Shape

A magazine from the Sapa Group # 2 2006

› ROLLER SKIS FOR THE RIGHT GLIDE

› CHINA A NEW HIGH-TECH SUPERPOWER
› RESEARCH IN FOCUS IN FINSPÅNG

TOUGH JOB
FOR COOL CAR ALUMINIUM BEAM SATISFIED VOLVO’S
STRINGENT SAFETY REQUIREMENTS
CONTENTS

Sapa’s winning concept

T
he level of activity is high at Sapa. The
year kicked off with strong demand on the
European extrusion market and demand has
since remained firm. We see favourable demand
on most markets where Sapa is active. All business
areas are experiencing market growth and healthy
business development.
Having been at Sapa for six months now, I
am still amazed by the complex geometries and
numerous functionalities that can be built into an
aluminium profile and the wide possibilities that our
profiles, building systems and heat transfer material
offer. Sapa has a winning concept! Close proximity
to the market and our customers is one of our cor-
nerstones and success factors, as exemplified by a
number of new and exciting co-operation opportu-
06
nities with new and existing customers.
During September, we inaugurated the extension
Wave of innovation in China.
Red-hot economic growth facilitates research and development.
of our heat transfer plant in Shanghai and, in connec-
tion with this, the company celebrated its 10-year
anniversary. We foresee continuous strong growth
on the heat transfer market, especially in China.
Continuous improvement and people manage-
ment were top of the agenda when Sapa’s 98 man-
agers met in Portugal to review the past year and
set the pace and direction for 2007. Application
sharing was on the agenda, with the aim of sharing
best practice throughout the Sapa Group.
Sapa is one of the leaders in all of our business
areas, a position we intend to strengthen. We will 04 10
do this by being customer focused and offering
Hydro-formed beam solved safety Skier keeps in shape using aluminium
high competence in all parts of the operations. We
problem in Volvo’s C70 sports car. roller skis.
work in accordance with Genesis,
a method that is based on con-
tinuous improvement throughout
our business. This, together with
a strong benchmarking system
involving application sharing
throughout the Group, and a
high focus on people and peo-
ple management is how we will
shape the future.

14 20
Corrosion in car radiators the force Old ice-hockey arenas become modern
Lennart Evrell,
driving Marja Melander. pleasure domes.
President and CEO

Sapa is an international business group that Shape is the Sapa Group’s customer magazine that Production: OTW Publishing
develops, manufactures and markets value-added is issued twice annually in ten languages. Shape is Printing: Davidsons Tryckeri, Växjö, Sweden
aluminium profiles, profile-based components and also available via the Internet at www.sapagroup.com Cover photo: Magnus Glans
systems, and heat-exchanger strip in aluminium. Changes of address: Customers should inform
Sapa has sales of approximately EUR 1.6 billion and Editor-in-Chief: Eva Ekselius their contact person at Sapa, employees their
some 8,200 employees throughout Europe and in Editor: Anna-Lena Ahlberg Jansen salary department and others the Communications
Shaping the future the United States and China. Graphic design: Karin Löwencrantz Department on +46 8 459 59 00.

2 SHAPE • # 2 2006
 BRIEF NOTICES
PHOTO CHRISTER OLOFSSON

Easier to order a taxi

Reserving taxis will be easier and smoother and “This system will be generally available through-
there will be better order in taxi queues. This is the out Sweden,” explains Lagerholm.
intended purpose of the taxi automats that were The taxi automats are manufactured using extrud-
installed at Gothenburg Central Station last sum- ed aluminium profiles from Sapa, which are avail-
mer and will be installed at Stockholm Central able in designs with frontal glued glass, concealed
Station in the autumn. hinges and tamper-proofed edging.
“This should remove the chaos in large taxi Lagerholm and Co manufactures Internet sta-
areas,” says Arne Lagerholm at Lagerholm & Co, tions, signs, lighting cabinets and frames. The com-
which manufactured the automats jointly with pany has designed products based on aluminium
Megatech. profiles for more than 30 years. Today, 140 different
Using the taxi automats will give travellers the types of profiles are used in production.
possibility of reserving and paying for taxi journeys, “Sapa’s engineers are a valuable resource. With
collecting tickets via the Internet and receiving infor- regard to this design, for example, they advised us
mation on the precise location of the reserved taxi how to protect the electronics from the rain,” says
at the Central Station. Lagerholm.

Mobile boxes with profiles

A new vehicle from Peugeot, the Peugeot Boxline
pickup, was introduced into the Swedish market in
March. Ydre Skåp is the company that manufactures
the pickup box, using aluminium profiles from Sapa.
“We assisted in designing the front hood
adapted for the body. The entire platform was a
Award for
combination of sandwich material and aluminium
profiles with a collapsible aluminium rear clamp,”
says Thomas Blom, product manager for Transport
System at Sapa Building Systems.
Most of the aluminium profiles delivered from
light fixture
Ydre Skåp are of a standard model, but adapted to
the pickup.
“We will be making deliveries on a continuous
basis for the next few years. This is interesting and
fun since there has never been a pickup of this type
on the market before. It could cause ripples in the
water and hopefully more manufacturers will get in
touch,” says Blom.
For many years, Sapa has been supplying Ydre
Skåp with products for the transport vehicle market.
“We have a very satisfactory relationship with In April, the light fixture Orosso
Sapa and excellent contact with the Support was awarded the industry’s own Oscar,
Department. Since we’re very advanced with the Red Dot Award, an international design
regard to innovative ideas, we must have a supplier prize for innovative and distinguishing product
that is just as advanced. Sapa is that company,” design. Orosso was designed by Swedish industrial
says Peter Carlsson, Ydre Skåp’s owner. designer, Olle Lundberg, for Fagerhults Belysning. The fixture
was included in the company’s “Art of Light” concept, where various designers were
given free rein. For Orosso, Lundberg combined a round light source with ordinary straight
fluorescent tubes to create an unconventional form without sharp ends and light-consuming
corners. The body was made of extruded aluminium from Sapa Profiles and ends of cast
aluminium. The aluminium profiles were also chromed to achieve the right polished finish.
“We have had a long and satisfactory relationship with Sapa,” says Anders Löfvenhamn,
TEXT ULRIKA LOKRANTZ

purchasing manager at Fagerhults Belysning.

Orosso is intended for use in office buildings and conference rooms.

# 2 2006 • SHAPE 3
ON THE MOVE
PÅ VÄG

A crashworthy
assignment
The door beam in Volvo’s new sports model C70 was too heavy and did not comply with
safety requirements. When the car manufacturer contacted Sapa Automotive, it was
urgent. In just over six months, a hydro-formed aluminium beam was to be produced.

he steel door beam, which was normally used the first beams were delivered to Volvo’s plant in degree that it was time to purchase the tools that

T in other Volvo models, did not comply with

the high demands for crash safety, because
the cabriolet naturally did not have a roof to help
Olofström, Sweden, where the doors were assem-
bled. Simultaneously, a few months of intense
development work was in progress.
would be needed in production.
“Trying to fulfil all the demands was quite a
challenge. Calculations that were implemented
absorb the force during a collision. In addition, the “We had never produced such a complex com- digitally must agree in reality. And, before order-
steel beam was too heavy and did not comply with ponent before. In addition to the crash and weight ing manufacturing equipment and tools for sev-
requirements in terms of strength. demands, the beam also had to dovetail into a lim- eral millions of kronor, one has to be assured that
When Volvo and Pininfarina (the company that ited space,” says project leader Jonas Bjuhr at Sapa development work has been adequately imple-
designed the car and is also majority shareholder Automotive, Vetlanda, Sweden. mented,” explains Bjuhr.
in the plant where it is assembled) began discuss- An aluminium door beam has several distinct
ing a solution using hydro-formed aluminium, DESIGN AND CALCULATION were implemented advantages: the material is light, has excellent
Sapa was chosen as the supplier. in parallel with the development process. The strength and not least, high energy absorption
“We knew that we were highly skilled, but this technical calculations were performed by Sapa ability.
was a specific beam that no one had previously Technology in Finspång, Sweden, and simulated But there are also risks associated with mixed
designed and there were no references available. crashes on doors were also conducted there. material. The use of several metals can result in
In addition, rapid and intense work was needed,” “We evaluated approximately  different types a galvanic element and corrosion, although the
says Bo Einarsson, purchaser at Volvo Car before finding the right one. The final design was engineers at Sapa were able to avoid that problem.
Corporation. approved by crash calculations on an entire car at “In fact, everything turned out perfectly and, in
The problem was presented to Sapa in April Pininfarina, Italy,” states Bjuhr. the end, we got exactly what we expected,” says
 and, at the end of September the same year, In August , work had progressed to such a Bjuhr.

4 SHAPE • # 2 2006
 Before becoming a door beam, the profile is
processed in several stages, such as profile
washing, maturing and robot processing.
Finally, blind rivet nuts are assembled manually
How the door beam is made
(photo above).

He is also satisfied with the co-operation process are progressing as planned, which means at least
with Volvo and Pininfarina. , cars per year. The design life of a car model
“We had a satisfactory and open discussion is usually about five years and Sapa will be supply-
with Volvo in terms of technology, delivery, com- ing components for the c model as long as it is
mercial prerequisites and so forth. Pininfarina has being manufactured.
been very accommodating and we have had an Einarsson was unable to comment on the type
excellent relationship.” of door beam that Volvo will be using in future
Einarsson at Volvo also mentioned the open models. Steel constructions are still functioning
dialogue, which is a prerequisite for good results. satisfactorily in cars with roof beams.
He was also very impressed by the fact that Sapa For Sapa, the assignment contributes vital expe- Automated hydro-formed cell
was able to meet the tough deadline. rience for the future. 1. Aluminium profiles formed in a moulding.
“From the beginning, Sapa had a positive atti- “Yes, body components are an interesting area 2. A robot moves the component to a
tude and rapidly produced a concept, and when for us. This was a complicated and pretty major processing station where another robot
hydro-forming tools were to be ordered, it all went project, which we proved that we were capable to cuts the correct length and a third robot
very quickly. The company satisfied all of our conduct,” says Bjuhr. performs the initial processing.

”
demands,” states Einarsson.
The new c was presented last autumn and
sales in Sweden began in the spring. To date, sales
T E XT T H O M AS Ö ST B E R G
P H OTO M AG N U S G L A N S O C H VO LVO
3. The component then moves to washing
and maturing (heat treatment to increase
strength).

Automated processing cell

4. At the next station, a fourth robot imple-

We had never produced such

ments the main processing.
5. The final step is assembly of 11 blind rivet
nuts, which are used later to fasten the

a complex component before

beam to the door.

# 2 2006 • SHAPE 5
INSIGHT: CHINA

Quantity becomes
QUALITY IN CHINA
“Made in China” has long been regarded as synonymous with mass production. But China is now
changing direction and is focusing on attaining world leadership in research and development.
At Sapa Heat Transfer in Shanghai, everyone is well prepared.

iring on all cylinders, China has “Sapa Heat Transfer Shanghai, together with ing could promote its capability for innovation.

F
taken the pole position in Foreign our sister company in Sweden, function as a glo- Sapa’s Japanese customers have very long test-
Direct Investment (fdi) which, cou- bal solutions provider for brazed automotive heat ing periods before approving new products, the
pled with a scorching growth rate exchangers,” explains Sternsjö. “In other words, foundation of r&d, which leads to proper use of
of nearly  percent on average, has we provide rolled aluminium products specially equipment and when needed, trouble-shooting.
fuelled an economy at break-neck designed for all kinds of heat exchangers used in Sapa feels this has prepared and positioned it to
speed for nearly a decade. According the automotive industry, such as heaters, radiators, offer more.
to China’s Ministry of Commerce, evaporators, condensers, charge air coolers and oil
the number of foreign-invested research and devel- coolers.” NEW ALLOYS MEAN more r&d to meet requirements
opment (r&d) centres in China jumped from  When asked about the potential for r&d devel- for reducing material thickness. The industry
in  to nearly  in . In a September opment in China, Sternsjö smiles: started to move from copper to aluminium 
survey of multinationals conducted by the un “The ambition is definitely there. In a genera- years ago, mainly because the material was lighter
Conference on Trade and Development, China tion, the market will be more mature, but the and more cost efficient. Today, the industry is
was the most frequently cited location for r&d people are certainly open-minded, willing to learn driving toward smaller and lighter products with
expansion, far ahead of the United States and India and are very business oriented.” In China, many a long service life, with the focus on materials that
– China’s main competitor on the innovation track. foreign managers resort to micro-management in offer down gauging and corrosion resistance (all
Three decades of foreign investment trans- order to solve problems. “I resist this temptation important in Shanghai’s ultra-humid environ-
formed China into a manufacturing powerhouse. and prefer to focus on teaching and training – this ment).
No longer content to idly serve as a factory to is key because the future is now, this is year zero “In the past seven years, the competition has
the world, Beijing plans to technologically leap- and it makes for a more sustainable company.” mushroomed. The government is pushing to revi-
frog the competition by strengthening domestic talise the North East and Guangdong in the south
innovation. A campaign engineered to propel the WITH THE COMPETITIVE environment currently is always strong,” elaborates Sternsjö. “However
country into more advanced niches of a global prevailing in China, employee retention is a wide- they haven’t reached our production capacity and
economy – creating a juggernaut of low-cost, spread concern but Sternsjö believes that Sapa’s we plan to use r&d to further distance ourselves.”
high-tech innovation unlike anything the world  employees (averaging just  years old) appre- Sapa’s sales volume went from  tonnes in
has ever seen. ciate the corporate culture at Sapa.  to a projected , tonnes in .
The company’s gate glides open, revealing a Sapa’s present plant capacity is , tonnes
ROLLING WITH THIS new ideology, Sapa Group is neatly kept compound coloured in beige, trimmed per year. The plant’s present capabilities include
positioning itself on the cusp of this innovative smartly in blue. The parking lot is reaching levels a thickness range of .-. millimetres and a
wave. The Group established Sapa Heat Transfer of bumper-to-bumper parking, filled with newly width ranging from  millimetres and upwards.
(Shanghai) Ltd in , where managing director purchased cars. Ten years ago, we would have seen The plant earned ts certification in .
Torbjörn Sternsjö has spent the last seven years a line of bicycles, five years ago, shuttle busses fer- Since , Sapa has made investments totalling
with an hour-long drive to Jiading (in the outer rying employees. But today… it’s the car.  million u.s. dollars in production facilities that
reaches of Shanghai). Sapa believes that focusing on sales and market- include a new casting centre, an upgraded hot

6 SHAPE • # 2 2006
Yan Xiaohua at Sapa Heat Transfer in
Shanghai assessing the situation.
>
 ”
The ambition is
definitely there. In a
generation, the
market will be
more mature
”
Sapa’s new centre for research and development was opened in September.
Activities here include product development and materials testing. Jimmy Jiang is
R&D Manager at the centre.

> rolling line, a new cold mill, a new tension-level-

ling machine and a new building for finishing
it’s important that we don’t pack hot products.”
During our visit, finishing touches were being
able to carry out investigations and research into
chemical composition in a new chemical lab, work
production. Future plans include an upgrade of put to the inauguration of the new Sapa Heat with a metallographic microscope, investigate
the old casting centre by the first quarter of  Transfer Shanghai r&d Centre that opened on mechanical properties and install a corrosion cabi-
and the purchase of a new loop slitter by the third September . Guests from throughout China net for sea water acetic acid equipment (swaat) to
quarter of next year. and other parts of the world converged to see Sapa check for leakage (including oy testing for interior
Jimmy Jiang, r&d manager at Sapa Heat lay the foundation for innovation. This r&d cen- corrosion). The centre also houses a  million rmb
Transfer (Shanghai), provided a tour of a perfectly tre will show Sapa’s customers – such companies controlled atmosphere brazing (cab) furnace that
clean factory; green pavements trimmed with as Delphi from the United States and Behr of permits full-scale brazing.
yellow caution lines take visitors through the raw Germany – that they no longer have to look out- Although small in size (just , square
material area, through melting/casting on to hot side China for innovation, now that this capability metres), the centre stays attuned to the company’s
rolling, through cold rolling and on to finishing, has been brought to their doorstep. philosophy of being lithe and flexible… much like
where tightly wrapped products await shipping on This new r&d centre supports such activities the aluminium product it produces.
fresh pine pallets. Jiang holds up a Silica bag: as product development, material testing and
T E XT K U R T B R AY B R O O K
“We need this in Shanghai’s humid climate and inspection and technical service. Here Sapa will be P H OTO Q I L A I S H E N

8 SHAPE • # 2 2006
 INSIGHT: CHINA

A broader range
When Ericsson needed larger coolers for its radio base stations
in Asia, Sapa had the solution. Friction stir welding enables
Sapa Profiles in Shanghai to manufacture virtually any width
conceivable.

mericans say aluminum, the British alu- to a child’s Play-Doh machine – push the material

A minium. In China, it’s called lüˇ (a homo-

nym in Chinese for the word green). Ironic,
because environmentally speaking, aluminium is
in on one side and it comes out in one piece on
the other,” he explains.
Anyone who has spent an extended period of
known as the green metal. By any name, it repre- time in China soon learns that the cornerstone of
sents immense opportunity in a country moving innovation is resourcefulness.
to a blend of innovative production. Beijing has “Our strategy,” Littler smiles, “was to develop Managing Director David Littler
called for a strengthening of domestic innovation a very cheap solution to weld two smaller extru-
– a campaign that could catapult China’s develop- sions together using fsw, a technology invented in
ment with low-cost and innovative solutions in a the United Kingdom, and developed extensively ning at , rpm) being pulled across two side-
global economy as the watchwords. by Sapa.” by-side extrusions. It’s akin to drawing a spoon
For Sapa Profiles (Shanghai), the use of friction He places two extrusions side by side, drawing through a tray of quicksilver (mercury); not even
stir welding (fsw) is a problem-solving solution his finger down the joint. a ripple as the bit passes through. Littler likens it
for heat sinks produced for the telecommunica- “This has allowed Sapa to source profiles from to a zipper.
tions industry. As a major supplier of extruded smaller local presses – making the extrusion proc- “It just all comes together,” he smiles.
heat sinks, Sapa has taken the call from Ericsson ess cheaper and easier.” T E XT K U R T B R AY B R O O K
P H OTO Q I L A I S H E N
and other telecom customers to meet the need Littler points out that fsw has no negative
for wider heat sinks with more sophisticated fin effects on heat dissipation and no significant
configurations. In ,  millimetres was increase in scrap loss compared to direct extru-
an acceptable width for heat sinks (aka coolers) sion. “And after machining the fsw product, you
and could be easily produced using small press can’t see the seam and there’s no beading.”
machinery. Ericsson has expanded its Radio Base
Station production in China and Ericsson r&d in ERICSSON AND SAPA’S other telecom customers
Beijing has developed cheaper base-station solu- benefit from coolers being produced to European
tions that require more efficient and larger coolers standards but available at lower cost in China.
(heat sinks) of > millimetres in width, with a Lead times are reduced significantly when com-
fin height of  millimetres and a thickness of . pared to imported profiles and Sapa can provide
millimetres. While extrusion suppliers can pro- coolers at almost any width – opening the door
duce these in Europe, the realities of the market to new designs to develop wide coolers using fsw
demand a localised solution in China. technology exclusively and enabling Sapa to com-
pete with die-cast products. This translates to
A JUMP FROM its sister company Sapa Heat Transfer customers being able to source large amounts
(Shanghai), Sapa Profiles (Shanghai) is helmed by of products in China, which will in turn sup-
managing director David Littler, a man who first ply the growing Asian and u.s. markets.
came to China in  as a machine supplier. A For Sapa, market development is leading
textbook on management lays thick and heavy on increased demand. Sapa Profiles, like its
Littler’s office desk. sister company Sapa Heat Transfer, will
“I was schooled as an engineer, so this manage- soon expand into a larger facility.
ment position is new to me,” remarked Littler. It “I have my team running seven days a
becomes apparent during our talk that he needs week on three shifts,” he beams.
little schooling in management. On the factory floor, a glimpse of
“You can liken the aluminium extrusion process fsw technology shows the tool (spin-
IN THE LEAD
VINJETT

Roller skis for year-

alf Corin has his sights set on next year’s
Roller skis of aluminium are
actually no innovation. However,
thanks to a new design
R -kilometer Vasalopp race in March. This
will be the fifth time he skis the long trail
from Mora to Sälen, Sweden. His goal is to better
his personal record of  hours and  minutes.
developed by Sapa and Prior to the Vasaloppet, he will ski the -kilo-
Combisport, manufacturing meter Marcilonga race, which is Italy’s equivalent.
His preparations have already started.
has been simplified. In addition, “During the summer, I try to train on roller skis
they feel almost exactly like real during the week, in addition to swimming, run-
ning and table tennis. I do so because I don’t want
cross-country skis. to lose my feeling for skiing or the muscles that
I have built up. If you want to compete in long
races, you have to train long distances,” he says.

CORIN WORKS AS an automation engineer at Sapa

Profiles in Vetlanda, Sweden. He purchased his
first roller skis prior to competing in his first
Vasalopp. Despite living close to the highlands of
Småland, there is no guarantee of snow and thus
no opportunities for training as much as required.
Corin recently replaced his old wood-fibre skis
with Free-skate classic bronze roller skis made of
Long-distance skier Ralf Corin spends many miles aluminium.
on roller skis. “Skiing with roller skis requires a different

10 SHAPE • # 2 2006
 ”
The new skis are lighter,
provide excellent balance and
are robust and durable
”
Short starting stretch
for roller skis

Development work on the roller skis took

Sapa only a couple of months, despite having
to test several prototypes before the final solu-
tion for processing the profile was found.
Production of roller skis entails several
processing steps. First the aluminium profile is
punched to make space for the wheels, which
are mounted vertically. Cut-outs are then
made for the wheel mounts, the forks and the
Ralf Corin’s Free-skate classic bronze roller skis are designed for the classic style, meaning that the wheels holes for attaching the wheels.
have reverse lock-up.
To provide space for the broad wheels, the
forks are bent. Thereafter, the entire profile

round skiing is bent to create the span that puts spring in

the ski, thus providing a feeling just like a real
cross-country ski. The profile is hardened to
give it sufficient strength. Processing finishes
with colour anodising prior to mounting the
technique compared with normal skis, because the be assembled. The manufacturing process is also wheels, attaching decals and packaging the
wheels lock in reverse, meaning that you don’t roll shorter, since assembly steps can be eliminated. skis.
backwards. With ordinary skis, you have to stamp “Aluminium is also a competitive material with
your foot down, but roller skis are still the form of excellent durability. It is also light and easily shaped.
training that is most similar,” he observes. Development of aluminium materials has reached a wheels lock in reverse. “For training free style, a
The sporting goods wholesaler Combisport has very advanced stage, which means aluminium pro- different roller ski is required with slightly smaller
developed roller skis of aluminium, an idea that files offer many possibilities,” he notes. wheels that do not lock in reverse,” Corin explains.
the company had had for some time. Other common materials in roller skis are fibre- As the autumn progresses, Corin increases the
“We already sell roller skis made of wood, but glass, wood and composite materials containing length and frequency of his training sessions.
they are not only difficult, but also expensive carbon and fibreglass. Before the first snow falls, he wants to have ses-
to manufacture. We therefore contacted Sapa sions of more than two hours under his belt.
as a partner to develop a suitable aluminium CORNELIUS RELATES THAT the aluminium skis are “When the snow falls and you have trained the
profile,” relates Greger Cornelius, president of manufactured in a single span so that it is as simi- right muscles, it’s easier to get started and to put
Combisport. Sapa was responsible for developing lar to an ordinary ski as possible. The span is the enough miles behind you on real cross-country
the profile tool based on Combisport’s drawing of part of the ski that does not rest on the ground skis,” says Corin.
the roller ski. when the skier glides but instead is pressed down He then skis as much as he can, often with
Roller skis are not new on the market, but the toward the ground with each tramp. a headlamp in the evenings. As the Vasaloppet
solution that Sapa and Combisport developed is a “This also creates the right feeling when you approaches, he is careful to avoid germs that can
completely new design. push down on roller skis,” says Cornelius. result in colds.
“The roller skis are manufactured from a single “The new skis are lighter, provide excellent bal- “That’s what I worry about up until the last
aluminium profile and do not use wheel attach- ance and are robust and durable. Aluminium roll- minute. If you’re not completely healthy, you can-
ments of another material,” reveals Cornelius. er skis also cost less. The shock absorbing capacity, not compete, because the race is too demanding,”
This provides a number of advantages. With however, is somewhat poorer,” notes Cornelius. concludes Corin.
fewer components, it is easier to achieve the cor- Corin’s Free-skate classic bronze roller skis are
T E XT U LR I K A LO K R A N T Z
rect precision for the components that have to designed for the classic style, which is why the P H OTO M AG N U S G L A N S

# 2 2006 • SHAPE 11
PROFILE

Rock’n’roll and a 67 Ford Galaxie convert-

ible are Lars Axelhed’s passion in life.
Sapa is not the same company that it was 50 years ago.
One person who knows is Lars Axelhed, who has come
the whole way through buy-outs, name changes and
breath-taking technical development.
ars Axelhed was only  the first but simultaneously feels that working conditions summer. Wintertime, it is parked at his summer

L
time he walked through the gates of and the atmosphere at Sapa are very good. home. Sometimes he and his wife Birgitta com-
Svenska Metallverken in Finspång. “There’s never any friction, not even between the bine interests, such as the time they rented a car in
He had completed seven years of different Sapa companies in Sweden. I also have to the United States and drove around buying spare
primary school and was starting in say that Sapa has always had good management.” parts and also visited Memphis.
the occupational school that the “Graceland was awesome,” notes Axelhed.
company ran at that time. AFTER WORKING 50 years in a company, it is impos- Elvis may be king, but Fats Domino and Chuck
His father already worked at the sible not to have views about management. What Berry are the favourites. Both are naturally repre-
company, so it was an easy choice. And Axelhed then are Axelhed’s recommendations to manage- sented in his record collection of some  vinyl LPs.
never regretted it. On the contrary, he believes that ment?
T E XT E WA T H I B AU D
it was fortunate that he did not take another job. “It may sound obvious, but the most impor- P H OTO S U S A N N E K R O N H O LM
“I learned everything about mechanical engi- tant thing is to be  percent clear about what
neering: lathing, milling, planning, welding, drill- the company does. We have operations in many
ing, filing…” recalls Axelhed. countries, and quite simply those who lead the
The premises where he attended occupational company must keep tracks on what is going on,” Lars Axelhed in brief
school still exist, but that is about all. Today, says Axelhed.
operations are completely different, and Axelhed Technical development over  years has been
has followed the company’s development all the so considerable that the company is hardly the
way through buy-outs, name changes and breath- same today.
taking technical developments. “Everything is so much more advanced. The
“One of the most momentous events was in materials that we worked with then weighed 
 when what was then Gränges was listed on kilos. Today they weigh ten tonnes.
the exchange,” he recalls. “On the other hand, there was much more
heavy manual lifting before. Today, the job is not
Age: 65.
AFTER A BREAK for military service when he was as physically demanding, and there are tools and
Home: Single-family home in Finspång.
, Axelhed returned with greater ambitions. He lifting devices. On the other hand, there’s a mental
Family: Wife Birgitta (also born and raised
began his education to become an engineer at pressure at the workplace that was not there before.
in Finspång), sons Peter and Sonny and four
night school, four nights a week for five years in The machines have to be kept running at all times,
grandchildren, all living in or around Finspång.
parallel with his full-time job. In addition, he mar- which increases the stress,” observes Axelhed.
Profession: Mechanical engineer at Sapa
ried and built a summer home in his spare time. One of many innovations that Axelhed consid-
Industriservice.
“I’m still building the summer house. The latest ers important is friction stir welding, which makes
Union assignments: Cashier and negotia-
addition is glassing in the porch. I’m also still mar- it possible to produce large surfaces, such as floors
tor in local branch of the Swedish Union of
ried,” Axelhed reveals. for refrigerator ships and sides for the carriages of
Clerical and Technical Employees in Industry.
After night school, he became a mechanical underground trains.
Employee representative on Sapa AB’s Board
engineer, a job he has retained ever since. Today “Technical development must continue, and
of Directors.
he works with customisation and improvement of Sapa should develop towards manufacturing even
Travel: Six trips to the United States plus travel
production equipment at Sapa Industriservice. more advanced products from a technological
to Egypt, China, India and other countries.
Half of his working time, however, is devoted to viewpoint,” Axelhed relates.
Collects: Vinyl LPs and has some 400.
union work. Since , he has been an employee “The simplest production of profiles is like cut-
Cars: Volvo S70 for daily travel and 67 Ford
representative on Sapa ab’s Board of Directors. ting cookies. Anyone can do it. Sapa should con-
Galaxie convertible during the summer.
“In local trade union work, we have to support tinue its development toward more specialisation,”
Favourite TV programs: News, British
those who are unable to keep up. Not everyone says Axelhed.
crime series and comedy shows.
is as strong, but all employees are committed and Axelhed himself is heading towards retirement
Reading: Mostly biographies about Elvis and
skilled at their jobs,” notes Axelhed. and will have time to spend on his personal interests.
other rock legends.
As a union official, he has also been active in Highest on the list are travel, cars and rock‘n’roll.
Future plans: Dividing time between summer
the European Works Council, which he helped to His car, a  Ford Galaxie convertible that
home and travel.
form. He regrets that it is now being phased out he maintains lovingly, is only driven during the

# 2 2006 • SHAPE 13
BRIEF NOTICES

Home for dislocated persons

Floating houses may be the solution in the event
Sapa makes of disasters such as flooding when new buildings
must be put in place quickly. The same applies in

MAJOR
areas where there is more water than firm ground,
such as in the Netherlands.
The Dutch company Aqua-life is developing the
concept of floating housing. The company has built
a prefabricated house on an aluminium platform with
investment in France aluminium modules designed and manufactured by
Sapa in Benelux. The entire project from start until
the first prototypes were raised took three months.
Sapa is investing about 7.5 million euros “Aqua-life was looking for an aluminium supplier
in a new vertical lacquering plant in Puget, that could offer project-oriented technical support
France. and that also wanted to participate in the develop-
“With this investment, we’re meeting ment of a new product,” says Rikwijn Boon, project Waterfront location guaranteed with the Aqua-life home.
increasing market demand for volume, manager at Sapa.
quality and delivery times,” says Fernand Because the aluminium modules can be and have an estimated lifetime of 60 to 80 years.
Venturi, president of Sapa Profiles in assembled in the desired size, there is no limit to “The market potential is highly substantial, given
France. how large an area the platforms can occupy. The that a large proportion of the world’s most densely
In the new factory, aluminium profiles will modules consist of an open aluminium framework populated areas are in river deltas. At such places,
be powder coated while hanging vertically, and are filled with the plastic material EPS to make land is relatively inexpensive, since it is not possible
instead of the traditional method in which them float. In freshwater, the aluminium platforms to use conventional construction methods,” con-
they are coated horizontally. This technique can be used without extra corrosion protection cludes Boon.
results not only in greater productivity but
also in a surface with a very high finish.
“We’re increasing capacity significantly
for the benefit of both our profile custom-
ers and building systems customers, which
Joint effort for new customer
Sapa Profiles Ltd in the United Kingdom received Sapa Profiles Ltd received the order in February.
is a growing segment,” says Venturi.
one of it largest-ever orders this spring. A total of By May, everything had been delivered. To meet
According to Lennart Evrell, President
1,650 tonnes of aluminium profiles were delivered the delivery requirements, Sapa Profiles in Sweden
and CEO of Sapa, France is Sapa’s larg-
to Trax Portable Access. The profiles will be used as had to help out. In total, 200 tonnes of profiles
est single market.
mobile floors and walkways at sporting and leisure were delivered from Sapa in Sweden. This type of
“We have a leading position in France.
events or for temporary road and bridge construction. capacity utilisation between two Sapa companies
This investment will contribute to our con-
“The order was valued at about 4 million British is called cross-border trading, a concept that Sapa
tinued success,” says Evrell.
pounds,” notes Dave Humphries, sales director at would like to refine.
Sapa Profiles Ltd. According to Humphries, Sapa Profiles Ltd will
Trax Portable Access is a completely new cus- continue to work with Trax Portable Access.
tomer for Sapa Profiles Ltd. Sapa received the order “We’re in the process of developing a new
due to its ability to meet the customer’s requirements product together. If the trials go well, we will deliver
for delivery of such a large quantity in a short time. large volumes of materials to them during 2007.”

A happier salmon
In Norway, salmon are spawning more happily than in a long time. The reason
is an aluminium solution that has been used with great success in the rivers to
prevent the spread of the salmon parasite gyrobactilus, which kills the fish.
“The first treatment of a river was performed two years ago, and the parasite
has not returned. Neither have we found the parasite in any other rivers that we have
TEXT ULRIKA LOKRANTZ

treated,” says Espen Lydersen, researcher at the Norwegian Institute for Water Research,
who believes that the aluminium solution is the future.
The acidic aluminium solution is poisonous for salmon in higher concentration, but by adapting the dosage to
the water level and chemical properties of the water, the parasite dies. Previously, the insecticide rotenone was
used, which killed both the salmon and the parasite.

14 SHAPE • # 2 2006
With the aid of a microscope,
aluminium material can be
studied in detail.

Problem-solvers in Finspång

›
Research and development work should result in more than just reports;
it should solve problems and accelerate business development.
“That’s why it’s important for us to understand how Sapa’s products are
applied,” says Jan Strid, manager for Sapa Technology.
NEW TECHNOLOGY

“Research and development is particularly stimulating when we can solve problems for our customers,” Bosse Bengtsson and Johanna Elverson examine a
says Jan Strid. profile cross section.

apa Technology, the Group’s research and The facility also has special equipment, includ-

S development centre, is located in Finspång,

Sweden. Having started as a traditional
material-development laboratory, it now compris-
ing a vacuum oven and a cab oven, used to
develop soldering techniques, and a wind tunnel
to study heat transfer. In the courtyard building,
es an extensive operation that also encompasses there is a small cold-rolling mill, an anodising
Sapa Technology in brief pure product-design assignments. plant and a machine used for friction stir welding
“We are becoming increasingly integrated (fsw) technology.
into Sapa’s commercially operated business.
Sometimes, this extends all the way to the end- STRID EXPLAINS THAT the centre has enabled Sapa
customer, which is particularly stimulating. I to be a world leader within fsw.
believe we have a good balance between science “We didn’t invent the technology, but we were
and industrial considerations,” says Jan Strid, an important partner in its process design and
who himself has a background as a researcher. development within Sapa. We’re now developing
Following many years in Norsk Hydro, he joined the tools to fine-tune the process to enhance pro-
Sapa Technology in  and was appointed man- ductivity and finances.”
ager two years later. The goal is that Sapa will be able to improve
services to its external customers, and in this regard,
RESOURCES ARE DIVIDED between assignments from Sapa Technology can make a considerable contribu-
Sapa Heat Transfer and Sapa’s profile-related oper- tion – from material development to pure product-
ations, which includes Building Systems and the development projects. Thanks to its ability to model
• Functions as the Group’s research and Mass Transportation, Automotive and TeleCom both mechanical and thermal systems, it is possible
development centre. business segments, in addition to all the pressing to design load-bearing components for trains and
• Has 45 employees, 60 percent of whom plants. Work is conducted within a number of cooler components for electronic applications.
have a university degree and 20 percent technology areas – analysis and the environment, Simple assignments can also be successful. Strid
have a PhD. Employees include metallur- design and engineering mechanics, corrosion, sol- describes a case in one of Sapa’s foreign companies,
gists, physicists, chemists, metallographers, dering technology, mechanical properties, metal- involving a relatively small customer who required
design engineers, mechanical engineers and lography, metallurgy and surface chemistry. immediate assistance. This became a technical
engineering technicians, all of whom have Equipment comprises advanced computer service assignment for Sapa Technology, which
aluminium as a speciality. programs for simulation and modelling, plus was solved in the usual manner – one of hundreds
• Also responsible for the Group’s patent well-equipped laboratories with instruments for dealt with by the centre each year. However,
handling, technical documentation, lectures chemical analysis, mechanical tests, structural the results were so good that the customer later
and courses. and corrosion examinations, optical microscopes became the third largest for Sapa.
• Co-operates with Swedish and foreign uni- and a scanning electron microscope. The afore- “I’m sure there were other factors behind this
versities and schools of higher education. mentioned reveals elements down to some tens of success, but on such an occasion, it’s great to be a
• Participates in national and international nanometres (a nanometre is . of a mil- developer,” says Strid.
research projects. limetre), which means that research can also be
T E XT A N N A - LE N A R Ö N N
conducted at the level of atoms. P H OTO M AG N U S G L A N S

16 SHAPE • # 2 2006
”
I believe we have
a good balance
between science
and industrial
considerations
”
Passivation experiments can involve very simple equipment.

Car radiators in focus

Aluminium car radiators are highly resistant in this environment is the equivalent of one year of ble results pertained to the oldest car, but these
to corrosion, according to a new unique study real service life for heat exchangers on salted roads. alloys are no longer used.
from Sapa Technology, in Finspång, Sweden. Aluminium radiators can usually withstand 30 to 40 “Alloys are the all-important element. It’s impor-
days in the chamber. tant to have the right combination of fins and tubes.
To examine how aluminium corrodes, Sapa Marja Melander, research engineer at Sapa The 0.1 millimetre thick fins that provide the tube
Technology uses a seawater acetic acid test Technology, has studied how well the tests cor- with galvanised protection are of a more basic alloy
(SWAAT). The material is tested in a salt fog cham- respond to reality in the first study to be published than the tube, while the tube, which is approxi-
ber, where it is exposed to moisture, heat and a salt in Europe. mately 0.3 millimetres thick, is often made from a
spray with a low pH sprayed at intervals. 24 hours “I study corrosion in radiators and in aluminium long-life material.
components in air conditioners in cars that are Melander’s study comprises four sections, the
between four and ten years old,” says Melander. first of which concerns radiators. In the autumn,
Functioning components are collected from ten the condensers will be examined, then the evapora-
different cars that have driven between 65,000 and tors and the intercoolers. Results from the first sub
380,000 kilometres. A few of the radiators lie on study* have already attracted international attention.
a workbench in the corrosion laboratory. They are Melander presented her material at the Aluminium
somewhat black and dirty after being exposed to the Brazing Conference in Düsseldorf in the spring and
elements, road salt and many kilometres of driving. at the International Invitational Aluminium Brazing
Hardly any corrosion, internally or externally, Seminar in Detroit in October.
could be seen with the naked eye. Only when “When the study is complete, I hope to be able
Melander studied the material with an optical light to examine heat exchangers from cars driven in Asia
microscope did she discover various types of corro- to see how the climate has affected the external
sion, but to a very limited extent. corrosion and the status of internal corrosion on the
“I’m surprised to see there is so little corrosion inside of tubes,” says Melander.
on the inside of the tubes,” she says. * Corrosion Study of Brazed Heat Exchangers
Research Engineer Marja Melander. When the material was compiled, the most nota- in Cars after Real Service Life

# 2 2006 • SHAPE 17
BRIEF NOTICES

New shapes for Sapa

Napkin rings in aluminium. This was one of the results when young Finnish
designers were given the task by Iittala to create new objects inspired by
designer Alvar Aalto.
“This year, it has been 70 years since Alvar Aalto launched his well-known
Design. To celebrate, we have developed a special collection inspired by him,”
says Tuija Aalto-Setälä, communications manager at Iittala.
Three designer groups were invited: the graphic design agency Dog
Design, industrial designers Pentagon Design and fashion designer
Hanna Sarén.
“We asked them to base their designs on Alvar Aalto’s curvy
shape and to use a material other than glass.”
Pentagon Design developed the napkin ring in aluminium. Other
products resulting from the co-operation included a wooden pot
stand, a gingerbread cutter, a bowl, a tray and an ice-cube tray.
The Alvar Aalto design was launched at the world exhibition in
Paris in 1937. The irregular shape is typical of Alvar Aalto’s design
language and influences both his architecture and furniture design.
“Alvar Aalto got much of his inspiration from nature and the contours
of a lake can be visualized in this design,” explains Aalto-Setälä.

A bright solution and

, lighting
str e e t furniture e s that
jects as ht diod
e s ign s such ob ttin g s in clude lig m in iu m.
stonia, d pany’s fi n in alu
o n s , b ased in E . S in c e the com to m -b uilt solutio ich lig h t
ti s h
Roller In
ven
a nd e xt erior use d e ve lo ped a cu ro u nd tu be in w
t,
r interior f heat, S
apa has n shaped
into a
e to redu
ce hea
fittings fo at deal o t has bee ling flang ales
te a g re iu m th a d a c oo v i S aksen, s
genera
e xt rud ed alumin e , w e h ave fitte in u te s,” says Taa
“We use
d tual tub le of m
glued. O
n the ac in a coup
e s a re w o uld burn up
dio d ht diode ferential. l was
e, the lig ium is pre r materia
o the rw is
a in E s ton ia.
e u s e of a lum in
e rm ore, no othe
r at Sa p field, th ed. Furt h
enginee plication we wish d the fitt
ing.”
Swedish bus shelters in Russia
r th is ty pe of ap ro file exactly as t diode an
F o n th e p n th e lig h
ld des ig e
“We cou e betwe in Septe
mber.
exchang elivered Sapa has delivered aluminium profiles to meet a
s olv e the heat s w e re d
able to m profile historically large order. The profiles will be used in
aluminiu
The first the 200 bus shelters that the Swedish street-furni-
ture manufacturer, Team Tejbrant, has exported to
St Petersburg, in Russia.
“It’s our standard product, entirely in aluminium
and glass, featuring an advertising display case.
It’s the same as those used all over Sweden and
that we sell throughout the world. There are about
one thousand of them in Stockholm,” says Johan
Isaksson, design manager at Team Tejbrant.
TEXT ULRIKA LOKRANTZ

It is one of the largest orders ever for Team

Tejbrant and the company hopes it will receive
more large orders from Russia.
“We believe that we will. We’ve gained a firm
foothold with this delivery,” says Isaksson.

18 SHAPE • # 2 2006
High speed
co-operation
When business progresses
favourably for the Finnish
Wärtsilä company, Sapa Profiilit
also develops well, which is the
current situation. The engine
manufacturer has been a
customer of Sapa for 18 years.
Wärtsilä’s order books are
full and a positive trend can be
seen on all of the company’s
graphs.

he Finnish company Wärtsilä is a leading

T supplier of complete propulsion systems for

vessels and offshore installations. The com-
p a n y is also a significant supplier of power plants
The gigantic Queen Mary 2 cruise
liner is propelled by four engines,
which deliver a total of 157,000
horsepower. The liner can reach a
for decentralised energy production. top speed of 30 knots.
Currently, there is considerable demand for the
company’s products.
“At present, our operations are developing
extremely well and we expect sharp growth in the
next number of years,” says Lasse Rintala, strategic ten meters long and is covered by up to ten alu-
purchasing manager. minium hatches that can be opened. Hard facts about
The co-operation with Sapa Profiilit in Espoo The engine hatches are divided into two parts, Sapa Profiilit Oy
commenced in , when Sapa received an order both the upper and lower hatches are from Sapa.
for nine profile tools. Quite a lot has happened A third Sapa product is the air block, which has
since then. a vital function.
Today, approximately  profile tools are used “It’s used to start the engine. Compressed air is
to work various engine components and Wärtsilä is used to get the pistons to move up and down. Each
Sapa Profiilit’s principal customer. Deliveries have engine has  to  cylinders,” explains Lindén.
increased to approximately  tonnes per year. One example of the trend towards an increasing
“Sapa is our main supplier and since we use an amount of aluminium (an average of  kilos per
increasing amount of aluminium in our products, engine) is that piping is being replaced by profiles.
the next few years will be a challenge – even for “It’s easy to fasten components, cables and other
• The company has been in operation since
Sapa,” says Rintala. fittings to the profiles, which makes them more
the 1970s and has had its current organisa-
versatile than piping,” says Lindén.
tion since 1991.
PROCESSING OF ALUMINIUM profiles has become The people at Wärtsilä are happy with the
• Sapa Profiilit’s sales office in Espoo, Finland,
more advanced over the years. co-operation and describe it as first-class and
is responsible for Sapa’s profile operation in
“When a girder is to have  holes, it becomes efficient. Sapa attributes the success to competent
Finland.
complicated. During pressing, it’s only possible to sales staff, an excellent network of sub-suppliers
• Refining of profiles is performed by a number
make holes in one direction. The remainder must and the fact that it is a reliable partner.
of subcontractors in Finland and by Sapa-
be made in post-processing. Since the girders can “It is important to deliver the right quality at
owned Fima in Finspång, Sweden.
weigh up to  kilos at this stage, we require large the right time. This is an absolute requirement
• The company has 12 employees (three of
machines,” explains Henrik Lindén, who works when it comes to customers like Wärtsilä,” says
which work with building systems).
with technical support at Sapa. Lindén.
• Sales totalled approximately 9,5 million
Engine hatches are one example of what Sapa
T E XT T H O M AS Ö ST B E R G euros in 2005.
manufactures for Wärtsilä. A liner engine is up to P H OTO WÄ R TS I L Ä

# 2 2006 • SHAPE 19
The Läkerol arena in Gävle,
Sweden, has been completely
VINJETT
PROFILEN
renovated over the course
of a year. The arena has the
capacity for just over 8,000
spectators following the
remodelling.

Ice hockey’s
In Sweden, ice-hockey halls have been transformed from
dilapidated arenas to modern entertainment temples for the
entire family. Inspiration came from the large NHL arenas in
Canada.
“We had to scale everything down to Swedish conditions,”
says architect Ulf Bergfjord.

20 SHAPE •# 2 2006
new luxury home
ne of Sweden’s national sports, ice hockey, Molson Centre. These are larger than the Swedish the exterior give

O was played for many years in old dilapi-

dated arenas with minimal comfort.
Spectators were almost exclusively men, who
arenas, so we had to scale everything down to
Swedish conditions,” explains Bergfjord.
The Swedish ice-hockey clubs have realised that
an open impres-
sion toward the
surrounding
cared little for comforts. The sponsors were their arenas must be able to attract a wider audi- environment.
uncomplaining gentlemen from the local business ence. Furthermore, the arenas must be suitable for Aluminium pro-
community who were satisfied with free coffee at more than ice hockey; they must also be able to host files have been
the interval. concerts, conferences and other sports. Other com- used to construct
However, a wave of modernisation is currently mercial operations, such as shops, must be present entrances, win-
Architect Ulf Bergfjord
lifting ice-hockey arenas to a new level adapted to in, or available in direct connection to, the arena. dows and glass
the modern entertainment industry. “In Karlstad, the task was to design an ice- facades.
“Basically, the old halls had a hole in the wall hockey arena that was suitable for other events. Håkan Furukrantz, promotional manager at
where hotdogs were sold. The new arenas have The Cloetta Centre in Linköping, is almost the Sapa Building System, Sweden, explains:
large restaurants, sports bars, sizeable vip spaces opposite; it’s an events arena where ice hockey can “In such large glass facades, aluminium is ideal.
and boxes,” says architect Ulf Bergfjord from the also be played,” says Bergfjord. It results in aesthetically pleasing facades, and
Bergfjord and Ivarson architect office. An arena designed to welcome hockey support- aluminium is also largely maintenance free. It is
Bergfjord and Ivarson were the architects of ers one day and concert visitors the next must be, cost efficient in the long term.”
the Löfbergs Lila arena in Karlstad, Sweden. The by definition, significantly more comfortable and To date, Sapa’s aluminium profiles have been used
Löfbergs Lila Arena was inaugurated in  and flexible than the old ice-hockey halls. in six of the new arenas in Sweden: the Swedbank
became the template for many of the new arenas “The new arenas are almost like the new city Arena in Örnsköldsvik; the Läkerol Arena in Gävle;
that have appeared throughout Sweden. marketplace – a place people go to see and be the Ejendals Arena in Leksand; the Kinnarps Arena
“We travelled to the nhl in  and looked at seen,” says Bergfjord. in Jönköping; the Löfbergs Lila Arena in Karlstad
the new arenas there. The arenas that influenced Externally, the arena is also more aesthetically and the Cloetta Centre in Linköping.
us included the Ottawa Senators’ arena, Corel pleasing and modern looking than before. Large
T E XT JA N N E P E T T E R S S O N
Centre, and the Montreal Canadians’ arena, glass facades in the entrances and other parts of P H OTO H A N S B O N N E V I E R

New arenas for Swedish hockey clubs

The Läkerol Arena The Löfbergs Lila The Kinnarps Arena The Ejendals Arena The Cloetta Centre The Swedbank
City: Gävle. Arena City: Jönköping. City: Leksand. City: Linköping. Arena
Inauguration year: City: Karlstad. Inauguration year: Inauguration year: Inauguration year: City: Örnsköldsvik.
2006. Inauguration year: 2001. 2005. 2004. Inauguration year:
Total cost: EUR 17.4 2001. Total cost: EUR 14.7 Total cost: EUR 14 Total cost: EUR 27.2 2006.
million. Total cost: EUR 19.6 million. million. million. Total cost: EUR 21.2
Architect: Bergfjord & million. Architect: Flensborns Architect: Sweco Architect: Bergfjord & million.
Ivarsson Architects. Architect: Bergfjord & Arkitektkontor. FFNS Falun. Ivarsson Arkitekter. Architect: Bergfjord &
Made of aluminium: Ivarsson Architects. Made of aluminium: Made of aluminium: Made of aluminium: Ivarsson Arkitekter.
Facades, doors, win- Made of aluminium: Facades and doors. Facades, doors, fixed Facades, décor pro- Made of aluminium:
dows, powder-coated Facades and doors. windows, fire doors, files, windows and Facades, doors, décor
facade sections, doors powder-coated facade doors. profiles, powder-coated
and door leafs. sections, interior sec- facade sections,
tions and natural ano- windows and décor
dised windows. profiles.

The Läkerol Arena The Kinnarps Arena The Swedbank Arena

# 2 2006 • SHAPE 21
ON THE MOVE

Expertise yielded
new assignment
It was skills in friction stir welding, FSW, that convinced train manufacturer
Bombardier to turn to Sapa. In co-operation, the two companies have
developed the most advanced cooler ever manufactured by Sapa.

Spain’s S 130 high-speed train, with a liquid cooler from Sapa.

BOMBARDIER TRANSPORTATION PLACES rigorous Sapa has been involved in to date,” says project was nothing similar to copy,” explains Nyström.
demands on the liquid coolers used in its trains, manager Henrik Nyström. Since the cooler has to be light (depending on
such as good cooling capacity, high strength Two problems needed to be tackled. Firstly, it the model, three to six are used per train), alumin-
and surface fineness, which impose considerable was necessary to find a flow that resulted in mini- ium was the obvious material. It is cheap and easy
demands on processing. Furthermore, the compo- mal temperature variations on the cooler’s surface, to design already at the profile stage. By remov-
nents must be light. so that the heat would not damage the electronics ing all unnecessary metal, the team succeeded in
The problem with the coolers from the previous in the cooler. reducing the weight to  kilos.
supplier was that they did not perform according “The old cooler had a vertical liquid flow. We “Since an increasing amount of equipment is
to Bombardier’s requirements. discovered that a horizontal flow was better from used in a modern train, we work to reduce weight
“We wanted a supplier that could assume the viewpoint of temperature,” says Nyström. in various ways,” explains Zimmermann.
responsibility for the entire process. Sapa Mass From the beginning, Bombardier was interested
Transportation in Finspång, Sweden, had the SECONDLY, THE WORK involved assembly of the in purchasing – coolers annually. However,
equipment, expertise and necessary skills. cooler in such a manner that it provided enhanced demand has already increased and  will be
Together, we could rapidly solve the problem,” strength and surface fineness. This is when Sapa’s manufactured next year. Sapa has already delivered
says Tobias Zimmermann, project manager at fsw skills came to use. In the old coolers, mig  coolers to Bombardier.
Bombardier in Turgi, Switzerland. welding was used, which exposed the material Both companies are very open to more co-
The development work commenced in the to a higher temperature. The result was poorer operation projects in the future.
spring of . In September this year, Bombardier strength and an increase in the deformation of the “I would be happy to work with Sapa again,”
and Sapa presented the finished product at the metal when cooling. says a pleased Zimmermann.
InnoTrans Exhibition in Berlin, Germany. “The challenge was to combine cooling capac-
T E XT T H O M AS Ö ST B E R G
“It’s the most advanced and complex cooler that ity and assembly into a finished product. There P H OTO B O M B A R D I E R

22 SHAPE • # 2 2006
A lift for persons with
MOBILITY IMPAIRMENTS
The Danish company Vela represents innovation – also when it
comes to chairs for persons with mobility impairments. The com-
pany’s new model is specifically adapted to the child, and
not the reverse.

ela is a Danish furniture producer that The transition from steel to alu-

V manufactures such products as office chairs,

children’s chairs and chairs for persons with
mobility impairments. Previously, the company
minium is not only appreciated in
Vela’s marketing department,
the development department
used a traditional steel structure for the back sup- and production also see several
port and frame, but after contacting Sapa Profiles advantages.
in Grenå, Denmark, it decided to develop a pillar In the past, it was necessary to
of aluminium. The solution was used in Hip Hop specially order such chair compo-
– an ergonomically designed chair for children nents as wheels and electric motors,
with mobility impairments. otherwise they would not fit the steel
“The aluminium pillar gives the chair an excit- profile. Now, it is possible to purchase standard
ing and exclusive look, at the same time as it components and form the aluminium profiles
significantly increases user friendliness,” says Helle around these. This provides a much more flexible
Lennø Weesgaard, marketing coordinator at Vela. and economical production.
For example, the child previously could not “Sapa has been extremely flexible and has A CNC processed aluminium
lean backwards, but now the seat cushion can be made a large contribution during the entire profile has provided an extra lift
angled at a comfort- co-operation,” explains Michael Vestergaard, for design and functionality in
able resting position. development manager at Vela. “We will definitely Hip Hop 300.
Furthermore, the continue on this track with the next models.”
pillar allows the seat The pivotal factors involved in the selection of
to be adjusted fur- Sapa were the company’s size, stability and good both application and design. The Hip Hop chair
ther downwards and reputation in the market. In addition to delivery has already attracted huge interest throughout the
higher up, making it reliability, Sapa’s technical skills were also highly world. Everybody is talking about it, which makes
easier for the child to valued. it difficult to keep up with demand in produc-
participate in various “The co-operation with Sapa has resulted in tion,” says Weesgaard.
Aluminium pillar. activities. a product with unique advantages – in terms of T E XT J I M H A N S E N

Steel exchanged for aluminium

Gustafs Interiors in Sweden, is one of Europe’s sible for us to design a system that meets all the
leading manufacturers of wooden panels for cov- requirements and that is angularly stable. Sapa
ering walls and ceilings. However, the company has done a great job in helping us solve the tech-
has been finding it difficult to find a mounting sys- nical problems.”
tem that is sufficiently stable for ceiling panels. Gustafs Interiors decided to develop its own
“We now offer the market’s only aluminium mounting system for its panels, since the systems
mounting system for suspended ceilings. In co- made of steel had several disadvantages.
operation with Sapa Profile’s engineers, we have “Mainly from the viewpoint of stability, and as
designed and dimensioned the Capax system, a result, with regard to safety, functionality and
TEXT ULRIKA LOKRANTZ

which has been available in the market for two aesthetics. We considered steel, but found that
years,” says Peter Markoff, product development aluminium was superior. For a small type of prod-
manager at Gustafs Interiors. uct, aluminium is more economical and also more
“Using aluminium profiles, it has been pos- flexible,” says Markoff.

# 2 2006 • SHAPE 23
 AND FINALLY

Icebound at the North Pole

TARA IS A two-masted schooner that has sailed the But, despite the boat being made of aluminium,
At the moment, the French expe- oceans for nearly  years, of which the recent it weighs  tonnes and in places the hull is more
dition boat Tara is icebound at years have been spent as a research platform for than four centimetres thick.
the 82nd parallel. The risk of environmental studies. This year’s expedition During the winter, seven crewmen will imple-
started in September, in co-operation with unep, ment various studies involving meteorology, solar
Tara being crushed by ice is non- the un’s environmental programme. The assign- radiation and glaciology.
existent, because of its specially ment is to study climatic changes for two years, In early spring, the relief crew will arrive, but
icebound in the vicious grip of the polar ice. not until the summer of  will the polar ice
developed aluminium hull. This is the reason why Tara was built specifically release its grip on Tara. The drift ice will then have
to cope with tremendous strain. The engineers, taken the boat nearly , kilometres from its
Bovet-Petit, designed a -meter long hull, which current location.
at certain pressures from the sides “slide up”, almost
like a cherry seed being pressed between your fin- Follow the expedition on www.taraexpeditions.org
gers. The choice of material was just as important
T E XT DAG E N A N D E R
as the hull design. It must withstand tremendous P H OTO F R A N C I S L AT R E I LLE / A D O DA M O C LE S
strain and, at the same time, be lightweight.

4 SHAPE • Nr 2 2006