ShapeA magazine from the Sapa Group • # 2 2003

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

ALUMINIUM THE HOT CHOICEFOR THE MOTOR INDUSTRY

A VISIT TO THE NEWFACTORY IN BELGIUM

ALUQUEEN READY TO SETSAIL AROUND THE WORLDAGAIN

8MYTHS ABOUTALUMINIUM

The super bike

No 2 2003 • SHAPE 3

CONTENTS IN BRIEF

2 SHAPE • No 2 2003

Fantastic views in south-east LondonThe first phase in a new building project in Deptford insouth-east London has been completed. Sapa BuildingSystems supplied a number of products, including windows, doors and inner walls. The buildings havebeen given a clean, modern design. The penthouseapartments are fitted with Glostal 325 walls, givingresidents an outstanding view over London. The apart-ments on the lower levels have Monaframe slidingdoors and Proframe 325 windows in a dark greyshade. The building contractor is St James Homes,and Sapa’s products were fitted by WyndaComponents in collaboration with SBD.

Sales right on track

A business conceptwith added value

autious signs of optimism are starting toemerge in both American and European eco-nomies after two or three years of fairly weak

economic activity. In most industrial sectors weare still a long way from the record levels seenduring 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 productivityand reduce tied-up capital, so that we are in astronger position to face the market.

In close collaboration with professional, deman-ding customers, we have continued to developour ability to create significant added value for ourcustomers. We have invested and structured ourefforts in important sectors, and formed threestrategic business segments – Building Systems,Automotive and Mass Transportation.

WE HAVE CONTINUED to invest in the markets in theUSA, China and Eastern Europe, and we havealso set up new production facilities in marketsthat are new for us, such as Lithuania and China.

We have completed several important acquisi-tions, the most recent of which is Remi ClaeysAluminium in Belgium, see page 4.

We are proud of having been able to developSapa through a combination of excellent growthand profitability over a long period of time. Thefact is that the annual rate of growth has been 10per cent a year since 1990, which means that ourturnover has increased by a factor of three.

The biggest challenge is to always surpass pre-vious successes. We are aware of what it meansto work continuously to refine our business model,so that our most demanding customers continueto perceive us to be competent, effi-cient and competitive business part-ners.

As we approach theChristmas period, I would liketo thank our customers forthe faith that you haveshown in Sapa as a busi-ness partner. I would also liketo thank all employees in thecompany for your loyalty andexcellent work during 2003, andfinally I would like to wish us all aprosperous, successful 2004.

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Shape is a magazine from the Sapa Group,published twice a year in eight languages for cus-tomers, shareholders, analysts, journalists, emp-loyees and other interested parties. Shape is alsoavailable on the Internet: www.sapagroup.com

Editor in Chief: Eva Ekselius.Production: OTW Publishing.Changes of address: Customers should informtheir contact person at Sapa, shareholders theinstitution that manages their account, employ-Shaping the future

A visit to the new factory in BelgiumWhere profiles and welded tubes are manufactured . . . . . .4-6

Eight myths about aluminium…but the truth is quite different . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

“It’s like sitting in an armchair”The pro gives marks to the new bike . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-9

“Have faith in the employees”Sapa’s founder in a major interview . . . . . . . . . . . . . . . . . . . . . . . . . . .10-11

New seats attract attentionWhy Sting and The Tube from Denmark are successes . . . . . . .13

Aluminium the right choice for the motor industryMore profiles in new cars . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14-15

Sapa’s first female Factory Manager“Take your chance when it comes” . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16-17

The seven seas await AluqueenThe aluminium boat will soon be casting off again . . . . . . . . . . . . . . .19

Staffan BohmanPresident and CEO of Sapa

ees their salary department and others theCommunications and Investor RelationsDepartment. Tel. +46 (0) 8 459 59 00.Sapa is an international industrial group of com-panies that develops, manufactures and markets

value-added aluminium profiles, profile-basedcomponents and systems, and aluminium heatexchanger strips. Following divestments andrestructuring in 2003, today’s Sapa has sales ofapproximately SEK 12 billion, and has approx.

7,600 employees in companies in Europe, theUSA and China. The company is one of Europe’sleading manufacturers in its field. Major customersegments include the construction and enginee-ring industries.

Sapa AB is listed on the Stockholm StockExchange’s O-list.Q4 2003 February 6th 2003, Q1 2004 April 15th(AGM), Q2 2004 July 15th, Q3 2004 October18th, Q4 2005 February

A hammock for angels creates a secret place in the parkA hammock for you to rest your tired thoughtsat the end of the day.

That was textile artist Anita Graffman’s visionwith “Hammock for angels”.

“As it hangs between the trees, it forms asecret place in the park,” she says.

The piece of art is sponsored by Sapa, andis a part of the “Culture Park Project” exhibitionat Djurgården in Stockholm. Since August thisyear seven artists have each displayed theirown work, all on the theme of evening time.

“I’ve used materials that withstand wind andrain. I took a double-strength fishing net andembroidered it using aluminium foil in various

colours and thin wires that light up with the aidof electricity. The hammock was then suspen-ded from silver-coloured aluminium profiles,”says Anita Graffman.

The hammock measures sixteen metres byfour metres, and took almost four months tocreate. The idea for the piece came from apoem that the artist herself wrote. The openinglines are: “People walk in the park. Theirthoughts drift up between the trees, over themeadows and water.”

“People come here to the park to reflect.Now their thoughts can also have a place torest,” says Anita Graffman. The angels’ hammock can withstand all kinds of weather.

Sony ordersloudspeaker standSapa has won another important orderfrom Sony. The aluminium profiles are tobe used as components in a new gene-ration of speaker casings and speakerstands. Once more, the profiles will bemanufactured and processed by SapaAluminium in Poland, the only manufactu-

rer of aluminium profiles inEurope to hold the SonyGreen 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 SapaVertrieb in Germany.

“We’re competitivebecause we’re involved inour customers’ productdevelopment, and we candeliver specially adapted,cost-efficient, logisticallysmart solutions.”

The profiles are beingdelivered over the course

of one year, starting inAugust/September2003.

Residential area with a clean, modern design.

Sapa suppliespanels for localtrains.

Sapa Mass Transportation has won another orderfor FSW panels for Alstom LHB, who are building240 carriages for local trains for DB (DeutscheBahn). The order is for complete floor and sidepanels 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 Managerfor Mass Transportation.

“Initially the order was limited to side panels (the walls of the carriage frame). But the results ofFriction Stir Welding (FSW) were so impressive thatAlstom extended the job to include complete floorpanels.”

Deliveries to the rail industry are a significant areafor Sapa, and since last year have become a sepa-rate business segment within Sapa.

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Economic information:

No. 2 2003 • SHAPE 5

BUSINESS

4 SHAPE • No. 2 2003

Welkom!Shape welcomes the latest addition to the Sapa family

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:

“As far as aluminium profile-based con-

struction systems are concerned, RCA will

increase Sapa’s existing business by 50 per

cent. This is an important addition, which

gives us a strong position in the market.”

SAPA CURRENTLY has a well-developed business in

terms of aluminium profiles. Despite this,

RCA can complement Sapa’s product

portfolio in terms of pressing large,

complex profiles. The largest press

can handle profiles that are 620 milli-

metres wide and 26 metres long.

“When the large press was bought

in the early 1990s, it was one phase

in RCA’s ambition to be a specialist.

We had the technical expertise in

house, and the ambition to make real-

ly complicated profiles,” explains

Chris Depreeuw, RCA’s current MD.

He is backed up by Staffan Bohman:

“RCA has extremely good technical

capacity for extruded profiles, as well

as good market penetration, especially in the

Benelux countries.”

AT THE BEGINNING of the 1990s the company

was divided into three business areas so that

it could focus on the individual markets. The

business areas for profiles, construction sys-

tems (RC System) and Alutubes (welded alu-

minium tubes) are still there today.

During the last decade RCA has made a

number of investments in several areas. One

Sapa’s acquisitions in recent years1999 Intexalu in France. Manufactures aluminium profiles.

1999 Aluvar in France. Manufactures building systems.

2000 Anodil in Portugal. Manufactures aluminium profiles.

2000 Anodizing in the USA. Manufactures aluminium

profiles.

2002 Pressweld in Great Britain. Manufactures aluminium

profiles.

2003 RCA in Belgium.

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

A

*

* “Welkom” means “welcome” in Dutch and Flemish.

» We had the technical expertise inhouse and the ambition to makereally complicated profiles «

»

How the acquisition took placeThe first serious discussions with manage-ment at Remi Claeys Aluminium took placein 2000 without any agreement beingreached. Sapa maintains good relationswith RCA.Contact was re-established with manage-ment at the beginning of 2003, and theresponse was positive. An initial meetingwas held shortly thereafter, and in earlyApril agreement was reached to buy themain owner’s (the Desimpel family) holding, which amounted to 54 per cent ofshare capital. During the summer Sapareceived the go-ahead from the competi-tion authorities, and in October Sapa tookover 100 per cent of the shares.

BUSINESS

6 SHAPE • No. 2 2003

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

pieces can be pro-

duced, as little as

0.3 millimetres,

with fine toleran-

ces. The tubes are

also given a sur-

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.

Name: Thierry Devos, 32.Position: Supervisor, profilemanufacturing. Number of years at RCA: 12.“I know that Sapa has greatexpertise in and experienceof extruding aluminium profi-les. I hope that we can learnfrom Sapa, and also that wecan pass our knowledge ofproducts such as large profiles on to Sapa.”

Name: Eric Decoster, 38.Position: Supervisor inpacking.Number of years at RCA: 18“There have been regularchanges at RCA. Now thatSapa’s taken over, there willbe a number of benefits.”

Name: Jan Verslyppe, 41.Position: Sales manager,Alutubes business unit.Number of years at RCA: 20.“We believe that the deal ispositive for RCA. Of course,it’ll take some time to adaptthe companies. Sapa willgive us opportunities toexpand into markets wherewe currently have no presencewithin Alutubes.”

Facts • Remi Claeys Aluminium

Questionnaire • What do you know about Sapa?

»

» Welded alumini-um tubes willalways be there,but it’s a smallmarket with littlegrowth «

Head office: Lichtervelde. Turnover 2002: 293 million eurosNumber of employees: 1070.Number of business units: 3.ALUTUBESDivided into two parts:Lichtervelde, supplying consu-mers and industry, and RCAutomotive in Remscheid(Germany), manufacturing tubesfor various kinds of heat exchangers. Minorityholding in the Alabama Tube Corporation (FortPayne, USA) Capacity (annual): Foundry: 27,000 tonnes,cold-rolling plant: 30,000 tonnes, cutting:30,000 tonnes, four seam welding machines:25,000 tonnes.PROFILERManufactures 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) alsohas a foundry with a capacity of 35,000 tonnes.RC SYSTEMThe Belgian business is based in Landen (headoffice), Gent and Lichtervelde. In France thereare operations in Strasbourg, Bordeaux, Lyon,Lille and Angers. Germany (Velbert), Poland(Wroclaw), Czech Republic (Kladno), Turkey(Istanbul) and Holland (Breda).

LichterveldeBrussels

Belgium

Germany

France

TheNetherlands

Great Britain

Luxembourg

• •

Lage Knutsson from Sapa Technology inFinspång 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 duringcooking, which is said to bedangerous.

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 abuilding material, as it is highly

inflammable.Aluminium powder, used in such products

as fireworks, will burn, but solid aluminium

does not burn – it melts.

5. Aluminium can cause Alzheimer’sDisease.

In older studies, researchers found higher

contents of aluminium in the brain tissue of

patients with Alzheimer’s Disease than in

healthy people. It was therefore believed that

aluminium was a contributory factor to the

disease, but at the global conference on

Alzheimer’s in 2000 this risk factor was dis-

missed by medical experts.

6. You should not use aluminium foilwhen cooking, as it spoils the taste

of food.Aluminium does not emit any flavour, and it

is a material that provides a tight seal by cre-

ating a hundred per cent barrier against

light, oxygen, moisture, odour and taste.

7. The aluminium in the ground isharmful.

This is not true. If that were so, plants would

die and people and animals that eat grain

that is grown in the earth would be harmed.

8. You should not use aluminium trayswhen baking.

Aluminium is 100 per cent recyclable. Many

bakers prefer aluminium trays, as they produce

better baked products, partly because the

trays can better withstand high temperatures.

No. 2 2003 • SHAPE 7

GENERAL

Aluminium does not cause Alzheimer’sDisease. Aluminium saucepans are not hazardous. Aluminium does not burn. There are lots of myths about aluminium. Here is the truth.

and the tru

th

8 myths about aluminium

Facts:Aluminium• Aluminium is the 13th

element in the periodic system,chemical symbol Al.

• The surface of the Earth contains onaverage approx. seven per cent aluminium.

• Over millions of years, plants, animalsand humans have been adapted to thisenvironment.

• Aluminium, like iron, can be considerednon-toxic.

No. 2 2003 • SHAPE 9

ENGINEERING

8 SHAPE • No. 2 2003

ndreas is a member of the Swedish

national action sports team, and BMX

cycling is his job. BMX bikes are small

bicycles that can be used to perform routines,

but when this professional “freestyle rider”

gets to try out the Bigha, he waxes lyrical.

“This bike’s a real pleasure in terms of 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.

“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.

“There’s just as much strength in this

design, but I still think you’ll ride faster on a

normal bike, as they have bigger wheels. On

the other hand, this bike’s more comfortable

if you’re riding a long way,” says Andreas

Lindqvist.

“The fact that the front wheel’s small

doesn’t really affect the power, as the bike is

driven by the rear wheel. So you don’t need

to pedal more to build up the same speed as

on a traditional bike.”

According to the designer, the Bigha is a

bike that is built for adventure and discovery,

but it can also be used in a city environment.

The bike was developed and manufactured

in Oregon, USA by a team of 20 experts in

the fields of industrial design and enginee-

ring, as well as professional cyclists. Bigha

means “just because” in the Apache Indian

language, and this was the starting point

when the bike was developed.

Facts • Sapa Inc.• Sapa is currently the USA’s major supplier of specially manufac-

tured bike frames. • The concept is called “Billet to bike”, and involves pressing

specially adapted hollow profiles, which then undergo severalstages of processing.

• The process is completed by environment-friendly powdercoating.

• The end product offers both superior strength and rigidity.• Sapa has pressed and processed both the main frame and the

mounted seat for the Bigha bike.

The Bigha aluminium bike is no ordinary bike. Professionalcyclist Andreas Lindqvist can confirm that.“It’s so comfortable. It’s like sitting in an armchair.”

Lean back and enjoy!

Name: AndreasLindqvistAge: 29 Profession:Professional BMXFreestyle cyclist forten years. Member ofthe Swedish nationalaction sports team.

Cycling pro gives the newaluminium bike top marks

»Why should cyclists have to sitawkwardly and stare down at theasphalt, when they can sit upstraight and enjoy a better view? «

A

Facts • Bigha

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

• Bigha is a bike for excursions andadventures, for day trips out intothe woods. Put it in your car bootand drive out to a park.

• Originator John Acresexplained Bigha in the SanFrancisco Chronicledaily newspaper asa bike for those“who want out-door entertain-ment, who want to

switch off the TV, get out andexplore the real world”.

• A Bigha bike costs around 3,000dollars, including freight. Thebike is sold direct from the

manufacturer via theInternet, which redu-

ces all kinds of inter-mediaries.

• website:www.bigha.com

apa is still a company

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

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

and back-slapping. As we

stroll around the area, we

have the chance to take a

look at production and also

play a game of billiards.

When Lars Bergenhem

and Nils Bouveng started

the company four decades

ago, very quickly something

developed that later came to

be called the Sapa spirit.

So what is the Sapa spirit? “Whoever’s closest, does it,” says Nils

Bouveng.

And that’s the Sapa spirit in a nut-

shell, it appears. It is actually the only

thing that appeared on the organisation

chart when Sapa was being built up.

Nothing complicated, straight to the point.

What has the Sapa spirit meant for thecompany?

“The Sapa spirit is and always has been the

key to our success. Without it, Sapa would be

just another average company,” says Nils

Bouveng and continues:

“The Sapa spirit was born out of the two

objectives that Lars and I set up when we founded

the company: we wanted to enjoy ourselves and

to get rich. The spirit is based on kinship, healthy

rivalry within the company, respect for the

individual, security and faith in the company”.

Sapa has grown to become a large group ofcompanies. What is most important if we’re toretain the Sapa spirit?

“Strong leadership. Both Lars and I were

strong leaders, and we dared to surround our-

selves with strong people. We had tremendous

faith in our employees and close contact with

them, we had an openness that created mutual

trust, and we could instil our belief in Sapa’s

business concept into them,” says Nils Bouveng.

If you ask Sapa’s current President and CEO

Staffan Bohman to define strong leadership, he

immediately refers to the two founders.

“As a leader you must be clear, you must dare

to make demands and be able to motivate the

organisation so that you get extraordinary

efforts from ordinary people. Just as it has been

ever since Nils Bouveng and Lars Bergenhem

founded Sapa. Of course, all of this means that

you must like the people who make up Sapa.”

DOWN THE YEARS the Sapa spirit has been developed,

but never losing sight of the basic values. Just

as important is the focus on profitability and

cost control. From the very outset, Sapa was

one of the industry’s most profitable companies.

The secret is to put figures on everything, as

Lars Bergenhem explains.

“For example, we counted and evaluated ten

profiles, and only accepted the six that we knew

we could make money on. Our competitors we-

re welcome to the other four!” says Lars

Bergenhem with a laugh.

“For the first ten years I authorised every

single invoice!” interjects Nils Bouveng.

Good profitability has been maintained long

after the founders left Sapa. To find out how

this has been achieved, we ask Staffan Bohman:

“Easy, it’s down to the four core values and

to our employees. Their efforts are the reason

why, year after year, we’ve succeeded in gro-

wing faster and with higher returns than many

of our competitors. The fact that we achieve

this is because 98 per cent of decisions are ma-

de by the operational companies, not by those

of us at group management level.”

No. 2 2003 • SHAPE 11

INTERVIEW

10 SHAPE • No. 2 2003

Entrepreneurial flair. Leadership. Innovation. Customer orientation.These were some of the principles when Sapa was foundedin 1963. 40 years later, the company has a turnover of almostSEK 13 billion. Despite this, the principles remain the same.

’’The Sapa spiritis the key tosuccess’’

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

S

SAPA

AT 40!1963-2003

Name: NilsBouvengAge: 74 Family: Wife andfour children,plus grandchildrenLives: Outside Vetlanda. Leisure interests: Hunting elk, deer and hare.And my wife takes me on trips all over theworld.

Lars on … … life in retirement“It’s a golden age, even if it’s sad to get old.When I’m in London I work at an asset mana-gement company where I’m a part-owner. It’sreally great to work with young people.” … tips for politicians to improve theentrepreneurial climate nowadays “Politicians shouldn’t get involved in every-thing. Remove unnecessary bureaucracy andleave entrepreneurs in peace. Then we’d havea good climate for entrepreneurs.”

Name: LarsBergenhemAge: 73 Family: Wife andtwo children,plus grand-children Lives: On the Bjäre peninsula and in LondonLeisure interests: Golf, travel and a 1935Dodge.

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

Nils and Lars have just started up thepress. It is 1963.

England reaches 35, Poland 10 It’s not only Sapa as a whole that is celebratingthis year. Poland is celebrating its tenth anniver-sary, Sapa’s British business its thirty-fifth.

The story in Britain began in 1968 with asales office, then in 1973 the company startedto produce profiles on a press at the plant inTibshelf. Down the years the presses have beendeveloped in terms of both technology and pro-ductivity. Sapa is now one of the leading profilemanufacturers in Great Britain, producing morethan 40,000 tonnes of high-quality products.

SAPA AT 40 - THE LANDMARK DATES

1963 Lars Bergenhem and Nils Bouvengforms 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) withone press (1,650 tonnes) and anodisation.

1969 Sales office opens in London.1970 Own construction system: SapaSpont. Sapa and Nokia create the Nordalexcompany.1971 Anodisation of boat masts inVetlanda. 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’ssalary for all. Sapa is a sponsor of theAmerica’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 SEKone billion, profit SEK 100 million.1984 Aluminiumwerk Offenburg wholly-owned subsidiary. Biggest order so far –

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

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

1997 Carl Gustaf XVI opens a new press inFinspång. 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 Poland2000 Gränges renamed Sapa. Acquisition ofAnodil 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. Salesoffices opened in Spain, the CzechRepublic and China.2003 Processing operations start up inShanghai. Remi-Claeys acquired.

No. 2 2003 • SHAPE 13

PRODUCT DESIGN

12 SHAPE • No. 2 2003

ting received its premiere at a furniture

fair at Stockholm in February this

year, and then at the furniture fair in

Milan. Since then, the chair has attracted

tremendous interest.

Both designers have a bright future ahead

of them. The design is innovative, and no-

thing has been done to hide the chair’s origin.

“No, quite the reverse, we really want to

show that it’s aluminium profiles that sup-

port the construction,” says Fredrik Mattson.

“Extrusion is an extremely production-

friendly, cost-efficient method. The material

means that the furniture can be used both

indoors and outdoors.”

AS ALUMINIUM can be produced in such thin

dimensions, the metal is suitable for the

manufacture of stacking furniture. One of

the criteria was that the chair should take up

a minimum of space when stacked. At pre-

sent the chair adds a total of 13 millimetres

in height when stacked, which means that a

stack of ten chairs is no higher than 13 centi-

metres plus the legs.

The special feature of the Sting chair,

which has aroused so much attention, is the

fact that the whole seat is extruded in one

piece. It is one of the broadest tools that

Sapa has manufactured.

“Aluminium is corrosion-resistant and can

withstand all kinds of weather, it’s also an

incredibly robust material. It gives a piece of

furniture an extremely long service life,” says

Fredrik Mattson.

The chair’s underframe is made of stain-

less steel, and the soft upholstery, on models

that have it, is made of polyurethane, a kind

of rubber. The legs act as a peg, locking the

whole construction into place, which is why

no glue or screws are needed for assembly.

New profile with a stingThe Sting aluminium chair is a success. The piecehas been produced by furniture manufacturer BlåStation together with designers Fredrik Mattsonand Stefan Borselius.

Facts • Exciting aluminium chairs down the years

S

In 1938 the Italian designer GioPonti developed a chair for theMontecatini company. Even thoughthe chair contained standardisedparts, this didn’t stop Gio Pontifrom creating a unique chair.

In 1988 the Argentinean designerJorge Pensi created the Toledo,a chair that has won many prizes.With the Toledo, Pensi succeededin making use of the special qualities of aluminium.

In 1999 the American designerand architect Frank Gehrydeveloped an alternative toPensi’s Toledo. The chair isextremely light, but still has asolid appearance.

In 2000 the British designerRoss Lovegrove created theGo Chair. With its simplicity andelegance, Lovergrove’s chair isone of the most innovative chairdesigns of recent years.

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

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

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

customer’s national flag. Marketing

your company by flying a flag is also

a cheap, simple way of getting your

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.”

Fly the flag with Sapa

Close collaboration

Simple to put up, will not break and virtually maintenance-free. Sapa’s flagpole made from aluminium profile has manybenefits. In conjunction with Sapa’s 40th anniversary thepole is available at a reduced price to all customers.

I

Styrbjörn Lüning.

Thule and Sapa have been collaboratingfor a long time. Now this partnership isbeing further intensified, as Thule, whichdevelops and produces rack systems forcars, has opened a factory only 20 minutesaway from Sapa’s plant in Trzianka, Poland.

Sapa and Thule enjoy a successful partnershipin Poland, which has been given an extraboost precisely because the companies areso close to one another.

But it’s not only in Poland that the companieshave ended up close together. In Sweden, ittakes about an hour to drive between Thule’splant in Hillerstorp and Vetlanda, while inBritain it only takes half an hour, and with Thuleopening 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 easierand means more efficient logistics,” explainsAnders Thålin, Account Manager for Thule atSapa.

Johan Wilhelmsson, buyer at Thule, empha-sises that the short distances mean that de-liveries of aluminium profiles are reliable, andthat the risk of damage to the profiles duringtransport 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.

Taking along a few bikes is no problem.

Bold designsA look at Danish innovation.

Sapa has supplied profiles for TheTube, drawn and designed byKarsten Eriksen. The chair was dis-played at the Scandinavian FurnitureFair in Copenhagen.With his company, Klapstuhl, KarstenEriksen has a vision of innovation in thechoice of materials, design profile andproduction methods. The chair is part of arange of furniture called Tubed Furniture,which has been produced by C-Frisk. Theprototype was developed in collaborationwith Sapa Profiler in Grenå, Denmark.Product development was quick. The firstprofile came out of the press after only3–4 weeks, ready to be made into a chair.

The design is entirely down to KarstenEriksen, but Sapa was able to offer supportin the form of good advice and adaptingthe profiles to facilitate production, interms of such matters as the choice ofalloy, anodisation and lacquering.

“Now, together with Karsten, we’veshown that there is innovation in theDanish furniture industry,” says FlemmingLarsen at Sapa Profiler.

The full range of furniture can be seenat the C-Frisk website www.c-frisk.com

Do you want to buy a flagpole at a special price?Contact and order: www.sapagroup.com/flagpoles

SAPA

AT 40!1963-2003

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-

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

now into version 5 of the

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.”

No. 2 2003 • SHAPE 15

ENGINEERING

14 SHAPE • No. 2 2003

T

»At the moment the Audi A2 is the car withthe highest aluminium content, 37 per cent «

A heavier car means higher fuel consumption and a poorerenvironment. But replacing steel parts with aluminium onesreduces the weight considerably.Niclas Hagert at Sapa Automotive highlights the importantparts that go to make up the whole.

An easy choice

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-

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.

By using a developed ASK aluminium body, the Audi A2 isabout 43 per cent lighter thanhad a conventional methodbeen used. The A2 is nowcoming off the assembly line inNeckarsulm, Southern Germany.

Sapa supplies alu-minium componentsto Volvo, for itemsincluding enginebrackets, roof racksand seat rails.

Why the motor industry is increasingly turning to aluminium

NiclasHagert.

1) Fuel distribution pipe inthe engine

This pipe distributes fuel to thevarious cylinders in the engine.Sapa has developed a totallynew production method, lea-ding to a cheaper, simpler endproduct. The fuel distributionpipe made from aluminium pro-file has been used in all Volvossince 1991, representing 300-400,000 parts a year.

2) Engine bracketThis is a part that secures theengine to the chassis. Hereuse is made of aluminium’sexcellent impact properties toperform duplicate functions: tosecure the engine in place andalso to absorb force in theevent of a collision. Thesebrackets are currently suppliedto the Volvo Car Corporation.

3) Roof racksThe light weight and designproperties of aluminium makeit ideal for the manufacture ofroof racks. Aluminium can beused to create shapes thatwould be impossible in steel,for example. The racks areused on cars such as theVolvo Combi and on Scaniatrucks.

4) Instrument panel beamsAn instrument panel beamforms the frame from which thewhole instrument panel hangs.Aluminium is used here becauseit is light and easy to shape.Sapa supplies panel beams to

Plastal, who in turn manufactureinstrument panels for cars.This product can be found inthe Iveco Daily.

5) Seat railsThese rails enable you to slidethe seats forwards and back-wards. Sapa manufactures therails for exclusive cars, such asMercedes, Volvo and Saab.

6) Airbag casingThe airbag on the passengerside is contained in a casingtogether with an explosivecharge. In the event of a colli-sion, the charge is detonatedand the airbag is inflated. Theairbag casing is Sapa’s singlebiggest product, and is suppli-ed to Autoliv, who manufacturethe actual airbag.

7) Charge air pipeThis part is contained in Volvo’sprestige R-line cars. These havea 300 hp engine in which thecharge air pipe transports theair from the turbo to the engine.This part is hydroformed, atechnique that enables you tocreate complex geometries andchange the cross-section alongthe length of the profile.

8) Rear seat backrestThe backrest is contained inVolvo’s V70 Cross Countrymodel. The strength require-ments for the product areextremely strict, as the passengers’ seat belts areattached to the back frame.

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

1

8

7

65

432

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 BEEN Factory Manager since April this

year. Previously she worked as Planning

Manager at Sapa in Vetlanda, Logistics

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 inthis 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.

IN SWEDEN much has happened in this field in

recent years, and here people no longer raise

their eyebrows when they see a female

manager in an industrial company. But

Ulrika does attract more attention when tra-

velling on business.

No. 2 2003 • SHAPE 17

CAREER ARCHITECTURE

16 SHAPE • No. 2 2003

T“The building’s inviting and attractive, and

makes a positive first impression,” says Vegar

Andersen, the group’s Information Manager.

Lindorff works on the selection, care and

development of customers. In sectors such as

banking, finance, telecommunications and

the public sector, Lindorff provides clients

with one-stop solutions for payment follow-

up and customer development.

The architects, Didrik Hvoslef-Eide AS,

satisfied the demand for a first-class client

entertainment centre by making maximum

use of light, space and the beautiful

surroundings.

“Industry should do more to attract women. Throughout entire organisations, not just inmanagerial roles. Even when they’re at university, girls have to be told that heavy industry isan 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.

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

”Take your chance when it comes’’

Ulrika Molander is Sapa’sfirst female FactoryManager.She is very happy in herrole, and hopes for morechallenges in the companyin the longer term. “It’s a shame that morewomen don’t get technicalqualifications and move intoheavy industry,” she says.

“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 nowomen 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.”

DESPITE A GREAT INTEREST in engineering, it is

above all the camaraderie at the workplace

and the sense of team spirit that Ulrika

appreciates.

“Sapa has an open attitude to people,

and not just in terms of gender. There is

a wide range of different ethnic 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.

Sapa is working to attractmore female managersSapa is taking part in a project that aimsto increase the proportion of women inmanagerial roles in business. It is beingrun by the Swedish Center for Businessand Policy Studies (SNS). By sponsoringthe project, Sapa is showing that thisissue is being prioritised within the group.

“We believe that it’s an important issuein the sector where Sapa operates, withthe preconceptions about the industrybeing dirty and heavy. This just isn’t thecase any more,” says Gabriella Pihl,Information Manager at Sapa.

A careers survey has been conductedat Sapa in Sweden to investigate thebreakdown between genders. “The resultshows that we have a lot of work to do.We’ve now taken the same survey toother companies in the group.”

The project will end in February 2004,after which Sapa will continue to work onthe matter internally.

» It’s going too far to talk about male and female. It reinforces preconceived notions «

About LindorffObject: Lindorff office and client entertainmentcentre. Year built: 2002.City/region: Lahell/Hyggen, NorwayBuilding proprietor: Lindorff Holding A/SArchitect: Ark. Didrik Hvoslef-Eide A/S, OsloContractor: Ole K. Karlsen Entreprenør A/SProducer: FasadeConsult Aluminium A/SSapa supplied the following products: façades(SFB 4050), doors (SFB 2050, 2074), glassroof: SFB 5050. Surface treatment: natural anodisation. Glass in roof: clear glass, 6-16-6laminated on the inside.

Nice work!An architectonic masterpiece. This is how Lindorff’s newhead office in Lahell, half an hour’s drive from Oslo, hasbeen described.

No. 2 2003 • SHAPE 19

ENGINEERING THE WORLD

18 SHAPE • No. 2 2003

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.

IN 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.”

The small car that’s a big help

Have you always wondered how to fit ascrew joint in a corner? Stay with Shape’sprofile school and you’ll find the answer.

There are several benefits in screwing an edgejoint, 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 costHere you can see three different principles

used with frames for windows and doors. Eachof these principles will give you a compressionforce 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 inthe profile and the corner angle. A recessedscrew is used for assembly. Recessing the

assembly holes in the profile is a relativelyexpensive process, and you can achieve thesame result using a separate flange plate or aspecial screw. The corner angles can be madeusing an extruded aluminium profile or in a

compression-moulded version.Figure 1. The separate steel flange plate has arecess for the screw. This joint has a tremendouscapacity, as the flange plate with its larger dia-meter can withstand a greater pressure on theedge of the hole in the profile than a screw alonecan. In constructions that are subject to extremeforce, the profile thickness can be reduced. Figure 2. The screw has been specially manu-factured with a thin flange and a recess. Thereis a corresponding recess in the corner angle. Figure 3. A compression-moulded cornerangle is fitted in an open groove in the outerpart of the profile in a window frame. The cor-ner angle is fitted with two oblique clampingscrews, which provide the compression force.No processing of holes is required here. The application of the design may need to becompleted with filler or glue to achieve thenecessary seal and durability.

TFacts: No licence required

ince 1990, when Dutchman Wim

Dijksterhuis bought the aluminium

yacht, it has sailed around the world a

few times. He has taken his wife Marianne,

daughter Susanne and the Jack Russell terrier

Purdy along on these journeys.

“Aluqueen really attracts attention when

she arrives, with her special design, form

and character. Aluminium’s ideal for

creating attractive shapes,” says Wim

Dijksterhuis.

“Aluminium’s a strong metal in relation to

its weight, which is why it’s mostly

replaced steel in the yachting world. If

Aluqueen had been built in steel, its

total weight would have been 20 tonnes

rather than 15 tonnes, as it is now.

Aluminium is also a corrosion-resistant

metal, so it doesn’t need as much main-

tenance as a steel boat.

“In general Aluqueen needs much

less maintenance than other boats. It’s

quite simply easier to sail in an aluminium

boat. The only problem with aluminium is

that the metal conducts electricity. If the cur-

rent passes out into the water, galvanic cor-

rosion can occur in the hull.

But galvanic corrosion can be avoided by

fitting sacrificial anodes and painting the

outside of the hull so that the metal doesn’t

come into contact with the water. This has to

be done every ten years.”

Galvanic corrosion occurs due to the

incorrect installation of electrical compo-

nents or the use of unsuitable combinations

of other metals.

Exactly which parts of Aluqueen are made ofaluminium?

“The hull, deck and cabin.”

In the last 20 years it has become increa-

singly popular to use aluminium to build

boats. The material is mainly used for the hull.

During the summer months Wim

Dijksterhuis organises sailing competitions.

During the winter months Aluqueen is on

dry land – unless the family’s out on a voyage

around the world. Between 1997 and

2001 he and his family went on a really

long voyage. Purdy the dog is actually

frightened of sailing, and spends most of

the time hiding in the machine room.

What’s your next project?“In 2004 I’ll be organising two more

sailing trips.”

Will Purdy be coming along?“Yes, of course.”

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 theshell plating. In a few days her owner Wim Dijksterhuis sets off on yet anotherjourney around the world.

The Aluminium QueenAluqueen was built bySapa in 1983, based ondrawings by boat designerPelle Pettersson.

It was used as a promo-tional yacht to market alu-minium as a material. Withten sleeping berths, a con-ference room, microwaveoven, fridge, freezer and ice machine, the yachtwas incredibly advanced and luxurious for its time.

“We produced Aluqueen in connection withthe 50th anniversary of aluminium in Sweden, asthe first motor yacht with aluminium profiles inthe shell plating. The design actually means thatinstead of shaping the plate to form a hull, theshell plating is welded using special aluminiumprofiles,” explains Anders Norlin, project managerat Sapa.

“Our intention was to show what can beachieved with aluminium. Fine, curved shapesand a surface that looks just as smooth as aplastic boat, without the angular shapes that arecommon in boats with a hull made from panels.”

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

S

The Access Shopper is small, attractive andextremely practical.

The Access Shopper is a vehicle for people with restrictedmobility, 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.

• Requires no driving licence, nor is therean age limit for driving it.

• The vehicle is powered by a battery thatwill last for up to 40 km.

• The maximum speed is 10 km/hour, whichis the requirement for it to be permitted onpedestrian areas and pavements.

• Since its launch in July, 25 Access Shoppershave been sold in Norway. The next launchwill be in Germany, to be followed by theNordic countries. From start to finished pro-duct, the development process lasted onlyseven months. An Access Shopper costsaround SEK 125,000.

Profile School/ The many benefits in screwing edge joints

“Aluqueen reallyattracts attentionwhen shearrives, with herspecial designand form ”

Wim and Marianne Dijksterhuis.

FINALLY…

20 SHAPE • No. 2 2003

Passengers in Nottingham can findshelterThe wait for a tram will now be more comfortablethanks to Sapa, who delivered 19 tonnes of alumini-um profiles to be used for shelters in a new tramsystem built by NET, Nottingham Express Transit.NET designed the shelters together with a companycalled Metalfast and the design company Woodhouse.

The design of the shelter was refined and adap-ted for production by Sapa’s designers. Thismeans that only five different profiles are required,including one used for seats in the shelter. Thefirst phase in the project involves shelters for atram route between the northern and southernparts of Nottingham. It will be officially opened atthe end of 2003.

Nottingham plans to further extend the tramsystem in the next few years. The tram project asa whole has created much interest in the Britishmedia, and is a continuation of similar projects inManchester and Sheffield. Several tram systemsare being planned in other major cities in the UK.

Award-winning school furnitureThe British furnitu-re manufacturerVaritech has pro-duced an award-winning furnituresystem for schoolsand universities.The furniture hadto be easy to dis-mantle and move,while at the same time still being strong and dur-able. Sapa in England developed the concept incollaboration with Varitech. Four of the profiles aremanufactured at Sapa in Tibshelf, while the fifthand largest profile is manufactured in Sapa’sFrench facility in Albi. “System 24/15” has attrac-ted a lot of interest in education circles, and hasalso won the “Special recognition award for inno-vation”, a competition held by the East LancashireChamber of Commerce.

Telephone box suitable for peoplewith disabilitiesSapa has delivered profilesfor a new kind of telephonebox, which will be installedin Sweden by TeliaSoneraand Outstanding Media.The phone boxes are suit-able for people with dis-abilities, which meansabove all that they are largerand thus easier to enter in awheelchair. The new phoneboxes also have space foradvertising in the form ofan illuminated panel. In oneyear 400 phone boxeshave been installed in over 40 municipalities.

Collaborationfor greatercrash safetyThe Crash Zonedevelopment pro-ject is a collabora-tion betweenVolvo Trucks,Scania, theUniversity ofLinköping and foursuppliers (Sapa, Finnveden, Accra Teknik andPrirox) to improve crash safety in both private carsand trucks. Crash Zone involves several projectsrunning in parallel for a period of six months, andall tests are conducted in theoretical models.Each participant presents their own proposal.Scania has presented a proposal for how itshould look, fitted to a truck.

Sapa expands inLithuaniaSapa is continuing to expandin Lithuania by opening a factoryto manufacture componentsbased on aluminium profiles.The business will open at thebeginning of 2004, and thecompany will initially employ 20 or so people.

“We’re now stepping up our efforts in an attrac-tive growth market,” says Lars Forsberg, manufac-turing manager at Sapa Profiler AB.

“Many of our customers are setting up productionfacilities in Lithuania, so we’ve decided to follow suitby starting our own manufacturing unit.” Sapa hashad a sales office in Lithuania since 1998.

Autoliv buys deflectorsSapa has won a new order from Autoliv Swedenfor deflectors for the passenger airbag for plat-form 2 (P2X). The platform includes Volvo modelsVolvo V70, S80, S60, XC90 and C70.

Customised IKEA trainingAt the beginning of October a customised trainingcourse was heldfor IKEA’s purcha-sing strategists,buyers and productdevelopers from allover the world. Thecourse was held onan intensive day inFinspång, Sweden,where Sapa hastwo manufacturingunits.

“The training programme has been developedspecifically for IKEA. The concept has been drawnup together with IKEA’s training co-ordinator,”explains Tor Zetterström from Swedish companySapa Profiler AB.

“The aim is to provide key people in IKEA withgood training about aluminium as a material and toshatter the myth that aluminium is an expensive metal.”

The participants also paid a study visit toSapa’s pressing plant in Finspång.

“It was a rewarding day,” says Ulf Svensson,Sapa’s contact person for Ikea. “We showed thebenefits of aluminium, and we had the chance tomake contacts with key people at IKEA.”

Pool fence protects childrenThe French company Distral has developed afence for swimming pools made of laminatedglass and aluminium profiles. The fence is used tokeep children safe from falling in the pool. Thefence also has an alarm device, in case anyonetries to climb the fence and enter the area aroundthe pool. Anotherbenefit of the fenceis that it providestotal cover, meaningthat it protects thepool from litter andother airborne dirt.

“We chose alu-minium profiles foraesthetic andpractical reasons. The profiles fit in well in allenvironments, and are easy to manage,” says MrManenc at Distral.

Interested IKEA employeesfrom Germany, Bulgaria,Turkey, Vietnam andThailand. A new group willbe trained in the spring.

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

1,000 phone boxessuitable for disabledusers are to be produced.

Scania’s suggestion for atruck with greater crash safety.

Lars Forsberg.

The pool fence also has analarm..

Prize-winning furniture.