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Member Member Spotlight: Spotlight: Meet Meet Corrina Corrina

Dedicated to the success of our members and industry.

NOMMA Officers President Michael D. Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA President-Elect Belk Null Berger Iron Works Inc. Houston, TX Vice President/Treasurer Chris Maitner Christopher Metal Fabricating Inc. Grand Rapids, MI Immediate Past President Ed Powell Powell’s Custom Metal Fab. Inc. Jacksonville, FL NOMMA Directors Doug Bracken Wiemann Iron Works Tulsa, OK Chris Connelly DeAngelis Iron Work Inc. South Easton, MA Gib Plimpton Myers & Company Architectural Metals Basalt, CO Fred Michael Colonial Iron Works Inc. Petersburg, VA Rob Mueller Mueller Ornamental Iron Works Inc. Elk Grove Village, IL Curt Witter Big D Metalworks of Texas Dallas, TX Steve Engebregtsen R & B Wagner Inc. Butler, WI Bob Paxton Lawler Foundry Corp.

Birmingham, AL Pam Beckham Mittler Bros. Machine & Tool Foristell, MO Executive Director Barbara H. Cook Forest Park, GA

President’s Message

Meeting the Demands of Time

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usinesses like ours and organizations like NOMMA are finding themselves faced with the challenge of refocusing and reconfiguring resources to better meet the needs of clients and members. The world today is changing rapidly. Technology has increased data transfer by light years. For business, customer expectations are much higher and more demanding in regards to choice, vendor, and delivery. The increased pace and wide variety of sources has made immediate availability the expected result.

For associations, the members are torn between the needs of their business and the needs of their family. The model of the family unit is much different with both parents working.

The immediate needs and wants of the children have a higher priority level than in the past, and the children themselves are exposed to much more information, choices, experiences, opportunities, and attention. I am sure it’s not the first time you have heard this. The phenomenon of change is timeless. It is just that it is occurring at a faster pace while affecting a broader spectrum. This speed and breadth makes adaptation more difficult for businesses and organizations with any kind of history.

In other organizations that I belong to, I have observed that members feel the demands from their business and family are so strong that there is little time for anything else. If they are to dedicate time to an outside activity, it must be justified by a return. To spend time at a social event might be enjoyable, but it doesn’t pay the bills, and won’t benefit the family.

One of the reasons why NOMMA continues to grow is the subtle shift in emphasis toward more education. Social functions where networking, trading stories, and exchanging ideas takes place will always remain a part of NOMMA. Yet, education sessions, technique demonstrations, and continuing education opportunities provide for all of this while offering a strong return on our investment in time.

In following this trend toward providing more easily accessible information, the NOMMA website has been expanded to include many valuable resources, and will continue to grow. New ideas and programs for the site and our other programs are in development and will help to enhance and strengthen our commitment to the industry.

Our goal is to provide you with the information and knowledge you need, at the time you require it, so that you can better serve the demands of your customers.

The point of this column is that as the sands of NOMMA shift to better meet the changing needs of the membership, you may find some new concepts more difficult to appreciate than others. I would urge you to allow some time for the benefits to manifest themselves before passing judgment. Keep in mind that NOMMA is about the family of members helping and supporting each other. The better NOMMA is able to serve another member, the better equipped it is as an association to help you.

Plan now for:

METALfab 2002

Mar. 5-9, 2002 • Galveston, TX 4

FABRICATOR September/October 2001

Ornamental Miscellaneous Metal Fabricator To join NOMMA,&see page 81

www.nomma.org

Table of Contents Vol. 42, No. 5 • September/October 2001

FEATURES

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Moody Gardens - METALfab Preview

24

Beams of Steel and Light

28

A Well Bred Horse

36

African Adventure

40

A Challenging Installation

46

Code Wars

54

Built on Tradition

62

Meet Corrina Mensoff

69

Save Time and Money With Electrostatic Painting

74

Top Job Update

NOMMA’s 2002 convention takes place in a tropical paradise.

A fabricator produces a sports arena centerpiece.

Excellent craftsmanship results in an award-winning horse.

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Passionate attention to detail made these animals come to life.

Metalsmiths brave frigid weather to complete a job.

Are you staying current with the myriad of building codes?

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A NOMMA member builds upon its long and rich history.

An artist-blacksmith makes her dream come true.

Reduce painting time and eliminate wasteful overspray.

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The corrected entries from the 2001 contest, category G.

DEPARTMENTS President’s Message 4 News Roundup 76 Business Briefs 80 New Products 82 Tips & Tricks 83 New Members 84 Products & Inventions 86 NOMMA Network News From the Bookshelf 88 Coming Events 91 Nationwide Suppliers 92 Working Smarter 94 Classifieds 97

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Introducing Our New Reader Service System Now you can request information from advertisers directly on our web site.

} Quick Responses From Advertisers } Choice of Response Formats, Including E-mail, Fax, Phone, Or Mail. } Direct Links To Advertiser Web Sites } Complete Advertiser Contact Information } Ability To Search By Company Name, Product, or Category

www.nomma.org For additional information, see page 98.

ABOUT THE COVER: This roof ornament netted Welding Works of Madison, CT a gold award in the 2001 Ernest Wiemann Top Job Contest. The job required about 12 tons of aluminum plate and 6 tons of support steel and stainless hardware.

Creating a suitable support structure for the horse was one of the challenges of this project.

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Editor’s Letter Vol. 42, No. 5 • September/October 2001

Editor J. Todd Daniel Associate Editor Rachel Squires Business Manager Liz Ware Senior Writers John L. Campbell Susanne Gargiulo

“Must Have” Books

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Executive Director Barbara Cook 2001 Fabricator Advisory Council Patrick S. Kelly Decor Cable Innovations Sharon Picard South Attleboro Welding Corp.

Ornamental & Miscellaneous Met­al Fab­ ri­ca­tor is the of­fi­cial pub­li­ca­tion of the Na­tional Or­na­men­tal & Mis­cel­la­ne­ous Metals As­so­cia­tion (NOMMA). Published bi­monthly at For­est Park, Ga. For editorial, advertising, and spe­cific dead­line in­for­ma­ tion, con­tact NOM­MA, 532 Forest Pkwy., Suite A, For­est Park, Geor­gia 30297; (404) 363-4009; Fax (404) 363-2857. E-mail: nommainfo @aol.com. Cir­cu­la­tion: 9,800.

ISSN 0191-5940.

Publication dates are the 15th of January, March, May, July, September, and No­vem­ ber. Closing dates: Insertion orders - first Fri­day of the month prior to pub­li­ca­tion; cam­era-ready art or film - second Friday of month prior to pub­li­ca­tion. Please call for a rate card and calendar.

Subscription rates: 1-year U.S. CanadaMexico - $24.00; 2-year U.S.-CanadaMex­i­co - $44; 1-year all other countries $38.00; 2-year all other countries - $72.00.

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.

Opinions expressed in Fabricator are not necessarily those of the editor or NOM­MA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA.

MAG

Magazine Association of Georgia Proud Member

s I read the conversations on NOMMA’s e-mail discussion list I’ve noticed that often fabricators respond to the question of a colleague by referring them to a good book. Indeed, the answers to many fabricating questions can be found between the covers of a few popular publications. I’ve also visited many shops over the years and keep seeing the same titles on bookshelves.

No doubt, a mainstay of our industry is the “Gold Books,” a five-volume set that contains 1,600 design ideas. I’ve just learned that the series has been reprinted, and is now available in two hardbound volumes.

Cost is $140 plus shipping, and they can be ordered by calling (801) 9645835. Another well of design ideas is MacFarlane’s Castings, a two-volume set that costs $118.50. The books can be ordered by calling Historical Arts & Castings at (800) 225-1414.

If your interest is metal art and blacksmithing, then definitely check out publishers Dover Publications Inc. (www.doverpublications. com) and SkipJack Press (www. bookmasters. com/skipjack). SkipJack offers several popular titles, including Julius Schramm, Samuel Yellin, Metalworker, and New Edge of the Anvil.

For finishing, one book that I see referenced all the time is Architectural Metals by L. William Zahner. It costs $120 and is in stock at amazon. com.

To obtain a list of additional titles, visit www.nomma.org and click on the “Lit Guide” link. We maintain an online database that’s updated often.

By stocking your library with these and other popular titles, you will have the answers to most of your questions right at your fingertips.

FABRICATOR July-August 2001

METALfab 2002 Preview — March 5-9, 2002

METALfab 2002 takes place at a tropical paradise, and you are invited!

By Todd Daniel Editor

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icture yourself relaxing on the grounds of an elegant hotel surrounded by lush, tropical gardens. You feel a gentle warm breeze as you contemplate what attraction to visit next. No, you’re not in a faraway land — you’re in good ol’ Texas at the stunning Moody Gardens of Galveston Island.

Located 50 miles south of Houston, the 242-acre complex is the site of METALfab 2002, NOMMA’s 44th annual convention and trade show. Moody Gardens is one of the most unique venues ever for a NOMMA convention, and features a rainforest pyramid, six-story IMAX theatre, Discovery Museum, and man-made beach. At the center of the gardens is the 303-room Moody Gardens Hotel, which

The beautiful, 303-room Moody Gardens Hotel.

serves as host hotel for METALfab.

Plan now to bring your family and shop staff to this once-in-a-lifetime event, which takes place March 5-9, 2002. In addition to the dazzle of Moody Gardens and nearby Galveston, you’ll be treated to all the favorite activities that make METALfab great — outstanding education sessions, the trade show, shop tours, theme dinner, Top Job Jamboree, awards banquet, and more.

A One-Of-A-Kind Location

Moody Gardens is somewhat unique among U.S. resorts in that it is actually a nonprofit educational and recreational facility. Nestled throughout the grounds are a

In addition to the hotel, three looming pryamids dominate the skyline of the Moody Gardens complex.

The Colonel, which docks at Moody Gardens, offers daily cruises.

variety of educational attractions. Interestingly, the facility began as a therapy center and later expanded its mission to entertain and educate the public. Over the past two decades, the gardens have gained international acclaim for their hippotherapy riding program for people with head injuries, as well as their animal and horticultural therapy programs.

In addition to the hotel, the most noticeable structures on the grounds are the three towering pyramids, which each house attractions. On your walk from the hotel, the first pyramid you’ll pass is actually a giant aquarium that features thousands of colorful fish, sharks, penguins, and other creatures from the deep. Opened in 1999, the

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Children and adults alike will enjoy the Discovery Museum. below: The special effects at the Ridefilm IMAX theatre literally puts you in the action.

Many of the deluxe rooms at the Moody Gardens Hotel provide breathtaking views.

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FABRICATOR July-August 2001

130,000-square-foot building showcases marine life from around the world. Just across the road is the Rainforest Pyramid, 10-story attraction containing butterflies, birds, and exotic plants from the rainforests of Africa, Asia, and the Americas. As you walk through the giant greenhouse-like structure, you’ll see rushing waterfalls, gentle pools, and a Mayan Colonnade. You’ll also discover the Butterfly Hatching Hut and popular Bat Cave.

Next door is the equally

impressive Discovery Pyramid, which houses traveling exhibits and interactive science displays. A favorite attraction of this building is the IMAX Ridefilm Theatre that contains wraparound screens. To view a film, guests are buckled in their seat and literally move with the action.

If you find the IMAX Ridefilm theatre exciting, then you’ll really be thrilled with the nearby IMAX 3D theatre. Put on your 3D glasses and enjoy a truer-than-life experience as you gaze at a six-story screen. The

Take a journey to the deep in the Aquarium Pyramid.

400-seat theatre, which features top IMAX films from around the world, is the first 3D facility of its kind in the nation.

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Outside Adventures Abound

Throughout the superbly landscaped complex are outdoor features that include a jogging trail, dancing water fountain, and horse stable. As you enjoy a relaxing stroll, there are several gardens to charm you, including the Herb Garden, Garden of Life, and Hope Rose Garden.

Perhaps the most prominent outdoor area is Palm Beach, which features dark blue lagoons and white sand that was barged across the Gulf from Florida. At the nearby pier, you’ll likely see the Colonel, an 800-passenger vessel that’s an authentic reproduction of an 1800s paddle boat. The

The Old Galveston Square is at the heart of downtown Circle 77 on Reader Service Card

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FABRICATOR September-October 2001

huge craft offers tours during the day and dinner cruises at night.

The Hotel and Convention Center

The Moody Gardens Hotel is an attraction in itself and features deluxe sleeping rooms, including Jacuzzi suites. To invigorate your body, there’s a full-service spa and workout room. Events during METALfab will

Galveston Island Trivia

take place in the various meeting rooms and the 15,000-square-foot ballroom. Elegant and casual dining options are available, and there’s even a swim-up bar by the pool. The hotel is situated next to the Galveston Island Convention Center at Moody Gardens, where the METALfab trade show takes place. An interior walkway joins the two buildings.

Beyond Moody Gardens

Moody Gardens is only a part of the exciting Galveston Island,

See the proud ship Elissa at Pier 21’s Texas Seaport Museum

F During the turn of the last century Galveston Island was the second largest immigrant entry point in the U.S., followed only by Ellis Island.

F Today, Galveston has become a popular spot for cruises. Both Royal Caribbean International and Carnival Cruise Lines offer cruises that depart from the local port.

F Galveston Island is actually part of a barrier reef that averages two miles in width. The island contains some of the finest beaches on the Gulf.

F Over 1,500 buildings in Galveston are listed on the National Register of Historic Places.

F Galveston Island is one of the top locations for bird watching.

During fall and spring migrations, many rare bird species make a stop on the island. In fact, 75 percent of all North American species travel through Galveston during the fall and spring.

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F The island is also a popular fishing spot. Public fishing is permitted at the rock jetties and along the beachfront. Plus, there are several fishing piers and charter boats available.

F The Great Storm that struck Galveston in 1900 is the greatest natural disaster in U.S. history.

Winds exceeding 120 miles per hour created a tidal surge that devCircle 38 on Reader Service Card

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a community rich in history and fun things to do. Surrounded by 32 miles of sandy beaches, the island features elegant, Victorian-style homes and century-old commercial buildings.

In the City of Galveston, visitors will find a wealth of culture that includes theatrical performances and the famous Strand National Historical Landmark District. In the 1970s, restoration efforts began in this area, which features an amazing array of Victorian cast iron architecture. Some of the notable buildings in this district include the Strand Emporium and La King’s Confectionery. This area is also the site of the Mardi Gras!

Galveston Entertainment District, where an all-out celebration is held each February.

Three blocks from the Strand is the newly revitalized Postoffice Street Arts & Entertainment District, an area featuring galleries, shops, restaurants, pubs, and the Grand 1984 Opera House. The district is one of Galveston’s most popular shopping and dining spots, and carriage rides

Rig & Museum and the Texas Seaport Museum, which features the 1877 sail ship Elissa. Still other museums include the Galveston County Historical Museum, Mardi Gras Museum, and the Railroad Museum, which has a great display of Pullman cars, cabooses, and miniature trains.

In addition to the museums and shops, another “must see” in Galveston is the historic seawall, which was built a few years after the devastating 1900 hurricane. The seawall is ideal for walking, jogging, or cycling, and features a 2.5 mile art The Moody Mansion survived mural that spans from 27th to 61st streets. the hurricane of 1900 and is now a museum.

are available.

If you enjoy visiting museums, there are several to see. One noteworthy museum is the Lone Star Flight Museum, which is home to one of the finest collections of restored aircraft and aviation exhibitions in the nation. Other one-of-a-kind museums are the Ocean Star Offshore Drilling

Historic Homes

A description of Galveston is not complete without covering the city’s famous homes. Prior to the Great Storm of 1900, the town was a thriving hub of trade and commerce, and many wealthy businessmen built their dream homes in the area. Among the more famous houses is Bishop’s Palace, 2328 Broadway, which was

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FABRICATOR September-October 2001

built in 1888 for a Galveston attorney.

The exquisite residence features fine woodwork and various fireplaces that were imported from around the world.

Another impressive home is Ashton Villa, 1402 Broadway, an ante-bellum mansion that showcases antiques, family heirlooms, and original art.

Originally built by one of Texas’ wealthiest businessmen, James M. Brown, the home was later owned by his daughter, Miss Bettie, who hosted many social gatherings.

The Moody Mansion, located at 2618 Broadway, is a historic estate that’s also a museum. This limestone and brick mansion was built between 1893 and 1895 and features rare handcarved wood, stained glass, coffered

e For th ch s U n ea Joi ight B N y a Frid On Friday evening, the Moody Garden’s waterfront will come alive with a NOMMA beach party. Wear your favorite Hawaiian shirt, grab a beach ball, and enjoy a night of barbecue, beach music, bonfire, and beach olympics.

ceilings, and Moody family heirlooms.

At this home, you’ll see how Galveston’s “rich and famous” citizens lived during the early 20th century.

Other noteworthy homes in-

Look what’s playing at the IMAX theatres! During your visit to Moody Gardens be sure to catch a movie at either the IMAX Ridefilm or IMAX 3D theatres.

Into the Deep Journey to an enchanting underwater world of swaying kelp forests and glowing corals. Swim nose to nose with colorful garibaldi, starfish, and sharks; play tag with sea lions; observe the frenzied mating of the opalescent squid and other rarelyseen behavior of the creatures of the eternal undersea night. Filmed off the coast of Southern California.

Wings of Courage (3D) This inspiring true story of courage and loyalty is set in Buenos Aires, Argentina in the 1930’s. It tells the dramatic tale of three legendary pioneer aviators who make the first historic and dangerous airmail flights across the treacherous Andes Mountains.

Stars Val Kilmer, Craig Sheffer, Tom Hulce, and Elizabeth McGovern.

The following will also be showing, but descriptions were not available at press time: L5: First City In Space and Haunted Castle.

clude the Michel B. Menard Home on 33rd Street, the Samuel May Williams Home, Avenue P, and the Powhatan House on Avenue O. The Powhatan, built in 1847, is considered one of Texas’ most beautiful Greek revival homes.

Transportation

Galveston Island and the Moody Gardens complex is 50 miles south of Houston on Interstate 45.

By air, you would arrive via Houston’s two major airports — William P. Hobby Airport (40 minute drive) and the George Bush Intercontinental Airport (90 minute drive). Once you arrive in Galveston, getting around is easy thanks to a new electric shuttle bus service. Shuttles run approximately every 30 minutes from 11 a.m. to 9 p.m. and offer stops at Moody Gardens, the downtown area, and the beachfront. Cost is $1 per person.

Weather

“Near perfect” is one way to describe Galveston’s weather. March temperatures average a high of 67º F and a low of 55º F.

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Hotel Registration

To reserve your room at the Moody Gardens Hotel, call (888) 3888484. Rate: $142 per night (single/ double). When calling, be sure to mention that you are with the National Ornamental & Miscell-aneous Metals Association (NOMMA).

Registration Information

Complete hotel and convention registration information will appear in the Convention Guide, which will be included with the next two

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FABRICATOR September-October 2001

Top Job Profiles

Photo: Kate Milford

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By Jonathan Glazer Sure Iron Works

n the 1860s, the leaders of Brooklyn’s political machine devised a plan that they hoped would increase the borough’s residential population and stimulate its manufacturing economy: the building of the Brooklyn Bridge. To accomplish this daunting engineering task, they called upon John Roebling, the pre-eminent engineer of the times and owner of a state-of-the-art wire rope factory in Trenton, NJ.

Over 100 years later, in the 1990s, the Mercer County Improvement Authority (MCIA), undertook its most ambitious project to date in an ongoing effort to create jobs in postindustrial Trenton: building a 10,000 seat sports and entertainment arena on the site formerly used by the Roebling Wire and Rope Company and the American Steel and Wire Company. In

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June 1999, as the construction neared completion, Mercer contacted Sure Iron Works (SIW), a Brooklyn based steel fabricator, to build the final aspect of the arena. The project called for three steel lighting towers that would transmit intersecting beams of light that converged above the arena’s roof.

When Steven Horn, president of SIW, first discussed the project with the MCIA, he was excited by both the Roebling connection and the technical demands of the project.

In just two months, the design and construction team consisting of SIW, Geiger Engineers, Rathe Productions, and MCIA had to finalize the design, generate shop drawings, identify qualified subcontractors, and complete fabrication.

Design finalization involved

juggling technical, aesthetic, and budget concerns. Although the MCIA knew that it wanted the towers to each consist of three inclined steel columns that would support a reflective mirror, they could not decide on the height or number of towers. At the end of July, they settled on three, 35-foot towers.

Each tower also featured a series of horizontal pipe supports for hanging decorative banners and a truncated steel cone of perforated steel plate.

The cone housed the lighting source; a 7,000 Watt xenon lamp spotlight capable of projecting a complete spectrum of colors.

With just one month of fabrication time remaining, there was little margin for error or delay.

Perhaps the most difficult aspect of keeping the job on track was finding a qualified subcontractor to roll the steel

FABRICATOR September-October 2001

Photo: Kate Milford

cone with a two-week turnaround.

Fortunately, the owners of New Jersey Welding were willing to postpone August vacations and complete the rolling in just ten days.

The tight timeline and complicated finish work made it impossible to correct any fabrication and fitup problems in the field. To account for this, SIW needed to simulate site conditions. Using three W36 beams and a 1-inch sheet of steel plate, they constructed false work dunnage so that the entire structure could be erected in the shop yard. At the top of the towers, a series of channels tied the beams together and supported the mirror.

When the “shop erection” was completed during the last week of August, the towers were “tripped” down intact with a 50-ton hydraulic truck crane and shipped via wide load trailers to Palmer Industrial Coatings, an SSPC (Structural Steel Painting Council) approved finisher. Each piece of steel required three coats of Tnemic paint; designed to withstand long-term weather exposure. In mid September, they were shipped to the

Only two months were available to design the job, create shop drawings, secure subcontractors, and fabricate the job. Approx. labor time: 4,400 hrs.

arena site.

Using a 55-ton crane, the towers were erected in two days.

The site erection was completed on September 20, 1999: one week ahead of schedule. The job would have been finished earlier, but the torrential rains and powerful winds of Hurricane Floyd made site work impossible for several days.

With the towers in place, Space Cannon Illuminations installed the spotlights. Unfortunately, two of the tower mirrors had to be replaced after local kids tested their stone throwing ability. Once the new mirrors were installed, they were able to properly align the width and direction of the light.

By the evening of the arena’s first event on October 6, the towers were beaming light across the roof.

Outside the arena, a piece of machinery used in the wire rope making process stood as the last reminder of Roebling factory. Inside the arena, the Trenton crowd cheered as WWF wrestlers threw each other off the ropes of the ring.

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FABRICATOR September-October 2001

Built

Top Job Profiles

A Well Bred Horse Excellent workmanship, rather than excellent breeding, makes this horse special.

By Jeanne Howe

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elding Works Inc., located in Madison, CT, recently completed a major architectural ornamentation project that was shipped to the Midwest and installed on the Great Platte River Road Archway Monument. Stretching across Interstate 80 in Kearney, NE, this new 309-foot-long archway hon-

top: The completed Great Platte River Road Archway. The building that spans the highway contains two levels of interactive exhibits. right: A closeup of the horse on the northern tower. In all, the job required 12 tons of aluminum and 6 tons of support steel and stainless hardware. Total labor time: 3,350 hours fabrication, 400 hours engineering and office support.

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FABRICATOR September-October 2001

ors the pioneers who traveled west, 150 years ago, on the Great Platte River Road, whose path the Interstate now follows.

Welding Works’ role in this ambitious undertaking was the fabrication of the symbolic exterior ornamentation for the structure. Designed

by Kent Bloomer, the ornamentation includes two sets of 27-foot-high aluminum wings, which are mounted atop the north and south towers of the Archway. Wings were chosen by Bloomer to symbolize movement, transportation, and communication.

Bloomer also designed a 309-foot trellis to span the length of the archway.

Its braided wave style evokes the feeling of the Platte River. Completing the ornamentation is its centerpiece, an intricately detailed aluminum horse that leaps out of one set of wings, representing the Pony Express.

In all, approximately 12 tons of fabricated aluminum plate, sheet, pipe, and structural members were used in this project, along with six tons of support steel and stainless

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right:

A mock-up is made of the trellis end. One of the major challenges of this project was connecting the artwork with the structure.

hardware. All aluminum plate ornaments were cleaned and left in their natural finish. They were fabricated in pieces as large as possible to expedite final assembly.

Walter P. Camp, Vice President and person responsible for the financial aspects of Welding Works, negotiated the contract for the work with Kent Bloomer and originally developed the scope of the work. The company’s President, H. Price van der Swaagh, who is responsible for all manufacturing and engineering,

served as the central clearinghouse for all the information from the fabricator, engineer, contractor, inspector, and trucker involved in the project.

It was necessary for van der Swaagh to be involved in the daily problems and be out on the floor working them out. All told, the company expended 3,350 labor hours, as well as 400 hours of engineering and office support, to complete the project.

During the engineering and design phase of the project, the design of the wings was the first and most important step. However, each pair of wings needed an independent structure behind it for support and to interface the artwork with the steel structure on the building. The design of these structures was the responsibility of Doug Rutledge, Project Engineer at K L & A (structural engineer for the project), who supplied rough sketches of the support structure. As complete as the designs were, there were still countless challenges facing Welding Works as they married the artwork to the structure. Communication between Welding Works and the design engineers was ongoing, and the design engineers also made several on-site visits to Welding Works.

The welding for the project was done exclusively with the GMAW process. Welding Works certified procedures, as well as eight welders, to AWS standards for 5052-H32 and 6061-T6 aluminum material. The filler wire was 5/64-inch diameter E-4043.

The shielding gas was straight argon.

The material varied from .090 thick sheet to fi inch thick plate, with the majority being .190 and fi inch thick.

Welding Works used Miller power sources in a variety of output poten-

FABRICATOR September-October 2001

tials with Miller XR-30 wire feeders. These state-of-the-art feeders allowed Welding Works to feed the 5 /64-inch E-4043 wire, which is very soft, over a distance of 30 feet. This was essential for the job, since the varied shapes and sizes of the artwork were so dissimilar. Some of the pieces were 12 feet by 26 feet, and at times welders were working 30 feet in the air. The vast majority of the welds were fillets in the size range of 3/16 to ⁄ inch.

Cutting was accomplished by conventional band saw for the structural shapes (beams, angles, structural tubing, etc.). The plate shapes, which comprised the majority of the feathers and tendrils, were cut on an AIRCO optic-eye burning machine. This machine has the capacity of cutting six feet wide by 16 feet long sections. Welding Works retrofitted the cutting machine with a Thermal Dynamics STAK-PAC with two power modules and a machine torch. This allowed the company to cut fi inch thick plate, the thickest used on the

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A full-scale mockup was created at the fabricator’s plant to ensure that the horse would fit on the archway and to develop the struts to hold the artwork.

Dimensions were based on a survey of the building’s roof.

project. Welding Works added a C&G

height sensor for automated cutting.

The shapes were taken from eighth scale and quarter scale models and blown up to full-scale flat patterns.

These patterns were then made into black-on-white templates so that the optic-eye tracer could follow the shapes. An operator was thus able to cut a multitude of varied shapes with speed and accuracy.

Forming presented a considerable challenge. The models in eighth or quarter scale were the only source of information regarding how much the elements were to be formed. Bloomer’s studio scaled the models and developed rolling and forming templates for Welding Works to use. A trial and error method was generally employed in arriving at the finished look of each shape. Once the shape was developed, Welding Works used a press brake and two rolling machines.

For the wings, fi inch aluminum plate was plasma cut to shape, and individual feathers were rollformed to templates, then welded to a central hub. The horse was

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the most time-consuming element of the sculpture due to the many pieces requiring hand forming. Measuring 14 feet high by 4 feet wide by 17 feet long, its intricate frame is comprised of over 300 aluminum plates of 1/4 and fi inch thickness that are welded to three main support plates. Over 400 pieces of .090 aluminum were hand-cut and fitted into place to give detail and texture to the skin. After the skin was tacked, all seams were fully welded.

The supports for the horse were critical – the horse had to appear as if it were standing on its hind legs, without any visible support structure.

Three main support plates were created inside the horse, forming a box-like structure. Two external supports were camouflaged by the mane and tail.

In addition, Welding Works completed the trellis that now stretches across the length of the archway, a process that required hand-feeding 1,700 feet of aluminum pipe into a hydraulic pipe bender. The trellis consists of 16 sections, each requiring multiple and differing radii.

To ensure the artwork’s fit on the archway and in order to develop the struts that hold the artwork, fullscale mock-ups were required for both the north and south towers of the building. Welding Works employed two types of mock-ups. The data to place the foliage were developed from a survey of the building that was taken on the roof in Nebraska. The artwork was laid out and supported in its proper relationship to the building and to itself. Struts were then developed to hold all the foliage. To further ensure that the artwork would fit when it reached Nebraska, a complete vertical mock-up of all the assemblies was performed. The survey was used to develop pedestals that represented the building pedestals. The steel support system was erected in Welding Works’ yard, and then all the artwork was hung on the steel in full scale.

Each end was also mocked-up fullscale, with all the elements placed in their proper relationship. Struts were developed for each piece as well.

This simulation of the existing conditions at the site and

test-assembly were especially important. Due to the complexity and the irregular shapes, Welding Works had to make sure that all assemblies fit together and would go on without any interference. Structural engineers were also able to clarify many items that were impossible to calculate on paper.

In addition, the test-assembly enabled Kent Bloomer to view the completed ornaments and determine if the artistic criteria had been met.

After test-assembly at Welding Works, the ornamentation was delivered to Nebraska. It took five oversize truckloads to transport the project to the site. Now that it is installed on the Great Platte River Road Archway Monument, it helps welcome visitors to two levels of interactive exhibits housed in the archway, which make the Wells Fargo Stagecoach and Pony Express “come alive.”

This job netted Welding Works a gold award in the 2001 Ernest Wiemann Top Job Contest. The company joined NOMMA in 1992.

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Top Job Profiles

African Adventure Tedious design work and precise fabrication made this plant and animal gate come to life.

By Francis X. Flaherty Flaherty Iron Works

laherty Iron Works was excited when asked to bid on entrance gates for the newly remodeled African Plaza at the North Carolina Zoological Park in Asheboro, NC. This 1,200-acre zoo received national recognition when it became the home of Ham, the first chimpanzee launched into space. We were contacted

by Ellen Greer, Director of Design at the zoo, and asked to submit photo samples of our work along with our bid.

She indicated she would be interested in a design similar to one used in a stair railing we had done for a restaurant in Washington, D.C. The rail had incorporated outlined faces using fi inch round bar. She thought we might do something similar by using fi inch round to outline African animal shapes. Our bid was based on that type of design in the two sets of entrance gates. We thought, “We can do that,” and drove to North Carolina to bring her a sample. That’s when the fun began!

Ms. Greer really liked the sample but thought it might be nice for one of the window guards that were also included in the proposal. The gates were to be much more detailed, she said. The following design process proved to be as challenging as the fabrication.

Ms. Greer had rounded up for us a box load of books on African wildlife, flora, insects, and birds. There were to be two sets of entrance gates to the African Plaza.

Greer requested that one set of gates represent the African grasslands and the second set represent the African rainforest. Each set of gates was to include three to five sculptured animals, at least three different types of foliage, and a variety of birds and insects. We were to refer to the books 36

A closeup of the right gate leaf. All animals and plants had to be replicated with the utmost accuracy.

in order to familiarize ourselves with which animals lived where. We had to decide such things as: Should a bongo be included in the grasslands gate or the forest gate? And what does a bongo look like? There were things we needed to learn in order to come up with an acceptable design. We came home with books in hand and realized that designing these gates would be quite involved. That’s when we contacted Laura Chandler of Chandler Studios to come up with a design that would incorporate all of Ms. Greer’s requests.

Yet still, coming up with a drawing that would receive final approval was quite a task. We learned there is a difference between African and Indian elephants, and we wouldn’t want an Indian elephant in the African Plaza gates.

Drawings were submitted, and we received feedback such as: “avoid excessive sweetness, and don’t make the animals smile,” and “the bongo has 10 to 16 stripes — use a minimum of 10,” and “the stalks of the red hot poker plant should be thicker.” All these requests for detail added to the cost of design and fabrication. An amended proposal was sent to the zoo and accepted to cover the costs of increased time and labor.

A final drawing to scale (3 inches to 1 foot) was approved, and the fabrication finally began. We took the FABRICATOR September-October 2001

18-inch by 22-inch drawing and enlarged it to the exact measurements of the gate. Then using contact transfer paper, this drawing was transferred full scale to our worktable.

We learned to do the work with full-scale drawings in a NOMMA class given by Lloyd Hughes several years ago.

The frame was made from 2-inch square tubing, hammered to look like vines. Some of the larger animals, trees, etc., were plasma cut out of 3/16 inch plate then hot hand-forged using the power hammer and anvil. Another request from the client was that the gates: “work well from both sides.� So each part had to look just right front and back. To give texture, we did a lot of MIG welding. Locking mechanisms were brass sleeved with stainless steel bar.

The hinges from Interstate were custom-made the whole length of the gate. Originally, the client wanted the gates metalized and powder coated but after seeing the natural finish, they liked the look and wanted that type of finish.

So we went to Nichols Co., who specializes in clear coat finishes, and were able to provide the look they liked and a finish that would hold up outdoors.

When the gates were installed in March 2001, everyone was really pleased with the final product. The design process had taken eight months; the fabricating four months.

Now, each day hundreds of people walk through these gates and enjoy the amazingly lifelike and beautiful things that can be done with ornamental metal.

Flaherty Iron Works has been a NOMMA member since 1974. This job received a silver award in the 2001

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The double leaf iron gates are 7 feet wide by 61/2 feet high. The frame is made of 2 by 2 inch square tubing, hammered and forged plate, 5/8 inch rods, and 1/4 by 11/4 inch flat bar. Approx. labor time: 160 hrs.

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Top Job Profiles

A Challenging Installation Harsh weather and an extremely narrow street made the installation of this gate and fence system a challenge. Because crane access was impossible, the company relied on the strength of 13 individuals to complete the job.

By Natalia Khripko Russian Blacksmithing

his past year in Savannah, GA was the first time our company entered the Ernest Wiemann Top Job competition. The piece we submitted was a gate fabricated for a client who lives near Moscow. When we sent our entry, everyone involved in the job was anxious for the results — designers, our blacksmiths, and even the client.

When we won the award, it was a considerable surprise to all of us, and it is especially rewarding to know that we are the first Russian company to win such recognition in America.

This project was very challenging and had many variables to contend with, even from the beginning. It started with the first visit from the client’s architect. He saw our work at an exhibition and liked the quality and the variety of styles of our designers. He explained that our task was to make all handiwork in Art Nouveau, since that followed the theme of the house and is also the client’s favorite

The modern design of this gate and railing fits well with the house. The total project is 80 feet long and 7 feet high. The job consists of six fence sections, the gate, and wicket. Designed by the fabricator, the frames for the gate and wicket were welded from 11/16 and 15/8 by 31/8 inch square tubes. The paint is a graphite color. Approx. labor time: 960 hrs.

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style. Usually our clients look through our collection of designs and photos and choose the most attractive ones. In other cases they simply specify the style with the designer and provide us with an opportunity to construct something different. For this project our client and his architect chose a rather surprising composition. It was the pedestal for a street lamp. In the style of that pedestal, Elena, our designer, designed all of the outside fencing for the house, which had a lot of large fence sections, piazza fencing, balconies, and a porch railing.

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left: Inspiration for the design came from a street lamp pedestal (right).

Because of the narrow street, it was decided to create a rolling gate that actually enters a neighbor’s property when in the open position.

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Some problems appeared when we began to form the fence project. The client did not like the head caps. He found them too aggressive or too far from the chosen style. That’s when we realized it would be best to show the client each element as we went along. For example, we had to show him the already beaten fence elements so he could study them. At last we found a head cap design that was good for everybody, but then other problems arose.

One problem was that our client’s house is located on a very narrow street, which made it impossible to open the gates outwards. This is typical of houses in this area. The other problem was the width. The gates had to be very wide — about 17 feet. The only option was to have rolling gates, but that was also a problem since there was a marble porch on one side and the neighbor’s fence on the other. The client resolved the situation by getting permission from his neighbors to let the gate roll into their lot when opening.

The easiest part of the project was choosing the color. Everyone concurred that plumbago, a color that complimented the roof, was the best choice. However, we were very afraid to use this Zinga zinc clear coat because we hadn’t used that type of paint before. But soon our apprehension went away. Once the finish was complete, we were pleased with our handiwork and everyone on our team felt a sense of pride.

As already mentioned, we live in Russia where hard frosts are common. When we were mounting the gates it began snowing and FABRICATOR September-October 2001

ornamental steel design reflex blue

right:

A view from the inside shows the pedestrian “wicket” gate. below: The 17-foot wide driveway gate.

the temperature dropped very low.

Of course we could have delayed mounting, but it would have been too much trouble to make a second trip, so we decided to begin. Because of the narrow street, it was impossible to use a crane, so we gathered 13 people to raise the gates from the vehicle and place them in position so that we could attach the special frame. This part of the installation took all day.

The next morning it was very difficult to start work because the gates were frozen to the frame.

We don’t know how it is in the U.S., but in Russia the more people that are involved with a project, the more opinions there are for solving problems. Ideas from our group included heat (but then the suffusion would be damaged), beat it with a hammer, shake it, or come back in the spring.

Yet, as the 13 of us were arguing and struggling with the gates, everything suddenly thawed, so we quickly set all the rubber gaskets and greased all joints.

It took us three days to set the gates, which was quite good considering the bad weather. Although it’s not humble to say this, we think the new metalwork is the home’s most attractive feature. Now, the house stands out from all others in town.

We would like to acknowledge all the participants in this project for their patience and professionalism.

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Top Job Profiles

Wa

rs

The battle for uniformity isn’t over yet. And in the meantime, fabricators are getting buried in the paperwork.

By Susanne Gargiulo

et’s see, there’s the Southern Building Code (SBC), the International Residential Code (IRC), the International Building Code (IBC), Southern Building Code Congress International Inc. (SSBCI), Building Officials and Code Administrators International (BOCA), International Congress of Building Officials (ICBO), and now also the new National Fire Protection Association code (NFPA). Not to mention jurisdictional varieties of those codes — or even worse: the implementation of several different codes in the same region.

In some states, every city and county adopt their own code, and in other jurisdictions they write their own codes — word for word. Phew, it’s a jungle 46

out there. Then, of course, there are the supplements and amendments that get tossed in along the way, and also the version — or year — of a code.

No doubt, a fabricator must stay on his toes to keep up, especially if he works in more than one jurisdiction.

It is probably not necessary to reiterate the importance of code compliance. Not only is it needed to pass inspection; but also the threat of a lawsuit is always present, and in that case code compliance is your best — perhaps even your only — defense.

Knowing the local code and the local inspector is a smart thing to have on the fabricator’s list of priorities. For fabricators who deal with several codes, either because their jurisdiction supports different codes or because

they ship to areas where other codes are applicable, compliance can get tricky. It pays to be cautious. Be familiar with the local code and when in doubt, check with the local inspector. They are there to help you, not hinder you, and it is a lot easier — and cheaper — to comply before, rather than after the railing is up. You can’t possibly know all the codes, so use the local inspector as an inexpensive and efficient resource.

De-Coding the Mystery

In a perfect kingdom, everyone would agree to adopt and comply with one code. That way there would never be issues of variety or difficulties with compliance. Unfortunately, this is not a kingdom and even if it

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were, people probably still would not agree. For years, regional codes have been dictating regulations, and within those codes cities, counties, and states have adapted and made changes to suit their own standards. It all makes for a cocktail of differences. There are three primary regional codes: BOCA, founded in 1915; SBCCI, which began developing codes in 1940; and ICBO, which published its first set of codes in 1927.

Numerous jurisdictions still run with either one of the regional code bodies, but in 1994, BOCA, SBCCI, and ICBO got together to

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Need Code Help In A Hurry?

Check out the following sites: ICC: www.intlcode.org ICBO: www.icbo.org BOCA: www.bocai.org SBCCI: www.sbcci.org NFPA: www.nfpa.org NOMMA: www.nomma.org

create a set of “master codes.” The council they created, the International Code Council (ICC), aimed to streamline coding through model codes for

national use. There are about a dozen ICC codes, covering everything from building to zoning, energy conservation, plumbing, etc. The ICC codes most relevant to fabricators are: the International Residential Code (IRC) and the International Building Code (IBC).

The push to streamline the nation under the ICC codes has began, and according to a November 2000 report, 1,200 U.S. jurisdictions have adopted the new, unified codes so far.

The challenge is to have these codes adopted nationwide, and there is still a ways to go. Richard Kuchnicki, Executive VP of the ICC, remains positive, stating that: “We are hopeful that all jurisdictions will adopt it in the next few years.”

That would be quite an accomplishment. Does that mean we may have our kingdom after all? Belk Null, general manager of Berger Iron Works in Houston, TX and NOMMA’s president-elect, doesn’t think so. “No matter how much we try to have one code, it will never happen,” he says. “Cities will always have their own building code, and the best we can hope for is one building code that everyone modifies from.”

Complicating the matter is the National Fire Protection Association, currently working on its own set of codes scheduled for release in 2002. An effort to work together with the ICC on agreeable codes failed, and the agency is therefore releasing its own code. The adoption of that code by jurisdictions would clearly interfere with the ICC plan of complete streamlining.

The Fabled “Ladder Effect”

Of course, we can’t talk about codes without discussing the

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“ladder effect.” The creative pitfall, the dreaded rule, the frightful word that dooms anything that has the slightest climbable aspect to it, and has the scroll-happy fabricator shaking, shuddering, and begging for mercy. For those who have yet to fall prey to the rule it is a ghostly fable that sounds too bad to be true, but for those who live with it, it is a disruptive and seemingly unsolvable proposition.

Working under the BOCA code, Phillip Ayoub of Schoenherr Iron Works in Warren, MI, has had his showdown with the ladder effect.

He and his client were faced with a dilemma when the outside railing didn’t pass inspection due to the ladder effect. “They wanted to tear everything down unless we covered it with Plexiglas,” he says. “It just seems like in the past eight months everything is all of a sudden attributed to the ‘ladder effect.’ A scroll is now suddenly a ‘ladder effect,’ and most all the castings ... are now hard to get around. I’ve had to put Plexiglas on my last two jobs,” he says, admitting he is concerned about it.

Bob Paxton of the Lawler Foundry Corp. agrees. “It is literally 60 percent of our catalog that would be subject to the ‘ladder effect,’” he says, adding, “The problem is that the code is very subjective; it is left in the eye of the beholder.”

Tony Leto, president of J.G. Braun Company and immediate past chair of NOMMA’s Technical Committee, agrees, noting that inspectors are simply interpreting it wrong. “It was never meant to impact on ornamental railings,” he says, “but local inspectors are interpreting it that way.”

The ladder effect is currently in effect in areas where the BOCA code, or the IRC 2000 code, has been adopted. Note that:

• The 2000 IRC does have the “ladder effect” in it, but the 2001 Supplement to the IRC does not, thanks in part to NOMMA’s efforts.

• Codes are printed every three years.

• Supplements are yearly inserts.

• Many states do not adopt FABRICATOR September-October 2001

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the supplements.

For the ornamental metalworker, the “ladder effect” is potentially harmful. “You can do a variety of work with steel that they cannot do with wood,” says Ayoub. “And with this rule you lose the ornamental beauty. It’s costing us jobs because we can only do up and down, so people start going to wood because it’s less expensive.” Ayoub is now unable to give his customers what they want because their dream designs are falling victim to the ladder effect. “When they have to pick the fifth best, they start getting frustrated,” he says, “and before we used to get so many compliments. Now, unless the customer is willing to pay for Plexiglas, they get few options.”

NOMMA Also Works On Gate Construction Standards

Brent Nichols, leader of NOMMA’s Gate Construction Safety Task Force has spent the past two and a half years working on construction guidelines for automated gates, and that standard is awaiting publication soon. Nichols says, “Right now there are no codes to deal with in the construction of gates, and this document will address that.” While it is a voluntary standard, it is an important document that compliments UL 325, which went into effect March 1, 2000. Once finalized, the standard will appear on the NOMMA website at www.nomma. org.

Fabricators Can Make A “Code-able” Difference

It is code regulations such as the “ladder effect” that make it important for fabricators at a local level to get involved with the adopting and interpretation of codes in their

jurisdiction. “We have been telling members for years that they need to go to their local building officials to have things changed,” says Belk Null.

And they can have an impact. Thomas Zuzik, Jr. of Artistic Railings Inc. in Garfield, NJ fought the ladder effect

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— and won. He was the victim of a lawsuit, filed when a client climbed a railing he had installed, accidentally fell, and impaled himself on a bush. He says the suit was completely ridiculous, and makes the point that if someone wants to climb over something they’ll find a way. “Code needs to stop potential accidents, not control intentions,” he says.

Zuzik fought it, and last October he had the New Jersey Code Advisory Board vote “yes” to remove the “ladder effect,” which should be completely removed from the residential and commercial codes by this September. Still, he remains vigilant and on the case because in a few months New Jersey will adopt the 2000 IRC and IBC building codes, which includes the “ladder effect.”

“Hopefully they will strike it,” he says.

There are so many good reasons why fabricators should stay vigilant on a local level. “Every fabricator needs to get involved,” says Zuzik.

Anyone can fall prey to a disruptive

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code if adapted by the local jurisdiction, so remain proactive and make your voice be heard on local code changes or adoptions. “I can write a building code tomorrow if I want, “ says Zuzik. “The ICC has a process through which you can comment, make proposals, and make your case at an annual meeting. Then a panel of industry professionals vote on it, and it becomes part of the building code,” he says, adding that while it is positive that anyone can make a change, it also means fabricators should remain vigilant around proposed codes, such as the “ladder effect,” that could hurt them. Here are some suggestions on how to get involved:

• Contact the agency that governs your local jurisdiction and become active in the adoption of new codes, supplements, and changes. Stay informed and make your voice be heard.

• Know your local inspector, and educate them as to what they do.

(To get the latest information on the ICC codes, go to www.intlcode.org.

For other code sites, see the sidebar.)

• If you are subject to the 2000 IRC, courteously bringing your local inspectors’ attention to the 2001 Supplement may help “weigh” their interpretation in your favor.

• If that does not work, it may be necessary to have it changed in your local code. While it does take effort, it is possible. Zuzik is living proof.

If they are interested, fabricators can also apply to be part of the code building body. The ICC has code development committees to which anyone qualified can apply to take part in. NOMMA, for instance, recently applied to have a representative on the IRC Building & Energy and IBC Means of Egress committees.

In addition, NOMMA is continually getting more proactive in the codes process. In the past two years, members of the Technical Committee attended numerous hearings and meetings to guard fabricator’s interests on the “ladder effect” and other issues.

More recently, the association hired a part-time technical consultant to attend hearings and update technical information for members.

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Americans With Disabilities Act (ADA)

Yet another area where the NOMMA Technical Committee is active is accessibility standards.

When the ADA Accessibility Guidelines (ADAAG) were up for review last year, committee members spoke at hearings and submitted comments. This year, ANSI A117.1, the private-sector equivalent to ADAAG, is up for review, and the Technical Committee has sent in comments for this standard as well.

Bye-bye Scroll?

The bottom line is that fabricators can and should come together locally and “stand up for their scrolls” or whatever other issues arise in the future. Those scrolls, along with all the other fanciful twists, turns, balls, and leaves, are what sets the ornamental metal fabricator apart from everyone else. Think about it: would a baker not protest if they banned the use of yeast?

“I love it when we give people what they enjoy,” says Ayoub.

“That’s why I do this.” So, whether we like it or not, codes are very much

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Member Spotlight

left: Company president Frank Finelli, bottom: The office and shop. right: An art deco residential railing fabricated by Finelli Ornamental.

Founded by an Italian immigrant, Finelli Ornamental Iron Co. continues to build upon its proud past.

By Todd Daniel Editor

A

small desk on the second floor of Finelli Ornamental Iron Co. says it all. On the desktop sits a copy of Fabricator magazine and some old, tattered notebooks. Company founder Michael Finelli used the notebooks when he began his business in 1961, and the 1977 Fabricator highlights the company on the cover. It was that year, just 13 months after joining NOMMA, that the firm received its first gold Top Job award.

Today, the desk sits in the up54

stairs office area like a museum piece.

To the staff, it serves as a reminder of the traditions and legacy that have made Finelli Ornamental a successful and respected firm.

Since those early days in the 60s and 70s, the family business has grown to 13 full-time and 3 part-time employees. The company occupies a 15,000-square-foot shop in Solon, OH, and regularly produces high-end jobs for owners as far away as Hawaii, Florida, and the Bahamas.

But it wasn’t always that

way. Oldest son Frank Finelli, who is now company president, remembers a time when his dad went door-to-door selling ironwork. When he sold a job, he’d fabricate, paint, and install it, and would then start knocking on doors again.

“It’s kind of funny,” Frank says. “I remember when I was around 12 to 15 years old we’d make the railings and paint them. At about 4 p.m. we’d be thinking it was time to go home, and he would say, ‘Let’s load the truck and go install them.’”

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Now 72, the elder Mike is essentially retired and spends much of his time at a summer home in Georgia.

The day-to-day operations are now managed by the two Finelli sons — Frank and Angelo — as well as Jim Korosec, who serves as vice president of design development.

It is Mike’s high business ethics and passion for metalwork that still guide the company today. An Italian immigrant, Mike arrived in the U.S. in 1945, with 10 cents in his pocket. He was only 16 at the time, and immediately began searching for work. His career began by working for an uncle in Washington, D.C., and he eventually ended up at a Cleveland steel mill. Later, he joined a local ornamental firm.

In 1961, Mike’s destiny took a major twist. He was working for $1.80 an hour at the time and asked for a nickel raise. The raise showed up on his paycheck for a couple of weeks, but then one day he noticed he was back at his old rate. When he questioned his boss, the man replied,

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A craftsman hand brushes primer around all joints. Such attention to detail has resulted in zero callbacks for rust or paint failure.

“I can’t afford to pay you that.” After that incident, Mike decided to venture on his own.

“I think a lot about the way my dad is goes back to the struggle he had to even get to this country,” Frank says. “I think that struggle made him

ready for almost anything.”

Even up until the early 1990s, Finelli Ornamental still relied on storm doors and other smaller, miscellaneous products for much of its revenue. But then one day the firm shifted gears and began concentrating on the high-end residential market. The turning point, according to Frank, was February 28, 1992 when they won a major contract for a $1.5 million villa. Producing the $90,000 railing for the home was scary but it gave the staff valuable experience for handling larger jobs.

“We learned how to handle that type of situation, that kind of pressure, and that kind of expectation,” Frank says. From there, the company made other bold moves, such as buying a $2,000 magazine ad. “We were saying ‘wow, is this ludicrous or what?’” The investment in advertising has been a success for Finelli Ornamental, which now specializes in highend railings, gates, and fencing.

And overall, the company’s greater commitment to image and visibility is paying off. In recent years,

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tennessee fabricating

Each month, the company holds a special event for staff. In May, specialty pizza was brought in for lunch. Other events have included breakfast and

Finelli Ornamental has done work for such celebrities as Mike Tyson, Don King, and billionaire Al Lerner, who owns the Cleveland Browns. The company has also won several Top Job awards, including a 1999 bronze award for a wine cellar gate.

Without question, it is the image, professionalism, and self-confidence that propels the staff toward greater accomplishments. Visitors can see this commitment to excellence in the office area and huge showroom, but it is most evident in the shop. The shop floor is impeccably neat and organized, and the clean white walls, huge windows, and spacious workstations create a comfortable work environment where craftsmen can do their best work.

The company’s commitment to high standards is also reflected in the way it treats clients and employees. For clients, there is great emphasis on keeping promises, fair business dealings, and being honest when problems arise.

“It all goes back to following through,” Frank explains. “What we have found in our business is that when you’re doing work for somebody, you must do the things you said you’re going to do, you must be on the job when you said you’re going to be on the job, and you must deal with any issues that need to be dealt with.”

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site or to simply tighten a screw, then he’s probably going to find another fabricator. “We try not to give a reason for going somewhere else,” Frank adds.

Employees are also treated respectfully, and emphasis is placed on motivation and encouragement.

To reinforce the company’s strong commitment to safety, craftsmen are given a $50 bill each time they go six months without a lost day due to a workplace injury. Another fun thing the company does is provide a monthly meal. Sometimes it’s a cookout on the grill and other times they’ll order pizza. And on occasion, employees may come into work to find Frank cooking breakfast for them.

In keeping with Finelli Ornamental’s continued emphasis on the long-term, the company provides a generous retirement profit-sharing plan. Under the plan, 10 percent of each employee’s gross annual pay goes into a retirement account, plus they receive a percentage of profits.

At Finelli Ornamental, average total contributions have been 22 percent.

Finelli Ornamental crafted this nonferrous railing based on an interior designer’s concept. Installation, particularly the setting of the curved areas, was challenging and took a tremendous amount of time in the field. Approx. labor time: 800 hrs.

“My philosophy is to keep us competitive, get the jobs we need to get done, do it efficiently so that we have a profit, and at the end of the year share it,” Frank says. “If you’re really teaching teamwork you’d better live it and you’d better show it.”

Many of the company’s core values, knowledge, and innovative ideas can be traced to the Finelli’s

long association with NOMMA. For instance, the idea for the $50 safety incentive is from a NOMMA education session. In the shop, there are many ideas in use that were picked up from visiting fellow NOMMA members or convention shop tours. During the 1993 shop tour in Lexington, KY the Finelli’s borrowed two ideas — a rotisserie jig that saves labor time and

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pre-drawn lines on layout tables. And while once visiting a fellow NOMMA member, Frank got the idea of creating a centralized inventory station by stacking 5-gallon cans on a rack.

During a recent interview, Frank talked about two NOMMA members who have particularly impacted the company. Bill Valerius, who formerly operated Valerius Blacksmithing, took brother Angelo Finelli on as an apprentice in the 1970s. Also with him were wellknown NOMMA members Lloyd K. Hughes and Kevin Merry. The three-month apprenticeship not only changed Angelo’s life, but it gave Finelli Ornamental a foundation of valuable Old World skills.

Another NOMMA member who has had a positive influence on the company is Bill Merry of Herndon & Merry Inc., Nashville, TN. Frank’s face lights up when he talks about his admiration for Bill.

“Bill Merry taught me what image really means; how to portray yourself, the character of a man,

r&d hydraulics

The Finelli’s borrowed this inventory storage system from a fellow NOMMA member. The five-gallon drums hold commonly used components.

the integrity of a man. This is what NOMMA’s all about,” Frank says.

Once, he asked Bill if he could visit his shop, and the Merry’s graciously opened their doors to both their home and business. Frank says it wasn’t so much the shop that

impressed him, but the man. “You can put a building anywhere, but it’s hard to duplicate the man.”

While the Finelli’s have borrowed their share of ideas over the years, they are inventors themselves and are always trying to improve efficiency. As Frank says, “miles are dollars,” and the shop is carefully laid out to reduce walking. Multiple pieces of key equipment are duplicated to further reduce foot traffic, and nearly everything is placed on wheels. For example, one centralized band saw can conveniently serve three workstations, and if the machine needs to be moved, it can be rolled across the shop and plugged into an electrical outlet specially configured for that unit. Four drills and a tapping machine are also clustered in a central area to reduce walking time.

While efficiency helps to improve profits, it also creates an environment for maximizing quality. Less walking and waiting for machines means more time to focus on the small details that have helped the firm secure its reputation as a top

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FABRICATOR September-October 2001

quality shop. At Finelli Ornamental, a NOMMA #4 joint finish isn’t even offered; nor is a #2 or #3. A #1 finish is the company’s standard finish. When using tubes, the seam is always ground smooth.

For priming, the company goes the extra mile by spraying the insides of channels. Better yet, craftsmen hand brush all joints with primer, since spray doesn’t always reach the crevices. The extra effort has resulted in zero callbacks for paint failure or rust.

“Everything’s in the preparation, just like a house,” Frank says. “If you don’t have the foundation right you can forget the house.”

Originally setting out to be an engineer, Frank graduated from John Carroll University and the Cleveland Engineering Institute, and started his career in the engineering department of a fabrication firm. When his dad went to Italy in the late 1970s for a visit, Frank returned to the shop to help out and has remained there ever since. Brother Angelo, who is vice president, has worked at the firm

Looking over a layout in the shop.

since high school, and gained valuable training during his apprenticeship with Bill Valerius. Jim Koresec, vice president of design development, has an architectural background, and is involved with design, sales, operations, and some estimating. Another member of the leadership team is Jim Mellott, who serves as shop foreman.

In the office, Frank’s wife, Nancy Finelli, keeps things running smooth.

Together, the staff works as a closely-knit team. To improve communication, the company recently began holding quarterly meetings where the men gather in a non-pressured environment, such as a Saturday

morning, and discuss general issues.

This gives management an opportunity to fine tune the company and keep everything on course.

The regular workweek for the firm is 6 a.m. to 4:30 p.m. Monday through Thursday and Friday until about 2:30 p.m. Overtime is an option for Friday afternoon and Saturdays.

The goal is always to keep the backlog to 4-6 weeks, since a longer period may prompt clients to look elsewhere.

While Finelli Ornamental has yet to get their formal mission statement in writing, Frank easily sums it up: “Doing the best that you possibly can with the utmost fairness and integrity that will ultimately make that customer very happy.” The ultimate reward isn’t a check, Frank says, but rather seeing a satisfied customer.

The old desk sits at the top of the stairs, where each day it is viewed by staff and clients. It serves as a constant reminder of the heritage that has made Finelli Ornamental strong.

Symbol-ically, the notebooks serve as a reminder of the great integrity that founder Mike Finelli gave the com-

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Member Profile

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she’s on the way up and coasting. A landmark project, which she completed in the spring of 2000, established her as a high-end, self-employed fabricator of architectural metal. “It was my first project where I needed a crane for installation,” says the proud but modest artist.

Mensoff has studied with such names as Michael Bondi and Elizabeth Brim. In 1997 and 1999 she was a studio assistant for Nol Putnam at the Penland School of Crafts in Penland, NC and cherishes a tool they forged together. “As a studio assist you’re there to maintain equipment, assist with demos, help Mensoff students on projects, and fabricated work on projects yourthis variaself,” Mensoff said. “I was tion of her phoenix rebuilding one of the gas symbol to forges when Nol gave me accent the a hammer. It’s a tool I use interior of all the time. We took it off a client’s house. its handle and we forged

it, upset both ends of it, and then we signed it ‘Nol Putnam, Corrina Mensoff’ and then the symbol for iron. He told me that I should always remember to feed my soul.” Looking around her studio, it’s obvious that this artist does. Covering her studio walls are variations of her phoenix symbol, six-foot mythological, metal birds in

FABRICATOR September-October 2001

Photo by Jill Buckner

It takes a strong person to hammer and forge hot steel. It takes an even stronger person to make his or her dream come true. Corrina Mensoff of Phoenix Metalworks in Atlanta, GA does both.

“My parents always told me I could do whatever I set my mind too,” says Mensoff explaing that as a little girl the fire in her father’s forge sparked her passion for metalwork. “I love the idea of creating with something that’s bigger than I am.”

But at first, Mensoff started out small, making silver jewelry in high school. Then she studied metal sculpture in college. After several apprenticeships, including a journeymen apprenticeship in a 200-plus all male welding shop, Mensoff, still in her twenties, had her own forge and began prospering as an independent artist blacksmith.

Now blazing her own path in the Atlanta-area market, you could say

Artist Metalsmith with a Fire and Forge of Her Own

Meet Corrina Mensoff:

Photo by Jill Buckner

flight, and other non-commissioned combinasculptures — expe- This scale drawing is part riences expressed of a gate proposal. Typithrough metal. cally when going from a Creativity small scale drawing to an actual piece, Mensoff and the drive that completes a drawing, brings creative pas- photocopies it onto acetate, and then copies sion into fruition it onto nice paper. Finally live in this studio. she completes a color Its circular layout rendering, which she puts suggests ambion overhead to do a fullscale drawing. And then tion as it follows the jig making process the flow of work. begins.

“The metal comes

Photo by Jill Buckner

master-halco (monumental) 4C

Mensoff has also

created a small in, gets cut, model or sample of then forged, the proposed gate, finished, asmade of copper and sembled, and steel. then out the door,” says Mensoff.

Her tools, organized according to size and mounted like a shrine above her self-made forge, suggest devotion and pride. The tool from

Mensoff makes or enhances many of her tools, shown here arranged on a wall of her studio.

Putnam remains one of Mensoff’s favorite as does a pair of tongs from Madison, GA’s legendary Floyd Daniels. “I like the idea of passing on tradition by preserving the use of old tools,” says Mensoff. “My tools are a FABRICATOR September-October 2001

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cutters, TIG welders, saws, and sanders.”

“The tools are like my hands,” she says, holding a 2-inch by 2-inch square that’s been forged out (split and curved). “I use this to get into difficult spots. I made it while taking a class led by Brent Kington,” (also at the Penland School of Crafts).

A Recent Project

Recently, Mensoff used the jig to secure a ribbon of copper on an elaborate nonferrous bed frame.

She says the project was particularly tedious, especially since there was no paint used. Every step was meticulously planned to avoid any inflections of the metal. Plus, the project, which was completed and installed in July 2001, incurred a fairly extensive design process. This led to its art nouveau style.

“There was a lot of engineering going into how the parts were going to fit together and come apart,” says Mensoff. She and her assistant, a longtime friend and fellow blacksmith, had to figure out how to assemble

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Mensoff welds handforged leaves to a lemon tree gazebo, another recent commission.

the bed frame in her studio so that it would also fit up the stairs and into the second floor bedroom of her clients’ house.

“Originally they wanted it all one-inch solid stainless steel, big and heavy. But we had to do away with the heavy stuff as we realized it would probably do away with the structure of their second floor,” she says laughing.

The frame is made of all

⁄ inch by 1-inch bronze, 3/8 inch by 1-inch copper, and fi inch by 1-inch brass. The clients’ last name is Lamar, and the center presents an abstracted “L.” “Actually we didn’t intend for it to be an “L” but they picked up on it, and so we then emphasized it a little more by making it bolder, subtle but with a more bold, thicker material.”

While working on this project, Mensoff also began forging a

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American Spiral

Photo by Jill Buckner

lemon tree gazebo for another client.

Since she likes to concentrate on what she does best, forging and detailed design, she contracts out some of the more monotonous work. For example on the lemon tree gazebo, Mensoff contracted someone else to roll the 16-foot by 11-foot tube needed for the gazebo’s roof. Then she also had a local casting company cast the lemons for the four trees which comprise the gazebo, while she and her apprentice, a woman who recently graduated from Georgia State University with a sculpture degree, made the molds for the casts.

“I’m in love with the process of hot forging, and I love how one job varies from the next. From the

The exterior grab rail of this iris handrailing is made from 1 inch forged iron; the iris is copper.

meticulous and perfect (the bed frame) to a lose interpretation (the lemon tree gazebo). The material I like to work with ranges from sheet metal, to bar stock, tubing . . . And I love copper. It feels like such a wonderful material.

You can stretch it and push it. It’s very forgiving.”

The Long Road to Full-time Commission Work

Although Mensoff enjoys commissions coming into her shop on a regular basis now, getting started as an independent metalsmith wasn’t an easy ride. It took a combination of skill, education, ambition, and networking to get a shop of her own in full swing. She often worked two jobs FABRICATOR September-October 2001

at a time and completed side projects with borrowed equipment after hours.

Working for other people, she says, took valuable time away from her own creative energy. “I was driving around in a beat up old truck with parts of projects in the back, and at the end of the day I’d ask shop owners, ‘Ok, can I do a little welding now?’”

After double majoring in metals and sculpture at the Massachusetts College of Art, Mensoff moved to Atlanta. After all, she says, Georgia played an important role in the revival of the artist blacksmith craft in the 1960’s. Anticipating a difficult path

This “modern archaic” railing is made of forged and fabricated stainless steel, copper, and brass.

Photo by Jill Buckner

Photo by Jill Buckner

The “Bloomberg Table” is made of forged iron and copper.

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Fireplace ensemble made of forged iron and copper.

Photo by Jill Buckner

after college, she set herself up with an apprenticeship before completing her last year.

“Anywhere I went traveling I’d call up the area’s local

blacksmiths to see as many shops and talk to as many people as I could. I needed to formulate what I wanted to do and what direction to go in, so I talked to a couple of metalworkers in Atlanta.”

Although her first apprenticeship involved more “mass production” than she’d originally hoped for, the experience taught her about running a business and working with others. The shop specialized in production furniture and cabinets, “real fabricated, squared off, contemporary stuff,” says Mensoff. “But I got my first couple of

Sumter

Mensoff entertwined copper, brass, and bronze for this nonferrous bed frame.

Photo by Jill Buckner

clients there, and I learned a lot.”

“Networking has been a

strong tool for me.

There’s a strong community of blacksmiths in the Atlanta area and I’d say virtually all of my work has Circle 80 on Reader Service Card

After a series of drawings and samples the clients decided on this art nouveau deisgn based on a Belgian artist’s work.

come through referrals,” she says.

One day, Mensoff recalls, a woman came in to a shop where she was working and wanted a fireplace screen. “The shop didn’t do custom work so they referred her to me. In school I sold candlesticks and jewelry,” says Mensoff. “So I was always doing small projects on the side. But this developed into more and bigger work. The woman had just built a dream house and kept having me do little projects, chiseling designs, then a door. I learned more of measuring, making things fit, and timing a project so I could let the client know when it would be completed.”

Still working on the door project for the client, Mensoff says she found herself apologizing for taking so long with it. Being without a shop and spending most of the day working for other fabricators was really taking its toll. But like a fairy godmother, the client advised her to bite the bullet and set up her own studio. “She handed me two checks. One for the midpoint deposit on the door project and one for $2,000, a no-interest loan.“

So, in 1996, Mensoff gathered the bear necessities to set up her own studio. Even though the commissions didn’t exactly roll in at first, it was a start. “I wasn’t really set up yet; it wasn’t efficient,” Mensoff said. “So I picked up a job with a welding plant, American Bowa, and got my certification.” Mensoff worked as a journeyman apprentice alongside 200 other welders at the plant in Cumming, GA. She had to first take a welding test, which her professor in college had prepared her for, and was the only woman the company had ever hired.

The work enhanced her abilities without draining her creativity. At the end of the day, she retained enough energy for her own work. “And I got some great scrap,” she says. “It exposed me to what was really out there. I had been exposed to artists, and now I saw the industry.”

Mensoff believes that all things happen for a reason, and a tragedy proved her right. In 1998, in the midst of exhibiting at shows and building her clientele her little studio was robbed. However, it led to a substantial creative commission. “Right FABRICATOR 67 January-February 2001

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Mensoff’s current studio is located in the west end warehouse district in downtown Atlanta. The door to the right opens to her office; the metal gate on the left opens to a metal working area. Both rooms are adjoined by an interior door. Her handmade forge is toward the back.

International Gate Devices

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before the Roswell Studio Arts Show my shop got broken into. They took all my tools, my work. They took my time,” Mensoff says, wincing slightly at the memory. “I had to cancel the show. And of course I had no insurance.” But it turned out that the woman running the show had met another local artist who painted chairs and was interested in Mensoff’s work. Aside from buying up just about everything Mensoff had left from the robbery, and after looking at photographs of past projects, the chair painter commissioned the artist-blacksmith to make her some chairs.

“It was a big break,” says Mensoff. “I worked out a budget for the chairs and the designs. All of a sudden I was making something worth more than $1,000. And the chairs had interesting mechanical connections.”

Needless to say, Mensoff eventually recovered from the robbery and developed a strong enough client base to sustain herself full-time.

“I paid the woman who lent me the $2,000 the last installment just the other day actually,” says Mensoff proudly.

Continuing her education by attending classes and teaching has also helped develop her career. Aside from being a studio assist, Mensoff has held workshops at the Spruill Center for the Arts in Atlanta and at Peters Valley Craft Center. Education acts as a form of networking, she says, helping her obtain commissions while introducing her to other professionals in the field.

Now Mensoff works out of a larger studio. It’s a warehouse space in FABRICATOR September-October 2001

Technique

Save Time and Money with

Electrostatic Painting

By Larry Utterback, ITW Ransburg

Many shops have production problems because their painter just can’t keep up. Production just can’t paint fast enough to keep up with the benders and welders. Electrostatic guns can make painting faster and easier. In some cases, electrostatics can almost cut the painting time in half, depending on the application, saving valuable time and money and increasing your production.

around effect significantly reduces Volatile Organic Compound (VOC) emissions, which provides significant cost savings and reduced work time.

It Actually Pays for Itself

An electrostatic gun actually pays for itself in paint savings.

Payback is achieved with:

• Reduced labor and material costs

• Reduced VOC emissions

• Reduced spray maintenance costs (filters)

• Reduced costs for the disposal of hazardous materials

• Reduced work time with electro- static wrap

• Positive environmental impact

What is Electrostatics?

Electrostatics basically eliminates wasteful overspray by getting as much of the coating material on the target as possible. This is achieved by negatively charging the atomized paint particles (atomization) so they are attracted to the grounded work piece. Opposites attract. Any item that is electrostatically conductive and can be grounded — to earth, can be electrostatically sprayed.

Further atomization is achieved as charged particles repel each other to form a fine cloud.

As a result of the electrostatic attraction, spray that would normally be lost ends up on the backsides of the workpiece to produce a wraparound effect.

The REA 70 Cascade (mobile) Elctrostatice This wrapGun comes with an Aviator Control Unit.

FABRICATOR September-October 2001

Paints Many people believe that electrostatic painting requires special paint. This is not true. A variety of paints can be used with electrostatic equipment including, but not limited to: • Epoxies • Enamels • Eurethanes • Polyesters • Water reducables (with certain types

of guns) • Baking paints

Even coatings that are not necessarily conducive to electrostatic spray can be altered by chemical additives to adjust the paint’s conductive polarity. Most paint suppliers today are capable of these techniques. Even non-metallic surfaces such as plastics can be made conductive for electrostatic spray by wiping with conductive pretreatThis electrostatic gun and its control unit mount to the wall.

ments.

Applications such as laminate countertops, molded plastic doors, and

other non-metal items are routinely sprayed electrostatically. Some nationally-known paint suppliers offer paints for electrostatic applications that are mixed and ready to go to work right out of the can and there’s no mixing required.

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Electrostatic Equipment

Various types of electrostatic equipment are available for most any application. Equipment styles range from automatic or manual, air spray, High-Volume / Low-Pressure (HVLP) spray, air-assisted airless, and pure electrostatic atomization. The type of equipment used is dependent upon the application and desired results.

Manufacturers of electrostatic equipment even have packaged portable systems for on-site electrostatic finishing. Certain equipment utilizes

the electrostatic force generated by a power supply to atomize paint without compressed air or hydraulic pressure.

This means overspray is non-existent and transfer efficiencies in the 95 to 98 percent range can be achieved.

Portable Painting

Contractors can actually go on-site for open-air painting to finish or refinish various products such as metal office furniture, fences, lockers, recreation equipment, amusement park rides, and outdoor furniture.

Electrostatic painting makes

R & B Wagner

This is one of ITW’s many electrostatic sprayguns. Unlike the No. 2 Process Gun, first introduced in 1941, it does not require special paint.

otherwise impossible or outrageously expensive jobs possible and affordable. For example, one of our clients told us about a customer of theirs who wanted a frame for a sheet of glass painted. They were told that the job would require the framing to be taken apart, taken off-site, painted, returned, touched-up, and then reinstalled. Finally the glass could be put back into place. A contractor using our No.2 Process electrostatic gun was able to paint the grids, on-site, without removing them from the facility.

Thanks to the high transfer efficiency of electrostatics, the solution saved the company half the projected cost and

postville

made their customer happy.

For more info on electrostatics, call ITW Ransburg (800) 233‑3366, or visit our web site: www. itwransbur.com.

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t eabout 15 Myths L n’t o Electrostatic Painting D

Keep You From Saving Time and Money

The process is too technical; Not everybody can use it.

Most electrostatic guns have the same type of controls for atomization, fluid control, and fan width that exists on other non‑electrostatic guns.

Anyone who can operate a conventional gun can usually master electrostatic equipment in 30 minutes or less.

One key to success is good equipment maintenance — don’t abuse the gun.

While electrostatics can’t paint anything except metal, almost any product can be finished electrostatically. Some may require pretreatment with chemical sensitizers to produce a conductive surface or with some products a metal object may be placed behind the part to create a ground image for attraction.

Many black rubber items have enough carbon content to be sprayable.

Electrostatics are expensive to operate and maintain.

Yes, electrostatics cost more then a conventional spray gun. However, an electrostatic gun is 3 to 10 times more efficient in terms of spraying paint on the parts. A true return on investment calculation needs to be made on each application.

Electrostatic guns are not durable and very fragile.

Spray guns are not hammers! All spray guns are designed for the purpose of atomizing and applying coatings of paint. Unlike metal conventional spray guns, electrostatic guns must be made mostly of strong plastic. With today’s technology, most electrostatic guns are very rugged and do not break easily.

Electrostatic gun cables are heavy and awkward.

Today’s high voltage cables are almost as small and flexible as low voltage cables. The ITW Ransburg line of cascade guns only need about 10 volts supplied to the gun, therefore the cables are much smaller and flexible than older style cables. The Ransburg style classic guns are now constructed of lighter materials and employ modern construction technol-

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ogy.

Electrostatics require special paints.

Most air spray, airless, air‑assisted airless, and HVLP electrostatic guns do not need special paints because the charge is applied outside the gun by a charging electrode. However, ITW’s No. 2 Process Gun needs paint in a specific resistance range because its atomization is purely electrostatic.

Electrostatics can’t spray waterbornes.

Waterbornes are the most conductive paints made. This makes them ideal for electrostatic applications. However, special isolation hardware is required.

Electrostatics technology is equal to HVLP.

HVLP is an efficient, low energy process that shows a measured improvement in transfer efficiency over standard air spray. But electrostatics, because of the high voltage charge, show an additional measured improvement in transfer efficiency

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over HVLP. Electrostatic guns are available in air

spray, HVLP, airless or air‑assisted air less. Electrostatics can’t paint in corners. Painting corners electrostatically may be accomplished by following this technique: Utilize air pressure to drive the paint into difficult areas or by narrowing fan width to effectively increase delivery rate per inch of pattern width.

Electrostatics can’t spray metallics.

Metallics and other conductive coatings can usually be sprayed by use of a coiled fluid tube or other similar fluid supply modification to prevent the voltage from leaking back to ground.

electrostatic field can become charged and then deposit onto the work surface. But all painting, whether electrostatic or conventional, should be done in a clean environment.

Electrostatics make parts attract dust.

Any airborne dust or dirt particles that come in contact with the

Electrostatics makes paint stick better.

Electrostatics spray is merely an improved method of application

AGS

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guns is similar to the charge used in xerography or that we experience from

fibers charging when we walk across a carpet and touch the door handle. This electrostatic charge has no damaging affect on the human body.

with higher transfer efficiency than conventional spray. Adhesion of the coating is a function of the cleanliness and preparation of the work surface.

Electrostatics can make you sterile, ruin your wristwatch, or make your hair fall out.

The electrostatic charge used in manual and automatic electrostatic

Electrostatics just doesn’t work.

One of the biggest causes of electrostatic guns not being successful is failure to provide a conductive substrate or maintaining an adequate ground on the product. A fact of life with electrostatic equipment is that hooks and racks must be cleaned and maintained to provide a ground circuit that is below one megohm in resistance. Good ground makes the conductive part positive while the gun voltage is negative — therefore the attraction.

Painting aircraft electrostatically can cause damage.

Electrostatic application uses

static charge (high voltage 60‑100 kV) at very low current (amperage) flow.

The typical current flow to the target from an electrostatic spray gun would be under 100 microamperes of current with the average being 20‑60 microamperes (millionths of one amp).

Aircraft in flight is subject to static at all times due to air friction and that of water vapor passing over the skin of the aircraft. Aircraft is designed to tolerate and dissipate the static without harm to the structure or the avionics.

Large static charge (much larger than that received from electrostatics) in the form of lightning usually does not damage the aircraft.

Electrostatics magnetizes the paint.

Electrostatics is not electromagnetic. Electrostatic spray uses the process of bombarding paint droplets with air ions. The resulting negative charge on the surface of the paint particles helps attract the paint to any positive, grounded, conductive product. Electrostatics may be used on non‑ferrous metals including

Jansen

Krieger

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Top Job Contest Update GOLD G. Stairs Complete

New Winners For 2001 Ernest Wiemann Top Job Competition, Category G The following are the corrected winners of Category G. After the contest results were announced in March, a rule violation was discovered in this category. The NOMMA Board of Directors voted to remove the first place winner, and each successive winner was advanced. The new winners are shown on this page and on the NOMMA web site: www.nomma.org.

B. Rourke & Co. Ltd., Lancashire, England.

SILVER G. Stairs Complete Big D Metalworks, Dallas, TX

Architect: The Lauck Group Contractor: BKT Construction Inc.

BRONZE, G. Stairs Complete, Berger Iron Works Inc., Houston,

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NOMMA’s Newest Video Is Now Available

“Almost The Last Word in Finishes” Cost: $36 NOMMA members, $45 nonmembers.

Presenter: Lloyd K. Hughes of Lloyd K. Hughes Metalsmithing Length: 72 min.

To order: See pg. 96 or visit: www. color. The result is fabulous, and you nomma.org

As promised, the second edition of NOMMA’s education video series is out! Again Lloyd Hughes of Lloyd K. Hughes Metalsmithing, Lexington, KY presents the subject matter with his comfortable, charismatic, and encouraging manner. This time the subject is finishing. In the 72-minute demonstration, Hughes explains how to apply over 12 different finishes using a variety of chemicals and materials, from oil and wax finishes to hot

and cold patinas.

Although Hughes makes it look easy, he stresses the importance of reading up on finishes before tackling any new project. Hughes offers good tips for preparing surfaces and ways to make certain jobs easier. For example when creating an antiqued finish, Hughes grips a thin sheet of plastic over his barely dried glaze as a means of removing the excess glaze and bringing out more of the base

can do it too. But like Hughes says, read up and practice on scrap material first.

“Almost The Last Word in Finishes” was produced in May and is available now as part of NOMMA’s Educational Video Series. Parts and materials used in the video were donated by: Lawler Foundry, SculptNouveau, and Tennessee Fabricating.

Future video subjects include fences, gates, and working with nonferrous metals.

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News Roundup Code Harmonization Keeps Trucking On

What once was a dream in 1994 has turned out to become a rocky road. Seven years ago, at the urging of architects and builders, the code community unveiled plans for a new unified code. Such a code was published in 2000, but the road to harmonization remains a distant goal.

For starters, some jurisdictions have opted to adopt the competing National Fire Protection Association codes instead, while other states and cities seem content to use the older, existing codes, such as the UBC. This year, as jurisdictions around the country begin to implement the 2000 International Codes, a new level of problems is rising to the surface.

By Todd Daniel

The newest challenge is that while there is one unified code, there are still three model code organizations — Building Officials and Code Administrators International (BOCA), International Conference of Building Officials (ICBO), and the Southern Building Code Congress International (SBCCI). Each code body may train inspectors and interpret codes differently. Thus, what’s acceptable in a BOCA state like Pennsylvania may be rejected in a SBCCI or ICBO state, even though all parties are using the same code book.

Brian Black of the Eastern Paralyzed Veterans Association recently commented on this potential dilemma in a letter to the code bodies.

He said, “While there is now only one International Building Code, three separate organizations are still determining what that single code says!”

Yet, a white horse may be on the way. Right now, the International Code Council is merely an umbrella organization of the three code bodies, but plans are underway for a full merger. At the fall code hearings, each organization is scheduled to vote on merger plan. Approval of the resolutions will set in motion plans for a formal merger vote during the 2002 fall conference. The target date for the complete merger is January 2003.

Last year, code officials adopted a resolution that approved the intent of a single model code organization, and the vote this fall will be to accept a specific plan of action and timetable.

“We are acting on the members’ resolutions and are proceeding as promptly as possible,” said Jon S.

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FABRICATOR September-October 2001

Traw, P.E., of ICBO. “We understand that in consolidating each of the business functions there are many legal issues and outside interests that have to be considered.” According to Traw, the code bodies have already consolidated their certification services, and the lessons learned there will aid in the overall merger.

Once merged in 2003, the code bodies are still looking ahead toward a greater dream — going international. While naming the current codes “international” may have been a dead giveaway for some, the group’s overseas ambitions have become more visible this year. In past months, the ICC has formed new partnerships around the world and has started a foundation, called, “Building A Safer World Foundation.” Expected to be fully operational by the end of the year, the new foundation “will facilitate other organizations in becoming more directly involved and financially supportive of the ICC goals.”

Multi Lock

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FABRICATOR September-October 2001

School Construction Bill To Rev Up Again

Now that Congress has returned from their summer recess, a bill to provide funding for school construction is expected to take the front burner. Known as “America’s Better Classroom Act of 2001,” the legislation would provide over $22 billion in revenue bonds.

For fabricators, passage of the bill would mean more bidding opportunities for both new construction and renovations. So far, the legislation has 240 cosponsors and many more committed floor votes, making passage likely. Sponsoring the bill is Rep. Nancy Johnson (R-CT) and Rep. Charles Rangle (DNY).

The need for school construction aid is most urgent in California, were student enrollment is increasing by about 37,600 students per year. During a hearing of the

House Ways & Means Committee, California school officials said they needed $7 billion for maintenance and renovations and $9.6 billion for new construction over the next three years.

Once approved, the legislation would generate funds by leveraging $3.57 billion in tax incentives to create interest-free construction bonds. Rather than interest, the federal government would provide tax credits, and the responsibility for the bond principal would remain at the state and local level.

According to several sources, the bill’s inclusion of the DavisBeacon provisions has generated some controversy. Favored by labor but opposed by GOP leadership, DavisBeacon requires federal contractors with contracts in excess of $2,000 to pay mechanics and laborers prevailing wages and fringe benefits.

Subcontractor Wins Delay Damages Case

Realizing the danger of a potentially bad precedent, the Ameri-

North Cray

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can Subcontractors Association (ASA) swung its Subcontractors Legal Defense Fund (SLDF) into action during a highly publicized legal case.

The issue involved owner liability for owner-caused delay damages suffered by a subcontractor.

The case involved a subcontractor seeking damages against New York City’s Metropolitan Transit Authority. After the case ended unfavorably in the lower courts, the subcontractor, with the help of the SLDF, made a successful appeal to overturn the decision.

Under the original trial court decision, general contractors and subcontractors would have been prevented from changing “no damage for delay” clauses without owner approval. Fortunately, the appellate court reversed the decision and ruled that the general contract language, which required owner “approval of the Subcontractor and the form of the Subcontract,” only gave the owner the right to pre-approve subcontractors, and not to pre-approve particular terms of agreements between the general contractor

and subcontractor, such as “no damage for delay” terms.

According to the ASA, the decision of the appeals court makes it more likely that subcontractors will finally be fairly compensated for owner-caused delays on projects.

“ASA’s Subcontractors Legal Defense Fund sent a strong message about the right of subcontractors to collect delay damages,” said ASA president Gerry Martin. “When a subcontractor suffers financially because of others’ management practices, the subcontractor’s request for delay damages must be taken seriously. This principle has been affirmed in New York state.”

The ASA’s legal defense fund supports critical legal activities to protect the interests of all subcontractors, and is funded solely by contributions. In the past, the ASA has won some major cases, including a 1999 appeal to the New York Supreme Court that would have revived contingent payments. For more info on the ASA and their legal

program, visit www.asaonline.com.

OSHA Sends Letter To Targeted Firms

In early August, the Occupational Safety and Health Administration (OSHA) announced that it had sent letters to 14,000 workplaces notifying them that their industry and illness rate exceeds national norms.

“The sites we are identifying are on notice that they need to improve,” said Labor Secretary Elaine L. Chao. “High injury and illness rates have a significant personal cost to employees and a financial cost to employers.”

Of the firms that received letters, OSHA is planning to visit about 1,000 sites that experienced especially high injury and illness rates.

Firms with poor records were identified from a survey taken last year. The national average

Mac Metals

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FABRICATOR September-October 2001

for absences related to workplace injuries is three instances per 100 full-time workers. Letters were only sent to those firms that had eight or more lost workday incidents per 100 employees.

Included with each letter was a copy of the firm’s safety record, along with a list of the most frequently violated OSHA standards for the company’s industry. OSHA is encouraging firms with poor records to hire an outside safety consultant or to get assistance from insurance carriers or a worker’s comp agency. The agency has also provided information on a free safety and health consultation service funded by OSHA in each state for small companies.

The 14,000 firms that received the letter are listed on OSHA’s website (www.osha.gov) under the Freedom of Information Act section.

Estate Tax To ”Sunset” By 2011

While the most visible result of the recently passed tax relief act is the rebate check in your mailbox, the new legislation will provide other benefits as well. Called the “Tax Relief Recon-ciliation Act of 2001,” the law provides $1.35 trillion in tax relief and will provide numerous tax reductions over the next decade. In addition to tax-rate reductions, citizens will enjoy relief in the form of child credit increases, marriage penalty relief, education incentives, retirement plan provisions, alternative minimum tax relief, and estate tax repeal.

For businesses, probably the most important benefit is the “sunsetting” of the estate tax, which is slowly being phased out. Complete elimination of the tax takes place January 1, 2011, and will cost the federal government $50 billion a year. However, accord-ing to a bulletin published by the Sheet Metal and Air Conditioning Contractors’ National Association (SMACNA), even though the federal estate tax is on its way out, individuals must still pay state estate taxes.

FABRICATOR September-October 2001

“Great invention . . . but can it endure the harsh oxidized elements in the upcoming Rust Age?”

CML

Circle 110Removal of the Card estate tax on Reader Service

may mean that more revenue is freed

Ironwood

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Business Briefs • Capital Metals of Phoenix, AZ, an Industrial Metal Supply Co., has moved to a new, 83,000 square foot building. The new facility, which includes an air-conditioned, 10,000 square foot retail showroom, is located in Southeast Phoenix at 5150 South 48 St., across from Diablo Stadium. For more info, call (818) 729-3333.

• User Solutions Inc. announces the immediate availability of Resource

Manager for Microsoft Office. Built from the ground up as an add-on to the familiar Excel spreadsheet program, Resource Manager is a low-cost, scheduling and tracking solution for small to medium size firms and can be easiliy implemented. Resource Manger enables users to manage labor, materials, and work centers to assist in managing customer orders, delivery and services, cycle times, inventory shortages, and tracking schedules. For

more info, call (248) 486-1934, or visit: www.usersolutions.com.

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Don’t Be Left Out Rolling Blackouts can happen any­where.

With ’s line of UL325-compliant battery back-up gate operators, you can still get in or out.

Model RSL-D

Model CRS-D

Model MSG-D

OPERATOR SPECIALTY COM­PA­NY, Model

www.laborresearch.org Check out this web site from the Labor Research Association. While it’s main forcus is to provide research and educational services for trade unions, non-union members of the ornamental metal industry can benefit from up to date labor news on economic, political, and union trends, while staying abreast of the trade and global economy.

Interstate

Model

WEB SITES

• Comco, a company specializing in micro-abrasive blasting, has recently published a series of technical bulletins designed to clearly explain how the process of micor-abrasive blasting works, as well as its limitations, and which industries can benefit from the technology. For more info, call (800) 7966626, or visit: www.comcoinc.com.

• Chemical Coaters Association International (CCAI) announces the release of their fourth edition Powder Coating Training Manual in Spanish. The manual contains fundamental information needed to operatea powder coating systems and manage the process efficiently and profitably.

For more info, call (513) 624-6767, or visit: www.finishing.com/ccai.

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FABRICATOR September-October 2001

Join NOMMA Today ...

Membership Category - Check One q $290 - Fabricator q $440 - Nationwide Supplier (Firms selling to fabricators beyond 500 miles of their headquarters) q $340 - Regional Supplier (Firms selling to fabricators within 500 miles of their headquarters) q $265 - Local Supplier (Firms selling to fabricators within 150 miles of their headquarters) q $215 - Affiliate (Teachers and educational organizations) Company Name __________________________________________ Your Name ________________________________________ Address __________________________________________________________________________________________________ City _____________________________ State _________ Zip _________________ Country ______________________________ Phone ____________________________ Fax __________________________ Sponsor (if any) ____________________________ E-mail _______________________________________ Web _______________________________________ Company Description/ Specialty ________________________________________________________________________________ Signature ___________________________________________ Payment Method: q Check q VISA q MC q AMEX q Discover If paying by credit card: Acct. No. _______________________________________________________ Exp. ______/______ Exact name on card ______________________________________ Signature ______________________________________ Checks should be made payable to NOMMA (U.S. dollars, check drawn on U.S. bank)

By signing this application, you agree to abide by NOMMA’s Bylaws and Code of Ethics upon acceptance.

MEMBERSHIP YEAR RUNS FROM JULY 1 TO JUNE 30.

Return To: NOMMA, 532 Forest Pkwy., Suite A, Forest Park, GA 30297. (404) 363-4009. Fax: (404) 366-1852.

Membership dues payments are not deductible as charitable contributions, but may be deducted as an ordinary and necessary business expense.

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F

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These are just some of your benefits as a NOMMA member.

• Starter Kit. As a new member, you receive a Membership Directory, Supplier Directory, educational publications, and sales aides.

• Discount Rates. You receive discounts on all NOMMA publications and association sponsored events, including educational seminars and METALfab (NOMMA’s annual convention and trade show).

• Affiliation. As a member of the industry’s trade association, you show customers that you support the industry and subscribe to NOMMA’s code of ethics. You also receive a membership certificate, decal, and camera-ready logos to use on your stationery and business forms.

• Chapters. If there is a local chapter in your area, you may participate in educational programs, social events, and other chapter activities.

• Subscriptions. You receive a subscription to our industry trade magazine, Ornamental & Miscellaneous Metal Fabricator, and membership newsletter, The Scroll. The newsletter contains valuable industry information that you won’t find in the magazine, including an economic report, code updates, and news on government agencies that affect our industry (OSHA, EPA, IRS, etc.). Better yet, we also include a copy of The Business Owner, a newsletter that covers small business issues such as taxes, business succession, etc..

• Insurance. Enjoy competitive rates by participating in the NOMMA-endorsed commercial insurance program.

• Industry Awards Competition. Enter your best work in the Top Job Awards Competition for an opportunity to compete with the best in the industry. Press releases are sent to local newspapers, and the publicity is GREAT!

FABRICATOR January-February 2001

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Updated: 5/01

New Products & Ser­vic­es • Command Tooling Systems’ Taper Check

This testing system ensures tool-holder performance to avoid interruption in production. Taper Check allows testing for shear wear with components in place, enabling operators to replace worn toolholders before tool or spindle damage occurs.

Available in 30, 35, 40, 45, or 50 taper toolholders, Taper Check allows users to service a variety of machining centers. For more info, call (952) 9342375, or visit: www.commandtool.

com.

• Alvin Products’ Heat

Block

paste from Alvin Products protects surfaces during soldering, brazing, welding, and other heat treamtents.

The nontoxic, heat dissipating paste is water based and cleans easily.To prevent heat transfer, spread the heat-sink onto the surface, and remove after repair or heat treatment with a damp cloth or running water. For more info, call (978) 975-4580, or visit: www. alvinproducts.com.

• Architectural Products

By Outwater’s Backsplash

This new heat absorbing

Classic Iron

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Tips, Tricks & Jigs

¶¶¶¶

How to Paint Your Metal Spiral Stair Kit

Tips from The Iron Shop then wiped down

Paint your spiral stair after installation.

Although it is possible to paint the stair prior to installations, it’s not recommended because parts (especially the center pole) can get scratched, making it necessary to touch up after installation.

What type of paint should be used?

Use a quality, oil-based enamel. Never use a water-based or latex paint. For exterior installations, use an oil-based paint with a rustinhibitive additive.

How many coats of paint will the stair need?

If the stair is being painted a dark color, two coats are usually sufficient. If the stair is being painted a light color, three coats are often required to cover the black primer. For exterior installations, three coats are always recommended for rust protection, no mater what color you are using.

What is an easy way to apply the paint?

Apply the first coat of paint using a two-inch wide roller with a tight nap. Roll the paint onto the entire stair. There will be certain areas where the roller will not reach. For these areas, use a one-inch angled brush. Apply enough coats of paint to cover. Go back over the stair with the two-inch roller, applying enough paint to cover.

This technique will give the look of a spray-painted stair, without the hassle of having to mask the environment around the stair.

Can the polyethylene handrail that comes with the kit be painted?

FABRICATOR September-October 2001

The Iron Shop does not recommend painting the polyethylene handrail; however, a few customers have gotten satisfactory results by roughing up the surface with sandpaper and using special automotivetype paint used for painting flexible bumpers. Your other alternative is to purchase an aluminum handrail instead of the polyethylene. It must first be sanded with #000 steel wool

with rubbing alcohol to clean it. Next apply one coat

of etching primer. Finish painting the aluminum handrail by applying two coats of quality, oil-based enamel in your choice of color.

For more info, call The Iron Shop at (800) 523-7427, ext. PR-FAB, Send pictures and information about or visit: www.theironshop.com. your favorite tips, tricks, or jigs to: Todd Daniel at Fabricator, 532 Forest Pkwy., Ste. A, Forest Park, GA 30297.

Or e-mail: todd@nomma.org.

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g-s co.

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New Members

Welcome NOMMA’s 21 Newest Members

An Iron Works Los Angeles, CA Jose Marron Fabricator

Architectural Iron Works LLC Romeo, MI Courtland Lee Fabricator Walid Al Baker Doha, Middle East, Qatar Walid Al Baker Fabricator Bork Welding Inc. Homer City, PA David Bork Fabricator

CI Banker Wire & Iron Works Inc. Muskego, WI George R. Boxhorn Nationwide Supplier Cofab Steel Corp.* Randleman, NC Jerry Parrish Fabricator

Creative Metal Products & Fencing Inc. Boynton Beach, FL Josh Aaron Fabricator Craftsmen Railing Keyport, NJ Ray Cottone

Tri State

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Fabricator

Edge Wapiti, WY Eugene Grondin Fabricator European Ornamental Iron Work Franklin Park, IL Michael Pietanza Fabricator Intek Fabrication Inc. Naples, NY Bryan D. Gordon Fabricator Intercorp Inc. Milwaukee, WI

David Wareham Nationwide Supplier Interstate Arch. & Iron Inc.* Cliffside Park, NJ Steve Heaps Fabricator J Dye Metalfab Glendora, CA John Dye Fabricator Kientzy Machine & Fabrication Inc. Troy, MO Bob Kientzy Fabricator

universal entry

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FABRICATOR September-October 2001

Ledgerrock Welding & Fabricating* Concrod, MA Robert Caras Fabricator Lee Custom Iron Kalamazoo, MI Eric Lee Fabricator

Fabricator Oakley’s Machine Shop Inc. Roxboro, NC Arthur Oakley Fabricator Ron’s Welding & Fabriction Coudersport, PA Rod Oulette Fabricator

MJ Snyder & Co.* Marshall, IL Mark Snyder Fabricator

Solomon’s Custom Iron Orange Park, FL Solomon Teofilo Fabricator

Newark Wire Works Edison, NJ J.P. Spellman Local Supplier

Transpacific Industrial Supply Inc. Ontario, CA Green Chang Regional Supplier

Nimba Forge Port Townsend, WA Russell Jaqua

This list is comprised of new and returning members as of August 3, 2001. For more info on new members, call NOMMA head­quar­ters (404) 363-4009, or visit: www.nomma.org.

INDUSTRY SHAKERS Michael Wendell Hypertherm Inc. announces the appointment of Michael Wendell to the position of Engineering Manager of their Manual Systems Team.

• Wendell comes to Hypertherm from Canon Virginia, a leading manufacturer of office equipment and supplies, where he served as senior mechanical design engineer. Previously he was senior project manager at Eastman Kodak in Rochester, NY and senior project engineer for Xerox Corporation in Webster, NY. • The Sheet Metal and Air Conditioning Contractors’ National Association (SMACNA) recently recognized Linda Hughes, executive director of Orange Empire SMACNA, as the Chapter Executive Legislative Advocate of the Year at their annual legislative awards dinner. Hughes also serves as president of the California Coalition for Construction in the

comeq

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Inventions & Products¶¶¶¶

An Answer for much-needed Battery Back-Up Gate Operators

By Automatic Gate Supply Co.

W ith certain parts of the country more susceptible to wind storms, lightning, rainstorms, ice storms, hurricanes, tornadoes, rolling blackouts, etc., that can knock out power indefinitely, the need for having a dependable battery-back up system is obvious. So Automatic Gate Supply

• #12DS-N

Company announces the development of a 200+ cycle battery back-up system that can be fitted onto all gate operators manufactured by AGS, including residential and commercial sliding and swinging gate operators. This is due entirely to our use

BRASS-BRONZE DARKENER

SINGLE DIP OXIDERS Oderless - Stable - Used Cold

•

JAX

NO. 11

GREEN PATINA

78-11 267th Street • Floral Park, N.Y. 11004 Tel. Area Code 718-347-0057 Circle 23 on Reader Service Card

Steptoe & Wife

of D.C. motors. They have developed the means to retrofit all existing AGS swinging gate operators with D.C. motors as well.

What does this mean in practical terms? As an example, at more than 200 complete cycles, a gate will operate for more than 20 hours at 10 cycles per hour, or more than 40 hours at 5 cycles per hour. Of course only rarely will a business or residence actually maintain a constant rate of operation, so these numbers of hours will spread out over many days before battery drain will exhaust the battery.

The new D.C. battery backup system works similarly to A.C. systems, except it costs less and requires less power. And it’s easily controlled by a switch. One position tells the operator to automatically initiate battery operation when power ceases, and then to remain open when the battery is low on power. The alternate position tells the operator to simply open the gate on power failure and leave the gate in the open position until power is restored.

Send pictures and information about your innovative products and inventions to: Rachel Squires at Fabricator, 532 Forest Pkwy., Ste. A, Forest Park, GA 30297. Or e-mail: nomma2@ earthlink.net

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NOMMA Network News

By Todd Daniel

Michigan Interprets “Ladder Effect” Rule

When the 2000 International Residential Code went into effect in Michigan on July 1, residential fabricators wondered how the “ladder effect” would be interpreted.

During the final weeks before the July 1 implemention, NOMMA members around the state sent letters to the state’s Bureau of Construction Codes urging them to strike the “ladder effect” clause. NOMMA also sent a letter, which urged the state code office to remove the controversial code.

While the “ladder effect” was not removed, the Bureau of Construction Codes did offer a conciliatory interpretation. In a letter sent to Michigan fabricator and NOMMA vice president Chris Maitner, Henry Green, the bureau’s executive director stated, “Horizontal rails, bars, or wires spaced equidistance apart would in

Chicago Gathering

NOMMA members in the Midwest met in mid July for a chapter organizational meeting and education session.

During the education program, Roger Carlsen of Ephraim Forge Inc. led a class on custom castings. A thanks goes to Crescent City Iron Supply for hosting the event.

effect crate a “ladder” for climbing.

The key word is “equidistance,” which would ban horizontal pipe, bar, and wire railings whenever the distance is equally spaced.

While Maitner said he is pleased with the interpretation, and

added that the horizontal designs are a popular seller.

This year, the 2000 International Residentail Code is going into effect around the country. For the latest information, visit NOMMA’s website at www.nomma.org.

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From the Bookshelf A Definitive Book for the Ornamental Metal Industry I think what’s most compelling about this particular decorative metalwork book by Dona Meilach is the distinction it provides between “assembly line vs. hand-forged work” (26). Her strong explainations make obvious the different applications and the different costs that custom work incurs, articulating that assembly line work is not intended for ornamentation, but strictly functional uses. “In assembly line production, bars and scrolls are pre-cut to size and assembled by welding. The scroll ends, usually made by cold forming and bending on a jig, are flat, straight, and blunt. There is no texturizing from the hammer or other

tools. The parts that are joined, the uprights and horizontals on a fence, for example, are welded much as one would glue two sticks together. Often the welded joints are not ground down to a smooth joint and can have bumps, protrusions, and beads” (26). And since Architectural Ironwork is written primarily to a consumer audience, this educates the consumer as well as boost the ego of the custom forge craftsperson.

In addition, the 240-page book is beautifully illustrated with over 375 color photographs showcase the work of highly acclaimed metalsmiths. Elegant rails and gates depict

Architectural Ironwork

By Dona Z. Meilach

the influence of different artistic movements since the eighteenth century, from the neoclassical style to Art Nouveau and the modern minimalist look of the twentieth century. Most importantly, Meilach says in her preface, readers “will never again climb a staircase or open a gate without

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FABRICATOR September-October 2001

1777, or visit: www.schifferbooks. com.

A Book for the Shop, Not the Coffee Table Decorative Ironwork: Tools,

The back cover features work by Jean Lamour, Lars Stanley, Michael Bondi, Jean-Pierre Masbanji, Kirsten Reese, Jean Whitesavage and Nick Lyle.

noticing its construction and details” (5). For that matter, they’ll never look at a “new” piece of architectural metal without having any clue as to the artist who rendered it as metalsmiths today sign their work with “registered touchmarks” (10).

Even though Meilach uses the terms interchangeably, Architectural Metal-work seems geared more toward ornamental fabrication than artist blacksmithing, as its pictures and text illustrate large scale, functional architectural elements rather than purely ornamental sculptures and decorative accents. Chapter one provides a brief introduction and history to ornamental metalwork, depicting the different materials, styles, and elements it makes use of. Meilach has arranged the book to take readers through an open house tour of metalwork, as she begins chapter two with those decorative metal components found in doorways and entryways, like awnings and canopies, door handles and locks, and other related hardware.

Heading further indoors, chapter three on interior stairways shows readers the different parts that comprise a rail, from geometric design shapes of the balusters and banisters to the structural elements which play into the design process, such as stairs treads, risers, and stringers. (The chapter’s section on plant forms showcases beautiful forged leaf railings by Joel A. Schwartz and abstract vine and cornstalk inspired railings by Scott Lankton!) Chapter four covers, pictorially and textually, exterior metalwork, such as grilles, screens, railings, balconies, gates, and fences.

To order, call (610) 593FABRICATOR September-October 2001

Techniques & Inspiration

By Dona Z. Meilach

This 1996 book by Dona Z. Meilch, Decorative Ironwork: Tools, Techniques & Inspiration, a second edition to her 1977 edition, is geared

R&F Metals

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Mittler

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more toward the artist blacksmith end of the ornamental metal industry. Unlike Architectural Ironwork, this book is written with the artist/ metlasmith in mind rather than his or her potential customers. In it Meilach details the tools and techniques used by today’s metalsmith. Motivated by a “concern with the trend, how it is growing, where it appears to be moving; [the book] introduce the reader to the potential of forging techniques and how they may be adopted to his own work.” By the depth of informatin it’s apparent Meilach did more than research her area of expertise, art history, for this one (iii).

The book focuses on the smaller size products of blacksmithing, and the forging of their individual components. And although the majority of its pictures are black and white, Decorative & Sculptural Ironwork showcases an extensive collection of outstanding metalwork in its 312 pages, with many images depicting step by step technique instruction.

To order, call (610) 593-

It’s Finaly Here: The Gold Books Anniversary Edition from R.J. Cunningham

By Todd Daniel

1777, or visit: www.schifferbooks.com.

Imagine a collection of books with over 1,600 ornamental iron designs. Now imagine dimensions and occasional technical notes and what you have are the Gold Books, a series of publications that have aided fabricators for decades.

The publications originally started out 50 years ago as a single idea book published by R.J. Cunningham of R.J. Cunningham Designs, a long-time fabricator and honorary lifetime member of NOMMA. Eventually, the small idea book grew into a five-volume set.

While Mr. Cunningham is retired, his son, Robert J. Cunningham, still sells the publications. Re-

cently, Cunningham Designs released a hardbound 50th anniversary edition. The hardbound version holds the original five Gold Books in a handsome, two-volume set.

The books are 11⁄ by 15 fi inches and feature 520 pages of designs and ideas.

According to the younger Cunningham, the anniversary edition features all of the original drawings, but they’ve been digitally enhanced and printed on better paper. The volumes also feature a textured cover with gold leaf lettering. Because of the difficulty in binding the large books, Cunningham says this is the first and probably the last time they’ll be offered in this format.

For more info, contact: R.J.

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Email us at: rmi@mesh.net • www.rogers-mfg-inc.com VISA and Mastercard Accepted 90

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FABRICATOR September-October 2001

Coming Events October 15-17, 2001

Coating 2001 offers a variety of coating-related technologies in one venue at the Orange County Convention Center in Orlando, FL. Eleven of the industry’s trade associations sponsor the event. For more info, call (513) 624-9988, or visit: www.finishing. com/coating.

October 23-25, 2001

The Society of Manufacturing Engineers, Amercian Machine Tool Distributers’ Association, and the Association for Manufacturing Technology present a co-located event at the International Exposition (I-X) Center in Cleveland, OH for a Machine Tool and Metalworking Exposition. For more info, call (800) 733-4763, or visit: www.sme.org.

October 29-November 3, 2001

The 4th European Forge Sym-

Beacut

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FABRICATOR September-October 2001

SPOTLIGHT

November 11-14, 2001

Fabtech International takes place this year at McCormick Place South in Chicago, IL. It features 1,000 exhibiting companies in 425,000 square feet of exhibit space, and should attract 32,000 attendees from over 50 different countries. There’s 30 technical conference sessions to choose from.

Registration is free until October 26.

For more info, call (800) 432-2832, or visit: www.fmafabtech.com. pos-ium, held in Albi, Tarn, France, is a convention and trade show. This year’s eductation sessions, led by seasoned European metalsmiths,

professors, and engineers, focus on the aesthetic and physical properties of composites: multi-layered blocks of ferrous or corpus metals. For more info, call (011) 563- 49-3072.

November 6-8, 2001

The American Blacksmithing School in Oakland, OR, holds a variety of classes throught the year. This seesion on Forge welding gives students the opportunity to learn drop-thetongs, and such welds as chain, ring, fold-over, cleft, lap, T, Y, and basket welds. For more info, call (541) 4592609, Or visit: americanblacksmith. com.

February 11-14, 2001

Las Vegas, NV is the host city for Fencetech ‘02, the yearly convention and trade show for the American Fence Association. Thousands are expected to attend this year’s event.

Gate pro

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Nationwide Supplier Mem­bers

142 Nationwide Suppliers

Back the Association through Membership Bold denotes new members.

Company Phone A Cut Above Distributing 800-444-2999 Advanced Fabricating Machinery 603-642-4906 Advanced Measuring Systems 330-602-1203 Allen Architectural Metals Inc. 800-204-3858 Alloy Casting Co. Inc. 800-527-1318 Alvin Products Inc. 978-975-4580 Al-Zalzalah Steel Works Factory 011-965-473-0017 American Punch Co. 800-243-1492 Antech Corp.

520-320-1810 AP Automation 770-205-2213 Apollo Gate Operators 210-545-2900 Arcadia Steel 877-501-3200 Architectural Iron Designs Inc. 201-222-7444 Architectural Prod. by Outwater 800-835-4400 Armstrong-Blum Mfg. Co. 847-803-4000 Arrow Iron 201-333-8920 Artezzi 800-718-6661 AST Waterjet Inc. 800-532-0383 Au Forgeron de la Cour Dieu Inc. 800-299-4229 Automatic Gate Supply Co. 800-423-3090 Automatic Gates Construction Co. 901-383-2529 Avantage Orn. Fence Supply 800-231-4586 Aztec Castings Inc. 800-631-0018 Julius Blum & Co. Inc. 800-526-6293 J. G. Braun Co. 800-323-4072 Buff Polish & Grind Ind. Supply Co. 940-455-2269 Builders Fence Co. Inc. 800-767-0367 Byan Systems Inc. 800-223-2926 California Wire Products Corp.

800-486-7730 Carell Corp.

334-937-0947 Centaur Forge Ltd. 800-666-9175 CI Banker Wire & Iron Works Inc. 262-679-9609 Classic Iron Supply 800-367-2639 The Cleveland Steel Tool Co. 800-446-4402 CML USA Inc. 407-857-1122 CNA Commercial Insurance Co. 800-CNA-6241 Colonial Castings Inc. 305-688-8901 Colorado Waterjet Co. 970-532-5404 COMEQ Inc. 410-933-8500 Crescent Brass Mfg. Corp. 610-372-7834 Crescent City Iron Supply Inc. 800-535-9842 Cross River Metals 210-824-1750 D & D Technologies (USA) Inc. 714-430-1100 DAC Industries Inc. 800-888-9768 DAESA, US 800-323-7287 Décor Cable Innovations 312-474-1100 Decor-Iron Supply 503-657-9188 DKS (DoorKing Inc.) 800-826-7493

Company Phone Doval Industries 800-237-0335 Duff-Norton 704-588-0510 E.T.S. Inc. 601-939-4451 Eagle Bending Machines Inc. 334-937-0947 Eagle Iron Supply Inc. 972-289-7688 Eastern Metal Supply 800-343-8154 Eastern Ornamental Supply Inc. 800-590-7111 EDF Equipment Sales Inc. 407-351-7017 Elegant Aluminum Products Inc. 810-293-1020 Encon Electronics 800-782-5598 EURO-FER SRL 011-39-044 5440033 FAAC International Inc. 800-221-8278 FABCAD.USA 800-255-9032 FabTrol Systems Inc. 541-485-4719 Feeney Wire Rope & Rigging Inc. 510-893-9473 Freightquote.com 913-642-4700 FSB USA LLC 011-34-92-580-2483 The G-S Co. 410-284-9549 GTO Inc. 800-543-4283 E.G. Heller’s Son Inc. 818-881-0900 Hewi Inc. 717-293-1313 Impressive Reflections 503-666-5827 INDITAL U.S.A. 800-772-4706 Intercorp Inc. 414-383-2021 Interstate Mfg. Associates Inc. 603-863-4855 The Iron Shop 800-523-7427 Ironwood LLC/Brian Russell Designs 901-867-7300 ITW Ransburg Electostatic Systems 800-909-6886 Jancy Engineering Co. 319-391-1300 Jansen Ornamental Supply Co. 800-423-4494 Jesco Industries Inc. 517-542-2903 King Architectural Metals 800-542-2379 Joachim Krieger 011-49-64-258-1890 Kuwait & the World Co. 011-965-484-9577 Lavi Industries 800-624-6225 Lawler Foundry Corp.

800-624-9512 Lecky Metal Ornaments Pte Ltd. 011-65-749-9651 Lewis Brass & Copper Co. Inc. 800-221-5579 Liberty Brass Turning Co. 800-345-5939 Mac Metals Inc. 800-631-9510 Marks U.S.A. 516-225-5400 Master-Halco 888-643-3623 Mittler Bros. Machine & Tool 800-467-2464 Frank Morrow Co. 800-556-7688 Multi Lock Inc. 954-563-2148 MyAutomaticGates.Com 901-386-0015 Nationwide Architectural Metals Inc. 800-851-5053 New Metals Inc. 888-639-6382

For A Detailed Listing of NOMMA Supplier Members, Please Visit Our Web Site: www.nomma.org 92

FABRICATOR July-August September-October 2001 2001

Nationwide Suppliers Company Phone

Bold denotes new members.

Company Phone

Nitek Inc. 972-447-9628 Ohio Gratings Inc. 800-321-9800 Omega Coating Corp.

888-386-6342 Overseas Supply Inc. 713-290-9885 Phillips Machine & Tools Co. 919-934-3345 Pietrocola & Sons Iron Suppliers Inc. 800-933-5993 Polished Metals Ltd. Inc. 800-526-7051 PPG Industries 440-572-2800 Production Machinery Inc. 410-574-2110 R & B Wagner Inc. 800-786-2111 RAMSET Automatic Gate System 818-504-2533 Regency Railing 972-407-9408 Riteway Artistic Forgings 305-836-9232 Robertson Grating Products Inc. 877-638-6365 Robinson Iron Corp. 256-329-8486 Rockite, Div. of Hartline Products Co. 216-291-2303 Rogers Mfg. Inc. 940-325-7806 Sahinler Form Metal San. Ve Tic. 011-90-224-4700158 SECO South 888-535-7326 Sharpe Products 800-879-4418 Signon USA 718-438-1500 Soheil Mosun Limited 416-243-1600 Sparky Abrasives Co. 800-328-4560 Stairways Inc. 800-231-0793 Steel Masters Inc. 602-243-5245 Steel Supply Inc. 713-991-7600 Steptoe & Wife 800-461-0060 Suhner Industrial Products Corp.

706-235-8046 Sumter Coatings Inc. 888-471-3400 Summers Welding & Fabrication 724-495-3145 SURE-T LATCH Inc. 940-668-8954 Sur-Fin Chemical Corp.

800-282-3533 Tennessee Fabricating Co. 800-258-4766 Texas Metal Industries 800-222-6033 Texas Stairs & Rails Inc. 800-633-6874 Triebenbacher 800-522-4766 Triple-S Chemical Products 800-862-5958 Triple-S Steel Supply 800-231-1034 Tri-State Shearing & Bending 718-485-2200 Tubular Spec. Mfg. Inc. (TSM) 800-421-2961 Universal Entry Systems Inc. 800-837-4283 Universal Mfg. Co. Inc. 800-821-1414 Vogel Tool & Die Corp.

708-345-0160 Wasatch Steel 801-486-4463 Wrought Iron Handicrafts Inc. 800-456-7738 Yavuz Ferforje Ve Demir Tic San 011-90-258-269-1664 *Join NOMMA! 404-363-4009

For A Detailed Listing of NOMMA Supplier Members, Please Visit Our Web Site: www.nomma.org

Working Smarter - Not Hard­er

Be a Multicultural Manager

By Carlos Conejo , Ethnoculturist

What’s Your “M Culture” Quotient?

• Are ideas that your managers discussed at staff meetings and thought were crystal clear totally misunderstood by the workforce?

• Do tempers seem to flare within different cultural groups at the slightest provocation?

• Is production or service suffering due to ineffective communication or lack of communication?

• Do you suspect that some of the differences are tied to cultural differences, but you don’t know what to do?

94

You’re probably discovering that today’s work force is a cultural salad bowl. Everyone is in the same bowl, but striving to keep their own identity or culture. At the same time, you’re probably discovering that the old ways of managing are just not working.

Solving such issues is not going to be easy. Managing in a multicultural world is a tremendous undertak-ing. But here are four steps to start you on your way to becoming a truly multicultural company.

Step #1 - Identify the Diversity

This is a lot more difficult than it sounds. Start collecting data about your work force. You will be amazed at the number of identifiable cultural groups. There are at least 25 major cultural groups in today’s work environment, and there may be several sub-groups in each of these major groups.

I was recently speaking in Toronto, Canada, and discovered that there are over 80 ethnic groups speaking over 100 languages in that city. Finding eight to ten sub-groups in a small company is not unusual.

Don’t generalize. It’s very dangerous to do so, and can be fatal to any company. For example, if you are located in the Southwest, don’t assume all of your Latino workers are Mexican. Let’s say you only have the eight to ten different backgrounds in your company. Understand that each

of these cultures gathers and interprets information differently, and that’s where your problems begin.

Step #2 - Discover the Norms

Get detailed information on your cultures. There are not too many places to gather this information, but there are some good reference materials at the library. Depending on the size of your company, it might be a wise idea to hire an ethnoculturalist, diversity, or cultural change consultant.

Get detailed information from your employees. Ask what the favorite or lucky colors in their country are, what superstitions people believe in, what are some family norms and values? Remember you can also learn plenty by practicing MBWA – Management By Walking Around: Look, listen, ask …learn!

Step #3 - Discover Differences

Different cultures gather and process information differently, in a way that is unique to that culture. Hispanic employees from different countries even have different words for the same thing. Sometimes logic and reason evade other cultures or us. For example there is no guilt in some Eastern cultures. There is no heaven or Hell, but there may be karma. So it’s tough for us to understand when we may be coming from a Judeo-Christian point-of-view. Such differences cause cooperation and communication

FABRICATOR September-October 2001

barriers, and make the workforce an uneven playing field.

Step #4 - Develop A Plan of Action

Do some reading. Most businesses and even business schools are behind the times when it comes to dealing with cultural issues in the workplace. But there are plent of cultural studies programs out there.

Picking up literature from a local college or university cultural studies program may provide some interesting and helpful information.

Then plan staff meetings where you can share what you find with your employees in a way that sparks interest in understanding diversity and encourages their tolerance for difference. Invent “group” projects, where employees ask each other about cultural beliefs and practices.

Or you may wish to hire management or supervisory staff from

FFF

“The two languages to learn for the next millennium are Spanish and Chinese. ” FFF

the predominant cultural group. Allow employees to create affinity employee groups such as a Hispanic or Asian or African American clubs. Better yet, create a mentoring and learning “track,” which focuses on mutual collaboration and your organization’s common goals and objectives. When employees get to know each other better, they’ll be more likely to cooperate with each other, making your job as manager easier.

Keep in mind too the power of language. It can be a strong barrier.

Be understanding and supportive of employees whose native language is

not your own. Organize opporutnities to for employees to learn English and other new languages.

The two languages to learn for the next millennium are Spanish and Chinese since Latinos are America’s fastest growing minority group, and China’s Gross National Product (GNP) will surpass the U.S. GNP in about 20 years.

As we become more of a global economy in the new millennium, it becomes more crucial for all of us to better understand what diversity means. It means gender, race, culture, norms, values, information gathering and processing, comfort zones, and much, much more.

Carlos Conejo is a marketing expert and ethnoculturalist. This article was adapted from his new book: Motivating Hispanic Employees: A Practical Guide to Understanding and Managing Latino Employees. For more info, call: 805-494-0378, or

Advertiser Index

Use this index when filling out the Reader Service Card. Firms in boldface are first-time advertisers.

Pg.

37 84

73

85 61

88

11 signs Inc.

10 signs Inc. 103

35 water 105

17

69

58

81 14

48 20

15

46

75

25 Tool Co. 132

53 Tool Co. 132

85

42 ance 29

68 107

34

40

Circle No. Acme Metal Spinning Alvin Products Inc. 17 American Spiral Corp.

Antech Corporation 115 Architectural Iron De103 Architectural Iron DeArch. Products by OutArtezzi 27 ABANA 142 Atlas Metal Sales 25 Beacut Abrasives Corp.

Julius Blum & Co. Inc. J.G. Braun Co. 40 Byan Systems Inc. 94 Classic Iron Supply 26 The Cleveland Steel The Cleveland Steel CML USA Inc. 110 CNA Commercial InsurColorado Waterjet Co. COMEQ Inc. 10 Crescent City Iron Sup-

FABRICATOR September-October 2001

Pg.

Circle No.

ply Inc. 41

13 D & D Technologies (USA) Inc. 48

78 DAC Industries Inc. 55

43 DecorativeIron.com 1

44 DKS, DoorKing Systems 19

70 Doringer Cold Saw 45 24 Duff-Norton 77

59 ETS Inc. 117

86 Carell Corp.

137

27 Eagle Bending Machines Inc. 120

39 Elite Access Systems Inc. 4

26 Encon Electronics 57

9 FABCAD.USA 87

60 Forge & Anvil Metal Studio 113

66 Forges Magazine 141

54 FSB USA Inc. 44 79 GatePro.com 52

56 The G-S Co. 82

20 GTO Inc. 56

46 E.G. Heller’s Sons Inc. 102

74 Heritage Bldg. Systems 143 4 5 Hossfeld Mfg. Co. 33

7 INDITAL U.S.A. 111

82 International Gate

Pg. Devices 24

100

11

68 Russell 70

88 Supply Co.

73 23

74 93

26 Signage 122

64 Hardware

61 Metals Inc.

50 47

51 47

47 Products 39

2 per Co. Inc.

60 Products 22

41 Works 63

76 71

41 53

18

Circle No. The Iron Shop Ironwood LLC/Brian Jansen Ornamental 75 Jax Chemical Co. Jesco Industries Inc. Kaltech Architectural Kayne & Son Cus. 81 King Architectural 136 Lawler Foundry Corp.

Lawler Foundry Corp.

Lawrence Metal Lewis Brass & Cop21 Liberty Ornamental Lindblade Metal Mac Metals Inc. Majka Railing Marks U.S.A. 95

NOMMA Videos & Publica-

Publication information is also on our web site: www.nomma.org

VIDEOS Qty.

De­scrip­tion

Almost the Last Word in Finishes (EDU2 - 72 min.) A complete primer on finishes covering everything from patinas to gold leafing.

Straight Stair Railings (EDU1 - 60 min.) Complete rail fabrication process, from mea­sur­ing to installation. Design and layout tips included.

Special Finishes (98A - 113 min.) Covers faux fin­ish­es, surface prep., and rec­om­mend­ed books. Includes rust, aged cop­per, antiquing.

Basics of Forging (97A - 120 min.) Learn the fun­da­men­tals of hot metal forging. Meth­ods, tech­niques, and short cuts are covered. In­ cludes both class instruction and live dem­os.

Aluminum & Brass Forming (97B -120 min.)

Covers temperature ranges, alloy se­lec­tion, and forming meth­ods. Power ham­mer tech­niques are also dem­on­strat­ed.

Spiral Stairs (96A - 100 min.), Dem­on­stra­tion of spiral stair systems built both horizontally and ver­ti­cal­ly. Also covers ma­te­ri­als planning and ad­vanced layout tips.

Forging Aluminum, Bronze, and Brass (96B - 120 min.), Forging alu­mi­num, brass, and bronze using a gas forge and torch.

Practical Jig Making (94A - 90 min.) Jigs, cus­ tom tooling, and other tricks to make shopwork more efficient. Touches on forging, stair layout, and struc­tur­al.

Forming Brass/Bronze Cap Rail (94C - 90 min.) A classroom discussion on hot and cold bending tech­niques.

Designing for the 4-Inch Picket Spacing Rules (94D - 120 min.) Creative de­sign so­lu­ tions that comply with the 4-inch spac­ing codes.

Security Storm Doors (93B - 70 min.) Sales techniques, accessories, pros and cons of buy­ ing from a third party or building them your­self.

Installations (93C - 70 min.), Tips & tricks for organizing your truck and managing your crews.

Also covers structural installations.

New Cutting Techniques (93D - 70 min.)

Ad­vanced technologies for cutting metal. This pro­gram was a real hit among attendees.

Aluminum Fabrication (92D - 120 min.) Mix­ing aluminum with other metals, hinges, fin­ish­ing & more.

Metal Finishing (92F - 105 min.) Paint fin­ish­es and what rules affect each.

Stair Layout and Planning (92G - 105 min.)

Spiral, circular, and railing stringers- see a unique jig for laying out spiral stairs.

Pipe Rail Fabrication (92H - 105 min.) Short­ cuts, cleaning joints, and much more.

Round-table Problem Solving (92L - 105 min.

A popular program at conventions.

Price

$45

Updated: 7/01

Qty.

De­scrip­tion

$45 $45 $45 $45

Price

$4

$65 for 25

$40

or­na­men­tal metal applications.

Consider Metalwork (29C) Brochure con­ tains 10 illustrations and explains 5 rea­sons

Pkg. of 200

why customers should buy met­al­work.

Glossary of Architectural Metal Terms for

$6

Stairs and Railing (29D) Contains over 200 def­i­ni­tions. Ideal for educating ar­chi­tects and

$6

$2 employees. $35 A Guide to the Development of the Iron­ for 25 work­er’s Skills (29F) A 9-page guide on $2 fabricating, tools, terms, and stair lay­out. $40 Driveway Gate Brochure (29H) Four-page for 25

$45

full-color, glossy brochure that highlights 15$2 drive­way gate designs. Ideal sales tool. $35 Guideline 1: Joint Finishes (29I) Vol­un­tary for 25

$45

$2 $35 guide for weld joint finishes. Includes tubing, piping, and solid bar. Contains 16 photos. for 25

$45

Interior Railing Brochure (29J) This fullcol­or brochure shows a wide spectrum of rail­ing de­signs available to home own­ers.

$5

$45

Walkway Brochure (29K) A full-color pre­ sen­ta­tion of 14 gate designs, ranging from straight pickets to elaborate forged jobs.

$5

$45 $45 $45 $45 $45 $45 $45

$45

To­tal

Ideas in Ornamental Metal (29A) An “idea $7 book” for showing customers. The 23-page $70 book features over 200 color photos. for 25 Ornamental Ironwork (29B) A 21-page bro­chure featuring sketches of practical

$45 96

To­tal

PUBLICATIONS

Total

Prices include shipping.

Deduct 20% If NOMMA Mem­ber

Grand Total

Allow 4-6 weeks delivery.

Additional chrg. for express.

Name____________________________________________ Company ________________________________________ (No P.O. Box please)

Street Address____________________________________ City/State/Zip______________________________________ Payment: q Check q AmEx q VISA q Mastercard q Discover Card No. _______________________________________ Exp. ____/____ Signature ___________________________________________________ Cardholder’s Name ___________________________________________

Mail, phone, or fax order to: NOMMA, 532 Forest Pkwy., Suite A, Forest Park, GA 30297. (404) 363-4009. Fax: (404) 366-1852.

Payment in FABRICATOR U.S. dollars drawnSeptember-October on U.S. bank or money order.

2001 • Prepayment only.

Classifieds Business for Sale

Central Virginia Ironworks.

Well-established with good customer base. Great lease and cash flow. Fully equipped shop with boom truck. All types of miscellaneous fabrication.

Seller has other interests. JG Commercial (540) 371-4343.

For Sale

Iron fabrication shop for sale.

Owner retiring. 90 K. Average profit, 450 K per year. We build about 400 spiral and circular stairs a year. Partnership possible. Ph: 707-538-2285.

Fax: 707-538-3203.

Project Manager

Steel fabricator specializing in miscellaneous and light structural is looking for a project manager.

Must have steel detailing experience, manual or auto cad. Career opportunity. Located near Memphis, TN. Full benefit package and relocation allowance. Send resume in confidence

FABRICATOR July-August September-October 2001 2001

Next closing date: August 10 Rates: $25 for 0 - 35 words, $38 for 36 - 55 words, $50 for 56 - 70 words. No logos or boxed ads. Pre-pay­ment only.

San Antonio, TX 78213, www.mantexcollection.com, sales@mantexcollection.com, 1-800-559-2923 ext. 81, Fax: 1-419-781-0871.

Business for Sale

Long established and wellknown metal artifact restoration company in the Washington D.C. metro area. Owner’s salary and cash flow approximately $100K. Asking $125.

Owner will train. Call Ventureforth at (703) 836-2100.

Seeking Qualified Candidates Purchasing, Sales and Estimating, Misc. & Structural Detailing, Field Checkers, Shop Personnel and Helpers. Benefits to include: paid holidays, paid vacation, health insurance and life insurance. To apply please visit our website at www.hallmarkiron. com, email resume to jmiller@hallmarkiron.com, fax (703) 550-0106, or call (703) 550-9560. EOE Opportunities. AISC Certified Metal Fabricator celebrating 35 Years.

Sales Reps and Distributors Wanted

Interesting line with architectural metals, ornamental accessories, lamp bases and furniture parts at very competitive prices. Excellent commission plans. CALL US! North Cray Company, LLC, 101 Sunflower,

Business for Sale

A well-known Northern Virginia ornamental and structural ironwork company for sale. Revenues $700K. Long established and good client based. With or without property.

Owner will consider financing. Call

to Gallaway Industries, P.O. Box 6, Gallaway, TN 38036 or call (901) 867-3859.

97

Reader Service

Three Easy Ways To Respond We’ve added an Internet-based Reader Service system. Now you can receive a faster response to your inquiries — they can even arrive by e-mail.

Other advantages include: ü Complete advertiser profiles on-line. ü Direct link to advertiser’s web site. ü Find products by category.

1. Web

Simply go to: www.nomma.org and click on the red “Reader Service” button.

2. Fax

Fill out the form below and fax to (941) 213-2199.

3. Mail

Complete the form below and mail to: MediaBrains P.O. Box 12079 Naples, Florida 34101-2079

Reader Service Coupon 200) Are you a NOMMA member?

q Yes q No 201) Type of Business: q Fabricator q Supplier q Architect q Other

Vol. 42, No. 4 July-August 2001

Interested in NOMMA?

Membership Exhibiting In Information Circle 66 METALfab Circle 67 Advertising Attending In Fabricator Circle 68 Convention Circle 69

Name Phone Company Address City State Zip

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 Send to: MediaBrains, P.O. Box 12079, Naples, FL 34101-2079

Expires 1 yr. after publication date.