We congratulate: 50 years Kermi - AFG Arbonia-Forster-Holding AG

Division Heating Technology
and Sanitary Equipment
Division Kitchens and Refrigeration
Division Windows and Doors
Division Steel Technology
Division Surface Technology
Logistics
AFG Arbonia-Forster-Holding AG
Amriswilerstrasse 50 · P.O. Box 134
CH-9320 Arbon
T +41 71 447 41 41 · F +41 71 447 45 88
afgworld@afg.ch · www.afg.ch
Heating Technology and
Sanitary Equipment
Heating Technology
Heating Technology
Heating Technology
Kitchens
Refrigeration
Kitchens
Windows and Doors
Doors
Windows and Doors
Precision Steel Tubes
Profile Systems
Surface Technology
Logistics
The magazine of AFG Arbonia-Forster-Holding AG December 2010
We congratulate:
50 years Kermi
Victory Page 10
AFG sponsors
Swiss Sailing
Association
n Heating Technology and Sanitary Equipment Pages 12 – 17
n Kitchens and Refrigeration Pages 18 – 27
n Windows and Doors Pages 28 – 33
n Steel Technology Pages 34 – 39
n Surface Technology Pages 40 – 45
Elegance Page 34 Start Page 42
Forster takes architecture
and technology
to new levels
STI | Hartchrom
builds modern
factory in China

Contents
n Prelude
Editorial ............................................................................ 1
n In a nutshell
News ................................................................................ 2
n Focus
50 years Kermi: traditional innovation ............................... 4
n AFG Arbonia-Forster-Holding AG
Top level sailing with AFG as main sponsor ........................ 10
Asia Pacific: Kermi is winner! ............................................. 11
n Heating Technology and Sanitary Equipment
Arbonia keeps things warm and cosy
at the Palazzo Mantegazza ................................................ 13
Comfortable climate in the Rhine Valley ............................ 14
Kermi wet room and shower enclosure: an attractive couple 16
New – Kermi Walk-in-Shower XS:
The new height of shower freedom .................................. 17
n Kitchens and Refrigeration
A Piatti kitchen on the catwalk .......................................... 19
Piatti bracket handles: the most convenient handles
of all times? ...................................................................... 20
kitchenfriends.ch – a new form of communication? .......... 21
Forster refrigerators: new range ........................................ 21
Forster Kitchen at Designers’ Saturday ............................... 22
Warendorf – new kitchens for personalities ....................... 24
New in Germany: Warendorf with Piatti ............................ 26
Three kitchen brands from a single source ......................... 26
«Starck by Warendorf»: customised dream kitchens .......... 27
n Windows and Doors
From idle production site to showpiece ............................. 29
Successfully restoring with «Energy and More» ................. 30
Saving energy with style .................................................... 31
RWD Schlatter optimised indoor climate ............................ 31
RWD Schlatter owns Switzerland’s
first smoke protection test stand ....................................... 32
20 years of Slovaktual – 20 years of success ...................... 33
Slovaktual gets a new showroom ...................................... 33
n Steel Technology
Visual elegance and a free view of the essential ................. 35
Roof glazing successfully tested ......................................... 36
VW + Forster Precision Steel Tubes: a dream team ............. 36
Steel windows and doors: even better heat insulation ....... 37
Forster Profile Systems: the perfect role model ................... 38
n Surface Technology
Modern bridges: quality down to the last detail ................. 41
STI | Hartchrom starts works for a modern factory in China 42
Thermal spray coating for the shipping industry ................. 44
Interesting exchange at the SMM in Hamburg ................... 45
STI | Hartchrom establishes niche market in the USA .......... 45
Imprint
AFG WORLD, the magazine of AFG Arbonia-Forster-
Holding AG, appears bi-annually in four languages
in Switzerland, Germany, the UK, the Czech Republic,
in Slovakia as well as in other countries around the
world.
Circulation 20,000
Editorial address
AFG Arbonia-Forster-Holding AG
Editorial AFG WORLD
Dr. Christoph Schönenberger
Amriswilerstrasse 50
P.O. Box 134
CH-9320 Arbon
T +41 71 447 41 41
F +41 71 447 45 88
afgworld@afg.ch
Production
Concept/Layout/Text Editorial:
E,T&H Werbeagentur AG BSW
CH-9401 Rorschach
Printing: dfmedia, CH-9230 Flawil
Title image: This year, Kermi GmbH in Plattling
celebrated its 50-year anniversary. The company
offers a comprehensive range of products in heating
technology and shower enclosures that leaves
nothing to be desired.
Focus
Quality or price?
Ladies and Gentlemen,
Dear employees
At AFG we maintain a very old Swiss tradition: the «Landsgemeinde»
(rural council). We use this term for our bi-annual
meetings of the managers of all divisions and business units.
The Landsgemeinde is a get-together that creates distance
from hectic everyday operations and makes space for visions
and strategies of concern to the whole group. At our last
Landsgemeinde meeting on 14 September 2010, we focused
on group strategy as well as economic and ecological material
management – three aspects that are closely interwoven. Our
commitment to quality, innovation and design has a direct impact
on these. It means that we don’t sell our products based
on price, but on quality. On the one hand, this frees us from
the ruinous battle in the cut-price arena, but on the other
hand, we are committing ourselves to the enormous challenge
of continuously developing quality at all levels: in production,
in consultations and services to our customers – and of course,
in our products. However, just because we bet on quality we
cannot simply ignore the price factor – this plays an important
role in our existing markets and those we want to break into.
Taking advantage of potential savings
The conclusion is obvious: saving without compromising on
quality means continually and sustainably optimising the organisation,
production and material management. We have
systematically applied this maxim in many areas. For example,
Kermi has installed a modern treatment plant for testing water
which is used for leak-testing radiators; this saves a significant
amount of resources and costs. Forster Kitchens is markedly
improving its production processes with more operations per
time unit. Warendorf’s new sawdust extraction system, which
is going to be operative from 2011, saves 70% of energy compared
to the previous installation and creates 30% additional
heat for the workshops. The new turning drum installed by
RWD Schlatter turns doors into any desired position for final
assembly and measurably improves efficiency while also making
work easier for the operatives in handling the 250 kgheavy
work pieces. With the help of sophisticated process
Prelude 1
management, the Division Steel Technology has managed to
eliminate «tailbacks» in its production processes and thereby
achieve a much better utilisation of the different workstations.
We could go on with this catalogue of optimisations and add
a number of other examples.
AFG is on the right track – thanks also to you
As a result of your forward-thinking, proactive approach AFG
is on the right track. This year, Kermi was proudly looking
back over 50 years of flourishing company history – and has
won a coveted prize in China. Arbonia shines with its new
«Chrome Collection». Piatti is exploring new avenues with
www.kitchenfriends.ch. Forster Kitchens and Refrigeration is
launching its new range at the beginning of 2011. EgoKiefer
is the best-known company in the industry. Slovaktual is building
a new factory for the European market. RWD Schlatter is
staking its claim as a pioneer in smoke protection; the Division
Steel Technology is involved in prestigious projects and the
Division Surface Technology is investing in a new production
facility at Changshu, China. Our success is also thanks to you –
in that you support AFG with attention and interest as customers,
shareholders, partners and readers. Once again you have
the opportunity to discover some fascinating facts about our
divisions and company in this copy of AFG WORLD. I hope that
you enjoy the read!
With heartfelt wishes to you and your families for a peaceful
Christmas and a dynamic start to a successful new year.
AFG Arbonia-Forster-Holding AG
Chairman of the Board of Directors and CEO
Dr Edgar Oehler

news
2
Focus In a nutshell 3
Clearer, simpler and more practical:
the new Warendorf Sales Manual.
Warendorf New Sales
Manual on the Internet
The new Warendorf Sales Manual will replace the existing
one as of 1 January 2011. It features important
improvements: it is structured to follow the sequence
applied in kitchen design. The chapters are clearer and
better structured so that articles can be found easier and
faster. The main registers are clearly marked and give an
overview of the grouping of the types of articles. In this way,
Warendorf has responded to requests by the trade partners,
who were actively involved in the re-structuring of the Manual
via the Trader Advisory Committee. In addition, the range of
products was streamlined considerably and adjusted to market
requirements. The calculation of prices was simplified.
All pricing was reviewed and adjusted to competitive levels
so that the high-gloss paint finishes and veneers in particular
are now highly attractive regarding price. The electronic version
of the new Sales Manual is already available and can be
downloaded from www.warendorf.eu. «
Certified by the Technical Inspection
Authority (TÜV): the EgoVerre ®
high-performance insulating glazing
by EgoKiefer partner Kömmerling.
New: documentation
«Forster fuego light»
A new documentation is available for the «Forster
fuego light» fire protection system. The two folders
comprise a total of 1,400 pages, covering comprehensive
and detailed information about cutting to size, fittings and
correct installation. The new design versions, the sliding
door and the metal tubular frame door are also included.
The documentation now also includes a CD with all CAD
drawings for the system. For further information please
visit: www.forster-profile.ch «
The new «Forster fuego light» documentation provides important
information for installers.
EgoVerre ® is leak-proof
EgoVerre ® is the only triple glazing system worldwide that has been
demonstrated to meet the required leak-proof values. In 1996, EgoKiefer
launched the exclusive EgoVerre ® high-performance insulating glazing in cooperation
with a leading company in the glass industry and has set a new standard in
the Swiss market. And today, 14 years later, there is practically no other insulating
glass that comes close to the EgoVerre ® performance. Recently, the EgoVerre ®
triple glazing with thermo-plastic edge seal was the only product worldwide to
pass the testing for triple glazing units in accordance with EN 1279. The certificate
confirms that, thanks to its thermoplastic spacing system, EgoVerre ® is superior
to all conventional insulating glazing as the tested loss of gas is minimal,
which means that the system’s thermal insulation properties are maintained
throughout its service life. «
Rebirth of the Swiss
steel kitchen in 2011
Exciting events lie ahead – Forster Kitchens’ new developments. In January 2011,
the future generation of Forster’s Swiss steel kitchens will be presented to the public
for the first time. The official launch of the new kitchen has been scheduled for
18 January 2011. In parallel, Forster is installing at least one new kitchen model in
its own kitchen centres. Visitors can expect surprising design elements, slender
shapes and haptically attractive surfaces in a harmonious range of colours. There
is a lot to see and to explain. In the spring of 2011, Forster Kitchens will be presenting
the new kitchen generation during launch events in local kitchen centres.
This is your chance to see the product, touch it, inspect it thoroughly and get
all the answers to your questions from the sales staff. You are also welcome to
make a personal appointment with a member of the sales team. For first-hand
information visit a Forster kitchen centre near you or the company’s website on
www.forster-kuechen.ch. «
New lustrous finish by Arbonia
With its «Chrome Collection» Arbonia is introducing
new design elements for superior bathroom designs.
From now on, designers and building owners who want
something more than just basic functionality for their
bathrooms can specify Bagnotherm
and Cobra therm room heaters
in a classy chromium finish. Fortunately,
bathrooms are no longer designed to
fulfil just basic functional requirements.
Because nowadays, we are also looking
for style. People with a stylish approach
to furniture, equipment, fittings and
exclusive bathroom furniture want to
match that style in their room heaters.
For these customers, Arbonia is now offering
the «Chrome Collection» designer
range of room heaters with an extremely
elegant finish. Models include an asymmetrical
design (Move), asymmetrically
swept heater (Cobratherm) or heaters
with curved cross tubes: the Arbonia
«Chrome Collection» gives owners and
architects a maximum range of options
These perfectly shaped chromium-finished
heaters are excellent interior design elements.
Keep informed and request the new
documentation (available from January):
forster.kuechen@afg.ch
for bathroom design. These perfectly shaped chromium elements
can be used to achieve special design effects – either
by providing the final touch to a lustrous bathroom architecture
or by introducing an exciting contrasting element in a
bathroom design with muted colours.
Naturally, the «Chrome Collection»
range is manufactured to the same high
standards as all Arbonia products. The
company places great emphasis on high
quality standards as well the ecological
and sustainability credentials or the manufacturing
process. Customers appreciate
the excellent quality of the state-of-theart
chromium-plating plant, which complies
with standards of the DIN EN ISO
14001:2004 environmental management
system. «Chrome Collection» room
heaters can be plumbed into a central
heating system or can be supplied with
electric heating elements for connection
to the mains network. For detailed prod-
uct information visit www.arbonia.ch «

4
50 years Kermi:
traditional innovation
In these fast moving times, it is no longer a matter of course that a company can
celebrate 50 years in business. However, when one considers Kermi’s development
from a handicraft enterprise to one of the leading manufacturers of heating
technology products and shower enclosures, this period seems rather short.
Design and innovation – the systematic implementation of
these policy maxims has made Kermi to one of the leading
suppliers of shower enclosures and heating technology products
in Europe. The company’s clear aim is to combine trendsetting
design, top quality, functionality, comfort and reliability
to best possible effect. Its success throughout the last five
decades has been based on a motivated workforce and stateof-the-art
production methods. Kermi was originally formed
for the manual production of heating oil tanks and today has
over 50 years of experience in the development of heating
technology products and over 30 years competence in building
shower enclosures. In this way the company rapidly established
itself in the market. Since 2001, Kermi GmbH,
with its headquarters in Plattling in Lower Bavaria, is a fully
owned subsidiary of the Swiss AFG Arbonia-Forster-Holding
AG group of companies.
Milestones in the company’s history
Time and again, the company history was forged by milestones
of innovation and design, which had a significant
effect on the company’s development and the market. It all
started at a time when radiators were still bulky and cumbersome
and bathrooms were nothing more than a sanitary
facility. In 1960, the partners Kerschl and Schmidt founded
Kermi OHG, a firm for the manual production of heating oil
tanks. Soon the positive business development made it necessary
to install an automatic production line. In 1967, company
owner Kurt Kerschl had the necessary entrepreneurial
foresight and started to manufacture panel radiators. Owing
to steadily growing demand, the first fully automatic production
line for panel radiators was commissioned in 1972. An
important improvement was the introduction of two-layer
coating. Under the umbrella of the Salzgitter group, Kermi
grew to one of the leading panel radiator manufacturers by
1975. In order to achieve a diversification of the product
Back then, the spray coating of the tanks was still carried out manually.
Company founder Kurt Kerschl.
Focus 5
This is the building in which the first
Kermi products were made.

6
range while utilising the existing distribution channels, the
company started with the production of shower enclosures in
1976. Sensing the market’s trend towards energy-conserving
products, the company introduces the NT 2000 low-temperature
radiator in 1981. This can be considered the first real energy-saving
radiator. About six years later, there was another
achievement as the V-compact version with fully integrated
valve set and valves preset in the factory was launched. In
terms of energy conservation and time saving, this version
is still unique today. Kermi’s competence in metal working,
acquired in the production of radiators, was brought together
by forming the Steel Service Centre in 1984. This provides
a contract service to customers requiring high-quality finished
and semi-finished products. The current position of the company
was significantly affected by developments in 1994.
Kermi started the production of designer radiators and radiators
for bathrooms. Highlight of the range: the Kermi Credo.
The production of panel radiators started in 1967.
«Today, Kermi offers a complete range
of products in heating technology and
shower enclosures, offering the optimum
solution for every application.»
The design of this first radiator with a real design input had a
significant impact on the development of designer radiators
until today. The Credo product name became synonymous
with bathroom and designer radiators. Its success was seamlessly
transferred to its successor which was introduced under
the same name in 2005. In 1997, the company added convectors
and heating walls to its production and distribution
programme, with the aim of becoming a full range supplier.
At the turn of the millennium, Kermi expanded its range of
shower enclosures with all-glass versions. This caught the trend
of the time and since then, the company has made regular
contributions in terms of design, quality and functionality. In
2001, the year it became a fully-owned subsidiary of AFG
Arbonia-Forster-Holding AG, Kermi rounded off its heating
technology range with the xnet area heating system and
expanded its competence into all aspects of heat transfer.
In 2005, at the ISH exhibition in Frankfurt, Kermi launched
Focus 7
In 1976, Kermi started producing shower enclosures.
a ground-breaking development – the X2 technology for multilayer
panel radiators. This innovative patented process saves
up to 11% of energy while at the same time increasing the
component of radiated heat by 100% and reducing re-heating
time by 25%. These effects are achieved without modifications
to the heating system and are still unique today. The year 2008
saw a special achievement of the company: the 50 millionth
panel radiator came off the production line in the Plattling
factory. By comparison: only 30 million units were produced
of the legendary VW beetle. 17 September 2010: the new
product group – the Kermi shower screen – was presented to
customers in time for the 50-year celebrations.
Full product range
Today, Kermi offers a complete product range in heating technology
and shower enclosures, offering the optimum solution
for every application. Products are regularly reviewed as the
company demonstrates its innovative strength in terms of
technology and design. The design of the radiators and
shower enclosures, most of which was carried out in-house,
is regularly awarded with prizes such as the «red dot product
design award», the «iF product design award», the «Design
Plus» accolade and the «universal design award». «
«Rondo» model from 1993.

8 Focus
9
Unforgettable
celebration
50 years young and still going strong: Kermi celebrated
its big number birthday and many guests came to
congratulate. The celebrations were backed up by an
entertaining programme.
Kermi celebrated its 50 th anniversary with a festive reception
on Friday, 17 September 2010, and an open day on the following
Saturday. On Friday at 16:00 hours, over 200 guests
were officially welcomed by the Management in the lounge
bar to commence celebrations of the 50 th anniversary. From
14:00 hours onwards, interested guests had the opportunity
of a guided tour of the works in a choice of languages.
A storage building at the Plattling facility was converted to
a true event location – which was very successful. Parts of
the Kermi exhibition stand created a special atmosphere in
the building due to its pleasant lighting effects. Paul Johannes
Baumgartner, who is well known from one of Bavaria’s
most popular radio stations, Antenne Bayern, was the presenter
for the evening. Before the first speaker stepped on
the podium, guests were shown a short film with pictures
of the company’s history over the last 50 years. The first
speaker was Knut Bartsch, who spoke for the Management.
Knut Bartsch gave an introduction to the beginnings of the
company and the most important milestones in the development
of Kermi GmbH and elaborated on the company’s
A perfect occasion: the customer event on Friday evening.
most important success factors. The speech by Dr Roger
Schönborn included a special highlight. He provided guests
with exclusive information about the new product group – the
shower screen. Kermi is picking up the trend towards «wet
rooms» in which showers don’t have a separate tray and is
offering a thoroughly innovative solution in combination
with Kermi’s shower enclosures. Dr Edgar Oehler, Chairman
of the Board of Directors and CEO of AFG, congratulated
Kermi on the occasion. Already at the acquisition stage
he felt sure that «this is a super company». In addition,
Dr Oehler spoke about the consequences of globalisation
and the development of the economy and Europe. After the
starter course of the celebration dinner, Kermi welcomed
Dr Edgar Oehler came to congratulate. Guest speaker Wolfgang Clement,
The Management of Kermi GmbH
former Federal Minister for Economic
Affairs and Employment.
with Wolfgang Clement (centre).
guest speaker Wolfgang Clement, formerly Federal Minister
for Economic Affairs and Employment. He congratulated
the company on its 50 th anniversary and thanked company
founder Kurt Kerschl for his entrepreneurial courage and
achievement. Wolfgang Clement gained the audience’s sympathy
with his humorous presentation. But he also had a
number of pointed questions regarding politics in the current
situation which prompted some animated discussions.
«Cello Mafia» – a good mix
After the main course, guests were whisked away to a world
of cellos. «One woman. Four men. Five cellos. The clink of
lumps of ice, dangerous passions, hot sounds.» This is how
the «Cello Mafia» describes itself. With its mix of music and
comedy it provided furious entertainment and an entertaining
evening. The celebration dinner was concluded with an
extensive dessert buffet and this very successful event came
to a close with an informal get-together over drinks in the
lounge bar. Directly after the customer event there was a
call for «re-arranging the hall», so that the 5,000 expected
visitors to the open day could be fed. The number of visitors
on Saturday far exceeded the expectation of the organisers.
As soon as visitors entered the company premises through a
festively decorated pagoda they were enticed by the inviting
smell of grilled beef from two young bulls (weighing more
than half a tonne each). For a donation of 1 Euro visitors
«On the open day
visitors could see
‹Kermi in action›.»
were given the beef and a free drink. The complete takings
from the sale of food was handed over to the Association
of Friends of the Deggendorf children’s hospital. A sizable
amount was collected from this event and the donations
obtained during the customer event on the previous day.
Kermi opened up almost all areas of the company so that
visitors could get an idea of the «Kermianer» activities and
production. In order to make everything more animated,
the Management had decided to show the production
of the shower enclosures and radiators in operation. This
gave visitors the opportunity of experiencing a factory
«in action». «
On the open day, several thousand guests
congregated in the festive hall.

10
Top level sailing with AFG
as main sponsor
Top yachtsmen from all over the world, many of them skippers from the America’s Cup, competed
for the ISAF Match Racing World Championship in St.Moritz and other nine events. The high level of
the competition, the international competitors and the chance to see this Match Race close up with
the magnificent mountain backdrop make the St.Moritz Match Race a very special experience.
AFG is main sponsor of the Swiss Sailing Association
and was well represented at the «St.Moritz Match Race».
Top ranking yachtsmen were racing in exciting duels.
From 31 August to 5 September 2010, the world elite of the
sailing sport met for the eighth time on Lake St.Moritz for
the prestigious «ISAF Grade 1 World Championship Match
Race». The «St.Moritz Match Race» is part of the «World
Match Racing Tour». Top ranking yachtsmen compete in duels
at the highest level. As in the previous three years, AFG
was the main sponsor of this world class event. The Engadine
with its impressive landscape and the high-calibre participants
again made this year’s event a unique experience. Guests
were able to watch proceedings close-up from the sailing
grounds and the stands. During the annual «Corviglia Challenge»
guest regatta, visitors had the opportunity to test
their skills on the water together with the professionals.
Mathieu Richard as «King of the Mountain»
After three very exciting races at the highest level, the well deserved
winner emerged: Mathieu Richard from France became
«King of the Mountain» for the second time since his win in
2008. The French team, who have been sailing together for
nearly ten years almost unchanged, celebrated their win with
champagne even while they were still on board. «We are very
happy and had an excellent day. In the semi-final and final
we were down 1:0 and managed to convert that into victory.
Focus AFG Arbonia-Forster-Holding AG
«Even top sportsmen
and women rely on support
from companies.»
That’s fantastic», said a beaming Mathieu Richard. The 8 th
«St.Moritz Match Race» included exciting and very evenly
balanced duels at a very high level. This has moved the best
of the Match Race scene even closer together. The 6 th event
of the «World Match Racing Tour» with a cash prize of CHF
150,000 has become a regular fixture in this spectacular
sailing class.
«AFG wants to create quality of life.»
Since the spring of 2007, AFG has been backing Swiss sailing
as the main sponsor of the Swiss Sailing Association.
Together with the Swiss Sailing Pool (SSP), which is responsible
for sponsoring at the Association, AFG has entered a
longer-term agreement with the 2012 Olympic Games in
mind. The aim is to support performance oriented young
sportsmen so that one or several olympic medals become
possible in 2012. «Sporting and cultural activities are not
possible without financial support from the business community,
because they are too expensive», says Dr Edgar
Oehler regarding the sponsorship. «AFG considers an increase
in the quality of life as its task. We do that with our
products but also by sponsoring individual projects.» «
Happy winners: the victorious team with Mathieu Richard.
Justly proud of their award «2010 Shanghai Heating Industry
Trustable Product»: Alex Chen, left, and Gerry Lu, Sales Managers
for eastern and southern China.
Award ceremony at the 7 th Shanghai International Forum. Far left:
Alex Chen, Sales Manager of Kermi Heating System for the eastern
China region.
Asia Pacific:
Kermi is winner!
AFG is on course in the Far East too. The award «2010
Shanghai Heating Industry Trustable Product», which
Kermi received on 17 August 2010 at the 7 th Shanghai
International Forum, marks a new milestone. This
award, which is selected by distinguished companies,
engineers, architects and interior designers, is considered
a top honour by the heating technology industry of
Shanghai. During its seven-year presence in China, Kermi
has made an excellent name for itself. Customers in China
also appreciate the typical Kermi virtues, such as quality,
energy efficiency, environmental compatibility and the
trendsetting in-house product design. Compatibility between
the existing Chinese heating systems and Kermi’s
products is very important to the Kermi team. Optimum
solutions which guarantee maximum comfort and outstanding
functionality are produced in close cooperation
with architects, site managers and building owners. Kermi
has made it in China and has full recourse to its 50 years
of experience and uninterrupted innovative strength. «
11

12
Heating Technology
and Sanitary
Equipment
Palazzo Mantegazza: futuristic architecture in a premium location in Lugano Paradiso, Ticino.
Heating Technology and
Sanitary Equipment
«The elements
were manufactured
exactly to
the architect’s
specifications.»
This spectacular view was also made possible by ASCO SWISS underfloor convectors
which curve smoothly around the sweeping panorama windows.
Arbonia keeps things warm and cosy
at the Palazzo Mantegazza
«Palazzo» means «palace» in English, and in a palace you expect to find only the very best.
The optimum indoor climate in the luxury building complex in Lugano Paradiso, which opened
in 2010, is ensured by Arbonia ASCO SWISS underfloor convectors.
The combined residential and commercial property with a
volume of almost 128,000 m 3 has a prime location directly
next to the lake. This majestic building is characterised by
its panoramic glass windows and swing doors as well as the
facade and roof elements which resemble sails. The elevenstorey
building accommodates commercial and office properties,
three exclusive «duplex villas» with a roof garden and
two penthouse apartments. In addition to a fully-equipped
multimedia conference room, the infrastructure also includes
a 900 m 2 fitness and wellness centre with indoor pool. The
five underground levels are occupied by a car park which has
space for 200 vehicles. The building was commissioned by
Geo and Sergio Mantegazza and designed and erected by
the architect Giampiero Camponovo from Ticino.
Highest functional and aesthetic demands
All rooms are fully air conditioned. To ensure a pleasantly warm
environment with regular air distribution the engineers and
planners chose ASCO SWISS underfloor convector elements.
A solution with underfloor convectors was the obvious choice
for the panorama windows. Due to their fast reaction time
and the excellent heat transfer efficiency the underfloor
convectors can heat even high and large rooms within a very
short time. An elementary factor for a feeling of comfort and
well-being is that unpleasant air flows (draughts) are prevented
with the use of underfloor convectors. The special building
design of the Palazzo Mantegazza required customised
underfloor convector elements such as curves, ellipses and
S-shaped segments in lengths of 3 to 16.5 metres. The individual
manufacturing options of the ASCO SWISS underfloor
convectors were ideal for this assignment, and the individual
elements were produced exactly to the specifications of the
architect at the Swiss ASCO SWISS works in Arbon.
Invisible and comfortable climate control
In addition to fast reaction times the underfloor convectors
have another decisive advantage; they are almost invisible, as
they are fitted into the floor with a very shallow installation
depth – an important factor in such a prestigious building as
the Palazzo Mantegazza, in which the architect did not tolerate
any compromises when it came to the aesthetic design. «
13

14
Comfortable climate
in the Rhine Valley
Rheintal – the Rhine valley – is famous for its changeable weather. This was also noticeable
in the AFG Kitchen Centre in Heerbrugg, St.Gallen, which showcases exclusive
exhibitions of the Forster, Piatti and Warendorf brands. A lack of ventilation combined
with large window fronts and internal heat sources, for example the lighting, often
made temperatures soar to unpleasant levels.
This all changed in summer this year and discomfort is now
a thing of the past. Perfectly adjustable room temperatures,
from the floor in the top storey and from the ceiling on the
ground level, now ensure a balanced indoor climate in the
AFG Kitchen Centre.
Prolux has the solution
Under the supervision of Christian Meng from the architects
Gisel + Partner AG, Arbon, Thurgau, proposals were put
forward for creating a pleasant indoor climate for visitors,
customers and the exhibition team. After product evaluation
the decision was made to install Prolux cooling products.
As a result it was possible to ideally incorporate the various
architectural and constructional conditions into the plans.
Prolux underfloor convectors ensure a pleasant indoor climate and blend elegantly into the existing architecture.
Perfect climate from above and below
Ceiling cooling convectors are used on the ground floor which
cool the entire storey in a pleasant and silent manner. They
stand out from the ceiling installations and blend elegantly into
the architecture. Underfloor convectors were chosen for the
first floor. Installed in a double floor, the pipes for the cooling
circuit disappeared completely. The air conditioned area was
divided into four zones to achieve the best possible distribution
and optimum comfort.
Climate and user-friendly kitchen centre
The results are a visual and technical success. It was possible
to create a favourable climate and user-friendly atmosphere
and enhance the quality of the exhibition rooms considerably.
With its products Prolux proves that the «cooling» sector is
one of its strengths and has created a perfect forum for the
three high-profile brands Forster, Piatti and Warendorf.
Heating Technology and
Sanitary Equipment
Mirjam Oehler, Head of the AFG Rheintal Kitchen Centre.
Mirjam Oehler, Head of the AFG Rheintal Kitchen
Centre, is thrilled with the pleasant atmosphere in
her salesrooms. She explained the advantages of
the new system to us in an interview.
Ms Oehler, how would you describe the «new climate»
in comparison to previous conditions?
Mirjam Oehler: Well, customers and staff are no longer
suffering from the high temperatures in the rooms which
were partly due to the large number of spotlights and
bad ventilation. In spite of the high outdoor temperatures
this summer we had a constant, well-balanced and very
pleasant temperature inside.
The Prolux ceiling cooling convectors perfectly match
the new Warendorf Philippe Starck kitchen.
How were you involved as the Head
of the Kitchen Centre?
I was intensively involved. Our wish list included individual
control for all seasons as well as consideration of the building
structure, the division and operation of the various sectors
and the temperatures in the various zones.
How have the new ceiling and cooling convectors
affected you, your staff and the customers?
The quality of the atmosphere in the room has changed
completely. Operation of the system is also very user-friendly.
Both our staff and customers really appreciate the new level
of comfort.
What is your impression now the renovation is finished?
The difference is tremendous. Our staff has been much health ier
and have needed much less sick leave. Beforehand the air outside
was more pleasant than inside. Today the temperature is
always well-balanced and can be easily controlled. The new
Prolux cooling convectors have really enhanced the quality of
the three-brand showroom. It is a pleasant place to be and customers
can take their time to concentrate on our products. «
15

16
Combined with the Kermi shower enclosure, the new Kermi wet room is an innovative solution.
Kermi wet room and shower enclosure:
an attractive couple
17 September 2010: Kermi celebrates its 50-year corporate anniversary, the Kermi shower enclosure is 34 years
old and it is Day One of the new Kermi wet room. The sanitary market is currently undergoing a clear shift from
shower trays to a tiled wet room solution in both new builds and in renovated buildings.
Kermi the shower enclosure specialist has picked up on this
trend and now offers a new, innovative Kermi wet room
solution combined with the Kermi shower enclosure.
Wet room product range
Kermi supplies a comprehensive wet room range with variable
heights and dimensions to suit all bathroom conditions for
varied and elegant luxury solutions. The system has a simple,
logical design and provides all necessary components from
the edge sealing strips, impact noise insulation and levelling
compound through to the drain, sealing set and naturally
the tileable wet room board and underfloor elements. The
wet room drain outlets can be of point (rectangular) or line
(channel) design, central, offset or next to the wall. The outlet
covers are made of stainless steel, and are alternatively
fully tileable as a line solution. Practical considerations also
played a key role during design, as the outlet cover and the
odour trap can be easily removed for cleaning.
Material – Processing – Installation
All different options are made of top quality materials and
are crafted to the highest standards, as all products from the
Kermi shower enclosure range. The wet room board is made
of XPS (extruded polystyrene foam). Due to its high pressure
and water resistance (closed porosity), XPS is used, for example,
for insulating buildings from the ground. The drain and
channel on the boards are already fully sealed at the works.
With this new product group the highest emphasis was placed
on creating a well thought out, easy to install system. The
Kermi wet room solution is available in all standard dimensions,
and a number of special versions are also possible.
The robust, pressure resistant boards and underfloor elements
can be individually adapted to the respective site conditions
(e.g. wall facings). The wet room created in this way is the
ideal basis for all Kermi shower enclosures. These have already
been ideally designed for flush floor installation for
some time. Keywords here are the track-proven lifting and
lowering mechanism, the optional shower enclosure height
of 2.20 m and the Diga model with its hinged and folding
design. «
Harmonious integration – the new Kermi wet rooms.
Heating Technology and
Sanitary Equipment
New – Kermi Walk­in­Shower XS:
The new height of shower freedom
With the growing desire for unimpeded freedom and individuality in the bathroom, which is
now a new «living room», the demand for generously dimensioned, variable walk-in solutions
is on the increase. Kermi also fulfils these wishes in an optimum manner.
With the Walk-in-Shower XS Kermi opens up new perspectives
for individual, sophisticated bathroom planning and
construction. This applies to both the design and comfort,
and especially for the unique degree of individuality due to
maximum versatility. Combined with the flush, tiled Kermi
wet room solution it offers a truly desirable combination for
maximum comfort and almost limitless shower freedom.
Pure aesthetics for a new feeling of freedom
The high-quality, generally 8 mm thick single pane safety
glass in compliance with EN 12150 is excellently held by a
slim, organically soft but absolutely strong round tube design
in keeping with contemporary, luxury aesthetic bathroom
standards with exclusive wall fixtures geared to requirements
100% shower enjoyment – 100% freedom: The Kermi Walk-in-Shower XS is the ideal solution.
17
and the bathroom situation – flush on the inside with the glass
for maximum cleaning convenience – or as an elegant ceiling
support.
Enjoy 50 and more options
The glass dimensions with a width of 1.80 m and a height of
up to 2.20 m offer a wide range of solutions to suit individual
wishes; in the FREE version as a minimalist solution for pure
bathroom architecture, for example as a free-standing glass
panel with double, absolutely reliable wall fixture or an equally
solid double ceiling support. On the WALL version the panel
can also be secured with an elegant matching wall abutment
profile or high-end designer fittings. «

18 Kitchens and Refrigeration
19
Kitchens and
Refrigeration
Perfectly staged: a Piatti kitchen by night.
A Piatti kitchen
on the catwalk
Every Piatti kitchen is a star. How is it prepared for its grand appearance?
And how is it staged attractively and appealingly? A glance behind the scenes
of Switzerland’s largest kitchen manufacturer.
1. Vision
At the beginning there was an idea, a vision of what the new
lead kitchen by Piatti could look like. Free-hand sketches
have provided the guidelines and a starting point for the
material and colour selection. Then trends are ascertained
and the latest products of the company’s are examined.
In consideration of different expert suggestions, the first
design illustration is created.
2. Preparation
At the same time, clarifications and preparations for the
kitchen photo shoot are underway. Designers draft the architectural
concept and the floorplan around the kitchen.
And a prop planner is going to faithfully and realistically
reproduce these premises in a photo studio. The concept
is complete, the kitchen leaves production and is ready to
be installed.
3. Set-up
The set construction commences in the studio. An artificial
room is created by using temporary walls that are painted
in a concrete look.
4. Styling
The final and very important role prior to the shoot belongs
to the stylist. The decorative accessories, which were carefully
chosen and purchased beforehand, are positioned
ideally to create a coherent overall picture with the kitchen.
Finally, a harmonious lighting atmosphere is conjured up
using artificial sunlight.
5. Finish
In the evening, the photo shoot team stages a summernight
party with especially hired models. A final polish in Photoshop
– and the studio behind the image is no longer recognisable:
this is how professional kitchen pictures are realised. «
The floorplan.
The set-up.
The finished kitchen – ready for the shoot.

20
Those who work in a kitchen on a daily basis appreciate user-friendliness and convenience. Something the new Piatti bracket handles achieve effortlessly.
Piatti bracket handles: the most
convenient handles of all times?
As unremarkable as they appear at first glance: the bracket handles are crucial
for a kitchen’s aesthetics and suitability for everyday use. Rob Ratelband,
Product Manager at Piatti, has grappled with this subject intensively.
«This is the most comfortable range of bracket handles of
all times», gush many testers who have tried out the latest
Piatti innovation. The future will tell whether this statement
rings true. In an interview, Rob Ratelband explains the benefits
of the new handle system.
Rob Ratelband, what are the new features
of the bracket handles?
First of all, there is the eye-catching new and simple design. The
bracket handles will visually impress customers. The technical
innovations of the handles simplify the installation on the fronts
and can now also fulfil any customer requirements as it can be
supplied with two different types of handles.
What are the reasons for choosing new bracket handles?
We now manufacture the bracket handles ourselves, which
saves time and costs. In addition, this means we increase the
selection of decorative colours that can be combined with the
bracket handles tenfold, providing a great customer benefit.
Are there any other advantages?
The ergonomic properties and handling of the bracket handles
were also very important to us. As the first bracket can now
be fitted directly below the worktop, the customer can open
drawers of unit doors in the substructure more conveniently.
The new handle comfort also makes it significantly easier to
use drawers, especially heavy unit doors.
Where can customers get a better impression
of the bracket handles?
The bracket handles have been part of our range since 22
November 2010. More information is also provided in our
«Handles» brochure at www.piatti.ch – and at the end of
the year a kitchen in the Dietlikon showroom will also be
equipped with them. «
Kitchens and Refrigeration
Inviting with a wealth of interesting
topics: www.kitchenfriends.ch
Forster refrigerators:
new range
kitchenfriends.ch – a new
form of communication?
Communication has changed. The Internet has created the technological
foundation for consumers to easily network with likeminded people –
at any time and anywhere in the world. Reminiscent of a global self-help
group, consumers have organised themselves in order to find their way through
the increasingly confusing jungle of offers. They visit social networks, forums
and chatrooms for recommendations, testimonials and product ratings.
Entertaining facts related to the kitchen
In the process, they have more faith in what fellow consumers have to say rather
than the manufacturers’ sophisticated advertising messages. Classic product
advertising is becoming less and less noticed and accepted. Piatti is launching a
new website at www.kitchenfriends.ch, which was designed to provide exciting,
interesting and entertaining facts about all matters related to kitchens in the
broadest sense. By introducing this page in addition to the product website
(www.piatti.ch), Piatti strives to build a kitchen fan community with the ability
to make a significant impact on the future direction of Piatti through published
contributions. Monologue is meant to result in dialogue, target groups become
lifestyles and sales arguments turn into testimonials. «
In 2008, replacement of the range commenced and was completed in 2010
with the final built-in refrigerators. The latest product generation by Forster
Kühlen excels with convincing advantages. Compared to the previous models,
the timeless design has become even more user-friendly. Customised settings can
be configured yet more conveniently thanks to the touch controls with temperature
display. The modern interior LED lighting saves around 80% of energy. In addition,
it gives off significantly less heat, which also has a positive impact on the
overall energy requirements. The patented tray system with self-locking snap lock
provides safer storage. The three large 14/6 refrigerators also come with separately
adjustable temperatures in the refrigerator and freezer compartments as well
as a holiday setting (cooling performance only in the freezer compartment). With
the new model series, Forster Kühlen has started producing high-quality built-in
refrigerators which achieve at least energy efficiency category A+. On top of this,
four devices are already offered in category A++. The positive feedback of sales
partners and end consumers confirms the expected high level of acceptance in the
market of the latest generation and the intended preservation and expansion of
the sales volume. «
The new Forster refrigerators
convince in every respect.
21

22
The visitors were fascinated by the original «giant table» idea.
Forster Kitchen at
Designers’ Saturday
On 6 and 7 November 2010, the Designers’ Saturday was held in
Langenthal BE for the 13 th time. Forster Kitchen was also present –
with a seemingly magical, accessible giant table which completely
mesmerised the audience.
It is held every other year and is becoming increasingly popular
among international design experts. This trend is also reflected
in the ever increasing numbers of visitors. This year,
for example, 17,535 visitors passed through the doors. The
dedication and originality of the exhibitors and organisers
have led to the unique positioning of the Designers’ Saturday.
Various company presentations are supported by renowned
institutions, design and art academies. The Designers’ Saturday
not only provides an overview of outstanding new products,
but also gives in-depth insights into the variety of contemporary
design and supplies plenty of inspiration for new
ideas. A panel of judges evaluates and selects the best exhibitor
presentations.
The Designers’ Saturday has become
an internationally renowned event.
A «giant table» evokes emotions
Visitors to the Forster stand can look forward to secrets and
surprises. A large three-dimensional wooden table is prominently
positioned in the Glas Trösch production hall. The
table is the pivotal place for families, a meeting-place and a
symbol of togetherness, of sharing ideas, of culture – and
simply the centre of the kitchen. It is a place of comfort
where children love to crawl under the table to share secrets
and experience magical moments in the semi-darkness.
Similar emotions were aroused by Forster’s «giant table».
The table cloth represented the boundary to its surroundings
and as the same time the exterior wall. A mystical lighting
atmosphere characterised the mood underneath. Spotlights
highlighted individual kitchen elements.
Kitchens and Refrigeration
«The table is
the central element
of the kitchen.»
Immersing in the «magical kitchen world»
Observers found themselves in a magical Forster world of discoveries,
which was linked to the products’ real features yet
still created a wonderful environment of reversed dimensions.
The focus was on steel as a material and its characteristics.
The furniture demonstrated the individual design options the
Forster kitchens offer and showed the processed material in
its original form. The aroma of freshly baked bread, which
subtly filled the room time and time again, reminded visitors
of where they were: in a kitchen. Magnetic accessories were
animated electronically and moved about on the furniture
elements. Kitchen devices started buzzing, a whisk started
spinning in a pot and a sponge proceeded to clean the
kitchen fronts.
Around 800 peelers dangled above the benches
at different heights.
The focus was on steel as a material and its characteristics.
23
A tangible fantasy world
The centre of the room was filled with benches made from
cardboard honeycomb. They served to demonstrate the solid
nature and interior life of the Forster kitchens. The seat panel
is made from a clear varnish steel plate. Above the seats,
hundreds of peelers dangle from a grid at different heights
and, with their reflections, immerse the room in a sparkling
light. The idea plays with memories, which we all have. The
reversal of the dimensions gives visitors a child’s perspective,
opening up to them a world of learning what is seen and
felt. Smiling faces, hundreds of cameras and mobile phones,
cupboard doors being opened umpteen times and fingerprints
on all elements are evidence of an excited audience’s
fantasy world that has become tangible. The organisers’
delight was shared by Forster who celebrated a successful
event. «
Excited anticipation: what will the next generation of kitchens look like?

24
Warendorf – new kitchens
for personalities
From 18 to 24 September 2010, the Küchenmeile A30 trade fair presented «Kitchens
made in Germany». Against this imposing backdrop, Warendorf staged seven kitchen
innovations in classy design on an exhibition area spanning 360 m².
Ambitious lifestyle kitchen: the black matt glass front,
combined with face veneer elements from American walnut,
gives this kitchen its sophisticated, homely feel.
In the picturesque region of East Westphalia more than
100 exhibitors showcased themselves along the A30 motorway
and on the historic «Gut Böckel» estate in Rödinghausen.
With the combination of the two product lines Warendorf and
«Starck by Warendorf», the kitchen manufacturer presented
an impressive range of creative design options. The pre-opening
the night before the exhibition opened already generated a
lot of interest. Stemming from Europe, Russia, China and other
regions, the increasingly international visitors were excited
about the elegant yet homely and comfortable Warendorf
kitchens.
Light, simple, cosy: an ideal-typical family kitchen featuring a front mix
of distinctively natural pine decor and high-gloss varnish in jasmine.
A kitchen that adapts to family requirements.
Extraordinary products for ordinary budgets
The general interest in the «Starck by Warendorf» products
is still going strong. This year, Warendorfer Küchen GmbH
emphasised the collection’s variety and presented all kitchen
models in light colours. With their subtly sophisticated effect
for smaller living areas of around 17 m², the kitchen designs
were very well received. Thus, the company proved that it
can not only supply luxury kitchens, but also high-quality designs
and elaborate functions for the medium price bracket.
Thanks to its abundance of variations, Warendorf offers a
suitable kitchen for any personality. «The trade fair illustrated
Kitchens and Refrigeration
Unique: combining two product lines results in a fascinating «mix».
Wall unit, island and tower unite. The combination of the smooth
varnish on the wall unit and the island finished in bronze glass create
a stylish ambiance. The cream white smooth varnish makes the tower
appear particularly light.
«The extensive range
of design options
makes individual dreams
come true.»
the range of design and combination options we are able to
offer our customers to assist them with realising their individual
dream kitchens. Our products combine extraordinary design
with sophisticated functionality – even on smaller living
areas and for average budgets», stresses Thorsten Prée, Chairman
of the Management at Warendorfer Küchen GmbH. «
25

26 Kitchens and Refrigeration
The «Primo» kitchen presents an attractive kitchen island
solution and a supplementary tall cupboard element with
a granite worktop. The functional island impresses with
generous pull-outs on the one side as well as drawers and
revolving doors on the other side.
The great interest in the multi-brand strategy was met with joy
(from left to right): Thorsten Prée, Chairman of the Management at
Warendorfer Küchen GmbH, Peter Leu, Head of Specialised Trade,
and Peter Holliger, Member of the Management at Piatti.
Three kitchen brands
from a single source
For the first time, AFG Arbonia-Forster-Holding AG will present its three
kitchen brands to an international audience at the LivingKitchen trade
fair from 18 to 23 January 2011 in Cologne. The trade fair objectives are
consistent with AFG’s strategy for internationalising the kitchen business; the
platform in Cologne therefore offers ideal starting conditions. The group brands
Forster, Piatti and Warendorf will present their brand and product strengths in
conjunction with a number of innovations on an area spanning 540 m² under
the roof of AFG in hall 4.2 isle B/No. 030, isle C/No. 039. «
New in Germany:
Warendorf with Piatti
Within the scope of the further internationalisation of
AFG, Warendorfer Küchen GmbH has also been selling
the popular Swiss kitchen brand Piatti since 1 October
2010. «Piatti is already the Swiss market leader. Together
with Germany and Australia, Switzerland is a key market in
terms of market share. With respect to consumer behaviour
these three countries are very challenging markets. Kitchens
that persevere in all three of those markets will sell anywhere
in the world», notes Dr Edgar Oehler on the integration of Piatti
into the two-brand strategy under the roof of Warendorfer
Küchen GmbH. The Küchenmeile A30 trade fair gave visitors
a first impression in the form of two displayed Piatti
kitchens. Thereby, Warendorf kicked off the implementation
of the planned brand strategy from which the customers of
Warendorfer Küchen GmbH benefit, in particular. Therefore,
the company can offer its customers kitchens in a broad
range of prices and styles – from low budget through to the
premium segment. «The two brands, which distinguish
themselves through their clear positioning and product structures,
appeal to very different target groups. This, in turn,
generates considerable demand. This expansion creates
space for an interesting individual and multi-brand portfolio
from which our sales partners benefit», says a confident
Bernd Mehrtens, Head of Sales Germany. «
«Starck by Warendorf»:
customised dream kitchens
By consciously using colours and materials, «Starck by
Warendorf» kitchens are in harmony with the most
versatile of lifestyles. Because far beyond «Starck’s
Favorites», a broad range of surfaces, shades and cupboards
offers virtually unlimited combination options.
Rather than a neo-baroque style with yellow mirror glass and
stainless steel, Starck’s «Primary» kitchen boasts an attractive
design. The key elements of this kitchen are the fronts in pure
white and black plastic as well as the white glass bistro table
with shiny chrome trumpet leg. The white kitchen furniture is
timeless and can be combined in a variety of ways. «Library»
in the «Minimal» collection features circumferential library
shelves and a guidable stainless steel ladder. A colourful highlight
is provided by the trumpet table’s light olive drawer
fronts with cooking and preparation function. This version
of «Library» exudes ease and therefore a unique vibrancy,
no matter whether it is used for kitchen utensils or books. «
«Primary» – convincing presentation in futuristic design.
The place for food and spirit, the «Library»
presents itself with elegant ease.
27

28
Windows
and Doors
A new building project for an old district – with MINERGIE ® -certified EgoKiefer AllStar AS1 ® plastic windows.
Windows and Doors
From idle production site
to showpiece
Today, the facade of the most innovative MINERGIE-P ® building project in western Switzerland
gives the centre of Vevey VD a completely new look. Not too long ago, the cityscape was
characterised by old, vacant commercial properties. The new building project with private
and commercial premises gives the old district a new lease of life.
On the former premises of «Ateliers de constructions mécaniques
de Vevey (ACMV)», a well-known rail vehicle manufacturer,
around 1,000 apartments, business premises, a daycare
centre, a school and numerous parking facilities spanning a
total area of 86,765 m 2 are going to be constructed by 2013
under the name of «Moulins de la Veveyse». The history of
this neighbourhood makes the project something very special
for its initiators. When the concept behind this exemplary
building project was designed, old commercial real estate in
top locations was turned into exclusive apartments using innovative
and high-quality products, and new residential and
commercial properties were created. The focus throughout
was on energy-efficient construction.
Energy-efficient construction with EgoKiefer
AllStar AS1 ® windows
Energy-efficient construction requires special attention to be
placed on the building envelope. For example, the developer,
Promotions Delarive SA, decided to use the MINERGIE ® -
certified EgoKiefer AllStar AS1 ® plastic windows. This new
EgoKiefer window line, which was launched in early 2010
in plastic and plastic/aluminium, fulfils the whole range of
customer requirements in all areas of new construction and
refurbishment. With the added values it provides in terms of
«The building
project is showing
its attractive side.»
Successful revitalisation of an old district:
new life is blooming on a former industrial site.
insulation, noise protection, security, ventilation, design,
comfort and modernisation, AS1 ® convinces in all areas. The
EgoKiefer AllStar AS1 ® windows reduce energy consumption
through windows by up to 75% – depending on the type and
age of the windows they replace – and therefore protect the
environment sustainably. Thanks to these excellent insulation
values, significantly more energy is conserved during the
life of the product than is used for production, delivery and
installation. «
Successfully in use: the MINERGIE ® -certified
EgoKiefer AllStar AS1 ® plastic windows.
29

30
The platform www.energy-and-more.ch
helps save energy and costs.
This attractive instrument enables customers to calculate their
individual energy and cost saving potential online. EgoKiefer is
MINERGIE ® ’s exclusive leading partner for windows and doors.
At www.energy-and-more.ch, interested visitors can find a
variety of interesting information related to MINERGIE ® as
well as the largest range of MINERGIE ® and MINERGIE-P ® -
certified windows and front doors in Switzerland.
Significant figures – thanks to EVALO
The virtual analysis instrument EVALO makes it possible to evaluate
the energy efficiency of an existing building online. Subsequently,
the desired refurbishment measures can be carried
out virtually. In parallel, EVALO shows the energetic improvement
on the basis of a clear before/after comparison, calculates
the required investment in consideration of any available funds
and provides detailed documentation that can be downloaded.
EgoKiefer includes climate protection.
A clear information medium
With its new platform www.energy-and-more.ch, EgoKiefer
provides home owners with a unique information medium.
Of course, this tool can also be used by professional building
designers such as architects to assist them in advising their
clients. In any case, the new EgoKiefer online tool facilitates
the cooperation and expert discussions among all parties involved
in the construction process. «
Successfully restoring
with «Energy and More»
On 1 January 2011, EgoKiefer will launch its new Internet platform
www.energy-and-more.ch which focuses on the subject of energy
conservation and climate protection. At the heart of the new microsite
lies the world’s first virtual building restoration platform EVALO. And that
is not all! Energetic building restoration is a huge trend. Around 50% of Switzerland’s
fossil energy consumption is caused by buildings. It is well known that
the most part of the energy is lost through windows, facades and roofs. The right
insulation is therefore crucial. A well-insulated building not only preserves heat
within its four walls, but also keeps the money in the home owner’s wallet.
Unique in Switzerland
At www.energy-and-more.ch, EgoKiefer provides interested home owners with
all the important information that is necessary for energy-efficient home refurbishments.
The Internet platform contains Switzerland’s only complete support
platform featuring all currently available national, cantonal and regional support
programmes. In addition, it also includes Switzerland’s first online energy saving
calculator.
Around 50% of the fossil energy consumption in Switzerland is caused
by buildings. EVALO is an effective tool to counteract this trend.
Windows and Doors
Saving energy with style
EgoKiefer is MINERGIE ® ’s exclusive leading partner for windows and front
doors and boasts Switzerland’s largest range of MINERGIE ® -certified front
doors. Now energy-saving door designs are being added to the range.
This gives EgoKiefer customers a number of additional design options with energyefficient
front doors. A building’s heat requirements are also influenced by the
quality of the front door. For this reason, it is important for planners or developers
to be able to quickly obtain information about a front door’s performance. The
MINERGIE ® module for front doors offers this service. It checks and marks products
that are manufactured and installed in accordance with the requirements
of a renowned quality standard and also fulfil the more stringent technical specifications.
« Functionality in perfect design: a MINERGIE ® -
certified front door by EgoKiefer.
RWD Schlatter optimised indoor climate
Today, special software makes it possible to optimise a
building’s indoor climate. RWD Schlatter also successfully
applies this technology. The company is able to carry
out isothermal and heat calculations. The process involves
a software-supported creation of thermo/hygro
component analyses and U-value calculations according
to EN 10 077-2. This also allows for thermal bridges to be detected
while a door and other products are being developed
and therefore be eliminated by means of constructional
changes. The objective is to prevent structural damage and
to save heating energy. A further application relates to the
hygric analysis (condensation analysis) which is used to
determine minimum temperatures on the interior surface of a
component in order to prevent condensation or mould from
building up. In the light of the ever denser building shells, e.g.
To evaluate the results, the temperature ranges can be presented as a colour scale,
or the materials can be displayed in colour to increase readability.
31
evidence of blower door testing (ascertainment of the airtightness
in the event of overpressure), this is becoming increasingly
important for MINERGIE-P ® in order to maintain a
pleasant and healthy indoor climate. The integrated material
database in accordance with various standards (EN ISO 12 524,
EN ISO 10 077-2, EN ISO 673, EN 6 946, DIN 4 108-4) makes it
possible to precisely determine the U-values of the door leaves.
As the software also calculates the framework conditions
(room temperature and heat transfer coefficients), it is possible
to generate U-value data according to SIA 343 for a door element
that is installed ready for operation (UD-value). To evaluate
the results, the temperature ranges can be presented as a
colour scale, or the materials can be displayed in colour to increase
readability. The result is holistic, high-quality products
that guarantee a pleasant indoor climate in the long term. «

32
RWD Schlatter owns Switzerland’s
first smoke protection test stand
Although smoke protection doors are currently not a major issue in Switzerland,
RWD Schlatter is investing in this testing method. Today, we primarily see fire protection
doors used in our country. Smoke protection doors or fire protection doors in combination
with smoke protection are currently only used in individual cases. The situation is very
different in the rest of Europe.
Here, smoke protection tests are an everyday occurrence. The
question arises why this big difference exists, and we recollect
the thesis that kept reappearing in recent years: «Fire is not
equally hot in all cantons.» In this area, the Association of
Cantonal Fire Insurers (VKF) has, with great dedication, managed
to achieve widespread harmonisation among the cantons
so that today checks and installations across virtually all
of Switzerland are carried out in accordance with the same
standards and provisions.
«Standards in chaos» despite harmonisation
It seems that the whole story of harmonisation is now repeating
itself, simply on a larger scale, within the scope of the
European Union. A distinction must be made between European
standards and national legislation. On the one hand,
the standards have been harmonised to a large degree, i.e.
a smoke protection check according to EN 1 634-1 applies in
Germany as well as in Italy or Switzerland. On the other hand,
different types of legislation in regard to fire protection apply
in different countries. Let us take Germany, for example: in
Germany, hotel corridors must be equipped with fire compartments
including a fire protection door in regular intervals.
In this way, a certain part of the building is protected against
the fire spreading to the next section in the event of a fire.
However, the hotel room doors along a corridor between
two fire compartments do not necessarily need to be fire-
resistant.
Effective fire protection element checks
Not so in Switzerland. Even though Switzerland also has the
regulation that fire compartments need to be fitted in regular
intervals, each single hotel room door also needs to be a fire
protection door. In other words: in Switzerland, fire protection
is realised in much smaller increments and therefore probably
offers much better protection in an emergency. Naturally, this
also impacts on costs. Some people might ask if this high level
of safety is really necessary. But this question is only asked as
long as people are not inside of a building on fire. With the
smoke protection furnace that has now been put into operation,
RWD Schlatter is able to test smoke protection elements
of up to 3.6 x 3.6 m in size. That means the majority of smoke
protection elements which will be required in the future can
RWD Schlatter is shortly also going to have one of these
smoke protection test stands on its premises.
be tested. Now the question may also arise why a Swiss door
manufacturer is investing in a smoke protection furnace given
that smoke protection is not even an issue.
Smoke protection is worth it
The answer is simple: firstly, we believe that smoke protection
is also going to become an issue in Switzerland in the
next few years. That means in the near future, when everyone
else only just starts grappling with the issue for the first
time, we will already be able to fall back upon extensive
experience in smoke protection. And secondly, we are convinced
that this will enable us to provide our customers with
added value in the medium term by offering an outstanding
product. Of course, tempers will flare again should the smoke
protection test be introduced in Switzerland. And some people
will once again complain about the many regulations
that are impossible to manage. But we should not forget
one important point in this discussion: in the event of a disaster,
more people die from smoke suffocation than from
the actual fire. This is precisely where prevention needs to
come in. Those who are aware of preventative measures and
do not apply them ultimately always act grossly negligent. «
Windows and Doors 33
20 years of Slovaktual – 20 years of success
On 10 and 11 September 2010 the Slovakian window manufacturer
Slovaktual, the youngest addition to the Division Windows and Doors,
is celebrating its 20-year anniversary. The company, founded and managed
by Marián Krč, is optimistic about the future. The two-day anniversary
celebrations were a successful expression of the pride in what has been
achieved and the anticipation of new challenges. Entertaining programmes for
young and old as well as wholesome fare created a fantastic atmosphere. Boasting
a market share of 35 to 40%, Slovaktual is the largest manufacturer in the
Slovakian window and door market. The company employs around 280 members
of staff and has a large dealer network comprising more than 150 points of sale
and over 200 employees in Slovakia, the Czech Republic and Austria. Thomas
Gerosa, Head of the Division Windows and Doors, shared his vision for the future
and explained the details of a trendsetting large-scale project: the Pravenec site
is going to be expanded into a production plant for Europe. Since October 2010,
it has also been producing the new AS1 ® window line, the latest EgoKiefer plastic
window generation, for the Swiss market. A further step will see the construction
of a new production hall with a direct link to today’s factory. With an investment
of 6.5 million Euros for the production hall and the new production line for the
Slovaktual and EgoKiefer window systems, the Division Windows and Doors is
systematically expanding its capacities in the Pravenec location. The new building,
spanning a hall area of 6,483 m 2 , is expected to be completed by the end of June
2011. The machines are scheduled to be put into operation in August, and production
is planned to commence in September 2011. «
Slovaktual gets a new showroom
Inviting and demonstrative: the new showroom.
The anniversary celebrations provided great
entertainment for young and old guests alike.
Since 1 July 2010, Slovakual has been represented in
Pravenec with a further showroom. Developers, planners
and tradesmen can inspect the whole range of
window types and installation solutions in a pleasant
environment. The window and door models have been
realistically integrated into the showroom to give customers a
solid impression of the products. Supported by a competent
team of consultants, they can test all the important product
functions. The generous showroom is a further milestone in
the systematic development of the Slovakian window and
door market. «

34 Steel Technology
35
Steel Technology
AMAG Competence Centre in Oberkirch, Lucerne: The facade and lift and slide door of Forster Profile Systems combine to form a whole.
Visual elegance and a free
view of the essential
Not only the latest car models were the focal point at the recently opened new AMAG
Competence Centre in Oberkirch near Sursee, Lucerne, but also the modern glass facades
which were created with the Forster thermfix and Forster unico systems.
On the 12,000 m 2 site in Oberkirch AMAG built new showrooms
and a customer centre with architecture which is fully
in keeping with the striking VW and Audi design. With the
new build AMAG Retail Sursee meets the demands which
must be met in the future by successful car showrooms.
At the same time it is a major employer in the region.
Stylish presentation with Forster thermfix
The generously dimensioned glass panels for the showroom
in the new complex spotlight the Audi, VW, Skoda, Seat and
Porsche to their best advantage. A main contributing factor
are the filigree steel facade elements made of the Forster
thermfix light system. They lend the facade a very stylish
and unusual character.
Impressive prototype
The Forster unico steel lift and slide element on the south
side of the Audi showroom is particularly worthy of mention,
as its dimensions by far exceed the normal framework. The
double lift and slide door with its side sections has spectacular
outer dimensions with a width of more than 10 m and a
height of 3.8 m. The manually actuated lift and slide sections
made of Forster unico each weigh around 350 kg and can
Construction site sign
Building AMAG Retail building, Oberkirch
Architect Schenker + Schenker, Oberkirch
Facade planning Gerhard Schimpl, St.Johann
am Walde, Austria
Site management Karl Steiner AG, Lucerne
Metal construction Huber Metallbau und Stalleinrichtungen
AG, Buttisholz
Year of construction 2010
Systems Facade in Forster thermfix light,
windows and doors in Forster unico
be pulled back to reveal an opening of 3,650 x 3,670 mm.
This prototype was developed in close collaboration with the
Technical Consultant Department of Forster Profile Systems.
All windows and the generously dimensioned entrance doors
are made with the Forster unico system and therefore guarantee
efficient and contemporary heat insulation. «
The corporate building stands for a uniform brand world. Maximum transparency with the slimline Forster profile design.

36
Roof glazing
successfully tested
The Forster thermfix light facade system has been tested and is now certified
as pitched glazing. The system passed the hardness test at the CSTB institute
(Centre Scientifique et Technique du Bâtiment) in Paris. In compliance with the
European product standard EN 13 830, the air permeability, driving rain impermeability
and the resistance to wind loads of a standardised test element were tested.
During the tests at various angles ranging from 10 to 75 degrees it became apparent
that the facade easily exceeded the required values – and also expectations.
For example the driving rain impermeability test was performed with a water pressure
which had been increased by 100 percent. The construction remained absolutely
watertight, even under this tremendous load. In addition to tightness, safety
aspects naturally play an important role. To simulate the impact of a person, a 50 kg
sand bag was dropped from a height of 2.50 m onto the glazing. The element also
passed this test with flying colours. The pitched glazing is a very valuable supplement
to the existing vertical facade. This solution is expected to be received with
enthusiasm by architects and metal construction companies. «
These drive shafts are mainly used
in the Polo and Golf models.
Hardness test passed with ease:
the Forster thermfix light pitched glazing.
VW + Forster Precision Steel
Tubes: a dream team
Forster Precision Steel Tubes has collaborated with Volkswagen to develop
a solution which enables the production of drive or side shafts from tubes
which have only been welded in compliance with DIN EN 10 305-3 using the
existing journals and the same welding method. Drive or side shafts in motor
vehicles are subjected to high loads, especially when they pull off. These shafts
are either made of solid material or tubes. For the latter seamless tubes in compliance
with DIN EN 10 305-1 or welded and subsequently cold drawn tubes to
DIN EN 10 305-2 are used. Various types of so-called journals are currently welded
to these standard tube lengths with the Magnetarc welding process (pressure
welding with an arc that is moved magnetically under shielding gas) and then
processed in several stages to make finished drive shafts (connection of the
gearbox/differential to the drive wheels). In recent years Forster Precision Steel
Tubes developed a solution in collaboration with Volkswagen in Wolfsburg with
the aim of producing these shafts using only welded tubes to DIN EN 10 305-3
with the existing journals and the same welding method. The joint assignment
was to produce standard tube lengths which on the one hand achieve the specified
mechanical values of the seamless tubes supplied today and also meet the
requirements regarding close tolerances, exact concentricity and straightness.
Volkswagen also demanded compliance with Formel Q and ISO TS 16 949. To
ensure that these high customer demands are met reliably for the process, various
prototypes and samples as well as trials on the test bench were necessary.
Finally the aim of producing shaft blanks which meet the specifications was
achieved. Today Forster produces these tubes in series with modern tube welding
systems and therefore makes a considerable contribution to easing the tremendous
price pressure in the automotive industry. Other substitution options
are currently undergoing trials. «
Steel Technology
Steel windows and doors:
even better heat insulation
The revolutionary Forster unico profile system has a
new family member – the Forster unico Hi. Only two
additional sealing components turn the thermally insulated
window and the thermally insulated door into
highly-insulated components. This product underlines
Forster’s long term ecological commitment. The system
profiles are made of 100 percent steel and do not require any
plastic insulators or profile filling. The combination of the latest
technology, energy efficiency, aesthetics and environmentally
compatible materials guarantees responsible and sustainable
construction. With Forster unico Hi the latest thermal
insulation requirements such as the EnEV 2009 in Germany
with a maximum Uw value of 1.3 W/(m 2 .K) can be achieved
without difficulty. Without additional measures the construction
permits the integration of up to 60 mm thick fillings (triple
glazing) and therefore achieves a Uw value of up to 1.0
W/(m 2 .K) depending on the glass quality. All system applications
are tested in accordance with EN 14 351-1 for CE marking
and are also available as burglary-resistant elements with
resistance class 1-3 according to EN 1627-30 or as bullet-
resistant elements FB4 in compliance with EN 1522. Since the
introduction of the system in 2007, Forster unico has been
very popular with planners and processors alike. With the
new features which have been added to the range over the
years such as the extremely slimline frame and door leaf pro-
With its improved heat insulation properties, the Forster unico Hi has a rosy future.
Forster unico Hi – with only two additional sealing components
a window with a high thermal insulation factor.
37
files, the lift and slide doors, the burglary and bullet resistance
tests and the comprehensive basic testing for CE marking,
Forster unico is a futuristic system with a wide range of
possible applications. «

38 Steel Technology
39
Mullion/transom facades and windows in the UNESCO Project School in Flensburg, Germany.
Forster Profile Systems:
the perfect role model
The Plantijn Hogeschool in Antwerp, Belgium, with Forster systems
for the facade and the entrance area.
The Forster door, window and facade systems are also
the preferred solution for building schools. Their durability
is evidenced by the many buildings which have
been put to the test in tough everyday conditions for
many years.
In addition to aesthetic aspects, the high demands to be met
regarding robustness and durability are the main priority. This
applies in particular to the doors, which have to withstand
tremendous stress and strain. It is therefore not surprising
that this aspect is paid special attention at the planning stage.
Normally only elements with excellent static properties are
considered during the project tender stage. What is more
obvious than to use the maintenance-friendly Forster steel
profile systems which can also meet all safety requirements
perfectly?
No panic – no injuries
In addition to safe fire barriers, reliable anti-panic functions
are also essential, for example – and sharp edges are also
avoided to minimise injury in emergencies. «
Fire protection doors and glazing in the PMS Pedagogic Secondary School
in Kreuzlingen, Thurgau.
In use for more than ten years: Facade, window and door elements
at the University of Avignon, France.
Fire protection facades and fire protection doors in the new canteen
of the University of Applied Science in Regensburg, Germany.

40
Surface
Technology
Functional beauty – a hard chromium-plated worm shaft for the plastics industry.
Surface Technology 41
A spherical cap which has been chromium-plated by STI | Hartchrom.
Modern bridges: quality
down to the last detail
Top engineering and best materials are needed to build bridges with large spans, such as the
Irtysh River Bridge in Kasachstan with a span of 750 m. Mageba, a company located in Bülach,
Zurich, is particularly successful in this industry.
«STI | Hartchrom
successful in civil
engineering
applications.»
The spherical bearing with PTFE discs pursuant to EN 1337 is used
in structures that are subject to strong torsional forces and heavy
imposed loads.
Today, Mageba produces well over 10,000 bridge bearings and 30,000 modular
expansion joints per year. In order to meet its quality obligations regarding spherical
bearings, the company has been cooperating with STI | Hartchrom since the beginning
of 2010. These bearings are some of the most hard-wearing construction elements
in a bridge building. Their special design and construction makes it possible
that forces and movements resulting from loads or temperature fluctuations are
transferred from the bridge girder to the bridge pillars while allowing for the necessary
movement at the same time. For bridges with large spans this is a prerequisite
for a long service life. Different bearings are used for different situations. For example,
spherical bearings are suitable for structures with heavy loads, strong torsional
forces and frequent lateral movements as well as bridges in very cold regions with
temperatures down to -50°C.
Cooperation intensified
As supplier to Mageba, STI | Hartchrom has been able to demonstrate
its capability in coating these components and prove
its competence for the first time also in the field of civil engineering.
One of the decisive factors was the high quality of the
hard chromium plating which is very suitable for outdoor applications,
also in locations with extreme temperature fluctuations.
The fine surface and low friction coefficient of the chromium
layer, together with the antiseize agent, provide excellent sliding
properties and a long service life. Other points in favour of
STI | Hartchrom were their fair price/performance ratio, competent
advice and short processing times. Mageba also very much
appreciates the good cooperation and intensive exchange of
information with the company. After this successful start, cooperation
in the field of civil engineering is set to be
expanded. «

42
STI | Hartchrom starts works
for a modern factory in China
The ceremony for the start of construction on the new production facility in Changshu took
place on 23 June 2010. This is an important step for STI | Hartchrom with which it breaks into
one of the most important growth markets for surface technology.
The newly formed STI | Precision Machining (Changshu)Co., Ltd. is based in Changshu, a large city
with nearly two million inhabitants located some 60 miles away from Shanghai, in the Jiangsu province.
Lions for luck and success
The lion dance is a traditional dance with music,
usually carried out by two persons under a «lion’s
dress». It is meant to chase away bad spirits and
demons from a building. As link between humans and
the heavens the Chinese lion is the bringer of good
fortune, happiness and prosperity. The lion dance is
always accompanied by a large drum, cymbals and
gongs.
«STI | Hartchrom
stands for quality
and flexibility.»
The high-profile guests were an indication of the importance
of this construction project, not only for STI | Hartchrom but
also for the Chinese government. Guests included representatives
of the local government of Changshu, the Swiss Embassy,
the Swiss General Consulate in Shanghai, the Swiss Chamber
of Trade as well as other influential business and political partners
of STI | Hartchrom. They were welcomed by Dr Edgar
Oehler, Chairman of the Board of Directors and CEO of AFG
Arbonia-Forster-Holding AG, Felix Aepli, CEO of AFG Asia
Pacific, Ying Zhao, Managing Director for Construction of
STI in Changshu as well as employees of AFG Asia Pacific,
Shanghai, and STI | Precision Machining (Changshu)Co.,
Ltd. The celebration started in true Chinese style with the
sounding of a gong at 10:08 hours. With that time of day –
number eight being a good luck number for the Chinese –
and the lion dance the omens were good for a successful
future. The STI | Hartchrom and AFG representatives were
pleased to have the support of Wang Xiang, General Secretary
of the Communist Party of China for Changshu, and other
prominent local politicians for the ground-breaking ceremony.
The cooperative relationship promises success for the future.
Surface Technology
STI | Precision Machining (Changshu)Co., Ltd. in figures
Site area: 4,300 m 2
Galvanising facility: 1,300 m 2
Grinding shop: 1,300 m 2
Research laboratory: 35 m 2
Logistics: 660 m 2
Stores: 250 m 2
Offices: 1,000 m 2
Start of construction: 28 June 2010
Scheduled completion: 1 st quarter of 2011
Start of production: 3 rd quarter of 2011
Cost of buildings and plant: about CHF 30 million
Reserved building land: 50,000 m 2
Knowledge and skills from different nations come together in
the newly formed STI | Precision Machining (Changshu)Co.,
Ltd. with the aim of jointly producing new peak performances.
Leading technology – for safety and ecology
In the first phase, the factory will comprise 4,300 m 2 of floor
space for a state-of-the-art galvanising facility and mechanical
production lines for processing perforated baskets and pistons
and the complete processing of cylinders. In addition, a research
laboratory will be integrated in the new building.
STI | Precision Machining will carry out all process steps on site –
from coating through to mechanical processing and quality
control. The company is leading in surface technology and
provides a complete service with maximum quality and flexibility.
All AFG and STI | Hartchrom subsidiaries apply top environmental
and safety standards as a matter of course.
STI | Hartchrom’s leading position in these areas was a prerequisite
for building the new facility in China where, today,
environmental regulations are enforced more strictly than in
Europe. For the Chinese authorities, this new surface technology
facility represents a milestone.
Guests and initiators at a glance (from the left): Ying Zhao, STI | Precision
Machining (Changshu)Co. Ltd., Managing Director for Construction;
Stefan Hasenzahl, Heidelberg Graphic Equipment (Shanghai) Co.
Ltd., General Manager; Stephan Tietze, Swiss Chinese Chamber of
Commerce, Vice President; Felix Aepli, AFG Asia Pacific, President and
CEO; William Frei, General Consul of Switzerland; Dr Edgar Oehler, AFG
Arbonia-Forster-Holding AG, Chairman of the Board of Directors and
CEO; Wang Xiang, Communist Party of China, Changshu, General
Secretary; Hui Jianlin, Changshu People’s Government, Mayor; Ge
Binggen, Changshu People’s Congress, Director; Zhu Lifan, Changshu
Standing Committee, Member; Chen Huiliang, Changshu People’s
Government, Deputy Mayor; Yin Liping, Changshu People’s Political
Consultative Conference, Vice President.
For the ground-breaking ceremony, the STI | Hartchrom and AFG
representatives were pleased to have the support of representatives
of the Changshu Government, the Swiss Embassy, the Swiss General
Consulate Shanghai, the Swiss Chamber of Commerce and other
prominent partners of the company from politics and business.
43
The future in Asia Pacific
For the printing and paper industry, mechanical and plant
engineering and the food and pharmaceutical industries
China is an important growth market. As a leading supplier
to these industries, STI | Hartchrom is following its customers.
With its new factory, the company responds to current market
developments, which are likely to continue into the future.
Production is scheduled to start in the third quarter of 2011.
It is intended to enter the market initially by supplying existing
European customers in the printing, paper and shipping
industries. Once the technology transfer has been completed,
other potential markets in China and neighbouring countries
will be explored. By the winter of 2011, the company expects
to have a workforce of about 100 employees. «

44 Surface Technology 45
STI | Hartchrom makes a significant contribution to lowering the life-cycle costs of ship engines.
Thermal spray coating
for the shipping industry
Thermal spray coating was first used by STI | Hartchrom for repairing piston rods for 2-stroke
diesel engines for ships. With this technology it was not only possible to reinstate the piston
rods to their original dimensions, but also to significantly improve their wear and dry-running
characteristics.
STI | Hartchrom was asked by a customer involved in the repair
of diesel engines to reinstate badly worn piston rods, the
diameter of which had reduced by up to 1.9 mm – a difficult
task. These piston rods are part of 2-stroke crosshead engines
and are responsible for transferring the force from the pistons
to the connection rods and hence are subject to heavy wear
through friction. Whereas today it is standard practice to
use hardened piston rods, this was not the case in the past,
a practice which had a negative effect on their service life.
As a consequence, there is a demand for repair methods that
can reinstate the original diameter of the rods and guarantee
a longer service life so that defective components don’t have
to be replaced completely.
Improving wear characteristics
Thanks to thermal spray coating it is possible to regenerate
heavily worn components. There is also a choice of different
spray materials so that the specific requirements of different
components can be taken into account. In this case the objective
was to reinstate the original dimensions and also to improve
the wear characteristics of the piston rods. The material
used was molybdenum; although this is not as hard as tungsten
carbide, it has outstanding gliding and dry-running character-
STI | Hartchrom has considerable experience in
repairing piston rods of marine engines. The picture
shows a piston rod in the grinding process.
istics. This dry-running characteristic is created by deliberately
spraying the layer porously so that it can take up lubrication
oil. Should it happen that the lubrication fails, this oil will
gradually be released again and thus prevent the components
from running dry. Tests have shown that, following this repair
method and after 45,000 hours in service, the piston rods did
not show any significant signs of wear. Another argument in
favour of STI | Hartchrom was the fact that the whole value
creation process can be carried out on the company’s premises.
This made it possible to offer consistent quality in all process
steps, short processing times and an attractive price structure.
The successful coating with molybdenum is only one example
of many possible thermal spray coating applications; in future
it is intended to use the technology not only in marine applications
but also in other fields. «
Interesting exchange
at the SMM in Hamburg
The 24 th SMM (Shipbuilding, Machinery & Marine Technology) exhibition
took place in Hamburg from 7 to 10 September 2010. The Swiss Embassy in
Berlin made use of this opportunity of the world-leading exhibition of the
shipbuilding industry to cultivate contacts. Envoy Dr. Urs Hammer, the Deputy
Ambassador, took his time at the STI | Hartchrom stand to have products, markets
and challenges explained to him in detail. An important subject was the cross-border
transit of goods, which has become a major success factor for STI | Hartchrom.
Most of the company’s customers are outside Switzerland and the correct formalities
for cross-border goods transport often present challenges for them as they lack
the necessary expertise. Therefore, fast and cost-efficient logistics, and competence
in handling cross-border goods transport are important factors in the competition
with other suppliers. Dr. Urs Hammer explained that the Swiss Federal Department
for Foreign Affairs and the State Secretariat for Economic Affairs, together with the
Swiss Representations abroad, provide a wide range of services which in recent
years has been more geared to small and medium-sized companies. He promised
to pass on STI | Hartchrom’s specific concerns to the State Secretariat for Economic
Affairs. «
STI | Hartchrom establishes
niche market in the USA
Coating geometrically complex and large components, such as extruder worms, to top
quality standards requires experience and expertise. Thanks to the development of a special
handling technology, STI | Hartchrom Inc. achieves quality levels that are unrivalled in the
American market.
In recent months, STI | Hartchrom Inc.
has invested in the development of a
finishing process for large conveyor
worms. These components are used in
extruders for producing packaging foils,
adhesives, moulded parts and various
compounds. Due to their complex geometry
and type of application, the
coating of these components requires a
high level of know-how from the coating
company. Discussions with a number
of manufacturers of these components
revealed that the coating layers, which
are sometimes of poor quality, can lead
to extensive downtime and costs. It was
found that one of the reasons for this is
the fact that coating tools are not optimally
adjusted. Because of the complex
geometry of the worms, it was not possible
to apply the chromium layer in an
With its purpose designed process,
STI | Hartchrom Inc. sets new standards
for chromium plating components with
complex geometries.
Dr. Urs Hammer, Envoy of the Swiss Embassy,
showed great interest in the concerns of
Swiss exhibitors at the exhibition. From the
left: Peter Burger, Chamber of Commerce
Germany/Switzerland, Zurich; Martin Mader,
STI | Hartchrom AG Steinach; Dr. Urs Hammer,
Swiss Embassy, Berlin.
even thickness using the standard processes
available on the market.
In some areas the coating was even
missing completely. For this reason,
STI | Hartchrom Inc., in close cooperation
with NFM Welding Engineers Inc.
and their end customer, DuPont, has
developed a coating process which
achieves quality levels that are clearly
a cut above. The first trial was a
full success which even exceeded
STI | Hartchrom’s expectations. NFM
also received positive feedback from
DuPont. As there is a known demand
for this process, STI | Hartchrom Inc.
is working on accessing this market
potential in the near future. «