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Ornamental and Miscellaneous Metal The official publication of the National Ornamental & Miscellaneous Metals Association

November/December 2003 $6.00 US

Job Job Profiles Profiles

A touch of Hollywood

Tips & Tactics

The risk of misusing equipment, page 13

Shop Talk

Is it REALLY a restoration?, page 18

page page 55 60

Biz Side

Dirty shop? Time to call Mr. Klean, page 69

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November/December 2003 Vol. 44, No. 6

This job made everyone feel like dancing, pg.

Tips & Tactics

Don’t get buried alive by shop clutter, pg. 69.

Biz Side

Member Talk

Ask our Expert 13 Using gate operators for anything other than their intended use poses dangers. Equipment 15 A look at hand-held concrete core drillers and the benefits they offer. Special Features 16 METALfab 2004 You are invited to attend NOMMA’s 46th annual convention & trade show. Shop Talk Choosing the best approach for a historic preservation project 18 Learn the differences between the four types of preservation work. Is the fly press right for you? 34 Learn the benefits and drawbacks of this handy tool.

The birth of a foundry 46 Lawler Foundry turns a vision into reality through a generous donation. By Todd Daniel

Pittsburgh’s finest overlook 48 A hillside park project marks another success for a rising fabricator. By John L. Campbell

Career spotlight: Profile of a shop superintendent 51 A background of working on yachts provides a nice fit for a high-end shop. Job Profiles A touch of Hollywood in Arizona 55 Completion of this stainless steel job makes the client want to dance.

By Mark Hoerrner

A “burning bush” brightens a remodeled room 59 A fireplace screen provides a visual delight whether opened or closed.

Brazing with safer fluxes 42 A new flux reduces health hazards without compromising performance.

Top Job time again! 62 A reminder for the 2004 contest and a sampling of 2003 jobs.

President’s Letter 6 “Close enough” isn’t really close at all.

Editor’s Letter 8 The sources for our article ideas, part II.

Dirty shop? Let Mr. Klean come to the rescue 69 This four-phase plan can restore cleanliness and order to your shop. By Steve Thompson, Bruce Paynter, and Bob Borsh

Six ways you sabotage your leadership ability 74 Need to change your leadership skills? Take a hard look at yourself. By Morrie Shechtman

What’s Hot! Biz Briefs 82 Firms protest U.S. steel tariffs. Chapter Events 86 Northeast Chapter tours historic firm. Coming Events 88 Get ready for METALfab 2004! New Members 89 NOMMA welcomes 18 new firms. People 90 Celebrating an 85th anniversary!

Reader’s Letters 9 Survey participants needed for blacksmith school survey.

Fabricator Poll 98 Any fresh hiring ideas?

Cover photo: Designed by the architect, this stainless steel stair and balcony system features a “random engine turn” finish, which was topped off with #8 mirror finish stainless steel spheres. Panels are a combination of laser cut shapes and rolled stainless steel true bar. Approx. labor time: 800 hrs. Award: Gold, 2003 Top Job. Fabricator: Magnum Architectural Inc., Phoenix, AZ. Photo: John Ormond, Ormond Photographic.

President’s Letter

Dedicated to the success of our members and industry. NOMMA Officers President Chris Maitner Christopher Metal Fab. Inc. Grand Rapids, MI President-Elect Curt Witter Big D Metalworks Dallas, TX

Fabricator Directors Iron Works Inc. Elk Grove Village, IL Rod Stodtmeister Stodtmeister Iron Sparks, NV Sally Powell Powell’s Custom Metal Fab Inc. Jacksonville, FL

Supplier Directors David T. Donnell Eagle Bending Machines Stapleton, AL Bob Borsh House of Forgings Houston, TX Pam Beckham

Mittler Bros. Machine & Tool Foristell, MO

NOMMA Staff Executive Director Barbara H. Cook Meetings & Exposition Manager Martha Pennington Communications Mgr. & Editor J. Todd Daniel Managing Editor Rachel Squires Administrative Assistant Liz Ware

Technical Consultant Tim Moss


2003-04 Advisory Council Jay Holeman Mountain Iron Fabrications

Rob Rolves Foreman Fabricators

Contributing Writers John L. Campbell William J. Lynott


saying he could not grant a variance because of a mistake we made. He and you might even have said it yourreiterated that the 42 inch height is a self: “Within a quarter of an inch— close enough.” minimum code. But not necessarily so! As the instrucOur solution turned out to be fairly tor in the video “Straight Steel Stair simple. The infill on our two-line pipe Construction,” I cautioned viewers rails was a 2-inch square mesh, held in to be aware of the finish floor heights place by a pair of 3/16 by 1 bars on either and know what floor materials will be side of it. Since the top rail was not used. a handrail (because there was a side Well, apparently, at our shop we mount) we made a suggestion that was did not heed my own warning. On acceptable to the owner, architect, and a recent commercial project we had building inspector. four stairways to build. One went up Our idea was to take three floors and wrapped around a that same 1 by 3/16 inch bar and weld center block core so there were only wall mount rails. Another one went it on the top pipe from the first to second floor, and had standing vertically 42- inch high, two-line pipe rails with to get our 42 inch a mesh infill and a side mount. For height. the remaining two stairs, we simply The other top rail on Chris Maitner had to provide tubing posts and a top the wood wrapped is president of the National rail, which the general contractor then rails was a horizonOrnamental and wrapped with wood and inset glass, tal 2 by 31/2 inch oak Miscellaneous and provided a wood side mount rail. board. They went for Metals AssociaAll rails, both sloped and level, were to my suggestion on tion. meet the 42-inch code. this rail as well, and When we fabricated our pipe and added a 3/4-inch square piece of oak to spindle rail we failed to facget their rails up to height. That cure also helped them tor in a change that called for the previously painted resolve a possible future concrete treads in the stair problem—that of students to now have a 1/2-inch thick or faculty resting drinks or tile. other items on the top flat The general contractor rail, which would have cremade the same mistake. ated a potential hazard for Consequently, our two-line anyone below. I guess what 42-inch high sloped rail, I’m getting at is that phrases as well as the contractor’s like “good enough for who Ouch, just an / inch it’s for” or “close enough” wood wrap on our rails on away, but still the the slope, turned out to be should never be acceptable inspector said “no.” 1 41 /2 inches above the nosing to a NOMMA fabricator. line. The level rails, which After all, it’s our duty to included 160 lineal feet of level glass set the standard of excellence for our rail around an atrium, varied from industry. 417/8 inches high down to 415/8 inches, depending on where you measured from the uneven concrete slab. The building inspector refused to budge, I’m sure we’ve all heard this before,

Treasurer Doug Bracken Wiemann Ironworks Tulsa, OK Immediate Past President Belk Null Berger Iron Works Inc. Houston, TX

Vice President/

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

‘Close enough’ isn’t really close at all

Mark Hoerrner


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Ornamental & Miscellaneous Met­al Fab­ri­ca­tor (ISSN 0191-5940), is the of­fi­cial pub­li­ca­tion of the Na­tional Or­na­men­tal & Mis­cel­la­ne­ous Metals As­so­cia­tion (NOMMA). O&MM Fabricator 532 Forest Pkwy., Ste. A Forest Park, GA 30297


Send story ideas, letters, press releases, and product news to: Fabricator at address above. (404) 363-4009. Fax: (404) 3661852. E-mail:


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In addition to the magazine, you’ll enjoy many more benefits as a NOMMA member. To join, call the headquarters office at (404) 363-4009. For a complete list of benefits, refer to the membership ad in this issue.


$25 for up to 35 words, $38 for 36–55 words, $50 for 56–70 words. Send items to: Rachel Squires, Fabricator, at address above. Ads may be faxed with credit card information to: (404) 366-1852. Deadline: 2nd Fri­day of the month prior to pub­li­ca­tion.


Subscription questions? Call (678) 387-0108 Send subscription address changes to: Fabricator Subscriptions, P.O. Box 921343, Norcross, GA 30010-1343. Fax: (678) 3870101. E-mail: 1-year: U.S., Canada, Mexico — $30; 2-year: U.S., Canada, Mex­i­co — $50; 1-year: all other countries — $44; 2-year: all other countries — $78. Pay­ment in U.S. dol­lars by check drawn on U.S. bank or money order. For NOMMA mem­bers, a year’s sub­scrip­tion is a part of membership dues.

Supplier Directory

Published each December as a separate issue. Space reservation deadline is July 31. Deadline for all advertising materials is August 31. For info, contact Rachel Squires at (404) 363-4009, ext. 14 or


Reprints of articles are available. For a quote, contact Rachel Squires at (404) 3634009, ext. 14 or

Opinions expressed in Fabricator are not necessarily those of the editors or NOM­MA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA. Circulation: 8,000.



How to reach us

Editor’s Letter

The sources for our article ideas, part II In the last issue I shared with you two

of my “secret weapons” for getting story ideas—our Advisory Council and “panel of experts.” In addition to these excellent sources, I must rely on other methods as well since there is always another issue around the corner. Under our new design format, Managing Editor Rachel Squires and I must come up with nearly 100 articles and columns per year to fill six issues. As you can imagine, we spend a lot of time searching the Internet, sifting through junk mail, and reviewing other publications trying to come up with new material. Yet, while we have hit dry spells, these are few and rare. That’s because we have a fantastic support base that keeps us going. Allow me to share more of my additional idea sources:

Supplier members

Since NOMMA’s beginning in 1958, suppliers have played an important role in the association’s growth and success. While suppliers support NOMMA in many ways, a great way they help the magazine is to provide IDEAS! On a regular basis, I’ll get a fax, article clipping in the mail, an e-mail, or a phone call. There are three suppliers that I would like to especially thank for regularly feeding me ideas: Stan Lawler of Lawler Foundry Corp., and Steve Engebregtsen and Tony Leto of The Wagner Companies. NOMMA ListServ

In my opinion, the NOMMA e-mail discussion list is one of the greatest benefits of membership. Lately, this e-mail list has featured nonstop and lively discussions on topics ranging from code inspectors to eye protection and from glass railings to handling stainless steel. The discussions provide an incredible wealth of information, which we often turn into stories. Currently, there are 141 subscribers on the

list, yet a quick look at the NOMMA roster shows we have e-mails for 616 of our 900-plus members. That means most of you have not plugged into this wonderful resource. To subscribe, simply go to the Member’s Only Area on the NOMMA website and click on “E-mail Discussion List.” Top Job Contest

Okay, now for my big secret. The vast majority of articles for our Job Profiles section comes from Todd Daniel past entrants in is editor of the annual Ernest Ornamental & Miscellaneous Wiemann Top Job Fabricator. Competition. Each year following the contest, we pick through the entries and select ones that we feel will make the best stories. On occasion, a fabricator will offer to write an article about his or her “Top Job” and we always say, “THANK YOU!” Other idea sources

The rest of our ideas comes from a variety of sources: other publications, our own research, calls received by the NOMMA office, and membership surveys. Yet, despite all these methods for obtaining material, we always need fresh input into the magazine. If you have a suggestion for an article, always feel free to e-mail us at: todd@nomma. org or rachel@

Fabricator n November-December 2003


Reader’s Letters Survey participants needed The School of the Building Arts Inc. (SoBA) is currently exploring the possibility of a partnership with the National Ornamental and Miscellaneous Metals Association (NOMMA). SoBA is located in Charleston, South Carolina and is a national school for the study of the building arts, which includes metalwork, plasterwork, masonry, timber framing, stone carving and carpentry, among other trades. W RI TE !

Tell us what you think

Mail Letter to the Editor, c/o Fabricator, 532 Forest Pkwy., Ste. A, Forest Park, GA 30297 E-mail Fax (404) 366-1852. Please include your name, company, address, telephone number, and e-mail. Letters are subject

SoBA is in the process of developing a college curriculum program which is planned to be launched in 2005. Both Associates and Bachelors degrees will be offered. SoBA recently worked with NOMMA to send out a survey request to NOMMA members to gather feedback for the school’s metalworking program. At this time we would like to invite all metalworkers to participate. The results of the survey will help SoBA develop a successful curriculum, specifically one that is tailored to blacksmithing. The survey is available online at the link below. By offering the survey electronically we are saving postage and printing costs. It is also easier to complete and a lot more fun than a printed version. We really appreciate your input and help. To complete the survey, go to:

asp?u=67681293969 For further information about the School of the Building Arts Inc. please feel free to contact us. Annette Dixon School of the Building Arts Inc. Charleston, SC (843) 577.5245 E-mail: A word of thanks I just wanted to write a short note to say “thank you” to you and Rachel Squires for your good work. Every issue of Fabricator gets better, and I’m thankful that we have the two of you to provide helpful information to our industry. John W. Steel Steel Welding Freedom, PA

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Tips& Tactics n

Ask Our Expert

Misapplication of equipment

Task force chair warns against using automated gate operators for any use other than vehicular gate operation. By Brent Nichols Automated Vehicular Gate Task Force Chair About two years ago I had requests to automate and provide controls for 16 garage doors that were hinged just like a double swing gate. Two doors were in Aspen, 12 in Edwards, CO, and two in Palm Springs, CA. They were no different than swing gates, only they were garage doors. The fabrication of the frames was no different than gates: mag locks to secure the doors, radio receiver and keypad to activate. Nothing to it. However, because of my involvement with UL 325 I had insight into a few requirements that as a gate installer, not a garage door installer, I would have never known. First, garage doors are federally regulated and failure to comply with the regulations is punishable by a large fine and imprisonment; this got my attention. One of the requirements of a garage door operator is that it must have inherent reversing, which means if it hits an obstruction it will reverse to the open position. Another requirement is that if the entrapment devices used malfunctions, the door can only be closed by depressing the button in the garage and holding it down until the door is in the fully-closed position. The purpose of this is to allow someone to be in view of the door while it is being closed. Researching options

After looking into this request for a garage door that functions like a gate, I started to research operators for swinging garage doors; there are none. I knew that I could design a safe system and looked at various gate operators that would comply with the garage door criteria. I could comply with all of the items except for one. The holding of the manual button down to close the door in the event that an entrapment device failed and the door would not close; none of the control panels allowed this. I went to UL asking them to help me with these these various projects. Their response to was, “Using a gate operator for a garage door operator; it would need to be tested by UL and installation criteria developed.” The cost and time for such testing was prohibitive. I then asked, if possible, if UL could be paid to visit the job site to inspect the installation and then put their stamp on the system after they saw it. This, again, was not an option. In my final attempt I sent a letter to UL and informed them if I didn’t install this system someone else probably would, and I thought they would rather have someone knowledgeable install these systems than someone of lesser experience. My final letter from UL stated that if a gate operator is used for a garage door November-December 2003 n Fabricator

application it is a “misapplication of a product for which it has been tested.” I was not finished yet. I spoke with a representative from the U.S. Consumer Product and Safety Commission. Their response was that if we have completed enough testing and documentation on the use of About the author: gate operators for garage doors, Brent Nichols, Picasso we could submit it for review Gate, Cheyenne, WY, and proceed—again a dead end. is chair of NOMMA’s As a final attempt I went to my Automated Vehicular Gate Take Force and he attorney and presented all the represents the assofacts, correspondence, and inforciation on the Ad Hoc mation I had collected. After Vehicular Gate Stanreviewing the information his dards Coalition. Brent also serves on the UL question to me was simple. “Is it 325 Standards Technical a garage door or a gate?” Under Panel. all definitions it is a garage door. He said that if an accident was a result of this installation he could not defend me; I could not meet the federal requirements for garage doors, even if I could produce the testing and test results. It is still the “misapplication of a product.” It was the attorney’s recommendation to walk from the job, and that is what I did.

Our Expert

An automated pedestrian gate???

I recently had a phone call from a NOMMA member who had a request to automate a walk gate to a pool area for both pedestrians and golf carts. The fabricator called me to ask if this could be done. The answer is “no,” it cannot. Even though it is called a gate operator, it is for vehicular use only. There are no pedestrian gate operators that I am aware of that will allow the automation of a pedestrian gate. In writing this column, I am not trying to provide legal council, only to convey that before adapting products for unintended uses, a fabricator should use caution. If questions arise, contact the manufacturer or distributor of the product in question. Request written authorization from them, which authorizes the use the product for the job’s specific purpose. Research the application yourself, and check with your attorney to find out any legal consequences you might encounter. 13

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Hand-held concrete drilling systems

Find out the applications and benefits of this developing technology By Tom Carroll CS Unitec Inc. By far, the most popular types of concrete core drilling equipment sold by CS Unitec Inc. are hand-held core drilling machines with a water swivel attachment and a safety slip clutch. Hand-held drilling of small-hole sizes saves time, and these machines, which come in two- and three-speed models, can drill up to 3-inch diameter holes by hand with wet diamond core bits. Placing the drill in a small stand allows the three-speed model to drill holes up to 6 inches in diameter. The combined weight of the hand-held drill and the stand is only 37 pounds, making this system lightweight enough to meet the needs of ornamental fabricators. The drill stand can be anchored or vacuumed to the surface being drilled. The water attachment makes it possible to cut cleanly through more brittle surfaces than masonry, while also suppressing dust. Benefits of lightweight systems

If a fabricator is making anchor holes using chemical anchors for railings, the hand-held drill by itself should be adequate. In fact the technology of chemical anchors, which were approved in the 1980’s and 1990’s, brought about a greater need for smaller, more lightweight concrete drills. Weighing just 16 pounds, the hand-held drill is ideal for drilling chemical anchor holes. The higher r.p.m. in second and third gear allows more efficient cutting through

materials ornamental fabricators are more likely to encounter, like tile or brick. When core drilling small-diameter holes, a higher r.p.m. saves time and is better for the longevity of the diamond core bit. Typical stand-mounted core drill rigs generally top out at 1,200 r.p.m and often weigh more than 100 lbs., while newer, smaller, hand-held models can go up to 2,800 r.p.m. and weigh less than 40 lbs. In addition, CS Unitec’s hand-held models have a built-in slip clutch for added safety. If the bit binds while drilling in second or third gear, it will automatically disconnect from the drill to protect the operator from kickback. Benefits of drill stands

In instances where the fabricator does need more stability, like when making larger diameter holes for more commercial-type work, the stand affords the drill more accuracy as well as mechanical feed pressure, which reduces operator fatigue. The 3-speed, wet diamond hand-held drill with a drill stand allows operators to drill up to 6-inch diameter holes while still offering a lighter and more portable drilling system. The drill can be taken out of the drill stand in less than a minute for hand-held use. Core drills vs. hammer drills

The rotary action of diamond core drilling cuts down on the stress and damage to the material being drilled. There is no hammering action as is typical with carbide core bits used on

A hand-held 3-speed concrete core drill can drill up to 3-inch diameter holes.

The fabricator shown here is drilling a a hole for a 3-inch diameter fence post.

hammer drills. The hammering action of carbide-tipped core bits can cause cracks and other damage to the underlying material. Hammer drill bits can also bind in the hole while drilling and cause kickback to the operator. In contrast, wet diamond core bits drill through concrete with steel reinforcement and steel rebar. Since typical carbide bits do not drill through steel, either the hole must either be relocated or a rebar cutter must be used. (Carbide core bits used on hammer drills can cause kickback.) Shopping advice

When buying core drills watch out for proprietary replacement parts and drill sizes. All CS Unitec models use standard 5/8 inch – 11 UNC, 1-1/4 inch – 7 UNC and fi inch – straight threads. Some larger manufacturers or distributors offer only proprietary connecting threads, which can make replacing parts and consumables more difficult and costly.


If you have topics for Tips & Tactics section, please let us know the idea. For consideration, please contact the Editor at 532 Forest Parkway, Suite A, For­est Park, Ga. 30297. Phone (404) 363-4009, Fax (404) 366-1852, E-mail

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You are invited to attend NOMMA’s 46th annual convention and trade show! Are you ready for the biggest industry event of the year? Use the following checklist to assist with your planning:

q General Information

The convention runs from Wednesday morning, March 3, until Saturday evening, March 6. For complete information on METAlfab 2004, refer to the Convention Guide bundled with this issue, which includes a registration form. You can also obtain the latest information by visiting our website at: q Hotel

The Hyatt Regency Sacramento is serving as host hotel for the event. Reservations must be made directly

with the hotel. Simply call (800) 2331234 and be sure to mention you are with NOMMA. The hotel is conveniently located adjacent to the Sacramento Convention Center and across the street from the State Capitol. q Travel

For air travel, call Jane Hughes at Avant Travel at (859) 271-3839 or (800) 627-7260. E-mail: The hotel is approximately 15 minute from Sacramento International Airport and taxis and shuttles are available. If you wish to rent a car, Avis Rent A Car is offering a special price for METALfab attendees. To reserve a vehicle, call (800) 230-4898 or visit When mak-

A special thanks to our METALfab 2004 sponsors Sacramento, CA March 3–6, 2004

March 3–6, 2004 Sacramento, CA ing reservations, be sure to mention promotion code: J947587. q Top Job Competition

To enter the Ernest Wiemann Top Job Competition you must be a NOMMA member. Deadline is December 19, 2003, however entries will still be accepted until January 5, 2004 by paying a late fee. q Trade Show Only

While full registration is recommended, you can attend the trade show only at no charge.

Lawler Foundry Corp. R & B Wagner Inc. J.G. Braun Co. Julius Blum & Co. Inc. Carell Corp. Colorado Waterjet Co. Decorative Iron D.J.A. Imports Ltd. Eagle Bending Machines Inc. Innovative Hinge Products Inc. Lavi Industries Mittler Bros. Machine & Tool Indiana Gratings Inc. Ohio Gratings Inc. Rogers Mfg. Inc. Yavus Ferforje A.S.


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Shop Talk

This fence repair is considered a rehabilitation project. Fabricator: Berger Iron Works Inc., Houston, TX.

n Not all historic preservation work is restoration. There are actually four different methods of treatment that can be considered when working on historic buildings. Knowing your client’s intentions concerning the structure can help you understand how best to go about treating its metalwork. Adapted from The Secretary of the Interior’s Standards for the Treatment of Historic Properties with Guidelines for Preserving, Rehabilitating, Restoring, and Reconstructing Historic Buildings, 1995, by Kay Weeks and Anne Grimmer. Do you ever hear someone say they’re “restoring” a building when they’re really rehabilitating or preserving it? It would seem to be a simple difference in labeling, but it’s really an important distinction in historic preservation because each approach achieves a very different “end product.” There are four treatment approaches for working on historic structures: Preservation, Rehabilitation, Restoration, and Reconstruction. The first treatment, Preservation, places a high premium on the retention of all historic fabric through conservation, maintenance, and repair. It reflects a building’s continuum over time, through successive occupancies, and the respectful changes and alterations that are made. Rehabilitation, the second treatment, emphasizes the retention 18

and repair of historic materials, but more latitude is provided for replacement because it is assumed the property needs to be upgraded for a new use. (Both Preservation and Rehabilitation standards focus attention on the preservation of those materials, features, finishes, spaces, and spatial relationships that, together, give a property its historic character.) Restoration, the third treatment, focuses on the retention of materials from the most significant time in a property’s history, while permitting the removal of materials from other periods. Reconstruction, the fourth treatment, establishes limited opportunities to re-create a non-surviving site, landscape, building, structure, or object in all new materials. Choosing the most appropriate treatment for a building requires careful decision-making about a building’s historical significance, as well as taking into account a number of other considerations:

For your information


Choosing the best approach for a historic preservation project

Know your 3 Rs (and 1P): Preservation: This treatment values and retains adaptations a building undergoes over time. Rehabilitation: This treatment emphasizes the retention of historic materials allowing for some alterations necessary to adapt the building for a compatible new use. Restoration: This treatment focuses on the retention of materials from the most significant time in a property’s history, while permitting the removal of materials from other periods. Reconstruction: This treatment involves recreating a non-surviving site or structure with all new materials. The authors are with the U.S. Dept. of the Interior, National Park Service, National Center for Cultural Resources, Heritage Preservation Services, Washington, DC.

Relative importance in history

Is the building a nationally significant resource—a rare survivor or the work of a Fabricator n November-December 2003

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“If hastily or poorly designed, a series of code-required actions may

jeopardize a building’s materials as well as its historic character.” master architect or craftsman? Did an important event take place in it? National Historic Landmarks, designated for their “exceptional significance in American history,” or many buildings individually listed in the National Register often warrant Preservation or Restoration. Buildings that contribute to the significance of a historic district but are not individually listed in the National Register more frequently undergo Rehabilitation for a compatible new use. Physical condition

What is the existing condition or degree of material integrity of the building prior to work? Has the original form survived largely intact or has it been altered over time? Are the alterations an important part of the building’s history? Preservation may be appropriate if distinctive materials, features, and spaces are essentially intact and convey the building’s historical significance. If the building

requires more extensive repair and replacement, or if alterations or additions are necessary for a new use, then Rehabilitation is probably the most appropriate treatment. These key questions play major roles in determining what treatment is selected. Proposed use

An essential, practical question to ask is: Will the building be used as it was historically or will it be given a new use? Many historic buildings can be adapted for new uses without seriously damaging their historic character; special-use properties such as grain silos, forts, ice houses, or windmills may be extremely difficult to adapt to new uses without major intervention and a resulting loss of historic character and even integrity. Mandated code requirements

Regardless of the treatment, code requirements will need to be taken into consideration. But if hastily or

poorly designed, a series of coderequired actions may jeopardize a building’s materials as well as its historic character. Thus, if a building needs to be seismically upgraded, modifications to the historic appearance should be minimal. Abatement of lead paint and asbestos within historic buildings requires particular care if important historic finishes are not to be adversely affected. Finally, alterations and new construction needed to meet accessibility requirements under the Americans with Disabilities Act of 1990 should be designed to minimize material loss and visual change to a historic building. Using Standards and Guidelines

The Secretary of the Interior’s Standards for the Treatment of Historic Properties with Guidelines for Preserving, Rehabilitating, Restoring, and Reconstructing Historic Buildings are intended to provide guidance to historic building owners and building managers, preservation consultants, architects, contractors, and project reviewers prior to treatment. The Guidelines have been prepared to assist in

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applying the Standards to all project work; consequently, they are not meant to give case-specific advice or address exceptions or rare instances. Therefore, it is recommended that the advice of qualified historic preservation professionals be obtained early in the planning stage of the project. Such professionals may include architects, architectural historians, historians, historical engineers, archeologists, and others who have experience in working with historic buildings.


• A property will be used as it was historically, or be given a new use that maximizes the retention of distinctive materials, features, spaces, and spatial relationships. Where a treatment and use have not been identified, a property will be protected and, if necessary, stabilized until additional work may be undertaken. • The historic character of a property will be retained and preserved. The replacement of intact or repairable historic materials or alteration of

Preservation: This job is classified as preservation because it acknowledges the adaptations the 1800s structure has gone through over time. Fabricator: Adams Street Iron Inc., Chicago, IL.

features, spaces, and spatial relationships that characterize a property will be avoided. • Each property will be recognized as a physical record of its time, place, and use. Work needed to stabilize, consolidate, and conserve existing historic materials and features will be physically and visually compatible, identifiable upon close inspection, and properly documented for future research. • Changes to a property that have acquired historic significance in their own right will be retained and Fill in 171 on Reader Service Card


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preserved. • Distinctive materials, features, finishes, and construction techniques or examples of craftsmanship that characterize a property will be preserved. • The existing condition of historic features will be evaluated to determine the appropriate level of intervention needed. Where the severity of deterioration requires repair or limited replacement of a distinctive feature, the new material will match the old in composition, design, color, and texture.

• Chemical or physical treatments, if appropriate, will be undertaken using the gentlest means possible. Treatments that cause damage to historic materials will not be used. • Archeological resources will be protected and preserved in place. If such resources must be disturbed, mitigation measures will be undertaken. When the property’s distinctive materials, features, and spaces are essentially intact and thus convey the historic significance without extensive repair or replacement; when depiction

at a particular period of time is not appropriate; and when a continuing or new use does not require additions or extensive alterations, Preservation may be considered as a treatment. Prior to undertaking work, a documentation plan for Preservation should be developed


• A property will be used as it was historically or be given a new use that requires minimal change to its distinctive materials, features, spaces, and spatial relationships. • The historic character of a property will be retained and preserved. The removal of distinctive materials or alteration of features, spaces, and spatial relationships that characterize a property will be avoided. • Each property will be recognized as a physical record of its time, place, and use. Changes that create a false sense of historical development, such as adding conjectural features or elements from other historic properties, will not be undertaken. • Changes to a property that have acquired historic significance in their own right will be retained and preserved. • Distinctive materials, features, finishes, and construction techniques or examples of craftsmanship that characterize a property will be preserved. • Deteriorated historic features will be repaired rather than replaced. Where the severity of deterioration requires replacement of a distinctive feature, the new feature will match the old in design, color, texture, and, where possible, materials. Replace-ment of missing features will be substantiated by documentary and physical evidence. • Chemical or physical treatments, if appropriate, will be undertaken using the gentlest means possible. Treatments that cause damage to historic materials will not be used. • Archeological resources will be protected and preserved in place. If such resources must be disturbed, mitigation measures will be undertaken. • New additions, exterior alterations, or related new construction will not destroy historic materials, features,

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Rehabilitation: This job is considered a rehabilitation because deteriorated sections of the railing were replaced and some detailing was not replicated. To do the work, the 70-year-old railing was removed from the premises and taken to the fabricator’s shop. There, the top rail was removed and the entire unit was sandblasted. The removal of the paint revealed numerous areas that needed repair or complete replacement. Among the re-made items for this job were 18 hand forged scrolls and two new leaves. The ball finials on the old rail were then replaced with compatible new urn finials. Once work was completed, the railing was sent out to be hot dip galvanized and then powder coated. Fabricator: Mueller Ornamental Iron Works Inc., Elk Grove, IL.

and spatial relationships that characterize the property. The new work shall be differentiated from the old and will be compatible with the historic materials, features, size, scale and proportion, and massing to protect the integrity of the property and its environment. • New additions and adjacent or related new construction will be undertaken in such a manner that, if removed in the future, the essential form and integrity of the historic property and its environment would be unimpaired. When repair and replacement of deteriorated features are necessary; when alterations or additions to the property are planned for a new or continued use; and when its depiction at a particular period of time is not appropriate, Rehabilitation may be considered as a treatment. Prior to undertaking work, a documentation plan for Rehabilitation should be developed


• A property will be used as it was historically or be given a new use that reflects the property’s restoration period. • Materials and features from the restoration period will be retained and Fill in 30 on Reader Service Card


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preserved. The removal of materials or alteration of features, spaces, and spatial relationships that characterize the period will not be undertaken. • Each property will be recognized as a physical record of its time, place, and use. Work needed to stabilize, consolidate and conserve materials and features from the restoration period will be physically and visually compatible, identifiable upon close inspection, and properly documented for future research. • Materials, features, spaces, and finishes that characterize other historical

periods will be documented prior to their alteration or removal. • Distinctive materials, features, finishes, and construction techniques or examples of craftsmanship that characterize the restoration period will be preserved. • Deteriorated features from the restoration period will be repaired rather than replaced. Where the severity of deterioration requires replacement of a distinctive feature, the new

Restoration: This project is considered a restoration because the intent was to bring it back to its early 1900s splendor. Items from later periods were removed and the gate was re-created to the original design. The entire structure was dismantled, parts were replaced or repaired, and the gate was re-riveted. Afterwards, the piece was sandblasted to white steel, primed, and finished. Fabricator: Parkey’s Welding & Design, Martell, CA.

FPO Sur-Fin

feature will match the old in design, color, texture, and, where possible, materials. • Replacement of missing features from the restoration period will be substantiated by documentary and physical evidence. A false sense of history will not be created by adding conjectural features, features from other properties, or by combining features that never existed together historically. • Chemical or physical treatments, if appropriate, will be undertaken using the gentlest means possible. TreatFill in 72 on Reader Service Card


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ments that cause damage to historic materials will not be used. • Archeological resources affected by a project will be protected and preserved in place. If such resources must be disturbed, mitigation measures will be undertaken. • Designs that were never executed historically will not be constructed. When the property’s design, architectural, or historical significance during a particular period of time outweighs the potential loss of extant materials, features, spaces, and finishes that characterize other historical periods; when there is substantial physical and documentary evidence for the work; and when contemporary alterations and additions are not planned, Restoration may be considered as a Understand the different treatments

For more info on the four types of historical work, visit: gov/workingonthepast/. Then click on section “D,” and go to “FOCUS ON: The Historical Model.”

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treatment. Prior to undertaking work, a particular period of time, i.e., the restoration period, should be selected and justified, and a documentation plan for Restoration developed.


• Reconstruction will be used to depict vanished or non-surviving portions of a property when documentary and physical evidence is available to permit accurate reconstruction with minimal conjecture, and such reconstruction is essential to the public understanding of the property. • Reconstruction of a landscape, building, structure, or object in its historic location will be preceded by a thorough archeological investigation to identify and evaluate those features and artifacts which are essential to an accurate reconstruction. If such resources must be disturbed, mitigation measures will be undertaken. • Reconstruction will include measures to preserve any remaining historic materials, features, and spatial relationships.

• Reconstruction will be based on the accurate duplication of historic features and elements substantiated by documentary or physical evidence rather than on conjectural designs or the availability of different features from other historic properties. A reconstructed property will re-create the appearance of the non-surviving property. • A reconstruction will be clearly identified as a contemporary re-creation. • Designs that were never executed historically will not be constructed. When a contemporary depiction is required to understand and interpret a property’s historic value (including the re-creation of missing components); when no other property with the same associative value has survived; and when sufficient historical documentation exists to ensure an accurate reproduction, Reconstruction may be considered as a treatment. Prior to undertaking work, a documentation plan for Reconstruction should be developed.

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The Secretary of the Interior’s Standards for the Treatment of Historic Properties, published in 1992, were reviewed by a broad cross-section of government entities and private sector organizations. The 1995 Guidelines for Preserving, Rehabilitating, Restoring, and Reconstructing Historic Buildings, by Kay D. Weeks and Anne E. Grimmer, were developed in cooperation with the National Conference of State Historic Preservation Officers. In addition to the printed version, the standards and guidelines are also available online at: tps/standguide/. Reconstruction: This method involves recreating a non-surviving piece from scratch, usually from drawings or photos. The project shown here, for example, was created from an historic photograph and artist’s rendering. The bronze candelabras and fountain spire were original designs by Jacob Wrey Mould, world renowned park designer. The job features intricate hand carvings and all components were cast in bronze. The finish is satin with a heat applied patina. All gilding is 24K gold. Fabricator: Allen Architectural Metals Inc., Talladega, AL.

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Fabricator n November-December 2003

FPO Regency Railings IMPORTANT: Make sure the corrective patch is repositioned after you place the file!!!!!

100 Glass St., Suite 101 • Dallas, TX 75207 Phone: 214-742-9408 • Fax: 214-742-9402 Fill in 92 on Reader Service Card

Shop Talk

Is the fly press right for you? n An

age-old tool is gaining new acceptance as more and more metalsmiths discover the benefits of this timeless gem.

Imagine a spinning top. At the widest

revolution point on that top you have nice wide circles and some speed in motion. At the place where the top’s point is balancing precariously on the floor, you have, in effect, a spinning needle. It stops. You twist it up and let it go again. It spins on its rapidly revolving point. You’ve now had your first class in using a fly press. Though widely used in blacksmith shops and forges across Europe, the machine has never really caught on in the U.S. But now, thanks to a few dedicated fans of inertia-based machines, fly presses may be making their debut in the future of American ornamental metalsmithing.

The press incarnate

A fly press is a simple machine when compared with a treadle or air hammer. It’s basically a big screw on a mount equipped with a large punch. The theory behind the fly press is a lesson in physics—the large wheel at the top of the press, usually about two feet in diameter, makes an average six-foot rotation when turned a few times. As the wheel is released, a fierce amount of inertial energy is released, multiplying the rotation effort geometrically. A couple quick turns generate a hammer strike pressure of 20 tons or more. “It differs in the respect (from an air hammer) that you lock dies in place and every blow will be in the same place every time,” Kayne says. “The treadle hammer is ideal for random marks, etc, but exacting work is not the forte of the 34

treadle hammer. With the hammer, you are concentrating on the power of the blow. The fly press is nearly silent. All you have is torsion and no angled strikes.” Even machines have ugly cousins in their family, and the fly press is no different. The ball or weight-arm press is mechanically similar to the fly press in operation but most critics agree the ball press is far more dangerous and unwieldy because of the configuration of the weight arm.

The fly press operates on the principle of inertia. The flywheel is attached to a screw that moves the ram up and down. When the tooling on the ram hits a piece of work it must slow down and stop the fly wheel, which produces tremendous force. Photo: Jock Dempsey, anvilfire. com.

The upside

“Almost anything you do on top of the anvil can be done on top of the fly press,” says Steve Kayne, owner of Kayne and Son in Candler, N.C. “It can be used for punching of rails, all kinds of twists and unusual effects. The limits of what the fly press can do are simply the limits of the human mind. If you can set up the fly press to do it, it can do it.” But having a heavy hammer strike akin to using an air hammer is not the only benefit. The press accommodates a wide array of tools that act as an additional set of hands for working with your product. Kayne sells fly presses in three sizes. The presses are not too costly, maxing out around $1,400 before shipping. This price point gives even the small fabricator little pause after having spent thousands outfitting a shop, and with the entry-level press starting at just over

For your information


By Mark Hoerrner

Equipment: Fly press. Pros: Ideal for punching, twists, and special effects. Moderately priced. Cons: The manually operated machine is labor intensive compared to automated equipment. Kayne and Son fo Fo r m ore In iForge/tutor/ press_tools/

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$900, it’s an easy purchase for the curious shop owner. Kayne believes the benefits of using a fly press in an average shop are considerable, and are more so in the smaller shop. He says this from more than just the salesman’s perspective, as his personal shop incorporates three forges and a

bronze foundry. “We have an intimate knowledge of the tools we sell,” Kayne says. “Many of the processes that people are using in the field, we are using in our shop. We are often called upon to explain a particular process or tool. We want to be sure that it will be an effective machine for the buyer to have.” Fly presses catch on Kayne learned fly press opWhile used in Europe and Asia for over a eration from his grandfather. century, fly presses are now gaining popuHe started at age eight in this larity in North America. The press is a highly country, but in a European-style efficient tool that is ideal for both producshop. His grandfather had eight tion and custom work. men in the shop, and of the eight men he had working for him, no

two were from the same country. This “United Nations” approach saw that men who spoke little English incorporated the fly press into what they did. Many had learned on the fly press in their home country. Thus, the variety of techniques used on the fly press came together in one central location, and Kayne learned from each of them.

The downside

Bob Bergman, owner of the Postville Blacksmith Shop in Blanchardville, WI, agrees that the fly press has some advantages. “It’s a very simple machine that takes up very little space, though it does

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need to be bolted down very firmly,” he says. “It’s great for handwork and light forging. It’s highly accurate; you can repeat strikes in the same place every time, and the tooling is easy to make for it.” But that’s where Bergman’s praise begins to trail off. “It’s a hand-operated machine,” he says. “It’s energy in, energy out, and has no real safeguards. If you are trying to forge stock or punch a hole, you have to work pretty hard. Most of the presses are in the 5–10 ton range of energy output. You are storing that energy, and that stored energy will be transferred to your part. It may not punch all the way through—you may have to hit it three or four times to get the desired result.” Safeguards, in fact, are a sticking point for many shop owners. Since the press works on inertia and must be well lubricated and free-moving to maximize strike pressure, it’s not the safest machine to operate. Laborers will find that they learn the lesson quickly, however. If adjusting a slotting or tool

“It’s a very simple machine that takes up very little space, though it does need to be bolted down very firmly.”

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and 20 tons of pressure strikes your hand, it’s likely you won’t make that mistake again. Bergman says he used a fly press for about three years in his own shop, applying knowledge he gained while apprenticing in England. His contention with the fly press is that it has limited operation quality; it’s useful for jobs requiring about one to one hundred parts, but beyond that, he recommends using a hydraulic press. Some of the things Bergman lists as disadvantages are seen as benefits, however, by Kayne. Kayne notes that because it’s a simple machine, skilled labor is not required to operate the press. In addition, it’s high degree of accuracy and repeatability can turn out piece after piece with a very accurate punch, indentation, or bend. Further, he says the presses don’t have fluid-filled tubes that could rupture and create a fire hazard, potentially Fabricator n November-December 2003

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hammer. In the rest of the world, there are many shops you can go into and they won’t have a power hammer, but they will have a fly press because of the things it can do so inexpensively for the operator. Further, in places where it’s not easy to get to a power source, the fly press is ideal.” The analysis

At Kayne & Son, for example, the fly press is available in three sizes with heights ranging from 261/4 inch to 331/4 inch. Photo: Jock Dempsey,

shutting down the shop. The tooling is perhaps one of the most attractive features of the fly press. In addition to its accuracy and ease of use, the press can be fitted with a wide array of tools for pattern enhancements, bends, and other creative uses. The presses will accept flat dies, press brake dies, “dolly p” tools, punch dies, curve-bending dies, offset bends, notching dies, forging dies, dishing

and hemispherical dies, and more. These tools give the metalworker a third hand, as Bergman says, and allow a variety of practical and creative applications. “For the practical blacksmith, many fabricators have the fly press set up in the forging area adjacent to their anvil and forge,” Kayne says. “Part of the project is done on the anvil, part on the fly press, and part on a power

For the small shop, it’s clear that the fly press can be a boon for certain projects with limited part runs. The tooling makes the machine highly versatile with an unlimited ability for specialized applications. No special power is required, so as long as the fabricator can create a custom stand, the fly press can be integrated into any area of the shop. Further, it does not require a journeyman or master blacksmith to operate, so unskilled labor and apprentices can easily use the machine to become a valuable part in the fabrication process. It’s a unique operation for students as it can be used as an ornamental shop learning tool. The accuracy of the machine

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Fabricator n November-December 2003

The accuracy of the machine

takes away part of the awkwardness apprentices have to overcome.

takes away part of the awkwardness apprentices have to overcome to contribute to a shop’s bottom line, and it speeds up the production cycle. For a larger shop that needs to develop tons of railing or parts for fencing, railing, or other massproduction components, the better investment might be a clutch-driven or hydraulic press. These will have a higher degree of safety for the operator, but as all large machines do, they take up more space, require electric connections, and create an additional fire hazard for those shops working with open flame. However, the larger, more automated machines can turn out parts far faster than the fly press. The restrictive part on these electric versions will be price, since they are significantly more expensive. The fly press adds a bit of “oldschool” smithing to any shop willing to take on the device, so some shop owners may want to purchase one simply for the nostalgia factor. All in all, the devices, used for hundreds of years, still have practical applications in their old age and would serve as a practical addition to most shops.

METALfab 2004

Sacramento, CA March 3–6, 2004

Shop Tours • Top Job Contest Education Classes • Trade Show Networking Opportunities

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Shop Talk

Brazing with safer fluxes A “peel test” was one of the various tests conducted to evaluate the new potassium biflouride-free silver brazing flux.

n Removing potassium bifluoride from flux eliminates, or significantly reduces, the emission of toxic hydrogen fluoride gas at brazing temperature, while maintaining quality of brazing. F

The past several decades have witnessed the elimination of many hazardous chemicals and metals from industrial and consumer uses. This includes the removal of cadmium from silver brazing filler metals. Eliminating potassium bifluoride from brazing fluxes represents a continuation of this trend and results in a safer and healthier brazing workplace environment. Removing potassium bifluoride from flux eliminates, or significantly reduces, the emission of toxic hydrogen fluoride (HF) gas at brazing temperature. HF gas can have both acute and long-term health hazards. While good plant ventilation goes a long way in keeping toxic gas concentrations at low levels, these levels may not be consistent throughout the plant—especially near brazing stations. The best way to drastically reduce toxic HF is to eliminate fluorides (or at least potassium bifluoride) from the flux.

Techni-chemical background

Brazing fluxes consist of borates, boric acid, fluorides, fluoborates, and various other chemicals. These chemicals are mixed, ground, or milled to give a uniform, fine particle size. The fluxes produced are available in the form of powder, paste, slurry, or liquid. In 42



Figure 1. Potassium-Boron-Fluoride pseudoternary diagram.

the case of paste fluxes, water or organic binders are added to the powder to form smooth, workable products. While only minor reactions take place in the mixing of these chemicals, significant changes occur when they are heated to the active temperature range. Heating transforms the assemblage of inorganic chemicals into a glassy complex; after all the organic material, water, and other solvents are expelled. The glass viscosity at brazing temperature is critical. It must be low enough to allow the flux to penetrate the narrow gap width between the joining members, and also be easily displaced by the molten filler metal. However, the viscosity must be sufficiently high to serve as a protective blanket, keeping the rate of oxygen diffusion to base metal surfaces below that of oxide removal by the flux.

For your information


By Y. Baskin, Superior Flux & Mfg. Co. and L. Bemis, CTP Corp.

Contacts: Y. Baskin Superior Flux & Mfg. Co. 6615 Parkland Blvd. Cleveland, OH 44139 Ph: (440) 349-3000 Fax: (440) 349-3003 e-mail: L. Bemis CTP Corp. (QS-9000 certified company) 350 Shelby Street Indianapolis, IN 46227 Ph: (317) 787-5747 Fax: (317) 782-9489 E-mail:

Fabricator n November-December 2003

The potassium-boron-fluorine the HF component causes flux Table 1: Physical Properties of Brazing Flux Without pseudo-ternary diagram (shown to be irritating to fingernails and Potassium Bifluoride * in Figure 1) is fundamental to skin tissue. Furthermore, when Form: Creamy Paste conventional brazing fluxes. Most hydrogen fluoride is released at silver brazing fluxes fall within the Color: brazing temperature, it irritates Off White shaded area of the diagram. mucous membranes and lungs, Specific Gravity: 1.5 Boron is represented by B2O3, and has long-term harmful effects potassium by K2O, and fluorine on bones. Water Content Less than 35% as the element (F). In this pseudoRemoving potassium bifluoride ternary system, B2O3 is the glass results in a safer flux during use Viscosity at 22° C / 140,000 ± 14,000 former. It is the viscous member at ambient temperature and at 72° F: Centipoises and provides protection for the elevated brazing temperature. Fluorine Content: 18.0% base and filler metals by lowering (Physical properties are shown the oxygen diffusion rate through in Table 1). To maintain acceptFlash Point: None the flux. K2O is the glass modiable performance, the potassium Freezing Effects: None fier, lowering the melting point bifluoride is replaced by a safer and viscosity of the glass; it also fluoride compound. The flux Heating Effects to 50° None activates the glass. Fluorides (F) works well on copper, copper C / 122° F: further reduce the melting point base alloys, silver, and ferrous and viscosity of the flux due to the base metals. Although the flux fact that fluorine disrupts crossperforms adequately on stainless linkages in borate glass structures. * not boron-modified steel, performance improves with Improved fluxing action primarily the addition of amorphous boron. contain potassium bifluoride (KHF2), results from greater oxide dissolution The boron-modified version works a compound consisting of potassium capability of glass owing to fluorine well on stainless steel and other hardfluoride (KF) and hydrogen fluoride content. to-braze ferrous alloys. Both flux types (HF). This compound imparts good Removing potassium bifluoride perform well with the entire range of activity to the flux, which results in Most commercial silver brazing fluxes silver brazing (BAg) and phos-copper excellent fluxing action. However,

















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(BCuP) filler metals. The brazing flux undergoes a torch test. To insure quality, the 6M flux went through nine months of testing.

Brazing alternatives

There are safer alternatives for brazing in commercial applications. An example of how a safer, more effective brazing process can be achieved is the joint effort between Superior Flux & Mfg. Co., Cleveland, OH and CTP Corporation, Indianapolis, IN. CTP Corporation, a fabricator of tubular assemblies for the diesel engine, construction, and agricultural markets, has used silver brazing flux in its operations for more than 25 years. In 1976, CTP Corporation began silver brazing tubular assemblies, when production averaged several hundred joints per month. By 2002, production reached levels in excess of one (1) million joints annually. As productivity continued to grow, CTP Corporation perfected its torch and induction brazing techniques using standard industry fundamentals, AWS BAg brazing filler metals, and AWS Type FB3-A brazing fluxes. Health and safety of the company’s brazing operators has always been a priority. Consequently, CTP upgraded its brazing ventilation system several times and completely eliminated the cadmium-bearing silver alloys BAg-1 and BAg-2 from the brazing process in the early 1990s. The new flux is evaluated

For 24 years, CTP Corporation preferred Superior No. 601 silver brazing flux from Superior Flux & Mfg. Co. over other alternatives, satisfied with its excellent braze joints. However, in 2002, Superior Flux & Mfg. Co. released a silver brazing flux that promised to be more operator-friendly. With an opportunity to further improve the health and safety elements of its brazing processes, CTP Corporation evaluated new Superior No. 6M, potassium bifluoride-free silver brazing flux to validate its performance. As a QS-9000 certified company, CTP Corporation had detailed brazing procedures in place to standardize the tests. A peel test was conducted on each braze set-up, providing accurate comparison of the new Superior No. 6M flux test results with the Superior No. 601 results. Superior No. 601 was Fill in 176 on Reader Service Card


Fabricator n November-December 2003

used as the base-line standard. CTP Corporation brazing operators were also involved in the flux tests, and their opinions and comments were shared with Dr. Yehuda Baskin, President of Superior Flux & Mfg. Co.

Table 2. Primary Skin Irritation Study

The testing period

The new Superior No. 6M flux was tested for nine months, from May 2001 until February 2002. During that period, Superior Flux & Mfg. Co. modified and improved the flux several times after receiving test results and brazing operator feedback and comments. The joint effort was successful, and CTP Corporation incorporated the Superior No. 6M into its silver brazing process in February 2002 with very positive results. Today, CTP Corporation’s brazed joints have the same high quality as previously produced by the Superior No. 601, with brazing operators benefiting from a safer and healthier work environment.

Primary Dermal Irritation Index (PDII)*

Flux Without Potassium Bifluoride

Potassium BifluorideBearing Flux



* The Non-Corrosive/Corrosive dividing measurement is 5.0. The Draize scoring system is used for defining the skin irritation levels.

Benefits of bifluoride-free flux

Removing potassium bifluoride from fluxes eliminates the active chemical responsible for “flux sores” and fingernail damage. Since most fluoride-bearing fluxes etch glass, it is not surprising that they actively attack exposed skin and fingernails. Results from toxicological tests on two silver brazing fluxes are shown in Table 2. The flux without potassium bifluoride is not a primary irritant and is non-corrosive to skin. In contrast, the flux containing potassium bifluoride is a primary irritant and is corrosive to skin.

The brazing flux goes through an induction test. November-December 2003 n Fabricator

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Member Talk

n Lawler

Foundry Corp. makes a generous donation of cash and equipment to erect a first-class foundry on the grounds of the National Ornamental Metal Museum in Memphis, TN.

By Todd Daniel Editor

operations, but this area must soon be vacated to make room for the museum’s new library project. Making the new foundry possible is a generous gift from Lawler Foundry Corp. of On the eve of the National Ornamental Birmingham, AL. In addition to providing Metal Museum’s 25th anniversary, the a $50,000 donation for construction, Lawler facility took another giant step forward on Foundry will also help to equip the facility. October 18 with the dedication of the new According to Lawler CEO Stan Lawler, “My Lawler Foundry. personal interest in the National OrnamenOnce completed, the foundry will provide tal Metal Museum has been sustained by the a much-needed addition to the museum museum’s commitment to furthering the grounds, which already include a gallery, public’s awareness of fine metalwork.” As a morning fog began to lift, Stan surhousing, a smithy, and conservation lab. For 10 years, museum staff and volunteers veyed the construction site prior to the had used a small area of a shed for casting ceremony and reminisced. “This foundry is probably bigger than my dad’s first foundry, which started out in a corner of his machine shop,” he said. In those days, the company, which was founded in 1933, was primarily a machine shop, but their small foundry continued to grow and eventually became the main part of the business. Stan has had a strong interest in the museum since the idea was born 28 years ago. According to NOMMA records, a group of members from the Memphis area proposed the idea of a museum Museum director Jim Wallace and Lawler Foundry CEO during the 1975 convention in Stan Lawler shake hands following the dedication cer46

In a dramatic ceremony, the first posts are raised. The steel was provided by longtime NOMMA member Keeler Iron Works of Memphis, TN.

For your information


The birth of a foundry

Project: Lawler Foundry Corp. has made a generous donation to build a foundry on the grounds of the National Ornamental Metal Museum. Background: Lawler Foundry is a long-time supporter of the museum, and Stan Lawler is a founding member of the board of trustees. Lawler Foundry Corp. P.O. Box 320069 Co n tact Birmingham, AL 35232 Ph: (800) 624-9512 Fax: (205) 595-0599 National Ornamental Metal Museum 374 Metal Museum Dr. Memphis, TN 38106 Ph: (901) 774-6380 Fax: (901) 774-6382

Fabricator n November-December 2003

Atlanta, GA. Over the next four years, turning the dream into a reality was an incredible effort that involved personal financial sacrifice and much hard work from a group of dedicated NOMMA members, both local and nationwide. On February 5, 1979 the museum officially opened its doors with its first exhibit. Another major moment in the museum’s history was the opening of the Schering-Plough Smithy on June 13, 1986. A well-equipped facility

In honor of Lawler Foundry’s gift and long-time support, the new foundry will be named “Lawler Foundry.” Located on the west side of the smithy, the building will house melt furnaces, a kiln, and molding equipment for a green sand operation. Plans are to use the facility for education classes, such as patternmaking, and demonstrations. The facility

The first casting is poured! The pouring demonstration is a powerful moment during the dedication ceremony.

will also be used by staff to create custom parts for projects. In addition, director Jim Wallace is exploring the possibility of a summer residency program. According to Jim, the building will be a place where, “We can maintain our technology and maintain our traditions.” With the foundation already laid and the posts up, Jim estimated the foundry would be complete in 5-6 weeks—just in time for the museum’s anniversary celebration in February. The building of the foundry also precedes another major event for the museum, which is the opening of a new library that will be housed in a renovated 1800s building on the opposite side of the smithy. The museum has already raised most of the $1.5 million needed for the project, and plans are to begin construction and renovation work next year. Near the foundry construction site is another structure that serves as a reminder of Lawler’s long-time support—the beautiful Riverbluff Pavilion, which provides a majestic view of the roaring Mississippi River. In 1984, Lawler Foundry poured the castings for the structure, which is today a favorite site for weddings. Two years later, Lawler again showed their support for the museum by sponsoring a gallery exhibit. The new Lawler Foundry is much more than just a building—it is part of a grand vision to preserve an ancient craft and to perpetuate the skills of metalworking. A thanks goes to Lawler Foundry Corp. for their donation and their continued support.

A highlight of the dedication program was a casting demonstration. As a large crowd watched, Bob Rogers, the museum’s volunteer foundry manager, poured molten metal into a mold to create a commemorative plaque. The casting reads: “Lawler Foundry, First Pouring - October 18,

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Member Talk

Fabricated by Armin Iron Works Inc. n Aldo DeCiantis ventured out in

1991 to begin his own ironworking business. His latest project, the West End-Elliott Overlook Park, shows his success.

Visiting Pittsburgh and its suburbs, an out-of-town motorist could have problems driving, trying to determine whether they’re going east or west, north or south. That’s because the early settlers built their roads along the rivers. They had three of them to traverse. The Allegheny on the north side and the Monongahela on the south merge at Pittsburgh to form the Ohio. Fortunately, Pittsburgh people are friendlier than most big city folks. Instead of trying to give longsuffering directions to the West End Bridge, they’re likely to say, “Just follow me, and I’ll show you where it is.” We were driving to the West End Bridge because the morning newspaper had a picture of Pittsburgh’s new $2 million dollar park renovation, a high overlook of the city where Armin Iron Works Inc. had been working for nine months fabricating some intricate steel work. Despite capricious compass directions, Pittsburghers often describe where they live by saying, “On the Southside, or the Northside,” meaning they live on that side of the river. Small wonder then that the bridge across the Ohio River, west of downtown, is called the West End Bridge. When driving south across the bridge, if you tilt your head toward the sky, you’ll notice a defoliated strip between trees on the skyline high up on a ridge. In the Midwest a ridge that high is called a mountain, but in Pittsburgh it’s just another hill. That’s the site of the new West End Elliott 48

Overlook Park. From the overlook, 375 feet above the bridge, you can see the whole city on a clear day. Downtown Pittsburgh is a cluster of tall buildings squeezed between the Allegheny River and the Monongahela. The city proper sits like a slice of pie between those two rivers. That’s why they call it the Golden Triangle. Some of the nation’s largest corporations are headquartered there. Although Alcoa has moved to smaller offices, U.S. Steel, which goes by the name USX, Gulf Oil, and Pittsburgh Plate Glass remain. Where the two rivers form the Ohio, there’s a large fountain marking Point Park. If you look closely, off to the left, you’ll see Heinz Field and PNC Stadium where the Pirates and the Steelers play their games. White wakes made by formula-one racers participating in the annual river regatta were visible on the Allegheny side the day Aldo DeCiantis showed us his work. Aldo, President of Armin Iron Works Inc., pointed down across the Ohio River to an area where his company is located: “On the Northside.” He lives further north in the suburbs. Two days after the grand opening of the West End Elliott Overlook Park, a small crew from Armin were adding the finishing touches to the main park entrance conspicuously marked by a large steel trellis. Armin Iron had the contract for all the steel structures, part of the city park renovation. “We’ve still got to install the necessary handrails for the handicapped,” said Aldo. The improvements to the park include a visitor’s center, walkways, an amphitheater, and

For your information


By John L. Campbell

Aldo DeCiantis of Armin Iron Works Inc. stands under the arc of the 6-foot pipe trellis his company fabricated for the new Pittsburgh West End-Elliott Overlook Park.

Member: Armin Iron Works Inc., established in 1991, Pittsburgh, PA. Notable project: Armin Iron had the contract for all the steel structures, part of the $2 million city park renovation of West End Elliott Overlook Park. Armin Iron Works Inc. Casey Ind. Pk., Columbus Co n tact & Preble Ave. Pittsburgh, PA 15233 Ph: (412) 322-1622 Fax: (412) 322-1624

Fabricator n November-December 2003

an arched trellis entryway. For Aldo DeCiantis the project was one of his company’s biggest. The day following the Grand Opening the Pittsburgh Tribune Review featured photographs of the trellis and visitors looking over the city from the deck of the amphitheater. “The stairway up to the deck weighed over 8,000 pounds,” said Aldo, pointing to the structure at the rear of the amphitheater. Inside are restrooms. The city plans to have a concession stand and gift shop. “That’s 4 inch by 12 inch piping with ⁄-inch thick steel treads and checker plate,” said Aldo explaining the hefty construction of the stairs. Armin Iron Works grew out of a family business, one which Aldo DeCiantis left in 1991. For years he worked for his father, a blacksmith who emigrated from Italy in the early 1950s. Aldo spent his summer vacations working in his father’s business. Successful as a high school athlete in football and wrestling, Aldo had aspirations to coach. Now he finds himself coaching his two sons, both of whom are active wrestlers, the oldest having won the state championship in the 115-pound class at age 13. “My Dad’s company fabricated fire escapes back in the ’60s, when the city of Pittsburgh passed an ordinance requiring fire escapes for apartment buildings,” said Aldo, taking us on a tour of the city. He pointed to a high brick building with about a ten-story fire escape. “I helped build that one,” he said. From a distance it looked like a black bull snake on Georgia clay. Like a lot of young men, Aldo had ideas he wanted to implement in his work, but he was unable to budge his father and other relatives who had seniority in the business. “It was like a family business,” said Aldo. “My father gave me some of his stock in the company. The day I resigned I gave my stock back to him … told him I was quitting to start my own business. He just stood up, shook my hand, and wished me success. I never would have done it if my wife hadn’t been so supportive. She told me I’d regret it, if I never tried.” Aldo says he’s never been sorry. His father has since helped him on many projects. November-December 2003 n Fabricator

Installing the guardrail under the trellis, an Armin Iron Worker welds a section to put the final touches on a nine-month project.

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A rear stairway from the interior of the amphitheater to the top deck weighed over 8,000 pounds. It was fabricated using steel pipe and 1 /4-inch checker plate.

“Early on in my business, I found NOMMA to be a good resource for me. I drove to Lexington, KY for my first NOMMA convention.” People like John Groll, another Pittsburgh fabricator, were very helpful in aiding Aldo to branch out into other areas of fabricating. He learned more about the process of securing larger, high-profile jobs. Work on the West End Overlook started in November 2002. Armin Iron was a subcontractor for Mazza Engineering Associates. Jimmy De Cecco of Desmone Associates was the architect. The trellis arches are 6-inch pipe rolled to a 6 feet radius and the purlins are 4-inch pipe. The height of the trellis is 15 feet, three feet of which is sunk in the concrete. One of the challenges was erecting the structure on a curved slope. To protect the steel from corrosion Armin Iron applied a primer of Mio-Aluminum Corothane, a Sherwin-Williams product. The general contractor applied a final finish using a teal-colored, two-part epoxy. The guard rail overlooking the 375 feet drop is 810 feet long, the top rail and posts are 2-inch pipe with a 2 inch by 2 inch by ⁄ inch welding wire mesh. Years from now, Aldo DeCiantis can drive his grandchildren across the West End Bridge, and say “Hey, look up there. Your Popa built that. Let’s drive up and have a look.”

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Who Cares... about Consistent Quality Parts that Always Fit? about Fair Low Pricing? about Listening to Our Customers?

We Do.

since 1944.

Preserving the Integrity of our Industry.

1-800-258-4766 2025 York Ave. Memphis, TN 38104 (901) 725-1548 fax: (901) 725-5954 www.tnfab. com e-mail:

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Cover Feature

Job Profiles

ject inThe scope of this pro ess steel inl sta ved cur cluded a el and ste ess staircase, a stainl and ail, rdr gua ss gla etched nces. stainless steel light sco hrs. Approx. labor time: 800

A touch of Hollywood in Arizona With the help of the project’s architect, contractor, and homeowners, Magnum Architectural helped turn a residential remodeling project into an elegant dance studio and ballroom space.


Room additions and expansions are prominent features of most residential remodeling projects. They allow homeowners to make room for a growing family, enjoy the benefits of modern technology, pursue a favorite pastime, and even operate a business in the comfort and safety of their homes. These additions come in all forms: bedrooms, garages, home offices, home theaters, game rooms, hobby and craft rooms, and exercise rooms, each presenting a unique set of challenges for designers, manufacturers, and installers of architectural and ornamental metal products. Sometimes, though, a project comes along that requires extraordinary effort to bring forth a vision or concept. This was the case when Magnum Architectural of Phoenix, AZ accepted a particularly challenging project that won the gold medal in the 2003 Top Job Contest in the All Interior Railings category. Magnum Architectural is frequently called November-December 2003 n Fabricator

upon to draw, fabricate, and install custom metalwork in residential remodeling projects, and at first this appeared to be fairly straightforward task: Fabricate and install stainless steel and glass guardrails and handrails, light sconces, and millwork cladding for a home addition project in an upscale community outside Phoenix. But this was no ordinary home improvement project; this was going to be a 6,000 square foot modern dance studio and ballroom! The owner’s vision was to create an elegant and exotic atmosphere for entertaining and dancing, a fantastic space in which, according to the owner, “you could film a James Bond movie!” Arizona ultra modern

In its final form, “The Studio” resembles an ultra-hip night spot, worthy of New York City or Hollywood, and includes a state-ofthe-art sound system, a large, solid hickory dance floor with fiber optic lights and Italian tile, a full-service bar, and a curved stainless steel staircase leading to an elevated lounge enclosed by a stainless steel and etched 55


By Tom Mayer Magnum Architectural

For your information

Member: Magnum Architectural, Phoenix, AZ. Award: This project received a gold award in the 2003 Top Job Contest, in the All Interior Railings category. Homeowners: Harvey and Sandy Belfer, Paradise Valley, AZ General contractor: The Normandy Co. Architect: Jonathan Martens, Martens & Associates. Magnum Architectural 2439 South 49th Ave. Phoenix, AZ 85043 in fo m o re272-3600 fo r(602) Ph: Fax: (602) 272-6980

Panels are a combination of laser cut shapes and rolled stainless steel true bar, which create a whimsical pattern while meeting the 4” code rule.

glass guardrail. The ceiling above the lounge is artfully painted to resemble a brilliant sky at twilight. The Studio has an open, airy feel with floor-to-ceiling glass doors that open to a spacious patio, complete with custom water features and breathtaking vistas of Phoenix’s Camelback Mountain. The Studio can accommodate up to 150 people for special events. Designed from scratch

At the initial meeting with the architect, owner, and general contractor, everyone agreed that the studio would be upscale and contemporary with stainless steel and glass used extensively throughout the space. Over a period of several weeks and through several meetings and onsite walkthroughs, the project evolved from a series of ideas sketched on notebook paper to completed shop drawings that addressed details best left to an experienced stainless steel fabricator who is comfortable working with glass and stainless steel. The architect, Jonathon Martens of Martens Associates, also of Phoenix, AZ, granted Magnum a great deal of latitude to determine the best materials, fabrication methods, and alternatives throughout the entire process. Decisions regarding design and finish were communicated to Magnum Architectural project managers prepar-

Decorative glass panels were incorporated into the upper level of the project. Note the decorative “diamonds” that are randomly placed on the glass. Fill in 84 on Reader Service Card


Fabricator n November-December 2003

The dance studio also features a full-service bar. The bar counter features the same “random engine turn finish” that is used on the railing posts throughout the project.

ing schedules and price estimates, to the project draftsman preparing manufacturing drawings, and to Magnum’s structural engineer to ensure that the stairs and railings would be strong and secure. While Magnum had a fair amount of latitude in drawing the studio, final approval still came from the architect, contractor, and homeowners. So ongoing review and analysis, both internally and externally, kept the studio moving forward on time and on budget. The last thing anyone wanted on this project was a costly “surprise.” Fabrication made easy(er)

Once the design details were made final, Magnum Architectural Field Service visited the home to obtain initial measurements then returned with templates for major structures and to mark where major components were to be attached to the floor. Then Magnum set about creating finished samples of the highly styled stair rail panels. Stainless steel bars were formed into curves and then welded to triangular plates, forming a ray pattern. Two of these patterns were then welded to stainless steel posts. This was a labor-intensive task that required painstaking precision and a great deal of handwork. Project managers opted to laser-cut the railing panels from half-inch stainless steel plates instead of welding them. This produces a much better result at less cost. The panels are a combination of laser-cut shapes and rolled stainless steel true bar finished in #4 satin. The stairway from the dance floor to elevated lounge rises 5 feet 611/16 inches.

The usable arc of the inside stringer is 12 feet; the outside stringer has an arc of 16 feet. Both stringers are fl inch rolled stainless steel. The support posts are 8 feet 9 inches tall, and are constructed of 4 inch by 8 inch by .25inch wall rectangular tube. They are stainless with a random engine turn finish and are topped with 6-inch diameter spheres with 11 gauge stainless polished to a #8 bright mirror finish in our shop. The handrail is 11/2 inch rolled stainless with circumferential finish. Stainless steel light sconce faceplates are inverted triangles measuring 13 inches across the top and 24 inches in height, with 103/4 inch by 133/4 inch openings for lighting fixtures. Finish is a random swirl using a grinder and a light touch. Magnum made three of these for the studio.

A top view shows the beauty of the posts, spheres, and decorative panels. The effect on the posts was achieved with the random swirl of a grinder.

The project went smoothly with a lot of shearing, bending, welding, grinding, and polishing. Even installation presented no surprises. The result was a win-win for everyone, with recognition by NOMMA an added bonus for Magnum. About Magnum Engineering and Magnum Architectural

Magnum Engineering and Magnum Architectural specialize in fabricating and installing custom commercial and residential architectural metalwork,

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As these views from the lower level show, the railing system provides an eye-catching focal point for the room. All total, the ballroom and dance studio addition is about 6,000 square feet and can accommodate up to 150 people during special events.

including contemporary glass, steel, and cable rail and stair systems, traditional handrails, guardrails, and ornamental metalwork, gates and entry doors, commercial signage, architectural metalwork, and light structural steel fabrications. Magnum Engineering was established in 1979 by Glenn Brockman to manufacture metal components, sub-assemblies, and finished products for transportation, telecommunications, and electronic equipment manufacturers. Greg Brockman joined his father at Magnum in 1988 and currently serves as Vice President of Magnum Engineering. Today, Magnum Engineering continues to produce components for industrial clients nationwide. Versatility is key to success, and both

Glenn and Greg recognized that rapid growth in commercial and residential construction in the Phoenix metropolitan area had created unprecedented demand for custom architectural metalwork in a variety of styles, materials, and finishes. Magnum Engineering, already adept at manufacturing custom components, responded to inquiries from architects and builders to manufacture stair systems, guardrails, handrails, light fixtures, countertops, doors, and other metalwork in office buildings, hotels, restaurants, retail shops, golf course clubhouses, and private residences. With Greg Brockman serving as

President, Magnum Architectural was founded in 1997 to provide field installation services for architectural products manufactured by Magnum Engineering. Today, Magnum Engineering and Magnum Architectural employ 45 people engaged in estimating, drawing, manufacturing, field service and administration, occupying a fully equipped 30,000 square foot manufacturing facility in southwest Phoenix.

METALfab 2004

Sacramento, CA March 3–6, 2004

Shop Tours • Top Job Contest Education Classes • Trade Show Networking Opportunities

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Job Profiles

A ‘burning bush’ brightens a remodeled room When a remodeling project left a pair of homeowners with an ill-inserted fireplace, they commissioned this fabricator to make a fireplace screen to camouflage the problem. The result is a fireplace screen that creates a different, yet appealing, visual impression when both opened and closed.


By Abraham Dueñas

I was able to design and fabricate a unique fireplace screen. The concept of the design originated from Todd and Pam Morgan. From an early age I wanted to be an artThey had recently remodeled their home and ist, thanks to all those kindergarten finger had an extra room added with a fireplace. paintings. So I have always grasped at the They were unhappy with the way the insert opportunities life has given me to express my looked and wanted a fireplace screen that artistic side, projects ranging from singing on would be an interesting piece both opened video tape in my own Zoro costume at age 8 and closed. Because they have children, the to playing my bass clarinet for my parents’ design needed to include a safety back screen friends when they visited (ouch!). to prevent any possible accidents. Sadly, as a result of my very After discussing all the posfirst artistic expression I sufsibilities, we came up with a fered a paddling from my first“before and after” effect firegrade teacher for artistically place screen. When closed the engraving my name into my screen depicts a burning bush. chair with a pair of scissors. When opened, one gets the My latest expression though, impression that the fire has alI’m happy to say, came with no ready dwindled and moved on such negative repercussions. to the backdrop—represented Combining the welding/fabShannon and Abe Duenas of by the open folded doors next ricating skills passed on to me Excalibur Metalsmiths. to the opening—leaving only a by my father Rafael Dueñas few leaves left to burn. and the artistic creativity (that had been The materials chosen were fl-, fi-, and 5/16discouraged by a certain first-grade teacher), inch bark texture bar. Copper was chosen November-December 2003 n Fabricator


For your information


Designed by the fabricator, this “burning bush” fireplace setting is made with copper leaves that were hammer formed and heated. The doors are hand-forged branches that are interconnected to form two bi-fold doors. For the finish, the entire piece was clear coated to create a glistening effect. Approx. labor time: 50 hrs.

Member: Excalibur Metalsmiths, Gaffney, SC. Materials: Copper in fl-, fi-, and 5/16-inch bark texture bar. Interesting finishing technique: The assembled branches where sprayed with a light mist of water, which formed a thin layer of rust. Then the doors and branches were buffed, leaving some rust in the grooves of the branches. The assembled leaves were heated individually to create a variety of fiery colors. Biggest challenge: Building the bi-fold doors to look like branches and making the flames visible in front and behind the branches when the doors close. Ph: (864) 425-0022 in fo fo r m o re

with each problem as it arose. The most challenging parts were building the doors to look like branches, making them bi-fold, and still showing the flames in front and behind the branches when the doors were closed. The work begins

top: In the open position, the impression is created of a dwindling fire,with only a few leaves still burning. A challenge of this job was getting the flames to look right in both the open and closed positions. left: Each copper leaf was hand formed and heated, giving every piece a unique look.

simply because it has a natural base, a fiery-orange color to work with when heated. The removable back screen is made of Roman expanded metal. I don’t know if it’s because I don’t like to plan ahead or because this design was so different, but I ended up designing, building, and then dealing

The first step was to lay out the design that would be viewed when the doors were open. I made a drawing exactly to scale on my table. The bars were then bent according to the design that was drawn, and the process was repeated with the doors. There was some tweaking made here and there to achieve the desired appearance. Once the bush branches where finished, they were sprayed with a light mist of water. After a day, an even layer of rust formed over the entire piece. To create a realistic bark look, my brother helped me to buff the doors and branches, and what rust wasn’t buffed off stayed in the grooves of the branches. After applying the burning leaves, I then heated each leaf individually to give each its own fiery color. Afterwards the entire piece was

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clear coated. A helping hand

Having a one-man shop can be very good. You have one personality to deal with, and you can listen to any radio station while you work (yes, even country). But it can also be bad, especially if you need to draw out, cut out, file, hammer form, buff, and polish an assortment of over a hundred little copper leaves with flames on them. I think that’s why we have apprentices. Thanks to my 19-yearold brother Samuel Dueñas, I didn’t suffer tendonitis after this job. While I worked on the doors he did most of the work mentioned above. To ensure uniqueness, each copper piece was cut with different variations. Once they were TIG welded to the branches, they were then carefully heated to add an extra color to each leaf/flame. The hammering of the flames was done with metal shaping mallets and a shot bag. After they were hammered, we added a 1/16-inch flange around the edges to make them stiffer.

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Once installed, two rods were fabricated to turn the gas on and ignite the flame. When they are not needed, they hang behind the doors out of sight. But they are handy enough when instant warmth is desired. After everything was finished and installed, the piece was then signed using a Dremel® tool with a dentist carbide bit. Having 10 years experience with various types of metal fabrication, I would have to say that this type of work is my favorite. Support of enthusiastic clients allows you to be creative, inventive, and, overall, enjoy your work. It has really been a good experience all around. And it The leaves and branches were attached to black was especially nice to see my project among other fine top job expanded metal, which features a Roman-style pattern. The branches were given a “forced” rust entries at this year’s METALfab. and then buffed. After all the work mentioned above, what I’m left with is two very satisfied clients. And that is as good as any reward.


Job Profiles

Top Job Time Again! Have you fabricated an outstanding job in the past two years? If so, consider entering it in the Ernest Wiemann Top Job Competition. The annual Top Job contest is a great way to earn recognition

for your company. In addition to receiving a beautiful award, press releases are sent out for each winner, and winning entries are featured on the NOMMA web site and in Fabricator magazine. To enter the 2004 contest, please see details below.

9 n e : D ec . 1 2 0 0 4 D eadli e : Ja n . 5 * n L ate D eadli

For your information

right: Trade show attendees examine entries in the 2003 contest. Each NOMMA firm is allowed one vote.


What is Top Job? The Ernest Wiemann Top Job Contest is an annual award competition designed to encourage and recognize industry excellence. Who can enter? You must be a paid member at the time of entry. If you are planning to join NOMMA, you must pay a full year’s dues. What jobs are eligible? Any job that your firm has fabricated in the past two years. Joint ventures are allowed, but only one company may enter the job. How do I enter? All NOMMA members were recently sent a 2004 entry booklet. New members will receive one in their new member kit. There is also a Top Job support area in the Member’s Only area of the NOMMA website. How is the contest judged? All entries are displayed in a gallery during the METALfab trade show. NOMMA members then walk through the gallery and enter their votes on a ballot form. Each member firm is allowed one vote. What is the Mitch Heitler Award? The award is chosen among the gold winners by the Mitch Heitler committee. It is considered the “best of the best” award and is presented only once annually.

*A late fee is required for each late entry.


left: The anticipation builds at the Saturday awards banquet as everyone waits for the winners to be announced. During the ceremony, winning entries are flashed on a screen as names are called.

right: Award recipients are presented with a beautiful cast plaque. Shown are Chris Huey and Doug Bracken of Wiemann Ironworks. The firm has won nearly 150 awards since the contest began in the 1970s.

Questions? Contact Top Job Chair Chris Connelly at (508) 238-4310 E-mail: Fabricator n November-December 2003

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Gallery To set the mood for the 2004 Ernest Wiemann Contest, we are pleased to present a sampling of 2003 entries. In this issue, we focus on interior railings.

right: This rail was designed by the fabricator and contractor. The rail features a 2⁄” bronze cap, fi” bronze square fan design, fl” square loops through 1fi” channel. All the bronze joints were mechanically fastened with flat head brass screws that were partially countersunk, and then the screwdriver slot was ground off and polished. The pieces were pre-polished before assembly. The bronze fan design was bolted to the fl” square loops with ⁄ - 20 flathead screws. This home is in a municipality that was still using the 6” sphere rule when the house was built. Labor time: approx. 800 hours. Fabricator: Groll Ornamental Iron Works, Pittsburgh, PA. Award: 2003 bronze, interior railing category.

FPO Texas Metal Industries (TMI)


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top & top right: The rail system consists of silicon bronze rail posts with leather wrapped steel horizontals. Posts are secured at their bases using hidden sleeve connections into Julius Blum glass rail shoe moulding. The entire shoe and curb assembly is clad in silicone bronze. One end of the top of each rail post is bored to accept the machined end of the leather wrapped steel horizontal member forming a tight slip fit. The opposite end of the leather member butts to the post and is connected by means of a stepped machined insert sliding into place through the top of each “T.� Each rail has places requiring another stepped machined insert that is pushed into locking position by a spring installed inside of the horizontal pipe. Set screws and epoxy were used to make the final installation extremely solid. Bronze posts were finely sanded and Scotch-brite finished. Dark reddish brown patina was applied to closely match the wood. The finish is a rubbed wax. Fabricator: Myers & Company Architectural Metals, Basalt, CO.

A business unit of Antech Corporation n 4261 South Country Club n Tucson, AZ 85714-2009

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below & right: This project involved a double staircase that was part of a grand entrance to the house. All design work was done by the fabricator, using a combination of prefabricated scroll panels and pickets. The real challenge was matching to a stairway that varied in both radius and pitch. Working off a pair of wood fixtures supplied by the builder, a steel fixture was constructed that allowed the horizontal channels to be shaped and subsequent design filled in. The finish consists of a black base coat with bronze brushed on the entire rail and gold applied to accent the details. The rail was delivered to the job in several parts and welded together on site. Labor time: approx. 120 hrs. Fabricator: Kelley Ornamental Iron LLC, Peoria, IL.

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top and right: The homeowner provided a photo of a railing she saw in Paris, and the railing was developed from the picture. The entire design was CAD drawn and submitted to the client for approval. Once approved, the urn shaped components were sent out for plasma cutting. The festoons are made from a single piece of 3/8” brass rod. The ends of the festoons were drilled and tapped for the finials. The brass finials were CAD drawn and cut on a CNC lathe. The rings were turned from 4” OD solid brass. All the brass was polished to a mirror finish and clear coated. The brass was all mechanically fastened to the railing with flat head screws. The finish on the steel is cast iron gray. There is a total of 28’ of stair rail, 21’ of straight balcony rail, and 8’ of curved balcony rail. Approx labor time: 650 hrs. (including 250 hrs. for brass work). Fabricator: Neiweem Industries Inc., Oakwood Hills, IL.

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left & top: This bronze and aluminum rail has a unique blend of oil rubbed bronze, polished aluminum, and polished cast brass medallions. The combination of materials and finish provide the eye with a treat of many shapes, surfaces, and finishes. Unique, custom designed, one of a kind “Wild Rose” medallions are framed in polished aluminum “V” and then surrounded with solid oil rubbed bronze. All total, there is 198’ of rail with all of the joinery concealed. A major challenge is that the design allowed no room for error. Approx. labor time: 2,150 hrs. (fabrication, finishing, and installation). Fabricator: Big D Metalworks, Dallas, TX.

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Job Profile

Dirty Shop? Let Mr. Klean come to the rescue

Figure 2. Clutter is a safety concern and influences employee attitudes as well as customer perceptions.

What you’ll learn! n Need

to re-take your shop and create a clean work environment? Let Mr. Klean show you how to implement an effective “clean” program.

By Steve Thompson, PhD, Bruce Paynter, and Bob Borsh Grinding is a dirty process, and nothing

clean ever came out of the back end of a chop saw. Milling, drilling, boring, grinding, sawing, shearing, torch cutting, and welding are all dirty processes. These processes produce chips, dust, fumes, particulate matter, oil spray, scrap, and other forms of shop contaminating material. Wooden pallets and packaging material, such as polystyrene peanuts, cardboard, banding straps, and shrink wrap plastic, contribute to clutter overload in the facility. [figure 1] At some point you may find that fabrication process by-products, shipping materials, shop clutter, and lack of organization of tools and supplies are beginning to affect work attitudes, customer perceptions, and employee safety [figure 2]. Rapid changes in the business environment or employee turnover may have stressed the intended infrastructure and business processes associated with management of shop floor clutter control [figure 3]. The solution to the clutter control can be achieved through implementation of November-December 2003 n Fabricator

an approach called Mr. Klean. Mr. Klean is a low-cost method aimed at establishing a systematic way to organize, clean, develop, and sustain a productive work environment. It fosters a mindset among management and employees that sponsors shop floor housekeeping and efficiency. To put it succinctly, “a place for everything and everything in its place” is the mantra. The end result is an increase in quality, a decrease in cycle time, and neutral, if not delighted, customers. Does it sound too good to be true? Well, it does in fact work. The Mr. Klean concept is a streamlined variation of the Japanese system called a 5S pro-

For your information


Figure 1. Incoming raw material and associated packing material requires “clutter management.”

Bruce Paynter is Facilities Managing Director at Applied Materials Inc.* and holder of numerous awards from city and state for excellence in managing the workplace environment.

*The views expressed in this article are those of the authors and are not statements made by Applied Materials Inc.

Bob Borsh is a partner of House of Forgings and a NOMMA Supplier Director. Steve Thompson, PhD is an Associate Professor at Texas A&M University and owner of The Dollar Eighty Ranch and Forge.

figure 3. This unsightly pile is a perfect target for Phase 0. 69

figure 4. Photo documentation and MBWA target locations.

gram which was developed to support elimination of business waste through Lean Manufacturing methodologies. The 5S methodology is based on application of five activities loosely translated from the Japanese as follows: n Sort: Separate needed items from un-needed items. n Set in order: Organize the workplace. n Shine: Cleanup. n Standardize: Create uniform approach across work areas. n Self-discipline: All participate in supporting a clean workplace. A challenge for U.S. workers with successful implementation of a traditional 5S approach lies in the somewhat rigid Japanese methodology combined with a “not invented here” mentality. The Mr. Klean approach is biased to leverage our individual “make it happen” spirit while retaining the learning of well-tested methodologies developed elsewhere. The Mr. Klean approach defines the broad criteria by which you want to manage your facility, then you involve the workforce, and finally, you enforce the standard of acceptable performance through daily tours and visual documentation. This provides a number of benefits. An important one is visible management, sometimes called MBWA (Management By Walking Around). You learn quite a bit by waking around and having impromptu conversations with the workforce. These are the people that really know the happenings of the facility. Reports and metrics can tell you quite a bit; however, there is nothing better than getting right down into the thick of it. Additionally, your presence reinforces the value of the program. You get to walk the walk and talk the talk in a systematic manner by conducting regular, sometimes daily, tours of your facility. Instant action

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The approach offered by Mr. Klean is to combine leadership with instant action and 5S basics. If you are really serious about cleaning up your shop, take action right now. Stop reading this article, and do something about cleaning Fabricator n November-December 2003

up the shop. The Mr. Klean approach in Phase 0 advocates no meetings, training, consensus, grand plans, or general agreements. Just identify some area that needs improvement and clean it up. Ideally this will involve the people actually working in that area, but not necessarily. At a minimum, get a broom and sweep the floor. Alternatively go straight to a building supply retailer or some other outlet right now and buy several trash cans, brooms, and dust pans, carry them into the shop and start the process. This is phase 0. Again, do something low cost immediately.

5. Substandard areas, such as cluttered corners, should be immediately addressed


Pick Mr. Klean

Phase 1 involves identification of an individual in the target area who has a passion for order and housekeeping, and possesses some leadership skills. This individual is designated Mr. Klean. Let this individual pick some other individuals as support and form a small, very informal team. It is frequently entertaining to allow the team to name themselves. One of us actually belongs to a team named “The Clutter Dogs.� It may be juvenile, but it creates a little good-natured spirit about an activity few individuals really care about. Empower this team and give them a small budget to support their activity. Identity and empowerment can be powerful incentives. Prioritize and document

A picture is worth a thousand words, so leverage current technology [figure 4]. One simple, yet effective, methodology to help prioritize Mr. Klean action is immediately buy a couple of one-time use cameras. Let Mr. Klean and friends shoot pictures of some areas that need improvement from a dirty, clutter, or organization perspective. It may be a liability risk, but it is better to address the issues now, rather then when it is too late. Post the photos on a prominent billboard somewhere before, but more importantly, after cleanup. The after photos should be moved to the appropriate work area to serve as a standard of performance. There is no November-December 2003 n Fabricator

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figure 6. Mr. Klean program in place at this warehouse site.

need to write extensive documents,

low, includ-

File photo

At this shop, cleaning is an ongoing activity. Notice the worker in the background.

simply provide a visual record as to the expected standard. Attack areas one at a time as business demands and standards of expected performance al-

ing before and after pictures of each area addressed. Visibly active management

At this point in the Mr. Klean process, improvement has occurred primarily in the as-is condition. Improvement to the to-be condition, the next phase of a Mr. Klean activity, will likely involve unforeseen time and money, therefore it is important to have firsthand knowledge of the real priorities and needs, as a flood of improvement suggestions can defocus value-add action. There is so much that you can tell about a workplace and the workers by taking a good, hard look on your own, but business growth, or for that matter grime and clutter, may well have forced key decision makers to limit time on the shop floor. To assure key Klean opportunities are not missed and low value-add activities not undertaken, implement (or re-implement) the old concept of management by walking around with a very specific focus on trash, dirt, scrap, waste, and clutter. As a part of the improvement to the to-be phase of Mr. Klean, conduct a 10-15 minute walkthrough of all areas of interest twice daily. It is recommended that a brief cleanup and walkthrough occur at the end of the workday with a specific focus on clutter, additionally access which tools and supplies are not available for the next day or next shift’s work. Sub-standard work areas or “corners” identified [figure 5] need to be addressed immediately. How are supplies distributed? Are some people hoarding key supplies? Should you look through those drawers? Is there an excess of materials not needed on an hourly basis cluttering a work location? Are packing materials blocking movement in high traffic areas? What about scrap? Instant action needs to be taken on key issues discovered. This walkthrough approach will not work if it evolves after a couple of days to brief chat or review of someone else’s walkthrough. Firsthand knowledge by the principal decision maker is needed. He/she is Mr. Klean’s sponsor and needs to demonstrate sustained support. A walkthrough before the morning shift to access barriers that will limit the workers maximum productivity is strongly recommended. Direct involvement, i.e. doing some

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Fabricator n November-December 2003

actual cleanup and organization work, by the key decision maker is not just nice to have, but a necessity. Avoid bureaucratic detours

At this phase in the process there is a natural tendency for someone to start talking about savings rollups, future savings forecasts, productivity improvement charts, etc. These bureaucratic activities are in general better off avoided and waste value-add time better applied to actually executing Mr. Klean work by and for those who actually understand the issues from first hand experience. If the key decision maker can’t justify the cost versus advantage of a particular activity on a daily walkthrough, then the activity in question is probably better viewed as part of some initiative, such as productivity up or backlog down. Mr. Klean should not be viewed as an initiative but as a vital part of the culture of doing business. Leadership is critical, and the Mr. Klean program has to be driven from the top. Management has to value the program and demonstrate their commitment with active participation. It is not really difficult; it just requires some basic self-discipline. The term zero tolerance is often used in safety and quality campaigns, it is the core philosophy in the Mr. Klean program. Never walk past a problem: you either own it until you fix it or you find the person responsible for fixing it. A successful program can create a clean culture shift and institutionalize a management system for facility excellence [figure 6]. If your business model, history, philosophy, bias, and culture are inconsistent with attacking a dirty and disorderly shop, then a Mr. Klean approach is probably better off left to others. If however, you are ready for shop floor improvement, give the Mr. Klean approach a try. It’s low cost, effective, and it works.


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Biz Side

Six ways you sabotage your leadership ability What you’ll learn!

Change-management expert Morrie Shechtman says if you’re leadership skills still need some tweaking, another executive certification program isn’t going to help. Discovering your own self-personality patterns will—and some of them may surprise you. n

By Morrie Shechtman With all your years of management experience, your leadership skills should be impeccable. You’ve taken every executive certification program

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Fifth Wave Leadership, by Morrie Shechtman, is published by Facts on Demand Press.

that’s come down the pike. You’ve been trained, coached, counseled, and seminar-ed to the point of overload. But somehow, your leadership style is wanting in effectiveness in ways both overt and subtle. Even though you

don’t want to admit it, you’ve noticed that the same problems keep cropping up over and over again. And frankly, you’re not sure how to turn things around at this point. Instead of looking outside yourself for help, try looking inward. The truth is, your success as a leader has much more to do with your level of self-awareness than with how many management books you’ve read and how many leadership programs you’ve completed. We all tend to repeat the same patterns over and over. That’s because we are all subject to our familiars, which are strong and persistent collections of attitudes rooted in childhood that cause us to act in certain predictable ways. It’s very difficult to change your leadership patterns if you don’t understand this basic truth. Further-more, the familiars that commonly manifest in the workplace can make it seem as though unproductive leadership behaviors are “normal”—an illusion that helps keep you mired in the same problems throughout your career. To make matters worse, the information- and technology-rich era we live in makes it harder than ever to be a leader. You have to be able to navigate a tremendously sophisticated maze of business possibilities and inspire and Fabricator n November-December 2003

For your information


About the Book: Fifth Wave Leadership: The Internal Frontier (Facts on Demand Press, January 2003, ISBN: 1-889150-38-X, $19.95) is available at bookstores nationwide, major online booksellers, or directly from the publisher by calling (800) 929-3811. About the Author:

motivate people on a deeply personal level. The two most critical skills in today’s world are making good decisions and building strong relationships. And that’s why it’s more important than ever to understand the behavior patterns that keep you from doing so. Certainly, the emotional baggage that’s weighing you down and keeping you from reaching your full leadership potential is varied and complex and requires stringent internal exploration to identify. But many of my clients and colleagues are struggling with the same basic leadership problems, and examining them may yield insights you can apply to your own life and career. Here are some of the most common reasons you may be failing as a leader: You live by the theory of scarcity rather than the theory of plenty.

The theory of scarcity holds that there

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Morrie Shechtman is an international change management consultant who has taught at distinguished universities throughout the United States, worked as a therapist and counselor, and now runs a successful management consulting company, Fifth Wave Leadership. Morrie Shechtman, Fifth Wave Leadership, ct co nta Web:

are very limited resources out there to meet your needs, and you must therefore accept any opportunity that comes your way. The theory of plenty says that there are infinite resources available to you, and you can pick and choose opportunities that mesh with your values and that ultimately benefit you. Believe it or not, you learned one of these mindsets before you were five years old—and it is still driving the decisions you make in your life and career! If you subscribe to the theory of scarcity, you have a sense of desperation about every business decision you make. You may take on clients that undermine your company. You may hire and keep toxic employees. You may become trapped in fragmentation (because there’s no discernable focus to your business) and isolation (be-


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cause you are too afraid to collaborate with people who might “steal” your business). On the other hand, if you live by the theory of plenty, you turn down business that isn’t right for you. You hire the right kinds of people and fire those that are harming your company. You make focused, discriminating business choices based on your values and vision. You collaborate freely, thus expanding your network and leading

A good leader must confront his employees on their negative be-

haviors and attitudes. If you just tell people what they want to hear, you perpetuate relationships that are comfortable but ultimately superficial and pointless. more people to see you as a resource. If you lose a client, so what? You know a better one will come along. It’s easy to see how this mindset makes you a better leader. You avoid and

5186-F Longs Peak Road, Berthoud, CO 80513

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discourage conflict

Do you think that conflict is somehow “bad” for yourself and your company? It’s not. Indeed, managing conflict is the very foundation of leadership. That’s because there is no growth without challenge, and there’s no challenge without conflict. A good leader must confront his employees on their negative behaviors and attitudes. Sure, it’s painful (for you and for them), but if you just tell people what they want to hear, you perpetuate relationships that are comfortable but ultimately superficial and pointless. And you give them the false impression that they are competent at doing what they’re actually incompetent at doing. And in the process you lose all credibility as a leader. Many people believe that teamwork means everyone agrees, supports each other, and gets along. Nothing could be further from the truth! Effective teams are made up of people who care enough about each other to generate conflict and confront the tough issues. If everyone agrees with their teammates without question, what usually happens is the whole team marches down the rosy path to self-destruction. It’s business suicide! So discouraging conflict between your employees may hurt your business.


You refuse to get involved in employees’ personal lives

Consider this truth: all business is personal. In our integrated, information-intensive culture, it’s difficult to live compartmentalized lives. There is no longer a firewall between personal and professional; we now live “blended” lives marked by a sense of fluidity. You as a leader already take work home, and chances are so do your employees. So why is it so difficult to accept the converse, that employees’ personal lives come to work with them? The reality is that the personal issues your employees deal with (or don’t) do affect their work—and therefore it


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is appropriate for leaders to address these issues. Here is an example. Suppose that you have a valuable employee who is involved in an abusive, dysfunctional relationship. You know about this, but figure that it’s a personal issue and none of your business, so you don’t broach the subject with her. Then one weekend she finally decides she’s had enough, so she flees the scene— just packs her bags and leaves town. Because no one was there to help her, she ends up leaving the company in a terrible bind. Good leaders realize that people’s un-dealt-with issues, whether they manifest at home or at the office, are the company’s greatest risk . . . and they work to eliminate that risk.    You intervene too early in

people’s struggles

One of the worst things you can do in business—as well as in society in general—is to intervene too early in the struggles people face. As soon as you do so you take responsibility for their lives, and they never discover how rich a resource base they possess. Your employees must find the path that works for them. If you take over they will know what works for you but not necessarily what works for them. Struggle is empowering, and there is dignity in it. As a leader you need to understand that struggling with their issues is how people get clear on what they believe. Their knowledge comes from their feelings, and you can’t teach feelings; people simply have to experience them. So if you just give employees the


If you’re the kind of leader that other people tend to put up on a

pedestal and turn to for all the answers, you may be crippling your company. That’s because charismatic people remove responsibility from everybody else, suggesting they can’t do anything on their own behalf.

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“right answer,” you circumvent this feeling process. And if you intervene too early it’s probably because of your own pain—it’s painful for you to watch them struggle. It’s similar to “tough love.” And it’s the only way they will ever grow and develop. You are charismatic

If you’re the kind of leader that other people tend to put up on a pedestal and turn to for all the answers, you may be crippling your company. That’s because charismatic people remove responsibility from everybody else, suggesting they can’t do anything on their own behalf. And what happens is that your employees are so mesmerized by you that they come to see themselves as followers—not as future leaders. Your company fails to grow and develop people to take over after you leave. And succession management is one of a leader’s prime responsibilities. In a sustainable organization, the leader is not charismatic but the culture is. A charismatic culture has a clear value


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system that constantly lets people know where they stand. It’s full of opportunities for growth. The fact is people want to make an impact on the culture that they live and work in. If everything they do is for someone else, they will always have a sense of dissatisfaction about their own roles. Charismatic cultures give people a sense of meaning in their lives. When they act on their own behalf they make a greater contribution and have a greater investment in the organization. You’re

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If you’re wondering why emotion needs to enter into the equation

at all, the answer is simple: people respond to feelings, not thoughts. If you mobilize people’s feelings they will contribute to a very strong culture. If you merely mobilize their thoughts, they will hold back their “gut reaction” and fail to give you full investment. moody

There are few guarantees in a global, information-driven economy. The world we live and work in is unpredictable and has become even more so since September 11. Therefore, the last thing employees want is an emotionally


unpredictable (i.e., “moody”) leader. They will gravitate toward a leader who possesses an emotional core that doesn’t vary. This does not mean they want an emotionally neutral “robot.” Rather, they want a leader whose reaction is consistent with certain events. Specifically, that means someone who reacts negatively to anything that goes against company values and positively to anything that is in line with company values. (See why it’s so important to clearly define those values?) If you’re wondering why emotion needs to enter into the equation at all, the answer is simple: people respond to feelings, not thoughts. If you mobilize people’s feelings they will contribute to a very strong culture. If you merely mobilize their thoughts, they will hold back their “gut reaction” and fail to give you full investment. People vote with their feelings. If it doesn’t feel right, they won’t do it. And if they don’t believe that you are driven by your feelings, they won’t follow you. Did you recognize yourself in any of these examples? If so, don’t be discouraged. Knowing the enemy is the first step toward defeating it. Once you’re aware of what’s holding you back, you can change your self-destructive patterns. You can drill down and examine the long-buried demons that are keeping you from optimal performance in your leadership role. Eventually, you’ll be able to diminish the power of your old familiars and create healthy new ones. And once your self-imposed road blocks have been demolished, you’ll be on your way to leadership excellence and, ultimately, a more meaningful and fulfilling life

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Nationwide Supplier Members As of October 28, 2003

Boldface denotes new members.

A Cut Above Distributing 800-444-2999 Advanced Measuring Systems 888-289-9432 Allen Architectural Metals Inc. 800-204-3858 American Punch Co. 800-243-1492 American Stair Corp. 800-872-7824 Apollo Gate Operators 210-545-2900 Architectural Iron Designs Inc. 800-784-7444 Armstrong-Blum Mfg. Co. 800-472-9464 Artezzi 800-718-6661 Atlas Metal Sales 800-662-0143 Aztec Castings Inc. 800-631-0018 Walid Al Baker Trading Est. 011-974-460-3303 Julius Blum & Co. Inc. 800-526-6293 J. G. Braun Co. 800-323-4072 Builders Fence Co. Inc. 800-767-0367 Byan Systems Inc. 800-223-2926 The Cable Connection 775-885-1443 Carell Corp. 251-937-0947 Chamberlain 630-279-3600 George Ciocher 201-861-3150 Classic Iron Supply 800-367-2639 Cleveland Steel Tool Co. 800-446-4402 CML USA Inc. 563-391-7700 Colorado Waterjet Co. 970-532-5404 Crescent City Iron Supply Inc. 800-535-9842 Custom Ornamental Iron Works Ltd. 604-273-6435 D & D Technologies (USA) Inc. 800-716-0888 D.J.A. Imports Ltd. 800-933-5993 DAC Industries Inc. 800-888-9768 Decorative Iron 713-991-7600 DécorCable Innovations 312-474-1100 DKS, DoorKing Systems 800-826-7493 Eagle Bending Machines Inc. 251-937-0947 EAGLEGate 801-321-8252 Eastern Metal Supply Inc. 800-343-8154 Eastern Ornamental Supply Inc. 800-590-7111 EDF Equipment Sales Inc. 407-351-7017 Elegant Aluminum Products Inc. 810-293-1020 Encon Electronics 800-782-5598 EURO-FER SRL 011-39-044-5440033 Euro Forgings Inc. 800-465-7143 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 The G-S Co. 410-284-9549 Geo. Bezdan Sales Ltd. 800-663-6356 Georgia Classic Design 770-506-4473 Glaser USA 847-782-5880 Graham Manufacturing 888-897-1026 GTO Inc. 800-543-4283 Hartford Stdrd. Stampings & Plating 270-298-3227 House of Forgings 281-443-4848 Indiana Gratings Inc. 800-634-1988 Innovative Hinge Products Inc. 817-284-3326 Interstate Mfg. Associates Inc. 603-863-4855 The Iron Shop 800-523-7427 Italfer Architectural Iron Inc. 905-455-6100 ITW Industrial Finishing 630-237-5159 Jamieson Mfg. Co. 214-339-8384 Jansen Ornamental Supply Co. 800-423-4494 Justin R.P.G Corp. 310-532-3441 King Architectural Metals 800-542-2379 80

Joachim Krieger 011-49-64-258-1890 Lavi Industries 800-624-6225 Lawler Foundry Corp. 800-624-9512 Lecky Metal Ornaments LLC 760-598-4118 LGC Non-Ferrous Castings 603-934-6370 Liberty Brass Turning Co. 800-345-5939 Mac Metals Inc. 800-631-9510 Marks U.S.A. 631-225-5400 Master-Halco 888-643-3623 Matthews International Corp. 412-571-5548 Mittler Bros. Machine & Tool 800-467-2464 Frank Morrow Co. 800-556-7688 Multi Sales 562-803-3552 New Metals Inc. 888-639-6382 Ohio Gratings Inc. 800-321-9800 Old Iron Doors LLC 205-970-0500 Omega Coating Corp. 888-386-6342 Orange Steel & Orn. Supply 305-805-6000 Overseas Supply Inc. 281-776-9885 Production Machinery Inc. 410-574-2110 R & B Wagner Inc. 800-786-2111 Regency Railings Inc. 214-742-9408 Rik-Fer 011-39-043-4630031 Robinson Iron Corp. 256-329-8486 Rockite, Div. of Hartline Prod. Co. 216-291-2303 Rogers Mfg. Inc. 940-325-7806 Sahinler Form Metal San. Ve Tic. 011-90-224-4700158 Scotchman Industries 605-859-2542 SEA USA Inc. 305-594-1151 SECO South 888-535-7326 Sharpe Products 800-879-4418 Signon USA 866-744-6661 Sparky Abrasives Co. 800-328-4560 Stairways Inc. 800-231-0793 Steel Masters Inc. 602-243-5245 Stephens Pipe and Steel LLC 800-451-2612 Steptoe & Wife Antiques Ltd. 800-461-0060 Striker Tool Co. (USA) Inc. 916-374-8296 Sumter Coatings Inc. 888-471-3400 Tennessee Fabricating Co. 800-258-4766 Texas Metal Industries 800-222-6033 Texas Stairs & Rails Inc. 281-987-2115 Transpacific Industrial Supply Co. 909-390-8885 Triebenbacher Bavarian Iron 800-522-4766 Triple-S Chemical Chemical Prod. 800-862-5958 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 West Tennessee Ornamental Door 901-346-0662 Wrought Iron Concepts 877-370-8000 Wrought Iron Handicrafts Inc. 800-456-7738 Yavuz Ferforje A.S. 011-90-258-2691664

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NE NOMMA Education Foundation F

In partnership with the National Ornamental & Miscellaneous Metals

The NEF Page provides the latest news and activities of the NOMMA Education Foundation.

NEF Logo Design Contest Ideas are needed for a new NEF logo. Do you have a knack for drawing? If so, please consider sharing your talents with us. The logo design should reflect both the industry and NEF’s educational mission. If your design is selected, you’ll receive official recognition in Fabricator and at the convention. Submit ideas by: December 31. Send to: Martha Pennington at the address below. You can also e-mail ideas to: martha@


New Title

NEF introduces two new books

The NOMMA Education Foundation has added two more titles to its growing collection. These books can be ordered on-line at www. or by calling the NOMMA office at (404) 363-4009. Historic Ornaments & Designs CD-ROM and Book By Dover Publications

Features 623 illustrations spanning many design traditions—from primitive tribal and Egyptian to Chinese and French Renaissance, with motifs derived from Pompeiian mosaics, metalwork, terra cotta vases jewelry, and much more. The 64-page book is 81/4 x 11” and the CD-ROM is contained in a sleeve on the inside back page. Cost: $16.95 nonmembers, $14.95 members.

Wrought Iron and Its Decorative Use By Maxwell Ayrton and Arnold Silcock

A superb treasury of decorative wrought iron, this 208-page volume presents an informative survey of the ancient craft’s practice throughout England. Its history can be traced simply by admiring the illustrations of gates, railings, and other works. Beginning with a general retrospective, the text cites specific examples throughout the ages, with particular emphasis on the artistry of Jean Tijou. Includes 241 black-and-white illustrations. Cost: $19.95 nonmembers, $16.95 members

A scene from the 2003 auction.

Auction Items Needed

Help support the educational mission of NEF by donating an item to the 2004 NEF Auction. The auction takes place Thursday and Friday (Mar. 4 & 5) during the trade show with a grand finale at the Friday evening theme dinner. Items donated can include anything from metal sculpture to gift certificates from suppliers. You can display the product by either bringing it to the convention, providing a photo, or sending the item directly to NEF prior to February 5, 2004. To donate or for more info, contact Martha Pennington at or (404) 363-4009, ext. 11.

The fair market value of items contributed to NEF are tax-deductible as a charitable contibution to the extend allowed by law.

Support NEF today with your tax-deductible gift.... q I will help the NOMMA Education Foundation deliver quality education programs and services for the industry. Name:__________________________________________________________________________ Company:_______________________________________________________________________ Address:________________________________________________________________________ City:_________________________________State:___________Zip:________________________ Phone:_______________________ Fax:____________________ E-mail:_____________________ I would like to pledge: q $25 q $50 q $100 q $500 q $1,000 q Other $_______ Type of donation: q Individual q Corporate Check One: q Check q Credit Card (choose type below) q Visa q MasterCard q Discover q American Express Card Number: ______________________________________________________Exp. Date: ____/_____ Signature:______________________________________________________________________________

If paying by check or credit card please include this form, along with remittance, and send to:

NOMMA Education Foundation

532 Forest Pkwy., Ste. A Forest Park, GA 30297 Phone: 404-363-4009 Fax: 404-366-1852

What’s Hot? n Biz Briefs Forge & Anvil Metal Studio moves to expanded facility Forge & Anvil Metal Studio of Ontario, Canada, a fabricator specializing in custom forgings from artistic to industrial, has recently moved to an expanded facility. “Our stock of gas forges and anvils has been expanded to include more styles and sizes including Mankel gas forges,” says owner Dean Piesner. “We have moved right into the 21st century with our very own forklift.” While the firm moved to a different town, their web site remains the same:

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Inside Biz Briefs 82 Chapter Events 86 Coming Events 88

New Members 89 People 90 Products 92 Literature 92

PMA leads demonstration to end section 201 steel tarMetalforming executives brought a metal stamping production line to Capitol Hill recently to urge President Bush to terminate the Section 201 steel tariffs after results from the International Trade Commission 332 report confirmed that small steel-consuming manufacturers are laying off workers and moving production out of the U.S. due to the higher cost and reduced availability of steel. Members of Congress, including Representatives Joe Knollenberg (MI-09), Pete Hoekstra (MI-02) and Mark Kirk (IL-10) and Jim Zawacki, Precision Metalforming Association (PMA)

chairman and chairman of GR Spring &555 Stamping Inc., led the demonstration. “We have brought this fully operational metal stamping production line to the west front of the Capitol building to dramatize how important manufacturing is to the future of our economy,” stated Zawacki. This press can make parts only if we can obtain high quality, competitively priced steel. We have the skilled employees who need jobs. What we need is for the President to end the 201 steel tariffs right now.”

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No major changes for Div. 5 in MasterFormat expansion MasterFormat™, a widely used format in the U.S. for nonresidential building specifications is undergoing expansion. The Construction Specifications Institute (CSI) has updated MasterFormat every five to seven years. The last revision occurred in 1995. The expansion now under way addresses two developments in the construction industry: “dramatic growth in the scope and complexity of buildings’ computer and communications systems and rapid advances in the types and uses of construction materials.” According to CSI’s web site, “The new edition of MasterFormat addresses existing topics more fully and adds new ones. Coverage expands to include specifications formats for heavy civil engineering projects (roads, bridges, etc.) and industrial construction (factories, power plants, etc.).”

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Biz Briefs Chamberlain Group acquires Elite Access Systems The Chamberlain Group Inc., a manufacturer of residential garage door and gate operators, recently acquired Elite Access Systems Inc. and Elite Entry Phone, a manufacturer of automatic gate and telephone access control systems. According to Chamberlain’s CEO, J. David Rolls, the acquisition of Elite will give Chamberlain one of the nation’s broadest lines of perimeter access control products. “The combination of these two companies is essentially an industry-changing event,” Rolls says. “Elite has built a stellar reputation as a company dedicated to providing its customers with superior safety, quality, performance, and service. We intend to preserve and strengthen the Elite brand name.”

However, a quick glance at the most recent draft, available on line at www., reveals that changes in the document under Division 5, the metals industry, are more organizational changes in the document itself rather than content changes. It appears that revision of the document’s content is more likely to affect the wood and plastics industries. While the new document will not be officially published until the last quarter of 2004, drafts of the new document are posted on the CSI web site. Further, the web site will offer information about the implementation process of the new document throughout 2004. MasterFormat is a product of CSI and Construction Specifications Canada. For more info, visit www.

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What’s Hot n? Biz Briefs New metalsmith school Pieh Tool Company Inc. announces the opening of the Bill Pieh Resource for Metalwork school, offering educational opportunities to metalsmiths. For more info, call (888) 743-4866, or visit:

Attempts to reintroduce ‘ladder effect’ are defeated During the week of September 8,

NOMMA Technical Consultant Tim Moss attended the 2003 ICC hearings in Nashville, TN. This hearing was important since Elliott Stephenson, a longtime advocate of the “ladder effect,” had submitted an array of proposals to further restrict rail design.

International Residential Code

The International Residential Code

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NOMMA’s Technical Consultant Tim Moss

(IRC) hearings began on Tuesday, September 9. There were nine proposals submitted that dealt with guards and handrails, including two submitted by Stephenson. In addition, Stephenson proposed a “definition” for climbable guards. The committee voted to deny these proposals. On a related issue, there was one proposal for adding guards to retaining walls. The committee approved this after modification to remove references to the “ladder effect.” Another proposal was to change the wording for the distance between handrail and wall to read “11/2 inches clearance between handrail and the surface it is affixed to.” In the area of stair geometry, there were six various proposals, but none of them changed the existing stair requirements for residential. International Building Code

On Friday, September 12, the action continued with the International Building Code (IBC) hearings. Again, there were four proposals submitted by Stephenson, which were all denied by the committee. Several organizations joined NOMMA in opposing the Stephenson proposals, including NAHB and the National Multi Housing Council/National Apartment Association. In addition, two IBC committee members were vocal as well in their opposition to reintroducing the “climbable guard” language. Also during the day, there were several proposals dealing with stair geometry and the results of the votes were mixed. In summary, the fall ICC hearings Fill in 55 on Reader Service Card


Fabricator n November-December 2003

went well for NOMMA and we successfully stopped a reintroduction of the “ladder effect” into the building codes.

ASA seeks input on new OSHA initiative

The American Subcontractor’s Association will respond to a recent OSHA initiative to reduce permissible exposure limits (PELs) to crystalline silica. According to the ASA, OSHA is considering a rule that would affect those working in highway repair, drilling, and masonry work. The new OSHA initiative involves reducing “PELs to crystalline silica, establishing a no rotation of worker policy, requiring high efficiency particulate air filters and creating demarcation zones.” OSHA’s unified agenda, 1618. Occupational Exposure to Crystalline Silica, explains that silica exposure remains a serious threat to nearly 2 million U.S. workers, including more than 100,000 workers in high risk jobs such as abrasive blasting, foundry work, stonecutting, and tunneling. Overexposure to silica causes silicosis, a disabling, nonreversible, and sometimes fatal lung disease. Although there is apparently no cure for the disease, it is “100 percent preventable if employers, workers, and health


professionals work together to reduce exposures.” ASA’s government relations department is seeking member input for the initiative to develop new rules governing employee exposure to crystalline exposure. The Small Business Administration’s Office of Advocacy already has established a panel of government and small business representatives to evaluate the impact of the OSHA initiative on small businesses. ASA is coordinating with other construction associations to provide input to both the Office of Advocacy and OSHA. For more info, contact ASA’s Luke McFadden at lmcfadden@asa-hq. com or (703)-684-3450, ext. 1321.

Biz Briefs Promotional media services Producers of the Home & Building Solutions national television series are seeking participants for its half-hour program. For a fee, a 5–7 minute editorial story will be included in a 30-minute episode of Home & Building Solutions. This allows a fabricator to get his or her message out to a targeted audience. Participants also receive a 6–8 minute corporate demo tape for trade show or other promotional use. For more info, call (954) 7835515, or visit: www.premiermedia. tv.

• #12DS-N


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

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What’s Hot n? Chapter Contacts Florida Bob Ponsler, Wonderland Products Inc., Ph: (904) 786-0144 New York Paul Montelbano, Duke of Iron Inc. , Ph: (631) 543-3600 Northeast Keith Majka, Majka Railing Co. Inc., Ph: (973) 247-7603 Southern California Hans Duus, Hans Duus Blacksmith Inc., Ph: (805) 688-9731 Upper Midwest Breck Nelson, Kelley Ornamental Iron LLC , Ph: (309) 697-9870

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Meeting Spotlight

NE Chapter VP reflects on chapter’s last meeting at Ryan Ironworks By Sharon Picard Vice President Northeast Chapter

September 27th the Northeast Chapter of NOMMA held a meeting at Ryan Iron Works in Raynham, MA. Paul Berube, division manager of Ryan Ornamental, a division of Ryan Iron Works, hosted the gathering. After the chapter business meeting, Paul gave a brief history of Ryan Iron. The company dates back to the late 1890s. Edward Thomas Ryan incorporated the business in 1918 as E. T. Ryan Iron Works. EG & G, a national conglomerate, purchased the family owned business in the mid 60s. The current owners, Howard Shea and Paul Kelley acquired Ryan Iron in 1973. Since this time, Ryan Iron has grown tenfold to the size it is today. Ryan utilizes 62,000 square feet of

fabrication space on a 6.5 acre parcel of land. Berube proceeded in giving the attendees a tour of the facility beginning with the estimating department. This department of eight estimators utilize a computer software program developed specifically for Ryan Iron. What used to be a manual process was transformed into a computer based program. The next stop was the drafting department. Here is where full sized drawings are used for layout. The drawings are taped down to a table and fabrication begins. This process enables the mechanics to immediately start working on the project. As we continue our tour, Mike Spring, Production Manager of Ryan’s main fabrication facility, directed us through the main floor describing the

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flow of projects through production. The layout of equipment and the design of processes fostered an efficient working environment. Berube then took us to his domain, a separate 12,000 square foot facility dedicated to nonferrous work. As we entered the building an employee was fitting parts on a large stainless steel rail. The railing was positioned as it would appear in the field. There were approximately seven other employees working on different projects. One individual was finishing a stainless steel bench. Another individual demonstrated how a machine appropri-

ately named as “Timesaver” polished a large piece of stainless rectangular tubing in less than a few minutes. There was a pipe polishing machine in another area of the shop. The employee at this station was polishing brass pipe in 20 foot lengths. The polishing machine also is used for stainless steel and aluminum pipe. The tour was concluded in the ornamental shop with a luncheon. The day provided a valued educational experience.

Chapter Updates Next Florida chapter meeting On November 15, 2003 NOMMA’s Florida chapter will meet at Klahm & Sons in Ocala, FL. Jack Klahm and Phil Heermance of Art’s Work Unlimited will give demonstrations. Contact: Chapter President Rick Holloway, Sunmaster of Naples Inc., Naples, FL, Ph: (239) 261-3581.

Northwest Chapter meets at Crescent City

On Saturday, September13, the Northwest Chapter met at and toured Crescent City Iron Supply Inc. A few other local suppliers were also present. Participants were treated to an Intermediate CAD class led by Dave Filippi of FABCAD.USA. The group also voted on a slate of officers for next year.

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Host David White of Crescent City Iron Supply (l) was accompanied by other area suppliers like R & B Wagner’s Steve Engebregsten (r).

Dave Filippi of FABCAD.USA gave an intermediate level AutoCAD demonstration. Fill in 24 on Reader Service Card November-December 2003 n Fabricator


What’s Hot n? Coming Events

March 3–6, 2004 METALfab 2004

This year NOMMA’s 46th annual trade show and convention takes place in Sacramento, CA. The NOMMA Education Foundation will present three education seminars immediately prior to convention. Those interested in sponsoring, exhibiting, and attending should contact the NOMMA office. See page 16 for more details on METALfab 2004. Contact: NOMMA, Ph: (404) 3634009, Web: metalfab/metalfab.html.

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Coming Events March 27, 2004

AFA Chicago Table Top 2004

The Chicago chapter of the American Fence Association holds its annual Table Top Trade Show at the William Tell Holiday Inn, Chicago, IL. Contact: AFA Chicago, Web: www., E-mail: March 30–April 1, 2004 METALFORM 2004

METALFORM Louisville, the regional exposition of the Precision Metalforming Association (PMA), visits the Kentucky International Convention Center in Louisville, KY from March 30-April 1, 2004. The Symposium, the exposition’s educational arm, presents networking opportunities for offering innovative concepts and applications for advancing metalforming business operations. Contact: Show Management, METALFORM, Ph: 216-901-8800, Web: April 6–8, 2004

AWS Welding Show 2004

The American Welding Society will hold it annual welding and fabricating exhibition, AWS Welding Show 2004, again in Chicago, IL at McCormick Place, Lakeside Center. Contact: AWS, Ph: (800) 443-9353, Web: July 7– 11, 2004

2004 ABANA Conference

The 2004 ABANA Conference will take place on the campus of Eastern Kentucky University (EKU), in Richmond, KY. This biennial conference for the North American Artist’s Blacksmith Association (ABANA) will host a variety of demonstrations, exhibitions, vendors, and tailgaters from around the world. There will also be an auction, a raffle for a power hammer, and “Iron-in-the-Hat.” Contact: ABANA, Ph: (706) 310-1030, Web: conference/conference.html.

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New NOMMA Members as of 10–10–03 ABC Fence Co. Inc.* Bridgeport, CT Henry G. Poirier Fabricator Aluminum Arts of Arkansas* Hot Springs, AR Ken McCoy Fabricator Aluminum Railing Specialists Inc. Pompano Beach, FL David P. Kissack Fabricator Atlas Metal Sales Denver, CO Jerry Simms Nationwide Supplier David Brown Iron Designs San Diego, CA David Browne



Chamberlain Elmhurst, IL David Sarson Nationwide Supplier

Midwest Welding South Saint Paul, MN Jeff Davis Fabricator

Castle Industries Ltd. Saskatoon, SK Canada Kenny Snider Fabricator

Ornamental Iron Fabrication LLC Interlochen, MI Doug O’Brien Sr. Fabricator

Foster Fence Corp.* Houston, TX Harry Holloway Fabricator Horst Around House Lagrangeville, KY Werner Horst Fabricator The Iron Gate Shoppe Puyallup, WA Larry Holien

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Great Falls, MT Steven Raska Fabricator Scotchman Industries Inc. Philip, SD Peggy Palecek Nationwide Supplier SEA USA Inc. Miami, FL Constantino Alfonsi Nationwide Supplier

Portable Welding Specialist Orlando, FL John Jiminez Fabricator Ramsy’s Orn. Iron Works Kountze, TX Danny Ramsey Fabricator Steven Raska

Western Heat LLC Greeley, CO Pete Niehoff Fabricator

*Denotes returning member.

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What’s Hot n? People Spotlight n

Liberty Brass Turning Co. , Long Island City, NY Owners: Peter and David Zuckerwise Ph: 800-345-5939, Web:

Liberty Brass Turning Co. celebrates anniversary Interview with Peter Zuckerwise Co-owner of Liberty Brass Turning Co. Fabricator: Which anniversary is this? Zuckerwise: This is our 85th anniversary. Our on line catalog represents a small sampling of what we have done over the past 85 years. Fabricator: What are you doing to celebrate? Zuckerwsie: Continuing to give good service!

Owners l to r: Peter and David Zuckerwise

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Fabricator: What is the history of Liberty Brass Turning Co.? Zuckerwise: We are a third gen-

eration machine manufacturer of decorative hardware as well as functional industrial components. My grandfather, Max Zuckerwise, came to this country from Poland with a tool making background and started a machine company in Lower Manhattan in 1919. In 1950 under the ownership of my father, Jack, the company was moved over the 59th Street Bridge to Long Island City, NY. My brother David and I officially took over as partners in 1993, although we’d worked for the business previously. I’ve been here since 1979. Fabricator: What does the company specialize in? Zuckerwise: We manufacture component hardware for ornamental fabricators and metal fence fabricators. Our facilities list includes over 40 automatic screw machines, turret lathes, both vertical and horizontal milling machines, a full assortment of drilling and tapping equipment plus seven CNC machining and turning centers. We work in brass, aluminum, steel, and stainless steel. We offer a full line of solid brass and aluminum balls from fi inch round through 5 inch round. We are a custom job shop—no job is too large or too small. Fabricator: How has NOMMA helped your business? Zuckerwise: We appreciate all of NOMMA’s members. Advertising and making contacts through NOMMA has helped our business tremendously. Fabricator: What is your business philosophy? Zuckerwise: Our business is based on customer confidence. We provide service and quality at competitive prices.

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Fabricator n November-December 2003

Home & Garden Show features The Iron Shop

The Iron Shop, a manufacturer of spiral stair kits, was recently featured on an episode of Home and Garden Television’s program Renovations. The 30-minute weekly show is geared toward intermediate and advanced home renovators and remodelers. The episode featuring the Iron Shop covered the renovation of a beach house.The Iron Shop was featured in the second part of the two-part episode. In the first half of the show 25-foot wooden pilings were driven into the ground to support a new second story addition.

The addition, including a roof deck, was framed and an existing second floor deck was extended. A new roof was completed and new cedar siding and textured cement board were put up on the exterior of the house. An exterior metal spiral stair kit from The Iron Shop provides access from the first floor to the house’s newly added second floor and its roof. “We really enjoyed taking the production team from Home and Garden Television’s Renovations through our plant” said The Iron Shop’s coowner Ron Cohen. “It

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was a great experience having them here.” The show’s host, Barte Shadlow, and Cohen took viewers on a tour through The Iron Shop to show how a spiral stair kit is created from start to finish, beginning with the production process and ending with the company’s shipping department. Later, the program showed the stair being installed. “Shadlow was extremely well-versed on our product,” Cohen said. “And do-it-yourself savvy.”

People NOMMA’s past president Jerry Grice is recognized for his knife smithing skills Jerry Grice of Jerry Grice Welding

Inc., Tallahassee, FL won “Best Folder” at the 2003 Spirit of Steel Knife Show in Dallas, TX. In an interview printed in a NOMMA newsletter (The Scroll, December 2001), Grice talked about why knife making has been a good transition into retirement for him: “It’s nice because I can take a year’s worth of work in a suitcase to a show. I don’t have to haul it in a flatbed!”

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What’s Hot n? Literature Industry-specific design books from NEF The NOMMA Education Foundation (NEF) now offers a collection of Dover books specific to the ornamental and miscellaneous metals industry. There are over 13 books to choose from filled with design ideas, historical and cultural information, and helpful tips. Ornamental Designs from Architectural Sheet Metal: The Complete Broschart & Braun Catalog, ca. 1900 is edited by Broschart and Braun. This generously illustrated book brings back into print a rare turn-of-the-century catalog depicting over one thousand ornamental sheet metal designs offered to architects, interior


Products FAST-er Laser


Hypertherm Inc. The new FAST Laser (Flow Accelerated Screen Technology) from Hypertherm Inc. offers a faster, cleaner cutting laser system. The FAST laser’s accelerated high-velocity oxygen flow along the beam path increases cut speed by fueling the exothermic reaction. It also reduces sensitivity to common plate fabricating conditions and variables, most notably plate chemistry and condition. The system utilizes a patent-pending design to create a dual-flow zone that allows significantly higher oxygen

assist-gas pressures in the tightly defined cut zone established by beam geometry. It eliminates the uncontrolled burning in the surrounding zone that is normally induced by increased assist-gas pressures. FAST Laser cutting heads deliver up to a 20 percent increase in cut speed over standard CO2 laser heads on plate steel. They also significantly expand the capacity and quality range of plate-laser cutting systems. FAST Laser’s combined benefits produce substantial gains in productivity and unattended operation potential. Plus, the Hypertherm LH2100™ laser cutting head offers two different focal lengths: 7.5 and 10.0 inches. An optional integrated Mariner™ CNC controller with on-board FAST Laser process intelligence is also offered.   Contact: Hypertherm, Ph: (800) 643-0030, Web: New catalog

Cable Connection

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Ultra-tec® Cable Railing Systems is offering a new catalog featuring its stainless steel tensioning and mounting hardware. Includes new and existing tensioning and mounting devices that are streamlined and, if desired, can be largely concealed inside railing end pots. Fittings can be field installed or cables provided with hardware attached, ready to install. The catalog includes illustrations of existing installations using various Ultra-tec cable railing products. Contact: The Cable Connection, Ph: (800) 851-2961, Web: Safeguard system

Scientific Technologies Inc. Scientific Technologies Inc. introduces the LazerSafe LZS-003 Safeguarding System for Hydraulic Press Brakes.

Designed and developed exclusively for hydraulic press brakes, LazerSafe combines operator safety and machine productivity. It uses a flat band of laser light that continuously covers the zone below the punch over a 40 millimeter width so that the operator can work within 20 millimeters of the front of the punch and within 10 millimeters of the rear of the punch with no disruption to the approach speed or bending process. The optical design detects obstructions as small as 4 millimeters while remaining tolerant of vibration. Because the transmitter and receiver are mounted on the ram of the press, the operator can stay close to the workpiece as the tools close at high speed. Plus, the location and size of the beam allows for multiple bends in

Literature from previous pg.

designers, and home

builders by a major American supplier. The book features an assortment of ornamental designs with Ornamental over a thou- Designs from sand detailed Architectural Sheet illustrations of Metal egg and dart enrichments; bead flute, and ogee enrichments; drapery and drop ornaments; urns, vases, wreaths, and more. The measurements available and per-foot price (ca. 1900) are included for each item. Spanish Decorative Ironwork edited by Luis Labarta has over 300 illustrations depicting nearly 1,000 years of Spanish ironwork. This volume is reproduced from a


Artist-Blacksmith’s Association of North America

Join the Revival!

Two Quarterly Publications: The Anvil’s Ring The Hammer’s Blow Resources: Supplier Directory Hot-Line Help Job Listings & Referrals

LeeAnn Mitchell ABANA P.O. Box 816 Farmington, GA 30638-0816 Ph: (706) 310-1030 Fax: (706) 769-7147 E-mail: Web: Fill in 127 on Reader Service Card November-December 2003 n Fabricator

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What’s Hot n? Literature from previous pg.

100-year-old publi-

cation and includes crafted items ranging from shears and scissors to monumental grilles Spanish Decorative Ironwork of Spanish cathedrals. Pictures include a detailed brass chest from Castile, a Roman door from the Catalan region, Castilian chandeliers, a Catalan balcony, and more. A small sampling of ironwork from France, Germany, and Italy appears at the end of the book. continued

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the material without interruption of the beam. Contact: Scientific Technologies Inc., Ph: (800) 479-3658, Web: www.sti. com.

versatile tool for today’s metalsmiths. Contact: Pieh Tool Co. Inc., Ph: (262) 210-3228, Web: www.

Metalsmith tongs

Hornell Inc. Hornell Inc. announces a new helmet and respirator system. The new Speedglas® Flex View with Adflo® combines a retractable auto-darkening Speedglas lens with a powered air-purifying respirator (PAPR). Full eye, face, and respiratory protection is provided while the Adflo powered air-purifying respirator creates a positive atmosphere of filtered air within the helmet that is 25 times cleaner than the air outside the helmet. The respirator’s design includes a stackable filter configura-

Pieh Tool Co. Inc. Billy Tongs™ are named for the late Bill Pieh of Centaur Forge and represent the latest from Pieh Tool Co.’s Pieh Legacy Collection, a new line of tongs. Their design was inspired by tool designs of Vaughans (especially the box jaw, bolt and wolf jaw) and Peddinghaus (rivet and open mouth) and Dan Boone. The designs were further enhanced by Amy Pieh to make a stronger, lighter, and more

Helmet/respirator system

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tion. Users can stack the helmet’s High Efficiency particle filter onto an optional Adflo cartridge for additional protection against organic, sulfur dioxide, chlorine, and hydrochloride gases and vapors. The helmet includes a spring-mounted lens auto-darkening clear lens that can rest securely on top of the helmet during weld prep. Contact: Hornell Inc., Ph: (800) 6289218, Web: Pressed-tin ceilings

Chelsea Decorative Metal Co. The latest pressed-tin ceiling design from Chelsea Decorative Metal Co. is a 24-inch repeat Victorian pattern available in 2 feet by 4 feet sheets. Other patterns, ranging from Victorian to Art Deco, are available in 3, 6, 12, and 24-inch repeat patterns. The material is a rust-resistant and paint retaining tin-plated steel. Sheets can be used for ceilings and walls as wainscoting or as a backsplash. Chelsea Decorative Metal Co. offers 20 designs and 11 cornices (the cornice come in 4 foot lengths). Free catalogs are available. Contact: Glenn Eldridge, Chelsea

Decorative Metal Co., Ph: (713) 721-9200, Web: www. thetinman. com.

Literature from previous pg.

Ornamental Ironwork, edited by A. Durenne, is another great inspirational source. Carol Belanger Ornamental IronGrafton work selected over 675 illustrations from a turn-ofthe-century publication featuring various decorative designs. Design motifs range from intricate floral to minimalist patterns. To order these Dover books and a list of others, contact NOMMA/ NEF, attn: Liz Ware, Ph: (404) 363-4009, Fax: (404) 366-1852, E-mail: Liz@nomma. org, Web:

Finishing pretreatment

Houghton International Inc. Houghton International’s Surface Finishing division has formulated a new liquid iron phosphate product for hand wash and steam wand applications. Houghton Steam 19 provides superior cleaning and pretreatment of metal surfaces, preparing them for subsequent painting, coating, or finishing. Contact: Houghton International Inc., Ph: (616) 666-4000, Web: www.


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As a NOMMA member, you receive valuable tools to help your business:

• Fabricator’s Journal - A publication of the NOMMA Education Foundation, this booklet features “how to” articles on topics ranging from finishes to core drilling. • TechNotes - Get the latest updates on codes, standards, and regulations that impact YOUR business. • Member’s Only Area - Access the “Member’s Only” area on the NOMMA website for free downloads and technical support for UL 325, ADA, and codes. • The Business Owner - Obtain the latest advice on small business issues, including legal concerns, taxes, estate planning, and more.

Additional membership benefits: • Starter Kit - Soon after you join, you’ll receive a kit containing a Membership Directory, Supplier Direc-

tory, educational publications, and sales aids. • Discount Rates - You’ll enjoy discounts on all NOMMA publications and association sponsored events, including educational seminars and our annual convention. • Affiliation - You receive a membership certificate, decal, and camera-ready logos to use on your stationery and business forms. • Subscriptions - Membership includes a subscription to Ornamental & Miscellaneous Metal Fabricator. • Top Job Competition - Enter your best work in our annual awards contest, which is open to member’s only. • Technical Affairs Division - Your dues support the work of our technical team, which insures that fabricator interests are represented at code hearings and other meetings around the country. Membership Category - Check One: q $305 - Fabricator q $465 - Nationwide Supplier (Firms selling to fabricators beyond

500 miles)

q $355 - Regional Supplier (Firms selling to fabricators within 500 miles) q $280 - Local Supplier (Firms selling to fabricators within 150 miles) q $230 - Affiliate (Teachers and educational organizations)

Please note:

• The membership year runs from July 1 to June 30. • Membership dues payments are not deductible as charitable contributions, but may be deducted as an ordinary and necessary business expense. • By signing this application, you agree to abide by NOMMA’s Bylaws and Code of Ethics upon acceptance. • Make checks payable to: NOMMA (U.S. dollars, check drawn on U.S. bank).

Company Name __________________________________________ Your Name ________________________________________ Address __________________________________________________________________________________________________ City _____________________________ State _________ Zip _________________ Country _______________________________ Phone ____________________________ Fax __________________________ Sponsor (if any) ____________________________ E-mail __________________________________________________ Web ______________________________________________ Company Specialty/Description ________________________________________________________________________________ Signature ___________________________________________ Payment Method: q Check q VISA q MC q AMEX q Discover Credit card no.____________________________________________________________________________ Exp. ______/_______ Exact name on card ______________________________________ Signature ______________________________________

Return To: NOMMA, 532 Forest Pkwy., Suite A, Forest Park, GA 30297. (404) 363-4009. Fax: (404) 366-1852. Updated: 9/03

Classifieds Architectural ironwork installation foreman wanted Architectural ironwork installation foreman for large Los Angeles workshop. Minimum three years experience installing staircase railing, doors. Travel required. Send resume to: 1801 E. 50th St., Los Angeles, CA 90058. Workshop The Center for Metal Arts announces a new series of hands-on intensive workshops with international educator and blacksmith Uri Hofi: Comprehensive Foundation Course in Blacksmithing I, February 2-6, 2004, and a new Advanced Comprehensive

Deadline for next issue (Jan/Feb): Dec. 12 Course in Blacksmithing II, February 9-13, 2004 open to graduates of the Foundation Course. For more course schedules see the Skills Training page on Call (888) 8629577 or e-mail for course registration. Limited spaces.

or state of your choice without identifying you. Employer pays fee. The right location, the right job, at the right money. ProCounsel: Buzz Taylor. Call toll free (800) 545-5900 or (214) 741-3014. Fax: (214) 741-3019.

Recruiter Employment nationwide in structural/miscellaneous steel fabrication. ProCounsel is in communication with over 3,000 structural/ miscellaneous and ornamental steel fabricators. We can market your skills (estimator, project manager, detailer, shop manager) to the city

Business For Sale Located in Northern California, specializing in the installation and maintenance of custom entry gates. Established in 1972, large client list, turnkey business, busy year round, good equipment. $160,000. Phone: (707) 477-7685.

To place a classified ad, call the editorial dept. at (404) 363-4009, ext. 15. Or fax text to (404) 366-1852, attn: classifieds. Or e-mail:

Advertiser’s index RS


Company Name

56 Acme Metal Spinning 84 38 All-O-Matic Inc. 165 79 American Fence Assn. 83 75 American Spiral Corp. 61 65 Antech Corporation 115 29 Architectural Iron Designs 103 25 Arch. Products by Outwater 105 93 Artist-Blacksmith’s Assoc 142 9 Artist Supplies & Products 86 82 Atlas Metal Sales 25 49 Julius Blum & Co. Inc. 20 36 Byan Systems Inc. 94 86 Carell Corporation 137 68 Classic Iron Supply 26 41 Cleveland Steel Tool Co. 132 54 Cleveland Steel Tool Co. 132 47 CML USA Inc. 110 76 Colorado Waterjet Co. 107 84 COMEQ Inc. 10 November-December 2003 n Fabricator

Use this index as a handy guide when filling out Reader Services cards. Firms in boldface are first-time advertisers.

92 Counsel Industries 168 74 Crescent City Iron Supply 41 12 D & D Technologies 48 23 D.J.A Imports Ltd. 118 84 DAC Industries Inc. 55 91 DECO Orn. Iron Supply 147 22 DécorCable Innovations 171 67 Decorative Iron 1 3 DKS, DoorKing Systems 19 92 Doringer Cold Saws 45 27 Eagle Bending Machines 120 44 Eastern Metal Supply Inc. 176 66 Encon Electronics 57 45 FAAC International 49 10 FABCAD.USA 87 75 Federal Iron Works Co. 173 77 Glaser USA 123 20 Graham Manufacturing 177 57 The G-S Co. 82 76 Hawke Industries 16 52 Hebo GmbH 150 14 House of Forgings 130

87 International Gate Devices 24 90 Interstate Mfg. 114 90 Iron Craft 185 58 Iron Designs USA 184 100 The Iron Shop 11 78 Ironwood LLC 70 32 Jansen Ornamental Supply 75 85 Jax Chemical Co. 23 66 Jesco Industries Inc. 93 65 K Dahl Glass Studios 159 94 Kayne & Son 81 61 King Architectural Metals 136 72 Joachim Krieger 65 86 Laser Precision Cutting 99 7 Lawler Foundry Corp. 47 2 Lewis Brass & Copper 21 71 Liberty Brass Turning Co. 38 78 Liberty Ornamental 22 83 Lindblade Metal Works 63 95 Mac Metals Inc. 71 60 Marks U.S.A. 34 50 Master-Halco 90 91 Mittler Bros. 35 40 Multi Sales Inc. 37 21 New Metals Inc. 104 97

Fabricator Poll


Any fresh hiring ideas?

Everyone probably agrees that finding and retaining qualified employees can be as difficult as getting your first bid. These fabricators came up with the following advice:

Does anyone know of any new or creative ways to find skilled fabricators?

— question submitted by Allen Guidry, Florida Aluminum & Steel Fabricators, Fort Myers, FL

“Try the Internet.” Tony Palmer Brassworks Ltd. Providence, RI We have had very good results listing our job openings on the internet only, specifically www.careerbuilder. com, and not even bothering with newspaper ads. The benefits are: 1)We can say as much as we need to without paying a premium—there’s generally a very generous limit on the number of words you can use. This way, we can describe EXACTLY what we’re looking for. 2)We don’t have to be bothered with phone calls. 3)At least the respondents are computer savvy, especially if they can attach a resume. Also, I generally exchange a few emails with them before I even set up an interview. You can learn a lot about a potential job applicant just by e-mailing with them. 4)The listings generally run for a month, so there’s plenty of time.


the shop.” Terry Driscoll Custom Iron Inc. Zumbrota, MN We’ve tried numerous times to establish a second shift and had terrible results. Productivity and accuracy went way down. I don’t believe we ever really found the right self-directed second shift supervisor. Anyway, we expanded our facility as an answer to capacity. We went from 12,000 square feet to 95,000 square feet. We were concerned with being able to staff it. However, the new modern environment seems to be helping to attract quality people from the area. We’re now concerned about what we call “feeding the monster,” so I like the suggestion I heard to farm some of our work out. That said, we may have some extra capacity to help you out, depending on what you need done. Particularly during our frosty Minnesota winters.

“Ask local colleges.”

Rob Rolves Foreman Fabricators Inc. Saint Louis, MO We had a second shift for a couple of years and the ability to turn small projects around overnight was fantastic, but in the end we didn’t feel the quality of work nor the amount of work we were getting done at night was worth it. If you can get the good, quality fabricators you speak of the problem of supervision is negligible. We tried mostly younger, entry-level guys and could never get the level of supervision we needed. Some of them were good workers, but they needed a foreman with the ability to continue their education in life and metal fabrication. Our best method to locate decent workers was in going to the local colleges. They are glad to take scrap metal off our hands, and in return they give us the names of their GOOD students—not just any student.

Belk Null Berger Iron Works Inc. Houston, TX bnull@BERGERIW.COM I would look at the phases of your work and then look to see if there is an outside vendor who can handle one or two of those phases. We do no brake work. We only do small quantity rolling or bending of pipe. We have two very good saw shops who cut large quantities for us. We found that this allows us to spend our time in the fit-up, assembly and finishing of our pieces. We also do no finish paint. We have an excellent painter who comes to our shop at night to paint what we have. We also utilize a couple of shops for overflow work. You might want to consider training a few of your good structural people to do ornamental. It is easier to train a proven worker to work in a new area than to train someone from scratch. It is also easier to find structural people to replace those you transfer.

“Consider vendors.”


Send Us Your Ideas? Do you have a question you’ve been anxious to ask fabricators? Simply telephone the Editor at (404) 363-4009; Fax (404) 363-1852 or e-mail your question to 98

Fabricator n November-December 2003

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2003 11 fab  
2003 11 fab