2006 03 fab by NOMMA

Vol. 47, No. 2

Job Profile

A Cayman Islands fabricator lets his artistic side loose with this 2006 Top Job entry. See page 60.

Ornamental & Miscellaneous Metal Fabricator March/April 2006

Tips and Tactics

Learn a quick and easy rule for roll bending. See page 12.

Special Feature

METALfab 2006 follow up: Exhibitors share their wares. See page 44.

Fab Feedback

Setting pipes and posts in freezing temps. See page 90.

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Inside

March/April 2006 Vol. 47, No. 2

Ever install one of these—an uphill automatic swing gate? It works and it won a 2005 Top Job Bronze award too. See page 56.

Tips & Tactics

Member Talk

Job Profiles

Roll bending: A two-part rule . . . . . . . . . . . . . . . . . . . 12 Two quick and easy equations can help you make better bending decisions.

Swimming to the top of Katrina’s storm . . . . . . . . . . . . . . . 34 A NOMMA member rebuilds his business despite stormy setbacks.

By John G. Sherrell

By Lee Rodrigue

Website development for those NEF Special Feature yet to dive in . . . . . . . . . . . . . . . . . . . . . . 16 NOMMA Education Creating an effective online presence Foundation . . . . . . . . . . . . . . . . . . . . . . . 42 is easy and so worth it. By Jeremiah Goode Find out what NOMMA members have to say about NEF instructional videos. Navigate the web and get the most of what’s out there . . . . . . . 18 Special Feature Make these helpful websites and e-mail tools some of your favorites. METALfab 2006 By Rob Rolves Trade Show Report . . . . . . . . . . . . . . 44 If you missed the show, you won’t want to miss a recap of what exhibitors Shop Talk showcased at METALfab 2006. Safety concerns complicate blasting . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Job Profiles Knowing about respirators may help. By John Campbell An uphill battle ..................................56 Figuring out the uphill swing was If you’re maintaining an in-house blasting almost the easy part on this job. operation, tips on respirators can help reduce risks.

By Rick Worries

Designing and fabricating a grand copper shower ..................60 A metal artist shares his process. By Karoly Szucs

A new decorating idea for older homes ................................64 An ornamental radiator cover solves a decorating problem. By John Caldwell

Biz Side Sole proprietorship or corporation? . . . . . . . . . . . . . . . . . . 68 Find out if incorporating is the right choice for your business. By WIlliam J. Lynnott

What’s Hot! Nationwide Suppliers . . . . . . . . . . . 74 New Members . . . . . . . . . . . . . . . . . . . . 74 Biz Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Coming Events . . . . . . . . . . . . . . . . . . . 81 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 Working Smarter . . . . . . . . . . . . . . . . 87 Classifieds . . . . . . . . . . . . . . . . . . . . . . . . 88

President’s Letter . . . . 6 Editor’s Letter . . . . . . . 8 Reader’s Letters. . . . . 10 Fab Feedback 90 Setting pipe in freezing NOMMA is already meeting Running a successful business Thanks for the article weather. its long-term goals. means going the distance. on components last issue. Cover photo by Justin Uzzell. Shower by Artisan Metal Works Ltd., Grand Cayman Islands. See story page 60.

March/April 2006

Fabricator

President’s Letter

Whatever it takes Dedicated to the success of our members and industry. NOMMA OFFICERS President Doug Bracken Wiemann Ironworks Tulsa, OK

Vice Pres./Treasurer Breck Nelson Kelley Ornamental Iron LLC Peoria, IL

President-Elect Chris Connelly DeAngelis Iron Work Inc. South Easton, MA

Immediate Past President Curt Witter Big D Metalworks Dallas, TX

FABRICATOR DIRECTORS Rob Mueller Mueller Ornamental Iron Works Inc. Elk Grove Village, IL

Don Walsh Pro-Fusion Ornamental Iron Inc. San Carlos, CA

Sally Powell Powell’s Custom Metal Fab Inc. Jacksonville, FL

Terry Barrett Royal Iron & Aluminum West Palm Beach, FL

Fred Michael Colonial Iron Works Inc. Petersburg, VA

Bob Foust Bob’s Ornamental Iron Studio Kansas City, KS

SUPPLIER DIRECTORS David T. Donnell Eagle Bending Machines Inc. Stapleton, AL

Gene Garrett Regency Railings Inc. Dallas, TX

Bob Borsh House of Forgings Houston, TX

Meetings & Exposition Manager Martha Pennington Communications Mgr. J. Todd Daniel

Administrative Assistant Liz Johnson Technical Consultant Tim Moss Editor Rachel Bailey

2006 ADVISORY COUNCIL Jay Holeman Mountain Iron Fabrications

Doug Bracken Wiemann Ironworks

Tom McDonough Master Metal Services Inc.

Nancy Hayden Tesko Enterprises

Rob Rolves Foreman Fabricators Inc.

Goal: NOMMA will be an indispensable resource for knowledge exchange and industry business services.

At this writing, NOMMA staff is working on building the NOMMA Knowledge Base, a searchable database in addition to the NOMMA Listserv which allow members to find solutions for most of their fabrication questions. Imagine, having solutions from your peers for brazing and welding brass cap rail and finishing stainless steel just a few clicks away! Part of that Knowledge Base is also the new and improved online supplier directory and a concentrated effort to add even more value to the convention and trade show. Goal: NOMMA will be recognized as the public policy advocate for our industry.

NOMMA STAFF Executive Director Barbara H. Cook

I have heard the expression “whatever it takes” more than once in the last several weeks, and I think it is an appropriate theme for my last column as NOMMA President. Your elected board and staff, I believe, would do whatever it takes to meet the needs of the membership. A review of NOMMA’s strategic plan through 2009 shows that we are already working toward meeting four major long-term goals.

Curt Witter Big Metalworks

Currently, NOMMA represents industry interests in national code writing meetings. Keeping the interest of our members in front of code officials at the International Code Council is vital if we are to survive and prosper. Later this year NOMMA will introduce templates for standard terms of contract for use by our members to help them in their on going business efforts. GOal: NOMMA will promote our industry to design professionals and specifiers in the building and construction industry.

industry, our members, architects, and designers. These specs follow the CSI format as closely as possible and are tailored to fit a specific variety of products. The Technical Committee needs a great deal of input from the membership on this project but the results should be the basis for ornamental and miscellaneous metal specifications for years to come. Combine this with the soon to be released NAAMM/ NOMMA Finish Manuals and Standard Trade Doug Bracken Practice Guidelines, is president of and you’ll see how NOMMA is building the National Ornamental and the best set support Miscellaneous documents this indus- Metals Association. try has ever seen. Goal: NOMMA’s financial security will allow it to achieve its purpose and goals.

NOMMA has long enjoyed financial security due in large part to our diligent staff, executive director, Barbara Cook, the success of the Fabricator magazine and the loyalty of the membership. The NOMMA Education Foundation, a new vehicle for funding is emerging as an important component in the overall long term strategy. But, the costs to achieve all that NOMMA needs to achieve are increasing. NOMMA’s board continues to investigate ways to manage costs, increase funding, and retain and increase membership to continue the positive financial trend. It should be no surprise that NOMMA is well on the way to meeting these goals right now. I encourage you all to get involved in any capacity to help move NOMMA forward into its next 50 years! Respectfully submitted,

NOMMA is just starting a series of model specifications for use by the Fabricator

March/April 2006

Fabricator

How to reach us Ornamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA). O&MM Fabricator / NOMMA 1535 Pennsylvania Ave. McDonough, GA 30253

Editorial Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph: (423) 413-6436. Fax: (770) 2882006. E-mail: fabricator@nomma.org.

Advertising For information, call Rachel Bailey, Ph: (423) 413-6436. Ads are due on the first Friday of the month preceding the cover date. Send ads on CD to: Fabricator at address above. E-mail ads to: fabricator@nomma.org (max. 5 megs by e-mail). Or upload ads to our website where a downloadable media kit is available: www.nomma.org.

Membership In addition to the magazine, enjoy more benefits as a NOMMA member. To join, call (888) 516-8585. For a complete list of benefits, see membership ad in this issue.

Classifieds $25 for up to 35 words, $38 for 36–55 words, $50 for 56–70 words. Send items to: Rachel Bailey, Fabricator, at address above, or E-mail: fabricator@nomma.org. Ads may be faxed with credit card information to: (770) 288-2006. Deadline: 2nd Friday of the month prior to publication.

Subscriptions Subscription questions? Call (888) 5168585. Send subscription address changes to: Fabricator Subscriptions,1535 Pennsylvania Ave., McDonough, GA 30253. Fax: (770) 288-2006, or E-mail: fabricator@nomma.org. 1-year: 2-year: 1-year: 2-year:

U.S., Canada, Mexico — $30; U.S., Canada, Mexico — $50; all other countries — $44; all other countries — $78.

Payment in U.S. dollars by check drawn on U.S. bank or money order. For NOMMA members, a year's subscription is a part of membership dues.

Supplier Directory Published each December as a separate issue. Deadline for all advertising materials is August 31. For info, contact Todd Daniel at (888) 516-8585 or todd@nomma.org.

Reprints For a quote, contact Rachel Bailey at (423) 413-6436 or fabricator@nomma.org. Opinions expressed in Fabricator are not necessarily those of the editors or NOMMA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA. Circulation: 9,000.

Editor’s Letter

True success comes from endurance Well I don’t mean to brag about myself, but I will. On January 8, 2006 I completed a marathon, and I don’t mean the January-February issue of Fabricator. I literally ran an entire marathon. I did it in honor of my niece, Lauren Rachel Squires, a six-year-old leukemia survivor who’s taught me a few things about resolve. Her dad and my other brother ran with me the whole way. And I’m here to tell you there’s a reason a marathon is 26.2 miles, other than that’s the distance between Athens, Greece and Marathon, Greece. It’s that long because that kind of distance separates people who go the distance from people who don’t. It takes incredible stamina to run that many miles in a row, believe me. But I believe it takes just as much commitment to truly succeed at your craft. Many of you already know that it takes more than just pure talent to make it in this world. You have to put that talent to the test every day. I have a newfound appreciation for people like you, readers of Fabricator, who have the heart and the determination to make your talent a profitable enterprise. Being a small business owner takes incredible stamina. You have to withstand 80-plus-hour work weeks, sacrifice time with your family, and swallow your hard-won pride. Withstanding the hard times makes the good times better. I’m sure many of you, as small business owners, feel like most days are marathons. (Technically they’re not, unless you are actually running 26.2 miles in a row.) But still, you know it’s all worth it when you get that bid, or finish that job, or follow through on a decision that is best for the company but by no means is an easy task. This issue of Fabricator is full of

inspiring stories, fabricators who just don’t know the word quit. Like Joe Strain of Strain Metalworks. I told you last issue about this incredible person whose goal is to rebuild his fabrication business in Manderville, LA regardless of the setbacks he’s suffered from last hurricane season. Even Strain says, “The great thing about being a fabricator, about working with metal, is that it teaches you how to deal with a really unpleasant situation and turn it into something good.” (His story appears on page 34.) Then there’s Rick Wories of Builders Ironworks Inc. who faced and won an Rachel Bailey is uphill battle from editor of start to finish on his Ornamental & 2005 Top Job Bronze Miscellaneous Award winning Metal Fabricator. driveway gate. (See page 56.) And this year’s Top Job contest reveals some resolute fabricators too. John Caldwell of AAA Iron Works took the job other fabricators in his area wouldn’t, and he ended up creating an innovative niche in the marketplace, an ornamental radiator cover. (Read about it on page 64.) Determination is key, but remember: slow and steady wins the race. For those of you who are thinking of incorporating, don’t get too far ahead of yourself. Business tips on page 68 can help you see if forming a corporation is really the best choice for your business right now. So, whatever business decisions you make this year, don’t lose heart, keep the forge burning, and never lose sight of your goals. Enjoy the read,

Fabricator

March/April 2006

Fabricator

Corrections and Readers’ Letters Address corrections Got a few address corrections to make from our January-February 2006 issue. On this page last issue I gave the wrong ending for Steve Barringer’s Power Hammer School website address. It is www.powerhammerschool.com. So check that out if you’re interested in enhancing your fabrications with some forging detail. Also, Steve’s school is at his shop B2 Design Ltd. in Mooresville, NC (not SC). Sorry about that Steve. Then on page 86 last issue I told you about the good work D.J.A Imports Ltd. did for our industry by holding an interactive workshop at Trinity College in Hartford, CT. D.J.A. is located in the Bronx (not Brooklyn). My apologies, Gina.

Tell us what you think Mail Letters to the Editor, c/o Fabricator, 1535 Pennsylvania Ave., McDonough, GA 30253. E-mail fabricator@nomma.org Fax (770) 2882006. Please include your name, company, address, telephone number, and e-mail. Letters are subject to editing for clarity, grammar, and length. W RI TE !

Great article, thanks for the extra copies Thanks so much for all the extra copies of the Fabricator with Lee’s story in it [“Using Components Effectively: The Art of the Everyday Job,” page 66 of the January-February 2006, featuring Madden Fabrications and Kervin Brothers Ornamental Iron Inc., by Lee Rodrigue]. If you knew me any better you would have known I don’t have that many friends

We also received a couple letters from readers interested in helping out some of our NOMMA members who suffered loss from the storms that hit the U.S. Gulf Coast region this past summer and fall. NOMMA is not legally set up to act as a source of fund

to give that many copies to, but I appreciate it. I may be a little biased, but Lee does a great job with his technical articles. He even made Gary Kervin sound like he knew what he was talking about. (Those kinds of comments are probably why I don’t have any friends!) Thanks again and thanks for putting together a great magazine every time! Greg Madden Madden Fabrications

collection for disaster relief. To offer assistance, please contact shops directly. You can also view postings concerning Hurricane Katrina listed in the members only bulletin board section of the NOMMA website: www.nomma.org.

928-422-1000

Fabricator

March/April 2006

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Technique

Tips & Tactics Contact: John Sherrell Eagle Bending Machines Ph: (251) 937-0947 Web: www.eaglebending machines.com

Roll bending: A 2-part rule Stay out of trouble, save time and money, and remain within the laws of physics. By John G. Sherrell, Eagle Bending Machines One of the most common questions people have regarding roll bending is how small or tight of a radius can a given profile be bent. This is an important question for many reasons. What an architect, engineer, or artist can put to paper regarding curved and bent shapes may or may not apply to the material that has been selected or may not even apply to the laws of physics. When it is your task to turn these designs into reality here is a handy rule-of-thumb that can: 1) keep your out of trouble, 2) save time, and, 3) help you make design recommendations that are more likely to fall within the laws of physics. It is a two-part method called the Eagle 10-20 Rule. When roll bending any profile, the inside of the radius is compressed and the outside of the radius is stretched. Roll bending feasibility is dependent upon how well a profile can hold up to these forces. The Eagle 10-20 Rule is not machine specific and can help determine if a profile is suitable for roll bending at a given radius with non-heated material. Part 1: Multiply the material height by 10 to get the minimal roll-able diameter. Equation: Material Height x 10 = Minimal Inside Diameter

It may be possible to roll bend smaller diameters but the 12

effects of material deformation and distortion will be more significant. If the required radius is at or below the calculated minimal inside diameter, it is best to physically test the material to determine the results and bend quality. Part 2: Divide the material height by the material thickness. If the result is greater than 20, the material will fail/distort and is not suitable for roll bending. Equation: Material Height ÷ Material = Less than 20

You can think of a scale of 1 to 20, where “1” is very easy and “20” is very difficult. With profiles which score 15 to 20 it may be necessary to roll the part in multiple passed to relieve stress off of the profile. Or it may be necessary to use a filler (nylon or shot medium) to provide additional support to withstand the bending pressures. If the score is high, testing is recommended to determine results or roll bending quality and profile esthetics. Scores that fall below 15 indicate the profile will be easier to roll bend. Easier means that these profiles will require fewer roll bending passes and will take less time to produce. More detailed information on roll bending can be found at www.eaglebendingmachines.com.

Profile A: The “Eagle 10-20” bend factor for profile A = 2 ÷ 0.125 = 16. This bend factor is below 20. 1A and 2A: Profile 1A was rolled to a 20” I.D. in two passes. Profile 2A was easily rolled to a 30” I.D. using a single pass. Profile B: The “Eagle 10-20” bend factor for profile B = 2 ÷ 0.075” = 26.6. This bend factor is above 20. 1B, 2B, 3B, and 4B: Profile 1B collapsed under the roll bending pressure and could not be rolled to a 20” I.D. regardless of the number of passes used. Profile 2B exhibited sidewall deformation when rolled to a 30” I.D. in one pass. Profile 3B required 5 passes to roll to produce an acceptable 30” I.D. with no sidewall deformation. Profile 4B was rolled to a 104” I.D. in a single pass with no sidewall deformation. Conclusion: The selection of profile A for a 30” I.D. is able to be rolled 5 times faster than material B, produces a better quality bend, and will save labor cost.

Fabricator

March/April 2006

Marketing

Tips & Tactics Contact: Jeremiah Goode Wrought Iron Concepts Inc. Ph: (877) 370-8000 E-mail: jgoode@wroughtironconcepts.com Web: www.wroughtironconcepts.com

Website development for those yet to dive in Having a professional website attracts new business, serves existing customers, and saves time and money. By Jeremiah Goode, Wrought Iron Concepts Inc. A professional looking website is one of the most powerful sales tools available to small businesses today. It can attract new customers, project a positive image of the company, and more importantly save you a significant amount of selling time when working with your clients. In this article I’d like to provide some basic tips and suggestions on: Getting started Creating a professional look Saving valuable selling time Attracting more business If you employ the services of a website development company, many of the following details will or should be covered, and your answers should be handled by a knowledgeable professional. These companies, however, can sometimes charge thousands of dollars for their services. So if you’ve decided to develop a site on your own, or are looking at a template website design, the following information should prove to be very valuable. Picking a website address

First, having a website that is easy for your customers to locate is your first step to a successful website campaign. In order for your customers to easily locate your website you should choose a domain name that is associated with your company’s name. A domain name is your website’s address on the World Wide Web, i.e. www.wroughtironconcepts.com. There are many domain name extensions available for you to use:.com, .net, .org, .biz, etc.; however, .com and .net are the most widely used. A website hosting provider would be the place to contact in order to register and acquire your domain name. Website development

Next comes the design and layout part of your website— also known as website development. A good website allows customers to easily locate what they want to find. Your homepage should be professional, clean, and easy to 14

Wrought Iron Concepts places their contact information in a highly visible spot on their web page, front and center, along with immediately visible pictures of their work.

navigate. Your company contact information should be listed on the page and easy to see. You also want to have information on that page that describes your company and the services you offer. Also, keep the amount of text on your home page down to one or two paragraphs. This will help keep your customer’s attention. Now, it’s tempting to have large flashing banners, moving parts, or background music on your home page—resist this temptation at all costs! They work great for advertisements on other search engines, but for most people they are a distraction. If you must have moving banners or flashing elements on your site, keep them as SMALL as possible. Remember this is the first thing your customers will see when they visit your website; you want to have as professional of an image as possible. Even if you are a part time welder who works out of his truck, having a professional looking website gives your company a larger presence, which will help you sell and maximize a job. 24/7 Selling tool

Your new website is now open 24 hours a day, seven days a week, so having the right information available will allow Fabricator

March/April 2006

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March/April 2006

Fabricator

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customers to make concise decisions without calling and asking a lot of questions. Typically, the right information would include photos of your work. If a homeowner or builder is on your website, you want them to view photos of your past projects. Your website should have an organized project photo gallery where your customers can brainstorm for ideas from the comfort of their own home computer. They can print out pictures from your online picture album on their printer and mark up the pictures with their own design ideas. This allows the customer to be involved in the design process without tying up a lot of your time. It’s also helpful if you can incorporate a parts catalog on your website to allow customers to look at other types of accessories or ornamentation they could add to customize and make their project unique. Imagine the sales call when a customer walks in and says, “Mr. Jones, I’ve been to your website, and I like this style gate, only with this type of spear on top and with a waterjet cut-out of a horse.” Have prospective customers visit your website before meeting with them in person. It WILL save you time and money. Also, a professional and sales-effective website should have some sort of contact form, allowing visitors to send a request for bid or other information simply by filling in a few boxes and pressing send. These forms are usually emailed to the company’s e-mail address, but many times this

information can be sent to your fax if you do not use e-mail. Attract people to your site

Attracting people to your website will attract more business in general. And although having a professional looking and informative website is one thing, you have to make it easy for current and potential customers to find it. There are many ways that potential customers can find your website. Most search engines use keywords and other text throughout your website and compare that information to the words that searchers are searching for. In order to attract the right audience via search engines you want to choose keywords that are relevant to the content you are displaying on your website. You should limit your keywords to around 30 keywords in order to get the best results from search engines. Other, and frankly much more effective, ways of attracting potential customers in your local markets are to list your website address in all of your advertisements, phone books, business cards, and especially vehicle signage. Word of mouth is also a great way to inform customers about your website. When new customers call you for information, direct them to your website where they can read and view all your information and advertisements on their time, not on yours. These tips and guide lines will help you in creating a positive image on the internet.

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Fabricator

March/April 2006

Fabricator

Working the web

Tips & Tactics Contact: Rob Rolves, Foreman Fabricators Inc. Ph: (314) 771-1717 E-mail: rrolves@foremanfab.com Web: www.foremanfab.com

Navigate the web and get the most of what’s out there These tips on utilizing the Internet (and websites listed on page 20) can help maximize your online experience. By Rob Rolves, Foreman Fabricators Inc. As mentioned in the January-February 2006 issue, computers and the Internet have changed the way we do business, even for the small business owners that make up our industry. Last issue I went over tips to help make your life easier when dealing with your personal computer (PC). This issue I’d like to help you help yourself to the World Wide Web. There is so much out there just at your fingertips. But sometimes, the intricacies of computers and the web make the reality of that phrase ironic because knowing which buttons on your keyboard to press makes all the difference. That said, let’s see if I can offer some tips to make your online surfing experience a little easier. Quickly accessing frequently used sites

There are so many websites that can be helpful that it would not be practical or even possible to list them all here. (See side bar on page 20.) But once you find one you like, there is a little trick you can do to make it easier to access it again. You can add it to a file group in an easily accessible location on your browser’s menu options so that it’s easier to find it back without having to remember the address. The terminology for saving web pages may be different depending on your browser (the program you use to look at web pages, such as Microsoft’s Internet Explorer), but all browsers 18

should have a method for you to save a page so you can simply click on that link and go straight back to it later. On Internet Explorer this tool is called “Favorites,” and it is found on the menu that usually runs along the top of your screen when the Internet Explorer window is open. The way you reorganize your favorites is up to you. But as with all things computer related, the more consistent your organization method is, the more time you’ll save. Your browser has many different functions that make surfing the web easier. Take a look at all the buttons and menu options and see what attracts you. If you’re afraid you’ll do some damage, go to “Help” and find the menu option you were curious about, and read it to see where it will take you. Using e-mail as a resource

You can find almost anything on the Internet, and coupling that with email you have quite a bit of information available. Many companies have e-mail systems where you can send a note to a vendor, and they can research a question for you while you go about your business. A phone call can do the same thing of course, but sometimes there are long distance charges and an e-mail leaves you with a written record of your request and the vendor’s reply, which can be advantageous when you just can’t remember exactly what their reply was.

Another huge benefit of e-mail is NOMMA’s Listserv which is essentially a large round table for all who are part of it. Any e-mail sent to the Listserv address goes to all registered users. It’s a convenient way to carry on a group conversation and to get your questions or thoughts out to a large group at once. Many of the people you seek out on a regular basis at METALfab are on it giving you their ear year round. Email Todd Daniel for more information (todd@nomma.org). I can’t recommend this forum enough, and as more people get on it, the better it will become. A trick for Google

One website I will mention here is Google and its ability to define a word for you. At the search box type in “define:X” The “X” signifies whatever word you want to look up. Remember to put a colon after define. Google will look for definitions on the web, and the benefit is it will come back with different meanings for different contexts and industries. Selling scrap on Ebay

Many are familiar with the online auction site Ebay. This may be an outlet for projects that somehow were left behind in the shop. Using your digital camera you can take a picture of that job and post it on any online auction site (there are others out there). This is a great way to possibly get some cash in your pocket for that old job that you thought you were going to have to scrap. Fabricator

March/April 2006

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Hot sites Associations related to our industry

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Stainless steel Aluminum CDA ASA NAAMM Metal Manufacturing DASMA

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National Ornamental & Miscellaneous Metals Association, publisher of Fabricator magazine Specialty Steel Industry of North America Aluminum Association Copper Development Association American Subcontractors Association National Association of Architectural Door & Access Systems Manufacturers Association International American Galvanizers Association American Fence Association Artists-Blacksmith Association of North America American Institute of Steel Construction International Code Council Occupational Safety and Health Administration

General information

Snopes

www.snopes.com

Mapquest Google map

www.mapquest.com Maps.google.com

SIC/NAICS codes

www.census.gov/epcd/www/naics.html

Area codes

www.mmiworld.com/codelist.htm

Zip codes

http://zip4.usps.com/zip4/welcome.jsp

Weather loop

www.intellicast.com

Weight Calculator

www.metalsuppliersonline.com/ research/FreeWeightCalc.asp http://phonespell.org www.straightdope.com/index.html

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Attempts to clarify general rumor from fact. Good place to check for email hoaxes. Get a map of an address or driving directions. Can get satellite view, map view, or something between. Can cross reference between the two business classification code systems and learn more about business activity across North America. Many sites like this one, listing of area codes and what areas they cover. Part of www.usps.com, you can get zip code, zip+4, other lookups and postal information. You put in your own zip code to get looping satellite radar. Get material weights. Find out what your phone number spells. All the important things in life explained, settles many office wagers.

Business operating tools

Hire Success

http://hiresuccess.com

IRS EFTPS

www.irs.gov www.eftpssouth.com/Eftps/

One of many companies that can help test new applicants to help you hire better. Internal Revenue Service, tax information and forms. Tax payments via electronic funds transfer, can be arranged online.

Citizen information

Voting U.S. Senate U.S. House

www.vote-smart.org http://senate.gov http://www.house.gov

Independent review of people running for office. Official site of U.S. Senate. Official site of U.S. House of Representatives.

Computer aids

Ad-Aware Spybot 20

www.lavasoft.com Program to help with spyware. www.safer-networking.org/en/index.html Program to help with spyware. Fabricator

March/April 2006

Shop Talk Respirators for abrasive blasting should be NIOSH approved as a Type C or CE Continuous Flow Class Respirator.

Safety concerns complicate blasting Learning more about respirators and other equipment required for safe blasting can make your in-house operation more compliant. By John Campbell Sand blasting in manufacturing is as generic as the word aspirin to pharmacology. For decades sand was the abrasive of choice because it was efficient, inexpensive, and available almost everywhere. The downside is its friability, the brittleness of 22

quartz with its tendency to break into small dust particles. Sand cannot be used more than once in blasting because 70 percent of the hard quartz turns to dust, and itâ&#x20AC;&#x2122;s the silica dust thatâ&#x20AC;&#x2122;s so deadly. In fact a leading state for promoting safety on the

For your information NIOSH The National Institute for Occupational Safety and Health offers information on respirators. Visit: www.niosh.cdc.gov/niosh/ homepage.html Respirators: Respirators and other safety gear shown in this article are manufactured by E.D. Bullard Co. (www.bullard.com).

Fabricator

March/April 2006

job, California, has made it illegal to use silica sand as a blasting media. But other blasting media present safety concerns as well. Because of developing safety regulations associated with blasting, its legal and moral practice has become complex and expensive to manage. Respirators are important pieces of equipment to know more about because in all blasting operations, where abrasive media are propelled at high pressures for cleaning purposes,

ventilation is a problem. Some media are more friable than others. Tiny particles remain airborne for long periods of time; and when inhaled, dust can be a serious health hazard. If the surfaces being blasted contain toxic materials like lead, beryllium, cadmium, or chromium, the pulverized dust can harm the respiratory system. Heavy metal poisoning from lead affects the kidneys and other vital organs. No one disputes the employersâ&#x20AC;&#x2122; responsibility and moral obliga-

tion to implement safety measures to protect their employees. To that end respirators are recommended. But the type of respirator and its maintenance are important factors in their effective safety applications. The 411 on respirators

Many people think of a respirator as an air-purifying mask that captures foreign particles in the air on a filter. Other types are chemical filters using cartridges or canisters to protect against gases and vapors. Neither of these types of respirators is adequate to protect operators from the dust created by blasting equipment. Only continuous flow, air-fed helmets with a positive air pressure inside the helmet are suitable for use in blasting abrasive media. This equipment, the helmets, hoods, and full-face models, must be approved by the National Institute of Occupational Safety and Health (NIOSH). In enclosures like storage tanks and blast rooms all personnel must wear approved respirators at all times. The Occupational Safety and Health Administration (OSHA) enforces the use of supplied-air respirators. They also caution against using any blasting media with more than 1 percent silica sand content. Air-fed helmets for abrasive blasting are classified by OSHA as Type CE, continuous flow air respirators. These headgears not only furnish the operator with clean, fresh breathing air, they protect the head from ricocheting abrasive, and they muffle noise. They also provide a wide range of vision and offer head impact protection. The maximum sound level inside the helmet must not exceed 80 decibels on the A scale as covered by OSHA regulations. The window lens protects the operatorâ&#x20AC;&#x2122;s face from rebounding abrasives, but the operator should wear safety glasses as well. Dressed in a blast suit, gloves, and an air-fed helmet the operator looks like an astronaut ready to step out on the moon. As an additional safety feature, some helmets can be equipped with a two-way FM radio because the old method of tapping the operator on the shoulder to shout â&#x20AC;&#x153;turn off the Fabricator

March/April 2006

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residue is shoveled). If operators remove their helmets during clean up they expose themselves to dust being drawn out of the blast area by the ventilation system. Blocking off the blasting site and adjusting the size of the zone will prevent unprotected personnel for inhaling toxic particles. OSHA recommends that safety personnel monitor the atmospheric dust in the area of blasting activity. The humidity, ventilation, and type of abrasive media have an influence on the size of the blasting zone. Other safety equipment

The basic equipment for pressure blasting includes an air compressor providing up to 125 psi air pressure, various regulation hoses, an ASME coded blasting machine, an oil-less air pump, and as shown here the appropriate helmets and protective gear.

nozzleâ&#x20AC;? is not always practical. Depending on the nozzle design and the blasting pressure, the velocity of abrasives leaving the nozzle can reach speeds of 660 feet per second compared with 1100 feet per second for

the speed of sound. Often after blasting, operators will remove their respirator helmets too soon or when they remove their protective suits, they inhale dust. Cleanup is one of the worst times (when

The entire setup for pressure blasting is complex and fraught with hazards requiring regular, every day maintenance monitoring. The basic equipment consists of an air compressor to provide up to 125 psi air pressure with hose leading and attached to an American Society of Mechanical Engineers (ASME) coded blasting machine. The compressor has to be upwind or located where dust wonâ&#x20AC;&#x2122;t get sucked into the compressorâ&#x20AC;&#x2122;s

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intake. Then, there’s a hose from the blasting machine to the operator who is holding an appropriately sized blasting nozzle. That hose must have regulation hose couplings, safety pins and safety cables; and it has to be inspected daily for weak spots. Threads must fit tightly and worn gaskets replaced regularly. If the air compressor is lubricated with oil, there’s the risk of carbon monoxide and oil vapors contaminating the air supply. A separate oil-less air pump is necessary to provide Grade D air to the operator. These small, low-pressure air pumps feed ambient air to the operator’s helmet at a regulated rate of 6 or 7 cubic feet per minute (cfm). Every year there are a few deaths where air-hoses are connected by mistake to inert gas outlets. In Europe all air-fed hoses must be color-coded green. Prevent static buildup

Static electricity is generated by the friction of abrasive media whipping through plastic or rubber hose. Dean

Klingbeil at U-Spray Inc., Milwaukee, WI, tells of an experience his brother had preparing an automobile for painting. He was blasting with a plastic abrasive and the automobile with its rubber tires was not grounded. “The static buildup was so great, the arc knocked him on his ass,” said Dean. “It’s worse in the winter time, when the air is drier. We are very conscious of static electricity. I won’t use walnut shells or any organic materials where there’s dust created that might be explosive. Nor, will I blast the under carriage of an automobile. It’s just too dangerous.” To avoid static buildup Clemco Industries Corp., a manufacturer of safety equipment, recommends using static-dissipating hose and coupling gaskets. There’s nothing more unnerving than a static shock on non-metal blasting jobs where the operator becomes the ground for the electricity to travel. This is especially hazardous when blasting in a confined area like a storage tank where there might be

flammable fumes of some sort. Setting up operations in-house

NOMMA member Tom Forsythe at Castle Iron in Cherry Hill, NJ, is in the midst of installing a powder coating line and a blasting room for recycling abrasive media. They blast with aluminum oxide. “This is going to be a new company called Castle Coatings,” said Forsythe. “We want better control of our scheduling, which an in-house painting facility will give us.” To supply enough air for the blasting facility Castle Iron purchased a used screw-type compressor for $30,000. For the blast room operator they bought the Nova 2000 air-fed helmet made by Allegro Industries. “That only cost about $400,” said Forsythe. However, adding in the costs to recycle abrasive media, the ventilation, and auxiliary safety equipment like a carbon monoxide filter, the blasting room will cost Castle Iron another $5,000 to $6,000. “It’s too early to tell,” said Forsythe, “but our

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total investment with the powder paint line and the upgraded blasting facility will be about $75,000.” In-house training

Training in the use and maintenance of abrasive blasting equipment cannot be over emphasized. More often than we realize there are employees who cannot read written warnings and operating instructions on product labels. An untrained or uninformed operator is a danger to

himself and those around him. Blasting equipment suppliers

Some of the major manufacturers of safety equipment for abrasive blasting are E. D. Bullard in Cynthiana, KY; Clemco Industries Corp. in Washington, MO (the oldest in the business), 3M, and Allegro Industries. These firms sell through distributors. Each of them has an elaborate website describing their equipment, all of which costs between $500 and a

$1,000 depending on all the auxiliary equipment such as carbon monoxide detectors, temperature controls for air to the helmet, and air filters from the compressor to the air supply. Clemco publishes two comprehensive booklets describing the design and use of their equipment and abrasive blasting safety practices. Allegro Industries manufactures the Nova 2000 Abrasive Blasting Helmet®. The basic 3M helmet is their model 8100B. Outsourcing blasting operations

With all of the OSHA regulations (OSHA 29 CFR1910.135), the hazards involved, and the cost and maintenance of equipment, it’s not surprising that many NOMMA members subcontract out their blasting work. John Medwedeff at Medwedeff Forge and Design, a NOMMA fabricator member, is one of them. He sends his blasting work outside, and he’s very conscious of in-house air quality. “Our employees wear dust masks almost all the time to protect against particles from grinding, welding, and forging. We have exhaust fans that can turn shop air over every ten minutes if needed.” The Wagner Companies, a NOMMA supplier member, also sends their blasting work to a subcontractor, leaving the management of blasting equipment compliance and maintenance up to someone else. They use U-Spray Inc., which specializes in painting. In addition to several enclosed blasting cabinets U-Spray Inc. has two walk-in blasting rooms. Currently, they’re upgrading their ventilation system at a cost of over $50,000. “It’s not the cost of respirators and protective equipment for the operators,” said Dean Klingbeil of U-Spray. “It’s all the necessary auxiliary equipment that goes with a blasting facility.” Still, while some shops chose to outsource blasting operations, others prefer to invest in the necessary equipment and safety measures to continue blasting in-house. Depending on your production schedule, see which is more cost-effective for you. Either way, it’s good practice to be aware of the safety concerns associated with blasting. 30

Fabricator

March/April 2006

What is silicosis? Silicosis is a respiratory lung disease that develops over time when tissue in the lungs isolates microscopic particles of silica dust by forming fibroid nodules. These nodules grow with surrounding scar tissue. Gradually, and it often takes years, these nodules enlarge to reduce the lungs’ ability to transfer oxygen to the blood stream. The result is a lingering death by asphyxiation. Symptoms of silicosis are shortness of breath, fever, and a bluish skin pallor also called cyanosis. Silicosis has always been an occupational hazard for workers in the mining industry. When deaths due to silicosis peaked during the 1930’s, the Bureau of Mines began testing air quality and looking into methods of prevention. By 1972 a division of the Center for Disease Control

(CDC) took over testing and certifying of respirators. That agency of the federal government is known by the acronym NIOSH (National Institute of Safety and Health). They test and certify all respiratory equipment submitted by manufacturers seeking NIOSH approval. Regulatory limits began to be applied by the Occupational Safety and Health Administration (OSHA) during the 1970’s. Between the years 1968 and 2002 deaths due to silicosis declined 93 percent. That significant drop is attributed to several factors: training in the use and maintenance of respiratory equipment, improved respirator design and a 48 percent drop in mining employment since 1980. The three occupations most susceptible to silicosis are mining, sand

NIOSH certifies respiratory equipment, while OSHA applies regulatory limits for such equipment.

blasting, and construction. The use of sand as a blasting media was outlawed in Great Britain in 1950 and in Europe in 1966. Although there’s no such federal law in the United States, NIOSH recommends that abrasive blasting media with more than 1 percent free silica be prohibited. Silica sand blasting creates a severe hazard in the work place, the effects of which are progressive and deadly.

Fabricator

March/April 2006

Fabricator

Member Talk

Swimming to the top This isn’t even the boat that took out Strains shop! That boat, a tugboat, was three times the size of the rusty hull seen here. The truck shown here was in the shop during the storm.

of Katrina’s storm A NOMMA member shares his survival story in the aftermath of Hurricane Katrina. By Lee Rodrigue It’s difficult to comprehend the devastation of Hurricane Katrina without witnessing it. It’s equally hard to know how you might react to losing all your possessions at one time. You’d like to think you would be strong, doing what you must to survive, and not succumb to feelings of hopelessness. Would you slowly lose your resolve, allowing depression to take hold and pull you under? It’s impossible to know for sure, unless you’re Joe Strain of Strain 34

Metalworks, a NOMMA member who lost his shop, home, most of his tools, everything but his inner strength. Granted, Strain’s story is not the only one of courage and determination in the areas affected by Hurricane Katrina. There are plenty of NOMMA member shops who have pulled up their bootstraps and gotten back to the business of rebuilding New Orleans and the Gulf Coast. But Strain’s story is inspiring and captivating because he exemplifies the little engine that could. Strain believes he can succeed again, and

For your information Fabricator and storm victim: NOMMA Member Strain Metalworks 1840 Pine View St. Manderville, LA 70471 Owner: Joe Strain Ph: (504) 495-2557 E-mail: jstrain@nextel.blackberry.net Web: www.strainmetal works.com

Fabricator

March/April 2006

no doubt he will. Strain started Strain Metalworks about two and a half years ago after eight years of fabricating out of the workshop behind his house. During that time, he was also a captain for a yacht owned by an oil company executive, who asked Strain to make some stainless furniture. He started with building a few stainless yacht parts and discovered that he loved it and was good at it. A few other folks (including the general manager at Jimmy Buffett’s Margaritaville) found out about Strain’s skills, and soon Strain found himself in high demand. Eventually, he acquired more equipment, hired two more employees, and developed a small business based on high-end ornamental fabrication, focusing on non-ferrous and detailed work. All his skills are selftaught, and his love for his craft shows in his work. Joe and his wife, Mary Shea, owned a home just four miles from their shop in Slidell, LA. Their home was on the Mississippi side of the Pearl River, which forms the border between Louisiana and Mississippi. Getting to work was a quick five-minute ride down Highway 190, and Strain’s workday took him all over the Mississippi Delta area. Sometime in the summer of 2005, Joe and Mary Shea learned they were going to become parents. The excitement of this life-change was to be the second biggest event in their lives during 2005. Then on August 29, the biggest life-changing event of the whole Gulf Coast struck. Hurricane Katrina made its second landfall just east of New Orleans, near Hancock County, MS. It had decreased in strength to a Category 3 Hurricane just before landfall, but because of its size, it produced Category 4 winds (131–155 mph) over land well in advance of that last-minute decrease in intensity. It wasn’t the wind that destroyed Strain’s home, though. Or was it? It depends on who you ask. His homeowner’s insurance company says it was the 23-foot storm surge that arrived in Pearlington, MS that demolished his house and every other house in his subdivision. When it comes to deciphering what demolished his shop, that one is a little easier to figure out. The first boat that struck his shop was a huge tugboat, which ripped off a corner of the building, the front door, took out a material rack holding 10,000 pounds of stainless AND the 4 inches of concrete on top of the base slab, to which the rack was anchored with HILTI expansion anchors. After the building was knocked down, another boat crashed into it as well. Ironically, the smallest boat was the last one, which was 1/3 the size of the first tugboat. There’s no doubt that it collided with the building because it’s still there, its rusting hull an ominous reminder of the turmoil that was occurring in 9 feet of churning mud and salt water. This is where the story takes a strange twist: if it weren’t for the loose tugboat, broken from its moorings, Strain would be up and running today. He planned ahead, building racks on which to store all his equipment in the event of a hurricane. His racks were 9 to 10 feet in the air, and when he left his shop a few days before Katrina struck, there was nothing on the ground. Every piece of equipment had been March/April 2006

Fabricator

afford to pursue it. Ironically, the tugboat owners are now making more money than they ever have, using their fleet of boats (including the one that took out Strain’s shop) in the reconstruction efforts. Strain had a 30-year lease on his shop, paying only $350 a month for the duration of the lease—and this was for a 5,000-square foot shop! He made $25,000 This Millermatic might just work yet! Joe power-washed the salty mud from the machine, let it dry, and will replace worth of improvements, a few critical parts… as soon as he gets spare time. including cleaning the site to comply with Department of Environmental elevated above what would eventually Equality (DEQ) requirements, become the highest hurricane storm installing a proper septic system, surge in recorded U.S. history. pouring new slabs, and basically makThe corporation that owns the tuging the property marketable again. boat has taken no responsibility for Now that the building is gone, he can the damage, and it is unlikely that any get out of the lease at any time, but compensation will be gotten without a after making all those improvements, lengthy court battle. Strain is simply why would he want to? legally outgunned in that he cannot

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After the storm, Strain spent the first two months removing 15 semitruckloads of garbage. Because of his efforts, the DEQ released the prohibitions, allowing him to install power and start his shop. So he decided to continue working out of that facility because finding another facility for that price would now be nearly impossible. Of course, his house is gone, too. The house used to have a sea-plane hangar in the backyard, which is where he started his business 10 years ago. Some of his tooling was left there because “if something happened at the shop, [I] would be covered because of the tools at the house. If something happened at the house, there were the tools at the shop. I didn’t plan on losing both in one shot.” New Orleans was relatively fortunate. Strain’s home and shop were on the dry side of the eye, and he had 23 feet of water at his house. New Orleans is 40 miles west of Strain, and it was not even in the region of hurricane-force winds. It only suffered tropical storm winds. Unfortunately,

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the levies failed, which flooded the town. Because of the population density still in the city, this is where the greatest loss of life occurred. Although the media focused on the flooding in New Orleans, the worst destruction of property occurred to the east, where the eye landed and points east. “People come from New Orleans, and they’re in shock. They’re amazed at how destroyed my house is. There are a lot of people like me, and they’re really depressed. A lot of people are taking it really hard.”

About 50 percent of his tools are unaccounted for, mostly small hand tools, like grinders, routers, drills, etc. Some of the accessories are sorely missed, like the punches and dies that were in a stainless steel refrigerator, which floated off. Large tools that were on the upper racks were knocked 40–50 feet away, and were churned around in the mud and saltwater for days before the water fully receded. Strain is quick to point out that if he were to receive any kind of assistance, he would run right out and buy

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tools. He also notes that his wife still approves all new tool purchases. He says, “You gotta love a woman who, when you ask, ‘Can I buy a tool?’ responds ‘Does it make money? If so, then go ahead!’” Salvage has played a tiny part of the recovery. Although a lot of the machinery can be saved, the time required to do so makes it salvage prohibitive. Strain has found it a lot easier to get reliable equipment that doesn’t require days of rehabilitation, then use that equipment to make enough to get by. He’s keeping the old machinery around, in case he has time to try to recover it later. In the meantime, most of it has been pressure-washed and is being left untested, while efforts are made to protect it from the elements. Of course, the lack of tools is particularly meddlesome in Joe’s plans, because Katrina not only wiped out his shop and home but also created a booming market for construction. “That’s the thing that frustrates me the most. There is a TON of work down here. If you’re going to make money in the fabrication business, this is it. This is the place to be and the time to be here. What’s going on around me will be the largest re-building EVER. I’m struggling to do what I can, but I have to turn a lot of it away because I just don’t have a place to do it.” “I’ve got both new customers and existing customers, and it’s a booming market. There’s plenty of work to do, and not enough people to do it. It’s not like one home needs to be repaired. Every home needs to be repaired. The funny thing is that the ornamental part of this hasn’t even started yet.” Within a month, there were a few homes that were under reconstruction. Of those, about 50 percent are near completion now. It’s a slow process, caused mainly by the scarcity of skilled tradesmen. Most trades, particularly roofers, are able to command 200 percent of their pre-Katrina prices, just to help keep their schedules manageable. Strain isn’t having too many problems with the supply chain. He’s able to get most material, but he’s had Fabricator

March/April 2006

Fabricator

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Strain takes a survey of what’s left of his home. “And this is where my little home workshop used to be…”

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JuliusBlum&Co.Inc. is proud to introduce the first titanium handrail bracket, in stock, now available. Because of titanium’s high strength, Julius Blum & Co. designed the bracket to be thinner and lighter. Silvergray and softly reflective in appearance, titanium is nonreactive and can be combined with bronze, aluminum, steel or stainless handrails. Eco-friendly and low maintenance, titanium has outstanding corrosion resistance and requires no additional finishing. Call or email us today for your free copy of our current Catalog and accompanying CD to view our inventory in aluminum, bronze, nickel-silver, stainless steel and malleable iron. All items shown in our literature are carried in stock in large quantities for prompt shipment.

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some difficulty getting stainless steel. There have also been problems with people trying to sell material that has been under salt-water. He’s driven as far as Houston to get supplies but tries to avoid it. Strain points out that sometimes, the plans of the federal government are contrary to the desires of the local citizens. “The historical society of New Orleans is trying to salvage beautiful rails and columns, and FEMA contractors are coming in and saying ‘No, we’re going to destroy this house.’ They’re not worried about the architectural value of it, they just know that they get $10,000 to destroy this house as fast as humanly possible, and these historical people are getting in my way.” Personally, the Federal Emergency Management Act (FEMA) has not ben able to provide Strain with much help either. In five months, FEMA has contact Strain four times. Each time, it was to tell him that they had lost his case. As far as home insurance goes, Strain had flood insurance for his home, but not for the shop. Even though his house is destroyed, he still has to continue paying homeowner's insurance premiums until his flood claim is resolved. Coincidentally, the $2,000 provided to Strain by Fabricator

March/April 2006

his insurance company for living expenses almost covers the home insurance premiums he’s had to pay while waiting for his flood claim to be resolved. Actual living expenses are covered by Strain’s hard work with the equipment he’s bought using a line of credit, loaded on a trailer and used from dawn to late in the evening. “If I could say anything [as far as advice for other fabricators], it would be to bring your banker a coffee mug every time you go on vacation. They will remember you. Also, pay your bills at your welding supply because it pays off. They remember you, and they’ll take care of you when you need it.” His Miller representative has come through with some used demo units that really helped him get back up and running. Still, Strain’s not building many rails right now because it’s hard to do it without a shop. The biggest problem in locating a place to work is the fierce competition for space. The high demand created by displaced businesses in New Orleans and the lack of intact structures makes acquiring a shop space almost impossible. Property in Slidell went from about $35,000 to $55-60,000 an acre overnight, with most property being purchased by companies with large bankrolls and business interruption insurance. So what is Strain going to do differently now? First, he’s buying a piece of property. That way, he won’t lose the value of the improvements he’s made. Even though he’s only three miles from the coast, Strain insists that he wouldn’t move further inland. “I would have been fine if the boat hadn’t destroyed my building. The wind and the water weren’t the problem until my equipment got knocked into the water.” Strain sounds certain that he’ll pull through this just fine, and listening to him describe how he’s going to do it is awfully convincing. He points out, “If you’re not given a business, and you start one yourself, then you know how to re-start it. You have to be very careful to run lean when faced with a disMarch/April 2006

Fabricator

aster like this. It’s easy to go buy new equipment and truck, but the bills will come, and you’ll have to choose between paying for the equipment or buying groceries or paying rent. “The great thing about being a fabricator, about working with metal, is that it teaches you how to deal with a really [unpleasant] situation and turn it into something good. I don’t care what anybody says, but getting burned by a welder, getting flashburn, getting shocked… it all sucks. If a doctor got

cut every time he performed surgery, there wouldn’t be many doctors. But a metal guy will stick with it, letting slag burn through the folds in his shirt, and keep welding until the job is done. I think our profession helps teach us to deal with [difficult] situations. “Not everyone makes perfect slabs or lays drywall in a straight line. It’s up to the metalworker to learn how to work with the problems that are thrown at him, and that’s what’s helped me to prepare for what lies ahead.”

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For a Free Brochure call 610-831-1214 www.salterspiralstair.com/fab 41

NOMMA Education Foundation In partnership with the National Ornamental & Miscellaneous Metals Association

NOMMA Fabricators review NEF videos and DVDs Ever wonder if NEF’s instructional videos and DVDs are worth your investment? See what fellow NOMMA members say about their impression of them. Almost the Last Word in Finishes and Curved Stair Rail Fabrication

Both videos are excellent references. We will go back to them when those jobs come in. Almost the Last Word in Finishes was interesting and good; however, it didn’t offer all I needed to know. I bought the video in hopes of finding a process for oil rubbed bronze, and the video didn’t address that process. [Recently NOMMA members discussed rubbed oil bronze on NOMMA’s member’s only Listserv. NOMMA members can visit the archives to find that conversation.] Many of the processes on the video, although they revealed a variety of unique finishes, seem geared toward smaller projects rather than larger ones. It would be good to have that information expanded to applications on larger rails. The Curved Stair Rail Fabrication video was also very good. Initially I thought it would cover curved railAlmost the Last Word in Finishes Demonstrator Lloyd K. Hughes goes over how to apply over 12 different finishes using a variety of chemicals and materials, from oil and wax finishes to hot and cold patinas. (72 min. - DVD or video) EDU-2

For your information

ing, but it actually covered curved stair and rail. We struggle with achieving precise radius on curved rail. But the video covered a lot. Even guys who have done a lot of that would learn something. Jim Welsh Blue Metal Works LLC “Curved Stair Rail Fabrication”

I was satisfied with the video. It’s always good to see how other people do things, and even to see pictures of their shop. I hadn’t fabricated curved railing before, but Jack Klahm (featured in the video) was very clear and made everything very easy to understand. In the video he bends the horizontal members and tacks them up together on the job; then he takes it back to his shop for full assembly. It was good to see that because I get nervous working with just measurements. So it was good to see that’s how others do it. I also really liked the table bending jig he used. Curved Stair Rail Fabrication Watch Jack Klahm measure and make templates for a curved stair. He shows you ways to save money while also improving accuracy. This production covers many techniques. (70 min. - DVD or video) EDU-3

Contact: NOMMA / NEF 1535 Pennsylvania Ave. McDonough, GA 30253 Ph: (888) 516-8585 Fax: (770) 288-2006 Web: www.nomma.org

The only thing I would say is that he works on aluminum in the video, and I work mostly with steel. But I guess that is because he’s in down Florida. Still it would have been good to learn how the information translates to steel. But in all, I was satisfied with the video. Guy Mattei Mattei Inc. “Straight Stair Railing” It was a pretty good video, and I learned some new information. A lot of what was on the video I already knew about, but it’s nice to see someone else doing it—to confirm what you think you know. I really enjoyed the lamb’s tongue segment. It showed a quick and easy way to make a nice looking lamb’s tongue. With blacksmithing, you can always beat the metal into submission, but the old fashion way is often the hard way. A quick and easy way to make a product that looks like you spent much longer on it allows you to offer your client a cheaper price. As long as it looks the same, most of them are just as happy to have it. Chris Glover Wild Horse Forge & Ironworks Straight Stair Railing Follow Lloyd Hughes through each step of the fabrication process of a straight rail for exterior steps, including measuring, fabrication, adding final details, and installation. (60 min. - video or DVD) EDU-1

To order Videos and DVDs: A listing of more instructional products and their descriptions plus an order form are available online. Web: www.nomma.org/NEF/index.cfm

Fabricator

March/April 2006

METALfab 2006 METALfab 2006 took place at the Westin Savannah Harbor, Savannah International Trade and Convention Center.

Trade Show Report METALfab 2006 exhibitors recap their products and services. For a complete listing of METALfab 2006 exhibitors, visit: ww.nomma.org. of gate operator on the market. Ph: (800) 543-4283 Web: www.gtopro.com

Alloy Casting Co. Inc.

Access Control Systems

GTO/PRO offers the faster, extended life GTO/PRO 4000XL, which opens gates up to 1,000 pounds and 20 feet in about 18 seconds; and the GTO/PRO 3000, designed for gates up to 650 pounds and 16 feet. GTO/PRO also offers the first affordable residential wireless intercom with an integrated keypad that works with any brand 44

Alloy Casting Inc of Mesquite, TX showed a line of over 900 stock items of aluminum ornamental castings and aluminum hardware. Also at the booth were several examples of custom castings and cor-

rosion resistant castings that have been created for fabricators and architects across the U.S.A. The image shown here illustrates a group of three 10-inch by 40-inch leaf patterns; it is an example of a custom application. Ph: (800) 527-1318 Web: www.alloynet.com

Atlas Metal Sales

Atlas Metal Sales is a distributor of CDA655 silicon bronze sheet, plate, rod, bar, and tube. Atlas has a 35-year reputation for quality and competitive pricing serving the needs of fabricators, sculptors, and foundries. CDA655 silicon bronze forges well and is rated excellent for cold working, hot formFabricator

March/April 2006

ing, and welding. It has excellent corrosion resistance properties in fresh and seawater environments. Silicon bronze is a superb alloy for artistic and architectural applications. Atlas provides flexible payment plans, orders of any size and quantity, and shipments are generally made within 24 hours after receipt of order. Ph: (800) 662-0143 Web: www.atlasmetal.com

Auciello Iron Works Inc.

Binks, Devilbiss, Ransburg

The Ransburg #2 Spray Gun is the most efficient indoor/outdoor on-site finishing system available, with transfer efficiencies of 95% and up. The #2 Electrostatic System virtually eliminates drift

and waste, enabling on-site finishing for ease and cost-savings. The #2 Gun/Deuce Hand Spray Gun Unit comes complete with spray gun, belt, high-voltage cable, power supply, fluid hose and cart. Ph: 630-237-5106 Web: www.ransburg.com

Julius Blum & Co. Inc.

One of the many elements Blum dsplayed was their new 42-inch Double-Design Forged Steel Spindles.

Auciello exhibited the EZ Sleeve, a removable plastic sleeve for forming quick, accurate, clean postholes in concrete. The sleeve is removed after the concrete has set to leave a tapered hole. The sleeve is 1/6 inch thick plastic tapered tube with a pull-out tab on the closed top and a snap-on base. Color is safety orange. EZ Sleeve is the ideal way to form quick and clean post holes in concrete for installing railings, fence, or other posts. Ph: (978) 568-8382 Web: www.aiw-inc.com

Big BLU Power Hammer

The Big BLU is engineered, produced, and marketed by an American artist blacksmith. Its compact design fits through a normal service door. Its large 700 pound anvil and scientifically balanced 110 pound head enables it to operate without a custom foundation. The 18 inch throat and 180 degree foot petal ensures ease of operation with a variety of sizes and shapes, and 0–240 strokes per minute is obtained with a toe touch. The Quick Change dies made of S-7 heat-treated tool steel are easily interchanged. The Big BLU operates almost noise free except for hammer blows. It’s economical and user friendly. Ph: (828) 437-5348 Web: www.bigbluhammer.com March/April 2006

Fabricator

Bridges. Cable railings. Perfect match.

Ultra-tec

CABLE RAILING SYSTEM Contact us today to learn how easy it is to design a beautiful cable railing that you and your client will be proud of. Distributed throughout the U.S. and Canada by:

Manufactured in the U.S. by:

Ultra-tec

CABLE RAILING SYSTEM

The Wagner Companies 888-243-6914 414-214-0450 fax E-mail: catalog@mailwagner.com www.wagnercompanies.com

The Cable Connection 800-851-2961 775-885-2734 fax E-mail: info@ultra-tecrailings.com www.ultra-tecrailings.com

Each of the new spindles is a single piece with designs matching our popular patterns. #325, #327, and #328. Eye-catching patterns are created when alternated with single-design spindles. Made in the U.S.A. Ph: (800) 526-6293 Web: www.juliusblum.com

Byan Systems Inc.

Byan Systems Inc., automatic gate and access control products offer

unsurpassed quality and dependability with totally integrated electronic and

hydraulic designs. All Byan components are manufactured in-house from raw castings to finished product, insuring total quality control. We offer a four-year warranty on all models and controllers. All operators now come with adjustable mounting brackets for ease of installation. On-line product information and price quotations are available on our website. Technical support is always available. Ph: (800) 223-2926 Web: www.byan.com.

The Cable Connection

The Cable Connection’s Ultra-tec® Cable Railing System features sleek stainless steel hardware that is designed for cable railings, including some that are hidden inside the end

posts. Perfect for indoor or outdoor railings and decks using 1/8 inch through 3/8 inch diameter cable. Fabrication specifications are offered for various railing frame styles. Ph: (800) 851-2961 Web: www.ultra-tecrailings.com

CML USA Ercolina

Ercolina angle rolls are capable of bending a wide range of profiles and materials to centerline radius as small as four times diameter of the work piece. CE35 offers capacity to 11/2 inch pipe, schedule 40 pipe, and 11/2 inch angle iron. It’s designed to operate in the vertical or horizontal position with roll speed up to twenty feet per minute. All models include remote foot pedal for

FIRE YOUR FORGE TODAY!

Proven design Efficient-Reaches 2350 Degrees Versatile Portable Many Models Available

Call for Free Catalog - 800/446-6498

NC Tool Company Inc 6133 Hunt Road Pleasant Garden, NC 27313 336/674-5654

Fabricator

March/April 2006

hands free operation. Standard universal tooling adjusts easily to most material profiles and digital display tracks position of center roll for repeatability. Single-phase 220-volt connection makes this machine ideal for shop or home use. Ph: (563) 391-7700 Web: www.ercolina-usa.com

The Cleveland Steel Tool Co.

The Cleveland Steel Tool Co. exhibited two of its most popular ironworkers for the ornamental metalworking industry at METALfab. The 25 Ton machine is a compact, mobile ironworker that features two workstations: one outfitted for punching, and the second equipped with MultiShear Attachment for shearing round, square and flat bar stock, and angle iron. The 55 Ton Ironworker offers four workstations for non-stop metalworking action. A full line of ironworkers, related tooling and portable metalworking machines are available exclusively from The Cleveland Steel Tool Co. Ph: (800) 446-4402 Web: www.clevelandsteeltool.com

Colorado Waterjet Co.

Custom panels and components waterjet cut with your design from any material (steel, aluminum, stainless, bronze, etc). This cold cutting process is slag-free, HAZ-free and distortion-free. It eliminates the need for welding and grinding, and the chance of joints rusting. Endless possibilities for design: “If you can draw it, we can March/April 2006

Fabricator

cut it!”

and at less than half the cost.

Ph: (970) 532-5404 Web: www.coloradowaterjet.com

Ph: (708) 345-6660 Web: www.crescentcityiron.com

Crescent City Iron Supply Inc.

Still using lockboxes? Two cuts in gate frame, realign to square, blend frame into lockbox, grind and clean welds, paint inside lockbox, weld gate stop to latch post, takes a 1/2 hour. With LOCINOX: Drill and holes using template provided takes 15 minutes

The Wagner Companies R & B Wagner • J.G. Braun • Wagner Industrial

• Combined Wagner

and Braun Catalogs

• Cable Railing • Spiral Staircases • Bar and Foot Railing • Glaser Stainless Steel Railings • LumenrailTM Lighted Railing • Powder Coated Forged Railing Components • Regency Railings • N ew ADA Brackets

Beautiful Railings Begin With The Wagner Companies

Call today for a Wagner Master Catalog! (888) 243-6914 • (414) 214-0450 FAX catalog@mailwagner.com www.wagnercompanies.com • www.shopwagner.com 47

Custom Ornamental Iron Works

Custom Ornamental Iron Works is a leading manufacturer of wrought iron products in North America. Our highly dedicated manufacturing

department enables us to maintain extensive stock of our products, as well as custom make almost any product you may require. If the product you want is not in stock, we can usually have it made for you in one to two days. We are pleased to announce that our new catalogue, Stair & Railing Components Vol. 12, is now available. Our existing catalog of wrought iron, cast iron, and aluminum accessories is still available by request. If you are interested in receiving a free copy of any our catalogues, please contact us

High Performance Gate Hardware Crescent City stocks more than 3000 Fencing and Ornamental Iron Components in Chicago, Indianapolis and New Orleans, making Crescent City one of the most comprehensive fencing resources in North America. Crescent City is a customer focused, second generation family owned and operated company, serving the ornamental fencing industry since 1988. Crescent City ships within 24 hours on most orders and same day when needed. Your business is valued and we will continue to offer extensive inventory levels with prompt, dependable delivery at affordable prices. Your inquiries on special requirements are always welcome. Ameristar Ornamental Fencing Stainless Steel Gate Hardware Locinox Gate Locks & Gate Closers Maintenance Free Cantilever Gate Rollers

Crescent City Iron Supply www.crescentcityiron.com

Chicago • Indianapolis • New Orleans 800.535.9842 • Fax: 866.345.6661 48

any time. We look forward to the opportunity of presenting what we can do for your company. Ph: (604) 273-6435 Web: www.customironworks.com

DoorKing, Inc.

DoorKing offers a full line of slide, swing, and barrier gate operators for residential, commercial, and industrial applications. The company also provides a full line of access control products and accessories. DoorKing operators and electronic circuit boards are all manufactured in the USA and are tested and listed to the latest UL 325 safety standard. Ph: (800) 826-7493 Web: www.doorking.com

Eagle Access Control Systems Inc.

Eagle Access Control Systems Inc. manufactures gate operators for all residential and commercial applications. Designed for easy installation, Eagle Operators include standard features like twowire master/slave, motor brake, one pass, stop-reverse, global inputs plus surge and lighting protection. Eagle Operators carry a five-year or sevenyear warranty and are built to last with all-steel zinc-plated chassis, heavy-duty gear reducers, nickel-plated chain, and powerful AC continuous duty motors. From the new compact Eagle I to the heavy duty Eagle 2000 APT, Eagle has a solution for every need. Ph: (818) 899-2777 Web: www.eagleoperators.com Fabricator

March/April 2006

Eagle Bending Machines Inc. / Carell Corp.

Eagle demonstrated the 2006 ZM/ZH402 Roll Benders as an economical alternative to fabricators bending 2-inch square tube for gates and larger steel, bronze, or aluminum cap rails. Hydraulic and manual versions are standard with LED readouts, dual e-stops, foot pedal controls, and mobile operator control consoles. Full tooling options are available, scroll and twisting tools, angle rolling, and more. Plus, Carell Corp. demonstrated the T20 Ornamental Bar Working Machine and the NEW Embossing Attachment for production of cold hammered edge effects in flat and square bars.

Hartford Standard Co. Inc.

Hartford Standard Co. Inc. manufactures a variety of metal products including our coverall post cap line. We currently offer 14 sizes of heavy duty post caps ranging

from 5/8 inch up to 8 inches, made from various metal alloys, including aluminum, brass, copper, galvanized steel, steel, and stainless steel. For products samples or additional information contact us. Ph: (270) 298-3227 Web: www.hartfordstandard.com

HebĂś

Transform your business. Fabricate your own architectural components, HebĂś invented the modern wrought iron machine and is the worldwide

Ph: (251) 937-0947 Web: www.eaglebending machines.com

FabCAD.Inc

FabCAD.Inc demonstrated its automatic railing and gate drawing programs and CAD Starter System. This popular product has everything an ornamental and miscellaneous fabricator needs to develop attractive and accurate drawings. The package includes a customized version of AutoCadÂŽ LT, on line training movies, over 3,700 casting and forging designs, and pre-drawn gates, columns, rails, and fences. This year FabCAD added a new company to its design library, Rik-Fer USA. The latest features of the AutoRail program include an automatically produced bill of materials, the ability to automatically insert finials ball caps and spindles customization, features that add piece marks and dimensioning options, a new stair rail option, and enhanced gate options. FabCAD offers live online tutoring, along with its plotter services. Ph: (800) 255-9032 Web: www.fabcad.com March/April 2006

Fabricator

leader in this field. The machine is designed for decorative iron operations including scroll bending, forging, embossing, hammered tube, belly pickets, twisting, and texturing. It can be used for all applications including steel, aluminum, bronze, copper and brass.

ways, lift doors, and many other applications where security and access control are important. Our folding gates allow you to provide a low cost alternative when additional security is required or asked for by your customer. Ph: (312) 850-3710 Web: www.fgfred.com

Ph: (503) 658-2881 Web: www.heboe.com

King Architectural Metals Illinois Engineering

King Architectural Metals, in association with Koenig Eisen Ltd., has

With 45 years of Chicago manufacturing experience in the security gate business, let us show you how easy it is to sell these important products. Turn every service call into a sales call. Become a dealer today and enjoy the full membership benefits of online ordering, automatic tracking, and delivery status, or call for personalized service. Steel folding gates come in standard sizes for door-

and inspirational designs for railings, staircases, fences, gates, doors, window grilles, and fireplace screens utilizing components by Koenig Eisen. These components are exclusively stocked in North America by King Architectural Metals at their three full-service warehouses in California, Maryland, and Texas. Dimensions are included for most designs, item numbers are designated for all, and the designs are arranged by King Metals’ new Stock Material Family Codes, organized by size. No prices are listed in the design books. These designs can be instrumental in stoking creativity, or they also stand strongly on their own. Ph: (800) 542-2379 Web: www.kingmetals.com

Laser Precision Cutting Inc.

announced the first volume in a series of design concept books tailored specifically for the decorative and architectural metal trades. Volume 1, at 300+ pages, includes hundreds of unique

Laser Precision Cutting Inc. has been a leader in the metal cutting services industry since 1989. LPC utilizes laser cutters, a water jet, a press brake, and welding equipment to pro-

BALUSTERS • PANELS • SPEARS • SCROLLS • ROSETTES AND MORE... 13-94-E3

Forgings That Change The Ordinary Into A Work Of Art

13-94-E4 13-94-C5 13-94-C6

13-94-C7 13-94-C8

13-94- F3

2000 mm

( 6'-6" )

13-94- F4

13-94- F5 13-94- F6

1000 mm

( 3'-3")

7000 PRODUCTS • 3 LOCATIONS • www.kingmetals.com

800-542-2379 SAME DAY SHIPPING

Fabricator

March/April 2006

duce parts to customer specifications. LPC stands above all competition with their attention to detail, dedication to achieving customer satisfaction, and fast turnaround time. LPC’s job is the customer’s satisfaction. Ph: (828) 658-0644 Web: www.laserprecision cutting.com

C.R. Laurence Co. Inc.

C.R. Laurence’s full color, 224-page HR06 Railing Systems Catalog is now available. All the components, fasteners, alignment systems, and tools needed to create different styles of glass railings, using either dry glaze or wet glaze installation methods are included. Premium railing systems manufactured by CRL are the ARS Aluminum Railing System; AWS Aluminum Windscreen System; heavy glass base shoe for glass barriers and partitions; HRS Cap and Hand Rail Systems; and CRS Component Rail System. Ph: (800) 421-6144 Web: www.crlaurence.com

Lavi Industries

Lavi has a renowned reputation in supplying high quality tubing and

March/April 2006

Fabricator

fittings for nearly 20 years. We were the first in our industry to offer stainless steel fittings and we continue to set the standards in this market. As a premiere world supplier and manufacturer, Lavi offers a variety of components and tubing for architectural railings, kitchen and closet accessories and other architectural applications. Ph: (800) 624-6225 Web: www.lavi.com

ings and artistic forgings. Lawler continually develops new and different products for the industry and is the largest full-line producer and supplier of high-quality, low-cost ornamental metal components in the U.S.A. Ph: (800) 624-9515 Web: www.lawlerfoundry.com

Marks USA

ranty applies to all Marks USA products. Handsome design and solid construction have made these ornamental locksets the most popular in the country. For application assistance or brochure contact us. Ph: (631) 225-5400 Web: www.marksusa.com.

Metalform Ltd.

Marks USA introduces a complete

Metalform Ltd. is a top-tier pro-

lock line for the ornamental iron security storm door. Standard and thin line versions are available featuring screwless knobs and levers, proprietary no droop lever springs, cylinder collar security inserts and high strength solid steel hubs. Lifetime mechanical war-

ducer of wrought-iron products in Bulgaria. We are best known for our wrought-iron products, including window gratings, decorative fences, doors, lighting fixtures, garden lanterns, and chandeliers. Our other products are: beds, tables, chairs, armchairs, sofas, outdoor and garden furniture, racks, candlesticks, sundials, fireplace accessories, and numerous custom-made wrought-iron products.

Lawler Foundry Corp.

Lawler Foundry Corp. of Birmingham, AL displayed their traditional and latest ornamental iron cast-

Ultimate Tubing Notcher For A Great Piece Every Time Notches from 3/4” to 2” OD

Ph: 011-359-54-832442 Web: www.metalform.bg

Mid Carolina Steel Co.

Mid-Carolina Steel, located in Columbia SC, is the largest ornamental iron distribution center in the Carolinas. We offer a line of ornamental iron components and structural steel. Our large inventory includes products manufactured by companies such as Indital USA, Signon USA, New Metals, Frank Morrow, Sumter Coatings Paint, Gilder’s Paste, and Metal Finishes Plus. We provide products for residential and commercial iron work.

NOW 1HP Standard

Any angle is possible Perfect TIG weld fit every time Completely portable 115 volt operation Fast metal removal Ideal for prototype or production In use by over 80 NOMMA Member Shops. (Call us for a reference)

Calibrated Swivel Vise Allows Almost Any Angle

CALL OR CLICK for Free Catalog

1-800-467-2464 www.mittlerbros.com 52

Ph: 803-786-9888 Web: www.mid-carolinasteel.com

Mittler Bros.

Visitors to METALfab 2006 were treated to demonstrations of the new Variable Speed Ultimate Tube Notcher. This new piece of fabrication Fabricator

March/April 2006

equipment is targeted at users who work with specialty tubing ranging from 3/4 inch OD to 23/8 inch OD. The new machine enables the operator to tailor the speed of the cutter to the wall thickness and diameter of the tubing. With this “matched” speed customers will be able to notch small diameter thin walled tubing without the “grabbing” experienced on some single speed cutters as well as notch

used anywhere intrusion prevention

wider range of sheet sizes, including 6-foot tall sheets for residential fencing applications. Shown is the “Roman” design. Ph: (888) 639-6382 Web: www.newmetals.com

NC Tool Co. Inc.

is a must, such as in fencing, gates, window covers, and more. Great for strict building code compliance, DecoGuard is now available in a

NC Tool Co. Inc.’s forges are of unique design for large and small jobs. They are well insulated and user friendly. We have several models to choose from. They feature quite venture burners that reach 2,350 degrees

larger diameter heavy walled tubing with power to spare. Mike Mittler, CEO of MB, said, “This is a natural evolution of our standard Ultimate Tube Notcher and was brought about by customer input.” Ph: (636) 745-7757 Web: www.mittlerbros.com

Frank Morrow Co.

The Frank Morrow Company’s highly detailed metal trims are per-

fect complements for a wide variety of interior accents. Many solid bandings can be produced up to .062 inch thickness in copper and aluminum, making them ideal for exterior usage as well. Pictured here is F8534, Pine Bough banding, 4.165 inches wide. Ph: (800) 556-7688 Web: www.frankmorrow.com

New Metals

DecoGuard™ decorative expanded metal mesh, manufactured exclusively by New Metals Inc., combines an attractive design with the strength of steel. Available in eight distinct designs, DecoGuard can be March/April 2006

Fabricator

Ohio Gratings

Through a joint venture with

and fences in concrete outdoors. Both products are stronger than concrete in one hour. Ph: (216) 291-2303

Scotchman Industries Inc.

very quickly, no blowers required. A must have in every fab shop. Ph: (336) 674-5654 Web: www.nctoolco.com

NOMMA / NOMMA Education Foundation / Ornamental &

Meiser of Germany, Ohio Gratings, Inc. will manufacture a new Press Lock bar grating product manufactured from carbon or stainless steel under the named Meiser Bartley Gratings, LLC. This product is ideal for mezzanine walkways and racking systems in the material handling industry. With unique spacing capabilities Press Lock is also ideal for many architectural applications and American Disabilities Act (ADA) walkways. Ph: (800) 321-9800 Web: ww.ohiogratings.com

Miscellaneous Metal Fabricator

The National Ornamental & Miscellaneous Metals Association (NOMMA) was proud to once again sponsor its annual trade show and convention, METALfab. A special thanks goes to the NOMMA Education Foundation (NEF) for an outstanding education program. NOMMA is the industry’s trade association since 1958 and is the proud publisher of Ornamental & Miscellaneous Metal Fabricator. Ph: (888) 516-8585 Web: www.nomma.org

Rockite Division of Hartline Products Co.

Rockite is an anchoring and patching cement that sets in 15 minutes. New Kwixset Exterior Anchoring and Patching cement mixes with water and sets up in 15–20 minutes. Use it for installing railings

Scotchman Industries Ironworkers 45-150 tons have component tooling and fully integrated designs, for single and dual operators. Scotchman also exhibited circular cold saws manual to fully automatic, pivot and column; band saws manual to fully automatic; belt grinders/tube and pipe notchers; centerless grinders; deburring machines; and Scotchman’s Advanced Measuring Systems, quick, accurate measuring systems that can be adapted to almost any type of metal or wood working equipment. Ph: (605) 859-2542 Web: www.scotchman.com

Sumter Coatings

Sumter Coatings featured paints, primers, and topcoats especially for ornamental and miscellaneous metal. The firm’s popular Satin Shield Enamel was a featured product. Satin Shield is a fast drying direct-to-metal paint offered in assorted colors. Ph: (888) 471-3400 Web: www.sumtercoatings.com

The Wagner Companies

5186-F Longs Peak Road, Berthoud, CO 80513

The Wagner Companies’ new Calypso HammerHead WaterJet with industry-leading software provides a cost effective cutting platform for the widest variety of materials including steel, stainless steel, aluminum, brass, Fabricator

March/April 2006

Wrought Iron Concepts, Inc.

bronze, and exotic metals. Costs are reduced with this clean, single cutting process that often eliminates secondary operations. Ph: (888) 243-6914 Web: www.wagnercompanies.com

At MetalFab 2006 Wrought Iron Concepts, Inc. featured their quality ornamental iron components and a complete line of Customized Marketing Support Tools, including customized color catalogs, complete website solutions, online catalog links, compact showroom displays, and online purchasing, where you can save quotes, get instant shipping costs, and place and track orders online 24/7. Offering the lowest nationwide shipping charge including free same-day

shipping allowances, customers get their materials fast. Ph: (877) 370-8000 Web: www.wroughtiron concepts.com

Fabricate Your Own Architectural Components Hebo invented the modern wrought iron machine and is the worldwide leader in this field. For decorative iron operations including scroll bending, forging, embossing, hammered tube, belly pickets, twisting, texturing. For all applications including steel, aluminum, bronze, copper and brass.

HERE IS HOW YOUR BUSINESS WILL BENEFIT. • Own the same machinery world wide parts suppliers use • Labor cost go down, as your least expensive employees become the most productive • Computerized control makes for fast and consistent results • Create a profit center making custom components • Inventory can be reduced, no waiting for parts • Take your business to new levels of quality • Affordable: less than cost of one $10 hr employee

US Representative, Robert Rayson, Stratford Gate Systems Office 503.658.2881 Fax 503.658.2517 Cell 503.572.6500 Email: sgs@worldstar.com www.drivewaygates.com hebo Maschinenfabrik, Am Berg 2, 35285 Gemunden-Grusen, Germany. Phone ++49 6453 91330 Fax 49 6453 913355 Email: marketing@heboe.com www.heboe.com

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Job Profile

For this project the fabricator had to coordinate the driveway gates to swing uphill two feet over a ten-foot pitch using electronic gate operators.

An uphill battle Be careful when projecting completion dates. You never know what can come up, like physics, additional requests, and supplier delays. By Rick Wories, Builders Ironworks Inc. In the spring of 2004, I received a call from a gentleman who was interested in driveway gates for his upscale home in a suburb of Chicago. I had previously fabricated and installed a structural steel frame system for a custom limestone pergola by his swimming pool. He and his wife weren’t quite sure what they wanted in terms of style; all they knew is they wanted something fancy to serve as a grand statement to the entrance of their beautiful home. Because they wanted four tiered gate posts along with side panels complimenting the driveway gates, hand-forged components were out of the question due to cost constraints. After poring through various catalogues 56

they were drawn to the gate styles presented in the “Indital” Catalog. The next step was to design gates, piers, and panels that suited the owners’ tastes. I left the catalog with them and asked them to earmark various pages that had the ornamental components which appealed to them. After coming up with a design, we went to work on a proposed cost which I knew would be high based on the components chosen, especially the brass rosettes and spears. Problem #1: Money

I presented the bid to my clients, who, as I suspected, were shocked at the cost. As so often is the case, we needed to redesign the project in order to bring the cost within budget. By eliminating the brass rosettes

For your information Project: 2005 Top Job Bronze Award for Driveway Gates— Non-forged. Shop: NOMMA member Builder’s Ironworks Inc.., Crete, IL. Owner: Rick Wories Hinges: A modified (beefed up) uphill swing hinge at the bottom and a modified barrel hinge at the top. Gate operator: A modified older model EDKO medium duty gate operator with an adjustable friction clutch.

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Use of a standard uphill swing hinge would’ve been nice, but the 20% slope of the gate would not allow it. No matter where the top hinge was placed, it would either bind up or the gate post would hit the pier. A solution was found by using a barrel hinge at the top which pivoted on a sealed bearing axle welded to the pier.

and spears, as well as a few other component changes, we cut the cost by about 20 percent, which was now acceptable to my clients. Lesson #1: Present a proposal in person

I have been told by experienced salesmen that it is best to present the client a proposal in person whenever possible, for several reasons: 1) People want personal attention from you, the professional, when they are about to spend a sizeable portion of money on home improvements. 2) Your personal attention to them at the onset of the project indicates that you will be there to see the job through the entire process. 3) It indicates a willingness on your part to “look them directly in the eye” while you present what you believe to be a fair bid. 4) If other firms are bidding the job, it sets you apart at this most critical stage of securing the job and being awarded the contract. 5) Any questions the clients may have can be addressed immediately with all parties (i.e. husband and wife) present.

The fabricator also “beefed up” a standard uphill swing hinge at the bottom of the gates. The modified hinges allowed the fabricator to keep a 2' space between the gate post and pier, while also keeping the gates centered on the 18” wide piers.

told them we could start in about four weeks and complete the project about six weeks thereafter. Big mistake. Lesson #2: When clients add work, fabricator must add time

As the project material started to arrive to our shop, my clients contacted me with the request of two additional side panels, which required two more piers. They also asked that the side panels be installed before the driveway gates in order to grade and complete the landscaping. We were able to meet their request and the fabrication and installation of the side panels and piers went off without a

hitch. However, because we had to use the driveway gate components for this, we needed to order more material for the completion of the job. Also, to make matters worse, the parts needed were located in Italy, where, unbeknownst to us, Indital employees spend the month of August vacationing. Translation: 12-week delay. Once we received the materials, we were ready to begin fabrication on the driveway gates. The frames consist of 2 inch by 1 inch hammered bar. The 11/4 inch by 1/4 inch hammered bar was then rolled on our bender for the horizontal scrollwork. That needed to be duplicated in order to sandwich the 1/2

Problem #2: Time

Having received a signed contract along with a deposit check, we were ready to get started. Now came the inevitable question: “How soon can you get going on this, we’re very excited.” Having just come out of the slow months of January and February, I March/April 2006

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This beautiful driveway gate won a 2005 Top Job Bronze Award for the Driveway Gate–Non-forged category.

Wories’ EDKO gate operator distributor provided him with a modified medium duty operator, Its adjustable friction clutch can better handle the greater amp draw from pulling the gates uphill.

inch forged spears our client wanted, thus acting as a top channel. The 4 inch cast rosettes were welded into the 5 inch hammered rings, and placed accordingly between the horizontal scrolls. We also added forged panels to give the gates a more decorative look. Fabrication of the gates took approximately 30 hours. Problem #3: Swinging gates uphill

For some reason, I hadn’t given much thought on how we were going to swing the gates uphill two feet over a ten foot pitch, as well as do it with electronic gate operators. My first

course of action was to call Mike Wroblewski of Perimeter Access System Services to see if he had ever installed an uphill swing gate operator before. He hadn’t and recommended we swing the gates out. This was unacceptable to my clients; however, and I called Mike to work on a solution to the problem. Lesson #3: Put your talent to work

Now it was time to rely on the talents of my shop foreman, Brian Widstrom. If any one could figure this out, he could. He began by building a

mock-up gate taking exact dimensions from the field out of 11/2 inch tubing. Use of a standard uphill swing hinge would’ve been nice, but the twenty percent slope of the gate would not allow it. No matter where the top hinge was placed, it would either bind up or the gate post would hit the pier. A solution was found by “beefing up” a standard uphill swing hinge at the bottom of the gates, as well as using a barrel hinge at the top which pivoted on a sealed bearing axle welded to the pier. This allowed us to keep a 2-inch space between the gate post and pier, while also keeping the gates centered on the 18-inch wide piers. With the hinge problem solved and the gates fabricated, I contacted Mike from Perimeter Access to see if he had any solutions to the gate operators. Dealing with EDKO gate operators, Mike informed me that the current model operator wouldn’t work due to its amperage sensitivity shutdown feature. He proposed to build an older model that wouldn’t sense the amp draw caused by pulling the gates uphill and shutting down the unit, but at the same time have it conform to UL325 standards. Two sets of photo eye sensors were also installed for people and vehicle safety. Problem #4: Wrong color

With the uphill swing issue solved, we moved ahead with the project and delivered the gates to the powder coater. A week later, installation day had finally arrived. Our clients were more than patient of the time delays throughout the entire project, but the anticipation of finishing this job was strong. I felt a sense of relief knowing that this project would at last be completed. Lesson #4: No matter the time lapse, tell the powder coater the right color

When it came time to install the gates, a new problem came up, and it had nothing to do with the gate operators or hinges. The gates and the piers were two different colors.

Then my phone rang. It was Tim Wiersma, my road foreman. “Rick, we have a little problem”, he said. Would the homeowner not like the look of the gates tilted in the open position? Would the hinge system not work for some reason with the heavy gates? It Fabricator

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was neither. Tim continued to inform me that the gates were powder coated Statuary Bronze and the side panels and piers were Spartan Bronze. Ah, Murphy’s Law at work again! Due to the time lapse between installation of the side panels and piers and the installation of the driveway gates, I had apparently told the powder coater the wrong color—Spartan and Statuary Bronze are relatively similar when looking at a paint chart; however in the field are obviously different. So back to the powder coater they went. Two weeks later we installed the

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gates, hooked up the operators, and everything worked beautifully. The clients were truly impressed and extremely pleased how the entire project turned out. I learned from this job and another high end job this past year to be careful when projecting completion dates. It’s better to project longer than you think it will take to do the job. This way the clients will be pleased when the work is completed before the projected completion date rather than disappointed when completed after the date. Since business is so service-oriented insofar

as new construction goes, which is about 80 percent of our business, I tend to be too optimistic as far as completion dates go. As one colleague said to me once, “In our business, we basically go from one crisis to the next.” Facing the many different challenges of this project truly was an uphill battle. However, it was worthwhile not only because we accomplished swinging the gates in, but also had the pleasure of winning our first top job award in the driveway gate category at METALfab 2005 in New Orleans.

Job Profile

Designing and fabricating a grand copper shower Discover the design and fabrication processes behind this 2006 Top Job entry in the Unusual Ornamental Fabrication category.

By Karoly Szucs, Artisan Metal Works Ltd., and Christopher Anco

The shower is constructed so that it can be dismantled and taken inside during dangerous weather.

Even outdoor showers have to come in sometimes, if just to escape the threat of hurricane damage. Metal artist Karoly Szucs managed to incorporate that detail in this beautifully designed, functional, yet highly decorative, outdoor shower for an ocean front residence. Artisan Metal Works Ltd., located in the Cayman Islands, offers a host of custom metal fabrication services as well as creative metal art and sculptures to clients both onshore and offshore. Szucs is the artistic director and a partner of the firm. He is a certified fabricator/welder by trade, who, occasionally, has the

TOP:

Szucs chose solid brass and copper rods to create the stem like shape of the nearly 10-foot tall â&#x20AC;&#x153;flower shower.â&#x20AC;? To increase the structural strength of the stem, the rods were brazed to one another in areas where contact was made between the individual elements.

TOP RIGHT:

Szucs chose copper because of its natural beauty and resistance to the natural elements that the piece would be exposed to over time.

RIGHT:

The water control fixtures were carefully incorporated into the design.

opportunity to pursue his passion for creating metal art and sculptures. The majority of his artistic creations are contemporary and incorporate many elements from nature. This article describes just one of his many unique commissions from the design process through final installation.

st step: The design

The genesis of this project started simply enough. A client wanted a functional outdoor shower for his beachfront residence in the Cayman Islands. The working parameters for the commissioned piece were straightforward. Design parameters of the Cayman Shower

1) It was required to be a functional piece of art. 2) The project design needed to incorMarch/April 2006

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porate the natural surroundings and harmonize with the overall design and theme of the waterfront structures. 3) The design had to consider the structural demands of the environment: sun, salt water, and the ever threatening hurricane. 4) The design and budget for the project was to be approved by the client. Unlike most other projects where the client has at least an idea of what they would like the project to look like when completed, this particular client gave Karoly full artistic freedom to design the project. Consulting with the landscape designer was the first step in the design process. This was followed by an early morning stroll along the beach to the site with sketch pad in hand and than a number of photographs taken of the site. Preliminary concepts were sketched and presented to the client for discussion and approval. Szucs likes to call his sketches

For your information Project: Flower Shower, 2006 Top Job entry for Unusual Ornamental Fabrication. Shop: NOMMA member Artisan Metal Works Ltd., Grand Caymans. Co-owner: Karoly Szucs Photographer: Justin Uzzell

2006 Top Job award winners will be listed in late March on the NOMMA website. Visit: www.nomma.org

TOP AND TOP RIGHT: Szucs sketched preliminary concepts and presented to the client for discussion and approval. However, like most of his designs, this one evolved organically, during the creative and fabrication process.

concepts for the simple reason that he feels that his designs “evolve organically, and are revealed to him during the creative process.” It is his policy to explain this to the clients noting that the final project will be similar but not always to his sketches.

step: materials 2ndAcquiring

Once the design process was finalized and approved the next phase of the project was the selection of materials and the components of the shower that needed to be incorporated into the art. After thorough consideration, solid brass and copper rods were selected to 62

create the stem like shape of the nearly 10-foot tall “flower shower.” These materials were selected due in part to their resistance to the natural elements that the piece would be exposed to and also because of the way in which copper and brass naturally color over time.

step: the structure 3rdFabricating

Attached to a temporary base at the shop and supported vertically from above, the rods were systematically heated, twisted, and manipulated manually to form an interwoven “stem” around the copper tubing required for the functional aspect of

The structure was temporarily attached to a base and supported from above during fabrication.

the shower. To increase the structural strength of the stem, the rods were brazed to one another in areas where contact was made between the individual elements. This process continued until the full extent of the stem and neck of the “flower” were completed. Time and effort were an essential element in determining where the water control fixtures would be placed and how they could be tastefully incorporated into the project without seeming unsightly or out of character.

step: ornamentation 4thForging

Phase two of the project was the Fabricator

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fabrication of the petals which would top the stem and surround the 12inch shower head. Twenty-two gauge copper sheet was selected for this portion of the project. Although it was initially thought that this part of the fabrication would be straight forward it eventually became apparent that this would not be the case. Once the rough shapes were cut out of the copper sheet, they required multiple annealing sessions so that the copper could be formed into the complex shapes Karoly had envisioned without creating structural cracks. The work was tedious and at times frustrating, but the end result was well worth the effort. Once the petals were attached to the stem and all the functional hardware for the shower installed, attention turned to the last two phases of the project, coloration and installation.

step: 5thFinishing

The patina for the project was initiated chemically and then allowed to mature naturally in the following weeks.

step: 6thInstallation

Many different thoughts went into the process of deciding how this functional art piece would be installed at the beach side location with the possibility of high winds and surf due to seasonal storms and even the likelihood of an impact by a hurricane. In the end, the solution was to make the entire piece removable from its stone base so that it could be transported and safely stored away from the beach. The project was attached to the base with three quarter inch stainless steel bolts, and all water connections were made using quick-disconnect fittings which were discretely concealed for aesthetics. It takes approximately 10 minutes to remove the 220 pound shower from its base so that it can be stored as required. The entire project required a little over 220 man hours to fabricate not including the design process. March/April 2006

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Job Profile

This beautiful marble and steel radiator cover is a 2006 Top Job entry in the Furniture and Accessory Fabrication category.

A new decorating idea for older homes An ornamental radiator cover serves as the perfect solution to accent a room. By John Caldwell, AAA Iron Works Radiators are a functional necessity for most homes, but letâ&#x20AC;&#x2122;s face it; they are not always appealing to the eye. We at AAA Iron Works in Lorton, VA have found an alternative to this problem. This ornamental invention began when the soon-to-be client of ours decided to do 64

something about a decorating challenge in her older home. The homeownerâ&#x20AC;&#x2122;s challenge was a radiator in the dining room. She wanted additional serving space for use during dinner parties, and the longest wall for a piece of furniture was occupied by the radiator.

For your information Project: Ornamental Radiator Cover 2006 Top Job entry for Furniture and Accessory Fabrication. Shop: NOMMA member AAA Iron Works, Lorton, VA. Owner: John Caldwell

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The client came up with a solution: an ornamental radiator cover. Radiator covers are perfect for older homes. A decorative radiator cover can accent any room in your home to add that extra touch of style. The only problem with this novel idea was finding a fabricator who could build them one, particularly a fabricator who would assist a residential customer in creating a work of art. As a result of our yellow pages advertising, I received a call from the potential client, who asked if I would be willing to help her design an ornamental radiator cover. Apparently we were the only company in the area who was willing to accept this challenge. She told me she loved ornamental iron accents and had several throughout her home and wanted an orna-

mental iron base with a marble top. coats of red oxide primer with gloss I provided several possible styles, black, oil-based enamel were applied. and worked together with the client to Using ornamental iron and marble create the ultimate design. opened up the opportunity to transfer We used several ornamental pieces and store heat emitted from the radiafrom various NOMMA member suptor. In simpler terms, iron will put off pliers that fit the desired dimensions more heat. The whole project took sev(length, size, width), and the frame’s 1eral months, including the marble top. inch square tubing. Finding designs AAA Iron Works’ ornamental radiathat matched the size requirements and tor cover is the perfect combination of the client’s décor was very challenging. elegant and eclectic art. The client added, “Many guests have commented After a series of experiments, the final on it, and I love the fact that is a unique design was created. piece of art that is also functional.” The AAA Iron Works’ ornamental Whenever a potential radiator cover was made NOMMA Joint client provides an opportufrom 1 inch by 11 gauge nity for a new development, square tubing with #691 cast- Finish Guidelines are available on we believe in embracing it ings, and it was mig welded NOMMA’s website with the expectancy of creatin the shop. It was subse(www.nomma.org) under “Technical ing an innovative niche in quently cleaned down to a Support.” the marketplace. NOMMA #4 finish, and two

The Ornamental Radiator Cover is made from 1" x 11 gauge square tubing with #691 castings was mig welded in the shop. It has a NOMMA #4 finish and two coats of red oxide

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primer with gloss black, oil-based enamel From design to delivery, the project took approximately 48 hours. Delivery was set it and forget it!

Biz Side

Sole proprietorship or corporation? The wrong choice can be a costly mistake. See which of the five business classifications listed below best suits you. By William J. Lynott

Nearly three-fourth's of the millions of small businesses in the United States are sole proprietorships, According to the U.S. Department of Commerce. Obviously, that makes the “mom and pop” form of business a popular choice for entrepreneurs, but is it the best choice for you and your shop? That’s an important question; one that you should consider carefully whether you’re just getting started or if you’ve been thinking of changing your present form of business. Genevia Gee Fulbright, CPA, says there are several circumstances under which a sole proprietor may want to consider incorporation. “If the business has shown consistent growth, the owner wants the company to become more formal, or there is some thought about the possibility of adding a partner or additional shareholders, changing from a sole proprietorship to a corporate entity structure should be considered,” says Fulbright, who is the Senior Small Business Advisor for the National 66

Association of Black Accountants, Greenbelt, MD. There are three classifications of basic business entities from which to choose: sole proprietorship, partnership, and corporation. Each has its own distinct set of advantages and disadvantages. Even if you feel comfortable with your current business entity, you should be familiar with the legal, financial, and practical consequences of each choice. Sole proprietorship

The simplest and least expensive way to launch a new business is, of course, as a sole proprietor—little or no legal expenses, no complex tax structure, no one else to interfere with management decisions. Procedures for setting up a sole proprietorship are simple and can be done without the assistance of an attorney or accountant regardless of the state in which you are doing business. As a sole proprietor, you are the sole owner, unless you are in a community property state in which your spouse is

For your information Sole proprietorship is the simplest and least expensive way to launch a new business with little or no legal expenses, simple tax structure, and streamlined management structure. General partnership is viewed as essentially the same as a sole proprietorship except for management issues concerning partnership. A limited partnership is similar to a general partnership except the limited partner’s legal liability in the business is generally limited to the amount of his or her investment. Corporations are artificially created legal entities that exist separate and apart from the individuals who create them and carry on their business operations, offering various forms of liability protection. Limited liability corporations can be advantageous to small business owners under some circumstances because of the lower costs and flexibility of the LLC business structure.

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legally vested with a one-half interest. Your business profits flow directly through your personal tax return (using a separate tax form called Schedule C). You get to keep or reinvest all of the after-tax income produced by the business. If it ever becomes necessary, a sole proprietorship is the easiest of all business structures to dissolve. With so many advantages, it might seem that a sole proprietorship is the only way to go for the small business owner. But hold on, there are other things to consider. As a sole proprietor, you have unlimited personal liability for all debts against the business. Both your business and personal assets are at risk in the event of legal trouble. Other disadvantages include possible difficulty in raising funds from outside sources if you want to expand. Also, it may be harder for you to attract high-caliber employees.

share in the profits of the business? Will each partner receive an equal share? Under what circumstances and in what amounts will this be subject to change? How will the major financial decisions be handled? Such issues are extremely important and should never be left “to be decided later.” On what basis will cash withdrawals and salaries be authorized?

This is a potentially serious pitfall that should be resolved in detail and in writing. What happens if one partner dies? You just may find yourself in business with your partner’s widow or widower if you haven’t considered this possibility carefully. “To help avoid this, there are two things you should do,” says Fulbright. “First, consider purchasing key-person

General partnership

As far as taxes and most legal considerations are concerned, a general partnership is viewed as essentially the same as a sole proprietorship. Each partner is jointly and separately liable for the financial obligations incurred in the name of the business, and each is taxed on his or her share of the profits generated by the business. However, partnerships do inject some challenging personal issues. The choice of a business partner is fraught with potential danger. Some experts suggest that good friends or relatives rarely work out as business partners because of the inevitable disagreements over business issues. Of great importance in partnerships is a clear understanding of such issues as: How much capital will each partner be expected to contribute up front? Who does what? The job of each partner should be clearly defined and scrupulously honored. And don’t forget those little undesirable tasks. They can cause more misunderstandings than the big, important jobs. On what basis will the partners March/April 2006

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“If you try to swing a loan in the name of your small

corporation, you are likely to find that the lender will require you to sign personally.”

life insurance. Then, with the help of your attorney, draw up a written agreement clearly establishing procedures for buying out a partner’s interest in the event of death or any other unforeseen circumstance.” Limited partnership

A limited partnership is similar to a general partnership, but there is one important difference. The limited partner’s legal liability in the business is generally limited to the amount of his or her investment. This arrangement allows an investor to share in the partnership profits without being exposed to its debts in the event the company goes out of business. This protection stays in effect only as long as the limited partner does not play an active role

in the partnership operation. Corporations

Unlike partnerships and sole proprietorships, corporations are artificially created legal entities that exist separate and apart from the individuals who create them and carry on their business operations. In most cases, a corporation can be formed by simply filing an application for a charter with the appropriate department in the respective state. As part of the application, the incorporator will be asked to answer such questions as: What is the purpose of the intended corporation? What are the names and addresses of the incorporators? What is the amount and what types of capital stock will the corpora-

tion be authorized to issue? What will be the rights and privileges of the holders of each class of stock? In short, when you form a corporation for your business, you create a separate legal entity with the same legal rights and responsibilities as those conferred upon us humans. Because of that, some feel that incorporation is the answer to the entrepreneurs dream, and in some ways, that’s true. The corporate form of business will limit your personal financial liability, be more stable in the event of your death, and will make it easier for you to raise money for expansion and growth. In theory, the corporation will do all of these things for you. In the light of harsh reality, however, you should investigate carefully before you leap. One of the problems is the sometimes unrecognized differences between large, public corporations and the closely-held corporations typical in small businesses. If you try

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to swing a loan in the name of your small corporation, you are likely to find that the lender will require you to sign personally. In other words, you will be just as responsible for the loan as you would be in a sole proprietorship. In addition to potential tax savings, the most common motivation for going through the trouble and expense of setting up a corporation is the recognition that the shareholders are not legally liable for the actions of the corporation. This is because the corporation has its own separate existence wholly apart from those who run it. In the real world, however, if you find yourself on the wrong end of a lawsuit, you may find yourself as well as the corporation named as a defendant. So much for the protection of personal assets. What about selling stock to raise capital? Certainly, that’s one of the primary advantages of a corporation; but, again, the small corporation will

“Anyone considering incorporation should be aware that doing

business in that form will introduce complications that can be a nuisance to someone used to the simple life. “

find a large gap between theory and practice. Finding people willing to invest in a corporation controlled by one or two people might prove as difficult as Diogenes’ search for an honest man. Will a corporation stand a better chance of survival than a sole proprietorship or partnership in the case of the death of a principal? Usually, but not always. Many small businesses survive as a direct result of the talents of the founder and prime mover and shaker. In such a case, if he or she dies, the business may well follow along shortly regardless of the legal form bestowed upon it. Finally, anyone considering incorporation should be aware that doing business in that form will introduce complications that can be a nuisance

to someone used to the simple life. Corporations have to follow some rigid rules, file separate tax returns of their own, maintain specified records, and, in theory, at least, hold directors’ meetings. In order to make life a little easier for the small entrepreneur, a special form of corporation known as Subchapter S was created. It allows small business owners to enjoy the advantages of incorporation without such penalties as double taxation. Limited liability corporation

“Another form of corporation, The Limited Liability Corporation can be advantageous to small business owners under some circumstances,” says Fulbright. “Typically, the costs and flexibility of the LLC business struc-

INFILL PANELS

We will custom fabricate infill panels to meet your specific requirements. Available in diamond, rectangular and square mesh with or without standoffs. Standard frame is 1" x 1/2" channel with hemmed edges. The panels are available in steel, aluminum and stainless steel in 10, 8 and 6 gauge. All types of finishes available. Division 5,8 and 10. Call us today and let us take care of your infill panel needs.

Diamond Mesh

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1-800-609-8296

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Phone: 1-517-542-2903 Fax: 1-517-542-2501

www.JescoOnline.com March/April 2006

Fabricator

Diamond Mesh w/Standoff 69

“You should be aware that some states have passed laws intended

to make it more difficult to file incorporation papers in a state other than the one in which the business resides.” ture are helpful for smaller enterprises because: There are fewer requirements and restrictions placed on the business owners in how they pull money out of the business and how much they pull out as compensation (taxing authorities do not place the “reasonable” salary standard on LLC business

owner compensation). The LLC company does not pay entity level taxes on profits (the owners pay taxes on their allocated share of profits and losses can offset owner’s other income to the extent of active participation). The LLC provides greater protection from creditors and general law-

www.internationalgate.net

suits if run properly, compared to a general partnership and other entities. The LLC is a great way to hold real estate because it allows for easier distribution of assets without having to consider dividends or other forms of compensation to the business owners (i.e. C-Corp and S-Corp have to consider salary levels, distribution methods, etc.). If you are a sole proprietor considering incorporation, you may have considered using one of those companies that allow you to incorporate over the Internet, taking advantage of some state’s liberal laws regarding incorporating. That’s an easy and inexpensive way to incorporate your business; however, there are some pitfalls of which you should be aware. “If a business owner wants to incorporate in a state other than the one in which the business operates, he/she must understand that in most circumstances the state where the company resides will require the filing of an annual tax return. Also, an ‘authority to do business’ form must be filed in the resident state,” says Fulbright. “That means two state returns would be required instead of one.” Also, you should be aware that some states have passed laws intended to make it more difficult to file incorporation papers in a state other than the one in which the business resides. For example, California charges $800 a year for a license for a foreign corporation or LLC to operate in the state. “That’s why I recommend that clients who use the Internet to research information on incorporation consult with legal counsel familiar with the state laws in which the business will operate,” says Fulbright. Does all of this sound complicated? Well, it is. That’s why no single form of business structure can be said to be the best choice for every NOMMA member. As with most other business decisions, a sound knowledge of the alternatives provides the best foundation for the right choice. Before making any decision involving your business structure, you should consult with your own accountant and attorney. Fabricator

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Thanks for another great show!

METALfab 2006 See exhibitor listing on page 44.

Building Innovation, Artistry, Technology, and Well-Being

Thanks once again to our sponsors Sponsored Items Big BLU Hammer Mfg. Equipment for Uri Hofi demo FabCad.Inc. Canvas Bags Tennessee Fabricating Co. Name badge lanyards Upper Midwest Chapter of NOMMA Golf Prize Platinum Sponsors Industrial Coverage Corp. King Architectural Metals Lawler Foundry Corp. Silver Sponsors Julius Blum & Co. Inc. Carell Corp. Colorado Waterjet Co. Crescent City Iron Supply Inc. D.J.A. Imports Ltd. Eagle Bending Machines Inc. Mittler Bros. Machine & Tools Regency Railings Inc. Bronze Sponsors Atlas Metal Sales Ohio Gratings Inc.

New NOMMA members As of February 17, 2006; Asterisk denotes returning members.

Alfa Technologies Inc. Santa Ana, CA Adolf Fraidany Nationwide Supplier

CLS Enterprises Ocala, FL Derek Minetti Regional Supplier

All-Tech Southeast Inc. Quincy, FL Bev Kilmer Fabricator

Complex Industries Inc. Memphis, TN Barry Walls Nationwide Supplier

AR Iron LLC Henderson, NV Tony Sclafani Fabricator

Copper Iron Designs Inc. * Napa, CA Andrew Bradford Fabricator

Arc Angels Inc. Dunedin, FL Bill Coleman Fabricator Architectural Ornamental Metals Inc. Holly Hill, FL Raymond Alford Fabricator Arcsmith Specialty Welding Charlotte, NC Randal Brewer Fabricator Artistic Metal Creations Inc. San Fernando, CA Juan Vargas Fabricator Artistic Railings White Lake, MI James Peterson Fabricator Atlantic Iron Wilmington, NC Frank Campese Fabricator Brazos Metal Works Plano, TX Steve Blankenship Fabricator

Don Yacovella Chalfont, PA Don Yacovella Fabricator Ebington Ironworks Ebington, VA Jeremy Funderburk Fabricator European Wrought Iron Works Woodbridge, ON Phil Dâ&#x20AC;&#x2122;Angelo Fabricator Gator Cochran Const. Inc. Augusta, GA Martin Cochran Fabricator Harrells Steel Fab Inc. Houston, TX Jeremy Harrell Fabricator Heritage Forge & Wrought Iron Jackson, TN Mark Smith Fabricator

Calhoun Design & Metalworks Atlanta, GA Charles Calhoun Fabricator

Heritage Forge Inc. * Salt Lake City, UT Alexander Chumachenco Fabricator

California Wire Products Corp. * Corona, CA Sam Agajanian Fabricator

Industrial Metal Supply Co. * Sun Valley, CA Neil Sherman Nationwide Supplier

Christmas Hill Forge * North Freedom, WI William Tanneberg Fabricator

Jaguar Wrought Iron * Bakersfield, CA Josh Hubble Fabricator

NOMMA Nationwide Supplier Members A Cut Above Distributing 800-444-2999 Alfa Technologies Inc. 714-550-9278 Allen Architectural Metals Inc. 800-204-3858 Alloy Casting Co. Inc. 800-527-1318 American Punch Co. 800-243-1492 American Stair Corp. 800-872-7824 Ameristar Fence Products 888-333-3422 Apollo Gate Operators 800-226-0178 Architectural Iron Designs Inc. 800-784-7444 Arteferro Miami 305-836-9232 Atlas Metal Sales 800-662-0143 Auciello Iron Works Inc. 978-568-8382 Aztec Castings Inc. 800-631-0018 Big Blu Hammer Mfg. 828-437-5348 Brobo-USA 800-247 9333 Builders Fence Co. Inc. 800-767-0367 Byan Systems Inc. 800-223-2926 The Cable Connection 800-851-2961 Carell Corporation 251-937-0948 Chamberlain 800-282-6225 Classic Iron Supply 800-367-2639 Cleveland Steel Tool Co. 800-446-4402 CML USA Inc. 563-391-7700 Colorado Waterjet Co. 866-532-5404 Complex Industries Inc. 901-547-1198 Crescent City Iron Supply Inc. 800-535-9842 Custom Orn. Iron Works Ltd. 866-464-4766 D & D Technologies (USA) Inc. 800-716-0888 D.J.A. Imports Ltd. 888-933-5993

DAC Industries Inc. 800-888-9768 Decorative Iron 888-380-9278 DKS, DoorKing Systems 800-826-7493 Robert J. Donaldson Co. 856-629-2737 Eagle Access Control Systems Inc. 818-899-2777 Eagle Bending Machines Inc. 251-937-0947 Eastern Metal Supply Inc. 800-343-8154 Eastern Ornamental Supply Inc. 800-590-7111 Elegant Aluminum Products Inc. 800-546-3362 Encon Electronics 800-782-5598 Euro Forgings Inc. 800-465-7143 EURO-FER SRL. 011-39-044-544-0033 FabCad.Inc 800-255-9032 FabTrol Systems Inc. 888-FABTROL Fatih Profil San. Tic. AS 011-90-258-269-1664 Feeney Wire Rope & Rigging 800-888-2418 The G-S Co. 410-284-9549 Geo. Bezdan Sales Ltd. 800-663-6356 Glaser USA 888-668-8427 Glasswerks LA Inc. 800-350-4527 Greendale Railing Co. Inc. 804-266-2664 GTO Inc. 800-543-4283 Hartford Standard Co. Inc. 270-298-3227 Hayn Enterprises LLC 800-346-4296 Hebo - Stratford Gate Systems 503-658-2881 House of Forgings 281-443-4848 Illinois Engineered Products Inc. 312-850-3710 Indiana Gratings Inc. 800-634-1988 Industrial Metal Supply Co. 800-371-4404 Fabricator

March/April 2006

Innovative Hinge Products Inc. 817-598-4846 Interstate Mfg. Associates Inc. 800-667-9101 The Iron Shop 800-523-7427 ITW Industrial Finishing 630-237-5169 Jamieson Mfg. Co. 214-339-8384 Jansen Ornamental Supply Co. Inc. 800-4-JANSEN Julius Blum & Co. Inc. 800-526-6293 Justin R.P.G. Corp. 310-532-3441 King Architectural Metals 800-542-2379 Laser Precision Cutting 828-658-0644 Lavi Industries 800-624-6225 Lawler Foundry Corp. 800-624-9512 C.R. Laurence Co. Inc. 800-421-6144 LE Sauer Machine Co. 800-745-4107 Lewis Brass & Copper Co. Inc. 800-221-5579 Liberty Brass Turning Co. 800-345-5939 Logical Decisions Inc. 800-676-5537 Mac Metals Inc. 800-631-9510 Marks U.S.A. 800-526-0233 Master Halco 800-883-8384 MB Software Solutions LLC 717-350-2759 Metalform - Bulgaria 703-516-9756 Mittler Bros. Machine & Tool 800-467-2464 Frank Morrow Co. 800-556-7688 Multi Sales Inc. 800-421-3575 Mylen Stairs Inc. 877-303-9422 New Metals Inc. 888-639-6382 Ohio Gratings Inc. 800-321-9800 Overseas Supply Inc. 866-985-9885 Precision Glass Bending Corp. 800-543-8796 Pro Access Systems 813-664-0606 Production Machinery Inc. 410-574-2110 Regency Railings Inc. 214-742-9408 March/April 2006

Fabricator

Rik-Fer USA 877-838-0900 Robertson Grating Products Inc. 877-638-6365 Robinson Iron Corp. 800-824-2157 Rockite, Div. of Hartline Products Co. Inc. 800-841-8457 Rogers Mfg. Inc. 940-325-7806 Sahinler Form Metal San. Ve Tic. Ltd. 011-90-224-245-5465 Scotchman Industries Inc. 800-843-8844 SECO South 888-535-SECO Sharpe Products 800-879-4418 C. Sherman Johnson Co. Inc. 860-873-8697 Signon USA 866-744-6661 Sparky Abrasives 800-553-7224 Carl Stahl DecorCable Innovations 800-444-6271 Stairways Inc. 800-231-0793 Steel Masters Inc. 602-243-5245 Stephens Pipe and Steel LLC 800-451-2612 Striker Tool Co. (USA) Inc. 866-290-1263 Sumter Coatings Inc. 888-471-3400 Tennessee Fabricating Co. 800-258-4766 Texas Metal Industries 800-222-6033 Transpacific Industrial Supply Inc. 909-581-3058 Triebenbacher Bavarian Iron Works Co. 800-522-4766 Triple-S Chemical Products 800-862-5958 Tri-State Shearing & Bending 718-485-2200 Universal Entry Systems Inc. 800-837-4283 Universal Mfg. Co. Inc. 800-821-1414 Valley Bronze of Oregon 541-432-7551 The Wagner Companies 888-243-6914 Wasatch Steel Inc. 888-496-4463 West Tennessee Ornamental Door 866-790-3667 Wrought Iron Concepts Inc. 877-370-8000

New NOMMA members continued . . .

Lundyâ&#x20AC;&#x2122;s Co. Inc. Lynn, MA Kristin Larson Fabricator Michigan Orn. Iron & Fab. Inc. * Conklin, MI Steve Menn Fabricator Neikirk Ornamental Iron * South Houston, TX Jim Neikirk Fabricator Old South Ironworks Inc. * Johnson City, TN Dan Sanders Fabricator Oregon Detailing.com Portland, OR Lee Rodrigue Fabricator Palm Metal Works Columbia, SC Donald Duvall Fabricator Pascetti Steel Design Inc. Bernalillo, NM Rachel Pascetti Fabricator Piedmont Metals Inc. * Burlington, NC Tonja Troxler Fabricator Ramcast Ornamental Supply Co. Inc. * Los Angeles, CA Ismael Ramirez Local Supplier Raulfs Ornamental Iron * Pulaski, VA Glenn Raulfs Fabricator Rochester Stair & Railing Inc. Rochester, NY Lance Kellett Fabricator S & R Inc., Precision Cutting Specialist Springfield, TN Bill Salsman Fabricator

Sewell Metals Boiling Springs, SC Harold Sewell Fabricator Shire Valley Design Hamburg, PA Jeb Humma Fabricator Steel House Indianapolis, IN Mary Beth Sharp Regional Supplier Stewart Iron Works * Covington, KY C.T. Smith Fabricator Ten Compass North Las Vegas, NV Kerry Oâ&#x20AC;&#x2122;Bannon Fabricator The Drapery Maker & Canvas Workshop Inc. Fairhope, AL Joe Strange Fabricator Toscano Designs Chandler, AZ Russell Shumway Fabricator Unique Fabrications Pickford, MI Daniel Sherlund Fabricator Varis Welding Pilot Point, TX Mike Crow Fabricator West Gate Sheet Metal Riviera Beach, FL Tom Sterling Fabricator Wetumpka Iron Works Wetumpka, AL Jim Laney Fabricator Wetumpka Iron Works Wetumpka, AL Jim Laney Fabricator 73