2002 05 fab

Vol 43, No. 3

May/June 2002 $6.00

METALfab 2002 Review Top Job Profiles

Swirling river currents and winds on the bluff provide inspiration for this 2002 Top Job gold award winner.

Tips & Tricks

A simple tool catches a problem that might have been missed with straight measurements.

Dedicated to the success of our members and industry.

NOMMA Officers President Belk Null Berger Iron Works Inc. Houston, TX President-Elect Chris Maitner Christopher Metal Fabricating Inc. Grand Rapids, MI Vice President/Treasurer Curt Witter Big D Metalworks of Texas Dallas, TX Immediate Past President Michael D. Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA NOMMA Directors Doug Bracken Wiemann Iron Works Tulsa, OK Breck Nelson Kelley Ornamental Iron LLC Peoria, IL Chris Connelly DeAngelis Iron Work Inc. South Easton, MA Fred Michael Colonial Iron Works Inc. Petersburg, VA Rob Mueller Mueller Ornamental Iron Works Inc. Elk Grove Village, IL Rod Stodtmeister Stodtmeister Iron Sparks, NV David T. Donnell Eagle Bending Machines Inc. Stapleton, AL 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 Are You Getting All That You Can From NOMMA? Each year, I am asked “How can you invest so much time in NOMMA?” My response is always, “How can you afford not to?” Like all of you, I find that there aren’t enough hours in the day, or days in the week, to get everything done that I need to (let alone would like to). As prudent business people, we have to be careful where we spend our time and our company’s money. The bottom line is: did we receive an ample return on our investment?

Over the years, I have found that the hours I have put in have been returned many times over by the hours we have saved on the shop floor alone. The money spent to attend conventions and board meetings has been repaid by cost saving ideas and management skills that I have learned in seminars and demonstrations. But by far, the biggest benefits to my company have come from my volunteering to serve NOMMA. In addition to the benefits from communication and discussions that most people receive at convention, I get two more opportunities to network each year at the spring and fall board meetings. I have established relationships that have allowed me to get help with problems on jobsites in other states, get an order “pushed to the front of the line,” and get help with jobs we couldn’t get out.

The time and money spent on NOMMA is a small investment compared to the benefits my company receives and the more we put in, the more we receive. It is my sincere hope that each year you will continue to see the benefits of belonging to NOMMA. If you are having trouble seeing these benefits, ask yourself “What did I put in?”

About the Cover

METALfab 2003

March 4-8, ‘03 • Covington, KY 4

FABRICATOR May-June 2002

Photo: Jeff Bruce

Plan now for:

This sculpture was the winning design for an urban art competition in Memphis, TN. The sculpture is now located along a riverfront and is designed to reflect the feel of wind and water movement. The cantilevered canopy is made of carefully twisted 1/4-inch plate weighing 1 ton. The sides are made of three layers that wrap one and a half times around each other on the column. After applying polyurethane the sculpture was bolted together on site. Fabricator: Medwedeff Forge & Design, Murphysboro, IL, with a thanks to Keeler Iron Works of Memphis, TN for the column construction, painting, and logistical support.

Ornamental & Miscellaneous Metal Fabricator To join NOMMA, see pg. 78

www.nomma.org

Table of Contents Vol. 43, No. 3 • May/June 2002

FEATURES

12

METALfab 2002

40

Whirl

48

Class Is In Session

58

Sometimes You Can’t Say “No”

61

A Wild Project

64

A Fish By Aluminum or Copper Would Smell as Sweet

68

The Wrong Access System Can Keep Everyone Out

74

Borrowing and Lending Without a Tax Bill

NOMMA enjoys another outstanding convention and trade show.

A NOMMA member’s sculpture becomes a Memphis landmark.

This project gives new meaning to the phrase “on the job training.”

40

A tight deadline adds to the challenge of this demanding project.

A Disney job helps propel a fabricator in an exciting new direction.

The switch from aluminum to copper provides a double challenge.

61

The pros and cons of eight emergency access systems.

Learn how to borrow and loan money with the least tax impact.

64

DEPARTMENTS President’s Message 4 Coming Events 79 Restoration 80 NOMMA Network News 83 News Roundup 84 From the Bookshelf 89 New Products & Services 90 New Members 92 Industry Shakers 93 Nationwide Suppliers 94 Business Briefs 96 Tips, Tricks, & Jigs 97 NOMMA Chapters 99 Working Smarter - Not Harder 100 Classifieds 102

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Now you can request information from advertisers directly on our web site. } Quick Responses From Advertisers } Choice of Response Formats, Including Email, Fax, Phone, Or Mail.

Vol. 43, No. 3 • May/June 2002

Editor J. Todd Daniel Associate Editor Rachel Squires Operations & Marketing Manager Cynthia Smith Senior Writers John L. Campbell John L. Cochran, PhD Executive Director Barbara Cook 2002 Fabricator Advisory Council Patrick S. Kelly Decor Cable Innovations Sharon Picard South Attleboro Welding Corp.

} Direct Links To Advertiser Web Sites } Complete Advertiser Contact Information } Ability To Search By Company Name, Product, or Category

www.nomma.org For additional info, see page 104A.

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: fabricator@nomma.org. Cir­cu­la­tion: 9,500. 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

8

Photo courtesy of Dawn Trouard

Free Product Information

Editor’s Letter

Don’t Starve Yourself A few articles in this issue tell a similar story. A welder or roofing manufacturer decides to give up the day job and venture out on his own as a fabricator. There’s nothing more liberating than being your own boss.

But even when creativity and technical skill provide your bread and butter, some constraints still compromise your artistry. For me it’s getting up in the morning. But for you metal artists, it might have more to do with design modifications, budgets, and absurd deadlines.

As artists we understand how lucky we are to actually make money doing what we love to do, express ourselves through physical forms, even if we don’t have complete freedom of our creative energies. But we’re ok with that. The really tough part is putting a price tag on your creative energies.

Some articles in this issue also mention fabricators underbidding on a project or not realizing their work’s worth. Sure you don’t want to scare the client away, but you don’t want to discredit or starve yourself either. Before presenting a design to any client, have a good idea already of what materials and labor will cost.

That way you won’t just spit out a number when asked on the spot.

Remember, your friends in NOMMA can help you locate suppliers and offer technical advice to make things easier too. As Jay Mudge says, that’s what friends are for. Most importantly though, have confidence in your work.

You’re good enough, otherwise you never would have had the courage to take on metal fabrication as a fulltime job in the first place. So use your resources. Have faith in yourself and your beautiful work. And bring home

FABRICATOR May-June 2002

Attendees from around the world converged at Moody Gardens for a week of learning and networking.

T

he tremendous success of METALfab 2002 just proves the determination of NOMMA members to thrive despite a precarious business year. Held at Moody Gardens in Galveston, TX, the convention ran from Tuesday, March 5, through Saturday, March 9. The METALfab Trade Show was held during select hours Thursday, March 7, through Saturday, March 9. From the networking social events and education sessions down to the enthusiastic words of NOMMA’s newly installed president, METALfab 2002 met the group’s highest expectations.

This year’s convention

featured shop tours of five Houstonbased NOMMA member shops.

Typical of NOMMA events, the tours provided an opportunity for these members to share their trade and business knowledge with others in the industry. An outstanding education program hailed in the newly established NOMMA Education Foundation (NEF). The program showcased the new NOMMA Education Video Series and a variety of fabrication and business sessions. METALfab 2002 also introduced the first NOMMA Education Foundation Party for a Purpose (a Friday Night Beach Party) and silent auction. Proceeds from the party and auction benefit NEF.

Favorite annual events included the Trade Show, the Ernest Wiemann Top Job Contest (where projects recently completed by NOMMA members are judged for their technical skill and artistic beauty), and Saturday’s Awards Banquet. Top Job award winners are posted on the NOMMA web site.

This year’s Julius Blum award went to NOMMA’s Executive Director Barbara Cook; the Frank A. Kozik Volunteer Award went to Jack Klahm of Klahm & Sons Inc., Ocala, FL; The Clifford H. Brown award went to Ed Powell, Powell’s of Banner Elk, Banner Elk, NC, and the Mitch Heitler Award for the best of the Top Job Gold Award winners went to Design Metals of Gresham, OR.

left: During the Tuesday evening reception, some attendees were surprised when they came across these talking melon heads. top: This “dino” sculpture was an attention grabber at the Wednesday shop tours.

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FABRICATOR May-June 2002

Opening Reception The Pittsburgh delegation arrives!

Networking with new and old friends.

After a day of traveling, the Opening Reception on Tuesday night provides the perfect opportu足 nity to relax, visit with old acquaintances, and make new friends.

Euroquip

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The opening business meeting.

Membership Meeting Technical Chair Doug Bracken gives his committee report.

The audience listens to Lloyd Hughes’s enjoyable presentation on the NOMMA Education Foundation.

During the Annual Busi­ ness Meeting, attend­ ees heard reports from NOMMA’s leaders and elected 2002-2003 officers. A few lucky individuals received $100 door prizes.

Top Job Chair Rob Mueller gives a preview of the 2002 contest.

!

OOM rVARR e membe h t v r e e t , f g A eetin ed the m p i rd sh e boa ed to eryon and head of s ay buse n for a d o t s u .

Ho tours shop

gto

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FABRICATOR May-June 2002

Shop Tours

Most of Wednesday was spent touring NOMMA member shops in Houston.

left:

Entering the showroom of Peck & Co. Inc. top right: The visit to Triple-S Steel Supply included souvenir hardhats and a wonderful lunch. bottom left: A walk through the Stairways Inc. wood shop. bottom right: Touring the shop of Berger Iron Works Inc.

Member

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FABRICATOR May-June 2002

Education

Cutting technologies roundtable.

sumter coatings

Sally discusses human resource challenges.

Julius Blum Award

Barbara Cook receives the Julius Blum Award.

Barbara H. Cook, NOMMA’s executive director, was presented with the Julius Blum Award during the March 9 awards banquet.

Ms. Cook was honored for her dedicated and skillful leadership, which has resulted in continued and unprecedented growth for the association. She joined NOMMA on July 1, 1986 as assistant director and editorial associate. By the following spring, she had been promoted to editor of Ornamental & Miscellaneous Metal Fabricator magazine, and on July 1, 1988, she was named executive director. Most recently, Ms. Cook played an important role in the launching of the NOMMA Education Foundation.

During her 16 years of service with NOMMA, the association has grown from 492 to 1,038 members. In addition, staff size has grown from two to six full-time employees and NOMMA’s magazine, education program, and trade show have also grown in terms of both size and quality.

Presenting the award was Bob Paxton, a respected industry leader and supplier director. In his speech, Mr. Paxton recalled the early days when he first met Ms. Cook, and shared some of her many accomplishments.

The award’s namesake, Julius Blum, was the founder of Julius Blum & Co. Inc. Mr. Blum

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FABRICATOR May-June 2002

Education Cont.

Frank Kozik Award

Cynthia Paul is a favorite presenter at NOMMA conventions.

Jack Klahm accepts the Kozik Award.

Members of the Automated Vehicular Gate Coalition gave a talk on the “dos” and “don’ts” under UL 325.

Jack Klahm of Klahm & Sons Inc., Ocala, FL, received the Frank A. Kozik award for outstanding volunteer service, which was presented by NOMMA.

Mr. Klahm was given the award for his outstanding contributions to NOMMA’s education program. He has served on the education committee, he is a regu-

lar presenter at NOMMA conventions, and he has given numerous technique demos. At home, Mr. Klahm is active with NOMMA’s Florida Chapter and has hosted several meetings at his shop.

In presenting the award, past president Ed Powell recognized him for his “outstanding spirit,” adding that Mr. Klahm is “always willing to answer questions and share his knowledge.”

The award was presented during NOMMA’s 44th Annual Convention in Galveston, TX on March 9. It is named in honor of Frank A. Kozik, who served as the association’s first president in 1958-59. Mr. Kozik set a precedent for outstanding service by still contributing to NOMMA even after he retired from the board.

Marks USA

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FABRICATOR May-June 2002

Party For A Purpose

The Friday “Party For A Purpose” beach party and silent auc­ tion served as an important fundraiser for the new NOM­ MA Education Foundation.

top left:

The hula hoop contest. top right: Ed becomes the first recipient of the Clifford H. Brown Education Award. bottom center: Hans shows off his yo yo prowess. immediate left: Mark and Becky dance the night away.

Hey, who’s that hiding behind the Frisbee?

texas metal 032

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FABRICATOR May-June 2002

Awards Banquet

At the Saturday eve­ ning Awards Banquet, officers were installed and awards were pre­ sented.

top: Outgoing president Mike Boyler shows off his dinner — a delicious kangaroo. left: Banquet attendees make a toast. bottom: Mike introduces the 2002-2003 officers and directors.

Enjoying dinner prior to the ceremonies.

Incoming president Belk Null gave a moving induction speech.

byan 4C

PATINAS & ANTIQUING SOLUTIONS BROWN ANTIQUE FOR SOLID & PLATED COPPER BRASS.

BLACK ANTIQUE

VERDE GREEN/ TIFFANY GREEN OLD GREEN LOOK FOR COPPER BRASS

FOR BRASS & COPPER ALLOYS.

TURQUOISE BLUE

RUSTY PATINAS

BRIGHT DIPS

FOR STEEL, BRASS & COPPER

BLACK ANTIQUE FOR TIN/LEAD & ZINC SOLDERS, PEWTER, SILVER, NICKEL & FERROUS METALS

METALLIC COPPER & BRASS COATINGS (PAINTS)

FOR COPPER ALLOYS. REMOVES CORROSION/TARNISH

PEWTER LOOK

FOR COPPER ALLOYS AND STEEL

TIN LOOK

IMMERSION TIN FOR COPPER AND BRASS. IMMERSION COPPER FOR STEEL

AIR DRY LACQUERS 7 SAMPLE FINISHING KIT $50.00

TRIPLE-S CHEMICAL PRODUCTS, INC. 3464 UNION PACIFIC AVE., LA., CA 90023 TEL: (323) 261-7301 FAX: (323) 261-5567 Toll Free: 1(800) 862-5958

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FABRICATOR May-June 2002

2002 Ernest Wiemann Top Job Winners The following awards were given out during the Saturday night awards banquet in Galveston, TX, March 9 A. FINISHES Gold Christopher Metal Fabricating,

Grand Rapids, MI (A-2) Silver Unlimited Welding, Winter Springs, FL (A-4) Bronze Russian Blacksmithing Ltd.,

Moscow, Russia (A-1) C. GATES, DRIVEWAY — FORGED Gold Wrought Iron Art Ltd.,

Toronto, ON Canada (C-4) Silver Klahm & Sons Inc., Ocala, FL (C-7) Bronze TNC Industrial, Miami, FL (C-6) D. ALL INTERIOR RAILINGS Gold Design Metals, Gresham, OR (D-11) Silver Florida Aluminum & Steel, Ft. Myers, FL (D-7) TIE Silver Wilson Railing, Park City, IL (D-1) Bronze Pro-Fusion Ornamental Iron, San Carlos, CA (D-14) TIE Bronze Kelley Ornamental Iron, Peoria, IL (D-9) E. ALL INTERIOR RAILINGS — FORGED Gold Wrought Iron Art, Toronto, ON Canada (E-18) Silver Steve Fontanini, Jackson, WY (E-3) Bronze Bob’s Ornamental Iron Studio,

Kansas City, KS (E-14) F. ALL EXTERIOR RAILINGS AND FENCES Gold Bob’s Ornamental Iron Studio,

Kansas City, KS (F-4) Silver Christopher Metal Fabricating,

Grand Rapids, MI (F-1) Bronze Allen Architectural Metals, Talladega, AL (F-6) G. ALL EXTERIOR RAILINGS AND FENCES — FORGED Gold Mudge Metalcraft, N. Ft. Myers, FL (G-2) Silver European Ornamental Iron Work Inc.,

Franklin Park, IL (G-1) Bronze Aberdeen Forge and Anvil, Memphis, TN (G-6) H. FURNITURE & ACCESSORY FABRICATION Gold Design Metals, Gresham, OR (H-5) Silver Metal Smith Design, Ft. Myers, FL (H-4) Bronze Klahm & Sons Inc., Ocala, FL (H-6)

I. FURNITURE & ACCESSORY FABRICATION — FORGED Gold Wonderland Products Inc., Jacksonville, FL (I-6) Silver Flaherty Iron Works, Alexandria, VA (I-12) Bronze Wrought Iron Art Ltd.,

Toronto, ON Canada (I-11) J. GATES/DOORS Gold Deggingers’ Foundry, Topeka, KS (J-3) Silver Harmony Forge, Alpine, UT (J-8) Bronze Florida Aluminum & Steel, Ft. Myers, FL (J-5) K. GATES/DOORS — FORGED Gold Flaherty Iron Works, Alexandria, VA (K-12) Silver Greg Eng Metalsmith, Vista, CA (K-2) Bronze B. Rourke & Co. Ltd.,

Burnley, Lancashire, England (K-1) M. STRUCTURAL FABRICATION Gold Unlimited Welding Inc., Winter

Springs, FL (M-3) Silver Unreal Steel Inc., Atlanta, GA (M-4) Bronze ATFAB, Plant City, FL (M-5) N. UNUSUAL ORNAMENTAL FABRICATION Gold Columbia Wire & Iron Works,

Portland, OR (N-4) SIlver Greg Eng Metalsmith, Vista, CA (N-3) Bronze Allen Architectural Metals, Talladega, AL (N-10) O. RESTORATION Gold Klahm & Sons Inc., Ocala, FL (O-1) SIlver DeAngelis Iron Work Inc.,

South Easton, MA (O-2) Bronze WW Ironworks Inc., Fayatteville, TN (O-5) P. ART/SCULPTURE Gold John Medwedeff, Murphysboro, IL (P-7) Silver Phoenix Metalworks, Atlanta, GA (P-5) Bronze Deggingers’ Foundry, Topeka, KS (P-2) Mitch Heitler Award for Excellence Design Metals, Gresham, OR (D-11) Categories B and L did not open because the minimum entry requirement was not met.

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FABRICATOR May-June 2002

Awards Night

View winners on the web at www.nomma.org. We will also feature contest entries in upcoming issues.

A sampling of this year’s Top Job award winners.

Flaherty Iron Works Inc.

Pro-Fusion Ornamental Iron Inc. and Kelley Ornamental Iron LLC Wonderland Products Inc.

Klahm & Sons Inc.

Aberdeen Forge & Anvil

ATFAB

R&F Metals

Bob’s Ornamental Iron Studio FABRICATOR May-June 2002

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Memories.... right:

Dave and Lamar enjoy Friday’s “Party for a Purpose.” bottom: Allen, Stewart, and Tom are ready to begin the shop tours.

Mitch Heitler Award

Tony demonstrates the proper way to eat barbecue.

A thanks to John Ireland for contributing pictures for this year’s METALfab coverage.

Ironwood

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g-s co.

A bronze and stainless steel railing received this year’s Mitch Heitler Award for Excellence.

Design Metals was presented the industry’s highest craftsmanship award during the METALfab awards banquet on March 9.

The company received NOMMA’s coveted Mitch Heitler Award for Excellence for an entry submitted in the “All Interior Railings” category. The same entry won a Gold award in the Ernest Wiemann Top Job Contest.

Also during the awards ceremony, Design Metals received a Gold award in the “Furniture & Accessory Fabrication” category.

The winning entry was a bronze and stainless spiral guardrail and handrail. The challenging project features no exposed fasteners and was actually fabricated at the job site. The finish is a #4 brushed and the entire project took approximately 1,500 hours to complete.

Design Metals joined NOMMA in 1992 and is regularly represented at NOMMA conven-

Approximate labor time for the job was 1,500 hrs.

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FABRICATOR May-June 2002

A thanks to the following exhibitors who participated in NOMMA’s 44th annual trade show in Galveston, TX. For a detailed listing, visit: www.nomma.org.

Advanced Measuring Systems

888-289-9432 Stop gauging and programmable stop and positioning system.

Alco Fence Painters

304-366-2626 Electrostatic fence painting equipment and paint.

AP Automation

770-887-1692 Hydraulic and mechanical gate opera­ tors; swing and slide gates.

Apollo Gate Operators

210-545-2900 Gate operators and access controls.

Arcadia Steel, LLC

713-466-1834 Ornamental components.

Julius Blum & Co. Inc.

800-526-6293 Traditional railing to glass railing components.

J.G. Braun Co.

800-323-4072 Architectural metal products; ferrous and nonferrous.

Byan Systems Inc.

800-223-2926 Hydraulic gate operators and access control devices.

CAME

305-593-8798 Gate operators, access control.

Centaur Forge Ltd.

800-666-9175 Forging hammer, books and videos on

Exhibitor Listings

blacksmithing, hand tools.

CLYSZHP Inc.

626-289-8024 Cast iron spears; hinges, lock boxes, window release, aluminum castings.

Cleveland Steel Tool Co.

800-446-4402 Ironworker tooling, ironworker and related fabricating equipment.

CML USA Ercolina

407-857-1122 Tube, pipe, and profile bending ma­ chines, drilling machines, cutters.

Colonial Castings Inc.

305-688-8901 Gravity aluminum decorative castings, furniture, and light fittings.

Colorado Waterjet Co.

970-532-5404 Custom panels & components for rail­ ings and gates, cut with water jet. left: Bill checks out the latest powder coating products.

Controlled Products Systems Group

909-371-7212 Gate operators and accessories.

Crescent City Iron Supply Inc.

800-535-9842 Ornamental iron components and hardware.

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FABRICATOR May-June 2002

Cross River Metals

210-824-1750 Ornamental steel tubing and galva­ nized steel tubing.

Dave’s Design Shortcuts/AccuLine 954-646-2110 Portable drafting kit.

DecorativeIron.Com

right:

Ken (far right) gives a demonstration of the Torch Made automated cutting system.

713-991-7600 Ornamental supplies in cast iron, aluminum, and carbon steel.

D.J.A. Imports Ltd.

888-933-5993 Ferrous & nonferrous metals, gate & door hardware, machinery.

DKS, DoorKing Systems 310-645-0023 Access control products.

Eagle Bending Machines Inc.

251-937-0947 Bending machines, scrolling ma­ chines, bar working machines.

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Eastern Metal Supply

704-391-2266 Hand railings, wall and fence systems, fence suffengers, castings.

Elite Access Systems Inc.

949-580-1700 Gate operators, access control prod­ ucts, telephone entry systems.

EURO-FER SRL

011-39-044-544-0033 Wrought iron products; curls, stakes, holed bars, spikes, spires, panels.

FAAC International Inc.

307-635-1991 Automated gate operating equipment.

FABCAD.USA

800-255-9032 Ornamental computer aided design systems.

FSB USA LLC

407-351-7017 Multiple ornamental iron machinery, metal fabricating machinery, benders.

GTO Inc.

800-543-4283

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Automatic gate operators.

HEBÖ GMBH

cleveland steel tool

011-49-6453-913321 Wrought iron machine systems.

House of Forgings

281-443-4848 Ornamental iron products.

INDITAL USA

800-772-4706 Forged and wrought iron architectural components.

Intercorp Inc.

800-532-6303 Baroque Art Gilders Paste, 24 colors of waxed based mediums.

Interstate Mfg. Associates Inc.

603-863-4855 Ornamental gate hinges, precision machining and welding.

Iron Access Inc.

713-864-1229 Gate operators, access control, inter­ active video.

ITW Ransburg Electrostatic Systems

419-470-2000 Liquid electrostatic paint application equipment.

King Architectural Metals

800-542-2379 Ornamental components, lamp posts, urns, gate operators.

Lavi Industries

800-624-6225 Stainless steel and brass architectural railing and components.

Lawler Foundry Corp.

800-624-9512 Ornamental metal components and accessories.

Marks USA

631-225-5400 Locksets.

McGill Distribution

864-963-2521 Henrob welding and cutting torch.

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Mittler Bros. Machine & Tool FABRICATOR May-June 2002

left: Throughout the trade show hall, exhibitors demonstrated a wide array of equipment.

316-322-8200 Paint and coatings, including VOC compliant and water based.

Ornamental Steel Designs Inc.

931-358-5281 Ornamental patterns cut from plate us­ ing laser and plasma.

Premier Powder Coating Inc. 713-453-6282 Custom castings.

Production Machinery Inc. 636-463-2464 Ultimate tubing notcher, hydraulic tub­ ing bender, smart tools.

Frank Morrow Co.

800-556-7688 Metal stampings, banding, filigree gal­ leries, grey iron castings.

National Ornamental Metal Museum

901-774-6380 Decorative items, auctions items. jewelry.

National Ornamental & Miscel-

410-574-2110 Roll bending and cold sawing machin­ ery.

laneous Metals Association

404-363-4009 Industry trade association.

R & B Wagner Inc.

New Metals Inc.

888-639-6382 Ornamental forgings, expanded metal and grating.

NITEK Inc.

972-447-9628 All types of abrasives, welding rods, and castings.

Omega Coating Corp.

800-786-2111 Railing fittings and specialty tube and pipe bending.

Rail Wizard (R & F Metals Inc.) 301-868-7083 Rail Wizard - computer software.

Regency Railings Inc.

972-407-9408 Prefabricated ornamental iron compo­

Hartford Stamping

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FABRICATOR May-June 2002

nents.

Spiral stairways.

Rockite, Div. of Hartline Products Co. Inc. 216-291-2303 Anchoring and patching cement.

Rogers Mfg. Inc.

940-325-7806 Iron working machines to punch and shear metal.

Sharpe Products

800-879-4418 Handrail components, ells, brackets, caps, flanges, and custom bending.

Signon USA

718-485-8500 Unique, contemporary and classic wrought iron design.

Sparky Abrasives 800-328-4560 Abrasive supplies.

888-471-3400 Fast dry paints and primers specially formulated for ornamental and miscel­ laneous metals.

Sur-Fin Chemical Corp.

323-262-8108 Patinas, lacquers and metallic paints.

Tennessee Fabricating Co. 800-258-4766 Decorative metals and hardware.

Texas Metal Industries Inc.

800-222-6033 Aluminum castings, ornamental metal products.

Texas Stairs & Rails Inc.

281-987-2115 Metal treads, tube rolling and bending.

Thomas Industries

713-705-1868 Shur Shut gate closer.

Stairways Inc. 713-680-3110

Torch-Made

Sumter Coatings Inc.

800-590-7804 CNC profile/flame cutting machine.

Triebenbacher Bavarian Iron Works Co.

800-522-4766 Quality wrought iron components.

Triple-S Steel Supply Co.

800-231-1034 Welding equipment and fabrication accessories.

Tubo Decorado, S.A. De C.V. 011-528-313-9722 Steel decorative pipe.

Universal Entry Systems Inc.

800-837-4283 Gate operators and access control.

J. Walter Inc.

888-592-5837 Abrasives and chemical tools.

Entrypro

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FABRICATOR May-June 2002

Top Job Profiles

A twisting sculpture captures the essence of an historic riverfront town.

By John Medwedeff Medwedeff Forge & Design

I

n autumn 1999, the UrbanArt Commission of the Greater Memphis Arts Council held a national competition for artists to design sculptural shade structures for the Memphis, TN riverfront.

This would be the first public art commissioned by the city in 30 years. The “call to artists” encouraged artist/architect collaborations and provided detailed criteria that governed the selection process. One stipulation was that the design should provide a sense of the history, growth, and development of Memphis. Specific mention was given to the cotton industry and its historic connection to the riverfront.

The structure could not have a footprint exceeding 48 inches wide because it was originally to be placed in the center of a 12 foot wide walkway, the roof required 96 inches of clearance at the lowest point, and the structure had to be equipped with internal lighting and seating. The design would also be subject to the approval of the Memphis Landmarks Commission, Memphis Center City Commission, and the State Historic Preservation Office. It would have to meet structural and low maintenance requirements.

I sent my application materials including slides, resume, and a sketched proposal relating to cotton, of course. The selection committee liked my slides (previous work), but not my “King Cotton” proposal. I

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The 18-foot high sculpture is made of a central column built of 1-inch plate and a twisted canopy fabricated from 1/4 inch plate. Each side is made of three layers, with the material wrapping one and a half times around each other and the column.

was selected as a finalist and asked to submit a new design. Second chances are rare, and this one I accepted as a gift as well as a learning experience.

Never again would I, as an independent artist, submit a design with less than a truly heartfelt concept in a competition in order to fulfill a selection committee’s written expectations.

This project was particularly appealing to me because I am a former Memphis resident and still consider the city a second home. I decided to go for broke with the new design. I usually prefer to work in an abstract style, drawing inspiration from my direct experiences with

botanical, aquatic, and atmospheric phenomena. I lived and worked at the National Ornamental Metal Museum in Memphis while in college and the riverfront landscape was a big part of my life there. I felt that I could express my internalized knowledge of the land/river environment successfully.

I started sketching in my usual “organic/geometric” style, remembering the swirling river currents and the unobstructed winds on the bluff. At the same time I was trying to develop a new design concept that met the criteria that was detailed in the “call to artists.” The

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Photo by John Mann.

surfin 4C

Photo by John Mann.

A view from above.

Aluminum bench top.

cotton industry has little to do with the Memphis that I know. This time, I thought of Memphis’s rich heritage of great foundries, industrial forges, and large steel fabricators, many of which are still in business today. Historically, it was river and rail traffic that fueled the growth of Memphis. Now more than ever, powerful tugs push giant barges up and down stream. I considered the four bridges that span the Mississippi River at Memphis, with their huge sections of riveted and bolted structural iron. The double arched “New Bridge” is a superbly graceful and impressive form. Memphis is no Pittsburgh or Birmingham, yet iron, steel, and manufacturing have helped to shape the city economically, socially, and aesthetically.

Spiral forms occur often in my work. I had certainly used scrolls in my decorative architectural metalwork. I had even created forms with some reference to centrifugal forces such as in the Smysor Plaza Fountain (Fabricator, May/June 2000). I was thinking about the Mississippi River and its role in the landscape. But in my mind’s eye, I was also remembering the raging vortex of the F3 tornado that I had encountered five months earlier in central Illinois while driving home from a job site meeting regarding the installation of a sculpture — ironically titled “Zephyr.” I dodged the massive twister by only a few yards, accelerator pushed to the floor, and the engine screaming at 120 mph. The tornado loomed over me so close that I could not see around it.

Through the passenger and rear windows of my pickup truck I saw what at first looked like a churning wall of translucent concrete. The rotating FABRICATOR May-June 2002

loads of dirt, trees, corrugated metal, and other debris were organized into layers of ribbon like bands whirling counter clockwise in that same slow motion way that passenger jets traveling at 300 mph seem to hang in the sky as they land. The awesome power of the storm scattered cars and tractor-trailers like the toys of a mad child. There were injuries and death.

I was lucky.

For “Whirl,” the leaf-like forms that I visualized for the canopy were familiar to me. They have been evolving within my visual vocabulary for years, yet now I imagined a piece that had a greater sense of movement and energy than any sculpture that I had ever created. I do not think I would have arrived at this new understanding of my own forms without experiencing the terrible raw energy of that storm.

The deadline was “ASAP.” Pressed for time, I worked quickly, drawing with a Sharpie marker on a huge roll of 36-inch wide paper.

Sometimes I labor through this

Jeremy Crawford and Jenny Schuler count and organize parts on the eve of installation.

process and other times the ideas just come pouring out. I conjured a sculpture unlike any of my previous works. The organic qualities of my forgings transferred to cut and rolled steel plate and combined with structural steel’s signature bolt patterns, exposed welds, gussets, and fabricated beams. The design exhibited the qualities I had observed in the natural and made environments, fit within the broader context of my work, and met the technical requirements of building codes. I felt that the graceful design

would transcend the harsh sources of its inspiration, and actually be a restful relaxing place that would enhance experiences of socializing and enjoying the spectacular view. In all ways, it would be appropriate for the site. In 23.5 hours I went from concept to sketches to the completion of a 3/32 scale model of the 18 by 21 by 8 foot sculpture to delivery in Memphis, where I presented it to the UrbanArt Commission for consideration.

I knew that I had no need to collaborate with an architect to accomplish this piece. I had the vision to create the aesthetic. The person I needed was Rob Keeler, a long time NOMMA member with an engineering background, who, along with his brothers, Clay and Will, run Keeler Iron Works in Memphis. The Keelers specialize in large structural steel fabrication and are also very involved in Memphis’ vibrant decorative metal arts scene.

My unusual design was selected. Construction of the actual

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FABRICATOR May-June 2002

Photo by John Medwedeff.

not possible as we did not have a good way to support the weight.

Mocking up the layers of the canopy in cardboard and working our way down from the middle solved the problem. Later, we worked from the spiral outward, replacing three cardboard canopies with steel.

The left and right canopies and their spirals were later bolted together in four, three layered sections. Forming was done with pinch rolls, presses, and even twisting with a forklift.

The electrical wiring for the lighting

installed by electrician Mark Oshinsky was hidden in a conduit concealed in the fabrication of the column. Staff member Chris Winterstein and myself completed the forming of the spiral vortex in about six weeks.

Meanwhile, staff members Jenny Schuler and Jeremy Crawford constructed the 15.5 foot long cantilevered bench. It has an organic form and beveled edge that is consistent with the shape of the canopy layers. A steel substructure designed to carry a 2-ton live load is topped with

The column is raised.

piece began in December 2000, after a year of contract negotiations, and a lengthy construction document approval process, including blueprints sealed by a structural engineer, specifications, budgets, and schedules. The City of Memphis required the sculpture to meet building codes for snow loads, wind loads, seismic stress, electrical safety, and wheelchair access.

I worked with Rob to sort out many of the structural issues and to build the central column. We went to a subcontractor, Trumbo Welding, and worked with their men and the largest set of rolls I have ever seen.

Once the bending was completed, the three 1 inch thick plates making up this part were then fabricated in the Keeler’s shop.

The bench and cantilevered canopy, a carefully twisted ton of ⁄ -inch steel plate, was built in my studio, Medwedeff Forge and Design in Murphysboro, IL. Each side of the canopy is made of three layers of ⁄-inch steel plate laser cut by L. E. Sauer Machine Co. of St. Louis. The concentric layers, up to 23 feet long, wrap 1 1/2 times around each other and the column, concealing three light fixtures. The first challenge of the canopy construction was to decide which end to start working from. The first bends would set up the trajectory of the entire form. Therefore, starting at the bottom and working upward seemed too risky. Starting with the canopy and working downward was FABRICATOR May-June 2002

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Photo by Rob Keeler.

John Medwedeff installs the canopy.

a fabricated ⁄-inch thick aluminum top. Aluminum was chosen for its light weight, strength, durability, and all important user-friendly thermal properties. Precautions against theft of the aluminum were included in the fabrication.

The most difficult and time consuming work was constructing the gusset and flange system that holds the canopy together and gives it enough rigidity to hold its own weight. This phase required endless reaching into tight spaces to formfit about 70 pieces, drill, and weld connections. Some 400 stainless steel

screws, many of them counter sinks, hold the layers tightly in place. This took Jenny, Jeremy, and I most of the spring to complete. The benefits are strong connections that barely register in the consciousness of the viewer.

The sculpture was ready in July 2001. It was built to be fully disassembled for purposes of transportation, painting, and future maintenance. We had a trial run in the studio of reassembling the sculpture to prepare for installation day. It took seven hours. The piece was sandblasted and I transported it to Memphis.

The finish, epoxy primer and a deep

blue polyurethane paint were applied in a marathon weekend of painting at Keeler Iron Works.

It seemed the weather wanted one last word. Our first day of installation started with scorching heat and ended with lightening, torrential rain, and sustained 40 mph winds. The next two days were pleasant and installation was completed on August 1, 2001.

I certainly felt two and a half tons lighter when I headed for home, and quite satisfied. The piece that I titled “Whirl” has expanded my abilities and given me an opportunity to create a landmark for a city that has enriched my life. The piece is located in Vance Park overlooking Riverside Drive and Tom Lee Park, two blocks south of Beale Street.

“Whirl” has been very well received. There were so many people and organizations who contributed to the success of this project, and to all of them I am grateful, especially Keeler Iron Works, the UrbanArt Commission, the National Ornamen-

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FABRICATOR May-June 2002

Top Job Profiles

Class IsIs In In Session Session Class A large project becomes the ultimate learning experience.

& below: This 15fi foot diameter gazebo is built from 1” x 2” and 1” x 3” bars. All scrolling vines are 1” round solid and were formed by hand. Total weight is about 3,000 pounds and the piece took about 1,200 hours of labor time.

left

By Tim Brogdon Aberdeen Forge & Anvil

I

n 1995, with the influence of Jim Wallace and the National Ornamental Metal Museum in Memphis, TN, I found a passion for blacksmithing. I was determined to provide a living for myself moving metal. Over the next four years, I accumulated a substantial amount of tools, forging equipment, and a brief apprenticeship with a local smith, Charlie McKinney. Quality projects were few and far between and I did a lot of repairs and straight fabrication to make ends meet. My idea of a large commission was 35 feet of tubular handrail for a local stone cutting company. All the while I was searching for an opportunity to prove to myself that I was capable of designing and carrying out large-scale architectural artwork.

In June 2000, the Metal Museum provided yet another pivotal point in my life. They referred me to Peggy and Sidney Evensky who wanted an arbor built for their new home, which was in the preliminary stage of construction. I was immediately excited about the possibilities. The piece that the clients envisioned was more of a cross between an arbor and a gazebo. More importantly to me, they wanted me to design the work.

At the first meeting they admitted that they enjoyed Art Nouveau and French country (the house is modeled after a French chateau).

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FABRICATOR May-June 2002

Then they asked me the obvious question, which I had very naively in my excitement failed to consider — “How much?”

ornamental steel design reflex blue

I became even more excited as these styles were very familiar to me. I knew, given their stylistic preferences, I had a lot of room to create and instantly had visions of long snaky, scrolly, viney lines spewing off in every direction. On top of it all, I was to design and build two balcony railings for the front of their home as well.

So, off to the drawing board I ran. I drew and I drew and I drew. I created many drawings and found out just how hard it is to draw a 3-dimensional spherical object in a 2-dimensional plane. Then it was back to the client with a stack of sketches in hand. They loved them all. Then they asked me the obvious question, which I had very naively in my excitement failed to consider — “How much?”

A fair question, right? But I was floored. Then they said, “Oh yeah, did we mention that we have an absolute deadline of May 11, 2001? This has to be installed by then because we are having friends fly in from all over the country for a housewarming.” I said, of course, “No problem.” Bold or crazy? You decide.

In the past, I had no difficulties estimating straight fabrication jobs and even large production jobs that had come through my little shop. However, estimating the cost of forged artwork let alone building and installing something on this large of a scale was a slightly overwhelming proposition. But I knew that this was the opportunity I had been waiting for years to stumble across.

I had never fabricated a job that couldn’t be carried by two moderately healthy individuals. Obviously this was going to weigh at least 2,000 pounds and probably more (finished weight is 2,800 pounds). This was a horse of an extremely different color.

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To make matters even more interesting, I discovered that I had zero access to move the work to the installation site. The piece was to sit behind the house on a brick retaining wall.

The lot is basically triangular and the house crosses the lot in such a way that there is approximately 10 feet of clearance on one end of the building and a small walk gate on the other.

Someone joked that we would need to fly it in. In the end we virtually did just that.

I sat down and began to really design the thing and estimate the cost at the same time. The learning curve was enormous, and I owe a huge debt of gratitude to Rob and Will Keeler for their unfailing support and confidence. I knew I had to build it in sections and thought that we might pos-

bottom:

A view looking up shows the elaborate design.

The gazebo was fabricated in two large sections.

At the job site, it was necessary to lift the gazebo 55 feet high and lower it in the backyard 120 feet away.

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FABRICATOR May-June 2002

Well, there was much dickering about the price, redesigning the work to cut costs, and quite a considerable amount of concern about more than a ton of steel hopping over their home.

We were going to try to cut costs by sitting a crane in their new yard as opposed to the street, which would provide 50 more feet of reach. This also meant an accelerated installation date, as they also wanted the landscaping completed before the party.

To make a long story short, we lifted the gazebo from the A pair of balcony railings were also provided for the house. Each 8-foot railing was crafted from solid steel, and all scrolling “vines” were hot forged. The twists in the center were made by hand street with a 140-ton crane. and the center bar was crafted from three separate pieces. The large “C” scrolls and adjoining The operator told me that even leaves were fabricated from seven individually forged pieces. The finish includes a two-part that giant crane was at 90 perepoxy, three coats of zinc-laden primer, and hand rubbed satin black enamel. cent capacity given the weight of the gazebo and the fact that sibly be able to carry small sections in no more than two sections. We would it had to be raised 55 feet vertically and assemble them in the rear of the assemble it in front of the house in and dropped 120 feet away. Needless house. Remembering the frustration the street, and I would hire a crane to to say, I was on pins and needles the of previously wasting time on installift it over the center of the Evensky’s whole time. lations, I made an executive decision brand new multi-million dollar home.

Once the plans were comthat at the time made me feel truly Wow, did I ever feel like I had hit the plete and the budget was agreed upon, gutsy — minimize onsite labor and big leagues! headaches by building the gazebo in

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right:

The “leaves” were hammered in a bowled tree stump to give them depth.

top: This piece was the most difficult to make. While it is an “S” scroll, it also subtly bends in two other planes in order to fit the 3-dimensional space. To avoid unnecessary welding and grinding, this particular 6-foot long section of 1” round vine was hot bent in two heats around the fixture.

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it was time to begin work. I used a CAD program to spec the curved vertical structural members and the lower horizontal ring. A large local fabricator was contacted to roll, machine the connecting points, and fabricate these pieces as the mason assured me he would unequivocally meet a very specific tolerance of 1/8 inch in the radius of the retaining wall. Sometimes we dream big dreams.

The wall grew five more vertical feet over the course of the next several months and in so doing went out of round and off my working radius by over an inch. This was, of course, after I had had a 15-foot diameter circle rolled out of 1 inch by 3 inch solid material. Trust me, I didn’t modify my ring.

Regarding the actual creation of the gazebo, the most interesting aspect from a fabricators’ point of view is probably the large fixture I built to create the appropriate curves of lines through 3-dimensional space around the exterior of the sphere.

The gazebo is divided into six sections or frames and all are identical to each other. A skeleton framework of tubing was created that supported a sheet metal “skin.” The design of the infill was drawn on this full-size skin. I was able to move this entire fixture from one framed section of the gazebo to the next in order to perfectly place parts. I discovered that what I thought were true arcs across horizontal 2-dimensional space were actually 3-dimensional, which moved subtly in three directions at once. For the gazebo to be viewed correctly from underneath, I had to constantly remind myself of this fact.

All of the “leaves” were torch cut and welded onto the ends of forged “stems.” After connecting the leaves to stems, the leaves were FABRICATOR May-June 2002

forged into a bowled tree stump to give them depth. The 3-inch diameter “buttons” connecting the vertical structural members to the bottom horizontal ring are forged in one heat from 1 inch by 2 inch solid bar using an 18-ton hydraulic press and an air hammer. All of the mechanical

connections were made with fl inch bolts. Over 20 fixtures were used to hot bend countless feet of steel (and I have the radiant burns to prove it).

I began work January 13, 2001 and the gazebo was installed April 23, 2001. I took six days off in between. The railings were built in

the few weeks that followed before the scheduled housewarming party.

Would I do it again? Yes, in a heartbeat. That single project has been the greatest blessing for my career and my confidence. Every once in awhile, you just have to jump in head first.

Aberdeen Forge & Anvil

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These “leaves” are the culmination of hot forging and fabricating.

The fixtures shown on the shop floor.

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FABRICATOR May-June 2002

Job Profile

Sometimes You Can’t Say ‘No’

Time constraints heightened the challenge of fabricating this rail.

Both the time shortage and geometric design made this metalsmith feel right at home.

By Igor Lipko, Lipko Iron Work

In February 2001 I received a call from Jacques Brunet of French Architectural Designs & Fabrication, who asked me to look at several projects.

We set a meeting to look over drawings and discuss details.

Previously, I had worked with Jacques on some smaller projects, but what he showed me this time exceeded my imagination. He presented three different projects: a $42 million home in Birmingham, AL, a smaller project for the well-known John and Patsy Ramsey, and a show house on West Paces Ferry Rd. in Atlanta, slated as a stop during the Decorator Home Show on March 20.

All of the designs were interesting, but the show house was the most challenging and appealing. The proposed railing featured a beautiful combination of geometric lines and scrollwork.

At this point, I need to provide a little background. I came to the United States from the Republic of Georgia 10 years ago. In Georgia, there is a very rich and old blacksmithing tradition, and about 80 percent of the projects are a combination of scrollwork and geometric lines. In the U.S., this type of work is considered “French” or “Italian” style.

Of course, I really like work58

Geometric designs demand a zero margin of error.

ing with floral designs, but geometric designs require a higher skill level and more patience. All details must be identical; there is no margin for error.

In this case, the drawing in front of me was exactly such a design. The project called for 170 linear feet of railing, and only about 20 feet of this was straight, while the rest was spiraled or curved. The spiral stairways connected the basement with the first and second floors.

Immediately, I thought about the responsibility of this project, and about the hundreds of people — if not thousands — who would be going through the show house. Among these people would be many professionals and critics who understand this type of work.

The most difficult part of the project would be the time, since the

deadline was just over a month away.

Being late was not an option because materials had already been printed and an Atlanta Symphony benefit event had been set for opening day. However, a shortage of time was nothing new for me — when I lived in the Soviet Union there was always a shortage of something.

So, we shook hands on the deal and I started work that same day.

First, I measured at the job site and began creating templates and jigs. From a technical viewpoint, the job was not difficult but it was critical that we plan carefully and think ahead.

In the beginning, creating the templates was the most important part. Typically, I make templates from 1/2 inch tubing. It’s important for the template to be exactly in the middle of the nosing. Afterwards, I return to the shop and bend a 2-inch solid top rail the same shape as the templates. I then go back to the job site to make exact adjustments. Normally, this procedure is not difficult, but with the show house it was a problem because the home was nearly finished. The marble was down and the walls were painted, and it was time-consuming to lay down the plastic and provide all the extra protection needed in the home.

After the top rail was adjust-

FABRICATOR May-June 2002

ed, it was then time to build the fames.

I always build frames in the shop, except for the spiral sections. Creating the frame is not difficult if you have the top rail bent exactly as needed and a perfectly level and large worktable.

To avoid a lot of welding at the job site, I always try to pre-fabricate the railing in as big of sections as possible. However, with spiral stairways this is impossible, and I build the frames at the work site instead. Once the frames are made, I provide temporary braces to keep it plum in the shop.

Once everything was brought

DKS

back to the shop, the real work began.

It was just four of us working on the project, but we are all highly qualified.

As I mentioned, when doing a project under such a tight timeframe careful organization is essential. Each of us did the job that we were most proficient at, and our varied talents worked out perfectly. For example, I am fastest at making scrolls and bending them into the same shape, so I mostly did the scrollwork. My son-in-law is best at fabricating, and my one employee was best at grinding, applying filler material, and painting. Of course, if

necessary we can do each other’s jobs.

I used two forges: one coal and the other is a toenail gas unit. I use the coal forge to make end scrolls and then I transfer the flat bar to the toenail gas forge, where the material is more evenly heated in all lengths. If you have a good jig and the same heat, all of your scrolls come out evenly and you don’t waste time making adjustments.

While forging, we also started fabricating the railing. Jacques, who supplied us with a set of fullscale drawings, helped us. Because of the many trades people and employees already going through the house, we first fabricated and installed the second floor balconies for safety reasons, and saved the two spiral stairways for dessert. During this phase, we worked very hard, usually starting at 7 a.m. and working 12- to 15-hour days. It took a tremendous amount of time to grind the railings and apply the needed filler material, and hand sanding the scrolls was especially time-consuming. Once these steps were completed, we applied red primer followed by black satin paint with graphite.

Finally, we had everything ready for the last installment. No one could have dreamed that the stairways would be completed on time.

The show and party was opening on Friday, and on Thursday at 5 p.m. we brought the spiral stairway to the home for installation. It’s impossible to describe all the difficult details of this installation, but by midnight the rails were in place.

I’d like to conclude by saying something about the designer, Jacques Brunet. Unfortunately, this was the last project where we worked together — Jacques passed away a week after the show closed on May 5. A true professional and extremely talented man, he was not only a designer but also a musician, chef, and painter. His paintings can be viewed at the Atlanta Museum of Art and many private collections. He had a wonderful personality and was the kind of person that you dream about working with. His memory lives through his many railings and sculptures that adorn homes and buildings throughout Atlanta.

Lipko Iron Work has been a

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Job Profile

A Wild Project The ATFAB team combines their talents to provide the right touch for an animal-themed hotel.

By Steve Waller, ATFAB

After Four years of industrial construction and 13 years with a local utility company operating and maintaining coal fired boilers, I came to the conclusion that I did not want to be welding and grinding in a “hot boiler” at age 55. So I decided it would be better to make the move at 35 years of age instead of 45. I spoke with a fellow co-worker, Steve Miller, who I had been working with at the power company. I had always admired his work ethic and thought we could go into business together. He liked the idea also. So we set to work on the company name; Steve’s wife came up with a good one. Since we planned to fabricate and weld, we decided on “ATFAB” (Any Thing For A Buck).

Well, working two jobs was pretty tough. Business wasn’t all that great the first couple of years, but Miller and I hung in there. Fortunately I could help out in my father’s metal roofing manufacturing facility while it was slow. That’s where I met a local stair fabricator named Jim Lane.

Jim made beautiful wooden stairs; however, a high school shop class 30 years ago was his only welding experience. I had sold him some roofing material for his shop, and he had seen some of my work. He later approached me about collaborating with him on certain jobs. Jim felt as though he was FABRICATOR May-June 2002

l to r: Kenny Brown, Steve Miller, Steve Waller, and Jim Lane (not shown) of ATFAB completed this grand stair rail for Disney World’s Animal Kingdom Hotel.

losing some business because of his inability to fabricate steel railings for some of his clients. He said with my welding ability and his stair building knowledge, he would be able to teach me everything I needed to know.

So at that point ATFAB came to a crossroad; stair and railings fabrication would be the direction I would take. The third job I bid for Jim Lane

was the grand stair case for Disney World’s Animal Kingdom hotel. It seems the hotel was well under way and the general contractor (GC) had not found a stair builder for a stairway. During one of the construction meetings a subcontractor responsible for all the balcony railings was told they would be required to undertake the grand staircase. The subcontractor

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was not a stair manufacturer, which they repeatedly told Disney and the GC. The sub was told, “It doesn’t matter, just find someone who can.”

Out came the Yellow Pages and Jim Lane was called on to bid the job.

Jim and I worked together for several hours on the bid, but in the end we did the job too cheap because the sub said they almost went with someone else.

Apparently we were “so much lower” than everyone else.

After winning the bid came the fun part: it was my first job that

required the submittal of shop drawings. Anyhow, after one month and six revisions, we were ready to start work. I had figured it would take two men over four weeks to complete the Jim Lane and Steve Waller collaborated their talents for this project.

Waller’s experience is with welding and metal roof manufacturing, while Lane specializes in woodwork.

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beams in the shop. In reality, it took six weeks and several late nights. Although the grand stair rail But then it was ready to for Disney was be installed in the hotel. a turning point I had figured it would in Steve Waller’s take about three to four stair fabricating career (it was days to do this. I got that the first time they part right. However, this had to submit was Disney World we shop drawings), were working for. They he says he’s not so sure he’s ready say for every worker for another job painting or stuccoing quite like this one any time soon. a wall there are two Imagineers (that is what they are called) standing behind him watching and changing colors and textures. I weeks and four more change orders do not know if that was true for the we thought we had finally completed painters, but let me tell you we had the project and were ready to collect four and sometimes five Imagineers our check. (Fortunately the change watching us. A week after we thought orders gave the overall job a small we had finished, I received a call from profit.) Now it was coming down to the sub. He said everything was fine crunch time. Grand opening was just but the Imagineers wanted to change around the corner, and the inspections a thing or two. That week I drove started taking place. The inspector back over to Disney and met with obviously was not consulted about the the sub and the Imagineers to discuss design of the stairway because he did the change orders. After three more not like the idea of 4-inch thick teak

wood spanning up 5 feet. So one more time with the change orders, we would make wedge-shape plates to match the teak out of 5/8 inch plate and the teak would be trimmed down.

The entire job from a skill level and time table perspective was different and challenging. After completing the job and seeing the results, I would have to say it was worth it.

But I’m not sure that I am ready for another one like it.

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Job Profile

First Aluminum then Copper: Copper repoussé bass.

A Fish by any Other Material Would Smell as Sweet Changing material from copper to aluminum mid-project creates some logistical challenges for this Florida fabricator.

By Jacob Mudge, Mudge Metalcraft

After 20 years working at a 100-plusman shop I started my own business, a small four-man, handpicked operation.

It’s so good to work with a talented force — people who love what they’re doing. About a month after starting up, I received a call from an architect friend who I’d worked with in the past doing upscale homes. He asked if I would be interested in doing the custom work on a private home. “Sure, put me down,” I said, and forgot about it.

Several months went by and the general contractor called. He said he had a dock railing with a nautical design that included fish and asked if I was ready to start work. “Sure, let’s go fishing,” I said. So we set up a meeting for the next day and before he hung up he said, “Oh by the way, you could look at the main house also,” but that’s another story. Before our 64

scheduled meeting, I stopped by the location and couldn’t believe the scale of the project, or quality of craftsmanship and material. I felt honored.

At the meeting, they showed me a rendering for the fish rail dock with sea grass and a tile or stone nautical design in the center. After getting the feeling of what they wanted I said that I would come up with a design.

At the beginning I thought of maybe using castings, so I called Jon at Alloy Casting Co. for some ideas such as pelicans, herons, sail fish, or sea horses. The problem was they were flat-backed or ill proportioned.

So I either had to make patterns or change the design. I decided to repoussé (aluminum fish in 3-D). I went to the bookstore and purchased some fish books and picked out several local species and enlarged them to full detail. I cut out the detail, pasted it on

a marked aluminum sheet, and cut it on the band saw. After cutting I hammered out the form of the fish. You can use a peen or repoussé hammer, but I cheated. I have a Pullmax Hammer, which is a sheet metal machine that has dies for different tooling. The tough part was getting the two halves the same depth and size. After I hammered the halves and the fins, I fit and formed them together. Organizing left and right was a little challenging. I also had a hard time coming up with a simple way of doing the eyes for my sample piece until I thought of using taxidermy eyes.

My aluminum materials list: • T-section for bottom rail.

• ⁄ inch hammered rod for grass.

• fl inch angle flattened and edges cut with a band saw for seaweed.

• Repousséd .90-inch sheet for fish.

FABRICATOR May-June 2002

• Four pieces of fl inch round rod put together with weld ends, annealed, and twisted to make the rope effect for the top rail.

I delivered a full-scale railing sample to the job site and everyone went nuts over it. They really loved it, BUT (that’s when I realized that “but” is a huge three letter word) they asked, “can you do it out of copper?”

Without stuttering I said, “Well, heck yes.” After leaving the meeting and driving back I kept looking in the mirror and shaking my head realizing that I’d hardly ever worked with copper.

Tennessee Fab

Now It’s a Copper Project

“Oh boy,” I said to myself, “Where do I get copper, what sizes, and what shapes, and how thick?” I went to a local roofing company and got what they call “16 ounce” and tried the same method that I had with aluminum. Everything was fine except I finally realized the copper sheet was too thin. I spent half the time patching blow out weld holes. Here’s where NOMMA really helped me out. Over the years I’ve developed friendships so that I can call people anytime to get help. A good friend and master craftsman and I have been working together on several projects. If he needs help or if I do, we work together. So I called Alex Klahm. We discussed methods and supply houses and called other friends. That’s what friendship is all about, helping out. I found a great supply house in Galveston, TX called Farmer’s Copper. I talked with Dick Farmer (by the way I got him to join NOMMA). Farmer also has other alloys like bronze, brass, and coppernickel products. Another source is Polished Metals of Hillside, NJ, which provides silicon bronze. We need to remember that without good supply houses to make our projects go easier some jobs would be tough or almost impossible.

Problem Solving in Copper

The number one problem I had working with copper was finding appropriate material sizes and shapes.

The only copper I could find came in sheets, bars, or rounds, meaning round stock or pipe, and round tube.

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65

right:

Some design modifications were necessary due to the available shapes of stock copper material.

Also note that Mudge used silicon bronze instead of copper for the hand rail.

T-shapes.

My copper materials list: • Two flat bars ⁄ inch by 1fi inch to make T-shape for the bottom rail.

• ⁄ inch round rod, hammered, for the seaweed.

• 1/8 by 1 inch flat for the sea kelp.

• 1fi inch silicon bronze for the top rail (note: I used silicon bronze for the top rail so that people won’t get verdi stains

left:

Mudge first made this sample rail in aluminum.

on their hands or clothes from using the rail; copper sometimes leave a chalky residue).

For the bottom rail I requested Buss Bar. It’s industrial standard bar for the electrical field. We clamped one piece of the flat bar to the table and ran a ⁄ inch router through the center at the right depth. Then we placed it vertically (perpendicular) on top of the other flat, which we plug welded from the bottom. We free-hand plasma cut the Fill in 155 on Reader Service Card

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FABRICATOR May-June 2002

Diagram of copper fish rail

inch by 1 inch. (note: Buss Bar comes in 12 foot lengths.) To make the vein lines 1/8 inch forged copper.

1 through the centers of the kelp we made Sea grass Top rail silicon bronze 1 /4 inch pipe. special tooling for the Pullmax and ran 12 foot lengths at a time. (Remember we had used angle in the aluminum sample; copper doesn’t come in angle.)

With all the parts and pieces made ahead of time it was easy to free-style the fish rail together. Everything fit between wood posts. But I wanted a nice looking attachment system. We took some Buss Bar and marked the ends round for the top and bandsaw cut patterns. For the locking system we milled ⁄ inch vertically and horizontally for the T-bottom section. We found the best method of welding was to TIG weld standard 14 gauge wire, which we picked up at a local hardware store, 1 stripped of insulation. Finish on project Grass sprouts /4 inch Bottom copper T-shape. forged copper solid rod was sanded, Scotch-Brited, and then turned natural.

I really enjoyed working with copper wave pattern of the perpendicular, flat. because of its pure form. It’s very forgiv The seaweed was easy. We took ⁄ inch rod and ing. However, I also ended up working with several hundred hammered it. We drilled the bottom and plug welded it to feet of bronze railing. Driving down the road again, looking the bottom rail’s horizontal flat bar. in the mirror I shook my head and realized I never worked

For the sea kelp we used the Buss Bar again in 1/8 with bronze that much before either.

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67

Industry Issues

The Wrong Access Control System Can Keep Everyone Out

by Tom Chronister, CPP

A security consultant lists the positives and negatives of emergency access system types.

As a professional fabricator, you may create ornamental gates for condominium complexes, private communities, industrial compounds, and apartment buildings.

Depending on the application and level of security required, access control systems may be completely automated or staffed around-the-clock. While gates and fencing are intended to keep out undesirables, they also do a great job of keeping everybody out, including emergency medical services (EMS) personnel, firefighters, and law enforcement whose job it is to answer calls for help emanating from within these residential and commercial fortresses.

As a security consultant and police officer, I have found that access control systems serve as a meaningful deterrent to trespassers and opportunistic criminals while giving those who live or work behind these gated communities and commercial compounds a greater sense of security. Unfortunately, these very systems meant to protect people and property may actually imperil both. Access control systems must be properly planned to ensure that public safety personnel are not unduly delayed when it comes time to make fast, efficient entry into protected properties. Understanding what solutions are available in the emergency access control market is the first step in avoiding a potential tragedy that could result when rescuers are denied access while responding to an emergency.

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Emergency entry products and their manufacturers.

Visit these web sites: Lock Boxes Key Systems www.perma-vault.com Knox® Company www.knoxbox.com Supra® Products www.supra-products.com Cards AWID www.awid.com Datacard® Group www.datacard.com HID Corporation www.hidcorp.com Motorola www.motorola.com Intercom Entry Control American Access Systems www.americanaccess.com Code Blue® www.codeblue.com Talk-A-Phone www.talkaphone.com Light Fire Strobe www.firestrobe.com Opticom™ www.3m.com/market/trans/its/prod_info.jhtml Tomar Electronics www.tomar.com Sound SOS™ www.sosgate.com Transmitters Linear Security www.linearcorp.com SecuraKey www.securakey.com LoopComm™ www.ustraffic.net Radio Identification Click2Enter® www.click2enter.net This represents an impartial list of manufacturers and vendors of emergency entry products.

Some technologies are proprietary in nature and are only available from one company.

FABRICATOR May-June 2002

Emergency Access System Types

There are eight basic methods that emergency personnel can use to bypass gated systems: keypads, third party, locks, cards, light, sound, radio signals, and forced entry. Each have there own strengths and drawbacks.

Keypads

Some gates come with combination locks or keypads that accept a numerical pass code assigned to emergency crews. The code is entered by hand and entry is made. Many keypad systems lack any real audit control as all emergency crews typically use only one code collectively. It is not uncommon for officers to find themselves completely locked out of a call for service when the code changes and no one bothers to inform the police department. There is usually some delay encountered in getting to the keypad and inputting the proper combination.

If the 911 center has an upto-date pass code that is not known to the responding officer, dispatchers will typically broadcast it over an unsecured police or fire radio frequency.

A common police scanner, available for purchase at most electronics stores, can pick-up such transmissions. If the transmission of the pass code was intercepted, the results could be costly.

Tennessee Fab

Third Party

By requesting access from a third party through an emergency dispatch callback procedure or intercom system, residents, guards, or employees can remotely grant access into the gated area. Responders might be able to get in by hailing a passerby or by tailgating a vehicle through the gate. During off-hours, no one may be present to provide access. In some situations the police may prefer not to alert people inside the complex of their arrival, such as when the call involves a crime in progress.

Locks

Rescue personnel can gain access by using a key that opens a lock or activates an electric switch. Some police agencies use lock boxes, but this solution is used almost exclusively by fire departments. Within the Fill in 89 on Reader Service Card

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Cards are inexpensive and easy to replace.

But like keys, managing a card system can be tricky. lock box is either a switch to activate the gate mechanism, another key, or an access card that can be used to open the barrier.

The downside to keys is accountability and the sheer number required to equip each emergency vehicle that may be dispatched to a particular location. A lost key might require the re-keying of all matching locks, switches, lock boxes, and the replacement of all existing keys — a costly proposition.

Cards

Access cards offer an audit trail of activity, as each can be associ-

ated to individual users or vehicles by the access control system. Common card technologies include touch-plate, embedded chip, and magnetic stripe.

These card types require the insertion into, or the touching of, a card reader. In the case of proximity cards, the pass-through speed of emergency vehicles is increased because actual contact with the card reader is not required.

If a card is lost, the permissions associated with it can be quickly removed from the access control system. Cards are relatively inexpensive and replacements can be put into use quickly. But just like keys, managing a card for each piece of emergency equipment can be an expensive proposition and an audit control nightmare.

signals during emergency responses so that the fire truck or police car gets a green light at controlled intersections.

Similar to those found on traffic lights, a compatible receiver can be attached to gate operators and provide emergency access to vehicles flashing the special strobe.

This solution requires that each emergency vehicle be equipped with an appropriate strobe emitter. Unless the city in question already uses Opticom™ to control traffic lighting, the system may prove to be cost prohibitive and impractical for this limited use. Another important point that law enforcement must consider is that using visible light to signal an emergency entry may tip off persons of their pending arrival.

Light

Some cities use the patented Opticom™ traffic priority control system manufactured by 3M™. Each emergency vehicle in the jurisdiction is equipped with a strobe light that contains a proprietary and coded infrared component that preempts traffic

Sound

A popular solution to the emergency access conundrum is sound activated entry systems. When an emergency vehicle gets within range of the proprietary audio sensor, the gate opens after detecting the sound of a siren for 2.5 to 4.5 seconds. Such

Crescent City

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This sun visor attached to a Santa Maria Fire Department rescue vehicle stores an assortment of signal transmitters for the different gated communities within the vehicle’s district.

systems are fairly inexpensive to purchase, are compatible with most gate operators, and are popular with fire departments.

While fire equipment responds to calls with lights and sirens most of the time, this is not the case with police. Depending on the circumstances, the last thing law enforcement may want to do is to tip-off their arrival by blasting a siren. Such systems only work on vehicles equipped with a siren. Other service providers like security and utility companies, which otherwise would have been provided

with a card, code, or key to gain access to the property, would find themselves locked out.

Radio Signal

Once a gate operator is equipped with a compatible radio receiver, any authorized vehicle can open a security gate in one of several ways: • Activating a manual transmitter.

• Equipping a vehicle with an “always on” transmitter.

• Use of a radio frequency identifier.

Manually activated transmitters require that users push a button to open a gate. This proven technology is used to activate garage door openers in most American homes.

Active or “always on” transmitters require no user action. Similar to those mounted on the windshields

Cards are inexpensive and easy to replace.

But like keys, managing a card system can be tricky of vehicles using automated toll roads, it continuously emits a radio signal.

Upon approach to a gate, the receiver detects the signal and activates the gate operator. Another type of transmitter is mounted on the underside of the vehicle. The signal is detected by a roadway loop similar to those used to detect cars at traffic signals.

There are several manufacturers for each of these technologies.

Although each offers rapid emergency access, every emergency vehicle must be equipped with a compatible device and the device must be maintained in an operable condition. The likelihood of each gated facility in a jurisdiction

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More of a method than a system and certainly last on the list of emergency access options is forced entry. using the same access frequency or technology is unlikely creating the need for each piece of rolling police, fire, or EMS stock to carry any number of gadgets to gain emergency access. Of course, the loss or theft of a transmitter or transponder poses particular concerns for facilities with matching frequencies. In the case of the always-on transmitter, simply driving past a gated complex may inadvertently activate the gate operator.

Radio frequency identification is the latest technology being marketed in the access control field.

Agencies are assigned specific frequencies by the FCC. By determining

which frequency was used to activate the gate bypass system, the system determines the identity of the user.

A patented receiver monitors 20 different frequencies programmed into memory by the user or installer.

Coordinating radio clicks with a visible light, the possibility that spurious radio traffic may inadvertently activate the gate operator is nearly eliminated.

Radio signal identification is quick — less than four seconds — and secure.

Receiver range can be set from within inches to about one-quarter of a mile away and handheld or vehicle-mounted radios can be used to open the gate.

An internal log in the receiver maintains details on what agency gained access and when — retaining 50 of the most recent transactions.

Forced Entry

More of a method than a system and certainly last on the list of emergency access options is forced entry. Crashing fences, cutting locks, and breaching gates are proven means for public safety to get where they need to go, but such tactics usually

result in collateral damage to facility equipment and/or emergency vehicles.

Jumping fences puts emergency responders at significant risk of injury and leaves them without access to equipment in their vehicles. As such, brute force and scaling barriers are considered a last resort.

Failsafe Systems

Although outside the scope of this article, security gates should also include “failsafe systems.” Such systems include manual release mechanisms that can be used during mechanical or power failures, and backup power supplies. While on battery standby, the access control system operates normally until available power reaches critical levels, at which time the gate system locks in the open position.

Quick, Reliable Access

If you have not thought about emergency access to gated projects before, now is the time to start. The popularity of gated systems is on the rise as more people feel increasingly

Sharpe

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vulnerable in light of recent national events and reconsider the priorities of safety and security at their homes and workplaces. Without proper emergency access controls in place, public safety response times are unnecessarily lengthened due to the blockade posed by improperly equipped gate opera-tors.

Working on independent solutions on individual gate jobs will complicate the issue. In doing so, every emergency vehicle and worker will be responsible for even more pass codes, keys, access cards, or transmitters. Some emergency unit visors are already covered with a myriad of transmitters and their key rings can’t get much bigger. And who will have to replace these access devices if they are lost or stolen? There are simpler technologies that guarantee reliable access through automated gates.

The existence of local ordinances should guide gate manufacturers and installers to the preferred method of emergency access. The absence of applicable codes should not be a factor as to whether or not

Majka

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such access is provided. Simply because your local jurisdiction has not implemented requirements does not mean you can ignore the benefits of emergency access equipment. It does not take much imagination to envision a lawsuit stemming from the delay of public safety personnel responding to the call of a heart attack victim from inside a gated community if the delay was a result of inadequate or improperly planned emergency access controls. How you give police and fire personnel emergency access is as important as giving access to them at all.

The Future

Radio frequency identification looks to have a strong future in the emergency access control arena, they’re easy to use and require no purchasing or tracking of additional equipment. Existing radios do the job.

Because many local ordinances were developed before this technology existed, cities still mandate older sound, light, and keypad bypass systems.

How you give police and fire personnel emergency access is as important as giving access to them at all.

With the introduction of this new technology, several agencies across the country, including the Napa Fire Department, Fairfield Fire Depart-ment, and the city of Oxnard (all in California), are making installation of public safety radio activated devices a requirement for future gated access properties. These municipalities are working with existing gated communities on voluntary compliance programs. Such devices can also be used on commercial roll-up doors and sally ports.

Chronister is a commander with a Southern California police department, a Certified Protection Pro-

Encon

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73

Business Issues

Borrowing & Lending Without A Tax Bill Knowing how to overcome obstacles in our tax laws can help avoid penalties and higher tax bills.

By Mark E. Battersby

The Internal Revenue Service has issued a guide to their examiners offering the best techniques for auditing shareholder loans. It explains how to determine whether a loan is bona fide and covers below-market terms and demand loans extensively. So what does that mean for you?

Many metal fabricating businesses borrow, or take a loan from the operation’s owner or shareholder. Or, in many cases, the owner or shareholder borrows the funds from the metal fabricating operation.

Either way, our tax laws create a number of obstacles. Knowing how to overcome them helps to avoid penalties and corresponding higher tax bills that result when IRS auditors restructure loans that don’t meet their criteria.

Loans and advances made to so-called “related parties” are common in many closely-held metal fabricating businesses, especially corporate loans to shareholders. Advances from shareholders to the incorporated metal fabricating operation run a close second, particularly in the early years of closely-held but thinly capitalized corporations.

The IRS’s interest in these transactions stems from the tremendous potential for tax avoidance — inadvertent or intentional. Less 74

formal loans without stated duration or interest also occur frequently. Under our tax rules, these are treated as “demand” loans and, unless extremely small, are subject to the provisions governing “imputed interest.”

Imputed Interest

Section 7872 (Below-MarketRate-Loans) of the Internal Revenue Code treats “foregone” interest on all below market rate loans as transferred from the lender to the borrower as of the last day of the calendar year and retransferred immediately from the borrower to the lender as interest.

When an incorporated metal fabricator makes an interest free (or low interest) loan to its shareholder, the IRS thinks that the shareholder has received a nondeductible dividend in the amount of the foregone interest and the corporation receives a like amount of interest income.

Fortunately, there is a $10,000 de minimis exception for compensation-related and corporate/ shareholder loans that do not have tax avoidance as one of the principal purposes.

If the corporate loan is made to an employee, someone unrelated to a shareholder, the scenario is similar except: • The foregone interest is character-

ized as additional compensation to the employee; • The corporation receives deemed interest in a like amount; and • The corporation can deduct the amount of foregone interest as a compensation expense but may be liable for employment taxes on the additional wages.

When a below-market (interest) rate loan is made between related entities, or a shareholder makes a loan to his or her incorporated business, the adjustments resulting after imputing the interest are: • The lender receives interest income in the amount of the foregone interest; • The borrower has deemed interest expenses in a like amount.

Although this transfer of taxable income between entities may appear to be offsetting, there can be a significant tax impact on the reallocation, depending on the relative tax benefits of the borrower and the lender and the deductibility of the expense deemed paid.

“Controlling” Not a Factor

Jones Ornamental Metals Inc. was a closely-held, incorporated metal fabricating business owned by William and Charles Jones and Steve Smith. In 1994, Jones Ornamental Metals made interest-free loans to

FABRICATOR May-June 2002

William and Charles as well as to entities in which they had interests. All of the loans but one were evidenced by promissory notes.

After the IRS determined imputed interest, the corporation petitioned the U.S. Tax Court, arguing that Section 7872 doesn’t apply to a loan to a shareholder without a controlling interest in the corporation or on a loan to an entity in which no shareholder of the lending corporation personally holds a controlling interest.

The corporation also argued that the IRS cannot make an imputed interest determination against the corporation without making corresponding adjustments to the shareholders’ income taxes.

Unfortunately, the Tax Court felt otherwise. First, the court rebuffed Jones’s assertion that Section 7872 applies only to corporate loans to a controlling shareholder because the law uses the term “shareholder” rather than “shareholders.” The court noted that the law refers to “any” shareholder, thus laying waste to that argument.

The Tax Court also found

it logical to treat such loans as being from the lender (Jones) to the indirect participant (its shareholders) through the business entity. In that way, the whole amount of the loan is attributed to the shareholder and any benefit ultimately received by nonshareholders flows from the shareholder, not from

the lending corporation.

Stock or Loan

When IRS examiners review the loans from shareholders and the common stock accounts of many metal fabricating business they frequently encounter thin capitalization.

DAC

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Under our tax laws, a business bad debt deduction is not available to shareholders who have advanced money to a corporation where those advances were labeled as a contribution to Thin capitalization occurs when there is little or no stock and there is a large loan from the shareholder. A special section of the tax law, Section 385, was enacted specifically to determine whether an interest in corporation should be considered stock or indebtedness.

The IRS’s objective when they encounter thin capitalization is to

convert a portion, if not all, to capital stock. Naturally, this conversion requires an adjustment to the interest expense account because at this point the loans will be considered nonexistent. The interest paid by the corporation that has been disallowed by the IRS examiner will now be classified as a dividend at the shareholder level to the extent of earnings and profits.

The courts have not always supported the IRS’s efforts to classify shareholder loans as stock in thinly capitalized businesses. In the eyes of the courts, equity is considered to be high risk. Money loaned is generally considered to be low risk. Thus, loaning money to one’s corporation limits risk because equity is only allowed a capital loss. But loans can be be classified as ordinary losses.

Loans Gone Bad

Under our tax laws, a business bad debt deduction is not available to shareholders who have advanced money to a corporation where those advances were labeled as a contribution to capital. A noncorpo-

rate taxpayer who incurs a loss arising from his guaranty of a loan is, however, entitled to deduct that loss but only if the guaranty arose out of his trade or business — or in a transaction entered into for profit. If the guaranty was connected with a trade or business, the resulting loss is an ordinary loss for a business bad debt.

If the guaranty was not connected with a true trade or business but was profit inspired, the resulting loss is a short-term capital loss for nonbusiness bad debt. No deduction is available if the guaranty payment does not fall within the above categories, if there is no legal obligation on the taxpayer to make the guaranty payment or if the guaranty was entered into after the debt became worthless.

Since the tax treatment accorded business bad debts and nonbusiness bad debts differs, the taxpayer must show that his dominant motivation in making the payment was business-related in order to obtain the more favorable tax treatment.

Battersby is a tax and financial writer based in Ardmore, PA.

Mac Metals

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Coming Events June 21-23, 2002

Snow Farm, The New England Craft Center has a number of early summer intensive workshops focusing on metalwork. Pat Bennett presents “Welded Sculpture for the Garden;” Thomas Mann presents “From Inspiration to Perspiration,” a class focusing on the development of design from personal to a production system, and Erica Wurtz presents Throwing Into Handbuilding:

Vessels & Sculptural Form. For more info, call (413) 268-3101, or visit: www.snowfarm.com.

June 28-30, 2002

New England School of Metalwork offers a variety of blacksmithing classes this summer. In June, Doug Wilson presents “Get a Grip: Tong Making” for seasoned beginners and up. This workshop responds to the deficiency of commercially made

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SPOTLIGHT June 5-9, 2002

The Artist Blacksmith Association of North America (ABANA) hosts the ABANA 2002 Conference this year at the University of Wisconsin-LaCrosse, LaCrosse, WI. The 2002 Conference features a variety of U.S. and international demonstrators. Exhibitions at the conference include an open ABANA Members’ Show, a juried exhibition of ABANA members’ work, a Chris Ray Retrospective, an exhibition of Cyril Colnik’s work, and more. For more info, call (612) 276-0271, or visit: www. abana.org. tongs. Students can enhance their forging skills while making flat jaw, V-bit, box jaw, and other specialty tongs.

For more info, call (888) 753-7502, or visit: www.newenglandschoolofmetalwork. com.

June 28-July 3, 2002

John Rais leads a workshop at Peters Valley Craft Education Center called “Mixed Metals Forging.” Students can learn how to forge different metals and join them into one piece. The class covers sheet forming, forge-welding, and mechanical joinery such as riveting. Though steel is the main focus for this class, students will also forge bronze, copper, and titanium. For more info, call (973) 948-5200, or visit: www.pvcrafts.org.

September 24-26, 2002

The Powder Coating Institute hosts Powder Coating 2002 at the Indiana Convention Center in downtown Indianapolis, IN. See the latest innovations and products on more than 150,000 square feet of exhibition space. The conference also includes seminars, workshops, technical presentations, and plant tours. For more info, call (513) 624-9988, or visit: www.pcishow.com.

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Join NOMMA Today ...

Membership Category - Check One q $305 - Fabricator q $465 - Nationwide Supplier (Firms selling to fabricators beyond 500 miles of their headquarters) q $355 - Regional Supplier (Firms selling to fabricators within 500 miles of their headquarters) q $280 - Local Supplier (Firms selling to fabricators within 150 miles of their headquarters) q $230 - 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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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..

• 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!

Updated: 5/02

Restoration

Restoring the Reliance Building in Chicago Big D Metalworks, Dallas, TX came up with new ways to fabricate and replace old stair rails and elevator grilles in this 19th century building.

Big D restored the brass trim around the outside bottom two floors of the building.

Initial restoration of the Reliance

Building began in 1890 after owner William Hale hired an architectural firm to make a 16-story tower out of the existing three-story building. The building was originally built as the First National Bank of Chicago. By 1890 it housed residents on its second and third floors and Hale requested they not be disturbed during renovation. A new basement, first floor, and

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K Dahl ADA Handrail Infill Panels Security Fencing Security Cages Sliding Gates Swing Gates In-House Design Dept.

Installation Dept.

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foundation were then constructed along with the additional stories.

Hale’s death in 1891 temporarily interrupted construction. It resumed in 1894, and upon completion in 1895 the Reliance Building achieved historical significance as “the earliest statement of the curtain wall skyscraper.”

Over the next 80 years the Reliance Building was remodeled and renovated to serve a variety of tenants.

But by the 1970’s the building had decayed significantly. It was saved from the wrecking ball due to the persistence of Mayor Richard Daley who had it designated as a Chicago Landmark on July 11, 1975. Nearly 25 years after this designation, plans were developed to resurrect the vacant and decaying building as a boutique hotel with upscale retail and office space.

In 1999 Big D Metalworks, Dallas, TX, was hired to complete the architectural metal restoration portion of the project. First, Big D had to extend the existing staircase, built in 1895, since its lower flight had been removed in one of the many renovations. The firm fabricated ground elevator grilles to match grilles on the upper floors, which had also been previously removed. In addition, Big D restored brass trim around the outside bottom two floors of the building. The deteriorated trim consisted of several different styles, but only a small piece of one of the styles was available for inspection along with what was visible in photographic records of the

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above:

This cast iron stair rail was originally built in 1895. This “before” shot shows the detail involved in renovating its posts, stringers, and risers.

building. To match the original look and stay within budget, Big D recommended using extrusions where possible and sand blasting the materials to match the look of the original brass castings. However, finding an extruder to produce the custom brass materials

for the trim was challenging.

Big D had to devise new techniques to replicate casting methods that were no longer available or were too costly. For example, the original construction of the staircase involved cast iron stringers and a cast iron railing system. Casting stair stringers discontinued decades ago, so the firm developed a technique to cast laminates out of aluminum and attach them to a steel plate. The 40-foot long, 21-foot tall elevator hoistway grill involved production of several custom castings and replication of forge work completed in the 1890’s. But Big D persevered and ended up winning several awards for their hard work on this project. Labor excluding installation: approx. right: Restoring the elevator hoistway grilles involved detailed forgework and the replication of several castings made originally in the 1890’s. Big D had to devise new techniques to accommodate some methods that are no longer available or were too costly for the project’s budget.

Everything metal from aluminum to zinc.

With over 4000 items in stock, we really do have everything from A to... Well, you get the picture.

Same Day Shipping From:

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• Dallas

• Baltimore

ph 800-542-2379 • www.kingmetals.com

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NOMMA Videos & Publications Publication information is also on our web site: www.nomma.org

VIDEOS

New Video Series

Qty.

De­scrip­tion Curved Stair Fabrication (EDU3 - 70 min.) Follow the complete process, from design to fabrication, with emphasis on detailAlmost the Last Word in Finishes (EDU2 - 72 min.) A complete primer on finishes covering everything from patinas to Straight Stair Railings (EDU1 - 60 min.)

Complete rail fabrication process, from mea­ sur­ing 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.), Dem­on­stra­ tion 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, cus­tom 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 so­lu­tions that comply with the 4-inch spac­ing codes.

Security Storm Doors (93B - 70 min.)

Sales techniques, accessories, pros and cons of buy­ing 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.)

Short­cuts, cleaning joints, and much more.

Round-table Problem Solving (92L 105 min. A popular program at conventions.

PUBLICATIONS Price

$45

Qty.

De­scrip­tion

Price

$4

$45 $45

cal or­na­men­tal metal applications.

Consider Metalwork (29C) Brochure con­tains 10 illustrations and explains 5 rea­

$45 $45

$65 for 25

$40

Pkg. of 200

sons why customers should buy met­al­work.

Glossary of Architectural Metal

$6

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

$6

educating ar­chi­tects and employees.

A Guide to the Development of

$2

$45

the Iron­work­er’s Skills (29F) A 9-page guide on fabricating, tools, terms, and stair lay­out.

$2

$45

Driveway Gate Brochure (29H) Four-page full-color, glossy brochure that highlights 15 drive­way gate designs. Ideal

$2

$45

sales tool.

Guideline 1: Joint Finishes (29I)

$2

$45

Vol­un­tary guide for weld joint finishes.

Includes tubing, piping, and solid bar.

Contains 16 photos.

$5

$45

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

$5

$45 $45 $45

To­tal

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

Total

$35 for 25 $40 for 25 $35 for 25 $35 for 25

Prices include shipping.

Deduct 20% If NOMMA Mem­ber

Grand Total

Allow 4-6 weeks delivery.

Additional chrg. for express.

Name____________________________________________ Company ________________________________________

$45

(No P.O. Box please)

$45

City/State/Zip______________________________________

$45 $45 $45 $45

Updated: 3/02

To­tal

Street Address____________________________________

Payment: q Check q AmEx q VISA q Mastercard q Discover Card No. _______________________________________ Exp. ____/____ Signature _____________________________Ph:____________________ Cardholder’s Name ___________________________________________

Mail, phone, or fax order to: NOMMA, 532 Forest Pkwy., Suite A, Forest Park, GA 30297. (404) 363Payment in U.S. dollars drawn on U.S. bank or money order. • Prepayment only.

NOMMA Network News

By Rachel Squires

NOMMA’s Latest Video Jack Klahm makes fabricating a curved stair rail look easy. He’s the host of NOMMA’s latest Education Video Series Curved Stair Rail Fabrication.

On the job site and in his own studio in Ocala, FL, Klahm takes you through each step, focusing to a large extent on measuring and making templates. From listening to and watching Klahm, viewers understand the importance of pre-bending, modifying the design to fit the logistics of the particular staircase, building an accurate and sturdy frame, and creating and bending the design elements to fit within the frame and helix of the stair.

After establishing the design (in this case the homeowners chose a staircase out of a magazine), Klahm goes to the job site to make a template of the stringer. He fabricates the first bottom flat bar of the rail to fit the exact radius and pitch of the stringer by using a piece of 1/8 inch luen, a portable drill, and a marker. Then he goes back to the shop and pre-bends the flat bar to the proper radius and helix and then he goes back to the job site again to fine tune the flat bar so that it rests perfectly flat along the stringer. Klahm offers several options for obtaining accurate curves and demonstrates how to use different equipment, like a pyramid roller and bending forks.

The entire video is approximately 70 minutes long. While it focuses on measuring and fabricating, Klahm does address finishing and installing as well. Whether you want to see how another shop does it or you’re ready to learn from scratch, this video offers a wealth of instructional information, much of which can be gained by simply watching Klahm’s detailed demonstration.

To order Curved Stair Rail Fabrication, see page 82. Or, call the NOMMA office at (404) 363-4009, ext.

20. You can also order from the web: www.nomma.org.

In the video Klahm anneals an aluminum rod and then hammers it (as shown here) and shapes it to fit the stair’s design.

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News Roundup

By Todd Daniel

OSHA Unveils New and Final Ergonomics Plan At long last, OSHA unveiled its comprehensive ergonomics plan in early April. The new program is designed to dramatically reduce ergonomic injuries through a combination of industry-targeted guidelines, tough enforcement measures, workplace outreach, advanced research, and dedicated efforts to protect immigrant workers.

“Our goal is to help workers by reducing ergonomic injuries in the shortest possible time frame,” said Labor Secretary Elaine L. Chao. “This plan is a major improvement over the rejected old rule because it will prevent ergonomics injuries before they occur and reach a much larger number of at-risk workers.”

Occupational Safety and

Health Administrator John Henshaw said his agency will immediately begin work on developing industry and task-specific guidelines to reduce and prevent ergonomic injuries, often called musculoskeletal disorders (MSDs), that occur in the workplace.

OSHA expects to begin releasing guidelines ready for application in selected industries this year. OSHA will also encourage other businesses and industries to immediately develop additional guidelines of their own.

The Department’s ergonomics enforcement plan will crack down on bad actors by coordinating inspections with a legal strategy designed for successful prosecution. The Department will place special emphasis on

industries with the sorts of serious ergonomics problems that OSHA and DOL attorneys have successfully addressed in the past. For the first time, OSHA will have an enforcement plan designed from the start to target prosecutable ergonomic violations.

Also for the first time, inspections will be coordinated with a legal strategy developed by DOL attorneys that is based on prior successful ergonomics cases and is designed to maximize

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successful prosecutions. And, OSHA will have special ergonomics inspection teams that will, from the earliest stages, work closely with DOL attorneys and experts to successfully bring prosecutions under the General Duty clause.

The new ergonomics plan also calls for compliance assistance tools to help workplaces reduce and prevent ergonomic injuries. OSHA will provide specialized training and information on guidelines and the implementation of successful ergonomics programs. It will also administer targeted training grants, develop compliance assistance tools, forge partnerships, and create a recognition program to highlight successful ergonomics injury reduction efforts.

As part of the Department of Labor’s cross-agency commitment to protecting immigrant workers, especially those with limited English proficiency, the new ergonomics plan includes a specialized focus to help Hispanic and other immigrant workers, many of whom work in industries with high ergonomic hazard rates.

The plan also includes the announcement of a national advisory committee; part of their task will be to advise OSHA on research gaps.

In concert with the National Institute for Occupational Safety and Health, OSHA will stimulate and encourage needed research in this area.

“Bureau of Labor Statistics’ data show that musculoskeletal disorders are already on the decline.

This plan is designed to accelerate that decline as quickly as possible,” said OSHA Administrator John Henshaw.

“Thousands of employers are already working to reduce ergonomic risks without government mandates. We want to work with them to continuously improve workplace safety and health. We will go after the bad actors who refuse to take care of their workers.”

Last year, Congress rejected the previous Clinton-era recommendations shortly after President Bush took office. The former rule was developed over a span of eight years, but was denounced by business groups as being excessively burdensome and complicated. Over the course of the

last year, the Dept. of Labor conducted three major public forums around the country and met with scores of stakeholders, collecting hundreds of sets of written comments and taking testimony from 100 speakers, including organized labor, workers, medical experts, and businesses.

Bush Administration Supports Filing of Protests With Federal Agencies

Contractors may exercise their right to file protests or claims

with federal agencies without fear of retribution as a result of a recent directive issued by the Office of Federal Procurement Policy.

The Office has told federal agencies that they cannot penalize contractors for exercising their right to file protests or claims when making past performance evaluations or source selection decisions. Office of Federal Procurement Policy Administrator Angela Styles said in a memo to agency senior procurement executives that agencies cannot “downgrade” contractors in past performance evalu-

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ations for protests or claims the contractors have filed or for choosing not to use alternative dispute resolution.

“Contractors should have the right to file grievances and claims with federal agencies without fear of being penalized for doing so. Contractors should not be prevented from working on federal projects simply because they have exercised their legal rights,” said Kirk Pickerel, president and CEO of Associated Builders & Contractors.

U.S. Chamber Supports Relaxed Immigration Rules

In mid-April, the United States Chamber of Commerce joined labor groups and immigration advocates and urged the Bush administration and Congress to push ahead on comprehensive reform, stalled since the Sept. 11 attacks, to expand legal avenues for temporary work and residency that will combat U.S. worker shortages and safeguard the economy.

“There are essential jobs in the United States that are going unfilled because we don’t have enough workers to fill them,” said

U.S. Chamber President and CEO Thomas Donohue. “We need to give immigrants a legal opportunity to take on those jobs. Only comprehensive reform, not stopgap measures, will allow employers to fill these jobs.”

By 2010, the U.S. economy will produce an estimated 168 million jobs, to be filled by just 158 million American workers, as the median age of an aging U.S. workforce reaches 40. The labor-shortage problem will only escalate as the baby boomers start to retire. Construction, hotels, restaurants and other sectors that rely heavily on unskilled and semi-skilled labor — or “essential workers” — will be particularly hard hit by this demo-

graphic trend.

“The current ups and downs in unemployment do not remove the long-term threat to employers from a shrinking U.S. labor pool,” said Donohue. “For our economic security, our leaders must end the stalemate and expand legal immigration.”

A leader of the Essential Worker Immigration Coalition, the Chamber supports broad-based systemic reforms that would expand temporary visa programs to include longer-term employment, revamp the green-card program to help employers hire valuable foreign workers permanently, and create legalization avenues for those already living and working in the United States.

“The reality is, millions of undocumented workers are here who fill an economic need, and we can’t afford to send them home,” said Donohue. “The sooner we fold them into an expanded immigration system the better for all concerned.”

The U.S. Chamber of Commerce is the world’s largest business federation, representing more than

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to the health, safety, and welfare of the public,” said Barbara Nugent, FASID, ASID President. “This law will give Kentucky consumers an identifiable choice when contracting for interior design services. Consumers will now know if an individual meets certain standards — standards that will benefit the consumer.”

three million businesses and organizations of every size, sector, and region.

Kentucky To Legally Recognize Interior Design Professionals

At a recent ceremony in the Kentucky state capitol, Gov. Paul E. Patton signed into law a new interior design title act. With his signature, Kentucky becomes the 23rd U.S. jurisdiction to legally recognize interior design. Eight Canadian provinces also legally recognize the profession.

The new law is a result of the efforts of the Kentucky Interior Design Legislative Organization (KIDLO).

Phyllis Moore, chair of American Society of Interior Designers’ (ASID’s) Legislative Advisory Council, stated, “This law will raise the accountability and professionalism of interior designers and will directly benefit Kentucky consumers of design services. Interior designers must be knowledgeable about many issues, from flammability ratings of fabrics and finishes, to building codes and how to comply

with the Americans with Disabilities Act. It was imperative that Kentucky join the 22 other U.S. jurisdictions which register interior designers.”

The law requires registrants meet the education and experience requirements set by the National Council for Interior Design Qualification (NCIDQ) and pass the NCIDQ exam. Registrants who wish to renew their certification will also be required to complete 12 hours of continuing education in the 12-month period immediately preceding the expiration date of their certificates.

“We are pleased to add Kentucky to the growing list of jurisdictions that recognize the benefit of legally recognizing interior designers

ASA Challenges Florida Court Ruling on ‘Duty to Defend’

On March 7, the American Subcontractors Association (ASA) filed an amicus curiae, or “friend of the court,” brief supporting subcontractors against a court ruling forcing them to pay a general contractor’s defense costs, even though the court had already rejected the basis for the general contractor’s claim against them.

ASA, invoking its Subcontractors Legal Defense Fund (SLDF), challenged a court’s ruling on indemnity provisions in contracts. The court ruled that, even when indemnification of another party cannot be enforced, the “duty to

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defend” that party, spelled out in an indemnity clause, can.

The case before the Florida Supreme court stems from a $9 million settlement agreement between the construction team and the occupants of a building that was deemed unsafe to occupy. After the settlement, the general contractor sued the subcontractors for the legal fees it incurred, arguing that the indemnity clause within the contract stipulated a “duty to defend” the general contractor. The trial court held that the indemnity in the subcontract agreements was prohibited by Florida’s anti-indemnity statute, but that the subcontractors nevertheless owed defense costs.

Based on each of the subcontractors’ individual contributions toward the

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settlement, the trial judge held each of the subcontractors liable for a pro rata portion of the general contractor’s costs. The subcontractors are appealing the ruling.

Florida’s 2nd District Court of Appeals is considering the appeal and ASA’s arguments in the case. ASA’s brief, prepared by Don Gregory of ASA General Counsel firm Kegler, Brown, Hill & Ritter, Columbus, OH, argues that a subcontractor should not be forced to pay defense costs when the underlying indemnity obligation is void: “The Lower Court erred in finding the subcontractors had an independent duty to defend Barton-Malow after ruling the indemnification clause-which contained the language regarding defense fees and costs-unenforceable and invalid pursuant to Florida’s antiindemnity statute. Such a ruling allows through the back door what Florida’s legislature intended to foreclose from the front door: risk-shifting and costly liability for non-negligent parties.”

The brief cites numerous cases holding that the obligation to pay defense

costs can exist only when there is a valid obligation to indemnify.

ASA’s Subcontractors Legal Defense Fund supports ASA’s critical legal activities to protect the interests of all subcontractors, and is funded solely by contributions. SLDF funds are invested to defend subcontractors in precedent-setting cases. For example, ASA successfully challenged a legal argument that, if accepted, would have disallowed delay damages in New York state. ASA also participated as amicus curiae in the landmark California and New York cases abolishing contingent payment in those states.

For more information about the SLDF, log on to the ASA web site www. asaonline.com.

Since its founding in 1966, ASA has provided its members with advocacy, leadership, education and networking. ASA’s vision is to be the united voice dedicated to improving the business environment in the construction industry. The ideals and beliefs of ASA are ethical and equitable business practices, professionalism, a safe and healthy work environment,

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From The Bookshelf

By Rachel Squires

Three Great Ironworking Books Author Dona Z. Meilach has more than 50 titles in print, on topics such as cooking, macramé, jewelry making, metalwork, woodwork, and design.

Three of her recently published metalwork books feature some great design ideas for members of the miscellaneous metals industry.

In 1977, Meilach published Decorative And Sculptural Ironwork, which became an important survey of forged ironwork in the U.S. at that time. The book was reprinted in 1999

by Schiffer Publishing Ltd. as a 7fiby 10-inch book with 70 new color plates. The black and white photos and text of the original 310 pages remain the same. The book focuses on technique, and images feature smallersized blacksmithing products.

The Contemporary Blacksmith is an 81/2- by 11-inch design book filled with 542 photos in 256 pages. Published by Schiffer in 2000, the book is less instructional than Meilach’s previous work and appeals more to the art community. Meilach collected over 500 works by nearly 200 artist-craftsmen from 16 countries to illustrate the unprecedented activity in modern ironwork.

Architectural Ironwork was also published by Schiffer in 2001.

The 240-page book is illustrated with 375 color photographs featuring largescale, functional architectural elements as opposed to purely ornamental sculptures or decorative accents.

To order, contact Schiffer Publishing at (610) 593-1777, or visit: www.schifferbooks.com. The books also appear on NOMMA’s web site.

Members can go to: www.nomma.org.

Click on the Members Only section and then click the On-Line Literature Resource Guide.

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New Products & Services • FabCad.USA , Petersburg, VA, announces the release of its new automated railing and gate drawing program AutoRail II. By inserting dimensions in a dialogue box, AutoRail II automatically draws railings and gates with a bill of materials. Only basic knowledge of CAD is needed to run this program.

AutoRail II is a new addition to FabCad’s popular Starter Package. New users can create drawings with very little start up time. The program is designed to run on AutoCad® and AutoCad® LT and with prior versions of FabCad’s software packages. For more info, call 800-255-9032 or visit: www.fabcad.com.

oil bath, belt-drive general pump; trigger gun with variable pressure wand for remote operation of the spray and low-pressure application of the soap, and more. Both models feature an oil-fired, vertical burner configuration with a five-year warranty on the cold-rolled, leak-free heating coil. For more info, call (800) 547-8672, ext. 175.

• D&D Technologies’ self-closing hinges are now 35 percent stronger. The new Mark 2 version of Tru-Close Model TCA1 Hinge features an improved design and added strength. Specifically, the hinge has new strengthening ribs, increased webbing and a larger bearing band; improved polymers with more fiberglass reinforcement; 35 percent increased point load (maximum weight) rating to

• Landa introduces a new line of hot water pressure washers with a vertical burner design and high cleaning power.

The electric-powered vertical hot water super-size line (VHWS) has two basic models with three electrical configurations for each. The VHWS pressure washers include the following features: quick-coil access for easy removal of the coil without having to remove the burner assembly; triplex,

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440 pounds, and pre-formed holes in the optional legs. For more info, call (800) 716-0888, or visit: www.ddtechusa. com.

• Liberty Brass Turning Co. Inc., Long Island City, NY, has a new line of solid brass square checkrings in stock. Use them to top off square tubing, effect a transition from square tubes to round, or to just finish off a square end. Liberty’s square checkrings have solid thick walls. They come in a polished but non-lacquered finish, fi inch through 1fi inch sizes, increments in slip 1/8 pipe through and ⁄ pipe through configurations. The parts are cold formed with check size tolerances .012 inches to .020 inches larger than the nominal sizes. They are 1/8 inch long and the outside diameters are 1 /8 inch larger than the nominal tube size. The depth of the square hole is 1/16 inch +/- 1/64 inch. For more info, call (800) 345-5939, or visit: www.libertybrass.com.

• DecorCable Innovations, Chicago, IL, announces the availability of the newly expanded JAKOB Inox Line of Vertical Cable Railing Systems.

Designed to meet building codes where horizontally strung cable is not permissible,

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JAKOB Inox allows the architect or designer to incorporate the look of stainless steel cable while remaining compliant to local codes. The system offers the simplicity of ordering pre-assembled components in lengths ranging from 20 inches to 47 inches with the choice of 12 mounting options.

It’s an inexpensive alternative to specifying custom railing products and delivers in 14 to 17 days. For more info, call (800) 444-6271, or visit: www.decorcable.com.

• Kee Industrial Products, Buffalo, NY, introduces new Kwik Kit, quickassembly safety railings. Kwik Kit provides safety barriers around machinery and equipment or in other areas where personnel access should be restricted because of safety concerns. Kwik Kit exceeds OSHA and BOCA standards and features 1.9 inch OD pipe, which is powder coated safety yellow. Assembling Kwik Kit requires only a hex key to tighten the large, set screws on the aluminum or galvanized cast iron/steel pipe fittings. No welding, drilling, or threading required, and kits may be secured using bolts or chemical anchors attached to base fittings. For more info, call (800) 851-5181, or visit: www.keeklamp.com.

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New Members

Welcome 28 New NOMMA Members

As of 2/22/02 *Denotes returning mem-

Accent Fence Inc. Egg Harbor City, NJ Greg Carnesale Fabricator

Balsm Corp.

West Branch, MI Mark Hickey Fabricator

FAB Shop Bridgeview, IL Thomas W. Gardner Fabricator

Iron Masters Oklahoma City, OK Robert Bryan Fabricator

ACME Forge* Houston, TX John Forseman Fabricator

Berlin Steel Construction Co. Berlin, CT Ray Baran Fabricator

Frankie’s Welding & Ornamental Iron* Sherman, TX Frankie L. Grant Fabricator

Jamieson Mfg. Co. Dallas, TX Bill Scudder Nationwide Supplier

Blackies Welding Works Inc. Corpus Christi, TX Solon G. Slosson Fabricator

Geo. Bezdan Sales Ltd. Burnaby, BC Canada Margaret Bezdan Nationwide Supplier

Castex Irvington, NJ Michael Nestico Fabricator

Ron Grasso Welding Festus, MO Ron Grasso Fabricator

Euro Forgings Inc. Toronto, ON Canada Henry Mercieca Nationwide Supplier

Greer Iron Works* Lubbock, TX Randy Jones Fabricator

Arte de Arquitectura de Mexico Dallas, TX Roberto Diaz Fabricator Auciello Iron Works Inc.* Hudson, MA Michael Auciello Fabricator Augusta Technical College Augusta, GA Tommy Lyles Affiliate

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K&R Specialties Houston, TX Steve Knight Fabricator Mid-Carolina Steel Co. Ltd. Columbia, SC Gayle Godwin Local Supplier Middle Fork Metal Works Fayetteville, AR Michele James Fabricator

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Minnkota Metalworks Inc. Hawley, MN Brad Halverson Fabricator

PMT West Palm Beach, FL Warren Sheffy Local Supplier

New Val Metal Works Hackensack, NJ David B. Gore Fabricator

Premier Powder Coating Inc. Houston, TX Henry Kim Nationwide Supplier

Old New Orleans Iron Forge Jefferson, LA James D. Estrade Local Supplier

Presidian Presidio, TX William D. Nugent Fabricator

Oscar’s Custom Iron Works San Antonio, TX Norma Hernandez Fabricator

Rocky Mountain Forge Grand Junction, CO Barbara J. Phefer Fabricator

Payne Metal Works Inc. Ennis, TX John F. Payne Fabricator

RV & Son Welding Inc. Kensington, CT Richard Vaillancourt Fabricator

Pine Knot Job Corps Pine Knot, KY Earl Brooks Affiliate

Spectrum Glass Inc. Englewood, NJ Dom Sorrentino Fabricator

Ol’ Joint

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FABRICATOR May-June 2002

INDUSTRY SHAKERS The following industry shakers were elected as directors of the National Ornamental & Miscellaneous Metals Association (NOMMA) at NOMMA’s 44th annual convention held in Galveston, TX on March 5-9, 2002.

Breck Nelson

Breck Nelson of Kelley Ornamental Iron LLC, Peoria, IL, has been elected as a fabricator director.

Nelson is a regular presenter at NOMMA conventions and is also the president of the association’s Chicago Area Chapter. Kelley Ornamental Iron has been a NOMMA member since 1997.

Rod Stodtmeister

Rod Stodtmeister of Stodtmeister Iron, Sparks, NV, has been elected as a fabricator director. Stodtmeister is an active participant at NOMMA conventions. Stodtmeister Iron has been a NOMMA member since 1984.

David Donnell

David Donnell of Eagle Bending Machines Inc., Stapleton, AL, has been elected as a supplier director. Donnell is an active member of NOMMA and a regular exhibitor at NOMMA trade shows. Eagle Bending Machines provides fabricating machinery for the industry and has been a NOMMA member since 1995.

E.G. Heller

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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 American Stair Corp. 800-872-7824 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 Arteferro Miami LLC 305-836-9232 Artezzi 800-718-6661 AST Waterjet Inc. 800-532-0383 Automatic Gate Supply Co. 800-423-3090 Avantage Orn. Fence Supply 800-231-4586 Aztec Castings Inc. 800-631-0018 Bayou Steel Corp. 800-535-7692 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 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 Colonial Castings Inc. 305-688-8901 Colorado Waterjet Co. 970-532-5404 COMEQ Inc. 410-933-8500 Crescent City Iron Supply Inc. 800-535-9842 Cross River Metals 210-824-1750 D & D Technologies (USA) Inc. 714-430-1100 D.J.A. Imports Ltd., dba Pietrocola & Sons 800-933-5993 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 Doval Industries 800-237-0335 Duff-Norton 704-588-0510 Eagle Bending Machines Inc. 251-937-0947 Eagle Iron Supply Inc. 972-289-7688 Eastern Metal Supply 800-343-8154

Company Phone Eastern Ornamental Supply Inc. 800-590-7111 EDF Equipment Sales Inc. 407-351-7017 Elegant Aluminum Products Inc. 810-293-1020 Elite Access Systems Inc. 949-582-1700 Emerdex Stainless SteelInc. 626-282-0099 Encon Electronics 800-782-5598 EURO-FER SRL 011-39-044 5440033 Euro Forgings Inc. 905-832-4177 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 FSB USA LLC 407-351-7017 The G-S Co. 410-284-9549 Geo. Bezdan Sales Ltd. 800-663-6356 Glaser USA 847-782-5880 GTO Inc. 800-543-4283 Hartford Standard Stampings & Plating Co. 270-298-3227 E.G. Heller’s Son Inc. 818-881-0900 Hewi Inc. 717-293-1313 House of Forgings 281-443-4848 Impressive Reflections 503-666-5827 Indiana Gratings Inc. 800-634-1988 INDITAL U.S.A. 800-772-4706 Intercorp Inc. 414-383-2021 Interstate Mfg. Associates Inc. 603-863-4855 Iron Access Inc. 713-864-1229 The Iron Shop 800-523-7427 Italfer Architectural Iron Inc. 905-455-6100 ITW Ransburg Electostatic Systems 800-909-6886 Jamieson Mfg. Co. 214-339-8384 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 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 Nitek Inc. 972-447-9628

For A Detailed Listing of NOMMA Supplier Members, Please Visit Our Web Site: www.nomma.org 94

FABRICATOR May-June 2002

NOMMA’s Nationwide Suppliers Company Phone

Bold denotes new members.

Company Phone

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 Polished Metals Ltd. Inc. 800-526-7051 PPG Industries 440-572-2800 Premier Powder Coating Inc. 713-453-6282 Production Machinery Inc. 410-574-2110 R & B Wagner Inc. 800-786-2111 Regency Railing 972-407-9408 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 866-744-666 Soheil Mosun Limited 416-243-1600 Sparky Abrasives Co. 800-328-4560 Stainless Steel Stock Exchange Inc. 908-206-9008 Stairways Inc. 800-231-0793 Steel Masters Inc. 602-243-5245 Steel Supply Inc. 713-991-7600 Steptoe & Wife 800-461-0060 Sumter Coatings Inc. 888-471-3400 Sunbelt Scenic Studios 480-598-0181 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 Torch-Made 800-590-7804 Triebenbacher 800-522-4766 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 Wrought Iron Handicrafts Inc. 800-456-7738 011-90-258-269-1664 Yavuz Ferforje Ve Demir Tic San *Join NOMMA! 404-363-4009

For A Detailed Listing of NOMMA Supplier Members, Please Visit Our Web Site: www.nomma.org FABRICATOR May-June 2002

95

Business Briefs • As of April 8, 2002 Encon Electronics will no longer technically support or sell any parts for Stanley, Linear, or Sentex gate operators manufactured before March 1, 2000. These machines are not UL 325 compliant and are a potential liability. However, Encon will continue to support any machines manufactured after March 1, 2000. For more info, call (800) 782-5598.

Web Site

• A gate by Architectural Iron Designs, Jersey City, NJ, hits the silver screen. The Oscar winning movie “A Beautiful Mind” prominently features a gate made by the NOMMA Nationwide Supplier member. It appears several times and Russell Crowe and Jennifer Connelly pass through it. “I had no idea it was for such a blockbuster movie,” said Architectural Iron Designs President Jay Shah. “We’re proud to have participated.”

www.wbdg.org The Whole Building Design Group provides a web site with upto-date information on a wide range of building-related guidance, criteria, and technology from a “whole buildings” perspective. The site is divided into two sections: design objectives and building types and includes summaries on particular design technique and technology topics. Visit: www.wbdg.org.

• The Lincoln Electric Co. offers a

Antech

limited time mail-in-rebate on nine of its commercial and industrial welders, including MIG and TIG power sources and engine-driven welder generators.

Customers purchasing select models between March 15, 2002 and June 15, 2002 must complete a rebate, including welder model number and product serial number. Mail form and a copy of the original receipt to: Rebate Offer, The Lincoln Electric Co., 22801 St. Clair Ave., Cleveland, OH 441141199. Requests must be postmarked no later than June 15, 2002. For more info, call (216) 481-8100, or visit: www.lincolnelectric.com.

• The Invention Submission Corp.

(ISC) announces the patenting of a safer design for a grinding wheel.

Specially-designed openings provide users with a clear view. The Window Wheel also cools the ground object.

It operates similarly to traditional grinding wheels and can be mounted on a standard arbor. ISC is submitting the invention to companies for review.

If substantial interest is expressed the company will negotiate for a sale or royalties for the inventor. For more info, call (800) 622-9855, or visit: www.isc-online.com.

• The Fabricators & Manufacturers Association International (FMA) announces the availability of a new training product, Metal Stamping 101, a certificate course on CD-ROM that focuses on stamping fundamentals. The fully narrated instructional CD-ROM incorporates video, computer-generated 3-D animations, text support, and still graphics. It can be used for a comprehensive group presentation or as a stand-alone, user-friendly, selflearning tool. For more info, call (815) 399-8775, or visit: www.fmametalfab. org.

Send business briefs to Fabricator, Attn: Rachel Squires, 532 Forest Pkwy, Forest Park, GA 30297, or e-mail: rachel@nomma.org.

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FABRICATOR May-June 2002

Tips, Tricks & Jigs

The Measuring Tool To facilitate fabrication of this custom railing, a wooden mock-up was produced on site. The mock-up was fabricated from pine and assembled using a hot glue gun. During production of this frame at the job site, we noticed a slight difference in the roof pitch that was not visible to the naked eye. If the railing was produced from measurements alone, this might have been missed.

A simple tool helped to insure accuracy of the finished product and made fabrication a one-man job.

A height tool fabricated from 6 by 6 by .5 angle with a 1 inch by .24 strap welded in place was marked in 1-inch increments. The tool insured a true height along the top rail. A few spacer blocks insured a true height along

the bottom rail. After attaching the wooden mock-up with spring clamps, we had the exact sized tool to use in fabricating the final rail.

Once at the shop, the measuring tool can be set up on a workbench or floor and leveled (note the opening for the gate). This provides a fullscale measurement ready for use. One person can now clamp in place the ironwork and weld without any further measurements because the framework is taken directly off the mock-up.

This provides a final product that is guaranteed to fit. As you can see from the photos, the finished product fit correctly the first time without any modifications.

A “thank you� to Jay Holeman of Mountain Iron Fabrications, Pilot Mountain, NC.

American Spiral

During routine measuring at the job site, it was discovered that there was a slight difference in roof pitch, which would have created a gap where the railing connects to the wall. A simple measuring tool allowed the fabricator to determine this difference and make the proper correction.

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FABRICATOR May-June 2002

97

left: The measuring tool is made of 6 by 6 by .5 angle with a 1 inch by .20 strap welded in place, which is marked in 1-inch increments.

top: Simple railing adjustments compensated for the slightly differing pitch in roof sides. left: A handy jig helps to insure accurate pickets.

DECO ORNAMENTAL IRON SUPPLY, INC.

Mittler

401 S. COUNTY LINE RD. FRANKLIN PARK, IL 60131 PHONE: (630) 350-0900 Fax: (630) 350-0902

NATIONAL WHOLESALE DISTRIBUTORS POST, BALUSTERS, LEAVES, ROSETTES HAMMERED BAR AND TUBING HINGES MACHINERY CUSTOM PUNCHED CHANNEL - FLAT BAR CUSTOM TWIST BAR - UP TO 1” ROPE TWIST BAR

CALL TODAY FOR YOUR FREE CATALOG! US DISTRIBUTORS FOR

CML MACHINERY, INC. ONTARIO, CANADA

HYDRAULIC BENDING MACHINES HYDRAULIC PRESS BRAKES BAND AND CUT OFF SAWS CALL FOR DETAILS

IN CANADA Fill in 35 on Reader Service Card

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(905) 669-5774

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FABRICATOR May-June 2002

NOMMA Chapters

By Rachel Squires

Don’t Just Talk About It, Start a Chapter How Chicago Area NOMMA Members Got Their Chapter Started and Where It’s Headed Starting a new chapter doesn’t take a lot of time. It does take a lot of people talking about it until they finally decide to hold the first meeting, says Breck Nelson of Kelley Ornamental Iron, Peoria, IL. He was recently elected president of NOMMA’s newest chapter, the Chicago Area Chapter. About two years ago NOMMA members in his area decided to start a chapter, and they contacted NOMMA’s Executive Director Barbara Cook. After members responded positively to a mailing soliciting their level of interest, an initial meeting was scheduled. Crescent City Iron Supply in Westchester, IL, hosted the first meeting this past December. According to Nelson, the success of the chapter mushroomed from there.

For the future, the Chicago Area Chapter plans to hold meetings at member shops, build a forum for sharing knowledge to increase the general level of professionalism in their area, and focus on education. Nelson feels strongly that this formula did much for Florida. He says, “The idea to start the Chicago Area Chapter came from the success of Florida’s chapter and what it’s done for individuals and fabricators in that state. It’s improved the whole industry down there.”

To anyone interested in starting a NOMMA chapter, Nelson suggests getting a list of members in the state. Start contacting them and gather together people who show interest.

“Once you get the first meeting, the rest will take care of itself,” says Nelson. “Take advantage of the resources the NOMMA office provides.”

The chapter’s next meeting is Saturday, June 8, 2002 at R & B Wagner’s new facility. Tours and demonstrations are planned in addition to the chapter’s regular business meting and

a continental breakfast. The Wagner Companies’ new location is 10600 West Brown Deer Road, Milwaukee, WI 53224; ph: (800) 786-2111 or (414) 214-0444; fax: 414-214-0450.

For more info on the Chicago Area Chapter’s upcoming meeting, contact Heidi Bischmann at the Wagner Companies (800) 786-2111, or Chapter President Breck Nelson, (309) 697-9870.

Breck Nelson is the Chicago Area Chapter’s first president.

What’s Going On In Florida?

The Florida Chapter held their last meeting on Saturday, May 4, 2002 in Kissimmee, FL. Attendees enjoyed a tour of Windsor Metal Finishing Inc.

Future meeting dates include: • August 24, 2002 • November 23, 2002 Florida Aluminum & Steel Jerry Grice Welding Tampa, FL Tallahassee, FL (800) 741-6010 (850) 878-1977 For more info, call Chapter President Bob Ponsler Wonderland Products Jacksonville, FL (904) 786-0144

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Working Smarter — Not Harder

Metal Words to Live By Senior writer Dr. John Cochran shares some anecdotes from his years in the ornamental and miscellaneous metals industry.

By John Cochran, PhD

No matter how many coats of paint a metal surface has you can strike an arc on it, unless you intend to.

The gate design will always call for the hinge to be on the same side as the customer’s Rottweiler.

You can think up many ingenious ways to stab a new electrode into the stinger when your gloves are rain soaked.

No one should ever be too proud to use a grinder.

When you’ve just about worn the grinding wheel down to the nub, you can always grind just a little bit more.

Welding overhead is one thing, welding upside down is another.

There’s no way to turn your head to get away from the stench of smoldering hair when it was your mustache that caught fire.

A four-cylinder Continental Red Seal engine sounds better than any opera ever written.

No matter how amazing a new exotic electrode might be, a standard 6010 or 6011 will always be the best.

The more effort you put into training your helpers, the

CML

better competition they’ll be someday.

Subs will be available every single time you don’t need them.

How you treat the customer should not be based solely on the business at hand, but on the potential to come.

Intelligent workers generally always wear safety glasses.

The hole your rod blows in light steel always occurs a half second before you finish the weld.

The weight of an anvil is proportional to your potential for a hernia.

You almost always smell your clothes burning before you feel the heat.

If the paint job on an ornamental scroll has no missed spots, you can bet it was dipped.

Even when you measure twice and cut once, you sometimes still end up cussing three times.

The only thing more slippery than wet steel is the bottom of your boots on wet steel.

A simple angle iron cut can be made wrong an infinite number of ways.

If the digging was easy, your post hole will probably be in the wrong place.

If the digging was very difficult, your post hole will definitely be in the wrong place.

You can tell a person’s gambling nature by whether or not he risks twisting the masonry fastener that last quarter turn.

Accountability seldom matches accounts receivable.

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FABRICATOR May-June 2002

The best foremen are people who know how to do the tough work themselves, but seldom have to.

One of life’s little pleasures is putting on a new pair of leather welding gloves.

It’s difficult for most welders to describe things without drawing soapstone sketches.

The only thing you forgot to put on the truck will be the first thing you’ll need.

Any welder who tells you he’s never flipped a hot rod down his boot might lie to you about other things as well.

The whistle from a plugged up oxyacetylene cutting tip is one of the most annoying sounds on earth.

White paint should be illegal.

Rolling up the welding leads after a productive day is a satisfaction that most business executives can’t even imagine.

IGD

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Advertiser Index

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

Pg.

R.S. No.

41 Acme Metal Spinning 84 97 American Spiral Corp.

61 50 Antech Corp.

115 96 Antech Corp.

115 11 Architectural Iron Designs Inc. 103 10 Architectural Iron Designs Inc. 103 29 Arch. Products by Outwater 105 33 Artezzi 27 102 ABANA 142 66 ARTMETAL 155 67 Atlas Metal Sales 25 32 Automatic Gate Supply Co. 139 75 Julius Blum & Co. Inc. 20 35 J.G. Braun Co. 40 24 Byan Systems Inc. 94 80 California Wire Products Corp.

154 54 Carell Corp.

137 86 Classic Iron Supply 26 59 The Cleveland Steel Tool Co. 132 34 The Cleveland Steel Tool Co. 132 100 CML USA Inc. 110 99 Colorado Waterjet Co. 107 83 COMEQ Inc. 10 70 Crescent City Iron Supply Inc. 41 3 D & D Technologies (USA) Inc. 48 75 DAC Industries Inc. 55 98 DECO Ornamental Iron Supply 147 63 DecorativeIron.com 1 19 D.J.A Imports Ltd. 118 60 DKS, DoorKing Systems 19 62 Duff-Norton 77 37 Eagle Bending Machines Inc. 120 43 Elite Access Systems Inc. 4

Pg. 73 13 164 45 5 46 38 16 28 14 36 71 93 102 88 51 7 101 57 114 104 84 28 9 75 61 46 44 80 159 91 81 136 84 52 53 21

R.S. No.

Pg.

Encon Electronics 57 Euroquip Metal Machinery FAAC International 49 FABCAD.USA 87 FSB USA Inc. 44 EntryProducts.com / A & D Glaser USA 123 The G-S Co. 82 GTO Inc. 56 Hartford Standard 106 Hawke Industries 16 E.G. Heller’s Sons Inc.

52

Hossfeld Mfg. Co. 33 House of Forgings 130 INDITAL U.S.A. 111 International Gate Devices 24 Interstate Mfg. Associates Inc. The Iron Shop 11 Ironcad Inc. 162 Ironwood LLC 70 Jansen Ornamental Supply Co. Jax Chemical Co. 23 Jesco Industries Inc. Justin R.P.G. Corp. 108 K Dahl Glass Studios

93

Kayne & Son 81 King Architectural Metals Laser Precision Cutting Lawler Foundry Corp.

Lawler Foundry Corp.

Lawrence Metal Products

99 47 47 39

2 21 56 83 92 76 73 20 98 55 92 54 47 91 79 87 93 78 49 58 62 31 85 67 27 39 87 50 163 72 15 17 78 103 77 23 88

R.S. No. Lewis Brass & Copper Co. Inc. Liberty Brass Turning Co. Inc. 38 Liberty Ornamental Products 22 Lindblade Metal Works 63 Mac Metals Inc. 71 Majka Railing 53 Marks U.S.A. 34 Mittler Bros. Machine & Tool 35 Pat Mooney Inc. 140 Multi Lock Inc. 9 Multi Sales 37 New Metals Inc. 104 Nimba Anvils 46 NOMMA Membership 66 North East Gate Operator 95 Ol’ Joint Jigger Tube Notcher 91 OSCO 97 Ornamental Steel Designs Inc. Postville Power Hammers 43 Production Machinery Inc. 7 R & B Wagner Inc. 6 R & D Hydraulics 121 R & F Metals Inc. 100 Regency Railings 92 Rogers Mfg. Inc. 112 Walter Scadden Blacksmith Sharpe Products 101 Shop Outfitters 98 Signon USA 151 Simsolve 157 Sparky Abrasives Co. 32 Spiral Stairs of America Inc. 36 Stairways Inc. 5 Steptoe & Wife 96

Classifieds For Sale

Custom ornamental iron fabrication facility specializing in Old World quality products, servicing retail and wholesale clients located in beautiful Santa Barbara, CA. Unlimited potential with many high-end clients. Experienced production and prototyping staff. Rapidly expanding product line. Owner available during transition. $60K down, terms negotiable. Call (805) 560-3636.

Employment

Employment nationwide in structural/miscellaneous steel fabrication. ProCounsel is in communication with over 3,000 structural/miscellaneous steel fabricators. We can market your skills (estimator, project manager, detailer, shop manager) to the city or state of your choice without identifying you. Employer pays fee.

The right location, the right job, at the right money. ProCounsel: Buzz Tay-

lor. Call toll free (800) 545-5900, or (214) 741- 3014. Fax: (214) 741-3019.

Mailbox@procounsel.net.

For Sale

Small Iowa fab shop for sale, established 1969. Owner retiring. Currently closed. Structural steel, joists, and deck. Building (67 feet by 322 feet plus office), $199k. Equipment and three bridge cranes, $99k. Possible financing. Fax inquiries to (319) 476-7927.

For Sale

Blacksmith/wrought iron shop on scenic Route 100 North, Pittsfield, VT, 3,900 square feet, large shop, fully equipped, large showroom, apartment, 2 half baths and 1 full bath, storage barn, located on two acres with plenty of parking, great location, established business for over 30 years. Call (802) 746-8822, or email: mtforge@globalnetisp.net.

For Sale

Large, three-phase Pullmax machine located in New York State.

Will consider best offer. Contact Ed Mack (845) 651-7550.

Classified Ad Rate: $25 for up to 35 words, $38 for 36-55 words, $50 for 56-70 words.

No logos or boxed ads. Prepayment only. Send items to: Rachel Squires, Fabricator, 532 Forest Pkwy., Suite A, Forest Park, GA 30297. Ads may be faxed with credit card information to: (404) 3661852.

Next closing date: Friday, May 31, 2002

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FABRICATOR May-June 2002