tencate corporate magazine txtures autumn 2013

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2013 | number 3 | autumn PROTECTING PEOPLE: TENCATE ADVANCED COMPOSITES

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TenCate publishes every quarter the corporate magazine called txtures. This is the autumn 2013 issue.

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2013 | number 3 | autumn

PROTECTING PEOPLE: TENCATE ADVANCED COMPOSITES

TENCATE ADVANCED COMPOSITES: MARkETS DEVELOP POSITIVELySustainability / Environment

TenCate Advanced Composites develops and produces composite materials and systems worldwide. Based on submarkets and applications, TenCate Advanced Composites can be divided into aerospace composites, personal protection and vehicle armour, and industrial composites. TenCate is in the top three in the global aerospace market (number one in thermoplastics); it also ranks number one in both the satellite industry and in armour composites. These positions were secured through the knowledge it has acquired of composite technology, the quality and characteristics of its materials and its qualifications for aerospace programmes.

Space & Aerospace Composites and Industrial Composites The Space & Aerospace Composites and Industrial Composites business units generated 25% growth in revenues last year and well over 11% in the first half of 2013. This is the result of autonomous growth due to the increased production volume of the delivery programmes to Boeing and Airbus and to the acquisition of PMC Baycomp in 2012 and of Amber Composites at the beginning of 2013. These acquisitions have enabled TenCate to expand its presence in the European and North American market for both aerospace and automotive and tooling. These acquisitions are a product of the strategy.

txtures 3 - autumn 2013

txtures is the TenCate magazine for employees andexternal shareholders. It is published four times a year.In txtures 2013 the value proposition and the processof value creation occupy a central role.

In this 44-page summer edition of txtures you will find articles on TenCate Advanced Composites and on such subjects as: Composites: focus and outlook 2Composites and the value chain 7The business model of TenCate Advanced Composites 12Digital textile finishing a fact 18Breakthrough in synthetic turf for professional football 26The RED engine: light and sustainable 32Landscaping project in Riyadh 34Geosynthetics for infrastructure 36

Composites: focus and outlookThe market for composites continues to develop positively. TenCate Advanced

Composites aims at achieving further growth in the aerospace industry and in

personal and vehicle protection. Meanwhile major steps have been taken in the

automobile and other industrial markets. The strategy is also aimed at cooperation

with participants in the value chain. The outlook remains structurally positive both in

the short and long term.

Cover photo: Production of thermoset composites

in Morgan Hill (California USA)

2 txtures | number 3 | autumn 2013

3

At the end of December 2012 thermoplastic composite was qualified for a leading car manufacturer.

Advanced ArmourThere was a 4% decline in revenues in the TenCate armour portfolio in 2012 and the first half of 2013. In Europe, and in particular in the United States of America, a number of orders for vehicle projects were postponed or cancelled. One of the reasons for this was cutbacks in defence budgets. New protection requirements in the United States, however, led to an increase in sales in the first half of 2013. Activities in armour for the aviation industry (for example Eurocopter, Embraer and AgustaWestland) are also developing favourably. The site in Primarette (France) has largely been set up for this application. As a result of the expected strong growth in the Asia-Pacific region, a sales office was opened in Singapore and in the United Arab Emirates in 2012. TenCate aims to be able to offer armour technologies and local support to its customers around the world, as requirements and standards vary from country to country.

Focus on compositesThe focus of the TenCate buy & build-strategy is currently on composite activities. TenCate aims to achieve further growth in space & aerospace and in the armouring of vehicles and aircraft. In addition, major steps have been taken in the past couple of years in the automobile industry and other industrial applications, such as tooling and pipelines for oil and gas extraction. These markets offer good opportunities for growth and favourable prospects. Here too customers are making ever higher demands on safety, reliability and specific product characteristics. The oil and gas industry will not use any new techniques or materials if there is even the slightest risk of large-scale pollution. As a result of European legislation, the need is growing within the automobile industry for a reduction in carbon emissions. This has resulted in the desire for weight reduction, which explains the interest in composite. For TenCate these are positive developments. The company can deliver the highest added value here. TenCate has a strong and broad technology base in composites for these new markets.

Alliances In its endeavours to achieve greater cooperation with partners in the value chain TenCate has entered into alliances with BASF and Owens Corning for automotive composites and with 3M for tooling. The aim of the strategic alliance with BASF and Owens Corning is to offer car manufacturers customized solutions of thermoplastic composites for the mass production of vehicles. According to BASF the next great advance in automobile production will take place with ‘a great technological leap: the use of continuous fibre-reinforced thermoplastic laminates of injection-moulded structures’.

The cooperation with 3M is providing a boost to new applications for composites. As a result of the growing demand for composites, the demand for moulds is also increasing. TenCate seeks to make a difference in the surface quality and sustainability of moulds. For this reason patented matrix resin technology from 3M is employed. The 3M™ matrix resin is used for the manufacture of customized and, above all, stronger, lighter and more sustainable TenCate prepregs.

Continued on page 4

The facility in Fairfield (California, USA) for the production of thermoset and thermoplastic prepregs

4 txtures | number 3 | autumn 2013

TENCATE ADVANCED COMPOSITES: MARkETS DEVELOP POSITIVELySustainability / Environment

Positive outlookFor TenCate Advanced Composites the market outlook remains structurally positive in the longer term. There are a number of reasons for this.

Aircraft manufacturers attach increasing importance to weight saving. The percentage of composites in aircraft is rising: the Airbus A380 comprises 25% composites, while the A350 XWB has now more than 50%. This makes it possible for aircraft to make longer flights with less kerosine (see frame). TenCate Advanced Composites has long-term contracts with international commercial aircraft manufacturers. The outlook for the military aviation market and for satellite programmes remains positive. In China contacts have been made with research centres for the development of aerospace projects. TenCate supplies thermoset composites from the US to an aircraft manufacturer in China. Meanwhile in China thermoset tooling products are

supplied from the UK and thermoset materials from the US and Canada for sports-related applications, and thermoplastics from the Netherlands for industrial applications, such as air conditioning units.

In the automobile industry TenCate is seeing a growing interest in thermoplastic composites. In line with European legislation the average carbon emission of all new cars in 2015 may not exceed 130 grams per kilometre or 95 grams of CO2 per kilometre in 2020. A reduction of 50 kilos will save 5 grams of CO2. The use of composites can make a car 200 to 350 kilos lighter. The vehicle will then emit considerably less carbon, be more manoeuvrable and have a greater radius of action with less fuel. The focus of TenCate is on those parts of the vehicle with critical (safety) characteristics. Development and production will take place in programmes jointly with suppliers and OEMs. In the automobile industry the first orders have already been placed.

The need for a higher level of protection for the occupants of army vehicles is growing. The US Army has plans for the modernization of its vehicles. TenCate Advanced Armour will shortly supply antiballistic materials for 50 Air Transportable Tactical Vehicles for the Dutch Commando Corps. On the other hand, uncertainty about budgets and defence expenditure persists for the time being.

The market outlook has meanwhile led to a change in strategy and towards applications in other, non-military markets. These include the construction industry, medical applications and the computer, smart phone and tablet industry. TenCate Advanced Composites is developing materials for these together with major material brands. These are predominantly stable markets, which do not have a project-based character and for which the outlook is positive. The same applies to law enforcement and the extraction of minerals. TenCate Advanced Composites USA is producing carbon

Continued from page 3

5

fabric for Reebok for the soles of running shoes; here too the product is lighter and stronger.

The future of compositesIn the world of materials, composites are said to have great potential. In the world of composites, there is a bright future for thermoplastics. When it comes to aviation, thermoplastics will increasingly be used in systems and in secondary structures and then in primary ones. Together with its partners in the value chain TenCate seeks to develop new applications and geographic areas for these. The focus on lower emission standards in the automobile industry will lead to increasing acceptance of composites.

In the case of thermosets, growth will be found mainly in increasing production volumes. TenCate aims to position itself here with specific materials and a high level of customer service compared with the largest players.

• TenCatestrivestoachievefurthergrowthin aerospace, in the armouring of vehicles and aircraft and in industrial applications such as automotive

• Theobjectiveofalliancesandcooperation is to offer solutions for the mass production of vehicles and to give a boost to new applications for composites

• Theoutlookremainsstructurallypositiveas a result of increasing interest in weight saving, a reduction in carbon emissions and a higher level of protection

www.tencateadvancedcomposites.comadvancedcomposites.europe@tencate.com [email protected]@tencate.com

An aircraft uses on average 0.03 kilograms of fuel per hour for every kilogram of weight on board. All commercial aircraft around the world fly approximately 57 million hours a year. A reduction of one kilo in weight per flight means approximately 1,700 tons less fuel and 5,400 fewer tons of carbon emissions a year.

In 2012 TenCate supplied composites for trolleys to Driessen. A standard inflight service trolley weighs approximately 19.2 kilograms. If the frame of the trolley is made of special aluminium and the doors and side walls of lightweight TenCate Cetex® thermoplastic composite, the weight of the trolley is only 16.3 kilograms (-15%). For an Airbus A380 with 550 seats and an average of 86 trolleys on board this means a weight reduction of at least 250 kilograms. What is even more important is that it will save 425,000 tons of fuel and 1,350,000 tons of carbon a year…

1 kg

See further on page 7

At the beginning of 2012 TenCate Advanced

Composites supplied composites for the solar

shield of NASA’s James Webb space

telescope, the world’s largest astrophysical

observatory. TenCate Advanced Composites

also supplies composites to Space

Exploration Technologies Corp. (Spacex)

for applications in space vehicles and

spaceships. This company develops a

range of products, including rocket

launching systems and rocket engines.

(Photo: NASA)

6 txtures | number 3 | autumn 2013

Sustainability / Environment

TENCATE ADVANCED COMPOSITES INCREASE AEROSPACE AND AuTOMOTIVE SuSTAINABILITy

Production of fuselage components for the Airbus A350XWB, with thousands of thermoplastic clips, made of composite from TenCate Advanced Composites

(photo: Hervé Gousse)

7

With its product portfolio TenCate Advanced Composites focuses on personal protection, defence and mobility. These three market themes are derived from the global trends of safety and sustainability. In this edition of txtures we focus on applications for aerospace (Space & Aerospace Composites) and on the industrial applications of composites (Industrial Composites).

The composites marketThe main segments in the global composites market are the construction industry, transport, electronics, aviation, the oil and gas sector, wind energy and sport. The illustration on page 10 shows the size of these segments. The largest part of this overall market consists of thermoset materials. In terms of volume, however, the potential for thermoplastic composites is much greater. Thermoset

currently dominates the space industry and military aviation sector. The same applies to aviation, but here thermoplastics are gaining ground. A large amount of thermoset is used in the automotive sector, particularly in the racing industry. Thermoplastics, by contrast, are much better suited to volume production with short cycle times. In the oil and gas extraction sector it is mainly thermoplastics that are used.

Value propositionIt is the drivers in these markets that in part determine the value proposition of TenCate Advanced Composites’ materials and systems: lower carbon emissions, weight reduction, corrosion resistance, limited material fatigue, savings on design and system costs and lower life cycle costs. Carbon fibre-reinforced composites are approximately 50% lighter than steel, some 30% lighter than aluminium

Composites and the value chainAll around the world safety and protection are gaining in importance. There is a

need for protection solutions that are both effective and sustainable, to further

limit the risks to which we are exposed, whether at work, when travelling or in

our leisure time. This requires strong, light materials with a long service life, such

as composites. The value proposition of TenCate Advanced Composites is

determined by its broad technological base and product portfolio, its global

presence and material characteristics.

Continued on page 8

and stronger than either of these materials. Moreover, the use of composites increases the safety and comfort of passengers and provides lower maintenance costs.

Automation of processesPopulation growth, new infrastructure projects, stricter requirements imposed on protection and safety, and an increase in the sustainability

of materials and processes are all positive developments for composites. This applies particularly in countries such as Brazil, Russia, India and China. In order to produce more composites and make them more competitive, it is crucial for the industry to innovate and automate. Automation helps to accelerate production processes and make them cheaper; it also guarantees the reproducibility

and quality of parts and reduces costs. Thermoplastics are suitable for automated volume production, such as that usually found in the automotive industry. They can also be recycled.

The aviation industry too faces the challenge of producing greater numbers of aircraft of the same quality and producing at lower cost

8 txtures | number 3 | autumn 2013

Sustainability / Environment

Continued from page 7

The acquisition of Amber Composites will enable TenCate to step up activities in Europe concerning thermoset composite material

TENCATE ADVANCED COMPOSITES INCREASE AEROSPACE AND AuTOMOTIVE SuSTAINABILITy

9

lighter parts for aircraft that will fly faster. The fuselages of for example the Boeing 787 (tape winding) and the Airbus A350XWB (tape placement) have been made in a fully automated process, in which fibre-reinforced plastic thermoset tape is placed on a mould using laser light. If this is done on a cylinder, then we talk of tape winding. If the tape is placed in hollow moulds, then we speak of tape placement. If thermoplastic composite is used, then impregnating fibres and curing are no longer necessary.Smaller fuselage parts may sometimes still be put in place manually. For cars, which have a more irregular shape, the development is to be found in robotized, 24/7 tape placement and injection moulding and in overmoulding (injection moulding two materials together).

Material, process and designTenCate Advanced Composites has a balanced technological base: thermoset prepregs and thermoplastic laminates, moulding components and unidirectional (UD) tape placement. In the case of moulding, UD tape is chopped into pieces to form ‘chips’ and is then completely melted. This gives great freedom of shaping, enabling more complex shapes to be produced.The basis for development and production is the triangle of material, process and design. The aspect material includes the mechanical and physical characteristics, purchasing price, and storage and quality costs. Under Design come thickness, fibre direction, part count, assembly and structural layout. Process includes such aspects as shaping under pressure, autoclave, welding, cycle time, energy consumption and process control. It is in particular the connection between these aspects in which TenCate Advanced Composites stands out from the competition.

The supply chain plays a major role in this. The basic materials are carbon, glass and aramid fibre and the resin systems PPS (polyphenylene

sulphide), PEI (polyetherimide), PEEK (polyether ether ketone). The combination of carbon fabric and PPS is used mainly in aircraft structures, pylons, tail-planes and doors. The combination of glass fabric and PEI is found primarily in aircraft interiors. These two combinations are the ‘workhorses’ of TenCate Advanced Composites. Carbon fabric with PEI is used for the air inlet of the engines of the A350 XWB and A380 and the floor panels of the Gulfstream, which form an integral part of the pressure cabin.

TenCate Advanced Composites supplies laminates in the right thicknesses and with the desired characteristics. A part of the added value lies in the application of functionalities to the material. Examples include a metal, fine-mesh layer that does not allow electromagnetic radiation to pass through and conducts lightning, an antislip coating or a corrosion-resistant layer for floor components.

Cooperation in the chainTenCate aims to achieve good cooperation with participants in the entire value chain. There are two reasons for this: reliability of delivery and the clustering of knowledge and expertise.

Reliability of delivery of the entire chain is essential, also in terms of quality. Armour orders are often project driven. In the aircraft and aerospace industry safety and reliability are paramount. As composites supplier, TenCate has close relationships with participants in the chain: suppliers of raw materials, the processing industry and end-customers. TenCate purchases its raw materials from the producers of resins, fibres, ceramics, ballistic metal and polymers. Long-term contracts have been concluded with a number of fibre producers. It is scarcely an option to change suppliers in the interim for price reasons, since this would involve going through qualification processes all over again.

In June 2013 TenCate signed a long-term agreement for the supply of continuous fibre-reinforced thermoplastic laminates and semipreg composites to Fokker Aerostructures. These materials will be used for the production of parts for the commercial, regional and military aircraft of aircraft manufacturers such as Airbus, Boeing, Gulfstream, Dassault and AgustaWestland.

The processing industry comprises tier 1 partners (suppliers of systems to OEMs) and tier 2 and 3 (suppliers of parts and components). TenCate Advanced Composites is one of the tier 2 and tier 3 companies. Customers in the aviation industry include OEMs such as Airbus, Boeing, Embraer and Dassault.

PlayersThere are many players in the composites industry, all of whom have specific expertise and technologies. By making acquisitions, alliances or innovation centres, they can jointly strengthen and make applicable the know-how that is already present. The Netherlands has a good position and reputation in the aviation industry and by continuing to invest in knowledge, technology and networks the industry is able to expand its role as innovator. Aircraft manufacturers like to see that a supplier is also a development partner. Open and closed open innovation is taking place with partners, customers and research institutes in for example TAPAS (Airbus), TPRC (Boeing) and eTAC (automotive). Airbus and Boeing are the innovators in the aviation industry; other aircraft manufacturers adopt these innovations where possible.

See further on page 12

10 txtures | number 3 | autumn 2013

Defense

Mobility

Defense

Mobility

98%

2%

32%

68%

25%

7%

68%

98%

2%

32%

68%

25%

7%

68%

AMERICAS

445

Revenues geographically

Revenues by client-group

The major part of the worldwide composites market consists of thermoset materials. The volume potential for thermoplastic composites, however, is much greater. In the United States of America and in Europe TenCate manufactures both thermoset and thermoplastic com-posites.

Composites Market in 2012The market volume of the global composites industry in 2012 was 8,700 metric tonnes, with a value of €77 billion. The reason for the relatively high value of the EU (34%) is the high level of technology involved. Asia is particularly focused on low-grade composite materials in large volumes.

The world of composites

TenCate Advanced Composites

ranks among the top three

composite producers in the

global aerospace market (number

one in thermoplastics) and is

number one in both the satellite

industry and the armour market.

826

TenCate employees

EMEA

Global composites materials shipments by market segment ($ million)

Space & Aerospace Composites and Industrial Composites

Transportation

Marine

Wind energy

Aerospace

Pipe & tank

Construction

Electrical & electronics

Consumer goods

Others

APAC

71310

€ 77billion

2011 $ 19,6502017 $ 29,928

8.7million metric tons

550,00043%

31%34%35%

23%34% 23

27 billionValu

eVo

lum

eM

arke

t26 billion 24 billion

3.7

2,804

2,398

2,318

2,642

3,366

3,689

1,322

591

521

4,284

4,056

4,432

3,631

4,775

4,956

2,145

798

851

million metric tons

million metric tons

million metric tons

Sustainability / Environment

TENCATE ADVANCED COMPOSITES INCREASE AEROSPACE AND AuTOMOTIVE SuSTAINABILITy

11

Defense

Mobility

Defense

Mobility

98%

2%

32%

68%

25%

7%

68%

98%

2%

32%

68%

25%

7%

68%

AMERICAS

445

Revenues geographically

Revenues by client-group

The major part of the worldwide composites market consists of thermoset materials. The volume potential for thermoplastic composites, however, is much greater. In the United States of America and in Europe TenCate manufactures both thermoset and thermoplastic com-posites.

Composites Market in 2012The market volume of the global composites industry in 2012 was 8,700 metric tonnes, with a value of €77 billion. The reason for the relatively high value of the EU (34%) is the high level of technology involved. Asia is particularly focused on low-grade composite materials in large volumes.

The world of composites

TenCate Advanced Composites

ranks among the top three

composite producers in the

global aerospace market (number

one in thermoplastics) and is

number one in both the satellite

industry and the armour market.

826

TenCate employees

EMEA

Global composites materials shipments by market segment ($ million)

Space & Aerospace Composites and Industrial Composites

Transportation

Marine

Wind energy

Aerospace

Pipe & tank

Construction

Electrical & electronics

Consumer goods

Others

APAC

71310

€ 77billion

2011 $ 19,6502017 $ 29,928

8.7million metric tons

550,00043%

31%34%35%

23%34% 23

27 billionValu

eVo

lum

eM

arke

t

26 billion 24 billion

3.7

2,804

2,398

2,318

2,642

3,366

3,689

1,322

591

521

4,284

4,056

4,432

3,631

4,775

4,956

2,145

798

851

million metric tons

million metric tons

million metric tons

12 txtures | number 3 | autumn 2013

Composites: business model The TenCate Advanced Composites business model determines how the market group operates in the value chain

and how it adds value to customer-focused system solutions. The business model of the TenCate material

technology group forms the basis for this, with its four cornerstones of end-user marketing, technological

innovation, product differentiation and cost leadership.

Friday, 14 June 2013: Hundreds of people witness the start of the maiden flight of the

Airbus A350 XWB in Toulouse (photo Airbus S.A.S. / A. Doumenjou)

Sustainability / Environment

TENCATE ADVANCED COMPOSITES INCREASE AEROSPACE AND AuTOMOTIVE SuSTAINABILITy

13 13

End-user marketing TenCate Advanced Composites brings its technological knowledge and the characteristics and sustainability of composites specifically to end-user marketing within its networks. The OEMs, which determine the specifications, are also included in these. This is where the materials are qualified. TenCate Advanced Composites can also pride itself on its reputation and qualifications among renowned

market players. New mobility concepts in the automobile industry require thermoplastic composite solutions for full-scale production.

Technological innovationTenCate sets the standard in thermoplastic composites. Innovation results in a strengthen-ing of the leading technological position, affordable technologies and the development of more sustainable materials. The percentage of

thermoplastic composites in aircraft is continuing to grow. Process innovations are focused on the processing of composites, in particular thermoplastics. Customers attach a great deal of importance to the innovative capacity of suppliers and TenCate, together with partners in the value chain, can offer them a range of innovations.

Continued on page 14

14 txtures | number 3 | autumn 2013

Continued from page 13

TenCate Advanced Composites makes tailor-made, customer-specific thermoset and thermoplastic composite materials

Sustainability / Environment

TENCATE ADVANCED COMPOSITES INCREASE AEROSPACE AND AuTOMOTIVE SuSTAINABILITy

15

TenCate Advanced Composites supports student teams both in the Netherlands and the US with mobility concepts such as solar cars. Most of these teams take part in international competitions, like the World Solar Challenge (see page 32). In this way technical students become familiar with the characteristics and the use of composite materials, thus creating a new generation of engineers with innovation strengths.

TAPASOpen and closed open innovation is taking place with partners, customers and research institutes in for example TAPAS (Airbus), TPRC (Boeing) and eTAC (automotive).

The Thermoplastic Affordable Primary Aircraft Structure (TAPAS) consortium consists of eight Dutch companies and institutes from the aviation industry who are cooperating with Airbus on the development of thermoplastic composites to increase the construction possibilities for the aircraft designs of Airbus. Affordable relates to the material and the processing; primary refers to primary aircraft structures, such as wing and fuselage parts. The Ministry of Economic Affairs has offered support for this. The recent biennial Paris Air Show saw the introduction of an innovative fuselage panel for Airbus, which was made of thermoplastic composite from TenCate Advanced Composites (see page 38).

TPRCWhile Airbus works with national centres, Boeing has set up international centres of expertise that are engaged in various parts of the development and production process. Examples include the ThermoPlastic composite Research Center (TPRC) near the University of Twente (the Netherlands) and the Advanced Manufacturing Research Centre (AMRC) of the University of Sheffield, UK.

Continued on page 16

16 txtures | number 3 | autumn 2013

The industry is searching for innovations that can be rapidly introduced into the production process. TPRC in the Netherlands is working on accelerating the development of thermoplastic composites. The technology of these composites delivers cost-efficient production and assembly processes for a wide range of applications. TPRC recently began successfully using a tape placement machine, a method of production which may become the standard in the processing of thermoplastic composites. The AMRC is a knowledge centre for machining and material research for the aviation industry and other high-calibre production sectors.

OICAM and AMMONTenCate is also involved in OICAM and AMMON as initiator and partner. The Open Innovation Center Advanced Materials (OICAM) is a network of companies and knowledge institutes that focuses on the sharing of knowledge, research and development relating to composites and other high-grade materials and material technology. Advanced Materials Manufacturing Oost (east) Netherlands (AMMON) is a business development and innovation programme in advanced materials, including composites.

Product differentiation TenCate supplies tailor-made products, which are geared to the needs of its customer groups. In the context of its system approach TenCate Advanced Composites is cooperating with other participants in the value chain to achieve the optimum configuration for protection. Co-creation ensures a rapid market launch time, provides control of the value chain and safeguards high quality. TenCate has the broadest product portfolio in the aviation market. Part of product differentiation is the development of new areas of application (both geographically and in terms of end- market) for thermoplastic composites in particular. TenCate also focuses on develop-ments in the field of unidirectional (UD) tape technology and on automotive applications for thermoplastic composites.

Cost leadershipTenCate Advanced Composites is the only producer to have facilities for the volume production of thermoplastic composites. As a major supplier to the aviation industry, TenCate knows what it is to produce the highest quality with the smallest possible tolerance.

An increase in production efficiency will be achieved through process improvements. The growth in the size of the market group is resulting in ever more economies of scale (purchasing power raw materials). The streamlining of production also contributes to cost leadership.

Sustainability and recyclingThe European Union is working on regulations for the reprocessing of aircraft, in line with those for cars. The EU has laid down that in 2015 85% of a car must be recyclable after use and 95%, recoverable. The aviation industry itself is cooperating with the waste-processing industry in making the reprocessing of aircraft more efficient and cost effective. Unlike thermoset, thermoplastic composite is recyclable.By smart designing and production and through the increasing use of basic materials that can be reprocessed, valuable waste substances can be given a new life.

www.tencateadvancedcomposites.comadvancedcomposites.europe@[email protected]

Continued from page 15

The production of composites for automotive is one of the new activities that should contribute to the future growth of TenCate.

Sustainability / Environment

TENCATE ADVANCED COMPOSITES INCREASE AEROSPACE AND AuTOMOTIVE SuSTAINABILITy

17

What are advanced composites?

The Advanced Textiles & Composites sector concentrates on impregnation and coating technologies for applying or processing

functional characteristics in and on textile materials. In the main this involves protective fabrics and (advanced) composites: prepregs,

laminates and unidirectional (uD) tape. Thirty years ago TenCate was at the basis of the development of thermoplastic composite; now

the company manufactures both thermoset and thermoplastic composites in Europe and the united States of America.

A composite is a homogenous combination of two or more materials, for example on the basis of carbon, glass or aramid fabrics. These fibre-reinforced synthetics are produced by mixing or impregnating the fibres with synthetic resin, which serves as a bonding agent. The combination is stronger than the materials themselves and offers numerous possibilities in terms of fibres, shape and characteristics.

Advanced composites are fibre-reinforced composites in a polymer matrix. They combine extreme toughness and stiffness with low weight and can be processed relatively easily into complex shapes. They require far less maintenance than traditional materials; have good impact and flame-retardant characteristics; are highly resistant to acids, fuels, chemicals and water; can endure innumerable cyclic loads; and are thermally insulating.

Thermoplastic composite (for example TenCate Cetex®) consists of two elements: a thermoplastic matrix and fibres. The matrix melts on heating and can then be shaped into the desired form. Low production costs, rapid processing time and extreme toughness are characteristics of thermoplastics. In principle thermoplastics are recyclable. The use of thermoplastics makes aircraft lighter, safer, stronger, more economical and more cost-efficient, and reduces noise.

Thermoset composite (for example TenCate Thermo-Lite®) remains hard and decomposes when heated. Thermoset is primarily applied in the space industry and the military aviation sector. Thermoset must be turned into scrap or burnt.

A prepreg is a fibre layer (fabric or UD tape) of thermoplastic or thermoset that is impregnated with a resin and pressed into panels. Prepregs are used for shaping layered composite materials (laminates) and applied for example in satellite antennas.

A semipreg is a fabric layer that is impregnated on the outside only.

Unidirectional (UD) tape materials of thermoplastic or thermoset. UD technology is complementary to that underlying TenCate Cetex® and has the same brand name. UD tape technology is more suitable for large parts, for example those for the fuselage and wings of aircraft.

Unidirectional tape

Carbon fabric

Reinforced thermoplastic laminate (fibreglass fabric impregnated with PEI)

18 txtures | number 3 | autumn 2013

Digital finishing on the basis of inkjet technology is a new process technology that applies high-grade functionalities (characteristics) to textile surfaces using picolitre drops (10-12) and the drop-on-demand method. This means that coatings and finishes can be applied to technical textile with the utmost precision. This development heralds a revolution in the field of process technology.

Advantages for technical textile The industrial application of this inkjet technology offers the technical textile industry many advantages. A wide variety of patterns and characteristics can be applied to different kinds of fabric at great speed. In comparison with existing technologies, it offers complete design freedom at relatively low cost. New functionalities can be quickly introduced during the production process and finishing materials are accurately deposited in measured qualities.

All in all the technology results in higher quality, reduced production costs and new opportunities for marketing and sales. The technology therefore enables TenCate to offer on-demand delivery and mass customization on the basis of a flexible, sustainable and cost-efficient production process.

SavingsDigital inkjet technology also means (depending on the application) savings in the use of energy (up to 60%), water (up to

Digital inkjet technology

TENCATE INTRODuCES FIRST DIGITAL INkjET MAChINE

Digital textile finishing

a factMonday 1 july, the day had arrived: the official introduction of the first machine on the basis

of digital inkjet technology. Theo Rietkerk, member of the Provincial Executive of Overijssel

for Economy, Energy and Innovation, activated the machine at TenCate Protective & Outdoor

Fabrics in Nijverdal. The introduction of this machine marks the transition from analogue to

digital finishing of technical textile.

19

80%) and dyes and pigments (up to 90%). This was partly the reason behind European and regional support for this important development. It was possible to build the machine thanks to support from the European Union, the European Technology Platform for the Future of Textiles and Clothing, the province of Overijssel, the University of Twente and the region of Twente. Mass customization means that substantial logistical savings can be made in the value chain, so both by TenCate and the distributors.

The new machine is the first in a series. By 2015 TenCate Protective & Outdoor Fabrics is expected to have a number of such machines, always with new or improved techniques. Before long the first machine will be producing between 200 and 300 square metres of (technical) textile an hour, using inks developed by Xennia Technology especially for outdoor fabrics.

• Digitalinkjettechnologyincreasesproductivity and applies numerous customer-specific characteristics at great speed

• Thetechnologyofferssubstantialsavings in the use of energy, water and materials

• On-demand delivery and mass customization are possible on the basis of a flexible and cost-efficient production process

The invited guests crowded round to see the first digital inkjet machine in operation

20 txtures | number 3 | autumn 2013

‘In our view groundbreaking technological innovation alone is the all-dominant driving force behind new business,’ says President and CEO Loek de Vries. ‘It generates unprecedented opportunities so that the constantly changing demands of the end- user can continue to be met both now and in the future.’

AchievementsAccording to Loek de Vries, the transition to industrial production, although small-scale at present, brings various advantages. ‘The achievements of this technology are rapid market-driven response, increased design freedom, new and improved characteristics,

TENCATE INTRODuCES DIGITAL INkjET TEChNOLOGyTechnological innovation

Groundbreaking innovationWhen it comes to the machine of TenCate Protective & Outdoor Fabrics for

finishing outdoor fabrics on the basis of digital inkjet technology, it’s a case of

technological innovation not product innovation. Technological innovation is one

of the cornerstones of the TenCate business model. ‘The keyword is connect.’

The inkjet machine before the official opening

21

greater flexibility, small volumes, low stocks and cost efficiency. Above all it makes a positive contribution to the environment.’

Connect‘In this new phase of industrial production, innovation offers opportunities between companies, inside and outside existing value chains. The keyword is connect. In this way you can discover techniques and technologies jointly and then innovate independently. Digital finishing of outdoor fabric is the promising first step towards new characteristics in innovative products that meet changing customer wishes where our materials can make the difference.’

Pearl of the manufacturing industryAccording to Theo Rietkerk, member of the Provincial Executive of Overijssel for Economy, Energy and Innovation, TenCate has worked its way up to become one of the pearls of the Dutch manufacturing industry. ‘Economic growth depends on companies such as TenCate. Growth depends on new products and product combinations − and that while reducing the burden on the plant.’He also went on to say that the result – the first machine – was a good example of cooperation. ‘Economy knows no boundaries. In the East Netherlands there is still much to be gained by cooperation and I am grateful to Loek de Vries for adopting the role of pioneer.’

• Groundbreakingtechnologicalinnovation is the driving force behind new activities

• Digitalfinishingofoutdoorfabricisthefirst step towards new characteristics of innovative products

• Digitalinkjetmachineisresultofresearch, open and closed innovation, and the further development of a demonstration model

22 txtures | number 3 | autumn 2013

Interim results 2013

TENCATE PuBLIShES RESuLTS FOR FIRST SIX MONThS OF FINANCIAL yEAR

TenCate to aim at growth in new markets and system solutions

Worldwide, government expenditure,

which plays an important role for TenCate,

in particular defence expenditure,

remained under pressure. The Geosynthe-

tics & Grass sector was also affected by

adverse weather, which was the cause of

delays in projects. The number of orders

recorded at the Geosynthetics & Grass

sector, however, once again showed an

upward trend during the first half of 2013.

Revenues for the first six months declined

by 5% to €514 million, while net profit

showed a decrease of 7% to €13 million.

Loek de Vries,

President and CEO

23

‘TenCate seeks to reduce its dependence on government spending by means of product development and by making its commercial organization stronger and at the same time strengthening the geographic market development outside the United States and Europe.The global markets in which TenCate operates will continue to grow in the long term as a result of more stringent requirements in respect of personal protection, sustainability, environmental protection and water management. TenCate is organizing its commercial activities increasingly around these themes and intends to further strengthen the organization in this field.

Market development of the TenCate Defender™ M portfolio outside the United States is going according to plan. Revenue volumes at present continue to be limited, compared with the historical revenues generated in the American market. There are currently several dozen wearing tests being conducted.’

Introduction‘Major growth (20%) was achieved in the industrial market for protective fabrics. The successful introduction of industrial protective fabrics in new end-markets is a good example of the increasing importance of the private sector within the overall TenCate product portfolio.

A new market for TenCate is law enforcement: police and security services too need increasing personal ballistic protection. The slogan ‘Protecting People’ will as a result be expanded through the development of new products.’

Growth areas‘In the first half of the year revenues in the American market for aerospace composites and revenues for industrial protective fabrics have presented a positive profile. Activities in the field

of composites represent one of the group’s main growth areas. Driven by European legislation, which has the objective of substantially reducing carbon emissions for the automobile industry, TenCate sees great interest in thermoplastic composite technology. In view of qualifications in the aviation sector and the great interest displayed by the automobile industry, revenues from composites are expected to generate above-average growth in the future. TenCate has previously made it known that it gives high priority to this development.

In the light of the above-mentioned trends relating to environmental protection and water management, the commercial organization for TenCate Geotube® systems was strengthened. Over the first six months there was an increase in revenues of approximately 20% in this area.’

Strategic developments‘Technological innovation is one of the cornerstones of the TenCate business model. In the field of digitization of production processes progress was made with the commissioning of the first digital inkjet machine for the finishing of protective and outdoor fabrics. It was possible to build the machine in part thanks to European and regional support. Digital finishing based on inkjet technology is a new process technology for applying high-grade characteristics to textile surfaces. The commissioning of the digital inkjet machine marks the transition from analogue to digital finishing of technical textiles. The machine will initially be used for applications in the outdoor market.’

Breakthrough‘TenCate has increasingly positioned itself with high-grade synthetic turf systems. The granting of the tender by the Coöperatie Eerste Divisie [Cooperation First Division] (Jupiler League) to TenCate Grass / GreenFields means that the breakthrough for synthetic turf in professional

football has been achieved. The Netherlands is a leader with this development, having the largest number of synthetic turf pitches in professional football.

Other examples of the system approach include the TenCate ABDS™ active blast countermeasure system and the TenCate Geotube® system. Currently the developments relating to the TenCate ABDS™ active blast countermeasure system are in the official qualifying phase of US government agencies. The system is complementary to the vehicle armouring offered by TenCate and increases the overall survivability of the entire vehicle.TenCate Geosynthetics has developed various TenCate Geotube® systems to offer total solutions for water management and environmental projects in cooperation with engineering firms.’

Developments in 2013 as a whole‘As a result of continuous pressure on government expenditure, market conditions are expected to remain challenging for the whole year. Increased order positions, however, inspire a measure of confidence.

The substantial shortfall in revenues that TenCate has experienced due to delays has not been lost. This is also the conclusion when we look at the recovery in revenues within the Geosynthetics & Grass sector during the first half of the year. In the synthetic turf market TenCate’s business partners have reported a well-filled order portfolio. A large number of projects still need to be completed during the summer.The same applies to the market for aerospace composites. Here too there were delays, and revenues have not yet reached the level anticipated. Higher revenues are expected for the second half of the year. In the long term the outlook for this market remains unchanged.’

24 txtures | number 3 | autumn 2013

Sustainability / Environment

TENCATE GEOSyNThETICS FOR MOuNTAIN WALL IN NORThERN ITALy

A solid slopeGeogrid and drainage composite from TenCate Geosynthetics form the basis for a new slope which carries a dual

carriageway in northern Italy: a solution with minimal impact on the environment.

Oggiogno is a small village in the hills above Lago Maggiore, fifteen kilometres to the south of the Italian-Swiss border. The provincial road that links this village to other towns and villages was destroyed in 2012 after a period of very heavy rainfall. In order to preserve this beautiful, green environment as far as

possible, standard solutions with concrete walls were considered unacceptable. For this reason the decision was taken to construct a safe slope reinforced with geosynthetics. Construction work began in February 2013 and, despite the abysmal spring weather, the slope was completed by the end of June.

Following this, the building contractor was able to start building a new dual carriageway on top of the slope.

The new mountain wall is 13.6 metres high and has an angle of inclination of 65° and a surface area of 1,300 m2. TenCate Miragrid® GX was

The slope after the landslide

(left) and after restoration

25

the material chosen for reinforcement of the slope. To ensure rapid drainage of rainwater, the drainage composite TenCate Polyfelt® Megadrain was installed behind the slope, since lack of good drainage was part of the cause of the landslide last year.The chosen solution had an added advantage:

no large quantities of building materials or construction machinery had to be brought in from elsewhere. In this way, despite the small and difficult area of operations, it was possible to continue working full steam ahead. As regards transport, the carbon footprint produced was modest.

The provincial road will shortly be reopened to traffic. The slope has been stabilized and seeded and will soon be entirely covered in greenery as before.

The slope of the provincial highway at Oggiogno

(Italy) reinforced with geosynthetics

The slope after the landslide

(left) and after restoration

26 txtures | number 3 | autumn 2013

TENCATE GRASS PROVIDES SEVERAL CLuBS IN juPILER LEAGuE WITh SyNThETIC TuRFSustainability / Environment

Breakthrough in synthetic turf for professional football

TenCate President and CEO Loek de Vries (right) and Ton Raaphorst, director TenCate Grass EMEA, signing the contract

PRODuCT – GreenFields® MX MARkET – top and recreational sport TEChNOLOGy –paten-ted weaving technology PROCESS –built in situ by the installer

PRODuCT – GreenFields® Evolution™ MARkET – top and recreational sport TEChNOLOGy – extrusion and finishing PROCESS – tufted in backing and installed in situ

27

In the next football season seven of the twenty clubs in the Dutch first division will have

synthetic turf with fibres from TenCate. The installation of an increasing number of

synthetic turf systems is the next big step in the reform of the jupiler League. The

collaboration between the Coöperatie Eerste Divisie and Royal Ten Cate was confirmed

in Zeist (NL) on Tuesday, 2 july.

FC Dordrecht, Almere City FC, SBV Excelsior and FC Volendam train and play on synthetic turf systems with GreenFields® Evolution™ fibres. Helmond Sport and FC Den Bosch train and play on synthetic turf systems from GreenFields with TenCate fibres, while FC Oss trains and plays on a synthetic turf system from Edel Grass with TenCate fibres.

The initiative for the installation of synthetic turf football pitches in the stadiums of these first division clubs was taken by the Cooperatie Eerste Divisie (CED) [Cooperation First Division], in close cooperation with the consultancy agency Hypercube and the engineering firm of KYBYS. The CED promotes the interests of the clubs in the Jupiler League and supports them in the further professionalization of this league.

Two synthetic turf systemsFor the participating clubs there is a choice of two synthetic turf systems at TenCate: GreenFields® Evolution™ based on XQ™ technology (tufted) or GreenFields® MX (woven and fully recyclable). Both systems satisfy FIFA

Two-Star standards. TenCate is offering the professional clubs the pitches through its subsidiary GreenFields, which together with selected partners sees to the installation of the pitches. In the case of the tried and tested GreenFields® Evolution™ pitch, the yarns are tufted into the backing. The GreenFields® MX synthetic turf system is based on a weaving technology patented by TenCate. This enables for example the synthetic turf blades to remain permanently upright. GreenFields® MX is the first official synthetic turf pitch in which a number of new developments have been combined. Players can now effortlessly twist and turn, speed up or make sliding tackles. The matrix weaving pattern also has a positive effect on the rotational resistance of the players’ feet. And particularly important is the fact that at the end of its service life this synthetic turf pitch is fully recyclable.

www.tencategrass.comgrass.europe@[email protected]

28 txtures | number 3 | autumn 2013

Synthetic turf is making steady progress in Dutch professional football.

Next season and the following one yet more clubs will have a synthetic turf

system from TenCate Grass.

‘Many clubs have embraced

synthetic turf’

Sustainability / Environment

TENCATE GRASS OFFERS SuSTAINABLE SyNThETIC TuRF SySTEMS

In the 2013–2014 football season once again more premier league and first division clubs will play on synthetic turf. Most of them have opted for a synthetic turf system from TenCate Grass and GreenFields. The installation of these systems is the result of the tender granted to TenCate Grass by the Coöperatie Eerste Divisie (CED) [Cooperation First Division]. This is initially for six pitches, including Helmond Sport and FC Dordrecht.

Pitch, price and conditionsThe CED made their decision on the basis of an assessment model, which considered such factors as pitch, price and conditions, and proposals for a partnership and joint venture marketing. Ton Raaphorst, director, TenCate Grass EMEA, was closely involved in the tender. ‘We offered the highest quality synthetic turf pitch, with as favourable conditions as possible.

Other factors involved were experience at the top level in the installation of synthetic turf, how TenCate handles sustainability in its strategy and how this translates into advanced synthetic turf systems. In our offer are two pitches: GreenFields® Evolution™ XQ™ and GreenFields® MX. We have made it attractive for clubs to opt for the woven GreenFields® MX, which is the best pitch with the best possibilities for combining different fibres. It is also fully recyclable.’

Service packageThe winning offer from TenCate Grass included the possibility of a 24/7 service package offered by GreenFields, the service provider. ‘We install the sub-base and the synthetic turf surface, we see to both minor and major maintenance and we clear the pitch of snow before the start of a league game. The clubs pay

off the loan with a fixed amount each month and pay monthly for the use of the pitch.’

Official partnerAnother part of the agreement is a partnership with the CED for an initial period of five years. The implementation of this partnership also scored a success. TenCate and GreenFields can now use statements made by the Jupiler League in their own communications. There is cooperation with clubs at local level.

‘The media exposure that we get has a positive effect on the Jupiler League and from there on the Premier League.’ Ton Raaphorst believes that this will provide an incentive for the further acceptance and purchase of synthetic turf pitches. ‘The same applies to top-class Saturday and Sunday amateurs and other amateur clubs, of which there are about 3,500 in the Netherlands.’

29

In recent years GreenFields has had about sixty pitches installed annually in the Netherlands. The installation, based on TenCate Grass components, is provided by C.S.C. Ceelen Sport Constructies. There are already some 1,500 synthetic turf football pitches in the Netherlands. The current trend is for amateur clubs, having purchased a synthetic turf main pitch, to install further pitches.

Playing characteristicsTenCate Evolution™ XQ™ and GreenFields® MX have excellent sports characteristics, maximum sustainability and a long-lasting natural appearance. They thus approach as closely as possible the playing characteristics of a natural grass pitch. The pitches – and in particular the high-grade and sustainable GreenFields® MX system – make it possible for a player to get his foot effortlessly under the ball, just as he would on natural grass. The player can also twist, speed

up and turn freely – just like on natural grass. The synthetic turf pitches make it possible to play technically excellent and attractive football. The number of cancellations during the league will be greatly reduced, particularly in winter.

Sufficient capacityFor the production company of TenCate Grass in Nijverdal the award of the tender has no effect. ‘There is sufficient capacity in Nijverdal and in our production unit in Oldenzaal. We can make a fair number of pitches. It is just that now we have to have several pitches installed within a couple of months and then they still have to be approved for the league.’It is expected that all the clubs in the Jupiler League will in the medium term have a synthetic turf pitch. That is also the aim of the CED. The acceptance of synthetic turf has grown significantly over the past few years,

especially in the first division. ‘There is not much difference in perception between the first division and the premier league,’ Ton Raaphorst feels. ‘The emotion is slightly different but many clubs have embraced synthetic turf.’

• TenderawardedtoTenCateGrasson the basis of pitch, price, conditions, experience at the top level, sustainability and other factors

• PartnersofGreenFieldsinstallthesub-base and synthetic turf surface, provide maintenance and clear the pitch of snow

• ProductioncapacityofTenCatesufficientto meet the growing demand

[email protected]

PEC Zwolle and Heracles Almelo played each other earlier this year for the KNVB (Dutch Football Association) Cup. Since the beginning of the 2012-2013 season both clubs

have had a GreenFields® MX synthetic turf system.

See page 30 for a list of TenCate pitches

Heracles AlmeloGreenFields® MX

FC Den BoschGreenFields® MX

FC DordrechtGreenFields®

Evolution™ XQ™

Almere City FCGreenFields®

Evolution™ XQ™

PEC ZwolleGreenFields® MX

FC OssGreen Future™ 2.0

Helmond SportGreenFields® MX

TENCATE GRASS IN DUTCH PREMIER LEAGUE AND JUPILER LEAGUESustainability / Environment

Football grass

The premier league clubs that play on synthetic turf of TenCate are

Heracles AlmeloGreenFields® MXPEC ZwolleGreenFields® MX

The first division clubs that play on artificial turf of TenCate are

FC Dordrecht GreenFields® Evolution™ XQ™Helmond Sport GreenFields® MXFC Den BoschGreenFields® MXFC OssGreen Future™ 2.0Almere City FCGreenFields® Evolution™ XQ™

For a list of the pitches installed by GreenFields and Edel Grass see the TenCate website.

www.tencategrass.comwww.greenfields.euwww.edelgrass.com

With the installation of a number of soccer pitches in Dutch professional football in the Netherlands, synthetic turf is steadily

growing. Three clubs in the Premier League and eight clubs in the Jupiler League will be training and playing on synthetic turf.

Late 2012, the Netherlands had a total of approximately 1,500 synthetic turf pitches. Many of them are built by C.S.C. Ceelen

Sport Structures.

30 txtures | number 3 | autumn 2013

31

Heracles AlmeloGreenFields® MX

FC Den BoschGreenFields® MX

FC DordrechtGreenFields®

Evolution™ XQ™

Almere City FCGreenFields®

Evolution™ XQ™

PEC ZwolleGreenFields® MX

FC OssGreen Future™ 2.0

Helmond SportGreenFields® MX

TENCATE GRASS IN DUTCH PREMIER LEAGUE AND JUPILER LEAGUESustainability / Environment

Football grass

The premier league clubs that play on synthetic turf of TenCate are

Heracles AlmeloGreenFields® MXPEC ZwolleGreenFields® MX

The first division clubs that play on artificial turf of TenCate are

FC Dordrecht GreenFields® Evolution™ XQ™Helmond Sport GreenFields® MXFC Den BoschGreenFields® MXFC OssGreen Future™ 2.0Almere City FCGreenFields® Evolution™ XQ™

For a list of the pitches installed by GreenFields and Edel Grass see the TenCate website.

www.tencategrass.comwww.greenfields.euwww.edelgrass.com

With the installation of a number of soccer pitches in Dutch professional football in the Netherlands, synthetic turf is steadily

growing. Three clubs in the Premier League and eight clubs in the Jupiler League will be training and playing on synthetic turf.

Late 2012, the Netherlands had a total of approximately 1,500 synthetic turf pitches. Many of them are built by C.S.C. Ceelen

Sport Structures.

Technological innovation

TENCATE PARTNER IN INNOVATION AND BuSINESS DEVELOPMENT

AMMON 3: from product to system innovation

TenCate is one of seven large companies in the eastern Netherlands that are working to produce technological innovations in new high-tech materials, products and systems at an accelerated rate, which can then be rolled out internationally. The driver behind this cooperation is the AMMON (Advanced Materials Manufacturing Oost-Nederland) (eastern Netherlands) foundation. AMMON has now entered its third phase: from product innovation to system innovation by means of system development, production and joint marketing.

From concept to product designWithin AMMON the partners develop concepts into professional business cases. Each process ends in what is known as a demonstrator. This forms the basis for the final product design, which is geared to high-volume production. AMMON guides the business plan through to the relevant market. Provincial authorities may play a key role in this: not as the subsidy provider but as the launch customer. The province of Overijssel, for

instance, is already a discussion partner and possible launch customer of new materials or systems. Examples include smart roads, bridges, the sustainable stadium, innovative mobility concepts and water treatment systems. TenCate is involved in a number of these projects.

Reflective asphaltNear Haaksbergen (Overijssel) a model of a smart road is being constructed. It has a surface of reflective asphalt incorporating small lights, which helps conserve energy. TenCate Geosynthetics supplied the fabrics for soil stabilization. Next summer a heating network based on geogrids from TenCate will be installed under the road, which will be linked to bridges and viaducts. This will prevent the road becoming frozen in winter. The proposed new, sustainable stadium for Heracles Almelo will incorporate the specially developed Vision system. Intelligent camera solutions from TKH will support critical security aspects relating to the stadium and improved processes in order to be able to carry out work on the pitch to

maximum effect. These solutions will ensure that visitors to the stadium enjoy the game to the full. The system is already available. Extra software is currently being developed.

Ccomposite bridgesIn Enschede two cycle bridges to be made of composite have been put out to tender and in the foreseeable future the first large bridge across the Twente Canal will also be built of composites. TenCate is working on this together with VIRO Engineering and Jansen Venneboer. The latter company specializes in engineering, inspection and maintenance and project management. For similar structures, recurring primary parts must be built, including I- en T-beams and for this purpose a new production company may be set up. For composites, the building and construction sector offers great potential.

The Advanced Materials Manufacturing Oost-Nederland foundation has moved on to the next phase. At the interface of technologies

the partners develop new product-market combinations, such as smart roads and mobility concepts. TenCate is involved in these

innovations with a range of materials and systems.

The installation of a heating network based on

geogrids from TenCate will prevent the road

becoming frozen.

TENCATE SPONSORS SOLAR CAR SOLAR TEAM TWENTESustainability / Environment

Light, quick and sustainable

The RED Engine of Solar Team Twente will be one of the entrants in the World Solar Challenge in October this year. TenCate provided the team with high-grade carbon fabric for the interior structure and the exterior of the solar car.

The World Solar Challenge is a biennial international race for solar cars. It starts off on 6 October in Darwin (Australia) and ends one week and 3,000 kilometres later in Adelaide. In the World Solar Challenge it’s a question of converting solar energy into sustainable power for the vehicle as effi ciently as possible.

The interior structure and the exterior of The RED Engine are made of high-grade carbon fabric from TenCate. Thanks partly to this, the red solar car from Twente weighs ‘only’ 139 kilos. Other companies too have contributed high tech materials, know-how and support to this mobility concept. The Solar Team Twente is composed of 16 RED Engineers: students from the University of Twente and Saxion. The team also took part in this race with earlier versions of the solar car in 2005, 2007, 2009 and 2011.

AerodynamicsThe infl uence of wind fl ow on the solar car is optimized by advanced computer simulations. The air resistance of The RED Engine is four times lower than the most economical passenger car at this moment.

CompositesCompared with current carbon fabrics, the carbon fabric from TenCate is over 1.5 times as strong and as light again. The application of the resin to the fabric is computer-controlled. The result is an optimal relation between the weight and strength of the composite laminate.

TelemetricsContact between the rider and the following car is via WiFi. The systems of the solar car are therefore managed and monitored from a distance. The positions of other competing vehicles can also be followed.

Assembly and fi nishingThe moulds are coated with a high gloss to achieve a solar car that is as smooth as glass.

BodyworkThe fabric with the resins is hardened in an autoclave of Fokker Aerostructures that is used for the production of high-grade composites for aircraft components.

Brake systemThe RED Engine has a dual brake system, the components of which are made in aluminium especially for the solar car.

Front wheel suspensionThe front wheel suspension of The RED Engine is as light as possible and yet strong enough to be able to travel at full speed over an Australian cattle grid. The hub is equipped with special bearings and a quick-change system adopted from the racing world.

Back wheel rimsThe electric motor of the solar car is integrated in the back wheel rims, enabling direct transmission. This delivers an output of approximately 98%.

Battery systemThe battery system of The RED Engine is compact and quickly changeable. It is equipped with a smart Battery Management System for optimal energy storage and battery control of the electric solar car.

Rib structureThe composite rib structure around the rider’s seat absorbs all the forces and protects the racing driver. The aluminium roll bar ensures the protection of the racing driver. The whole rib structure of the solar car weighs less than a child’s bicycle.

Steering systemThe steering system of The RED Engine has a push-pull cable system that is extremely light and guarantees accurate control.

www.tencateadvancedcomposites.comwww.solarteam.nl

32 txtures | number 3 | autumn 2013

TENCATE SPONSORS SOLAR CAR SOLAR TEAM TWENTESustainability / Environment

Light, quick and sustainable

The RED Engine of Solar Team Twente will be one of the entrants in the World Solar Challenge in October this year. TenCate provided the team with high-grade carbon fabric for the interior structure and the exterior of the solar car.

The World Solar Challenge is a biennial international race for solar cars. It starts off on 6 October in Darwin (Australia) and ends one week and 3,000 kilometres later in Adelaide. In the World Solar Challenge it’s a question of converting solar energy into sustainable power for the vehicle as effi ciently as possible.

The interior structure and the exterior of The RED Engine are made of high-grade carbon fabric from TenCate. Thanks partly to this, the red solar car from Twente weighs ‘only’ 139 kilos. Other companies too have contributed high tech materials, know-how and support to this mobility concept. The Solar Team Twente is composed of 16 RED Engineers: students from the University of Twente and Saxion. The team also took part in this race with earlier versions of the solar car in 2005, 2007, 2009 and 2011.

AerodynamicsThe infl uence of wind fl ow on the solar car is optimized by advanced computer simulations. The air resistance of The RED Engine is four times lower than the most economical passenger car at this moment.

CompositesCompared with current carbon fabrics, the carbon fabric from TenCate is over 1.5 times as strong and as light again. The application of the resin to the fabric is computer-controlled. The result is an optimal relation between the weight and strength of the composite laminate.

TelemetricsContact between the rider and the following car is via WiFi. The systems of the solar car are therefore managed and monitored from a distance. The positions of other competing vehicles can also be followed.

Assembly and fi nishingThe moulds are coated with a high gloss to achieve a solar car that is as smooth as glass.

BodyworkThe fabric with the resins is hardened in an autoclave of Fokker Aerostructures that is used for the production of high-grade composites for aircraft components.

Brake systemThe RED Engine has a dual brake system, the components of which are made in aluminium especially for the solar car.

Front wheel suspensionThe front wheel suspension of The RED Engine is as light as possible and yet strong enough to be able to travel at full speed over an Australian cattle grid. The hub is equipped with special bearings and a quick-change system adopted from the racing world.

Back wheel rimsThe electric motor of the solar car is integrated in the back wheel rims, enabling direct transmission. This delivers an output of approximately 98%.

Battery systemThe battery system of The RED Engine is compact and quickly changeable. It is equipped with a smart Battery Management System for optimal energy storage and battery control of the electric solar car.

Rib structureThe composite rib structure around the rider’s seat absorbs all the forces and protects the racing driver. The aluminium roll bar ensures the protection of the racing driver. The whole rib structure of the solar car weighs less than a child’s bicycle.

Steering systemThe steering system of The RED Engine has a push-pull cable system that is extremely light and guarantees accurate control.

www.tencateadvancedcomposites.comwww.solarteam.nl

33

Sustainability / Environment

TENCATE GRASS IN LANDSCAPING PROjECT IN CAPITAL OF SAuDI ARABIA

Grand green in Riyadh

34 txtures | number 3 | autumn 2013

In March 2013 the largest synthetic turf landscaping project in the world was completed not far from king khaled

international airport in Riyadh (Saudi Arabia). This two-tone landscape with a surface area of 200,000 m2 is based on

monofilament yarns from TenCate Grass.

35

The landscape which has been created close to King Khaled airport, to the north of the capital of Saudi Arabia, is a sand-strewn field of monofilament yarns in two shades of green. Using their expertise, the R&D staff of TenCate Grass in Dubai have developed a special blend of raw materials that guarantees greatly prolonged UV stability. This is to ensure that it would satisfy the ten-year UV guarantee – bearing in mind that Riyadh registers the

highest solar activity in the world. In addition, 250,000 kg of yarns had to be supplied in just three weeks at the height of the high season. This is an achievement that only TenCate could deliver, thanks to its global production capacity.

Arriyadh Development Authority (ADA) commissioned the project, choosing TenCate Grass and Hatko Sports (Turkey) as supplier and installer, respectively. And the reason? They are

partners that work efficiently as a team and for whom high quality is a must, not a luxury. Hatko Sports and TenCate have already carried out various projects together over the past years. And the project in Riyadh took only 150 days – from delivery to installation.

[email protected]

Sustainability/ Environment

TENCATE GEOTuBE® uSED FOR LAND RESTORATION IN NORFOLk

36 txtures | number 3 | autumn 2013

Salhouse Broad is a lake to the north-east of Norwich (Norfolk, UK). It formed as a result of the extraction of peat. The spit of land between this lake and the River Bure has been severely affected by erosion in the past sixty years. If this watershed were to collapse, river water would flow directly into the lake and cause great damage to the landscape, which is an important habitat for wildlife. The spit of land thus had to be restored and reinforced. At the same time it was decided to restore a former reed bed.

SedimentThe floor of Salhouse Broad is covered with an approximately five-metre thick, soft layer of sediment, which means that traditional methods to establish a solid structure are not adequate. TenCate Geotube® containers filled with local dredging material, however, are. Four huge TenCate Geotube® units measuring 8.5 metres wide were filled with about 3,000 m³ of sediment, dredged out of the Bure. This was used to form a 170-metre-long retaining wall. Some 9,000 m³ of dredgings were deposited behind the containers in order to restore the 7,000 m² reed bed and to bring the waterline back to its original state.

With an eye to stability, erosion protection and the fauna, the dredgings in the TenCate Geotube® containers were planted with reeds and grasses. This is vegetation that is very common here and is thus expected to catch on quickly. Once the reed bed has been completely restored, it is expected to attract a variety of animal species – and, of course, more tourists.

Innovative solutionsThis restoration was part of the European PRISMA project. It was set up to develop

innovative solutions for dredging, treating and reusing sediment from waterways. The Broads Authority worked closely with the experts from TenCate and the Dutch engineers from Besekk. During the ceremony for the 2013 Water Renaissance Awards in Birmingham (UK) held on 23 May, under the auspices of the Canal & River Trust, the Salhouse Broad project received an honourable mention in the Innovation category.

[email protected]

Restoration of spit of landTenCate Geotube® technology was used for the restoration and reinforcement of a spit of land in

Norfolk (uk) between the River Bure and a peat bog. The work itself had minimal impact on the

environment. The project received an honourable mention from the British Canal & River Trust.

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Through the application of TenCate Geotube®, the vulnerable spit of land between river and lake has been

restored and strengthened, and the new land will soon be covered with reed and sedge vegetation

(photo: Mike Page)

38 txtures | number 3 | autumn 2013

Sustainability / Environment

TENCATE AND TAPAS PARTNERS CONTINuE COLLABORATION WITh AIRBuS

Within the Thermoplastic Affordable Primary Aircraft Structure Consortium (TAPAS) eight Dutch companies and institutions involved in the aviation industry work together with Airbus on groundbreaking technological aircraft innovations. This initiative is supported by the Ministry of Economic Affairs. TAPAS 1 recently came to a close with the presentation of an innovative double-curved fuselage panel for Airbus. It is made of thermoplastic composite from TenCate Advanced Composites and was produced by Airbus, Fokker Aerostructures and other TAPAS partners. It is the first time that such a large-scale fuselage panel has been manufactured in thermoplastic composite. This demonstrator shows how the entire fuselage material of passenger aircraft may look in the future.

TAPAS – the sequelTAPAS 1 kicked off in 2009. The aim was to increase the development of thermoplastic composites for Airbus aircraft designs and bring them to a higher level of technology readiness. The demonstrator from TAPAS 1 is a heavily burdened torsion box, and here a redesign of the horizontal tail of the Gulfstream 650 business jet was the option chosen. Just like the fuselage panel, the torsion box represents a significant part of the primary construction of an aircraft.It is intended that TAPAS 2 will continue with the development of thermoplastic composites for wing and tail applications, suspension frames for motors and fuselage components.

‘It’s splendid to hear that the Dutch aviation industry has such a good name in this market,’

said Minister Kamp during the signing of the letter of intent. ‘Airbus and Boeing speak highly of the collaboration with these Dutch companies.’

www.tencateadvancedcomposites.comwww.tapasproject.nl

Development of aerospace composites gets follow-upOn 19 june at the Paris Air Show in France henk kamp, Minister of Economic Affairs, signed a letter of intent regarding the

extension of the Thermoplastic Affordable Primary Aircraft Structure Consortium. An innovative fuselage panel for Airbus,

which is made of thermoplastic composite from TenCate Advanced Composites, was also unveiled in Paris.

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The innovative fuselage panel for Airbus, the second demonstrator

40 txtures | number 3 | autumn 2013

Sustainability / Environment

TENCATE MIRAFI® hP570 FOR CONSTRuCTION I-84 BRIDGE ABuTMENT

For the construction of the abutment for a new overpass bridge on Interstate highway I-84 near Echo

junction in northern utah (uSA) the utah Department of Transportation (uDoT) has opted for two

sustainable materials: soil and TenCate Mirafi® hP570. The innovative method to replace the

overpass bridge helps save construction time and government money.

Sustainable foundation

The innovative method to replace the overpass bridge helps save construction time and government money.

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PRODuCT – polypropylene TenCate Mirafi® HP570 MARkET – construction and infra-structure TEChNOLOGy – weaving and coating technology PROCESS – material is delivered and processed on site

The state is building a replacement 58-foot-wide span bridge. Typically, bridge abutments are con-structed using steel piles and large cast-in-place concrete structures that require specialized labor and large equipment and take longer to build. The mechanically stabilized earth (MSE) system utilizing TenCate Mirafi® geotextile reinforcement allows for rapid construction and significant construction savings. This system also allows for flexibility in the appearance of the abutments by offering a variety of colors and textures of segmental retaining wall blocks that can be selected to provide an attractive end result.

UDoT is the first in the United States to use the reinforced soil technique, thus saving considerable time and money: $ 200,000 on the total construction costs of $ 3,200,000. ‘Concrete is expensive and time-consuming,’ says Tim Rose (deputy director Region 2). As I-84 traffic speeds over the bridge near Echo Junction, construction crews are laying the foundation for the replace-ment bridge below.

When the bridge abutment is finished, builders will slide the 20m-long bridge deck into place. This is expected to happen sometime in late summer.

‘We are pleased to see the many benefits provi-ded by our products highlighted so prominently in the Utah DOT project’, says Todd Anderson, TenCate Geosynthetics’ Vice President Sales & Marketing for the Americas. ‘Innovative design combined with efficient and effective TenCate Geosynthetics materials make a difference in cost savings and sustainable construction.’

[email protected]

The mechanically stabilized earth system utilizing TenCate Mirafi® geotextile

reinforcement allows for rapid construction and significant construction savings.

42 txtures | number 3 | autumn 2013

Zoe Lofgren (CA-19) has been a member of the United States House of Representatives for almost 20 years. Since the beginning of this year she has represented TenCate Advanced Composites (TCAC) facility in Morgan Hill. Some of America’s largest tech companies are located in the Congresswoman’s district, and she recognizes the importance of meeting with

and understanding the issues important to those companies, including TenCate Advanced Composites. Steve Mead, Scott Unger and Joe Morris, members of the executive team, showed her how advanced composite materials were made there. She was impressed by the high tech industry she viewed and enjoyed learning about TenCate’s operations.

Q&AAfter the guided tour Congresswoman Lofgren sat down and met with employees from TenCate Advanced Composites. The Congresswoman fielded questions from employees and discussed a range of topics with them – including issues occupying Washington. Michael Cichon (Director of Product Marketing) enjoyed the visit. “It was helpful for us to meet with Zoe Lofgren from the perspective of letting her know the high value global aerospace manufacturing employment that is within her district.”

Government RelationsBuilding and maintaining relations with members of Congress is one of the key objectives of the Office of Public and Government Relations of TenCate in Washington, DC. Visits like this one to Morgan Hill give companies such as TenCate Advanced Composites the opportunity to meet their representatives in person and discuss issues relevant to their business and employees. In the words of general manager Joe Morris, “It is always good that our representative in the American Congress understands what we do and that we have an avenue to her and her staff should we need support in the future.”

[email protected]

Government relations

TENCATE ADVANCED COMPOSITES RECEIVES CONGRESS MEMBER ZOE LOFGREN

The employees at the production and administrative facilities of TenCate Advanced Composite’s (TCAC)

location in Morgan hill, California, uSA, received a visit from Member of Congress, Zoe Lofgren, in late

April. The programme included a guided tour and a talk with TenCate employees.

Joe Morris giving Zoe Lofgren a detailed explanation

Visit in Morgan hill

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txtures winter 2013

A PREVIEW

In the 2013 winter edition of txtures you can expect articles on the following:

Protecting people:

The value proposition of TenCate GrassAerospace

Prospects and possibilities

Protecting people:

The value proposition of TenCate Advanced Armour

Applications of geosynthetics

Results of third quarter of 2013

(Photo: Airbus)

(Foto: Frank Uijlenbroek)

(Photo: Cpl Ian Houlding)

Volume 48 - number 3 - autumn 2013 txtures is the corporate review of Royal Ten Cate for its employees and external stakeholders. The magazine is published four times a year in a Dutch and English version. Reproduction of articles or parts of articles is authorized, providing the source is acknowledged and that passages and quotations are not placed in a different context.

Editor’s address Translations Design PrintingRoyal Ten Cate Gay Howells DeNK•creatieve vrijdenkers LulofCoen Heldeweg (chief editor) Janice Collins Almelo experts in gedrukte communicatiephone +31 546 544 305 [email protected]

Expand horizons

When it comes to synthetic turf sports systems, the factors that are of paramount importance are the technical qualities of the pitch and the sports experiences of the players. This also makes the game exciting for spectators: whether on the sidelines, in the stands or at home on the couch.

The innovative GreenFields® TX system was developed for top-class fi eld hockey. This synthetic turf gives fi eld hockey players the freedom to expand their sporting horizons.

www.tencategrass.com