Testing

Colnago always took par­tic­u­larly care to the rider safety. Our prod­uct analy­sis lab uti­lizes the high­est stan­dards in the indus­try. Our frames under­goes through impact tests and fatigue tests, fol­low­ing both the inter­na­tional homolo­ga­tion pro­to­col and our inter­nal secu­rity pro­to­col. Every frame must pass the homolo­ga­tion test in every size and in every spe­cific set-up before going in pro­duc­tion or before every test on the road.

Prototyping

Colnago pro­duc­tion process implies inten­sive use of pro­to­typ­ing tech­nolo­gies. Before real­is­ing the final model, we analyse spec­i­fi­ca­tions and dif­fer­ent vari­ables through sam­ples and lab tests. The first visual and dimen­sional analy­sis is made through visual pro­to­typ­ing soft­ware, which allows us to eval­u­ate infer­ences and eval­u­ate if what we could do in the pro­duc­tion phase. After that we go to the rapid pro­to­typ­ing phase, for a “real” visual analy­sis and a sec­ond dimen­sional ver­i­fi­ca­tion. We use 3D print­ing machines and we real­ize sam­ples in resins and plas­tic pow­ders. Once val­i­dated the visual sam­ple, we real­ize sev­eral bike sam­ples with dif­fer­ent fea­tures in order to fur­ther test them in lab and on the road.

Paint Process

It’s not enough for a bicy­cle to be beau­ti­ful: it also has to look beautiful.

Colnago frames are hand painted and, as a result, every one is unique. Your bicy­cle is painted by the same crafts­men who paint frames for the pro­fes­sional rid­ers of Team Europcar and Colnago – CSF Inox.

A Colnago paint fin­ish is an intri­cate and beau­ti­ful job. Except for the head badge, none of the coloured areas or logos on a Colnago frame is a stick-on decal; all are the result of the painstak­ing skill of our paint team.

The paint process starts with mask­ing tape and thread pro­tec­tors to keep paint out of the parts of the frame where none is needed. Then, we apply a layer of spe­cial primer that helps the outer lay­ers bond to the car­bon fiber.

When the primer has been dried in an oven at 50 Celsius, the painter applies laser-cut mask­ing decals and then adds the first layer of paint. Several more mask­ing steps and lay­ers of paint go to build up the even­tual colour scheme.

In time, the masks are all removed to reveal the final fin­ish. The only remain­ing step is to coat the whole frame in a layer of lac­quer that stops the ultra-violet rays in sun­light from fad­ing the paint and helps pro­tect the more intri­cate areas from damage.

It’s not enough for us to inno­vate in the tech­nol­ogy of our frames, we want to make them more beau­ti­ful too.

Frame Design

The per­fect bicy­cle must be bal­anced. It must be made to fit you, not the other way round. That’s why we make as wide a range of sizes as pos­si­ble of our frames, with 22 off-the-peg sizes in our C59 Italia and the option of cus­tom fit for rid­ers with spe­cial requirements.

Balanced han­dling is vital too. Colnago invented mod­ern bicy­cle rac­ing geom­e­try and has refined it to per­fec­tion with han­dling that is unwa­ver­ingly accu­rate but sta­ble at speed, so a long day in the moun­tains is a bat­tle against the gra­di­ent and your rivals, not against a twitchy bicycle.

Colnago ride qual­ity is rooted in the idea of bal­ance too. A frame must be stiff, to con­vey your power to the road, but it must not be harsh. Features like our 3PRS internally-ribbed tubes and over-sized chain­stays with leaf-shaped seat­stays simul­ta­ne­ously improve rigid­ity and dis­si­pate road shock.

Frame integrity is a cru­cial aspect of Colnago design. Our frames and forks are tested in the Colnago Lab to with­stand impacts far beyond inter­na­tional stan­dards, and to retain their strength after impact. That means your Colnago can still be rid­den to the fin­ish if the worst happens.

We’re always look­ing for ways to improve our frames. New ideas start with Ernesto Colnago’s sketches, and then computer-assisted design, finite ele­ment analy­sis, and rapid 3D pro­to­typ­ing allow us to test new ideas in days. Tomorrow’s Colnagos are already on the draw­ing board.

Materials

Colnago was the first frame builder to see the poten­tial of car­bon fibre in the evo­lu­tion of the cycling. He chose to match the lat­est tech­nol­ogy with the con­cept of cus­tom geom­e­try frames. Muscular exten­sion, flex­i­bil­ity and per­sonal pref­er­ence for posi­tion com­bined with aer­o­bic and ped­alling effi­cien­cies are too many vari­ables for a rider to be locked into the con­fine­ment of only a few frame sizes. This is why all the top Colnago frames offer lugged con­struc­tion to fit all rid­ers. Whether for one of the 130 Colnago-sponsored pro­fes­sional cyclists or one of the mil­lions of demand­ing ama­teur rid­ers around the world, there is a Colnago that offers the per­fect fit. With this con­cept, Colnago takes age-old crafts­man­ship into the future.

Research and Method

Even with the vast avail­abil­ity of car­bon fibre, there are a num­ber of poten­tial prob­lems that can exist in the man­u­fac­tur­ing process. Only with great invest­ment in man­u­fac­tur­ing tech­nol­ogy can a car­bon prod­uct be con­sid­ered safe and reli­able with no sac­ri­fice to per­for­mance. The tubes of Colnago frames are built with an advanced fil­a­ment wind­ing sys­tem. This process, which is per­formed over a solid, stain­less steel INOX core, yields a highly con­sis­tent wall thick­ness, even in cases where the tubes use intri­cate exter­nal and inter­nal shape and struc­ture. Moreover, thanks to the INOX “mir­ror treated” cores, all the dif­fer­ent lay­ers are com­pressed with extremely high pres­sures. This advanced process lim­its excess resin in the com­pos­ite, reduc­ing weight while increas­ing strength. This, plus advanced tube shap­ing and struc­ture, yield the high­est strength to weight ratio.

Construction prob­lems

If to build a tube on a rigid core to be later removed is easy to imag­ine, to per­form a com­plex struc­ture as bot­tom bracket junc­tion is pretty dif­fer­ent and show prob­lem­atic dif­fi­cul­ties to be solved because of its shaped and because of all the dif­fer­ent and simul­ta­ne­ous forces that come there together once in action. The fibres ori­en­ta­tion, the nature of car­bon type itself and the total con­trol of the join­ing walls are the fruit of an exhaust­ing research, lab­o­ra­tory and road tests. The car­bon junc­tions of Colnago Frames are built by the same fibres of the tubes: made in Italy with the high­est qual­ity stan­dards. As for the tubes are the sum of over­lapped lay­ers of uni­di­rec­tional type alter­nate with var­i­ously ori­ented wefts. The inter­laced lay­ers are com­monly named 1K and 3K, the best con­fig­u­ra­tions to give homo­gene­ity, strength and reac­tiv­ity to a win­ning road bike. This comes over any aes­thetic choices that some frame fac­tory take with­out a real tech­ni­cal base.

Any detail makes the difference

Length and shape of the join­ing sur­faces, lay­ers an ori­ent­ing of the fibres. Nothing is for noth­ing and every­thing is related to angles and dimen­sion in any sin­gle frame to obtain the max­i­mum homo­gene­ity in reac­tions. The junc­tions of Colnago frames take shape around a spe­cial high den­sity poly­mer to be man­u­ally destroyed after the poly­meri­sa­tion. This exclu­sive sys­tem makes pos­si­ble to build a cave com­po­nent with com­plex (mul­ti­fac­eted) shape with­out to renounce to press the strat­i­fied fibres under excep­tion­ally high pres­sures, as it hap­pens on the tubes.

Colnago and Frame Weight

The weight of the frame is a detail which is push­ing unsafe prod­ucts into the mar­ket­place. The often unre­li­able and incon­sis­tent tra­di­tional man­u­fac­tur­ing process with car­bon can pro­duce end-products with often sus­pect yield and fatigue strength. Circumstances can lead infe­rior frames to not only crack, but can result in cat­a­strophic fail­ure with­out warn­ing. Many processes used to lighten frame weight are sim­ply not proven to be reli­able. With tech­no­log­i­cal appli­ca­tion, it is pos­si­ble to see frames in the mar­ket­place with weights between 700g and 800g. These frames can be tempt­ing to the con­sumer look­ing for the light­weight advan­tage. Colnago believes in a limit of 1000g. It is sim­ply not worth sac­ri­fic­ing han­dling, safety and reli­a­bil­ity for the neg­li­gi­ble advan­tage of a few grams of sta­tic frame weight.

The com­par­i­son “Colnago is like a Ferrari”

The car­bon fibre pro­duc­tion in the entire Colnago 2013 prod­uct line is para­mount in the mar­ket­place. Not just the raw mate­ri­als, but through­out the man­u­fac­tur­ing process, no cor­ners are cut. This is one of the most impor­tant con­sid­er­a­tions in the final price of a Colnago bicy­cle or frame. Another aspect is Colnago’s unwill­ing­ness to go out­side of Cambiago, Italy for design­ing all aspects of the finest bicy­cles avail­able. This is why Colnago offers a unique style matched with the most advanced tech­nol­ogy. “Made in Italy” on a Colnago prod­uct truly means “Made in Italy”. Behind the Colnago sig­na­ture lies the most metic­u­lous and com­plex study of every aspect of the bicy­cle, from design table to final prod­uct. It is this invest­ment in detail that make Colnago logo on bicy­cle anal­o­gous to the Ferrari Horse on an auto. This a com­par­i­son that Colnago wel­comes with pride.

Eva Lechner: my dream comes true. A podium in the world cup on my Colnago

After a long time fol­low­ing it, finally I’ve real­ized my ago­nis­tic dream: a podium in a Cross Country MTB World Cup. Last Sunday in Offenburg, Germany, in front of a large crowd, I was able to cross the line in third place at the end of the third Cup event, won by the emerg­ing French ath­lete Julie Bresset. And it’s not the only good news. I’ve dis­cov­ered my fit­ness is improv­ing con­stantly. To be hon­est I was strug­gling a lit­tle bit dur­ing the first lap: after that I was just 11th! Then I’ve started feel­ing bet­ter and every­thing went fine, even because finally punc­tures or falls did not penal­ize my race. I said that every­thing went fine because com­pet­ing with Julie was impos­si­ble dur­ing the race. She is unbeat­able at the moment, so third is def­i­nitely a great result. Now I hope to improve in the next World Cup race, on the first week­end of July in Mount Sainte Anne in Canada.

Brambilla 4th in Giro escape

Brambilla rode into the win­ning break­away, but couldn’t quite match the pace on the day’s main hur­dle at the second-category climb. He con­tin­ued to fight all the way to the line and earned an impres­sive fourth on the hard-fought stage.

“I’ve been in four break­away attempts in this Giro. We are always attack­ing and try­ing to win a stage,” Brambilla said. “Perhaps the fatigue of nearly three weeks of rac­ing is catch­ing up with me. I was hop­ing to catch back on dur­ing the descent, but it was very tech­ni­cal and I wasn’t able to con­test for the stage.”

Colnago-CSF-Inox has been active through­out the Giro with break­away attempts and vows to keep fight­ing all the way to Milano, where the Giro ends Sunday.

Another rider who’s been at the sharp end of the action has been Stefano Pirazzi.

“It’s been very dif­fi­cult to try to win a stage this year because the GC fight was not set­tled until the climb­ing time trial at Nevegal. That meant that the breaks were almost always caught because the big favorites were still rac­ing for time bonuses and to attack,” Pirazzi said. “There are still a few stages left to go. We will keep attack­ing and try to leave this Giro with a stage victory.”

Brambilla ‘enjoys’ day of suf­fer­ing up Zoncolan

Brambilla latched onto the day’s main break­away on the road to Europe’s steep­est road and only got caught mid­way up the pun­ish­ingly steep road fea­tur­ing ramps as steep as 22 percent.

“It was a great day to be in the break­away, even though I was suf­fer­ing like a dog. I knew we needed more time to have a chance to win the stage, but the pelo­ton wouldn’t let us get away,” Brambilla said before the start of Sunday’s stage. “Then when we heard that the penul­ti­mate climb was taken out, it gave us more hope. We knew it would be dif­fi­cult with the favorites were com­ing behind us.”

Brambilla started Sunday’s even more chal­leng­ing 15th stage wear­ing the best climber’s green jer­sey. He started the stage ranked sec­ond behind Alberto Contador in the King of the Mountains clas­si­fi­ca­tion, but because Contador also holds the race leader’s pink jer­sey, Brambilla got to wear the green jer­sey in the marathon, eight-hour stage.

“The green jer­sey would be nice to win, but I have to be real­is­tic,” Brambilla admit­ted. “With Contador still rid­ing to win the Giro, he will keep earn­ing more points. The cir­cum­stances are not really in my favor.”

Brambilla vows to try his luck again in the Giro’s final week.

“The team really wants to win a stage in this Giro,” he said. “We’ve been on the attack almost every day. We hope to have the legs to keep on try­ing in the final week. I hope to recover from the hard effort. This Giro is very hard, so it’s not easy to win.”

Colnago-CSF-Inox vows to keep attack­ing at Giro

Manuel Belletti was dis­rupted by a crash in the clos­ing kilo­me­ters into Ravenna and couldn’t make his sprint and came across the line seventh.

“The crash dis­rupted my sprint. It was too bad, because I was in good posi­tion,” said Belletti, who was third in stage 2. “By the time I could regain my posi­tion, it was too late. This was the last chance for the sprinters.”

Despite falling short of a vic­tory in the first half of rac­ing, the team remains opti­mistic with still two weeks of rac­ing left to go in the 2011 Giro

Riders have been work­ing into break­aways and light­ing up the roads with attacks. Stefano Pirazzi and Simone Stortoni have both been at the sharp end of the action in the open­ing days of the Giro.

“We’ve been attack­ing just about every day. The team is moti­vated and we’re look­ing for our oppor­tu­ni­ties,” Pirazzi said. “The pelo­ton is con­trol­ling the stages and not let­ting break­aways to stay away. We will keep try­ing in the sec­ond half of this Giro. We are moti­vated to win a stage, so we will keep our eyes on any openings.”

Domenico Pozzovivo has set­tled into 25th over­all at 6:04 going into the deci­sive final bat­tle­ground in the Dolomiti.

“I think the sec­ond half of the Giro will suit us bet­ter. There will be chances for break­aways to stay clear,” Pozzovivo said. “I hope to try to win a stage and climb higher in the GC. I still believe a top-10 is possible.”

Efimkin hangs tough in Sierra Nevada

Bertogliati’s pres­ence kept pres­sure off the team and Team Type 1 leader Aleksandr Efimkin rode into the lead group of 40 going into the final sum­mit climb. At the base of the final climb, Efimkin suf­fered from dehy­dra­tion because he was unable to take water from the team car with less than 20km to go.

“Today’s stage did not go as planned. RadioShack obvi­ously came to win, and they drove the pace so hard up Mt. Hamilton that we were caught out. Aleks asked for a bot­tle with 7km to go, and the com­mis­saire told me I could no longer feed,” said gen­eral man­ager Vassili Davidenko. “When you are rac­ing for the gen­eral clas­si­fi­ca­tion and you vio­late the rules, the penal­ties can be both finan­cial and as addi­tional time. I take respon­si­bil­ity for fol­low­ing the rules, which did not ben­e­fit the rider, so tomor­row we will try to dig back some time we lost.”

Efimkin, who won the Tour of Turkey before head­ing to California, crossed the line 28th at 4:10 back.

Voeckler wins Dunkirk in another impres­sive showing

The French national cham­pion won Saturday’s deci­sive stage and fin­ished safely with the leader’s to wrap up the over­all title at the Dunkirk race, one of the most pres­ti­gious mid-sized races in France.

“Thomas appears to be stronger than ever. His team­mates pro­tected him from the wind, just like they did in the first three days. After his stage vic­tory on Saturday and the over­all, Thomas is reach­ing a new level,” said Europcar sport direc­tor Ismael Mottier. “The rest of the team is in great con­di­tion and we are sure to be at our peak with the season’s most impor­tant goals still ahead of us.”

The vic­tory was the eighth for Voeckler on the year in what’s turn­ing out to be one of his most suc­cess­ful in his career.

Hot start for Colnago in Giro d’Italia

Manuel Belletti darted to third in the sprint fin­ish in the 244km sec­ond stage from Alba to Parma in a solid first week­end of rac­ing for the Colnago-CSF Inox team.

“It was a hard sprint, slightly ris­ing with some head­wind. It was a real fight to find the right wheel and when I found some space I was able to move up,” Belletti said after the stage. “I didn’t win, but it gives morale for the com­ing days. We are here to ani­mate the race and to try to win at least one stage. There are many good sprint­ers here at this Giro, but today con­firms we’re on the right track.”

Sunday’s sprint capped a strong open­ing week­end for Colnago-CSF Inox in the 94th edi­tion of the Giro d’Italia. The team was among 23 start­ing squads for the 2011 Giro and posted a ride of 19th in the team time trial at just 1:02 behind spe­cial­ists HTC-Highroad.

Belletti, who won a stage in last year’s Giro, will be look­ing to make his pres­ence felt in the open­ing sprints and break­aways of the first week of the Giro.

Pozzovivo, Belletti to lead Colnago-CSF Inox at Giro

Domenico Pozzovivo will be man to carry the col­ors in the GC bat­tle while Manuel Belletti and Sacha Modolo will try their luck in the bunch sprint. In between, there will be plenty of road for the rest of the team to go on the attack and ride into break­aways in a bid to win a stage or grab the pink jersey.

“It’s a solid and tight-knit team. We final­ized our selec­tion after study­ing the results and fit­ness of the rid­ers in the past two races. We believe strongly in this group,” said team man­ager Roberto Reverberi. “Pozzovivo is in excel­lent form and can count on the sup­port of the team. With Modolo and Belletti, we can be right in the heat of the bat­tle for the sprints. The oth­ers will have their chances in break­aways. We are ready give our fans and spon­sors strong emotions.”

Pozzovivo, ninth in the 2008 Giro d’Italia, will be look­ing to climb as high as pos­si­ble in the over­all stand­ings. A bru­tal final week across the Dolomites suits his style per­fectly. He recently checked out some of the key climb­ing stages and liked what he saw.

“We exam­ined all the big stages and we know this Giro will be very dif­fi­cult. There will not be any cease-fires. It’s going to be a bat­tle every day,” Reverberi said. “There are many climbs suited for Pozzovivo, so we do not want to get dis­tracted. It will be a great Giro.”

Colnago-CSF Inox for Giro d’Italia
Domenico Pozzovivo
Manuel Belletti
Sacha Modolo
Gianluca Brambilla
Federico Canutti
Filippo Savini
Simone Stortoni
Marco Frapporti
Stefano Pirazzi

Efimkin wins Tour of Turkey

Efimkin clinched the over­all title after fin­ish­ing safely in the pack Sunday in what’s the biggest win in team his­tory for Team Type 1 – sanofi-aventis.

The Russian nearly won in stage 5 and woke up the next morn­ing intent on try­ing again. When he saw the race lead­ers strug­gling on hills mid­way through the sixth stage, Team Type 1 exe­cuted per­fect team tac­tics to put three rid­ers into the win­ning breakaway.

Efimkin grabbed the leader’s jer­sey and never looked back. Team Type 1 rode to defend his lead in the final two stages to secure a huge vic­tory after notch­ing a dozen sec­ond and third places in the open­ing three months of rac­ing in Europe.

“This is the biggest win of my career and I thank my team­mates for help­ing me do it,” Efimkin said. “We’re a strong team and every day in Turkey we got stronger. To have these glad­i­a­tors pulling for me and pro­tect­ing the leader’s jer­sey has made me a very happy man. I feel we have strong momen­tum for the next two months of racing.”

The vic­tory comes just a month after thieves heisted nearly all of Team Type 1’s bicy­cles, parts, tools and equip­ment in a rob­bery while com­pet­ing at a race in March.

“A few weeks ago at Coppi e Bartali all of our bikes were stolen. Everything. We lost wheels, we lost tools, we lost time trial posi­tions built into the frame­sets. But we took the right mea­sures to build back up. Everyone on the team, rid­ers, staff, man­age­ment, all put in over­time to get to where we are now,” said team gen­eral man­ager Vassili Davidenko. “Winning the Tour of Turkey this year is a great hon­our for us and a great reflec­tion of the pro­gram we built.”

Colnago-CSF Inox also enjoyed a fine run through Turkey, win­ning the third stage with Belletti, who also claimed the leader’s jer­sey for one day.

Up next for Team Type 1 is the Tour of California while Colnago-CSF Inox is head­ing to the Giro d’Italia.