Helping Shape Your Future

Helping Shape Your Future
Extruded Products

Hydro’s mission is to create a more
viable and sustainable society by
developing natural resources and
products in innovative and efficient
ways. Courage, respect, determination,
cooperation and foresight are values
which help us achieve these goals . . .
and values we live by.

At Hydro Aluminum, we define ourselves
by how we approach our work
as much as by what we produce. We
conduct our business with integrity
and encourage innovation and entrepreneurship,
while remaining deeply
committed to sustainability. This leads
to technological leadership, the ability
to produce high quality products and
services, and rewards for our customers,
employees, and communities.

Helping make better products
and better communities
Everyday, we help our customers make
better products. Whether it’s getting the
most out of an extrusion press, developing
a tailored alloy to assure superior
performance, or suggesting design
changes to reduce fabrication complexity
and cost, we work hard to exceed our
customers’ expectations.
When you choose Hydro Aluminum
Extruded Products, you partner with the
nation’s premier extrusion components
supplier backed by the resources and
dedication of a global aluminum authority.
We are committed to finding new and
better ways to improve our processes
through research, knowledge exchange,
innovation and investment to help our
customers transform designs and ideas
into elegant, cost-effective products.
Staying close to customers and reacting
quickly to their needs are two of our
most important operating principles. Our
decentralized organizational structure
empowers each facility to make decisions
at the local level and our culture of
entrepreneurship ensures that all
employees — from facility managers and
engineers to line staff — can make the
right decisions and recommendations
quickly. At the same time, our adherence
to standard performance benchmarks
ensures consistent quality performance
throughout our plant network.
We are firmly committed to sustainability
and mutual benefit. Metal produced
in North America contains mostly
recycled content and is a key component
for the manufacture of “green”
products. We believe that our work should
protect the environment and contribute
to our communities as it benefits our
employees and customers.
Our North America network consists
of 11 extrusion and fabrication facilities
and more than 3,000 employees with
roots that go back more than 50 years.
We are a unit of Hydro Aluminium, a
global extrusion technology leader and
one of the world’s largest aluminum
companies with 27,000 employees in
more than 100 production units located
in 28 countries.
• Integrated North American network of 11
extrusion and fabrication facilities from
New York to Mexico
• More than 600,000 sq. ft. of dedicated
manufacturing space
• Largest drawn tubing producer in North
America
• More than 50 years of extrusion
leadership in North America and Europe
About Hydro

Giving you the edge with
world-class technology
A typical extrusion press is over 10 feet
high, 40 feet long, weighs 25 tons with a
polished piston more than a foot in diameter.
It takes 100,000 lbs. per sq. in. of
pressure to push a billet through a die to
create an extrusion only inches in diameter
with a tolerance as tight as ± .005".
To effectively harness this enormous
machine and its powerful forces takes
sophisticated technology and a highly
experienced workforce. Hydro does this
everyday . . . and does it better than anyone
else.
Hydro operates more than 100 presses
around the world and is an acknowledged
world leader in extrusion technology.
Benchmarked against the best practices
throughout our global network, our presses
in North America produce extrusions
that provide dimensional consistency and
superior surface quality while meeting the
most stringent tolerances.
Constant innovation and knowledge
sharing means that we continually hone
our skills to produce the most accurate
and repeatable extrusions possible. Our
quality control standards, which are constantly
tested and expanded, assure that
the components we produce meet all
design specifications and the strictest
quality requirements.
We offer a wide range of services from
seven strategically located facilities in
North America. This network gives us
flexibility to assign projects to the best
qualified plant when specific expertise is
required or additional capacity is needed.
And when your extrusion requires
finishing, we offer high quality painting,
anodizing and other finishing solutions to
ensure that your extrusion achieves the
required aesthetic and performance characteristics.
Our in-house painting and
anodizing capabilities are complemented
by a network of well-established partnering
relationships.
To ensure a reliable source of metal
and help develop a metal sourcing strategy,
we can enlist our sister organization,
Hydro Aluminum Metal Products, the
leading supplier of billet with high recycled
content in North America and a
global metal sourcing leader. Metal
Products can also assist with alloy selection
and, if needed, tailor an alloy for
specific performance requirements.
With over 50 years of extrusion experience
in North America and global
extrusion technology leadership, Hydro
Aluminum has the capabilities and
resources to handle your toughest extrusion
challenge.
• World leader in extrusion technology
• 7 extrusion plants in North America
• Over 20 presses ranging in size from
7" to 12"
• State-of-the-art electrostatic,
environmentally-friendly (non-chrome),
paint lines certified to AAMA 2603
• Standard and clear “no-burn” anodizing
• Extensive use of prime-quality billet
with high recycled content
• Holland, MI Technology Center and
access to research centers worldwide
Extrusion/Finishing

The right process for your most
demanding tube applications
Every hour of every day Hydro produces
over 3,000 tubes that form a key element
of imaging systems in laser printers and
copiers . . . each tube produced with a
tailored alloy and specialty drawing
process to eliminate defects which could
impact print quality. At the same time, we
produce drawn tubing used in baseball
bats, leisure furniture, lawn care equipment,
wheelchairs and countless other
products, all with unique challenges and
demanding requirements.
When your application requires high
strength-to-weight ratio, more uniform
wall thickness, and superior surface finishes,
drawn tubing is the answer.
Drawing also enhances the bending, flaring,
and formability of the tube, allows for
better ovality control, and enhances
machinability.
Hydro uses a cold-drawn process to
produce high-quality seamless and port-
hole products. Through rigid manufacturing
standards, we maintain consistently
superior product quality with finished
diameters and straightness that far
exceed commercial tolerances.
Hydro Aluminum is committed to
working with you as a highly competent,
cooperative partner from the earliest
stages of product development through
high-volume production of your drawn
tubing components. Our unique set of
skills and experience allows us to reduce
development and production costs while
creating the highest quality drawn tubing.
We produce more drawn tube than
any other company in North America.
When manufacturers require precision
drawn tubing that meets the most critical
specifications, they turn to Hydro.
• Largest drawn tubing producer in
North America
• Three strategically located drawn
tubing plants (New York, Florida,
Arizona)
• 20+ high-speed draw benches
• Solution heat-treating capability
• Cut tubing lengths up to 30 feet
• Tolerances of finished diameters as
tight as ± .001"
• State-of-the-art straightening equipment
for finished tubing as straight as
.003" Total Indicator Reading per foot
Drawn Tubing

Uncompromising quality across
a wide spectrum of services
In Mexico, Hydro associates are assembling
extrusions and purchased components
into car seat sub-assemblies. In
Florida we are completing pole assemblies
for command tents for the U.S. military.
At our facilities in Ohio and Missouri
we are machining housings for radar
detectors and producing window frames
for most of America’s school buses.
At seven North America locations
Hydro Aluminum offers state-of-the-art
contract manufacturing services, for both
small- and large-scale assemblies, as
well as basic and complex fabrication
services.
For all contract manufacturing projects,
we develop the most effective programs
to assure success including process
development, sourcing of components,
and completion of Production Part
Approval Processes (PPAP) and
Advanced Product Quality Planning
(APQP). And, we will develop new technology,
expand plant capacity or make
additional investments as required to
advance the process.
We offer multi-stage fabrication,
including robotic welding and mechanical
fastening, and basic fabrication services
— cutting, drilling, punching, bending
and stamping. These are all supported
by value-added services such as
process engineering, warehousing and
Just-In-Time delivery to meet today’s
stringent requirements for inventory
management.
For both contract manufacturing and
fabrication, we deliver outstanding quality
using precision equipment and
advanced techniques to ensure that your
components meet your exact specifications.
And our contract manufacturing
centers are certified to meet ISO 9001-
2000, QS9000, or TS16949.
With our world-class talent, cuttingedge
equipment, and advanced manufacturing
and fabrication skills, we are
ready to perform any task required to
take your product to the next phase of
production.
• Over 600,000 sq. ft. of fabrication and
manufacturing floorspace
• A full range of fabrication and contract
manufacturing capabilities . . . we have
a facility that is the right fit for your job
• Cross-border manufacturing
• High production punch and cut
operations to advanced multi-step
manufacturing
• Component sourcing and project
management services
• CNC machining for milling, notching,
tapping, lathing, and countersinking
• Punch presses up to 200 tons
Fabrication/Contract Manufacturing

Touching peoples lives
From the morning commute and a long
day at the office, to an after school playdate,
a Little League game, a weekend
on the slopes, or a round of golf, Hydro
touches lives everyday.
Airbag canisters, car seat assemblies,
modular office systems, laser printers,
copiers, patio doors, deck furniture,
baseball bats, golf carts, golf bags, and
snowboards are just some of products
where you can find Hydro extrusions and
drawn tubing. These products touch
people’s lives everyday and . . . make
their lives better.
Hydro Aluminum produces extrusions
and components for a wide range of
industries and is a leading supplier to
many markets. We make more airbags
than anyone else in the world. Produce
more laser printer tubes than anyone
else. We are the number one supplier of
school bus window frames in North
America and a leading supplier of extrusion-based
truck assemblies.
We believe the best business partner
is one who understands your business
and markets as well as you do. This
requires a long-term view of business
relationships, the ability to listen and
learn, apply knowledge across industries,
and a shared passion for creating
the best products possible.
No matter the industry or markets you
are involved in, we welcome the opportunity
to leverage our expertise and technical
knowledge to help you develop
better, more effective products. And we
welcome the opportunity to learn about
your industry and contribute to the success
of your product.
• Consumer Products
• Building and Construction
• Automotive
• Trucks & Trailers
• Buses
• Marine
• Office & Casual Furniture
• Electrical & Industrial Equipment
Markets

Hydro plant network and metal sourcing
Plant network
In addition to headquarters in Baltimore,
Maryland, our network consists of eleven
extrusion, drawn tubing, fabrication, finishing,
and contract manufacturing facilities
that span from New York to Mexico.
Each plant has a unique set of capabilities
to best serve its core customer
base, but common systems and procedures
within the network allow for easy
transfer of work to accommodate fluctuations
in demand or unique production
requirements.
Our decentralized organizational
structure empowers each facility to make
decisions at the local level. This allows
our management and engineers to make
the right decisions quickly to best serve
our customers. Quotes are issued.
Production schedules are set. Shipping
is arranged. Invoices are mailed out—all
at the local level.
At the same time, our access to
Hydro technology research centers and
commitment to knowledge sharing within
the North American and global networks,
assures that the latest technology and
best practices are used at all plants.
Phoenix, AZ
Guaymas,
Mexico
Metal sourcing
Cassville, MO
Holland, MI
North Liberty, IN
Monett, MO
Commerce, TX
We are committed to providing a steady
source of metal for our customers.
Working with Hydro Aluminum Metal
Products, our sister organization and
metal sourcing partner, we can ensure
that you get the metal you need . . .
when you need it.
Metal Products is the leading supplier
of aluminum billet in North America with
more than 450,000 metric tons of casting
capacity in the U.S. and has an extensive
global casting and sourcing network.
They supply standard alloys in the 1000,
3000, and 6000 series and can develop
custom alloys, if needed, to improve
extrudability, manufacturability, and
product performance.
The Metal Products casthouse network
in North America uses proprietary
remelt technology to produce primarygrade
billet with high recycled content,
a key component for the production of
“green” products.
Working closely with Metal Products,
we can help manage your metal pricing,
assist with hedging and risk management,
and ensure a constant supply
of metal.
Kalamazoo,
MI
Fayettville, TN Belton, SC
St. Augustine, FL
Ellenville, NY
Baltimore, MD
Sidney, OH
Henderson, KY
NA Headquarters
Extrusion & Fabrication
Drawn Tubing
Contract Manufacturing
Casthouse Products
Architectural Assembly
Technical Center
Belton, SC
Toll-Free Phone: (888) 935-5754
Cassville, MO
Toll-Free Phone: (888) 935-5753
Ellenville, NY
Toll-Free Phone: (800) 431-1278
Fayetteville, TN
Toll-Free Phone: (877) 829-8366
Kalamazoo, MI
Toll-Free Phone: (888) 935-5758
Monett, MO
Toll-Free Phone: (888) 935-5755
North Liberty, IN
Toll-Free Phone: (888) 935-5757
Phoenix, AZ
Toll-Free Phone: (800) 459-3030
St. Augustine, FL
Toll-Free Phone: (800) 826-1966
Sidney, OH
Toll-Free Phone: (888) 935-5759
Transportation Components
Toll-Free Phone: (877) 537-4282
www.hydro.com/northamerica
Hydro Plant Network/Metal Sourcing

Hydro is a Fortune 500 energy and aluminum
supplier founded in 1905, with
36,000 employees in nearly 40 countries.
We are a leading offshore producer of oil
and gas, the world’s third-largest integrated
aluminum supplier and a pioneer in renewable
energy and energy-efficient solutions.
As we look forward to our next 100 years,
we celebrate a century of creating value by
strengthening the viability of the customers
and the communities we serve.
Copyright © 2005 Hydro Aluminum Printed in USA 09/05-5M/Card
Hydro Aluminum
801 International Drive, Suite 200
Linthicum, MD 21090-2254
Phone: (888) 935-5752
Fax: (410) 487-8053
www.hydro.com/northamerica
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