# 1 2010 SHAPE 1

HOW ALUMINIUM IS HELPING

TO COMBAT CLIMATE CHANGE
FIFA WORLD CUP WITH
PROFILES FROM SAPA
MOUNTAIN TOP MASTERS OF
PRECISION MANUFACTURING
ANTILLA
THE 27-STOREY HOUSE
A magazine from the Sapa Group # 1 2010
Shape

8 PAGE
LOOKING A CAT
IN THE EYES
JAGUAR TURNED TO SAPA FOR
COMPLEX DESIGN SOLUTIONS
Jaguar XJ, is like its predecessors,
sleek and luxurious. When the legend-
ary automobile manufacturer needed
help solving a complex roof design it
turned to long-time collaborator Sapa.
The resources saved through the
use of aluminium outweigh by far the
resources needed to produce it, says
Patrick de Schrynmakers, Secretary
General of the European Aluminium
Association, in an interview.
Mountain Top is a factory that suc-
ceeds in finding solutions for customers
when its competitors fail. The extrusion
company makes parts for spy planes,
among other products.
In recent years an unusual number of
motorists have had problems with cor-
rosion in their AC condensor. A study
by Sapa has shown that carwashes
are the most likely cause.
Do you wish you had a built-in refrigera-
tor in your golf cart? Then you should
check out Garia, the high-end golf car,
with an aluminium frame from Sapa.
Shaping the future
S
apa has managed to turn around the negative
de velopment we experienced in 2008 and the first
half of 2009. The financial crisis and the downturn
in the world economy caused a significant drop in vol-
ume for aluminium profiles. Sapa has made con siderable
efforts to offset this volume shortfall, indicated by the
fact that the number of employees has been reduced
by 1,100. At the same time we have taken on 200 more
people in sales, customer service and product develop-
ment since 2008 based on the realisation that a vital
factor in Sapas continuous success is our ability to
develop and strengthen partnerships with our custom-
ers. Thanks to these efforts Sapa is now well positioned
to capitalise on the market upturn which we know will
come even if it will take some time.
In order to become a truly global player, Sapa aims to
build a stronger position in Asia. In Sapa Heat Transfer
Shanghai, a approximately SEK 500 million investment
to almost double capacity is well underway and will be
ready for production in 2010. Further expansion in Asia
is high on our agenda.
Were looking forward to a closer and mutually benefi-
cial co-operation with our existing and new customers in
2010!
04
11
16
21
24
Sapa is an international industri-
al group that develops, manufac-
tures and markets value-added
aluminium profiles, profile-based
components and systems, and
heat exchanger strips in alu-
minium. Sapa has annual sales
of approximately SEK 25,1 billion
and around 13,000 employees in
companies throughout Europe,
and in North America, Central
America and China. Shape is the
Sapa Groups customer maga-
zine, and is issued twice annually
in 14 languages. Shape is also
available at www.sapagroup.com
Editor-in-Chief: Eva Ekselius
Editors: Carl Hjelm
Graphic design: Markus Koba
Production: OTW Publishing
Printing: Strokirk-Landstrms,
Lidkping
Changes of address:
Customers should inform
their contact person at
Sapa, employees their salary
department and others the
Communications Department
on +46 (0)8 459 59 00.
CONTENTS #1

HOW ALUMINIUM IS HELPING

TO COMBAT CLIMATE CHANGE
FIFA WORLD CUP WITH
PROFILES FROM SAPA
MOUNTAIN TOP MASTERS OF
PRECISION MANUFACTURING
ANTILLA
THE 27-STOREY HOUSE
A magazine fromthe Sapa Group # 1 2010
Shape

8 PAGE
LOOKING A CAT
IN THE EYES
JAGUAR TURNED TO SAPA FOR
COMPLEX DESIGN SOLUTIONS
2 SHAPE # 1 2010
Shaping
our future
Bjrn Wiggen,
President and CEO
# 1 2010 SHAPE 3
THE SHIPS, WHICH WILL be used
by both the us army and
navy, are known as Joint
High Speed Vessels (;usv).
They are fast knots
fully loaded and can
operate in shallow waters.
The ships are designed
to transport troops and
material into different crisis
zones, as well as providing
humanitarian aid.
A total of ten vessels will
be built over the next five years, and Austal then
has an option on two further vessels.
Its proof that our close collaboration with
the customer has been successful, that we meet
their strict requirements and have the necessary
technical know-how and experience, says Chris
Moyle, marine key account manager at Sapa
Mass Transportation.
SAPAS CONTRIBUTION consists of structural profiles
and Friction Stir Welded (isw) panels for the
decks, side shell plates,
bulkheads and internal
walls.
When vessels are pro-
duced in large numbers it is
a requirement that produc-
tion takes place in the usa.
Sapa will manufacture parts
at its newly acquired plant
in Connersville, Indiana.
The plant has exceeded
all our expectations. Im
very impressed by opera-
tions there, says Chris Moyle.
The us Department of Defense has over the
next :o years plans to buy new vessels of a
totally new class of ship, the Littoral Combat
Ship (ics). The most recent plan is to award a
contract for ten vessels over five years just like
the ;usv ships.
The next five years look promising and
I also see good opportunities beyond that,
concludes Chris Moyle.
TEXT THOMAS STBERG
A partnership with Austal Ships has brought Sapa Mass Transportation a large
new order. The deal to supply parts for a fast American military ship is worth
several million dollars per vessel.
CUTTING EDGE
In Friction Stir Welding (FSW), a rotating tool
is pressed into the metal to be joined and
drawn along the weld joint. The resulting fric-
tion rapidly heats the metal but, unlike fusion
welding methods, the temperature never rises
above the melting point. The pressure applied
to the tool causes severe mechanical deforma-
tion of the metal, and the surfaces are forced
together to create a joint that is free from
porosity and inclusions. The advantages over
fusion welding are greater strength, better joint
integrity and less deformation due to the con-
traction that occurs when molten metals cool.
Sapas contribution consists of structural
profiles and Friction Stir Welded (FSW) panels
for the decks, side shell plates, bulkheads and
internal walls.
About Friction Stir Welding (FSW)
Full ahead for
new high-speed vessel
A fully loaded JHSV vessel can do up to 35
knots.
4 SHAPE # 1 2010
DESIGN
JOYFUL
JAGUAR
When Jaguar was designing its recently launched
XJ model, it turned to long-time collaborator
Sapa for help solving a complex roof design.
T
he latest car from legendary automobile
manufacturer Jaguar is, like its predecessors,
sleek and luxurious. Features on the new
x; model include a full-colour uo touch screen
with a navigation system, interior mood lighting,
virtual instruments and a keyless starter.
Cashew seats with truffle upper facia, is the
official description of the cars interior design.
It sounds so good you could eat it. And dont
forget the panoramic roof with electrically ope-
rated blinds.
SUPPORTING THIS ROOF is a Sapa cant rail using
a hydro-formed extrusion, a solution that was
developed specifically for Jaguar. The cant rail
is made of a high-strength water-quenched
oo8: alloy, and while this alloy has
been used for structural applications
in the past, it is the first time it has
been used with hydro-forming.
By using hydro-forming in the cant
rail, Sapa was able to deliver a complex
extruded shape to high dimensional toleran-
ces, something which is extremely important
# 1 2010 SHAPE 5

Jaguars are renowned for their elegant,

sporting lines and the all-new XJ, with
its fluid, contemporary style, is the
boldest interpretation yet of Design
Director Ian Callums vision for Jaguar
in the 21st century.
6 SHAPE # 1 2010
considering the design and size of the x;s pano-
ramic sun roof.
We needed this car to meet all of the worlds
safety requirements so it has to perform well
in side impact, in roll over, and in roof crush.
We needed high strength as well as this elegant,
slim package, says Mark White, chief techni-
cal specialist for Body Engineering Jaguar and
Land Rover.
WHITE AND HIS team wanted a car that would feel
light and airy on the inside and look sleek and
elegant on the outside, something which requi-
red a small but sturdy cant rail.
The hydro-forming process ensures that the
cross-section of the profile meets highly accura-
te tolerances. Reference holes are hydro-pierced
at the same time as the extrusion is shaped for
maximum geometrical precision. These refe-
rence holes are used during the robot milling
process to ensure that all features are precisely
machined to the shape so that front and rear
panels fit perfectly in the final assembly.
SAPA SPECIALISTS FROM Sweden and the ux were
brought together to address the design challenges.
It was a demanding development for the team to
ensure that the rail, the panels and the assembly
process all came together to deliver the correct
assembly for Jaguar, says Barnaby Struthers, sales
area manager at Sapa Automotive. In Sweden,
the challenge was to ensure the geometry of the
rail given the nature of the alloy, while in the ux,
the main challenge was to ensure the most accu-
rate aluminium-stamped panels along with the
most robust assembly fixtures and processes to
deliver the best final assembly.
Sapa worked with an adhesive supplier to
develop a new two-part structural epoxy adhe-
sive. The project was nearly two years in the
making for Sapa, which has provided Jaguar
with many aluminium profiles and solutions
in the past. As with previous cars, the new x;
body is made of aluminium. This generates a
lighter vehicle resulting in much better driving
performance and handling, coupled with low
emissions.
THE BENEFIT OF working with Sapa is the very
pro-active approach the company takes towards
finding technology solutions that will make our
products work, says Mark White.
Another benefit with Sapa is that they are
very focused on making customer-orientated
parts, so when we demand a high level of accu-
racy or when we need a new process, Sapa is
very proactive in looking at solutions to deliver
these new designs that we are creating.
Sleek exteriors with spacious interiors and
maximum visibility are characteristics that most
DESIGN
The benefit of working with Sapa is the
very pro-active approach the company
takes towards finding technology solutions
that will make our products work.
MARK WHITE, CHIEF TECHNICAL SPECIALIST, JAGUAR
# 1 2010 SHAPE 7
global car manufacturers are looking for today,
Struthers points out. At the same time, increa-
singly stringent safety requirements have turned
these compact body structures into a design
challenge.
THE SOLUTION ON the Jaguar x; is to have a strong
rail extruded by Sapa to meet all the safety
requirements within the small space left due to
styling demands. In the end, only by using the
hydro-forming process were we able to generate
the very complicated shape which fitted along
the length of each car body side, he says.
The cooperation on the Jaguar x; appears
to have sparked an exciting new development
in vehicle manufacturing. As White says, We
believe that the hydro-forming and extrusion
processes will play a vital role for the manufac-
ture of lightweight vehicles in the future.
TEXT CARI SIMMONS
The all-new Jaguar XJ brings a daring new
spirit to automotive luxury. Sleek, sporting
and sophisticated, it offers a seductive mix of
striking design, breathtaking performance and
engineering without compromise.
Supporting the roof is
a Sapa cant rail using a
hydro-formed extrusion,
a solution developed
specifically for Jaguar.
The all-new XJ is constructed using Jaguars aerospace-
inspired aluminium body technology, which makes the
XJ lighter than its rivals by at least 150 kg.
8 SHAPE # 1 2010
8 SHAPE # 1 2010
A
ntilla is the private residence of Mukesh Ambani, chair-
man and managing director of Reliance Industries,
Indias largest private sector enterprise.
The home differs in that no two floors are alike in either plans
or materials used. Atop six stories of parking lots, Antillas living
quarters begin at a lobby with nine elevators, as well as several
storage rooms and lounges. Down dual stairways with silver-
covered railings is a large ballroom with its ceiling covered in
crystal chandeliers. It features a retractable showcase for pieces of
art, an array of ico monitors and embedded speakers, as well as
stages for entertainment. The hall opens onto an indoor/outdoor
bar, green rooms and powder rooms, and allows access to a near-
by entourage room for security guards and assistants to relax.
Together with his global architects and consultants, Ambani
chose Sapa Building System to provide the residence with 18o
double doors.
This is the first project for the Sapa Building Systems team
in India. The potential in India is huge. With one billion
people, the Indian market is the second biggest in the world
and extremely important, says Bernard de Bruyckere, Business
Development Manager of Sapa Building System International.
TEXT CARL HJELM
A six-story garage, hanging gardens from
top to bottom, a full-fledged cinema, and
four floors of indoor and outdoor
gardens. These are just a few highlights
of Antilla, the 27-story skyscraper home
being built in downtown Mumbai, India, for
the business man Mukesh Ambani.
ANTILLA
the 27-story home
Focus on flexibility and good care
British manufacturer Anetic Aid has developed the QA4 mobile multi-
purpose surgery system with day treatment centres in mind. It is a light-
weight, flexible and easy-to-use solution that performs both as a transport and
recovery trolley as well as an examination or operating table. It can be easily
fitted with a large array of equipment for all medical specialties.
Designers at Anetic Aid set a weight limit of 125 kg for the trolley (160 kg
for a powered version), which made extruded aluminium supplied by Sapa
UK the perfect material choice. The benefits of aluminium being a lightweight
material with great strength has enabled this trolley to meet the
required weight limit, which was a major design criteria.
The lightweight, L-shaped, aluminium
risers developed by Canam Group
were conceived as a quick and cost-
effective solution to achieve the vertical
expansion of existing stadiums. Structal-
Heavy Steel Construction, a division of
Canam Group in Canada, markets this
concept, for which there is an interna-
tional patent pending. These aluminium
risers are also used for new stadium constructions.
Since the risers are made of extruded aluminium rather than concrete or
steel, delivery lead times are much shorter. The aluminium is extruded by Sapa
Extrusions Inc. in Connersville and shipped to Canam Group in the Province of
Quebec. They are factory-assembled and shipped in ready-to-install sections
of varying sizes.
Using this solution to increase the seating capacity of Laval Universitys
Pavilion of Physical Education and Sports in Quebec City, Structal-Heavy Steel
Construction built a new 2,100-seat elevated grandstand in less than 15 weeks.
>
# 1 2010 SHAPE 9
>
BRIEF NOTICES
The Anemo Team two teachers and eight first-
year students of aeronautical technology of the
INHolland College at Delft, the Netherlands set
up a challenge: to prove they could build a wind-
driven car that could easily drive against the wind.
And they did it!
The car has been showed around the Netherlands
and even took part in the EcoExperience, an event
related to the UN Cop 15 climate summit. They
also participated in a wind powered vehicle race in
Denmark at the end of September.
The vehicle is fitted with a vertical turbine that
catches the wind in any direction, delivering mecha-
nical power to the wheels. Sapa Aluminium BV,
from Hoogezand, the Netherlands, sponsored
the project and contributed the structural tubes
that kept the weight of the Anemo car to just 90
kilograms, making it the lightest vehicle in the
WindTurbineRace 2009 at Stauning Airfield in
Denmark. More information about the team and
their new car can be found at www.teamanemo.nl.
>
An aluminium
rising star
Against the wind
A small package with energy to spare
Were used to plugging in adaptors to recharge batteries when our laptops or
mobiles run low, but what happens when we dont have access to mains
supply? There have been plenty of ideas, but few real successes so far.
A company called MyFC is hoping to change all this with its FuelCellSticker
technology. It has developed a fuel-cell-powered charger, which despite its
diminutive size can recharge empty batteries several times over.
The first commercial product will be launched soon. Sapa is supplying the
aluminium support frame that houses the fuel cell and conducts away the heat that is
generated electrically as the hydrogen inside the cells reacts with oxygen in the air.
>
10 SHAPE # 1 2010
T
he order, for 8 Electrical Multiple Units
(ixus), was placed by Deutsche Bahn
Regio ac, and Alstom will build the train
bodies. Sapas plant in Finspng, Sweden, will
supply structural profiles and Friction Stir
Welded (isw) panels for the floors and walls.
The contract includes an option for a further
8 trains.
THE TRAINS WERE designed in close consultation
with the Stuttgart rail administration. Each has
four carriages, will take up to , passengers
per train and will serve six lines in Stuttgart and
the surrounding area, carrying around o,ooo
passengers daily.
The order has good green credentials. Public
transport is a green option, as is the use of
electricity instead of diesel. The trains also have
various environmental technologies onboard.
Regenerative braking takes the energy from
braking and feeds it back into the trains elec-
trical grid. This contributes to reduce energy
consumption by 40 percent compared with pre-
vious trains. Waste heat from transformers and
inverters is also used to heat the train, giving
further environmental and financial savings.

SAPA AND ALSTOM have worked together since 1,,o,
when Alstom was looking for new suppliers.
Sapas ideas on isw and how the technology
could be used for longitudinal welding of train
side panels were central to its choice. Those ideas
perfectly matched Alstoms ambition to intro-
duce new production technology. Today, almost
1 years later, the companies are long-term
partners and Sapa brings considerable know-how
and design resources to the partnership, enabling
joint development of new solutions.
The order is worth a total of : million, of
which Alstoms share is 11: million. Production
began in December :oo, and the trains will be
delivered between February and December :o1:.
TEXT HENRIK EMILSON
When Sapa Mass Transportation and Alstom Transportation join forces
to win new order for EMU trains it is not just a project to raise their
green profile. It is yet another project that the two companies are
working on together as long-standing partners.
ON TRACK FOR A
BETTER ENVIRONMENT
T
he European Aluminium
Association (iaa) represents
the aluminium industry in
Europe and was founded in
1,81. Since :ooo, Patrick de
Schrynmakers has been its
Secretary General.
When it comes to the usage
of aluminium from an environmental perspecti-
ve, Patrick de Schrynmakers main point is clear.
Whether you consider the climate, the
environment, energy or our societies welfare,
the common challenge is, one way or another,
resource preservation. And it so happens that
aluminium, as a material, can greatly contribute
to preserving resources in several ways, he says.
Aluminium is the third most abundant
material in the Earths crust, so that bauxite
extraction not only requires minimal land
use, no more than o square kilometres a
year, but also allows for complete rehabilita-
tion afterwards, preserving local natural and
agricultural resources as mush as possible.
Then, when used in various applications,
aluminium enables reduction in the use of
several other resources throughout the life of
the product:
E Cars and trucks with lightweight alu-
minium increase road and pedestrian safety
to preserve human life, while also making
vehicles more energy efficient, and thereby
saving fuel.
E Aluminium packaging materials are
impermeable to light, air and moisture,
so they allow the preservation of valuable
resources such as food and beverages,
reducing food wastage and spoilage.
E Aluminium in buildings contribu-
tes to light and strong, sturdy and robust
structures. In windows, faades, curtain
walls, it helps to increase natural light and
heat intake through maximised glazed sur-
faces, thereby reducing the need for artificial
lighting and heating. This preserves consi-
derable amounts of energy. Meanwhile, alu-
minium is also safe from corrosion, so these
structures require minimal maintenance.
E Aluminium is 1oo per cent recyclable
over and over again, without any loss in
quality or properties, and with only per
cent of the energy needed to produce it in
the first place. Once produced, every ounce
of aluminium is there forever as a renewable
resource, provided it is properly collected at
the end of life of aluminium
products.
Being a net contributor
to sustainability is good, but
we know we can always do
PROFILE
Aluminium is part of the solution to climate change, says Patrick de Schrynmakers,
Secretary General of the European Aluminium Association. Interviewed by Shape
he explains how aluminium favours sustainability. All in all, the resources saved
through the use of aluminium outweigh by far the resources needed to produce it.
ALUMINIUM
the sustainable material

Patrick de Schrynmakers, Secretary General of the

European Aluminium Association.
# 1 2010 SHAPE 11
PROFILE
12 SHAPE # 1 2010
better. So for decades now, the
aluminium industry, across its
whole value chain, has worked
consistently to reduce its environ-
mental impact.
Firstly, de Schrynmakers explains, bauxite
extraction is systematically followed by land
rehabilitation, either to restore the original
wildlife, or to convert the extraction sites into
agricultural land for the benefit of local com-
munities.
Secondly, refining bauxite into alumina
requires energy and creates by-products. The
global aluminium industry has for several
years been active in reducing energy consump-
tion, reducing the amount of by-products and
disposing of them safely.
Since the 1,os, the energy use of alumi-
nium smelting per tonne of aluminium has
decreased by per cent.
Meanwhile, our sector of industry, like
every other, has its share of responsibility in
reducing greenhouse gas emissions. On a
purely voluntary basis, by :oo, the European
aluminium industry had already reduced its
emissions of perfluorated carbon by 8o per
cent, and its co
.
emissions by 1o per cent
compared to 1,,o levels. In total, this means
a per cent reduction in our greenhouse gas
emissions, which is much more than the most
ambitious policy objectives set so far.
According to de Schrynmakers, there clearly
is a great potential for further improvement
when it comes to recycling. The problem is
not recycling the scrap, it is making the scrap
available.
THIS PROCESS INVOLVES the consumers who
may or may not sort their household garbage.
It involves local selective collecting and sorting
schemes, either by businesses such as retailers,
or by public authorities, or both. It involves
the construction companies who dismantle
old buildings and recover the aluminium scrap
from them. It involves the car demolishers
who break up old vehicles and sort the various
re cyclable scrap from them.
If all these players sorted aluminium
scrap properly, our task would be easy, and
we would reach recycling rates close to 1oo
per cent very quickly. It takes a lot of com-
mitment, time, energy, dedication and invest-
ment from the aluminium industry to build
partnerships with relevant businesses, conduct
campaigns with relevant audiences, educate
consumers, train professionals, initiate, orga-
nise or support collection schemes, acquire
support from the population and from the
authorities, etc.
In building, automotive and transport app-
lications, supply chains are already very well
trained, and it is no wonder that we achieve recy-
cling rates of , per cent and more. With packa-
ging however, many more players are involved
in a much wider variety of ways, so the situation
is all the more challenging. Knowing this, the
overall o: per cent recycling rate for aluminium
beverage cans in Europe in :oo; is already an
outstanding achievement. The fact that some
countries such as Denmark even reach , per
cent is proof that it can work, and the very moti-
vation to keep on track everywhere else.
BUT DE SCHRYNMAKERS says that the efforts of
the aluminium industry go even further.
At the earliest stages of product design, it is
important that engineers working with alumi-
nium not only use their creativity to harness
the outstanding properties of the material, but
also conceive their products in a way that will
allow for straightforward recovery of the scrap
at the end of life, for further recycling.
According to Patrick de Schrynmakers there

Being a net contributor to sustainability is
good, but we know we can always do better.
Aluminium in windows, faades and curtain walls of buildings helps to increase natural light and heat intake through maximised glazed surfaces, thereby reducing
the need for artificial lighting and heating, which preserves energy. This is the Art Institute of Chicago.

are three main objectives for the aluminium
industry regarding sustainability:
E Sustainable production. Aluminium in
itself is a must for any sustainable society, so it
definitely makes sense to produce it. Therefore
the challenge is to produce it with the lowest
possible environmental footprint.
E Sustainable consumption. Aluminium in
products helps to save incredible amounts of
resources, in terms of human life and health,
energy, water, greenhouse gases, etc, so the
challenge is to make sure that as much alumi-
nium as possible gets into every product where
it makes sense.
E Sustainable resource management. When
aluminium is done contributing to sustaina-
bility in a given product, it is important that it
be collected for recycling. Products have to be
so designed as to allow for easy recovery and
sorting of scrap. And collecting schemes have to
be designed so as to channel the material from
the scrap yards to the recycling facilities. This
holistic picture is what the aluminium industry
calls ecodesign.
One point about the recycling objective
is often underestimated or misunderstood,
according to Patrick de Schrynmakers.
It is very commonplace today to consider
that a product with a lot of recycled material in
it is sustainable. But this is wrong. A product
with a lot of recycled content is not sustainable
at all if, at the end of its life, it is landfilled.
This is why the aluminium industry is very
keen on on stressing that the really responsible,
sustainable approach to metal re cycling is to
maximise end-of-life recycling.
Aluminium is part of the solution to climate
change, and definitely part of tomorrows sus-
tainable societies and economies, Patrick de
Schrynmakers concludes.
TEXT CARL HJELM
If all these players sorted aluminium
scrap properly, our task would be easy.
Bauxite mining:
Land use is minimal, 30
square kilometres a year;
reforestation or other forms
of rehabilitation exceed 80
per cent.
Alumina refining:
Alumina is a necessary inter-
mediate step from bauxite
to aluminium. The industry is
actively working on re ducing
its energy use and by-
products, and handling the
latter as safely as possible.
Primary production:
European production:
around 3 million tons a year.
Greenhouse gas emis-
sions have fallen by 45 per
cent from 1990 to 2005 in
Europe, while energy use is
down by 33 percent since
1950.
Product use:
Aluminium has many out-
standing intrinsic properties
which contribute to saving
resources, cutting emissions,
in creasing efficiency, preser-
ving health, avoiding spoilage.
The overall sustainability
benefits of aluminium are
difficult to estimate fully.
Recycling:
Aluminium is 100 per cent
recyclable. In Europe, re -
cycling rates range from
62 to 95 per cent. 75 per
cent of the aluminium ever
pro duced is still in use.
In Europe, 40 per cent
of the aluminium used
comes from recycling.
Facts about aluminium and sustainability
Aluminium is 100 per cent recyclable over and over
again, and with only 5 per cent of the energy needed
to produce it in the first place.
Cars and trucks with lightweight aluminium increase
energy efficiency and road safety.
Aluminium packaging materials allow for preserving resources such as food and beverages, reducing
food wastage and spoilage.
# 1 2010 SHAPE 13
14 SHAPE # 1 2010
WRAPPED IN
MODERN DESIGN
M
ediaset, Italys largest commercial broadcasting company, was
founded by the countrys Prime Minister Silvio Berlusconi.
Its headquarters, which were built in the 1,;os, were recently
in need of upgrading due mainly to new building re -quirements for
acoustic and thermal insulation.
Architect Franco De Nigris of Axistudio and technicians from cxs
Technical Service designed a massive double-skin glass facade, which
fits over the elegant curves of the original building. The sail-shaped
glass not only complies with current building requirements, but gives
a modern lift to the building while maintaining its architectural heri-
tage. The new structure was honoured with a Special Prize at the :oo8
ii Real Estate Awards in Italy.
THE GLASS FACADE consists of two layers of glass measuring a total of
1,oo m
:
. Each glass panel in the facade is 11o cm wide and varies in
height from ::o to oo cm. The use of silk-printed glass appears as an
opaque mirrored surface from a distance, but becomes transparent at
close range, revealing the shape of the original building which it pro-
tects. A middle layer between the glass panels and the original building
provides structural strength.
This middle layer was made with the tried and tested Sapa Building
System Ekonal i: sc system, which has a load-bearing structure
made of polytubular extruded aluminium sections for the static
uprights and tubular sections for the cross-members. The Sapa
system enables correct transfer of loads between uprights and
cross-members.
A SAPA ENGINEERING team worked closely with the technicians
from cxs to clarify all aspects of the facades unique design.
Particular attention was given to eliminating static, improving
acoustic performance, and ensuring that thermal insulation
was in line with Italys stringent new regulations for impro-
ving energy efficiency, says Joseph Fenucci, managing
director, Sapa Building System.
The requested thermal insulation was achieved by
using glass with high thermal performance. Holes in
the glass panels allow for drainage and ventilation
and help to eliminate stagnation and condensa-
tion, and a triple gasket seals securely against
water, he explains.
The glazing on the structure was secured with
a two-component silicone tested especially for
The Berlusconi familys media headquarters in Cologno Monzese,
Italy, got an award-winning facelift with the addition of a drama-
tic glass facade supported by a Sapa system.
structural gluing and applied to a supporting aluminium section
subjected to a special anodic oxidation treatment.
Designing the facade was a challenging task for the
Sapa and cxs teams but the sns Ekonal solution
proved to be an ideal solution for Mediaset,
says Fenucci adding: It fits the architects
re quirements in terms of design,
aesthetics, reliability and engi-
neering support.
TEXT CARI SIMMONS
As a leading player in the market for large format
scanning, Danish scanner manufacturer Contex
A/S is digitalising a good part of the world. The
company exports about 98 percent of its production.
Copy shops, engineering, architecture and construction
companies as well as governmental agencies and other
institutions in the field of GIS & Mapping are using Contex
high-end scanners in about 80 countries.
The chassis of our scanners, made of extruded and machi-
ned aluminium supplied by Sapa with a tolerance of 0.1 milli-
metre, allow us to be as precise as we need in the manufacturing
of our very accurate scanners, says Sren Pedersen, engineer at
Contex. Sapa also helped us in the development of the new SD
series of scanners that we were able to launch to the market exac-
tly the day we had planned to, with no delays nor compromises.
The largest Contex scanner, the SD4490, can handle originals
almost one and a half metre wide (1117.6 mm or 44") and deliver
a maximum optical resolution of 1,200 dpi.
>
# 1 2010 SHAPE 15
Green all year round
Building an all-season greenhouse for use in
Sweden is not something you do on a whim. Just
ask Grnsta, a Swedish company that designs and
manufactures greenhouses for nurseries and garden
centres that sell plants and flowers. Among other things
their greenhouses have to cope with snow loads of
100350 kilograms per square metre.
With their unbeatable combination of corrosion
resistance, formability and low weight, aluminium
profiles make an obvious choice of material for this
purpose.
One unique advantage of aluminium profiles is that
we can combine several different functions in one pro-
file, says Nils-Ola Pettersson, company CEO and head
of product development.
By working closely with Sapa, Grnsta was able
to improve its design solutions so that, for example, a
single profile can be used with different thicknesses of
plastic sheet, by changing the screw length, and the
risk of leaks and condensation can be minimised by
incorporating a cup shape inside the profile to collect
and lead away water.
Catching the sun
In the space of just five years Germany com-
pany Renusol GmbH has grown to become
one of the leading European suppliers of installa-
tion systems for solar panels. Renusols various
modular systems make it easy for customers to
install their low-impact, climate-friendly energy
systems.
Since early 2009 Sapa has been playing an important role as supplier of machined profile com-
ponents. Sapas Polish factory in Trizcianka not only supplies fittings, but also machines extruded
aluminium profiles to create ready-to-deliver mounting components such as supports and angles. The
components are developed as required in close consultation between Renusols technicians and
Sapas development engineers. As part of the close partnership, Sapa also supplements the installa-
tion kits with i.a. nuts and bolts.
Harrod UK equips
the soccer world
From Twickenham and Premier League Clubs
to Wembley Stadium, Harrod UKs goals and
nets are the showpiece of the venue.
Harrod UK and Sapa have worked together to
develop a new product, the Premier Curved Team
Shelter, which made its debut in Nigeria, during
the Under 17 World Cup Football Championships.
Aluminium profiles supplied by Sapa provided a
manufacturing solution, which was fabricated and
required a resilient surface finish. Aluminium also
enabled the introduction of a curved structure
which is strong yet lightweight.
The shelters are available as floor-fixed or sock-
eted options with a choice of red or blue individual
injection moulded polypropylene seats.
>
BRIEF NOTICES
>
>
Scanning the world
WRAPPED IN
MODERN DESIGN
16 SHAPE # 1 2010
SPECIALISING
IN PRECISION
INSIGHT: NORTH AMERICA
16 SHAPE # 1 2010
T
he name Mountain Top came about quite
naturally, explains Dave McCallen, gen-
eral manager of the plant.
Well, the plant is located in the town
of Mountain Top, which is literally on top
of a mountain in the Poconos range in
Pennsylvania. Before we moved here in 1,,:
the plant was known as Mideast, as its halfway
between New York and Philadelphia.
IN 2009, MOUNTAIN Top celebrated its oth anni-
versary. Dave McCallen relates that the plant
was founded in 1,, by two entrepreneurs in
Dayton, New Jersey, who wanted to focus on
a niche market for precision extrusion in small
volumes, rather than extrusion that anyone
can do. Mountain Top still has a clear focus
on innovation. The plant was one of the first to
produce purely extruded cylinder tubes for the
automation industry. It was also the first to sup-
ply precision components for textile machinery.
On top of that around 1:o years ago we
started making profile components with very
fine tolerances for Hewlett Packard and their
large-format printers, and we still do so today.
Close tolerances are one of Mountain Tops
specialist areas. Dave McCallen explains
that their customers often need solutions
that exceed the tolerance standard set by the
Aluminum Association.
When Sapa acquired Indalex, a US extrusion company, last
year, Mountain Top was one of the plants in the deal. Thanks to a
commitment to innovation the plant has succeeded in developing
solutions for several customers where its competitors have failed.
They want tolerances that are a quarter of
those in the standard. We are one of a handful
of extruders in the usa who can meet such tight
tolerances consistently.
Another of the plants specialist areas is preci-
sion machining. In this case it means achieving
very close tolerances on longer components too.
Mountain Top uses professional measurement
equipment to ensure that the tight tolerances are
maintained. At the end of manufacturing they can
offer customers a choice of options for finishing
products, including media blasting, scotchbriting,
clear and black anodising, plus a chemically pol-
ished finish known in the usa as Brite Dip.
Mountain Tops customers include
Honda, Subaru, Nissan and the mas-
sive American military vehicles and
passenger cars the Humvee and
Hummer.
# 1 2010 SHAPE 17
Sapas plant in Mountain Top, Pennsylvania.
MOUNTAIN TOPS SPECIALISATION allows the com-
pany to offer solutions its competitors cannot
deliver. Dave McCallen explains that the
secret behind their success is precisely their
commitment to innovation.
We were innovators right from the start,
and that company culture extends into eve-
rything we do. We have the right employees,
the right processes and a high level of innova-
tion, and thats why we are successful. Our
customers are able to get everything they
need from one place. We extrude, machine,
finish and in some cases even assemble prod-
ucts just the way our customers want them.
Mountain Tops customers include
Honda, Subaru, Nissan and the massive
American military vehicles and passenger
cars the Humvee and Hummer.
He describes it as an exciting development,
as it means that the innovative engineers at
Mountain Top now have access to Sapas net-
work and technical resources, in the usa and in
Europe. The same applies to sales, as it opens
up a new market and new possibilities.
So what does Mountain Top have to offer
Sapa, its new owner?
A great deal. I believe that Mountain
Top fits well into the Sapa Group. Sapa is an
innovator and Mountain Top shares the same
corporate culture. Weve already had many
visits from other Sapa units who have come
here to see our resources and our possibilities.
I believe we can offer Sapa our culture of inno-
vation, our capacity and the machining and
finishing facilities we have here at Mountain
Top.
MOUNTAIN TOPS CUSTOMERS will also benefit from
Sapas acquisition.
We now have access to an enormous net-
work across Europe and North America. If a
customer needs a profile that is bigger than
we can manage we can get it made within the
group. That opens up a whole new world of
possibilities weve not had before.
TEXT HENRIK EMILSON
Another customer is Parker Origa, who
manufacture bus doors. This company had
been searching for over a year for someone
able to deliver the fine tolerances their prod-
ucts required. No one had succeeded. They
turned to Mountain Top and following trials
they found a solution within four months.
Once wed set up the process to meet
the strict tolerances they required we could
finalise the process and so ensure consistent
production. None of our competitors had
managed that in over a year and half of trying.
This in turn meant that Parker could offer its
customers something that none of its custom-
ers could, which meant we gave them added
value.
SINCE 2009, Dave McCallen and all :oo collea-
gues at Mountain Top have been part of Sapa.
Mountain Top is the only extrusion plant in
North America that can make products with
the tight tolerances that are needed for radar
systems for planes equipped with AWACS
(airborne warning and control system).
18 SHAPE # 1 2010
TODAYS TECHNOLOGY
F
or more than 1 years Sapa has been supplying
the truck market with specially manufactured fan
rings in aluminium. Manufacturing began as col-
laborative venture between Scania and Sapa. It worked
out well, and since then Sapa has continued to work
closely with its customers.
The results speak for themselves. Sapa Automotives
customers now include in addition to Scania Volvo,
Renault, Mack and Nissan Diesel.
Over the years, Sapa has produced more than 1oo dif-
ferent models of fan rings, and in :oo8 alone supplied
18o,ooo fan rings to Volvo and ;,ooo to Scania.
The purpose of the fan ring is to channel the air and
improve air flow from the fan to the radiator, in other
words to improve cooling performance.
With its low weight, good stability and formability,
aluminium has proved itself to be an excellent material for
this task.
Roll bending the profiles creates a perfect circle, and its
easy to integrate useful features in the profile, says Laurent
Andrzejewski, marketing manager at Sapa Automotive.
For many years, Sapa shipped fan rings from Europe
to Volvos plants in the usa. But a year ago the company
began preparing to start up its own manufacturing opera-
tion in Portland. The first scheduled delivery was made last
October.
Loading the rings on pallets meant that we were ship-
ping a lot of air. It didnt make sense. Lead times are shorter
now were producing in the USA. It also gives us better
opportunities to offer parts to other local automotive
manufacturers who are likely to have similar needs, says
Laurent Andrzejewski.
TEXT THOMAS STBERG
They measure around half a metre in diameter and weigh very little. But
the aluminium fan rings made by Sapa fill an important role in hund-
reds of thousands of trucks. To meet demand from the US market,
Sapa has started manufacturing in Portland, Oregon.
Long-lasting success
for fan rings
The purpose of the fan ring is to improve air flow from
the fan to the radiator.
FloraHolland is, with an annual turnover of over
4 billion euro, the biggest cut flowers and plant
auction in the world. Operating from six locations in
the Netherlands, the company plans to consolidate
its fleet of 260,000 auction trolleys in 2012, which
currently consists of 15 different models.
Sapa will deliver 2,800 tons of fabricated profiles
needed for the modernisation of the trolleys. And
those that cannot be upgraded will be scrapped and
cast into billets in the melting department of Sapa
in Drunen. This large scale recycling was crucial for
FloraHolland and contributed to the choice of Sapa.
Dutch manufacturer Alcomij will handle final
assembly of the auction trolleys, and together with
# 1 2010 SHAPE 19
BRIEF NOTICES
Warming the soul
The Ice Lolly is a big-selling heat pump from
Octopus Energi AB, in Skne, Sweden.
Since 1980 the company has been manu-
facturing heating systems that aim to reduce
environmental impact and heating costs at the
same time. But now it seems the company may
be adding a new model to the range following
the popularity of the Ice Cross, a custom-built
solution for a church in Gdansk, Poland.
The cross, made from aluminium profiles sup-
plied by Sapa, is installed outside the church,
where it extracts heat from air and transfers it to
the churchs underfloor heating system. The heat
pump is regarded by churchgoers as a genuine
cross and local people have started to decorate
it with small dolls and handcrafted items.
A further cross has been sold to a church in
Bulgaria.
A global company in the solar energy sector is
setting a fine example. REC Wafer in Herya
industrial park, south of Oslo, now has the largest
solar panel installation in Norway. The company has
installed 250 square metres of solar panels at its newly
built factory and office buildings, giving a total output
of 33 kW. REC Wafer, part of Renewable Energy
Corporation, is a leading manufacturer of silicon wafers
for solar panels. The group of companies covers the
whole range of solar power needs, from ultra-pure
silicon to complete solar energy systems. The 150 solar
modules that are now in service at the factory in Norway
were manufactured by sister company REC Solar,
which uses aluminium frames from Sapa.
Sapa Building System, which supplies facade,
door and window systems, has also helped to make
REC Wafers new factory and offices highly energy-
efficient.
Ground conditions can change like the
weather. Construction, energy and tele-
communication companies as well as event organi-
sers know this better than anyone. That is why they
rely on TPA Portable Roads to reach the places
others cant.
TPA is a part of Vp plc, a British equipment rental
specialist for the construction, civil engineering,
events and industrial market sectors. With its
Traxpanel system of aluminium panels, TPA can
build a track that will adapt to different terrains and
>
>
>
>
Aluminium roads to go
can be even used by heavy machinery. Whilst the
surface of the panels is designed to offer optimal
vehicle grip there is a unique connecting feature
which keeps the panels firmly together for maximum
security and reliability.
TPA keeps 90 km portable roadway in stock.
Sapa Profiles UK manufactures the aluminium
extrusions, which are supplied to TPA fully fabrica-
ted and ready for assembly. Aluminium meets the
requirements for a strong but lightweight product,
which is also resistant to corrosion.
Practising what you preach
A bright prospect
its partner Hoza will also deliver additional 30,000
new trolleys. When the job is done, FloraHolland
will have about 290,000 trolleys at its disposal,
strengthening the position of the Netherlands as
the brightest star in the global flower market.
T
he three enormous doors are divided into
five sections and will be installed on a new
airport hangar at Abu Dhabi international
airport in the United Arab Emirates. Swedish com-
pany Megadoor will supply and build the doors,
joining the 1:-metre-long sections of extruded alu-
minium profiles on site and then installing them.
Sapa has been supplying aluminium profiles to
Megadoor since the companys foundation in the
1,oos. This is its biggest order to date.
Naturally weve also bought aluminium profiles
from some of Sapas competitors, but Sapa has
always been a regular supplier and we have a good
relationship, says Leifh-Gunnar Ollinen, plant
manager at Megadoor in Skellefte, Sweden.
Most of the order, for a total of around 1oo
tonnes of profiles, will be extruded in Finspng,
Sweden.
The profile sections are joined in pairs, welded
and supplied to the end customer in a width of 8o
millimetres.
When completed, the hangar doors consist of a
series of horizontal profiles with an external fabric
covering. The lightness of aluminium is a key
requirement when building such wide doors.
HANGAR DOORS ARE normally opened by sliding them
to the sides, which requires additional space either
side of the door and some form of track in the
floor.
With our design the doors are raised to roof
level. This means you only need the maximum
height mid-span, and considerably less at the
wingtips. That saves a lot of energy on air con-
20 SHAPE # 1 2010
Long-term business relationships pay off. This was demonstrated
yet again by Sapa in autumn in the shape of a large order for
aluminium profiles for hangar doors. The doors are 115 metres
wide and are used to give hangar access to the largest
passenger airliner in the world, the Airbus A380.
GIANT OF THE AIR
GETS ITS OWN DOOR
The three enormous doors for the new hangar at
Abu Dhabi international airport in the United Arab
Emirates are divided into five sections.
# 1 2010 SHAPE 21
TODAYS TECHNOLOGY
I
t is the thin oxide layer that forms naturally
on aluminium which gives the metal its
good corrosion resistance. In fact even if
the aluminium surface is scratched, the pro-
tective oxide layer repairs itself, restoring the
built-in corrosion protection.
Unfortunately, this natural corrosion protec-
tion does not work under all conditions. The
oxide is stable within a pH range of ,, but if it
is exposed to an environment that is more acid or
alkaline it is eaten away, and the aluminium cor-
rodes rapidly.
Over the last two years weve had reports of
corrosion damage in many condensers. Because
Sapa Heat Transfer supplies the material for these
condensers we wanted to know the cause. But we
were unable to find any defect in the material,
says Marja Melander, research engineer at Sapa
Technology.
A study of carwashes in Sweden, usa and
China shows that the problem is probably due
to carwashes replacing solvent-based degreas-
ing agents with greener, but corrosive, alkaline
degreasers.
The results are also supported by a similar
investigation carried out by Erbslh.
The condenser is located just inside the grille
of a car and thats probably the worst possible
location in terms of corrosion. It is very exposed
to carwash spray, as well as road salt and salts
present in the recirculating water system that
many carwashes use, says Marja Melander.
Because the corrosion was not due to a mate-
rial defect Sapa does not have direct responsibil-
ity for solving the problem. But in an effort to
find a solution Marja Melander still wants to
make carmakers and their suppliers aware of the
problem.
Car owners can also reduce the problem by
rinsing the condenser thoroughly with clean
water after going through a carwash. They
should not use a pressure washer, however, as this
can cause mechanical damage.
Many people are probably not aware of this
until the damage has already occurred. Car own-
ers are more aware of the external appearance,
such as paint damage, says Marja Melander.
TEXT THOMAS STBERG
GIANT OF THE AIR
GETS ITS OWN DOOR
Carwashes
speed up corrosion
It is widely known that aluminium resists corrosion. In recent years,
however, an unusual number of car owners have had problems
with corrosion in their AC condensers. An investigation
carried out by Sapa has shown that the likely cause of this rise is
that carwashes have started to use strong alkaline degreasers.
ditioning and heating, explains, Leifh-Gunnar
Ollinen.
The doors will be delivered to the customer,
Abu Dhabi Aircraft Technologies, in three consign-
ments in :o1o.
Sapa naturally hopes that Megadoors success,
and its partnership with Sapa, will continue.
Megadoor has a growing market in custom
solutions. The company has a good reputation for
hangar doors especially. This often calls for large,
heavy profiles, which we are good at, so I believe
this could lead to more business opportunities,
says Gunnar Nilsson, office manager at Sapa in
Ume, Sweden.
TEXT THOMAS STBERG
The Airbus A380 is the worlds largest
passenger airliner. It made its first
commercial flight in October 2007.
22 SHAPE # 1 2010
Sapa will play an important part in this summers FIFA World Cup in
South Africa. The newly built Cape Town Stadium that will host
seven of the matches is partly constructed with aluminium profiles
from Sapa.
96,000 cubic metres of concrete were used
The roof has a total weight of 4,700 tons
Some 9,000 glass panels were used to cover
37,000 square metres of roof
500 toilets and 360 urinals
115 entry turnstiles
16 lifts
More than 2,500 workers were employed
on site during construction, and almost 1,200
artisans received training from the contractors
Facts about Cape Town Stadium
T
he Cape Town Stadium, close to the popular
Waterfront area in Cape Town, can hold
o8,ooo spectators and is built of aluminium
and glass.
The architects have incorporated a number
of clever features in the design of the stadium.
The lighting and sound equipment have been
concealed inside the ,ooo-square-metre glass
roof, supported by structural aluminium members
developed and supplied by the German company
Kompetenzcenter-Metall GmbH in Cologne,
which used extruded aluminium profiles supplied
by Sapa.
Our task was to come up with a solution that
can cope with the enormous wind forces and
the thermal movements of the glass roof, says
Sapa profiles
support World Cup
Christoph Langen, cio of Kompetenzcenter-
Metall.
The solution was a fitting that supports the
sheets of glass without fixing them to the building.
The glass surface is supported as a freely suspended
unit, secured to the structure of the building at just
a few points.
The glass is free to move within certain limits.
This approach makes it possible to spread the
extreme forces that the glass roof is exposed to in
the shape of wind loads and large temperature vari-
ations of up to degrees over the course of a day.
THE SUPPORT FITTINGS in extruded aluminium were
supplied by Sapas plant in Hungary. The manufac-
turing tolerances and surface finish requirements
were very strict. Every one of the ,8,ooo support
fittings was individually documented. The compo-
nents were packed individually and shipped by sea
to South Africa, where a German glazing company
installed the glass roof.
For a small company like ours this project is
a milestone in our development. It proves that a
young, creative company with a very high standard
of technical know-how has a chance to succeed in
the aluminium industry, says Christoph Langen.
The Cape Town Stadium, midway between
Table Mountain and the Atlantic is now complete.
The football extravaganza can begin.
TEXT LUISE STEINBERGER
# 1 2010 SHAPE 23
Winning design
You may say that young Spanish designer Marta
Guerrero got as much talent as sense of timing.
She is the winner of the Sapa With You contest for
furniture specialists thanks to her eye-catching and
innovative ZigZag, a multishape drawer/shelving con-
cept built on aluminium profiles with shifting colours.
Her timing was not bad either. She won the prize
3,000 euros and a six-month internship at the Sapa
Application Center at La Selva Camp right after
graduating as an industrial designer.
Matteo Luppi, director of Sapa Profiles Spain, says
one of the goals of the initiative was to strengthen
links with the furniture market where there is a great
potential for aluminium applications. The Sapa With
You contest gathered participants from several
European countries and the United States.
>
The city of Tilburg, Netherlands, has the aim of becoming a carbon neu-
tral city by the end of 2045. As a step on the way to a sustainable city
development, Tilburg started to buy carbon-neutral lighting columns from
Sapa in 2009.
The columns are made of at least 95 per cent recycled aluminium. The
patented, reinforced profile reduces the column weight by 20 per cent. A
series of measures have been taken in order to save energy in the production
process.
Sapa compensates for the remaining carbon emissions through the
Climate Neutral Group. As a result, Sapa has permission from the Dutch
government and the Climate Neutral Group to add the Carbon Neutral eco-
label to its lighting columns.
But the Tilburg project goes one step further. Tilburgs worn out aluminium
lighting columns are transported to Sapa, re-smelted and returned to Tillburg
in the form of new columns. This makes the Tilburg circle a closed loop.
On display at Frankfurt
The Giotto city lighting column, developed together
with Grechi Illuminazione, an Italian lantern
manufacturer, will be one of the stars among Sapa
Pole Products at Frankfurt Light & Building 2010,
the worlds leading trade fair for architectural lighting and
lighting technology.
Sapa will show a selection of the products and solutions that
have made its Pole Products division a preferred partner within the
lighting industry.
We want to show how we turn aluminium profiles into innovative,
safe and attractive solutions for decorative and functional urban lighting
and traffic systems, says Nicole le Sage, Marketing & Communications,
Sapa Pole Products. The Giotto column will serve as a good example
of the companys strategy: From Profiles to Solutions.
Light & Building 2010 will take place at the Frankfurt Messe,
between April 11 and 16. Over 2,000 exhibitors and more than
167,000 visitors are expected.
Tell us your views
win a gift token!
To help us improve Shape we would like to hear your
opinions as readers. Five of those who reply will
receive an Amazon online gift token worth USD 100.
To take part, answer the questions here:
www.sapagroup.com/survey
BRIEF NOTICES
>
>
Carbon neutral
lighting
columns
The columns
in Tilburg,
Netherlands, are
made of at least 95
per cent recycled
aluminium.
ZigZag is a multi-
shape drawer/
shelving concept
built from aluminum
profiles with shifting
colours.
24 SHAPE # 1 2010
T
he Garia also offers a number of optio-
nal luxury upgrades including a built-in
refrigerator. Nice to have in case you get
thirsty while driving to the next hole.
Built according to the highest automotive
standards, the Garia will be a street legal Low
Speed Vehicle (isv), which means it can be
taken off the golf course and driven around
town when it is launched in the US market in
April. As Anders Lynge, creative director and
designer of the golf car says: The Garia is
from design to technology entirely inspired by
cars and not carts.
Garias goal was to achieve a
comfortable, high-end and high-
quality golf car, he adds. We wanted the Garia
to be both light and strong, and it was also very
important that it would be resistant to corro-
sion in all weather conditions.
Aluminium, which is corrosion resistant and
durable, was the most suitable choice of mate-
rial. The corrosion resistance of aluminium
is also important because golf cars are often
driven on golf courses close to the sea, says
Teija hlman, communications manager at
premium car manufacturer Valmet Automotive.
Aluminium also gives a prestige image to the
vehicle and is a good choice for a lightweight
body in an electric vehicle with heavy batteries.
Sapa supported Valmet Automotive with alu-
minium and frame engineering, and by adap-
ting aluminium parts to Valmet Automotives
production. Aluminium-frame electric cars
offer many benefits such as reduced emissions
and fuel costs. Whether or not they can help
lower a golf handicap remains to be seen.
TEXT CARI SIMMONS
PLAYING TO WIN
This is certainly not your average golf
cart. The Garia golf car was designed
by Danes, manufactured by Finnish Valmet
Automotive, the automobile company which
manufactures the Porsche Cayman and Boxster,
has an Italian drive train by the same company that
builds gearboxes for Ducati and sports
an aluminium frame from Sapa.