SAVING LIVES

W
ITH ALUMINIUM
HOW TO MEET
CHALLENGES OF TURBINES
SAPA IS TAKING OFF
IN AUSTRALIA
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LEARN IT ALL IN SAPAS PROFILE ACADEMY
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Shape
A magazine from the Sapa Group # 2 2012
Shaping the future
5
7
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The pyramid at the
Louvre in Paris sym-
bolises aluminium in
architecture, according
to Pedro Maarico.
DESIGN
A whole new way of using solar pan-
els can be seen in Seattle. At Safeco
Park they are incorporated in the
structure instead of being a stand-
alone array of panels.
Sapa has inaugurated a state-of-
the-art ABS block production cell at
its Pennsylvania facility in the United
States. The facility can produce up to
3.2 million blocks per year.
Sapas popular Profile Academy
helps designers, technicians, engi-
neers, architects and even CEOs
gain the competitive edge by increas-
ing their knowledge of aluminium.
By pushing the boundaries for form-
ing aluminium profiles Team Tejbrant
has created a new type of tram
shelter.
Sapas role in the construction of
a brand new terminal at the Perth
Airport marks its debut on the
Australian market.
N
ext year Sapa is celebrating 50 years of Entrepreneur-
ship. What started out as a one-press operation in
Vetlanda, Sweden, is now the largest aluminium
extrusion company in the world. From the very start
the founders of Sapa understood the value of working closely
with customers to make smarter and better solutions in the
material of the future Aluminium.
Sapa has unmatched capabilities within aluminium application
development with application specialists for virtually all industrial
segments, including the automotive industry, building systems,
solar, thermal management, wind power and mass transportation.
We learn as much as we can about our customers needs, but
we also want to help our customers to make best use of all the
benefits of aluminium applications. For several years Sapa have
been running Profile Academies for customers, where engineers,
designers, purchasers and product developers are trained by
Sapa specialists to learn about the possibilities that aluminium
offers. Since the start in 1994 almost 3,000 customers have
been through the Sapa Profile Academy, which is now available
both in Europe and North America. As of August 2012, the
essence of the Profile Academy is also available for all our
customers through the Sapa Design manual on our website
www.sapagroup.com (www.sapadesignmanual.com)
Sapa can also offer global resources within technology devel-
opment. Sapa Technology is the research centre for the group,
and focuses on long-term development of the enabling technolo-
gies. One example of technologies that have been developed for
industrial application by Sapa Technology is Friction Stir Welding,
which is now applied across the group. Sapa Technology also
contributes to spreading knowledge and awareness among
Sapas customers regarding the properties of aluminium and
its uses. When Sapa Technology was established in Shanghai
in 2011, technical customer seminars where arranged both for
Heat Transfer and Profile customers in the region, laying the
foundation for global knowledge sharing.
Creating solutions to meet our customers needs
for aluminium applications, has been the heart
and soul of Sapas business for 50 years, and will
remain that way for the years to come. We are
looking forward to developing tomorrows alu-
minium solutions together with you!
CONTENTS #2
Always with
the Customer
in Focus
Svein Tore Holsether,
President & CEO Sapa
Sapa is an international
industrial group that develops,
manufactures and markets
value-added aluminium profiles,
profile-based components and
systems, and heat exchanger
strips in aluminium. Sapa has
annual sales of approximately
SEK 35,7 billion and around
14,400 employees in companies
throughout Europe, North
America, Central America
and China. Shape is the Sapa
Groups customer magazine,
and is issued twice annually in
16 languages. Shape is also
available at www.sapagroup.com
Editor-in-chief: Eva Ekselius
Editor: Evelina Stucki
Graphic design:
Karin Lwencrantz
Production:
OTW Communication
Printing: Strokirk-Landstrms
Changes of address:
Customers should inform
their contact person at
Sapa, employees their salary
department and others the
Communication Department
on +46 (0) 8 459 59 00.
Sales & Marketing
Manager at Sapa Building
System Portugal
Has worked at Sapa
since 1999
Is based in sunny and
beautiful Lisbon, Portugal
Lives with his girlfriend
and one-year-old daugh-
ter Sofia
Enjoys photography,
the cinema, watching
football and other sports
on TV, and travelling as
much as possible.
W
hat are some of the cur-
rent trends in architectural
design and aluminium sys-
tems?
From an aesthetic point of
view, current trends point towards sober and
minimalistic lines in higher and wider-than-
ever windows and doors. This is mainly to
expand the amount of sunlight getting inside
buildings and to allow the inside and outside
spaces to bond architecturally by improv-
ing the flows between both those two spaces.
Paradoxically, this actually decreases the vis-
ible role of aluminium systems as, to achieve
the above goals, these systems should not be so
noticeable.
Technically, the design is most often driven
by newer and more demanding regulations for
reducing the carbon footprint and designing
passive buildings where there is no transference
of heat to the outside. Improving the buildings
energy efficiency and performance is where most
challenges reside. Fortunately, Sapa has not only
been able to cope with these challenges, but even
surpass the demands and define higher limits
and standards.
Are these trends more global than in the past?
Definitely. The world is getting smaller every
day. Architects and developers can get inspiration
for their projects and share their ideas and concepts
worldwide with minimal effort. In addition, the
economic downturn in Europe has pushed the
construction sector to move abroad as a cluster,
searching for newer and healthier markets, and tak-
ing their home countrys architectural trends with
them. As an example, our Slimslide sliding system,
developed by Sapa Building System Portugal closely
together with Pritzker Award-winning architect
Souto de Moura, is soon to be promoted and sold in
the Philippines. There are no frontiers anymore.
What is driving the demand for aluminium
in new buildings?
Aluminium is highly adaptable and design-
able and a lot more flexible than steel, PVC,
wood or just about any other material. It can
also be endlessly recycled, so when a building
is renovated or demolished, the aluminium can
always be used again. Aluminium is one raw mate-
rial where there is no lack of supply. With todays
environmental considerations, this is an impor-
tant aspect and architects are increasing their use
of aluminium in their efforts to design greener
buildings.

What is your favourite architectural use of
aluminium?
One building that symbolises aluminium in
architecture so well is the pyramid at the Louvre.
The whole structure is made of aluminium and
there was a lot of controversy when it was built in
the 1980s because people felt that adding a high-
tech futuristic building to classical architecture was
committing heresy. But although the two buildings
are in completely different styles, the architecture
blends together perfectly.
Im also proud of the Sky Business building that
Sapa worked on in Angola. It is on top of a hill in
Luanda and has become a landmark. It really shows
what you can achieve with aluminium.
What kinds of aluminium solutions do you
envisage in the future?
I think there will be increasing integration with
solar panels in buildings to offset the high costs of
other types of energy. Once the cost of producing
aluminium solar systems and panels drops, we will see
solar systems being used more and more.
Another aluminium application is modular houses
which are inexpensive, can be easily transported and
assembled, and made bigger or smaller. Africa, for exam-
ple, has a huge need for inexpensive housing and this is
a solution that could really help meet that need in the
future. TEXT CARI SIMMONS
ALUMINIUM MOVES WITH
THE ARCHITECTURAL TIMES
Aluminium has been used in buildings for decades, but there
are constantly new challenges. Shape magazine has discussed
trends and prospects for the future with in-house expert Pedro
Maarico at Sapa Building System in Portugal.
Meet Pedro Maarico
2 SHAPE # 2 2012 # 2 2012 SHAPE 3
Unlike other solar
installations, Sun
Storages installation
incorporates the solar
panels into the build-
ings overall structure.
IN BRIEF
Autorack Launches Aluminium
Van Roof Rack
Using an aerodynamic cross-bar profile,
Autorack Products Ltd, has created an
attractive, effective new product: their aluminium
Van Roof Rack.
The new rack minimises wind noise and drag, has
a sleek design and matches strength with aesthet-
ics. Its produced in the UK and extruded by Sapa.
Prior to launching the product, Autorack distribut-
ed other suppliers products but were encouraged
by their positive experiences with Sapa Profiles to
develop and manufacture their own range of van
accessories. Using Sapas extensive aluminium
profile knowledge and working closely with Sapas
team of design engineers, Autorack began design-
ing the Van Roof Rack.
Autorack has been in the industry for over 20
years. George Kamperis is Managing Director.
We have received a first class service from the
team at Sapa; they have proved to be invaluable in
the development of this new venture.
Specialist Structures Victorious
At Showmans Show
At a large exhibition for The Outdoor
Event Services Sapa customer
Specialist Structures won the Special
award for Best Exhibition Stand in the
show. The eye-catching design incorpo-
rated two buildings that were linked by
a bridged walkway that led to a viewing
platform. The reception area of the struc-
ture consisted of a double storey flat
roof building and a first floor mezzanine,
creating an airy atrium space. Other fea-
tures included luxury office space, deck-
ing and water features and high quality
finishes to the interior.
This system is ideal for creating a
show-stopping structure at any event,
regardless of the available space.
Aluminium profiles play an integral role
in the ingenuity of the system and Sapa
have proved to be invaluable in devel-
oping it, says Keith Lewcock, Chief
Executive of Specialist Structures.
Sapa Profiles UK, who provide
the aluminium profiles to Specialist
Structures, were delighted to play a part
in this award-winning structure that uti-
lises pioneering build technology.
5%
Only five per cent
of the energy that is
required to produce
aluminium is needed to
recycle it
Building integrated solar panels
is a new way of designing build-
ings. At a baseball stadium in
Seattle extruded frames from
Sapa were used for the project.
T
he Safeco Field baseball park in
Seattle, Washington recently rede-
signed its parking lot walkways with
architectural elements from solar
power company Sun Storage.
Sun Storage, an Oregon-based solar energy
provider, supplied the architecturally integrated
solar panel racking system.
UNLIKE OTHER SOLAR installations, Sun Storages
installation incorporates the companys solar
panels into the buildings overall structure. In
other words, the solar panels are part of the struc-
ture, and are not a stand-alone array of panels.
We are using the panels for more than just
generating power, says Jonathan Monschke,
President of Sun Storage. Architecturally, the
panels look like they belong there.
Typically, solar panels on a building are an
afterthought requiring a retrofit. In the case of
Safeco Field, the ,ooo square feet of solar pan-
els were integrated into the construction of the
parking lot walkways to power lighting, escala-
tors and elevators.
The solar panels are visible to the public
and are an important way for the owners to
show that they are running a sustainable sports
arena, says Monschke.
The contractor, InSpec, installed the system
that Sun Storage designed and engineered with
Sapa aluminium.
The solar panels at the Safeco Field are clearly
visible and hang over the structure of the walk-
ways. They have an annual capacity of :,ooo
xW.
TEXT ALEXANDER FARNSWORTH
SOLAR
PANELS
AS AN ARCHITECTURAL
FEATURE
This is Safeco Field
Safeco Field is a retractable roof base-
ball stadium in Seattle, Washington and
the home field of the Seattle Mariners.
It seats 47,860 people and opened on
July 15, 1999. Safeco is a Seattle-based
insurance company.
4 SHAPE # 2 2012 # 2 2012 SHAPE 5
INSIGHT: TRAFFIC SAFETY
SAVING LIVES
WITH ALUMINIUM
T
rafFix Devices Inc, a San Clemente,
California company, produces over
1oo traffic control and safety prod-
ucts such as signs, barricades, flags,
traffic cones, vests, channeliser
drums, weed control mats and other traffic
safety and control related products.
But one of the companys premier products
that is sold around the world is the Scorpion truck
and trailer mounted attenuator that has been
fabricated with Sapa aluminium tubes for years.
THE SCORPION IS a highly engineered plug and play
traffic safety device that can be deployed on con-
struction sites or road works to absorb the impact
of an out of control vehicle. It comes in different
sizes and is easily re-buildable after a crash.
The Scorpion is made of Sapa aluminium
tubes and includes four boxes filled with hon-
eycombed aluminium that work in tandem to
absorb the impact of a crashing car. The main
idea with these mobile road safety devices is to
protect a construction site or work zone from
possible vehicle impact.
From the testimonials we get back from
police departments around the world, these
Facts
TrafFix Devices products are sold to traffic
control companies, highway contractors, state
departments of transportation, military and
utility companies as well as cities, municipali-
ties all over the US, Canada, China, Australia,
New Zealand, Europe and the Middle East.
TrafFixs products are manufactured in
Fairfield, Iowa, Adelanto and San Clemente,
California and Tijuana, Mexico. The company
was founded in 1987 by Jack and Sue Kulp
and currently employs 150 people.
In North America, theyre mandatory. In China, theyre
needed. When it comes to automotive production
anti-lock brake systems (ABS) are a given, and global
producers need global suppliers.
IT STARTS WITH the ans block, a fist-size, light-
weight aluminium extrusion that houses this
sophisticated technology. The block must be
durable yet lightweight typically ooo grams or
so. And as automobiles and light trucks acquire
ever more features and functions, weight is
an especially important consideration, which
makes aluminium the material of choice.
In :o1:, Sapa inaugurated a state-of-the-art
ans block production cell at its Cressona,
Pennsylvania facility in the United States.
WE ARE THE ONLY ans block manufacturer that
produces precision cut-to-length blocks that
are also laser-inspected: any flaws are detected
before the block leaves the plant. This means
virtually 1oo percent compliance with the criti-
cal product specifications required for delicate
ans applications, says Kevin Stuban, director
of fabrication North America.
We are also the only ans block manufacturer
that can produce customised alloys as needed
such as a special Kobe alloy for Bosch. The entire
process is completely automated, which makes
Global partnerships:
Two sides of the same coin
Supply or manufacture? Many global businesses
do both, and all want the same things.
Pricing: Volume benefits
Timing: Ability to shift or expand production
as needed
Logistics: Local production for local delivery
Quality: Consistent product quality; facilities
learn from each other
Delivery: Quick problem-solving
Sapa ABS block
extrusions
Alloys customised to
product specifications.
Small grain structure
available. Especially
suitable for high volume
production.
attenuators actually save lives, says Jim Shilo,
Director of Purchasing at TrafFix Devices. A
drunken driver or a sleeping truck driver can
crash into the Scorpion and actually walk away.
It is astonishing.
According to Shilo, the quality of Sapas
aluminium (locally produced in California)
together with a consistency of product and
deliveries means that problems are very rare.
As our sales have increased, Sapa has been
a reliable and good supplier for us, says Shilo.
We have saved a lot of lives over the years.
TEXT ALEXANDER FARNSWORTH
ABS blocks poised
for expansion
it easy to replicate with no change in quality. It
truly is world-class production.
The facility can produce up to .: million
blocks per year for the industry-estimated 1:
million block North American market.
Looking farther afield, demand for ans
blocks in China, is expected to top 1,ooo
tons in 2015, about a tenfold increase since
:oo, according to Sapa projections. Leading
ans manufacturers such as Bosch, riw, Advics
and Continental need large-scale material sup-
pliers who can match their production needs.
Explains Agnieszka Tomczak, commodity buyer
for aluminium extrusions at riw. As a global
company, we have to balance our activities
to maintain profitability. For example, when
demand is soft in one part of the world, we may
have to adjust production and move resources
to areas where demand is stronger. We need
global partners who can respond accordingly
but also provide consistent quality. Our part-
ners, like ourselves and our customers, must be
global in perspective.
With more than 1oo direct and indirect
extrusion cells worldwide, and ans block
production in Italy, the Netherlands and the
United States, Sapa has the know-how and
experience for global ans block partnerships,
coordinated by a global customer team that
includes John Baars, global key account man-
ager for Bosch and Christian Khr, global key
account manager for riw.
TEXT MICHELE JI MNEZ
The scorpion, a highly engineered traffic safety
device, protects both drivers and roadway
workers. We have saved a lot of lives over the
years, says Jim Shilo at TrafFix Devices.
From the testimonials
we get back from police
departments around the
world, these attenuators
actually save lives,
6 SHAPE # 2 2012 # 2 2012 SHAPE 7
WIND INDUSTRY TODAYS TECHNOLOGY
MEETING
DESIGN
CHALLENGES
OF TURBINES
Advantages
Advantages of aluminium profiles that contri-
bute to increased customer benefits:
Lightweight with a high stiffness-to-weight
ratio
Excellent malleability provides design flexibi-
lity with: a) different functionalities integrated
in one profile and b) fewer parts and there-
fore fewer production steps
Corrosion resistant even in harsh environ-
ments
Excellent thermal conductivity
Approximately four times lower cost than
copper
Does not get brittle in Arctic conditions
High end-of-life value and easy to recycle
For many design departments
in the wind industry, aluminium
profiles are either too unknown
or thought to be weak, expen-
sive, or sensitive to corrosion.
However, experience shows
that aluminium profiles have
the potential to help solve some
of the turbine industrys major
product design challenges.
A
major challenge for the industry is
the change from a sellers to a buyers
market, resulting in dropping mar-
ket prices. This has been caused
by a combination of the economic
crisis starting to impact the market and the
increasing global competition. Therefore, one
of the major product design challenges is cost
reduction.
Another challenge, indirectly related to the
cost issue is weight reduction. With increasing
turbine size this is becoming more and more
important.
As the top mass dictates the neces-sary sup-
port structure, reductions in top mass will
have a direct impact on the total turbine cost.
These two challenges are even more tangible for
offshore wind, as cost per kWh is considerably
higher than for on-shore wind.
A FIRST MAJOR cost component is the raw mate-
rial. Even though aluminium is approximately
three times more expensive than carbon steel,
use of aluminium profiles can reduce cost of
components and structures that are currently
being made of carbon steel. This is done by
integrating different functionalities into the
profile design, making use of as many of the
advantageous mechanical, thermal and electrical
properties of aluminium as possible, says Arjan
Bouvy from the European Marketing team.
TO TAKE AN example: a - m long, steel walk-
ing platform in the nacelle area. The previous
component was made of a square beam for the
longitudinal bending stiffness and diamond
plate with welded stiffeners underneath for the
floor area. Different attachment points were
welded to the platform. Standard beam and
plate material with a wall thickness between -
mm was used.
The individual parts were made by cutting,
stamping, drilling and bending. They were con-
nected by welding and corrosion protected by
hot-dip galvanising.
IN CLOSE COOPERATION with the customer, this com-
ponent was replaced by one single aluminium
profile with the length and width of the steel
platform. It incorporated all required function-
alities. All need for welding and galvanising
was eliminated. Cable and other attachment
points, anti-skid surface as well as the stiffness
and floor functionality were integrated into one
profile. The reduced number of parts resulted
in reduced machining and assembly time. All of
this gave approximately o per cent weight and
per cent cost reduction.
Another example of integrated functionality
is the modulised tower platform concept. It uses
a few simple profiles and simple cutting, drilling
and cxc operations. It provides cost and weight
reduction, easy installation, reduced sensitivity
for tower diameter variances and lower cost of
shipping due to compact kit packaging, says
Arjan Bouvy.
COMPARING ALUMINIUM WITH copper, aluminium
has worse electrical conductivity. However, with
o per cent of the density and : per cent of the
cost of copper, it has 1. to : times better spe-
cific electrical conductivity per kg at a consider-
ably lower cost.
Copper also is an excellent thermal con-
ductor, approximately two times better than
aluminium. But as the same density and cost
principles apply as with electrical conductivity,
application of aluminium in coolers and heat
sinks can result in considerable cost benefits.
It should be emphasised, that in order to
use all possibilities and cut cost, it is absolutely
necessary to understand the customers design
constraints and the functionalities to be pro-
vided by the component or structure. Therefore
early supplier involvement in the design process
is vital, says Arjan Bouvy.
TEXT ARJAN BOUVY
# 2 2012 SHAPE 9 8 SHAPE # 2 2012
IN BRIEF
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Wondering how to create an environ-
mentally friendly solution, choose the
most suitable materials or select the
right finish for your aluminium product?
Sapas Profile Academy can help you.
Cooperation
in Japan
A new agreement has been signed by
Sapa AB and the Japanese company Kobe
Steel LTD. The deal means that Kobe Steel
will provide Sapa with production techno-
logy for high-quality aluminium extrusions to
be used in Sapas more than 50 extrusion
plants in Europe, North America and Asia.
This is a very positive solution for both
companies, says Svein Tore Holsether
President and CEO at Sapa.
Kobe ensures high-quality solutions for
its customers outside of Japan, and Sapa
gets access to complimentary technology
for our advanced profiles extrusions ope-
rations.
The agreement covers the full range of
processes ranging from melting and cas-
ting to extrusion, including Kobe Steels
proprietary aluminium alloys that are highly
valued by the market.
High tech for Vintage Cars
Foreign Auto Supply Inc. (FAS) had in vain
searched the entire world for automatic transmis-
sion coolers for the older but still very popular
Volkswagens from the 70s through to the 90s.
The company, located in the state of Maine, USA,
has built its reputation bringing back to life older
European vehicles for the American market, be
it the restoration of a vintage Porsche or VW
Beetle or the upgrading of the VW Camper van
with a modern, current production engine.
We decided to manufacture new coolers
and instead of replicating the original antiquated
design we explored the possibility of improving
the function and reliability of the component
using todays technology, explains Jon Gagnon,
President and CEO of FAS. They were happy
to be able to work together with an engineer at
Sapas North American Technical Center throug-
hout the whole design process.
It was extremely cool and satisfying to incor-
porate cutting-edge technology such as Friction
Stir Welding in the manufacturing of a compo-
nent for a 30-year-old VW, he says.
The new Automatic Transmission
Cooler Heat Sink design develo-
ped by FAS and Sapa performs
up to 30% better than the
original factory coo-
ler fitting in the
same original
location.
880 tons of aluminium welded tubes were recently
delivered from Belgium to Tianjin in China, for a desa-
lination installation. The installation is part of a large
electricity generation plant. In addition to electricity,
the power plant in Tianjin produces steam to drive
the desalination installation. The units will provide the
desalinated seawater required for use in the power
plants steam boilers, as well as clean drinking water
for the local residents up to 100 million litres per day.
We continue to focus on desalination projects
wordwide. Water supply, especially clean and drin-
king water, is a major concern all over the world.
At this moment, we are also active in a project in
Turkmenistan, says Inge Buyse at Sapa Alutubes
in Belgium.
The alloy for the welded tubes, which needed
to be salt water resistant, started with recycled
aluminium and was developed at Sapas plant in
Lichtervelde, Belgium.
The welded tubes go through a fully integrated
production process and Alutubes has also foreseen
in full the logistics services needed to deliver all the
welded tubes at the right time and in the right place
in Tianjin, says Inge Buyse.
Alutubes has more than 10 years of experience
with delivery of aluminium welded tubes for desali-
nation installation.
880 TONS
Foreign Auto Supply Inc decided to
manufacture new coolers and instead
of replicating the original design they
improved the function and reliability using
todays technology.
Peter Richter is responsible
for the Profile Academy in
Sweden.
# 2 2012 SHAPE 11 10 SHAPE # 2 2012
12 SHAPE # 1 2012
INSIGHT: PROFILE ACADEMY
S
ince its initial launch in
Sweden in 1994, Sapas Profile
Academy has been helping
companies gain the competi-
tive edge by increasing their
knowledge about aluminium.
Today, the popular pro-
gramme is inspiring designers,
technicians, engineers, prod-
uct developers, architects and even CEOs from
companies in Europe and North America.
We want to broaden the knowledge out
there when it comes to using aluminium pro-
files, says Peter Richter, marketing coordinator
responsible for the Profile Academy in Sweden.
We want customers to understand how
smart and practical it can be to use aluminium.
Sapas survival is dependant on new and inno-
vative aluminium products, so its very impor-
tant for us to encourage new ideas and creative
thinking.
SIGN UP!
The Sapa Profile Academy attracts participants from all fields including
construction, automotive, electronics, solar energy and many more. If you
would like to attend the Profile Academy, please contact your local Sapa
company. Participants are accepted on a first come, first served basis
as the number of places is limited. The program is currently available in
Sweden, Denmark, Belgium, the UK, Netherlands, Poland, Germany,
Slovakia, Italy, Spain, Portugal, the US and Canada.
THE PROFILE ACADEMY furthers these efforts by
providing a better understanding of extrusion,
fabrication, finishing, joining, design and
other processes, as well as providing a general
overview of aluminium as a material. It offers
theory, practical information, plant tours and
seminars by both Sapa professionals and exter-
nal experts.
The information can help engineers view
their designs from a different perspective and
implement clever and cost-effective solutions,
not to mention the significant relationship that
develops between the customer and Sapa as a
result, says Peter A. Hedman, Manager of the
North American Technical Center which is
responsible for the Profile Academy in North
America.
Flemming Larsen, Marketing Communication
Manager and responsible for roll out of the
Profile Academy in Europe says the programme
also fills a gap in education. We started the
Profile Academy because we could see that
the engineering schools didnt put much focus
on aluminium, he says. There is a real need
and demand to get information about the
possibilities and the limitations of working
with aluminium, in design and engineering. I
think that is why the programme is so popular
among technicians.
I wouldnt change anything
(with this event). Very know-
ledgeable presenters, clean
presentations, great hospitality
and just the right duration.
Design ideas, Friction Stir Welding,
Bending, and Joining were great topics
for me. This course will make me look
at extrusions in a new way.
One of the participants,
Minghit Dinh, a Design
Engineer at IKEA
Components AB, exa-
mines a profile used in
control panels at road
crossings.
A profile die can have many dif-
ferent shapes. In the background:
Hans Ericsson, Ronnie Pettersson
and Joakim Oxelbark, Research
Engineers at Sapa Technology AB.
Kjell Lvkvist from
Sapa Building
System inspects a
hydroformed profile.
What participants are saying:
What participants are saying:
THE FORMAT AND content of the Profile Academy
is adapted according to country and regional
needs and it is steadily expanding into new
countries. This year, for example, the Profile
Academy is being introduced in Germany, Italy,
Spain, Portugal and Canada.
The programme takes from two to four days,
depending on location, and upon completion
of the course, participants receive a diploma.
Judging by the evaluations following each
programme, participants appear to be very
pleased with the Profile Academy, says Larsen.
A typical response is that the programme was
an eye opener. Many people say they gained a
lot of information that they were not aware of
prior to the programme.
Another indication of customer satisfaction is
that many new participants sign up on the rec-
ommendation of a co-worker. In a recent evalu-
ation of a North American Profile Academy, 100
percent of the respondents said that they would
recommend the programme to a colleague and
this is typical of the response worldwide.
Every time we have a Profile Academy there
is a waiting list of customers who would like to
attend, but cannot due to size limitations, says
Hedman, adding that the number of North
American events was increased from two to six in
2012. He attributes the positive response largely
to the relevancy of the information presented to
the daily work of designers and engineers.
What participants are saying:
Lecturer Pontus
Isaksson, from Sapa
Profiles, talks about
how aluminium pro-
files are made.
# 2 2012 SHAPE 13 12 SHAPE # 2 2012
INSIGHT: PROFILE ACADEMY
Very good
material for
sparking ideas.
Very relevant to
todays product
designs.
What participants are saying:
PARTICIPANTS ALSO APPRECIATE the opportunity
to meet people from other industries at the
Profile Academy. Group work is a main part of
the programme in Sweden, where participants
select an item and together create specifica-
tions, designs and a presentation. I like to
mix buyers, constructors all categories in one
group as diverse groups tend to come up with
incredible ideas and really good products when
working together, says Richter, adding that
these diverse groups and companies learn a lot
from each other as well. Some people who met
through the Profile Academy still contact each
other for help and ideas, he says.
In his 40 years at Sapa, Peter Richter has seen
a lot of clever aluminium solutions from custom-
ers, but theres always more to learn, he adds. We
have to keep working at it. We havent found that
final solution yet!
TEXT CARI SI MMONS
One of the popular evening activities during
the course was a visit to Kleva mine. Henryk
Hrner, who runs the facility, explained that
the 320-year-old mine is now a tourist attrac-
tion.
Sapas E6 anodising plant in
Vetlanda, Sweden, is one of a
handful of its type in the world.
The plant is 26 metres high, since
profiles are anodised vertically,
suspended from the roof.
Therese Littman and Annika
Bengtsson (foreground)
are designers at Ericsson
AB. Behind them is Lisa
Wrmegrd, a Design
Engineer with Scania.
A study visit gave the
group a chance to see
the press that is used
to extrude profiles.
Peter Richter guides the group.
# 2 2012 SHAPE 15 14 SHAPE # 2 2012

1. The blank is
fed into the die.
2. The die
clamps the blank
in position.
3. The blank is
bent.
4. The die opens
and the bent part
can be removed.
DESIGN CUTTNG EDGE
T
eam Tejbrant, based in Hultsfred in Sweden, has been
producing street furniture for over 30 years. Sapa
has been an obvious partner right from start. When
Johan Isaksson, Technical Manager at Team Tejbrant,
began thinking about a totally new type of design it
was a natural move to email his thoughts to Claes Adelin at Sapa
Profiles in Vetlanda. Could they create a completely new frame
profile with a bending radius much tighter than usual?
The thing I like about Sapa is that theyre always enthu-
siastic about your ideas. Once we had described the idea and
started the project, it only took six months to come up with the
finished product, says Johan Isaksson.
A buyer was found even before the prototype was ready.
AMS, one of the biggest advertising companies in Poland, has
ordered twelve sets of eight-section-long shelters for its newly
built tram platforms in the city of Szczecin.
THIS IS A DISTINCTLY metropolitan shelter, intended for export,
which meant that there were very specific demands. As many
components as possible had to be prefabricated and integrated
with each other. The shelter also had to be versatile, easy
to transport and easy to install on site. The solution was to
bend the main supports in one piece, which meant pushing
the limits of what can be achieved with aluminium profiles.
This allows functions such as lighting, electrical connections
and water drainage to be integrated, as well as eliminating
visible screw heads from the profiles. The result is Utopia, a
strong product that can withstand weather, wind and vandals,
designed with smooth flowing lines.
Thats exactly the way we wanted it. It has to be design with
a purpose, says Johan Isaksson.
The biggest challenge was to achieve the tightly curved radi-
us and an attractive surface finish despite the degree of bend-
ing. The solution took shape as Johan Isaksson and technician
Claes Adelin bounced ideas off each other.
CHALLENGES THAT make us push the limits are always very stimulating!
One of the main elements for success is to be involved in the devel-
opment process, as this lets us consult and open up channels with
our various specialist resources at an early stage, says Claes Adelin.
Over the years this collaborative approach has led to many
innovative solutions.
We dont just need someone who can bend a profile. Sapa
has the collective expertise in processing and finishing that we
look for. We simply have a great partnership, says Isaksson.
TEXT SUSANNA LI NDGREN
Handles weather,
wind and vandals
The challenge of UTOPIA
The list of requirements for the formed main support is long; it is subjected to both snow
and wind loads, and the profile shape in the curved area has to meet close dimensional
tolerances. Visible creases or buckles are not permitted. Due to the constraints on profile
section and bending radius the biggest challenge was designing the bending die. The
development process included bending simulations that provided feedback for the dimen-
sions and final design of the die.
Method
Draw bending is a fast process for bending profiles to a specific radius and to angles of up
to 180. The method can be used on most types of profile section. The die is designed to
match the profile section and bending radius. An internal mandrel can be used to maintain
the shape of the profile in the formed area. Radii from R20 to R1500.
By pushing the boundaries for forming aluminium profiles
Team Tejbrant has created seamless, sustainable shelters that
integrate all essential functions.
Striking facades
from the UK
James & Taylor has been developing cladding
products to reflect the changes in British archi-
tecture since 1988. Working closely with Sapa
Profiles UK, James & Taylor currently markets two alu-
minium cladding solutions: Senses Aluminium Rain
screen and Eyetech Expanded Mesh (picture). Both
systems are designed and manufactured in the UK
and are cladding systems that are unique to James &
Taylor. Both solutions minimise environmental impact
and are fully recyclable.
Eyetech Expanded Mesh is a unique faade system
that gives a striking architectural finish. It has been
used on exemplary buildings across the world includ-
ing the Stirling Prize-shortlisted Young Vic Theatre and
the New Museum of Contemporary Art in New York.
The Eyetech system combines the benefits of using
aluminium (light weight, weather resistance, design
flexibility and 100% recyclability at the end of use) with
innovative engineered fixing solutions. The innovative
design of Eyetech produces a striking three dimen-
sional panel that appears opaque when viewed from
one angle and transparent from the other.
Senses Aluminium Rainscreen Cladding system
combines the precision of extruded aluminium sec-
tions from Sapa Profiles with the durability of anodised
finishes. Each tile can be a maximum of 250 mm and
is available in a wide range of anodised colours, allow-
ing the panels to create endless original architectural
facades.
James & Taylor is a highly regarded company with-
in their field and Sapa is pleased to be associated
with such a progressive and innovative business,
says Neil Hardacre of Sapa Profiles UK.
As projects are growing in scale, so does the quan-
tity of material required and Sapa is one of only a few
suppliers capable of providing todays increasing vol-
umes of aluminium profiles and structures in sufficient
quantity and quality.
16 SHAPE # 2 2012 # 2 2012 SHAPE 17
INSIGHT: AUSTRALIA
C
onstruction is almost complete on
a new aus1:o million regional
terminal at Perth Airport in Western
Australia. Perth Airport is recognised
as the fastest growing Australian
airport, with 11. million passengers travelling
through it in :o11.
The new terminal is being built largely to
meet the transportation needs of those working
in the countrys booming mining sector and it
will have the capacity to serve up to 36 aircraft
at a time. It has been designed by HASSELL
architectural design.
SAPA PROVIDED THE entire vertical and roof light
glazing systems for the new terminal. The
Elegance :sr curtain wall is being used for the
airside facade and skylights, and Sapas Elegance
8ii blast-resistant curtain wall has been added
to the landside facade. This was the only system
on the market which matched all specification
requirements for blast resistance.
The use of blast-resistant facades in air-
ports, railway stations and other national
infrastructure buildings is becoming increas-
ingly common, says Graham Hurrell, Business
Development Manager, Sapa Building System
International. Blast-resistant facades guard
against explosions and other threats. In the case
of Perth Airport, it will enable vehicles to pull
up close to the terminal and ensure that the
people inside the building are protected.
Sapa is one of the few companies in the world
with a blast-resistant system. We understand
blast technology and have more than o years of
experience developing blast-resistant products,
says Hurrell. We have the specifications, have
done all the testing and are ready to go as soon
as the customer places an order.
PERTH AIRPORT WILL also benefit from Sapas
curtain wall system which enables greater spans
between fixing to the structure of buildings.
With our stronger profiles we can tackle pro-
jects which others struggle with, Hurrell says.
This gives architects more room for creativity
as there is less steel work behind our system
and therefore less clutter. Higher ceilings can
be built for a more spacious look something
which is certainly appreciated when designing
an airport.
Building designers in Australia are also start-
ing to appreciate the use of European-designed
thermal break technology as they strive to con-
serve increasingly costly energy, says Hurrell.
They appreciate that thermal insulation can
work in buildings which are air conditioned, as
well as in those which are heated.
The Australian market is also being intro-
duced to new product designs. We can offer
more unusual shapes and handles than the quite
generic products in Australia, says Hurrell.
People are drawn to some of our more curved
surfaces, for example.
TEXT CARI SI MMONS
TAKING OFF
IN AUSTRALIA
While other parts of the world are in the midst of
an economic recession, the Australian economy is
in top gear, fuelled largely by a mining boom. This
has led to an increase in construction and higher
demand for aluminium profiles and solutions.
The aluminium market for curtain walls and other
solutions is a well-established one, with the total
market for extruded aluminium profiles at about
150,000 tonnes per year, in this country of just 22
million people.
Although Sapa has had some contact with
Australia in the past, it is now collaborating with
authorised distributor Facade Directions Pty Ltd
to bring a full range of products and solutions to
the market. Based in Sydney, the team at Facade
Directions has been appointed to distribute this
range on the Australian and New Zealand markets.
Facade Directions has more than 60 years of expe-
rience and industry knowledge.
Sapa can offer the market profiles and solutions
that stand out from the traditional local products,
says Graham Hurrell, Business Development
Manager, Sapa Building System International.
Sapa has European designs, ideas and fabrica-
tion methods that are new to this market. We have
the technological edge and capability to extrude a
wider variety of profiles and we have more energy-
efficient products than are currently available here.
Sapa tests all of its products to ensure that they
meet Australian standards and gain acceptance on
the market. We are essentially making these prod-
ucts Australian, he stresses.
Australians apparently like what theyve seen so
far. There are several other significant projects in
the pipeline.
TEXT CARI SI MMONS
A foothold in the region
Higher ceilings can be
built for a more spacious
look something which is
certainly appreciated when
designing an airport.
Sapas role in the construction of a brand new terminal at
Perth Airport marks its debut on the Australian market.
Sapa provided the
entire vertical and
roof light glazing sys-
tems for the terminal.
Perth Airport is recognised as the fastest
growing Australian airport.
At the check-
in desks Sapa
profiles have
also been
used.
# 2 2012 SHAPE 19 18 SHAPE # 2 2012
TODAYS TECHNOLOGY XXX
Having completed two circumnavi-
gations of the globe and numerous
other voyages, the INS Tarangini has
sailed approximately 100,000 nautical
miles.
This Indian Navy Training tall ship was
first commissioned in 1997 for naval
cadets. Its the only training ship of its
kind in the Indian Navy.
The Tarangini is a three-masted
barque, designed by the British naval
architect Colin Mudie, and constructed
in Goa. Today, the ship is having a major
refit including replacing three masts and
all the rigging.
Sapa Profiles UK has worked with
Altantic Spars & Rigging to supply the
alloy tracks used to attach the yards and
gaffs to the alloy masts. Fabrication of
the masts and spars has taken a team of
three 10 months to complete.
Charlie Hutton is Projects Manager
for Atlantic Spars.
The most important factor of our
relationship with Sapa is their reliability;
every project that we have worked on
with Sapa has been stress-free thanks
to the clear communications of their
staff and accurate delivery dates of the
profiles.
FROM START
TO FINISH
Sapa has complete responsibility for customers big seller.
CUE DEE QUALITY AND DESIGN sells masts, but
in particular clamps for antennae and other
equipment that is installed at a height. This is
a market that opened up for the company fol-
lowing successful attendance at a Swiss trade
fair in 1989. When big companies such as
Comviq and Ericsson began using Cue Dees
solutions in the construction of the GSM net-
work, business really took off. Today the com-
pany has 24 employees in Robertsfors, Sweden,
annual sales totalling SEK 100 million and
products that are used all over the world.
Production now stands at around 400 tonnes
of aluminium per year, and is still growing.
CUE DEE HAS DEVELOPED a winning product;
lightweight, adjustable aluminium clamps.
There is a lot of variation in the geometry
and dimensions of towers and masts, and
different types of clamps are needed depend-
ing on the height at which the equipment is
installed. With our clamps, fitters can climb
up and be confident that they can get the job
done, explains J-O Hemmervall, Research
and Development Manager.
By using aluminium profiles, Cue Dee was
able to integrate a combination of smart solu-
tions into its clamps so that they fit almost any
type of mast or tower.
A fitter doesnt want to haul 50 kilos of
steel 50 metres up. A light, corrosion-resistant
clamp that is highly adjustable saves a great
deal of effort, time and money, says J-O
Hemmervall.
We offer our customers a very versatile
product that covers most needs, which lets
IN BRIEF
Sapa Sets Sail
them quickly get on with expanding or upgrad-
ing their networks.
THESE SALES SUCCESSES put Cue Dees produc-
tion capacity to the test. Demand rose dramati-
cally and the company decided to extend its
partnership with Sapa.
Previously we bought in all the raw materi-
als and handled machining, packaging and
customer delivery ourselves. Today we out-
source the bulk of production and use our
own resources for small production runs and
specialist solutions. We send orders and delivery
instructions straight to Sapa and they take care
of the rest. The way we look at it is; why waste
our efforts doing something that someone else
who has more resources can do better than us?,
says Hemmervall.
Cue Dees customers look for production
capacity and a presence in the global market.
These are two more areas where Sapa was able
to meet expectations. At present, all deliveries
are shipped from Sweden, but there is a pos-
sibility that Cue Dee could offer local deliveries
to its global customers.
Its one future vision we are looking at, says
J-O Hemmervall.
TEXT ERICO OLLER WESTERBERG
Cue Dee is a company with
communication in its genes.
Todays successes in the tele-
com industry can be traced
back to the companys origin as
a manufacturer of antennae for
amateur radio enthusiasts.
Cue Dee has developed a
winning product: lightweight
adjustable aluminium clamps.
# 2 2012 SHAPE 21 20 SHAPE # 2 2012
IN BRIEF TODAYS TECHNOLOGY
BRITISH WATERWAYS CALLED upon Sapa to design
and manufacture a fully-fabricated, extending
aluminium stop plank assembly in spring :o11
and trials in London and Derbyshire have now
begun.
The stop planks act as a temporary measure
whilst repairs are made to canals when the
banks have been breached. Aluminium stop
planks are a welcome alternative to the wooden
ones currently in use across the ux. These
planks are telescopic and lightweight, they can
be used almost anywhere regardless of whether
there is a stop plank already on site.
Sapa, which specialises in design using alu-
minium profiles, continues to work with British
Waterways with the objective to create a system
that is quick and easy to install. The initial trials
have gone well and British Waterways plan to
develop the system further.
When designing an innovative system such
as this, a strong working relationship is para-
mount. With Sapa, we are working mutually
to improve the system for the future; they fully
understand our aims and are helping us achieve
them, says Chris Rainger of British Waterways.
TEXT LAURI E PRESCOTT
SECURED
WATERWAYS
British Waterways have been
working with Sapa Profiles
UK to develop a lightweight
aluminium emergency stop
plank for use in the event of
breaches in the canal waterway
systems.
THE ALUTUBES PLANT in Belgium had left some tough times behind
and the construction of a new bicycle shelter was a way to keep the
good mood up, according to a survey among the staff. The new chal-
lenge was to build it using recycled aluminium plates and the welded
aluminium tubes they produce.
That is the story of the UFO as the staff call the shelter 12-metre
wide and 16-metre long construction that performs as an additional
event area and as a shiny example of innovative aluminium use as well.
But that is not the end of the story.
When the Sapa Group also awarded the plant for its outstanding per-
formance, the money was invested in a very healthy and sustainable way:
a new bicycle for each of the 200 employees of the plant. What kind of
bikes? They feature welded aluminium tubes, of course.
METAL CRAFT, a producer of furniture components, has gradually switched its pro-
duction from steel to aluminium and become more competitive in the process.
Struggling to compete in a tough market, the arnovica, Slovakia-based company
turned to Sapa for an alternative solution to their costly steel components. The result
was an aluminium design that requires much less machining, cutting, drilling, welding
and assembly than steel components. With a single aluminium profile, Metal Craft was
able to cut its costs substantially, by eliminating the need for six machining operations.
Today, Metal Craft uses Sapas customised and fabricated profiles in its furniture
adapters designed mainly for the legs of beds. Metal Crafts main customer, a produc-
er of exclusive beds, is very satisfied with the new design and quality of the aluminium
adapters.
We are very pleased with the new adapters, says Marian Kral of Metal Craft. Sapa
has been a strategic partner in aluminium profile production, with technical support
and experience conveniently located just a short distance from our operations.
WIBE LADDERS, based in Nssj, Sweden, was
established in 1929 in Mora, originally under
the name of Per-Erik Berg & Co. The company made
its first aluminium ladders in 1948. A great deal has
happened since then, and today the company uses
1,100 tonnes of aluminium each year, making it the
largest Scandinavian producer of professional lad-
ders. Sapa makes the profiles for Wibe Ladders.
Thomas Pettersson is the companys Purchasing
Manager:
We are very satisfied with Sapa as a supplier.
They have impressive technical know-how and
are always looking for ways to develop products.
Several of our employees have also benefited con-
siderably from Sapas Profile Academy.
What are the benefits of working with
aluminium?
The most obvious are naturally weight
and durability. Not everyone feels the
same, however. In Denmark we still
sell 4,000 wooden ladders each
year, says Thomas Pettersson.
Aluminium treats in Belgium
Durable
professional ladders
A comfy fit
Metal Craft designs furniture
components, mainly legs for
beds.
# 2 2012 SHAPE 23 22 SHAPE # 2 2012
DESIGN
A large office building in central Stockholm is set to become yet another example
of aluminiums outstanding properties as a building material.
A SHINING ALTERNATIVE
SAPA WAS ENLISTED to develop an alternative in
aluminium for the 4,100-square-metre exterior
of a new office building that was originally
intended to be clad in brick. The request came
from building giant Skanska, who wanted to
avoid using a heavy and expensive ceramic clad-
ding that had not yet been proven in Sweden.
It wasnt something you could buy off the
shelf. So our technicians at Sapa Building
System had to design new profiles, says Mikael
Rhodin, project engineer at Sapa.
The list of requirements was comprehensive.
The exterior had to combine sophisticated
design, durability and environmental features;
it had to be easy to install and economically
attractive.
Our work began with designing the profile
to meet the specifications for water drainage
and wind load. We worked with a supplier in
Sweden, Preconal, to develop a snap-fit instal-
lation method. With the help of a paint sup-
plier in Switzerland we were able to achieve
the desired finish: the profiles had to give the
appearance of a white-glazed ceramic, and
combine enhanced UV-resistance with dirt-
repellence and a gleaming finish.
The owner, the client and the architect were
shown digital 3D models and mock-ups of the
profiles so that they could assess the appearance
and practical aspects in detail. We assembled
them in premises close to the construction
site to show the overall effect, relates Mikael
Rhodin.
Sapa received the inquiry in March 2011, the
contract was signed in May 2012 and installa-
tion began in August 2012. In total, 70 tonnes
of profiles will be supplied for the exterior.
No, I dont believe there are any other com-
panies in Sweden with the necessary expertise,
resources and drive to complete such a large
project without making compromises, says
Mikael Rhodin. TEXT ERICO OLLER WESTERBERG
Lustgrden is a new office building in Stockholm that will have an exterior clad with aluminium profiles.
24 SHAPE # 2 2012