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Bayards - a history in aluminium constructions

Global player

Investment in people and technology

Our organization

The corporate philosophy

Aluminium, what makes it so special?

Aluminium, our expertise

Design & engineering

Quality management

High speed milling

Welding aluminium

Friction Stir welding

The Bayards selling points at a glance

Shipbuilding

Aluminium helidecks

Helicopter platforms and additional structural

products for offshore and marine applications

Helicopter access to civil buildings

Defence products

The Fennek all terrain exploration vehicle

Civil architectural projects

Lord's Media Centre, London

Nichols bridgeway, Chicago

Barcelona traffic control tower

Stairhouse Riccione Italy

Civil aluminium stuctures

Bridges

The floating road

Proces vessels, tanks and silos

Transport containers

Special projects

Looking towards the future

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bayards - a history in aluminium constructions

In 1963 Mr. J. J. Bayards founded Apparatenfabriek Bayards in Nieuw-Lekkerland, a village near

Rotterdam. Almost 50 years later, Bayards developed into one of the most innovative construction com-

panies in Europe, a specialist in the application of aluminium, both in engineering and manufacturing.

At Bayards, we use the many benefits of this material to design and build high end products for

demanding customers all over the world in areas like offshore, shipbuilding, civil engineering, defence

industry and scientific research. Bayards has reached its strong position on the world market by a

synergic combination of experience, a strict quality policy, skilled workers and a reliable organisation

with continuing investments in modern engineering and production technologies.

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Over the years, we made a strong contribution to a lot of projects on national and international

markets where aluminium construction was involved. A choice of recent projects all in aluminium:

• Hulls and superstructures for sailing yachts and high performance super yachts

• Helicopter landing platforms for oil rigs

• Helicopter landing platforms for civil buildings like hospitals

• Demanding constructions for oil rigs like stairhouses and parts of living quarters

• The spectacular skybox for Lord’s Cricket Stadium in London

• The 43 metre stairwell for the Barcelona airport control tower

• The design and construction of the stairhouse of Riccione Conference Center in Italy,

winner of the European Aluminium Award

• The construction of the Nichols bridgeway in Chicago, a pedestrian bridge designed

by world famous architect Renzo Piano

• Road and pedestrian bridges, often of a striking design

• A construction for cooling the superconductor magnets of the Large Hadron Collider,

CERN’s newest generation of partical accelerator

• Nearly 400 chassis body’s for the all terrain reconnaissance defence vehicles ‘the Fennek’

• Special transport containers

• A number of defence projects like Canister frames for Patriots

These examples show the versatility of the markets and projects that we operate in. More and more

people and companies from all over the world find their way to the aluminium construction specialist

Bayards because they recognize our know-how and experience.

global player

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investment in people and technology

We believe well-trained personnel is a key success factor. Our employees in the engineering

department and on the shop floor increase their experience and know how not only through daily

practice, but through ongoing technical education as well.

Our people work with State of the Art technology. In the engineering department we apply sophis-

ticated CAD software, in the different workshops we use high tech welding equipment including

robot welding, friction stir welding and metal working machinery. For instance, we employ one of

Europe’s largest and most advanced high speed gantry milling machines. In this way we guarantee

our customers optimal engineering, high quality, cost-effective, long life structural solutions in

aluminium. That’s how we prepare for the future.

In our organization more than 130 highly trained people work together: engineers, machine operators,

designers, service-engineers, welders etc. The organisation is flat, driven by quality, cost effectiveness

and customer-service. Bayards knows that its future depends on its people. People who control the

complete process from a creative design up to project realization and after sales service.

People who don't step back for a challaging project and who always aim for the highest possible

customer satisfaction.

our organization

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BAYARDS

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the corporate philosophy

Our slogan is ‘Solutions in Aluminium’. It’s a simple way to express our capability to use the beneficial

features of aluminium to realize projects that fulfil completely the needs of critical and demanding

customers. Not only just after the project is completed, but on the long term as well. That’s why our

philosophy is based on the clear choice of aluminium and customer-oriented thinking.

This implicates:

• Creativity in engineering

• Cost-effective solutions

• High quality

• Reliability

• Team spirit

• Long term service policy

These factors together with the metal aluminium brought us success in the past, and will do in the future.

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aluminium, what makes it so special?

A hundred years ago aluminium was known as a rather exotic material. The next century it will

probably be one of the most popular metals in construction. This is because it combines some

outstanding features that, these days, become more and more important:

• Lightness in weight

• Long life cycle

• Environmental-friendly

• Corrosion resistant

• Easy to recycle - over and over again

> Over the years, Bayards has learned nearly everything about aluminium. And we’re still learning.

Our know how and experience is continuously growing. This knowledge includes:

• The different available alloys and qualities

• Long term behaviour and integrity in practical situations

Processing:

• forming: casting, extruding, cutting and bending

• machining: milling, turning, drilling

• finishing: surface treatment, anodizing, painting and powder coating

• all the applicable welding methods, including robot welding and friction stir welding.

So we know exactly what we can do with the material and where it finds its limitations.

aluminium, our expertise

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design & engineering

Bayards is not a company producing standard mass products. On the contrary, for us the tailor made

projects are the real challenge. Our innovative approach combined with the natural benefits

of aluminium enables us to engineer smart solutions to our clients’ challenges. Our specialized and

experienced employees have the knowledge and experience and, this combined with the latest State

of the Art equipment ensures that we can advise our customers about the feasibility of the project in

an early stage, even before designs are initiated.

quality management

Since the 1960’s, Bayards has specialized in satisfying the demands of various bespoke client

specifications. This has contributed greatly to the development of a formal Quality System according

to ISO & AQAP.

The company is also qualified by the German GSI according to DIN4113 and DIN6700 soon to be repla-

ced by EN 15085. Last but not least is the BWB qualification for the welding of “Panzer” aluminium.

On site test facilities include NDT testing methods, such as; qualified PT, RT, UT as well as helium and

hydrostatic leak-testing. Quality forms an integral part of the organization, embedded in procedures

and in the Bayards personnel attitude.

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high speed milling

High Speed Milling is a technique that combines high spindle speeds with increased feed rates. HSM is

the result of numerous technical improvements ensuring that milling has become faster and significantly

more precise than conventional milling.

The advantages of High Speed Milling are higher productivity owing to the reduction of machining

times, increase of the flow time of production, reduction of the number of technological operations

and most importantly, a significant increase of the surface quality.

With a HSM machine of 15 meters, Bayards has one of Europe’s largest, 5-axal, high speed and high

precision gantry milling machines.

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welding aluminium

Skilled and experienced MIG- and TIG-welders work with all national and international standards. To

complement this, where possible and practical, Bayards uses advanced, mostly digital equipment - inclu-

ding robots and friction stir welding - in order to deliver first class work.

friction stir welding

Friction Stir welding had developed tremendously since its invention nearly two decades ago. Today

the welding method is used widely for commercial production worldwide. The most common products

are panels for the maritime sector and the rail car industry. It is however rare to see more traditional

sub-contractor industries engage in Friction Stir Welding and offering this as part of their production

processes. Bayards has invested in one of the largest Friction Stir Welding installations available in a pri-

vate subcontractor industry. Bayards FSW-equipment is today fully operational and the State of the Art

Technology has broadened and enhanced Bayards’ capabilities. Bayards successfully uses the method in

shipbuilding and offshore construction.

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the bayards selling points at a glance:

• 100% specialized in aluminium

• Almost 50 years experience

• Own production sites

• Solid reliable organization

• In-house design department

• Continuously trained employees

• Broad structural experience

• State of the Art machinery

• Product references across the world

• Experience with a wide range of alloys

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shipbuilding

Shipbuilders have discovered the benefits of aluminium - light weight and corrosion resistance - long

ago. For over 30 years Bayards has been building aluminium assemblies and structures for inland and

ocean-going vessels:

• Hulls and superstructures

• Complete sailing and super yachts

• Wall and deck panels

Bayards builds ships in every shape and size, from engineering and production to on-site delivery. Over

the last 10 years we specialized “more and more” in the constructions of hulls and super structures for

the high end super yacht industry.

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complete delivery, worldwideBayards aluminium helidecks are supplied worldwide turn key including:

• Full deck drainage

• Deck integrated fire fighting system (DIFF)

• Integrated heating

• Lighting

• Instrumentation and telecommunications

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Bayards has been designing and building helidecks for over 25 years. They now represent the safest,

most economic answer to helicopter access in hazardous locations. There are two main executions:

fixed on an offshore platform or on a floating vessel. Our aluminium helidecks can be supplied turn

key with options like high friction Safedeck®, full deck drainage, Deck integrated fire fighting system

(DIFF), de-icing system, fire fighting equipment, lighting, instrumentation and telecommunications.

A Bayards aluminium helideck means easy assembly, light weight, long life, maximum security and

minimal maintenance.

aluminium helidecks

helicopter platforms and additional structural products for offshore and marine applications

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Bayards has extended its offshore helideck expertise to land-side needs. We realized several aluminium

helicopter platform constructions for hospitals, high rise offices and city centre helitransport services.

They’re designed and built according to international standards and available with all thinkable

options. Their light weight and availability of prefabricated kits means suitability for most locations and

easy installation.

helicopter access to civil buildings

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defence products

Bayards is an active supplier to the defence industry. Not surprising, because aluminium is the ideal

construction material for defence equipment: it must be light and strong. Defence projects ask for an

experienced supplier who is able to handle high grade welding and assembly work.

A recent order is the manufacturing of nearly 400 aluminium chassis for the new all terrain reconnais-

sance vehicle 'the Fennek'. This assignment sets the highest requirements on the company's machining

and welding capabilities. For this prestigious project we have set up a dedicated facility fitted out with

one of Europe's most advanced high speed machining centres.

Several projects carried out for the NATO army's and navy's testify of our versatile expertise in this area.

We were intensively involved in the production of decompression tanks, minehunters, transport

containers, Canister frames for Patriots and several different types of girder bridges.

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the fennek all terrain exploration vehicle

The vitality of this co-operation was recently confirmed with an order to build nearly 400 aluminium

chassis for the new all terrain reconnaissance vehicle ‘the Fennek’, an assignment setting the highest

requirements on the company’s organisational, machining, milling and welding capabilities. Bayards set

up a dedicated production line and fitted out a new production hall with Europe’s most modern com-

puter controlled high speed milling machines and welding machines including friction stir welding.

A new era of serial assembly of aluminium chassis and bodies for cars, trams, buses and trains has

begun. Lightweight, strong, sustainable, low maintenance, long-life, and recyclable.

The capability spectrum of Bayards as aluminium engineers extraordinary will inspire and stimulate

the creativity of design agencies and architects in this market.

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lord’s media centre, london

The impressive futuristic shape of the media centre for Lord’s cricket ground in London shows what

can be done with aluminium. First top and bottom were built, divided into segments, transported to

location and then reassembled. Light, elegant and functional.

This project was designed by FUTURE SYSTEMS and engineered by OVE ARUP & PARTNERS. Bayards

was involved in the manufacturing of the aluminium construction.

nichols bridgeway, chicago

The 600 foot (180 meters) pedestrian bridge, that opened in 2009, links the Chicago Art Institute with

the Millenium park. Nichols Bridgeway was designed by world famous architect Renzo Piano. In accor-

dance with Piano’s highly esthetical design Bayards engineered and manufactured the Aluminium

bridgedeck. In Chicago, this masterpiece is a symbol of the connection of the public world with the

world of art. For Bayards, the bridge is another proof that aluminium is not only extremely light,

environmental friendly and strong, the material is also perfectly suitable for constructions with high

esthetical requirements.

civil architectural projects

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barcelona traffic control tower

Another example of imagination in aluminium. The self-supporting stairway (43m high), designed by

architect Bruce Fairbanks and engineered by ing. M.E. & G.C. Giuliani, is made of special designed

aluminium profiles stiffened by cross braces.

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stairhouse riccione italy

The coastal town of Riccione, Italy is upgrading its infrastructure, services, and image, and in doing so

recently opened a magnificent new conference centre. This required high capacity, external stairing to

process the large numbers of visitors arriving and leaving the complex. To client specification Bayards

designed, assembled and installed a four series stairway; airy, attractive, safe, strong, and effective

to purpose.

With the Palarricione Stairways, Bayards was awarded with the European Aluminium Award 2008 in

the category Industrial Products for Building & Construction. The work is described as a combination

of elegance and industrial use of aluminium.

A

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civil aluminium structures

bridges

‘Aluminium bridges are the future’ is a quote we subscribe. With one restriction: this future has

already begun, as our own recent contributions show.

A few examples:

• The replacement of concrete bridge sections by aluminium to reduce structure

weight and raise carrying capacity

(Norway / The Netherlands / USA)

• A heavy drawbridge in Amsterdam

(designed by Prof. Ir. Jan Brouwer)

• The Westerdokbrug in Amsterdam

(designed by Meyer en van Schooten architects)

• Several pedestrian bridges in The Netherlands

(In cooperation with van Staade, van Ardennen and others)

• Replacement of deck elements of Kentucky Highway Bridge

for the Kentucky Transport Cabinet (KyTC) Ky, United States Of America.

• Replacement of deck elements for Haringvlietbrug

• Replacement and extension of pedestrian and service bridge for Maarssen

As the first case shows, a main activity in this field is replacing bridge structures with new ones

of aluminium. This can vary from the replacement of just some specific parts such as suspension

structures, decking or complete replacement.

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the floating road

Bayards continuously thinks about innovative civil structures in which aluminium can play a main role.

Together with our partners TNO, engineer office DHV, Jan Brouwer Associates and Ministry of Transport

Public Works and Water Management we developed a ‘floating road’ that can be used in areas of

poor accessibility.

The result of these efforts was a prefabricated aluminium module, suitable for one way passenger

traffic at 80 kmh. The design has already been used as a temporary road in swampy areas and some

other applications. It has proven itself as a solution for temporary diversion of bridges and roads that

have been closed for reconstruction.

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process vessels, tanks and silos

Bayards services in this domain include engineering, assembly, finishing and installation of various

process vessels and storage tanks for the chemical, petrochemical and food processing industries.

We have extensive experience in designing and building these structures; for more than 40 years we

have built storage and blending silos, tanks, pressure vessels, heat exchangers, reactors and condensers.

These products are made of a number of different alloys. Ranging from the pure aluminium (1000

series) to the exotic AlZn alloy (7000 series)

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transport containers

Efficient logistics is becoming more and more important. A key role is reserved for aluminium. Our

aluminium transport containers for products such as plastics, raw materials, foodstuffs and edible oils

serve the industry well. The product range includes mini, open top, insulated and accommodation

containers, trailer chassis and tank trailers. The container guarantees safe and economic transport of

sensitive bulk materials. The Bayards aluminium transport container that combines strength, smooth

wall and rounded corners, can be delivered with options for manhole, unloading hatch, butterfly valve

outlet, grappler pockets, all approved to ISO, UIC-TIR, CSC and Lloyd’s.

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Over recent years we have developed the capability of working on assignments with exceptional requi-

rements. A striking example is the manufacturing of components for the the European organisation

for nuclear research CERN (Conseil Européen pour la Recherche Nucléaire), the LHC (Cern’s newest

generation of partical accelerator.) is used for fundamental scientific research. Bayards was chosen for

this project after a severe selection procedure. The project involved high precision manufacturing of a

large number of complex extrusion profiles. These profiles were welded to form the so called bottom

tray of this new 27 km long accelerator. This bottom tray is also used for cooling the accelerator to near

absolute zero (-273 °C). Due to the cooling, enormous shrinkage occur which is compensated by flexi-

ble couplings at the end parts of the profiles. This involved precision machining, orbital welding, x-ray,

vacuum- and helium leak-testing. This project tested our expertise to the limit, it was finished to the

full satisfaction of our very demanding client.

special projects

BAYARDS

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looking towards the future

> In this brochure we describe a few appealing examples of projects in which we proved our creativity in

engineering, craftsmanship, quality and flexibility. The application of aluminium however is not limited

to mentioned projects.

Already in the near future we expect a wider application only from the trend that the transport

industry is very interested in light weight cars, trams, buses and trains. Minimizing of corrosion and

maintenance costs is another important trend.

With a proud and positive attitude Bayards is looking forward to build, together with you,

many more beautiful products in the future.

www.bayards.nl

The Netherlands (Head quarters)

Bayards Aluminium Constructies B.V.

Veerweg 2 - 2957 CP Nieuw-Lekkerland, P.O Box 9 - 2957 ZG Nieuw-Lekkerland, The Netherlands

Tel: +31 (0)184 683000 - Fax: +31 (0)184 684345 - Email: sales@bayards.nl

Bayards USA

Bayards USA LLC - 700 Louisiana Street - Suite 3950 - Houston, TX 77002, USA

Tel: +1 832 390 2544 - Email: sales@bayardsusa.com

Bayards Italy

Bayards Italia s.r.l. - Viale Abruzzi 13A, 20131 Milano, Italy

Tel: +39 0292 9512 11 - Fax: +39 0220 5726 33 - Email: info@bayards.it

Bayards Germany

Bayards Deutschland GmbH - Fraunhoferstr. 3, 25524 Itzehoe, Germany

Tel: +49 4821 778 650 - Fax: +49 4821 778 655 - Mob: +49 151 4611 7949 - Web: www.bayards-deutschland.de

Bayards South East Asia

Bayards SEA Pte. Ltd. - Level 31, Raffles Place, 6 Battery Road, Singapore 049909

Tel: +65 6725 6270 - Fax: +65 6725 6280 - Email: sales@bayards.nl

Bayards Middle East

Bayards Middle East LLC - P.O Box 502537 - Dubai, United Arab Emirates

Tel: +971 50 8785 009 - Email: sales@bayards.nl

Bayards Brazil

Bayards do Brasil - Praia de Botafogo 501, 1ª floor - Botafogo, Torre Pão de Açúcar, Rio de Janeiro 22250 - 040

Tel: +55 21 2586 6213 - Fax: +55 21 2586 6001 - Web: www.bayards.com.br