. Volvo Trucks, good training about aluminium as a material and to
Nottingham plans to further extend the tram Scania, the Scania’s suggestion for a shatter the myth that aluminium is an expensive metal.”
system in the next few years. The tram project as University of
truck with greater crash The participants also paid a study visit to
a whole has created much interest in the British safety.
Linköping and four Sapa’s pressing plant in Finspång.
media, and is a continuation of similar projects in suppliers (Sapa, Finnveden, Accra Teknik and “It was a rewarding day,” says Ulf Svensson,
Manchester and Sheffield. Several tram systems Prirox) to improve crash safety in both private cars Sapa’s contact person for Ikea. “We showed the
are being planned in other major cities in the UK. and trucks. Crash Zone involves several projects benefits of aluminium, and we had the chance to
running in parallel for a period of six months, and make contacts with key people at IKEA.”
Award-winning school furniture all tests are conducted in theoretical models.
The British furnitu- Each participant presents their own proposal. Pool fence protects children
re manufacturer Scania has presented a proposal for how it The French company Distral has developed a
Varitech has pro- should look, fitted to a truck. fence for swimming pools made of laminated
duced an award- glass and aluminium profiles. The fence is used to
winning furniture Sapa expands in keep children safe from falling in the pool. The
system for schools Lithuania fence also has an alarm device, in case anyone
and universities. Sapa is continuing to expand tries to climb the fence and enter the area around
The furniture had Prize-winning furniture. in Lithuania by opening a factory the pool. Another
to be easy to dis- to manufacture components benefit of the fence
mantle and move, based on aluminium profiles. is that it provides
while at the same time still being strong and dur- Lars Forsberg.
The business will open at the total cover, meaning
able. Sapa in England developed the concept in beginning of 2004, and the that it protects the
collaboration with Varitech. Four of the profiles are company will initially employ 20 or so people. pool from litter and
manufactured at Sapa in Tibshelf, while the fifth “We’re now stepping up our efforts in an attrac- other airborne dirt.
and largest profile is manufactured in Sapa’s tive growth market,” says Lars Forsberg, manufac- “We chose alu- The pool fence also has an
French facility in Albi. “System 24/15” has attrac- turing manager at Sapa Profiler AB. minium profiles for alarm..
ted a lot of interest in education circles, and has “Many of our customers are setting up production aesthetic and
also won the “Special recognition award for inno- facilities in Lithuania, so we’ve decided to follow suit practical reasons. The profiles fit in well in all
vation”, a competition held by the East Lancashire by starting our own manufacturing unit.” Sapa has environments, and are easy to manage,” says Mr
Chamber of Commerce. had a sales office in Lithuania since 1998. Manenc at Distral.

20 SHAPE • No. 2 2003