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NOMMA launches independent research study on climbability issues, pg. 32

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

May/June 2007 $6.00 US

Tips & Tactics

Electron beam technology, pg. 15

Shop Talk

The efficiency of liquid electrostatics, pg. 22

Biz Side

What to do if you get audited, pg. 66

Job Profile

An actor’s legacy lives on in the gates of a state park page 54

METALfab 2007 — a recap of NOMMA’s Destin convention, pg. 40

&(/(%5$7,1* 285 507+ <($5 7

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• Over 7,800 Standard Catalog Items • Over 48,000 Orders Shipped Annually • More Options Than Any Other Component Manufacturer

Our People . . .

• Wagner People average over 15 years in the metal industry • Wagner People average over 9 years with Wagner

Our Quality . . .

• Wagner has implemented a Business Process Excellence project to become ISO-9001 compliant in 2007.


Beautiful Railings Begin With


May/June 2007 Vol. 48, No. 3

This life-size grand piano sculpture is being crafted from bronze and stainless steel. See page 98.

Biz Side

Special Feature

Tips & Tactics Desktop design . . . . . . . . . . . . . . . . . . 14 An overview of 3D modeling software programs and how you can use them. Some NOMMA members share their opinions. Electron beam technology . . . 15 Electron beam free form fabrication can save time and money. By Sheila Phinazee

Shop Talk Liquid electrostatics . . . . . . . . . . . . 22 The coating material you choose is a significant portion of the cost of your product.

By John Owed

Member Talk NOMMA launches new study . 32 This independent research study will provide scientific data on climbability. By Todd Daniel

President’s Letter . . .6 A challenge is thrown out to NOMMA members.

METALfab 2007 . . . . . . . . . . . . 40 A recap of this year’s annual convention in Destin, FL — Top Job competition winners, education sessions, trade show, NEF auction, and more.

Caught, audited, and home free... maybe . . . . . . . . . . . . . . . . . . . . . 66 Reduce your changes of being audited. By Mark E. Battersby

Customer service blunders . . . . 70 Five big mistakes that could cost you customers.

Job Profiles

By Paul Levesque

Shades of the “old West” ......54 An actor’s legacy lives on in the beautifully crafted gates of a California state park. By Helen K. Kelley

Inspired by nature ..........................59 Blue Mountain Metalworks creates a handrail with “organic flair” that fits right into its outdoor setting. A very grand staircase ..............62 How Michael Migala’s small shop handled a very big project... with finesse.

Editor’s Letter . . . . . . 8 You’re never too old to learn new things.

Business stress . . . . . . . . . . . . . . . . . . 73 Don’t let it ruin your life! By William J. Lynott

What’s Hot! New Members . . . . . . . . . . . . . . . . . . . . 80 Nationwide Suppliers . . . . . . . . . . . 81 Biz Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Literature . . . . . . . . . . . . . . . . . . . . . . . . . 89 People . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Chapter News. . . . . . . . . . . . . . . . . . . . . 87 Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86 New Products . . . . . . . . . . . . . . . . . . . . 90 Classifieds . . . . . . . . . . . . . . . . . . . . . . . . 96

Reader’s Letters . . . 10 Forced patinas, corrosion issues, and Fabricator’s best.

Metal Moment . . . . 98 Two Indianapolis firefighters moonlight in metal.

Cover photo: The gates to the Leo Carillo Ranch in Carlsbad, CA are a reflection of the actor’s dedication to his profession, as well as a tribute to a man who was also a preservationist and conservationist. May/June 2007 



President’ s Letter Accept the challenge Dedicated to the success of our members and industry. NOMMA OFFICERS President Breck Nelson Kelley Ornamental Iron LLC Peoria, IL President-elect Terry Barrett Royal Iron Creations West Palm Beach, FL

Vice President/ Treasurer Bob Foust, III Bob’s Ornamental Iron Studio Kansas City, KS Immediate Past President Chris Connelly DeAngelis Iron Work Inc. South Easton, MA

FABRICATOR DIRECTORS Fred Michael Colonial Iron Works Inc. Petersburg, VA

Frank Finelli Finelli Ornamental Iron Co. Solon, OH

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

Douglas Bracken Wiemann Ironworks. Tulsa, OK

Bruce Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA

Curt Witter Big D Metalworks Dallas, TX

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

Wayne Haas Cleveland Steel Tool Co. Cleveland, OH

Gene Garrett Regency Railings Inc. Dallas, TX

NOMMA STAFF Executive Director Barbara H. Cook Meetings & Exposition Manager Martha Pennington

Administrative Assistant Liz Johnson Editor Helen K. Kelley

Communications Mgr. J. Todd Daniel

2007 ADVISORY COUNCIL Doug Bracken Wiemann Ironworks

Rob Rolves Foreman Fabricators Inc.

Nancy Hayden Tesko Enterprises

Rob Webster Web Metal Fabricators, Ltd.

Tom McDonough Master Metal Services Inc.


Curt Witter Big D Metalworks

As I accepted the presidency of NOMMA this year, I was overwhelmed at the inadequacy I felt in holding this position. Most of what I have learned about metalworking and business has come from those of you involved with NOMMA. I possess no great abilities or gifts to bestow on anyone, but what I do possess is a desire to give back some of what I have received. Over the past 10 years I have received a great education, learned many techniques, and made some great friends that have propelled my company and changed my life. Many of you have shared openly with me, challenging me to do better. Today, my firm has grown and expanded in ways I had never dreamed of before, and for this I want to say thank you. Someone once told me that success cannot be found in a bank account, home, car, or in other things we acquire; true success can only be found in helping others become successful. This may sound like a cliché, but I have found a lot of truth in that statement. The success NOMMA has acquired can only be contributed to one thing — the generosity of others. Over the last 50 years, education classes have been taught, techniques demonstrated, and advice freely given by NOMMA members, all for the benefit of fellow members. One has only to glance at the Top Job competitions at METALfab to see the results of this sharing. However, that is only a small part of the success of NOMMA. As great as the Technical Affairs Division, Code Advisory Council, informative publications, ListServ, NEF and more are, it’s the friendships made over the years that I cherish most. These friendships are the outcome of the investments of members who have gone before us. Their example and legacy of open communication and

sharing have built a camaraderie in this association not commonly found today. This is the fundamental truth that has helped NOMMA thrive over the years and continues today. As we look back at NOMMA over the last 50 years and see the many changes that have taken place in the world and our industry, you will notice that one thing has not changed. For NOMMA to continue to grow and meet the many challenges and needs facing our industry, we still Breck Nelson is need YOU. president of This associathe National tion was, and is, Ornamental and still built on the Miscellaneous sacrificial giving Metals Association. of everyone involved. There are numerous opportunities to help our industry and association face the many, constantly – evolving challenges before us. By volunteering to help teach an education class, work on a committee, or serve on the board, you will be investing in the lives and well-being of many of your peers. As we continue to talk about the history of NOMMA over the next few months, I would like to issue the following challenges. If you’re reading this and you’re not a member, please consider joining our association. If you’re already a member, please volunteer your time and talents, and take an active role in our future. Who knows? In accepting the challenge, you may realize just how successful you have become.


May/June 2007




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Highly portable air plasma cutting system

How to reach us

Ornamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA).

O&MM Fabricator / NOMMA 1535 Pennsylvania Ave. McDonough, GA 30253


Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph: (888) 516-8585. Fax: (770) 2882006. E-mail:


For information, call Todd Daniel, Ph: (888) 516-8585, ext. 102. Ads are due on the first Friday of the month preceding the cover date. Send ads on CD to: Fabricator at address above. E-mail ads to: (max. 5 megs by email). Or upload ads to our website where a downloadable media kit is available:


In addition to the magazine, enjoy more benefits as a NOMMA member. To join, call (888) 516-8585, ext. 101. For a list of benefits, see membership ad in this issue.


1-35 words: $50 member, $65 nonmember; 36-50 words: $75 member, $90 nonmember; 51-70 words: $100 member, $115 nonmember; 71-100 words, $130 member, $145 nonmember. Send items to: Fabricator, at address above, or E-mail: Ads may be faxed with credit card information to: (770) 2882006. Deadline: 2nd Friday of the month prior to publication.


Subscription questions? Call (888) 516-8585. Send subscription address changes to: Fabricator Subscriptions,1535 Pennsylvania Ave., McDonough, GA 30253. Fax: (770) 288-2006, or E-mail:

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

Supplier Directory

Published each December as a separate issue. Deadline for all advertising materials is Dec. 15. For info, contact Todd Daniel at (888) 516-8585 or


For a quote, contact NOMMA at (770) 2882004 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: 10,000.


Editor’ s Letter Old dog, new tricks When I accepted this job as editor of

Fabricator, I was flying somewhat blind. Sure, I had years of editorial and magazine experience on my resumé, but what did I know about the metalworking industry? Actually, nada. But Barbara Cook and Todd Daniel placed their faith in me, assuring me that I would learn... and that the NOMMA membership would be my best teachers. And you know what? They were exactly right about that. I may have come into this job at a “well-seasoned” age, but I’ve become an enthusiastic student once again. With your help, I’m learning about your businesses, your products, your creativity, and your dedication. And honestly, there’s no better learning experience than METALfab! It is a week packed with opportunities to attend educational sessions, learn about the Top Job competition, meet suppliers and view their products, go on a shop tour, watch live demonstrations, and more. Most of all, it’s an invaluable opportunity to network, share experiences, and make new friends. After attending my first METALfab this year, I came home with new knowledge, a legal pad filled with ideas for articles, dozens of digital photos, and a profound respect for this industry. And I cannot say enough about the friendliness and courteousness extended to me by you, the NOMMA family. So, my new friends, I would like to ask you to continue submitting your ideas for the magazine. Please let me know what you’d like to see on these pages — because, ultimately, this publication is for you. Also, I’d like to remind you to think way ahead and mark your calendars now for METALfab 2008, to be held April 1-5 in Memphis, TN. As you know, this is NOMMA’s 50th anniversary celebration. If you have not previously attended METALfab, this is the

one not to miss! Speaking of METALfab, you’ll find a recap of this year’s convention, plus photos, beginning on page 40. Also in this issue, Todd Daniel informs you about a major new NOMMA initiative — the launching of an independent research study on guard ‘climability.’ See his article in Member Talk, page 32. Learn more about 3D modeling software and electron beam technology in our Tips and Tactics section. Our Shop Talk article focuses on the benefits of liquid electrostatics — the paint method you choose could save you time and money. We have three creative and inspiring stories in our Job Profiles section. Our cover Helen Kelley is editor story features a of Ornamental & gate fabricated Miscellaneous Metal Fabricator. by Designs in Iron for the Carillo Ranch in Carlsbad, CA, which is listed on the national register of historic places. Also, Dirk Brown and his crew at Blue Mountain Metalworks fulfilled their client’s request for an exterior handrail that would fit in with the natural beauty of their vacation home in the North Carolina mountains. Finally, Michael Migala shares the tale of how his very small shop successfully took on a very large project, despite some initial “butterflies” in the stomach. To round it all out, in Biz Side, we have three timely articles that run the gamut from tax audits to customer service to dealing with stress. I hope you find this issue packed with useful information — and that you learn something new. (By the way, you really can teach an old dog new tricks. As you can see, I’m a prime example.) Thanks for reading!


May/June 2007

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Eastern Orna. Supply Freehold, NJ 800-590-7111

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Readers’ Letters We asked noted metalsmith Lloyd Hughes of Lloyd K. Hughes Metalsmithing to respond: The easiest way to add a patina is with those available from industry suppliers. However, there are various do-ityourself recipes available. I mix my own patinas using chemicals such as ferric nitrate, sufurated potash (liver of sulfur), or cupric nitrate, and heat the metal a few hundred degrees prior to application. Before applying the patina, go over the surface with something like Letters are always welcomed. Send to: Letters to the 7440 Scotch-Brite™ to give Editor, c/o Fabricator, 1535 Pennsylvania Ave., it some tooth. The cold patiMcDonough, GA 30253. E-mail: fabricator@ nas generally take many; Fax: (770) 288-2006. hours to reach full effect.

Customer is requesting forced patina on interior copper job I have completed a copper repoussé piece for a client, which will be kept inside. The client is now asking for a patina. Can you suggest a recipe or source for forcing a patina? ~ Kane T. Williams Kane Steel Designs Rancho Cordova, CA

Tell us what you think

Don’t get anxious when you don’t see immediate results. Before applying a top coat, go over the patina with a cloth or fine ScotchBrite™ to remove any chalky residue. Prior to applying the patina, make sure you submit a sample piece for client approval. If they want it top coated tell them to be aware that it will likely affect the final color. Need two-part finish for stairs near pool area I have a customer who owns several apartment complexes with pools that are in the center of the complex. They are two-story and have staircases close to the pool. The corrosion on the

The Best of Ornamental & Miscellaneous Metal Fabricator Since 1990, Fabricator has featured over 600 articles. We have placed some of the most popular articles in the Members Only area of the NOMMA website. Below is a sampling of the articles available to members. We are continually adding new articles to this section, so be sure to check the website regularly.

Metal Issues & Properties Combat Corrosion by Design Anticipate potential corrosion and rust problems during the design phase.

Duplexing: The Beauty of a Two-Part Finish Add hot dip galvanizing with powder coating and you have a powerful finish. But one challenge is selling your customer on the higher price. Read This and Weep Properly use weep holes to improve the quality and expand the life of your job.

Cast Irons That Bend Malleable and ductile iron both have unique properties—it’s important to know the differences of each.

Corrosion Wars Fighting corrosion is a never-ending battle, and the struggle gets particularly tricky when joining dissimilar metals.

Reconstructing the Past Don’t say “no” to those strange phone calls you receive. Instead, learn how to recreate the broken and missing metal objects of yesteryear. Welding Aluminum Setting up an aluminum welding operation will require some investment and a slightly different perspective.


Ornamental Design & History Chandeliers Bring Life Chandeliers are a great way to fill large, open spaces such as entryways, foyers, or business lobbies.

Dynamics of Design A little primer on art history, which comes in handy when discussing idea options with clients.

Ever Try A Laser? Creatively using laser cutting systems can increase efficiency and save money while creating dramatic results. Iron Castings Get Respect The long and prestigious history of iron castings.

Proud Acanthus Leaf Receive a history and design primer on the acanthus leaf, a basic design element for ornamental metalwork. Wonderful Fountain Understanding the history and traditions behind modern fountains.

Finishing Prepare to Powder Coat Powder coating castings is often problematic, but this article provides useful tips.

Welcome to the World of Patina Developments in patina products make this process easier, but it still requires

some skill and careful attention.

Tips & Tricks Dip Tank A homemade dip tank provides a quick way to paint your rails.

Marketing Stair Turn the stair in your shop into a living advertisement.

The Tool Truck Superb equipment and organization makes this vehicle a super-dooper installation truck.

Fabrication Hinges Getting into the Swing When your success hangs on hinges, then you must choose the right product!

Good Ironwork Practice Tips on the design, installation, and care of ironwork. Well suited for beginners.

Conquering the Tight Bend Techniques for dealing with wrinkles, collapsing, and warping.

Standards/Codes/Testing Need Your Rail Tested? A client says you must test your rails to ensure they meet building codes and ASTM standards. Your response is "what!??"

Fabricator  May/June 2007

metal on the stairs has led them to replace them all. In the past, the stairs have been painted. Would galvanizing the stringers and handrails of new metal stop this problem, followed by a good primer and paint? Where I weld the stringers to the header and the handrail to the stringers, is there anything else besides cold galvanizing to protect the metal and not leave a weak spot for corrosion to easily start? Is the corrosive agent the chlorine or just the high moisture content in the area? ~Mike Crow Varis Iron Works Pilot Point, TX The two-part process you are describing is called “duplexing.” We have a popular article on this topic in the Members Area of the NOMMA website ( The newly updated NAAMM/NOMMA Metal Finishes

Manual also has great information on both painting over galvanizing and corrosion management (see chapters 4 & 5). To answer your last question, three

properties must be present to create corrosion — water, oxygen, and salt. The salt-like properties in certain pool chemicals is the likely culprit.

‘Pipe Sizes’ correction on NOMMA website One of the most popular articles on our website clears the confusion over pipe sizes. A sharp website visitor noticed some missing or misplaced decimals in the article. The following passage should correctly read: The wall thickness of pipe is designated by various “schedules,” most commonly Sched. 5, 10, and 40. The exact wall thickness of any one schedule changes with the pipe size. A 1-inch Sched. 40 pipe has a .133 The Support area of the inch wall, but a 2-inch Sched. 40 pipe has a wall NOMMA website contains a popular article that clarithickness of .154 inches. fies the confusion on pipe A thanks to Windy Holzbach of San Francisco, sizes. CA for making the “catch.” To view this article and other technical support material, visit the NOMMA Support area at:

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1-800-423-4494 May/June 2007  Fabricator 11

Desktop design

Tips & Tactics

3D modeling software can be used in a wide variety of applications.

Solid modeling is useful in a variety of metalworking applications, including the design of curved stairs, objects that must be cast or molded, sheetmetal projects and more.

ABOVE: A screen shot from Google’s SketchUp product web page shows the clarity and detail that can be achieved using 3D modeling software.

Editor’s note: A recent discussion on NOMMA’s ListServ regarding various 3D modeling software packages was the catalyst for this article. See opposite page for some members’ comments and input. A little online research yields the following definitions and explanations: “3D computer graphics are different from 2D computer graphics in that a three-dimensional representation of geometric data is stored in the computer for the purposes of performing calculations and rendering 2D images. Such images may be for later display or for real-time viewing. Despite these differences, 3D computer graphics rely on many of the same algorithms as 2D computer vector graphics in the wire frame model 12

and 2D computer raster graphics in the final rendered display. In computer graphics software, the distinction between 2D and 3D is occasionally blurred; 2D applications may use 3D techniques to achieve effects such as lighting, and primarily 3D may use 2D rendering techniques.” There are many products on the market that have 3D capabilities, some of which interface better with other file formats than others. One such product, Google Sketchup, puts the power of 3D modeling into the hands of almost anyone who needs a user-friendly design software. SketchUp is a simple, yet powerful tool for creating, viewing, and modifying 3D ideas quickly and easily. Developed for the conceptual stages of design, this software allows for quick

For your information 3D modeling is the creation of 3D computer graphics based on wire frame modeling via specialized software. The modeling process of preparing geometric data for 3D computer graphics is similar to plastic arts such as sculpting, whereas the art of 2D graphics is analogous to 2D visual arts such as illustration. The modeling stage consists of shaping individual objects that are later used in the scene. There are a number of modeling techniques, including:  constructive solid geometry  implicit surfaces

 NURBS modeling

 polygonal modeling

 subdivision surfaces — From Wikipedia; Fabricator 

May/June 2007

and easy 3D form creation. The basic SketchUp program is available as a free download from Google’s web site. For those who require more than the basic 3D tools, Google’s SketchUp Pro 6 allows designers and planners to explore, communicate and present complex 3D concepts. Its import/ export capability gives the user the speed and functionality for use in a professional workflow. Users can create 3D models from photographs, match existing models to background photos, render sketchy effects, and mar models with 3D text, logos, and watermarks. Currently, SketchUp Pro 6's LayOut (beta version) feature, allows the user to integrate 3D models with 2D elements to create compelling interactive presentations. LayOut (beta) also enables output of large-format, high-resolution documents. SketchUp Pro is priced at $495 and is available for download (as is the basic SketchUp program) on Google’s web site, Another software product on the market, SolidWorks Office Premium is a complete 3D product design solution, providing design engineering, data management, and communications tools in one package. One interesting feature of this package is its ability to automate repetitive tasks. The productivity enhancing drag-and-drop and snapto-fit functions of SolidWorks software simplify the design process. Its “Smart Component Technology” is an innovation that automates assembly tasks such as selecting and inserting standard bolts into holes and adding washers and nuts in the correct sequence. Additionally, SolidWorks allows the user to download 3D models and 2D drawings of components from major suppliers directly into his or her designs with 3D ContentCentralSM. The program also maintains compatibility with built-in translators that allow the user to exchange CAD data using a wide variety of file formats. For more information about SolidWorks products or to request a price quote, log on to May/June 2007 


NOMMA members discuss the usefulness of 3D software as a design tool Simon Economides of Alpha Iron

Works, Rochester, NY, posed the following questions to fellow NOMMA members about their use of 3D modeling software.  What types of projects do you use it for? Do you use it all the time or just for complex geometry? 

How detailed are you models? Do you draw every pan, channel profile and clip angle or just get close and label everything in the details? Do you use any part libraries or develop your own?

Do you have any tips for how to approach building the model so that it's flexible?

Dimitri Galitzine, Design Development Associates, LLC, answered: In terms of the kind of work that NOMMA members generally do, solid modeling is extremely useful in various areas: 1. The design of stairs, particularly the curved type. Curved stairs are best described and understood in 3 dimensions and are somewhat complex to express and calculate in 2D. 2. The design of objects that will be cast or molded. You can design the original part as well as the pattern (which can the be made cheaply by rapid prototyping methods) 3. The design of punches and dies for subsequent machining by mill or EDM (electro-discharge machining, either wire or plunge) 4. In all cases, the design can be taken to a photorealistic stage for presentations that sell the job. I have used this method frequently for the sale of custom lighting fixture projects. Once the design is photorealistically rendered, it can be cut-and-pasted on existing images of the project site to clinch the sale.

5. Very importantly, the design of sheetmetal objects (including plate of any thickness) They can design, unfold, compensate for bend allowances and output .dxf data that will be used by any cnc cutting system to cut the blanks from the sheet. Current solid modeling softwares can recover archival 2D drawings and easily convert them to 3D solid models. The one thing to keep in mind is that solid modeling programs are less forgiving of errors and sloppiness in the design process and sometimes may take longer to convey a simple design than 2D drafting. However, in complex designs that require delivery of accurate information all the way from the client, architect, sub-contarctors, fabricators and the shop floor they cannot be beat for accuracy, clarity and error reduction. Dan White, Keuka Studios Inc., offered this insight: Google Sketchup is causing quite a stir in the CAD industry. Through an aggressive web marketing campaign Google Sketchup has attracted users of all ages and disciplines. Sketchup is not as powerful as many mainstream solid modelers (yet), but for anyone wondering about using 3D in their operation but afraid to invest, they should give it a try. It’s pretty simple (as CAD systems go) and the basic version is free. I have been using 3D CAD daily for nearly 20 years now and I remember when a good CAD UNIX workstation and software would cost over $50,000 and was very difficult to use. PCs helped bring the cost down to $2000 - $15,000 (average high end software is still near $6000). Finally, now with incredibly cheap yet powerful PC’s and software like SketchUp, the 3D world is poised for explosive growth. 13

Tips & Tactics

Efficiencies Saving time and money with electron beam free form fabrication

Electron beam technology simplifies building components for aerospace engineers in the air — and for metal fabricators on the ground.

Sciaky’s New Generation EBFFF System

By Sheila Phinazee Sciaky Inc. of Phillips Services

Industries (PSI) has introduced Electron Beam Free Form Fabricating (EBFFF) technology to save fabricators in a variety of industries valuable time and money. “It is truly a fascinating new process that shaves months and huge dollars off the development costs of new parts,” says Bob Phillips, Vice President of PSI. “Applications run the gamut— from aerospace to automotive to fabricating in general.” On the forefront in the development and production of electron beam (EB) welding equipment, Sciaky has designed and built Low Voltage, High Voltage, fixed and moving electron beam gun systems. These systems have been operated in aerospace, May/June 2007 


nuclear, and automotive industries. The Electron Beam Free Form Fabrication (EBFFF) process utilizes proven EB Welding technology to create metallic parts using a cost effective approach. Dean Hoffmann, General Manager of Sciaky says, “Using today’s CAD modeling capabilities, EBFFF deposits feedstock material in an additive layering process to produce near-netshape preforms.” “This process is conducted in a vacuum environment making it ideally suited to a wide range of aerospace materials including many reactive and refractory alloys,” he adds. EBFFF is cost efficient and saves time Utilizing mass-produced raw material to generate a finished

For your information Some pecific advantages of Electron Beam Free Form Fabrication (EBFFF) include:

 Machining Preforms:

Save 80-90% of metal purchase of hogout. Save 80% of overall delivery time. Eliminate rough machining steps and one step over hogouts. Go directly to final machining step.  Less costly than forgings:

Eliminates blocker die series and repeated heat treatments. Eliminates shaper dies and heat treatments. Cuts 90% off delivery time delays from making dies. Eliminates 80-90% of rough machining over forging. Go directly to final machining step.  Less costly than castings

Saves making molds and skips molten metals issues. Cuts 90% off delivery times.

 Ideal for meeting rapid response requirements and small lot orders


The figure above and tables at left show cost analysis data for using the EBFFF process. These cost elements are associated with market pricing of raw materials and deposition rate. The estimates assume the use of typical machining parameters for Titanium 6A14V material.

A schematic diagram of the EBFFF process, showing how metallic preforms can be manufactured from computer-generated 3D drawings or models. The deposition path and process parameters are executed by a real-time computer control, and the deposition takes place in a vacuum environment. The wire is directed toward the molten pool and melted by a focused EB. Parts are built up, layer by layer, by moving the EB and wire source across the surface of the underlying material. BELOW:


component using a processing technique like EBFF instead of specialized tools, saves fabricators and manufacturers time and money. For many, the production of components is hindered by the time it takes to get raw materials delivered, dies forged, molds casted, or other tooling completed. EBFFF reduces the amount of materials needed in producing components as well. Kenn Lachenberg, Sciaky Manager of Application Engineering points out, “The ability to rapidly procure components for industry is limited by the leadtime for raw materials, tooling (casting molds and forging dies, etc.), design, and the actual manufacturing of components.” “EBFFF has the potential to greatly reduce the manufacturing lead-time and cost for components by reducing the volume of materials required along with the resulting machining time, eliminating the need for hard tooling, and improving the flexibility of the design process,” says Lachenberg. How it works The EBFFF-built component starts out with humble beginnings as commercially available welding wire. The welding wire is deposited on a substrate plate of like material. Large depth-to-width ratio parts (ribbed aircraft structures, spars, etc) are ideally suited to this processing method. “With the EBFFF fabrication method, metallic preforms can be manufactured from computer-generated 3D drawings or models. In this operation, the deposition path and process parameters are generated from post-processing the virtual 3D model and executed by a real-time computer control,” says Lachenberg. The wire is then directed toward the molten pool and melted by a focused EB. Parts are built up layer by layer by moving the EB and wire source across the surface Fabricator 

May/June 2007

Because the EB process is

typically operated within a high vacuum environment, this provides for an oxygen-free atmosphere, so secondary inert gases are not needed to preserve chemical integrity of the material. of the underlying material that is commonly referred to as the substrate. The substrate material can become an integral part of the finished product. “In this manner, free-standing shapes, or preforms, are generated without molds or dies,” says Lachenberg. “Conventional techniques are then used to machine the preform to the final part geometry.” Compared to laser As a high energy beam, EB is often compared to laser. However, says Lachenberg, “The EB process has a number of advantages over high power lasers.” The EB is electronically focusable, the output power is scalable over a very wide range, and the coupling efficiency is much better. Lachenberg says, “This allows fine detail (0.030” wall thickness) to be deposited using power output as low as several hundred Watts, while high deposition rates (greater than 40 lbs. per hour) can be achieved with the same system at higher power levels.” For optical energy such as a laser beam, a portion of the incidence energy is reflected out of the melt pool and lost to the atmosphere. This prohibits some materials such as aluminum from being effectively deposited with a laser. “The coupling efficiency of an EB is very high and allows highly reflective materials to be deposited efficiently,” says Lachenberg. Also, because the EB process is typically operated within a high vacuum environment, this provides for an oxygen-free atmosphere, so secondary inert gases are not needed to preserve chemical integrity of the material.



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Shop Talk

Liquid electrostatics — calculating transfer efficiency and ROI

Electrostatic painting can save time and money.

ABOVE: Bell-type rotary atomizer with transfer efficiency up to 90 percent.

LEFT: Paint off the serrated edge of a bell cup.

Photos courtesy ITW Ransburg

 Coating material can account for a significant portion of

the cost of a finished product. By John Owed, ITW Ransburg Essential to all manufacturing

processes is a good understanding of the cost related to a specific product. Within the paint shop, there are many things that contribute to the coating cost of a finished product. These include pretreatment chemicals, labor, utilities, waste disposal, paint filters, coating materials and many other things. Typically, coating material will be one of the larger percentages of the total finishing cost. This number can easily be calculated by dividing the number of parts coated per minute, hour, day or year into the number of gallons of coating material used in the same time frame. Once this number is identified the manufacturer can calculate the per unit cost of the coating material. It has been said that you pay for coating materials four times: 22

. You pay someone to buy it origi1nally. 2. You pay someone to apply it. 3. You pay someone to clean it up. pay someone to dispose of Calculating Actual Transfer Efficiency Transfer efficiency is a measurement that quantifies how much of the coating material applied actually goes on the part coated. In effort to measure transfer efficiency great care, accuracy and attention must be given to detail and procedure. The following chart identifies the “advertised” transfer efficiency of various pieces of equipment.

For your information In 1888, Dr. Allen DeVilbiss invented the atomizer to apply medicine to his patients' throats. In 1907, his son's experiments with a spray gun led to the development of spray finishing and this simple device was adapted to apply paint. Today, this process finishes everything from toys to military vehicles. Spray finishing, as we know it today, is a derivative of Dr. DeVilbiss' original invention. In 1936, Harold Ransburg began working with electrostatics, charging paint and grounding the surface to be painted. The U.S. Patent Office granted him a patent for the electrostatic spray coating process in July 1941. Through continued experiments to improve the process, his tinkering evolved into the electrostatic coating process of today. Products spawned from this technology include rotary atomizers, such as bells and disks, that have become part of the leading edge of today's high transfer efficiency atomization processes. —From ITW Ransburg’s web site, Fabricator 

May/June 2007

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The following information is required to calculate Transfer Efficiency: ■ Amount of coating material sprayed by weighing the pressure pot before and after. ■ Amount of coating material applied by weighing the part coated before and after. ■ Solids by weight of the coating material.

Calculating Actual Transfer Efficiency The numbers that appear on the above chart are typically generated in a lab situation using an ASME approved test standard. These numbers work well when comparing the different pieces of equipment. Many things can influences transfer efficiency, they include: ■ Equipment used

Application method Temperature ■ Equipment maintenance ■ Humidity ■ Booth air velocity ■ Substrate coated ■ Operating technique ■ Coating material ■ Part grounding ■

Equipment required:

■ Scale with a resolution of .1 grams ■ Pressure pot with a quick disconnect for air and fluid ■ Foil (if the part weight is greater than the scale can accurately weigh).




May/June 2007


Pre-weigh parts to be coated, or foil which will be 1used to wrap parts Fill spray system with coating to be tested, shut off 2pot.fluid valve, relieve air pressure and weigh pressure

3Reconnect pressure pot 4Spray the parts being tested. Re-weigh the pressure pot (shut of fluid valve, 5relieve air pressure and weigh pressure pot) 6Cure parts according to recommended parameters the part(s) coated (allow to cool to ambi7entRe-weigh temperature) Calculating solids by weight The solids by weight for coating material can typically be found on the MSDS or material data sheet. However, if the material has been reduced, this number will not be accurate. The solids by weight of the coating material should always be checked using the following procedure. Equipment required: Scale with resolution of .001 grams Glass vial with lid ■ Foil dish (3) ■ ■

Procedure: ■ Collect a sample of the coating material being tested in the glass vial and place the lid on it to prevent evaporation. ■ Number the foil dishes (on the bottom) and weigh each one, record the “before” weight. ■ Weigh the vial of material and record the “before” weight. ■ Remove the lid and pour a quarter size sample into dish #1, replace the lid and reweigh the bottle. Repeat this procedure for dish #2 & #3 recording the bottle weights each time in effort to document the “wet” weight. ■ Place the three foil dishes into a metal container (one gallon can) and cure the coating material according to the manufacturers specifications.



May/June 2007

■ Once the coating material is cured and cooled to ambient temperature, reweigh the three foil dishes and record the “after” weight. ■ Use the following formula to calculate solids byweight. ■ Bottle weight “before” - bottle weight “after” = wet sample ■ Foil dish weight “after” - foil dish weight “before” = dry sample. ■ Average the three weights collected.

Transfer Efficiency Calculation Once all the necessary information has been obtained, the actual transfer efficiency can be calculated using the following formula: Material applied ÷ Material sprayed x % Solids by weight = Actual Transfer Efficiency

that is being used for a specific process. The manufacturer should use this information to develop a baseline for their existing system performance. This information should then be used to compare the various pieces of competitive equipment available in the industry. Of the previous measurement methods listed one of the easiest and most practical to work with is the amount of coating material used per part. Although transfer efficiency is a very good method for measuring system performance, it is often difficult for a manufacturer to generate this information in-house. When conducting trials at competitive labs, the manufacturer can attend these trials armed with their material usage per part information. During the trials this information is then generated and compared with the existing information. In addition to this the customer can also visually compare coated samples and film thickness consistency. Example:

Calculating Return on Investment When a manufacturer wants to upgrade or replace a finishing system, they need to have an idea of what the pay back will be in effort to write a justification. As noted previously the cost of the coating material is typically one of the largest percentages of the entire finishing cost. In the previous text of this article, various methods have been given for quantifying the amount of coating material

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In the above example, the manufacturer can realize a savings of $ 274,775 per year in coating material cost alone. The price of any potential investment for new equipment can be divided into this number to determine the length of payback. Conclusions It may seem like a lot of work to determine the current


Transfer Efficiency of an existing finishing system. But having the data, you can see how sometimes only a small increase in Transfer Efficiency can result in a much shorter Return On Investment. Keep in mind that this only reflects paint savings. More savings will be seen in less waste disposal, longer booth filter life, and less clean up labor costs.


May/June 2007


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Member Talk

NOMMA launches major study on the guard ‘climbability’ issue  An independent research program will provide a scientific

Photos: NOMMA Top Job archives.

analysis on guard safety in relation to young children.

Under a liberal interpretation of some code changeproposals, virtually all decorative rail designs would be outlawed.

By Todd Daniel Communications Manager Imagine a world where decorative guards

and railings are outlawed, as well as pipe and cable railings. Imagine a place that only allows vertical pickets, without even collars or birdcages. Sounds unbelievable? The fact is, a combination of extreme code proposals and liberal interpretations could easily wipe out a large portion of our industry. In 1999, we experienced a sampling of this scenario with the passage of the “ladder effect” in the 2000 International Residential Code. Though the clause was removed the following year, the highly subjective wording caused havoc in our industry for years. While many inspectors interpreted “ladder effect” to mean horizontal members, other inspectors were rejecting any job where a child could conceivably obtain a “foothold.” Even with the elimination of the “ladder effect” in the 2001 IRC Supplement, our industry’s challenges persisted for two reasons: 1) Many jurisdictions do not adopt supplements, and 2) Code change

proponents continued their efforts to reinsert climbability language back into the codes. When NOMMA’s Technical Committee returned from the contentious 2000 ICC hearings in Birmingham, AL, they warned the NOMMA Board that this issue was “not going away.” NOMMA responded to the continued concerns the following year by creating the Technical Affairs Division and hiring a part-time technical consultant. The push for more restrictions

Since the 1980s, code change proponents have continuously pushed for more restrictions in the name of child safety. During the past 20 years, these proponents, primarily led by Elliott O. Stephenson, have advocated proposals and changes that would virtually eliminate most decorative guard designs. They have tried to back their proposals on hospital emergency room data, live “experiments” at daycare facilities, and other sources. NOMMA has responded to the claims of the proponents by conducting its own exhaustive studies. Summaries of NOMMA’s

Support the NOMMA Education Foundation ... See Pg. 78 32

For your information Summary of Issue: NOMMA supports the current model building codes for guards and feel they provide for a strong and safe product. However, proponents are pushing for more restrictions without providing scientifically backed data to support their claims. A key concern: While child injuries from guards have been documented, no scientific correlation has been established between injuries and particular guard types. Where we are at: NOMMA maintains that guards which comply with current building codes are safe. NOMMA’s Code Advisory Council points out that many documented injuries are caused because: a) Furniture was placed against the guard and used for climbing, or b) The accident occured in an older structure built when codes allowed for either 6 or 9 inch openings. Fabricator  May/June 2007

early work are featured in two articles posted in the Support area of the NOMMA website. In short, NOMMA has challenged the research of the proponents for the following reasons:

 The informal studies conducted in preschool playgrounds did not follow scientific methodology and failed to consider many variables (also known as “factors”).  There is no known data any-

where in the world that conclusively correlates child injuries with specific guard configurations.  Data taken from the U.S. Consumer Product Safety Commission and used by the proponents was mis-

NOMMA Press Release

National Ornamental & Miscellaneous Metals Association retains NAHB Research Center to conduct independent rail climbability study MCDONOUGH, GA — The National Ornamental & Mis-

cellaneous Metals Association (NOMMA) has entered into an agreement with the NAHB Research Center to conduct an independent study on guard safety in relation to young children. The goal of the landmark study is to consolidate and analyze the pool of knowledge on guards and railing climbability, and to provide an objective dataset for the industry.Once details are finalized, the Research Center will embark on a comprehensive study to review existing data, determine any linkage between childhood injuries and specific guard designs, and recommend code requirements. The study will use advanced computer modeling to compare child anthropometric data with various guard configurations. These "virtual tests" will examine the capabilities of children in different age groups. Some of the human factors to be reviewed in the study include physical abilities, cognitive skills, and temperament. Guard design factors to be covered include height, spacing, orientation, size, and pitch. Since 1999 the NOMMA Technical Affairs Division has conducted extensive in-house research on guard climbability, however in recent years the need has become apparent for an objective, third-party study. In February 2006, NOMMA retained the services of Whorton Marketing & Research of Columbia, MD for an initial industry study. The Whorton study identified knowledge gaps in the current pool of research, and provided a foundation for more studies. Kevin Whorton, the principal of Whorton Marketing & Research, remains as an adviser, and will serve as a liaison between NOMMA and the Research Center. In 2004, the International Code Council created the Code Technology Committee (CTC) to examine guard climbability as well as other complex issues. Since June 2005, NOMMA has stayed actively involved in this process and is formally represented on the CTC Climbable Guard Study Group. During the course of the research program, NOMMA remains committed to sharing data with the Study Group. Ultimately, the results of the study will help the Study Group to formulate code change proposals that address any issues exposed by trends in the data, while concurrently allowing for reasonable latitude in rail design. The NOMMA Board chose the Research Center to May/June 2007  Fabricator

conduct the study because of their excellent reputation in the construction industry, their solid understanding of the issue, and their expertise in computer modeling. The Research Center is also well known by the CTC and is respected in the code community. Research conducted by the facility will be completely independent and objective. While a specific timetable has not been set, the Research Center hopes to complete the project within 90 days after an initial kickoff meeting. Since the mid 1980s, there has been an ongoing trend to regulate guards. While NOMMA applauds and supports code changes that provide proven safety benefits, the association is concerned about extreme code proposals that could eliminate hundreds of popular guard designs, yet have no scientific data to back them up. Some extreme proposals in the past have been based on emotion, assumptions, nonscientific experiments, and distortions of existing studies. NOMMA hopes to make a major contribution to the industry by providing an objective pool of knowledge that will benefit all parties. NOMMA, headquartered in McDonough, GA, was formed in 1958 to serve the ornamental and miscellaneous metals industry. NOMMA’s members produce a wide range of ornamental and miscellaneous metalwork, ranging from railings to driveway gates, and from sculpture to light structural steel. NOMMA provides a variety of educational services to the industry, including an annual trade show and convention, glossy trade magazine, continuing education classes, technical bulletins, and more. The NAHB Research Center, located in Upper Marlboro, Md., promotes innovation in housing technology to improve the quality, durability, affordability, and environmental performance of homes and home building products. Created over 40 years ago as a subsidiary of the National Association of Home Builders (NAHB), the NAHB Research Center has established itself as the source for reliable, objective information and research on housing construction and development issues. Through its various testing and certification services, the Research Center seal is internationally recognized as a mark of product quality and an assurance of product performance. 33

Tony Leto and other members of the NOMMA team helped to educate attendees on the climbability issue during METALfab 2007.

used. Most accident reports are too vague to confirm a climb-over injury linked to a specific rail type. When NOMMA conducted its own data search, we found “rail” injuries caused by everything from highway guardrails to bed rails.  Even when guard-related injuries are discovered, the overwhelmingly majority are related to large baluster spacing typically greater than 5 inches. Some other sources of injury found by our re-

search includes rail failure, falls against a railing, and even injuries from sliding down a railing! Commitment to safety

NOMMA takes offense to claims by the proponents that our guards are a “special enemy to the world’s children.” Far from being an enemy, NOMMA is strongly committed to safety. The association supports the current building codes, is an active participant in the code process, and we maintain a child safety area on our website. Our commitment to safety includes educating parents on the danger of placing furniture and planters near rails, and encouraging property owners to “retrofit” guards that have openings greater than 4 inches. We particularly support the position of the National SAFE KIDS Campaign that states, “Never let children play alone on fire escapes, high porches, or balconies.” According to Jim Wallace, director of The Metal Museum in Memphis, TN, metal railings go back as far as 1,000 AD. Thus, the products of our industry have protected the public for a millennium. In the last two decades, the model code bodies have passed various proposals that affect the height, strength, and spacing of guard elements. These requirements have helped to make our products even stronger and safer. Revisiting climbability

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As expected, the removal of the “ladder effect” in 2001 did not put the issue to rest. In the 2003/04 code cycle, the IRC Building/Energy Code Committee voted to establish a committee to study the issue. In 2005 we learned that the ICC Board had created the Code Technology Committee (CTC) to examine climbability and other complex issues. Since July 2005, NOMMA has sent a representation team to each CTC meeting. The group currently meets 45 times a year in different cities. In September 2005, the CTC formed the Guard Study Group, and NOMMA is officially represented in this group. Since the CTC’s inception, both NOMMA and the proponents have Fabricator  May/June 2007



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submitted a vast amount of data, which is available on the CTC website (see pg. 38). In the fall of 2005, NOMMA worked closely with the Guard Study Group to create a pack-

age of proposals that would make guards more “climb resistant.” A major turning point took place at the Las Vegas CTC meeting in December 2005, when all proposals “fell

through,” and everyone realized that a new direction was needed. Also during this period, Mr. Stephenson sent out an open letter that introduced the term “foothold.” At the time it was

Research project time line

In April, NOMMA signed a historic contract with the NAHB Research Center to conduct a landmark study on guard climbability. The following is the chronology that led to this major event.

• Mid-1980s: Increasing code requirements begin to affect guards and railings. • 1988: First articles on climbability appear in building code publications.

• 1990: Americans With Disabilities Act passes.

• 1999: The ICC passes the “ladder effect” term in the 2000 Residential Code, despite NOMMA’s request for disapproval.

• 2000: NOMMA submits code change proposal to remove the “ladder effect” from the IRC. The request is approved and adopted in to the 2001 International Residential Code Supplement.

• January 2004: The ICC Board creates the Code Technology Committee (CTC) to address lingering issues that are too complex to resolve during code hearings. “Climbable Guards” is included in the first batch of issues. Technology Committee.

• June 2005: NOMMA sends a team to the June CTC meeting in Chicago, and is represented at each successive meeting.

• September 2005: The CTC creates the Guard Study Group during their Detroit meeting.

• 2000: NOMMA publishes position paper on “ladder effect” in July/August Fabricator.

• 2001: NOMMA creates the Technical Affairs Division and hires a part-time technical consultant. NOMMA’s technical team publishes an article titled, “The Industry’s Response To ‘Climbable’ Guards” in the November/December Fabricator. • 2001: Southern Building publishes “Climbable Guards — Special Enemy of the World’s Children” in September.

• 2002: Attempts begin to submit more climbability restrictions into the codes.

• 2003: The IRC Building/Energy Committee passes a motion to establish a committee to study climbability. The issue is later assigned to the newly formed Code


NOMMA Technical Committee representatives dine with local members prior to the Detroit CTC meeting in September 2005.

• October-December 2005: NOMMA, working in conjunction with the CTC Study Group explores options for “climb deterrence.” At the December Las Vegas CTC meeting, the need for more testing is discussed.

• December 2005: A code change proponent releases an “open letter” that advocates “foot hold” wording in the current code cycle.

• February 2006: NOMMA hires Whorton Marketing & Research of Columbia, MD to serve as a research consultant and to assist in a new study.

• March 2006: Two new proposals on climbability are submitted for the 2006/07 code cycle. The CTC submits its interim proposal. • June 2006: The Whorton Group releases several reports on climbability. Concerns are expressed about the report’s objectivity, since Whorton Research was retained directly by NOMMA. In addition, the Whorton reports identify knowledge gaps and leaves the door open for more research.

• July 2006: The NOMMA Technical Team begins a nationwide search to find a research vendor to conduct an independent and objective research project. • September 2006: Climbability proposals are denied at the Fall Code Hearings in Lake Buena Vista, FL. Later in the month, the NOMMA Board passes a resolution of commitment to the research program.

• December 2006: A large delegation of NOMMA volunteers attend the Phoenix CTC meeting to update the committee on NOMMA’s research efforts. • February 2007: After much deliberation, the NOMMA Board chooses the NAHB Research Center to conduct a major study on climbability. The Research Center was selected from four candidates

• April 2007: A contract is signed between NOMMA and the NAHB Research Center. Following a “kickoff” phone conference, the work begins! Fabricator  May/June 2007



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feared that Mr. Stephenson would introduce his proposals into the 2006/07 code cycle. “It was a redirection point,” said Tom Zuzik, a long-time member of NOMMA’s technical team. “It was when we started trying to find someone to do an independent, third-party review.” Two months later, in February 2006, NOMMA retained the services of Whorton Marketing & Research of Columbia, MD to conduct a comprehensive study on guard safety in rela-

See Climbability Research Online NOMMA Ladder Effect Articles ladder%20effect/laddereffect%20 header.htm ICC CTC Climbable Guards imbable.html

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Search process begins

By summer, a nationwide search began to find a suitable organization for conducting an independent study. With the help of Whorton Marketing & Research and NOMMA’s Research Subcommittee, four suitable candidates were found. On February 28, 2007, after much deliberation, the NOMMA Board of Directors chose the NAHB Research Center of Upper Marlboro, MD to conduct the landmark study. The Research Center was chosen because of their impressive grasp of the issue, their skills with computer modeling, and for their solid reputation in the code community. Although the Research Center is a subsidiary of the National Association of Home Builders, they operate as an independent and objective entity. Contracting with the Research Center represents a major financial commitment for both NOMMA and the NOMMA Education Foundation. The NOMMA Board, NEF Trustees, and two industry suppliers have already made major commitments toward our fund-raising goals, but we also need the financial support of our membership and the industry as a whole. A thanks to those members who have already given! The Research Center’s findings will provide a solid dataset that will allow NOMMA to pursue two vital goals — ensuring that our industry’s products are safe, and ensuring that our industry is not unfairly regulated based on emotion-based claims, nonscientific data, and specious arguments.

Come help us celebrate NOMMA’s 50th anniversar during


New Distributors are Welcome. Call Chet or Terry for More Information.


studies from around the world. These documents provided the groundwork for the next step, which was the commissioning of a major, objective study by an independent third party.

2410 Hwy. 15 South • Sumter, SC 29154

Terry Spatz Coleman

(803) 481-3400 • Toll Free: (888) 471-3400

National Sales Representative

(800) 589-5545

M E TA L f a b 2008 Fabricator  May/June 2007

METALfab 2007

METALfab 2007: the week in review  Against the backdrop of

the Gulf Coast’s white sands and blue-green waters, METALfab 2007 was a week packed with educational opportunities, recognition of achievements, networking, and, of course, fun. The National Ornamental and

Miscellaneous Metals Association (NOMMA) held its 49th annual trade show and convention at the beautiful and luxurious Sandestin Golf and Beach Resort, February 28-March 3, 2007. In keeping with its theme, “Adding Value to Your Business,” convention attendees were treated to several days’ worth of excellent and informative educational sessions, discussions and presentations, a shop tour complete with demonstrations and more. METALfab kicked off on Wednesday with registration, the Welcome Reception, and the opening of the Supplier Showcase. This year’s Showcase — although on a smaller

For your information METALfab: NOMMA’s annual convention and trade show. Attendees: METALfab is open to members of NOMMA as well as nonmembers. Read Fabricator and visit NOMMA’s web site for event and registration details on METALfab 2008. Ph: (770) 288-2004; Web:

Exhibitors: TTo exhibit at the 2008 METALfab trade show, contact Martha Pennington via Email:, or log on to


scale — was highly successful, as attendees packed the exhibit hall to view the tabletop exhibitor displays. The next day began with the First Time Attendee Orientation, followed by the first of the week’s nonstop educational sessions. NOMMA’s annual business meeting and recognition luncheon were held mid-day, after which keynote speaker Glenn Shepard addressed the membership with an outstanding presentation, “Customer Service and How to Keep Difficult Customers Without Giving Too Much.” The Supplier Showcase was, again, open that evening, with a reception. The following evening, everyone was treated to a fabulous luau theme dinner, “Fabricators in Paradise.” Special events included the NEF silent auction and regular auction, presided over by auctioneers Carl Grainger and Roger Carlsen. The auctions raised $19,802 for NOMMA’s educational foundation. Entertainment was provided by the famous Landsharks, who were joined onstage by a few of NOMMA’s musically talented members for a couple of numbers. On Saturday, three tour buses carrying NOMMA members and staff departed Sandestin for a shop tour of Eagle Bending/Carrell Corp. in nearby Stapleton, AL. Owner David Donnell gave attendees the grand tour and treated them to a delicious boxed lunch. Afterwards, there were live

demonstrations on working with stainless steel, aluminum forging and white metal casting. The buses arrived back at the resort just in time for members to ready themselves for the Annual Awards Banquet, during which new officers and directors were installed, oustanding NOMMA members were recognized, and the Ernest Wiemann Top Job Awards winners were announced, including the winner of the Mitch Heitler Award for Excellence, which is selected from the gold level award winners. The grand finale of the evening was a visit from none other than the King, himself. “Elvis,” accompanied by two lovely backup singers, serenaded the banquet hall, ending with a reminder that he’d see us all in Memphis for Elvis (a.k.a. Joe Romeo) METALfab was in the building at 2008! METALfab 2007. Fabricator 

May/June 2007

Tel: 800-522-4766 Fax: 888-699-9666 Email:


Handcrafted, quality details.

Forged panels for the Custom Fabricator Please call: (800) 522-4766 For More Info

METALfab 2007

Thanks to all of our Exhibitors 2020 Software Solutions Inc. 651-257-8715 Bending software.

Crescent City Iron Supply Inc. 800-535-9842 Fencing and gate hardware.

ITW Ransburg 419-470-2000 Electrostatic paint equipment.

New Metals Inc. 800-345-0313 Expanded metal forgings.

Alloy Casting Co. Inc. 800-527-1318 Aluminum castings.

Custom Orn. Iron Works 866-464-4766 Components.

King Architectural Metals 214-876-0696 Access controls, architectural forgings.

Paxton & Thau Artistic Supply 205-290-2790 Ornamental forgings.

Auciello Iron Works Inc. 978-568-8382 EZ-sleeves.

DJA Imports Ltd. 718-324-6871 Components, gate hardware.

Big Blu Hammer Mfg. Co. 828-437-5348 Big Blu air hammers.

DKS DoorKing Inc. 310-645-0023 Access control products.

Julius Blum & Co. Inc. 800-526-6293 omponents.

Eagle Bending Machines Inc. 251-937-0947 www.eaglebendingmachines. com Bending machines.

Byan Systems Inc. 307-334-2865 Gate operators.

Engineering Export Promotion Council 847-297-8500

The Cable Connection 775-885-1443 Cable railing products.

E.P. Industries 011- 91-832-243-1081 Castings and wrought iron.

Carell Corporation 251-937-0947 Fabricating machinery.

Fabcad Inc. 800-255-9032 Ornamental CAD software.

Cleveland Steel Tool Co. 800-446-4402 Ironworkers, portable tooling.

Royal Forge PTE LTD 011-656-235-9893 Baluster, curls, gate-tops.

CLS Enterprises 352-369-0177 Cast ornamental panels.

GTO Access Control Systems 800-542-4283 Gate operators, access control.

CML USA Inc. 563-391-7700 Bending machines.

Hebo / Stratford Gate Systems 503-572-6500 Hebo machines.

Colorado WaterJet Co. 970-532-5404 Waterjet cutting services. Complex Industries Inc. 901-547-1198 Gates, fence panels. 42

House of Forgings Inc. 281-443-4848 Wrought iron components. Industrial Coverage Corp. 631-736-7500 Insurance programs designed for NOMMA members.

Laser Precision Cutting Inc. 828-658-0644 Laser cutting services. C.R. Laurence Co. Inc. 800-421-6144 Railing systems. Lavi Industries 877-447-LAVI Fittings and tubings. Lawler Foundry Corp. 205-595-0596 Components and accessories. Marks USA 631-225-5400 Mortise locksets. MB Software Solutions LLC 717-350-2759 Fabmate software. Mittler Bros. Machine & Tool 636-745-7757 Ultimate tubing notcher. Frank Morrow Co. 401-941-3900 Metal trims and stampings. National Ornamental & Miscellaneous Metals Association (NOMMA) 888-516-8585 Industryâ&#x20AC;&#x2122;s trade association.

Regency Railings Inc. 214-742-9408 Forged iron components. Rockite, Div. of Hartline Products Co. Inc. 216-291-2303 Anchoring/patching cement. Sharpe Products 262-754-0369 Bending and rolling services. Sumter Coatings Inc. 803-481-3400 Paints and primers. Tennessee Fabricating Co. 901-725-1548 Decorative metals, hardware. Texas Metal Industries 239-768-6690 Ornamental metal products. The Wagner Companies 414-214-0444 Components. Wrought Iron Concepts Inc. 877-370-8000 Components. Zareba Systems 763-551-1125 Automatic gate openers.

NOMMA Education Foundation 888-516-8585 Charitable education foundation. Fabricator 

May/June 2007

METALfab 2007

Thanks to our METALfab 2007 Sponsors

2007 METALfab Trade Show


 Industrial Coverage Corp.  Lawler Foundry Corp.  The Wagner Companies



Julius Blum & Co. Inc. Carell Corporation Colorado Waterjet Co. Eagle Bending Machines Inc. Fabcad Inc. Innovative Hinge Products Mittler Bros. Machine & Tool Regency Railings Inc. Paxton & Thau Artistic Supply


 Upper Midwest Chapter of NOMMA


The annual trade show was, as always, a popular part of METALfab. Shown here are supplier members Bavarian Iron Works (above) and Texas Metal Industries (right).

Superior to mild steel for decorative forge work Square bar Round bar Flat bar Call for a free sample



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May/June 2007

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METALfab 2007

Education Sessions METALfab 2007 delivered on its promise to give conference-goers all the tools they need for adding value to their products, their customer service practices, and their businesses as a whole. Educational sessions covered a wide variety of topics, from technology to human resources.

Throughout the convention, attendees consistently packed into conference rooms for dozens of informative education sessions. Here, 2006 NOMMA President Chris Connelly shares his personal experiences in a session entitled, “Five Keys to Running a Successful Subcontracting Business.” ABOVE:

ABOVE: Motivational speaker Glenn Shepard, who delivered the keynote address at METALfab’s annual business meeting and luncheon, also conducted three very dynamic workshops during the convention: “How to Get People to Pay,” “Managing Problem Employees and Difficult Supervisory Positions,” and “How to Supervise People and Lead a Team.”



May/June 2007


METALfab 2007

2007 Top Job Award Winners The annual Ernest Wiemann Top Job Competition is open

to all NOMMA members. Entrants provide a photo and description of their work, and entries are displayed during METALfab. NOMMA members are given the opportunity to peruse the gallery of pictures and cast their votes. Once the winners are determined, a committee then

reviews the gold winners and selects one job that merits additional recognition. This special job is presented with the Mitch Heitler Award for Excellence, and is considered the “best of the best.” The following awards were presented at the annual awards banquet during METALfab 2007: Mitch Heitler Award for Excellence Eureka Forge House Springs, MO Category A (Driveway Gates) GOLD: A.Y.’s Designs in Iron San Diego, CA SILVER: Royal Iron Creations West Palm Beach, FL BRONZE: Artisan Metal Works Ltd. Grand Caymans, Cayman

ABOVE: NOMMA members browse the Top Job gallery of photos and cast their votes in each category.


Category B (Driveway Gates - Forged) GOLD: Christopher Metal Fabricating Inc. Grand Rapids, MI SILVER: Klahm & Sons Inc. Ocala, FL BRONZE: Carnahan-White Inc. Springfield, MO


May/June 2007


Todd Kinnikin (left) of Eureka Forge accepts his award in the Interior Railings (forged) category. Eureka Forge also won the Mitch Heitler Award for Excellence.

Excellence in Traditional Components

Category C (Interior Railings) GOLD: Flaherty Iron Works Inc. Alexandria, VA SILVER: Kelley Ornamental Iron LLC Peoria, IL BRONZE: Neiweem Industries Inc. Oakwood Hills, IL Category E (Interior Railings - Forged) GOLD: Eureka Forge House Springs, MO SILVER: Carnahan-White Inc. Springfield, MO BRONZE: Wonderland Products Inc. Jacksonville, FL Category F (Exterior Railings & Fences) GOLD: Artistic Railings Inc. Garfield, NJ SILVER: Eileen Ruth Webb Palos Verdes Peninsula, CA BRONZE: Iron Touch LLC Louisville, KY Category G (Exterior Railings & Fences - Forged) GOLD: Bobâ&#x20AC;&#x2122;s Ornamental Iron Studio Kansas City, KS SILVER: Wonderland Products Inc. Jacksonville, FL BRONZE: Klahm & Sons Inc. Ocala, FL Category H (Furniture & Accessories) GOLD: Virginia Architectural Metals Fredericksburg, VA SILVER: Christopher Metal Fabricating Inc. Grand Rapids, MI BRONZE: Kelley Ornamental Iron LLC Peoria, IL May/June 2007 





METALfab 2007

Clifford H. Brown Award winner Michael D. Boyler of Boyler’s Ornamental Iron Inc., Bettendorf, IA, is the 2007 winner of the Clifford H. Brown Award, which honors individuals who make outstanding contributions in the area of industry education. Mr. Boyler is an industry visionary and a long-time advocate for education. He is the only NOMMA member to ever receive all three of the industry’s top awards — the Clifford H. Brown, Julius Blum, and Frank A. Kozik awards. He was unable to attend this year’s METALfab convention; Bruce Boyler accepted the award on his brother’s behalf.

2007 Top Job Winners, continued Category I (Furniture & Accessories - Forged) GOLD: Wrought Iron Art Ltd. Oakville, ON Canada SILVER: Vaclav Metalcraft Inc. Howells, NY BRONZE: Carnahan-White Inc. Springfield, MO Category J (Gates/Doors) GOLD: International Creative Metal Inc. Woodside, NY SILVER: Steel Magnolia of Northeast Georgia Bogart, GA BRONZE: Wiemann Ironworks Tulsa, OK Category K (Gates/Doors - Forged) GOLD: Wrought Iron Art Ltd. Oakville, ON, Canada SILVER: Fine Architectural Metalsmiths Chester, NY BRONZE: The Modern Forge Oakland Park, FL Category L (Stairs Complete) GOLD: Construction Services Inc. Decatur, AL SILVER: Princeton Welding Inc. Half Moon Bay, CA BRONZE: Big D Metalworks Dallas, TX Category M (Structural) GOLD: Sunmaster of Naples Inc. Naples, FL SILVER: Wiemann Ironworks Tulsa, OK BRONZE: SRS Inc. Metuchen, NJ Category N (Most Unusual) GOLD: Wrought Iron Art Ltd. Oakville, ON, Canada SILVER: McLellan Blacksmithing Loomis, CA BRONZE: Artisan Metal Works Ltd. Grand Caymans, Cayman Category P (Art/Sculpture) GOLD: Cape Cod Fabrications North Falmouth, MA SILVER: The Iron Hammer Murray, KY BRONZE: High Desert Forge Inc. Albuquerque, NM

Do you have a project you’d like to enter in the 2008 Top Job Awards competition? Entry details can be found on NOMMA’s web site, 50


May/June 2007

Shop Tour & Demos LEFT:

David Donnell describes the equipment that Eagle Bending Machines Inc. and Carrel Corp. sell.

On the last day of METALfab, three busloads of NOMMA members and staff were treated to a shop tour by David Donnell and the staff of Eagle Bending Machines and Carell Corp., Stapleton, AL. Lunch was served afterwards, and then three metalworking demonstrations, conducted by George Banderra, Jack Klahm and Roger Carlsen, completed the dayâ&#x20AC;&#x2122;s events.


George Banderra demonstrates working with stainless steel.

Jack Klahm shows the techniques of aluminum forging. RIGHT:


Roger Carlsen talks to the crowd about white metal casting.

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"Thanks to Ray Redlich of Eagle Bending/Carrel for providing pictures of the Saturday shop tour and demos. May/June 2007 


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METALfab 2007

NEF Auction and Theme Dinner LEFT: Ernest and Wiemann enjoy the festivities at Friday night’s luau/beach party. Themed “Fabricators in Paradise,” the evening featured a delicious buffet dinner, silent and live auctions, and entertainment by the Landsharks band.

What You Want U.S.A. Made


Incoming NOMMA President Breck Nelson holds up a beautifully sculpted angel for the bidding during the NEF Auction.

Custom Castings:

Steel, Iron, Alum., Bronze, Stainless, Nickel Silver

Newels & Pickets -

Cut & Twisted to Your Specs

ABOVE: NOMMA members pore over the items available for bid in the silent auction. The annual auctions raise funds for NOMMA’s Education Foundation.

Another addition to our ever-growing product line you’ve come to trust. Quality



Tennessee Fabricating Company 2025 York Ave. Memphis, TN 38104 1-800-258-4766


Everyone got into the spirit of the evening with leis, grass skirts and other festive attire. A good time was had by all!


Special thanks to all who contributed to NEF and its programs. Fabricator 

May/June 2007

NOMMA celebrates a landmark anniversary 50 years of serving the industry

Scenes from the early days of METALfab. Our cameras and clothes may have chaned over the years, but NOMMA’s commitment to serving the industry has remained steadfast.

In 1958, NOMMA was established in Memphis, TN by a group of people who felt that the industry would be better served and represented by a dedicated association. Now, we are gearing up to celebrate the 50th anniversary of their efforts. And where better to celebrate than the place where it all began — the land of blues, barbecue and Graceland! NOMMA will hold its annual conference, METALfab 2008, in Memphis, April 1-5, 2008. As always, it will be a week packed with educational and netMay/June 2007 


working opportunities, the Ernest Weimann Top Job contest, shop tours, NEF auction and silent auction, theme dinner and awards banquet. Look for the return of the ful-size trade show in 2008. In addition, we’re planning several celebratory events to mark this very special anniversary. So, please mark your calendars now and plan on joining us in Memphis next year for the most spectacular METALfab ever. Look for special articles commemorating NOMMA’s history in future issues of Fabricator.

For your information Who: All NOMMA fabricator and supplier members, exhibitors and staff What: METALfab 2008 When: April 1-5, 2008 Where: Memphis, TN Why: NOMMA’s 50th birthday party! More details will be posted as available on NOMMA’s web site,


Job Profile

Shades of the “old West” — the past lives on in Carlsbad

 Gates commemorate the former movie-star owner of

this historic

ranch-turned-state park. By Helen K. Kelley “Hey Pancho!” For those of you who were children in the 1950s, you’ll know the right response is, “Hey Cisco!” And for those who may be too young to remember, those immortal phrases were uttered on the popular TV western, The Cisco Kid. The series revolved around the adventures of the Cisco Kid and his mischievous sidekick, Pancho — portrayed by actor Leo Carillo. A successful character actor with a long career that included roles in several major Broadway plays and more 54

than 90 motion pictures, Leo Carillo found himself longing for a retreat where he could recreate an Old California-style working ranch. In 1937, he bought the 840-acre Rancho de Los Kiotes (“Sleeping Beauty” Ranch) in Carlsbad, CA. There, he constructed 18 buildings and structures (including a jail) that were necessary not only for authenticity, but also for actual ranch operations. Over the 20+ years, Carillo expanded his spread to 2,538 acres. Carillo’s ranch, which was remote at the time, also became a haven for many of his celebrity friends, who

For your information Project: Entry gates with Western/movie star flair Shop: Designs in Iron, a NOMMA member firm Materials:

 4” x 4” tube steel frame

 Reels: 12 gauge sheet metal

 Wheel spokes: 1/2” O.D. tubing  Wheel tape: 1/4” x 3” F.B.

 All material hot dipped galvanized  Epoxy black finish


May/June 2007

The design would have a

western movie theme, complete with wagon wheels, film reels, and flowing film tape.

Hollywood legends Clark Gable and Carole Lombard honeymooned on the Carillo ranch.


sought to escape public scrutiny. Sometimes, they would gather there for large parties that lasted several days. Hollywood legends Clark Gable and Carole Lombard spent their honeymoon at the secluded ranch. After Leo Carillo’s death in 1961, the property fell on hard times. Much of it was sold off to accommodate the Carlsbad area’s sprawling growth. In 1977, the city of Carlsbad was able to acquire a tiny 10.5 acre remnant of the ranch that contained and protected the most critical original buildings, and designated it for use as an historic park. A state preservation grant and additional contributions allowed for the restoration of these structures in 1992. Later, a required transfer of 16.4 acres from contiguous residential developers has expanded the park site to 27 acres.

Today, Leo Carrillo Ranch Historic Park serves as a true educational and recreational resource to the public. It is a tribute to a man who was not merely an actor, but also a dedicated preservationist and conservationist. Behind the design The city of Carlsbad and a community group, Friends of Leo Carillo Ranch, approached local artist Paul Hobson and asked him to serve on a team with an architect and landscape architect to develop a master plan for the park. This included the design of entry gates to the ranch. Hobson drew his concept for the gates from Leo Carillo’s rich acting history. The design would have a western movie theme, complete with wagon wheels, film reels, and flowing film tape. “The piece is really about Leo Carillo’s decision, after spending years on the New York stage, to return to his home state of California to make ‘talkies,’“ explains Hobson. “The gates


May/June 2007

LEFT: The gates are a metaphor of Leo Carillo’s life as an actor, as well as his efforts to preserve a disappearing way of life in the West.

are really a metaphor for Leo’s life. They symbolize his love of the old West and also his career in the movies.”


The gates were transported on a flatbed to the Leo Carillo Ranch Historic Park. The epoxy black finish makes for a beautiful contrast against the clear blue Carlsbad sky.

The idea takes shape When it came time to make the concept a reality, Hobson approached Mark Yturralde, who manages NOMMA member shop Designs in Iron in San Diego, to help him build the gates. “He chose our company because we’re known for our quality work and 30 years’ experience,” says Yturralde. Yturralde focused first on the basics of getting the gates off paper and into fabrication. “I basicallly took Paul’s design, interpreted it, and blew it up to the actual size,” he notes. May/June 2007 



LEFT: The gates under construction at Designs in Iron, San Diego, CA. Bending 1/4” x 3” F.B. to look like loose movie film wasn’t an easy feat.

The gates are as beautiful up close as they are from a distance, with their elegant blend of wagon wheels to movie reels.

Designs in Iron then submitted a price and timeframe for constructing the gates, which were approved. Now, it was time to get to work. Not as easy as it looks During fabrication, Hobson spent many hours working out problems as they occurred. For example, bending 1 /4” x 3” F.B. and making it resemble flowing reels of film was difficult. Making the gates structurally sound was also an important issue. “If you look closely enough, you’ll see that there are 3/16 stainless steel cables that pierce through all parts of the gate for support,” says Yturralde. Once these difficulties were worked out, it was time to finish and assemble the gates. All of the parts were pre-assembled, then broken down and hot dipped galvanized. Afterward, the parts were reassembled and welded, with careful attention to the grinding and finishing of areas that were visible. Gates are part of Carillo’s legacy The gates are as beautiful up close as they are from a distance, with their elegant blend of wagon wheels to movie reels. They provide the finishing touch to the Carrillo Ranch, which now lives on for future generations to enjoy.

Designs in Iron has come a long way since it opened in 1976 as a small shop in Chula Vista, CA. Within three years, the growing business relocated to its current 10,000 square-foot location in San Diego. The son of an iron worker, company president Mark Yturralde has managed Designs in Iron since its inception. 58


May/June 2007

Job Profile

Inspired by nature — Handrail sports “organic flair”  Creating a

functional railing with a durable finish — that fits in with the surrounding environment — presents an artistic challenge.

Last summer, Dirk Brown of Blue

No straight line here

Mountain Metalworks in Banner Elk, NC, was approached by a customer who wanted a handrail with “a natural organic flair” for his vacation home in the beautiful North Carolina mountains. Arriving at the job location with only a vague idea of what was needed, Dirk met with the homeowners who themselves are artists (but in the media of clay, rather than metal). After a successful meeting of the minds, an image was formed of the railing the owners had in mind. Dirk would have to create a rail that was to feel as if it was part of the earth itself, born of the mountains and forests of the Appalachian Range — and yet, be functional, long lasting, and beautiful.

Artistic inspiration for the design was taken from some of the old property fences in the area, which were made with locust poles that had been cut to make fence rails in square shape but with the square offset to create a diamond or rhombus impression. The rail was to be heated in the forge and then power hammered and manually worked to soften the sharp edges of mill produced steel and to give it the appearance of having been in place for many years. The handrail also had to wind its way along a natural stone wall that had some irregularities of its own and a direction change in the last 14 inches of rail, while still following the downward angle of the steps.

May/June 2007 


For your information Project: Free form forged handrail Shop: NOMMA member Blue Mountain Metalworks Owner: Dirk Brown False start-to-finish: The rail’s finish didn’t “take” properly on the first goround and rust popped through after a few months exposure to the outdoors. Dirk and his shop foreman, Paul Glover, kept coating the railing with linseed oil and heating it until the oil stopped burning off to achieve a more durable finish. Since the railing is not sealed with clear-coat, its finish will most likely have to be examined every year to see how it’s holding up under North Carolina’s weather conditions, which can vary between extremes in hot and cold temperatures.


LEFT: The nearly 8 ft. long handrail also had to wind its way along a natural stone wall that had some irregularities of its own.

It is anchored by “tree frog fingers” at its base and at the end near the bottom of the steps. An intermediate bracket provides extra stability. The piece is made of free form forged iron.

Dirk notes that the irregularities of the stone wall presented the first big challenge of the job. “We all know how to craft a straight rail going downstairs,” he says. “But to purposely make a rail crooked is not in our natures as ‘rail guys and ironworkers.’” It’s all in the details The highlight of the piece itself — and the part that gave Dirk and his guys the most joy to create — was the “tree frog fingers “ at the end and base of the railing that actually fastened the rail to the ground and the terminal point of the wall. Each one of these “fingers” was individually heated and hammered until it was just the right length to reach its fixing point on the wall or paving stone. Since the finished rail was over 8 feet in length, it was decided, almost at the last minute, to attach an intermediate bracket to reach over to the stone wall, which provided a little more stability. This change, of course, warranted the need for additional “tree frog fingers.”




May/June 2007

Once the piece had been made, it was necessary to make a “dry fit” visit to the wall to ensure the correct placement of the “fingers.” It was found that very little adjustment was needed to make a perfect fit. Dirk brought the rail back to the shop for finishing, where what he describes as “our not patented” mixture of beeswax, boiled linseed oil, turpentine and Japan drier was applied in just the right proportions to achieve the natural, aged, rust resistant finish that the artist/clients had asked for. Next, it was back to the client’s home to put the railing in place. “The final installation went like a dream,” says Dirk. “Unfortunately, the client was not in town at the time, but that gave us double the pleasure a few days later when he left a message on our machine telling us how happy he and his wife were with their new “piece of art.” The entire project was made from standard 836 iron bar, ¾” square solid and 11/2” square solid. It took approximately 24 hours of labor to complete the job.

The railing fits in perfectly with the natural beauty of the stone wall and its environment. RIGHT:

As with most ironshops, gates and railings are Blue Mountain’s bread and butter, but “every once in a while a little project comes along that inspires our creativity and workmanship to a higher level,” notes Dirk. For Blue Mountain Metalworks, this was one of those jobs. About Blue Mountain Metalworks… Dirk Brown recently bought Powell’s of Banner Elk from long time NOMMA member Ed Powell. Dirk renamed the business Blue Mountain Metalworks and hopes to carry on the fine tradition of workmanship and quality in iron that he learned from Ed and at Charleston Forge where he learned and practiced his craft for several years before starting BMMW. The shop has three full-time employees and one part-time worker. May/June 2007 


Take our word at face value. There’s a new look at Decorative Iron. Our new line of finished accent products are the very expression of uncompromised quality. Put the finishing touches to your home, garden, or patio with this endless selection of components. They are among over 4,700 items we have available online. Our products offer timeless beauty, strength, and the durability to last generations. Trust Decorative Iron with your next project and take our word at face value.

10600 Telephone Rd., Houston, TX 77075 Phone 713-991-7600 Fax 713-991-0022 Toll Free 1 (888) 380 - 9278


Job Profile

A staircase in all its grandeur begins with a magazine photo 

Got a small shop? A large-scale project doesn’t have to be intimidating.

By Michael Migala Migala Metal Design, LLC I admit I was scared. The scope of this

staircase and railing project was much greater than anything I had handled on my own before. Plus, we are a very small company, consisting of myself and one part-time employee. And, at the time this project was presented to me, I had only been in business for about two months. However, I did have some knowledge and skills to fall back on — I’d earned a Bachelor of Fine Arts degree in Blacksmithing from Southern Illinois University - Carbondale, after which I spent the next nine years working for two NOMMA member shops: Medwedeff Forge and Design in 62

southern IL. and Wonderland Products of Jacksonville FL. My experiences and training at these businesses gave me the confidence to go it alone. Ripped from the pages of a magazine... It began when the client handed me a ripped out magazine page with a picture of the design she wanted. I asked if I could use it as a starting point and work on a custom design for her particular home, and she agreed. I forged a sample panel for her approval and, with a few minor adjustments, she signed off. The interior balcony rails included three at 8.5 feet, one curved at 21 feet, three curved at 6 feet, and both sides

For your information Project: Grand staircase with balcony railings Shop: Migala Metal Designs, Harvard, IL Ph: (815) 943-4909; Web: Total number of ours on the job: 1,250 Experience pays off: While a project of this magnitude could be intimidating for such a small shop, Michael Migala had a real confidence builder — he knew he could rely on his experience from previous years of training with NOMMA member shops Medwedeff Forge and Design and Wonderland Products.


May/June 2007

of a curved grand staircase; all custom designed and hand forged. In addition, exterior work included 10 balcony rails averaging 8 feet each, one 22 feet curved rail, and five wall rails. The exterior was a much simpler design, but still required a lot of work. All of the scrollwork is hand forged from 3/8 x 3/4 except the corner “C” scrolls which are 1/2 x 1. All of the main verticals and horizontals are 1/2 x 1 with the posts being 11/4 sq. The top channel is 1¼ x ½. The corners of all the bar stock were hammered prior to forging. Design techniques; plus, help is on the horizon I spent several hours playing with different leaf shapes It should be noted that all of the work in this extensive job was produced in a 20’ x 40’studio. in the forge until I came up The estimated total hours put in by two employees was 1,250. with the design I wanted. The leaf blanks were water-jet cut, while I spent about six hours carving (grinding) a top and bottom die for my screw press. The 200+ leaves (11 gauge) were heated in the forge and pressed in one heat each, while the short stem was rolled on the next heat. I made a 3/8” kiss block for my power hammer and forged the 3/8 x 3/4 down to 3 /8 rd., and welded the leaves on to the bar. All of the scroll jigs were numbered and steel lengths were recorded. A new gas forge was built to accommodate the large amount of production forging. Within a short time, there were piles of scrolls everywhere! (It should be noted that all of this work was produced in a 20 foot x 40 foot studio.) I knew the rough opening for the three flat railings, so I built these and left the top channel long, allowing for final measurements when the walls were finished. I was also able to forge most of the scrollwork for the other balconies before the nosing was in place. At this time, I hired my first employee, J.R. Lodico, who had May/June 2007 



Each of these [sections of rail] took about 30 hours, most

of which was spent sitting on a bucket with a torch in one hand and a twisting wrench in the other. recently graduated from the apprenticeship program at the Metal Museum. J.R. had a specific amount of time to work with me, so we decided to concentrate on building the curved stair â&#x20AC;&#x153;skeletonâ&#x20AC;? next. The training he received at the museum proved invaluable during the short time we were together. Once the nosing was in place, I made accurate templates of the center balcony at the top of the stairs, and then built it. This became the anchor piece from which both sides of the stair rails were built. Using shop drawings from Cooper Stair Co., we were able to pre-bend each section of horizontals with the given radius at the studio. Then, we spent the first day at the job site finetuning these sections. Once they were properly twisted, holes were drilled in the stair treads to accept 3 inches of all-thread protruding from each vertical post. We elevated our horizontals, TIGwelding them to one post, and then screwed them to the other post using tabs that had been milled and countersunk prior to the job site visit. The third day was spent welding all sorts of supports to secure the rail positions until fabrication was complete. We found that the several days we spent in preparation for the job site really paid off. No worries â&#x20AC;&#x201D; the installation goes smoothly After spending three days at the job site building the stair rail skeleton, it took us only 30 minutes to take it down. Back at the studio, we set this part of the project aside and continued work on the balconies. It was at this point in the project that J.R. had to leave, but fortunately, I was able to hire Marc Beroukas, a 64


May/June 2007

young man with a machinist background, on a more permanent basis. Marc and I concentrated on finishing the three flat and one 21-foot curved balcony rails and were able to install these in one long day. It would have gone faster, but my nervous stomach cramps slowed me down. However, my worries weren’t necessary, because everything went well. For ease of installation, we made the balcony rails with the center panel detachable, so that we could carry the frame up the stairs separately. The 21-foot rail came apart in five sections. Again returning to the studio, we resumed work on the stair rails. All of the scrollwork was forged in just two days using existing jigs. To each section of the railing, we clamped ¼” plywood to create the curve and simply fabricated within the framework. We did have to work around our support bars, but this was not too awkward. Each section of rail took two days to fabricate. The most difficult part of the whole job was creating the volutes. Each of these took about 30 hours, most of which was spent sitting on a bucket with a torch in one hand and a twisting wrench in the other. Installation of the stair rail could not have gone better. We started at 8:30 a.m. and were finished by 2:30 p.m. The railing was elevated ½” as we assembled it, in order to have room to put glue in the holes. After it was screwed together, we realized that it was so tight we didn’t need glue. So, we just knocked out our spacers and the rail settled down, solid as could be. The curved balconies on either side were a different story, but we finally got those finished by 6:30 p.m. The finish on all of the work is gun blue with a clear Permalac cover. And the total job time for the interior work was approximately 1250 hours.

In closing, I would just like to say, again, how grateful I am for the patient instruction and training I received from John Medwedeff of Medwedeff Forge and Design, and those at Wonderland Products, specifically Kenny Koester and Joe Ponsler, without whom none of this would have been possible. May/June 2007 



Biz Side

Caught, audited, and home free... maybe

 There are few scarier phrases in the English language to a

business owner than “tax audit.” But there are steps you can take now to reduce the chances that the IRS will audit your company. By Mark E. Battersby

have all contributed to the increased success of the IRS’s auditors.

For many years, the children’s chant

of: “Who’s afraid of the big, bad wolf?” was more of a threat to many ornamental and miscellaneous metals fabricators than the Internal Revenue Service. Today, under pressure from lawmakers to cut the tax gap, the difference between the amount owed by taxpayers and the amount actually paid, it appears that the risk of an IRS audit is noticeably increasing. In fact, the IRS’s tax cheat dragnet brought in a record $47 billion during the 2006 fiscal year. Audits of individuals rose by 7 percent last year, while small business audits have more than doubled since 2000. The complexity of our tax laws and the confusion most fabricators face trying to keep abreast of those ever-changing rules 66

Avoiding audits Who wouldn’t like to ensure that their tax returns — or those of their metal fabricating business — escape examination by the IRS? However, some fabricators have discovered a sure-fire method to make sure their returns ARE selected: take big-time losses, operate as a cash business and keep sloppy records. Fortunately, avoiding audits is both legal and easily accomplished. There is no justification for sacrificing valid deductions, even if they are large or unusual. Obviously, all income and deductions should be reported truthfully. If that means a higher chance of audit, so be it. But remember, in this electronic age, most

transactions are reflected on the tax returns of your customers and suppliers.

For your information More informationon the red flags that can trigger a tax audit by the IRS and advice on how to reduce or avoid them is available through many online resources. It may also be helpful to study guidelines offered by the IRS on their web site. Here are a few recommended sites:


May/June 2007

An excellent strategy for avoiding an audit involves pointing out “oddball” items on the tax return. Give the IRS the answer before they ask the question. Attach a note, a brief statement, documents, and explanations for all unusual transactions. For large transactions that may fall into one of the innumerable “grey areas” of our tax laws, there is yet another tax form. Form 8275, “Disclosure Statement,” may help avoid penalties by disclosing questionable deductions, positions, or investments. Few experts believe using this form will increase the chance of an audit. When a good offense is not enough What happens if, despite your best efforts, the IRS requests your presence to review your tax returns? It goes without saying that the worst thing that any business owner can do is to ignore an audit notice. The best bet is a quick response. It also helps if the business owner works with the IRS to resolve the matter.

information to determine the existence of unreported income. The IRS can only ask for that information if it has a reasonable indication that there is a likelihood of unreported income based on the tax return and information reports from third parties. What the IRS is looking for Many experts agree that an improperly prepared tax return is a good way to ensure an IRS audit. Sloppy returns are also hazardous. Those business owners who fail to report all income send up an instant red flag in our computerized business world. Information mismatches produced by erroneous Form 1099 received by some metalworking professionals often creates disparities in reported income. If the amount reported on the Form 1099 is wrong,

the individual or firm that sent the form should correct it and file an amended Form 1099. Intentionally mismatching the information of the tax return can only draw attention. The biggest problem for most metals fabricating businesses – as well as their owners – is a lack of good expense records. The use of an automobile for business purposes is a clas-

The biggest problem for

most metals fabricating businesses – as well as their owners – is a lack of good expense records. If a small metalworking business has kept organized records, including bills, receipts and cancelled checks and has in place the proper internal controls, there is little need to worry. The IRS may interpret the operation’s situation differently, but there is no crime in having differences of opinion. seminar, schedule a free customized training Thanks to the IRS Restructuring s lize our fully equipped demo room. and Reform Act of 1998, small busiGain Confidence nesses now have many new protections in the audit process. First, the d Your Business IRS’s ability to conduce so-called “lifestyle” or “economic reality” audits uct Knowledge has diminished. Today, the IRS is generally, prohib- 598 FOR MORE ited from asking for extensive infor- R INFORMATION. mation about a taxpayer’s financial status, standard of living and other

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May/June 2007 


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Honesty and clarity can go a

long way toward preventing and dealing with an IRS audit. sic example. Although the vehicle may have been used 75 percent of the time to call on customers, many fabricators fail to keep a detailed record and, thus, are unable to state that clearly on a tax return. Records can be easily kept in the form of a log.

Those who use an office in the home to conduct business, keep records, or perform management chores may discover that the risk of an audit is not worth the small tax deduction. The home office tax form (Form 8829, Expenses for the Business Use of Your Home) has, for some time, been a definite audit flag. If the owner of a metalworking business has only a minimal amount of deductible home-office expenses and poor records, the risk of an audit

may not be worthwhile. Also, keep in mind that the use of an office in the home can substantially reduce or even eliminate the unique home office exclusion. That exclusion allows up to $250,000 ($500,000 on a jointly-filed return) of gain from the sale of a residence to be excluded or ignored. A business owner cannot claim the exclusion for gains that result on any portion of that residence that is not used as a â&#x20AC;&#x153;personal residence.â&#x20AC;?

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Taxpayer Rights The Taxpayers Bill of Rights, part of the IRS Restructuring and Reform Act of 1998, requires the IRS to explain a taxpayer’s rights and the IRS’s obligations during the audit, appeals, refund, and collection processes. A taxpayer is also guaranteed the right to be represented by any individual currently permitted to practice before the IRS. What’s more, any interview must be suspended when the taxpayer clearly requests the right to consult with a representative. Among the more important rights given any business owner whose returns are targeted for further examination is whether to be represented by a tax professional or attempt to answer the IRS’s questions alone. However, unless it issues an administrative summons, the IRS cannot actually require the taxpayer to accompany the representative to the interview. Another important consideration for every professional being audited is where to hold that meeting. Should the meeting be in the accountant’s office where all of the working documents are easily accessible? Should it be at the fabricator’s place of business, the place where all the records are kept, in order to demonstrate to the IRS auditor that there is nothing to hide and that the fabricating operation is a legitimate one? Or, should the fabricator and/or his or her representative trudge down to the IRS office, armed only with the specific documents and information requested by the IRS auditor? There is no one right answer. Ignoring the IRS does not work The IRS may issue summons to third party record keepers (attorneys, enrolled agents, banks, brokers, May/June 2007 


accountants, etc.) for the production of records concerning the business transactions or affairs of a metalworking operation — and its owner. Of course, the taxpayer must be notified of the summons and has the right to intervene. The taxpayer can, in fact, begin a proceeding to quash the third party summons. Appeal after appeal As mentioned, the majority of metals fabricators file relatively honest returns. The occasional error, misinterpretations, or honest disagreements with “gray areas” may result in additional tax assessments. However, from the initial screening for accuracy that each return receives until the final appeal is exhausted, mistakes in the favor of the taxpayer have been discovered in about 25 percent of all cases. The IRS is usually quite sympathetic to honest mistakes and more than willing to discuss underpayments of taxes that may result from the many so-called “gray” areas of our tax rules. On occasion, they will negotiate the amount of tax due. But they do not like fraud.

Deal with it Changes to our tax laws in recent years have resulted in tax professionals generally taking a more conservative approach in the tax advice they render and the tax returns they prepare. After all, if the IRS discovers a transaction has been mislabeled or incorrectly structured, and if the tax laws were ignored, the tax professional, as well as the taxpayer, face penalties. Despite the ultra-conservative position now taken by many tax professionals, no business – or business owner – should forego or ignore valid tax deductions. Often, disclosing those transactions or deductions on the tax return will be enough to pass the scrutiny of the IRS, eliminating a full-blown audit. At worst, disclosure may help avoid the levy of numerous penalties for taking a “frivolous position,” or claiming deductions that result in “accuracyrelated” penalties. Honesty and clarity can go a long way toward preventing and dealing with an IRS audit. Obviously, every metals fabricating business owner and manager need an audit strategy as well as a fallback position should those strategies fail. 69

Biz Side

Ring bell for service...

The five biggest customer service blunders of all time

 Transforming a dissatisfied customer into a satisfied one isn’t

easy. Good customer service can be your best weapon and your most valuable asset when it comes to creating a satisfied customer base.

By Paul Levesque

While howls of protest over poor cus-

tomer service continue to fill the air, there remain some businesses that manage to consistently deliver superior customer service year in and year out. These are the places where turbocharged employees pursue customer delight with a passion, places that ignite a flashpoint of contagious enthusiasm in employees and customers alike. Foremost among the lessons to be learned from such flashpoint businesses are the blunders to avoid—those fatal mistakes that trip up just about everybody else. 70

making customer servFirstice ablunder: training issue. Businesses of all kinds invest huge amounts in training programs that do not—and simply cannot—work. The function of such training is to identify the behaviors workers are supposed to engage in, and then coax, bully, or legislate these behaviors into the workplace. At best, this is almost always a recipe for conduct that feels mechanized and insincere; at worst, it intensifies worker resentment and cynicism. Instead of dictating what workers should be doing to delight customers, the better approach is to give workers opportunities to brainstorm their own ideas for delivering delight.

For your information Paul Levesque has more than 20 years’ experience as an international customer-service consultant. He has helped hundreds of corporate and small business clients become more customer-focused. Paul’s latest book is Customer Service From The Inside Out Made Easy (Entrepreneur Press, 2006). Paul Levesque is available for speaking engagements through 1-800-420-4155 ©Paul Levesque. All Rights Reserved.


May/June 2007

Managementâ&#x20AC;&#x2122;s role then becomes to help employees implement these ideas, and to allow workers to savor the motivational effect of the positive feedback that ensues from delighted customers. This level of employee ownership and involvement is a key cultural characteristic of virtually all flashpoint businesses.

Those businesses that

Managers are forever on the lookout for â&#x20AC;&#x153;hero storiesâ&#x20AC;? - examples of employees going the extra mile to deliver delight. Such feedback becomes the basis for ongoing recognition and celebration. Employees see themselves as winners on a winning team, because in their workplace thereâ&#x20AC;&#x2122;s always some new â&#x20AC;&#x153;winâ&#x20AC;? being celebrated.

deliver a superior total experience from the inside out (that is, as a product of a strongly customer-focused culture) are typically those that enjoy a long-term competitive advantage...

blunder: blaming poor servourth blunder: reserving top recogniSiceecondon employee Ftion demotivation. for splashy recoveries. Businesses looking for ways to motivate their workers are almost always looking in the wrong places. Employee cynicism is the direct product of an organizationâ&#x20AC;&#x2122;s visible preoccupation with self-interest above all elseâ&#x20AC;&#x201D;a purely internal focus. The focus in flashpoint businesses is directed outward, toward the interests of customers and the community at large. This shift in cultural focus changes the way the business operates at all levels. The reality in most business settings is that employees are demotivated because they canâ&#x20AC;&#x2122;t deliver delight. The existing policies and procedures make it impossible. Instead of â&#x20AC;&#x153;fixingâ&#x20AC;? their employees, flashpoint business set out to build a culture that unblocks them. Workers are encouraged to identify operational obstacles to customer delight, and participate in finding ways around them.

It happens all the time: something goes terribly wrong in a customer order or transaction, and a dedicated employee goes to tremendous lengths to make things right. The delighted customer brings this employeeâ&#x20AC;&#x2122;s wonderful recovery to managementâ&#x20AC;&#x2122;s attention, and the employee receives special recognition for his or her efforts. This is a blunder? It is when such recoveries are the primaryâ&#x20AC;&#x201D;if not the onlyâ&#x20AC;&#x201D;catalysts for employee recognition. In such a

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blunder: using customer feedback to uncover whatâ&#x20AC;&#x2122;s wrong. Third Businesses often use surveys and other feedback mechanisms to get to the causes of customer problems and complaints. Employees come to dread these measurement and data-gathering efforts, since they so often lead to what feels like witch-hunts for employee scapegoats, formal exercises in finger pointing and the assigning of blame. Flashpoint businesses use customer feedback very differently. In these organizations the object is to uncover everything thatâ&#x20AC;&#x2122;s going right. May/June 2007 


culture, foul-ups become almost a good thing from the workersâ&#x20AC;&#x2122; point of view. By creating opportunities for splashy recoveries, foul-ups represent the only chance employees have to feel appreciated on the job. Attempts to correct operational problems wonâ&#x20AC;&#x2122;t win much support if employees see these problems as their only opportunity to shine. Flashpoint businesses celebrate splashy recoveries, of courseâ&#x20AC;&#x201D;but theyâ&#x20AC;&#x2122;re also careful to uncover and celebrate employee efforts to delight customers where no mistakes or problems




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Fifth blunder: competing on price.

were involved. This makes it easier to get workers participating in efforts to permanently eliminate the sources of problems at the systems level.

It’s one of the most common (and most costly) mistakes in business. Price becomes the deciding factor in purchasing decisions only when everything else is equal—and everything else is almost never equal. Businesses compete on the perception of value, and this includes more than price. It’s shaped by the total customer experience—and aspects such as “helpfulness,” “friendli-

ness,” and “the personal touch” often give the competitive advantage to businesses that actually charge slightly more for their basic goods and services. Those businesses that deliver a superior total experience from the inside out (that is, as a product of a strongly customer-focused culture) are typically those that enjoy a long-term competitive advantage—along with virtual immunity from the kinds of headaches that plague everybody else.

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May/June 2007

Biz Side

Relieving the pressure: Don’t let business stress ruin your life  A little stress at work can be good... invigorating, motivating,

and inspiring creativity. But unrelenting stress can have an adverse effect by reducing your productivity. By William J. Lynott You may not have thought much

about it, but running your fabricating shop requires working in a very dangerous environment. No, not the physical danger that you’re aware of — a different more subtle kind of danger: The hidden stress inevitable in the life of every business owner or manager, stress that can accumulate to the point of serious damage in both your business and personal life. How common are stress related problems? “Up to 80 percent of visits to primary care physicians are for symptoms directly or indirectly related to the stress response,” says Vicki Rackner, MD, coauthor of Chicken Soup for the Soul. “While it’s true that we live in stress filled world, you can control your response to stressful stimuli. Manage your response to stress more effectively and you will May/June 2007 


have a happy, healthy heart. You will also have a healthier bottom line.” How do you know if the pressure cooker is having a harmful effect on you? “Some of the danger signals for stressed out entrepreneurs are weight gain, mental confusion, depression, suppressed immune function, and constant fatigue and insomnia,” says nutritional biochemist Shawn M. Talbott, Ph.D. Getting stress under control can help in each of these areas. Here are seven tips that will help you to avoid the severe and often permanent harm to you and those around you that can result from uncontrolled business stress:

Analyze and organize those comdemands on your time 1.peting Among the major causes of entrepreneurial stress are incompatible demands on the owner’s time and resources, according to management

For your information Feeling stressed out? Help is available! Here is one just one of many resources for information and stress assistance. The International Stress Management Association-USA is a non-profit organization dedicated to making for a lessstressful world. Its goals include:  Encouragement and improvement of scientific research, clinical, and educational applications of stress management.

 Improvement of clinical uses of stress management through high standards of professional practice, peer review, ethics, and education.

 Increased knowledge about stress management to the membership by way of meetings, educational programs, publications, and special interests sections.

 Dissemination of information to the public about stress management. For more information, log on to:


“Manage your response to

stress more effectively and you will have a happy, healthy heart. You will also have a healthier bottom line.”



consultant and author, Jim Stroup. “If you don’t have the time or expertise to do a given task, you outsource it,” he says. However, if you don’t have the resources for outsourcing, you wind up doing it yourself. That often means doing it poorly, further straining your resources.” What to do about this? “First, organize and prioritize the bewildering flurry of competing demands on your time, being sure to include key functions such as cash flow, marketing, and shop productivity,” says Stroup.“Next, analyze these tasks on the basis of their impact on your time and resources. Which ones have the biggest impact on the success of your business, and which ones can

be successfully delegated?” This simple procedure often helps an owner to better understand the business, according to Stroup. In turn, that reduces the stress resulting from a failure to understand how to assess and organize competing demands.

2. Know when it’s time to go home. “Learn how to turn off work and boot up life,” says consultant Jennifer Kalita, The Kalita Group.” Entrepreneurs often start businesses to get out from under an unreasonable boss, but now the only unreasonable bosses they’re working for are themselves. Make a commitment to business hours and stick to it. If you don’t, the line between your business and your personal life will become blurred. When that happens, it isn’t the business that will suffer; it’s you, your family and friends — all the things you need to keep your life in balance.” Dr. Rackner agrees on the impor-

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tance of turning off work. “The stressinduced fight-or-flight response served our species well when we faced saber-toothed tigers,” she says. “In business it often feels like a pack of tigers are right outside the door. Adrenalin and other stress hormones help you run away from danger or face challenges square on.” According to Dr. Rackner, stressinduced adrenalin becomes problematic when we use it as fuel for day-today activities. “Our bodies are designed for surges of adrenalin, not the day-in, day-out, sustained-release stress program followed by so many entrepreneurs. That impairs not only the body’s ability to function; it also impairs business productivity and profitability.”

. You know that you need a vaca3tion, but… You know how important it is to take some time for yourself and your family. You’ve been working hard and now you need to refresh and renew. However, if you’re like most business owners, the idea of walking away from your business for even a day or two causes so much anxiety that it’s hardly worth it. “Take heart.” says Liz Bywater, Ph.D., president of Bywater Consulting Group, LLC. “Vacation need not be an all-or-nothing approach to relaxation. There’s no need to divorce yourself entirely from your business in order to recharge your batteries.” Dr. Bywater suggests dedicating a


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small portion of each vacation day — an hour or less — to checking in with the office. “You can call your assistant, partner, or second-in-command, to see whether there are any fires to be put out,” she says. “If there are, you can decide who will deal with the problem and how. In most circumstances, you can delegate the work and continue to enjoy your day with confidence. If you absolutely must speak briefly to a client or customer, so be it. Hey, one phone call could pay for your whole vacation. “Once your daily check-in is finished, you can put away your cell phone, laptop, and PDA for the day and have some fun.”

4. Lean on your friends

“Entrepreneurs, working in a constantly-changing and often uncertain environment, must deal with a host of stresses,” says Jeanne Hurlbert, PhD, Professor of Sociology at Louisiana State University. “Although many fail to realize it, one of their most valuable resources in coping with that stress is their social networks.” According to Dr. Hurlbert, entrepreneurs generally think of “networking” as building the business contacts that help them find venture capital, enter new markets, or locate competent employees. “While it’s important that entrepreneurs’ social networks provide those resources, it’s at least as important that their networks provide the social support that can help them reduce stress and cope with stress that they cannot eliminate.” Hurlbert feels that business owners should recognize that the contacts who provide that kind of support generally aren’t the same individuals who provide referrals and sales leads. “Our close friends and family provide the support that helps us cope with a business downturn or other negative event,” she says. One of the most effective things entrepreneurs can do to combat stress is to build a balanced network that supports not only their business but also their personal lives, according to Hurlbert. May/June 2007 



“They also need to remember that even close ties dwindle if they’re not maintained. That’s why they need to devote time and energy to the personal side of their networks, just as they do for the business side.”

5. Enlist outside help.

“That may mean hiring a marketing or PR firm, or a reliable web designer, or a top-notch bookkeeper. The key is to farm out the kinds of work that take up lots of your time but don’t fall within your areas of expertise. Do what you do best. Have others do the rest.”

“It’s not unusual for small business owners to feel they have to do everything themselves,” says Dr. Bywater. “Sometimes it’s about keeping as much money as possible in the business and minimizing expenses. Sometimes it’s about quality control. Small business owners may think that if you want the job done right, you have to do it yourself, but that’s not so. True, there are many aspects of a small business that are best handled by the owner, but there’s also plenty of room in most businesses for effective outsourcing.” In order to focus on what you do best, you’ve got to take some things off your plate, according to Dr. Bywater.

Make sure that you and your sig6page..nificant other are on the same “If your home life isn’t running smoothly, you’re headed for stressville,” says Steve Kaplan, author of Be the Elephant: Build a Bigger, Better Business. “Do everything you can to help your spouse understand your business life. He or she can be a big help or a serious barrier to keeping a lid on your stress level.” Kaplan feels that finding ways to involve your family is an important weapon in the fight to control business stress. “The last thing most of us want to do after a hard day is go home and rehash everything,” he says. “Still,

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you need to remember that the person who hasn’t been with you during your workday needs to feel connected.” Involving family members in your life lets them know that you value their thoughts and it helps them to be more understanding during those missed dinners and birthday parties. That, in turn, will help you to keep stress under control, says Kaplan.

your own importance in 7the. Reduce business. You’ve heard it said many times — if you want something done right, do it yourself. It’s a classic philosophy with an undeniable grain of poetic truth. However, when it comes to running a small business, too many owners suffer from a dangerous overdose of do-it-yourself-itis. “Every small business owner has three basic responsibilities,” says Andy Birol, founder Birol Growth Consultants. “They are owner, president, and chief salesperson. No owner can do everything effectively in all three of these areas.” According to Birol, small business owners tend to be “control freaks.” “It’s difficult for many entrepreneurs to trust business responsibilities to others,” he says. “However, it’s critically important to develop the ability to delegate some of your work to those around you. The penalty for a failure to do that is an almost certain buildup of the kind of business stress that will eventually impose a harsh penalty on both the business and the business owner.” Every expert interviewed for this article ranked the failure to delegate as a major cause of harmful stress. While it may seem difficult, reducing your own importance is a major step in easing the pressure of running your business. Of course, these seven suggestions aren’t the only techniques for minimizing the constant strains in your business life, but together they can go a long way toward reducing your exposure to the damage of uncontrolled stress. Fabricator 

May/June 2007

Top Job 2008

Reducing stress one laugh at a time In today’s workforce, it doesn’t matter whether we’re the CEO or a front line customer service representative we all face stress. We’re often expected to work longer hours and do more with fewer resources. All the technology geared to making us more efficient simply means that we’re a phone call or email away - goodbye downtime, hello stress. In fact it’s one of the top two reasons for employee absenteeism and/or healthcare costs in the workplace (Ipsos Reid 2004). Hoping and praying that stress will go away is not the answer. We need to manage it as best we can and with any and all tools that are available. If we don’t we, along with our companies, could pay a huge price - burnout, anxiety or depression. So where does laughter come in? Stress is our body’s natural reaction to perceived danger. In order to deal with the threat, stress hormones are released, muscles tense, the heart beats faster and we breathe rapidly to get more oxygen to the lungs, brain and muscles. Recent scientific research has proven that laughter reduces stress. How does it work? When we laugh, our muscles tighten but relax right after. Everyone knows how those rigid stomach muscles can hurt when you’re having a good guffaw. Dr William Fry of Stanford University found that 1 minute of laughter is equivalent to 10 minutes of rowing. Also stress hormones are reduced and air is forced out of our lungs forcing us to breathe more deeply and slowly. This is great news! A good chuckle is one more tool for reducing workplace stress and is more fun than working out. The question is how can we use it? Does this mean we need to brush up on our joke telling or develop a comedy routine? Luckily, no. It is much easier than you think.

Good stress — is there really such a thing? While all stress must be managed, it is a mistake to think of all stress as bad. Some stress can be very good. Look at the following brief definitions.  Stress is your body’s response to any demands made on it.  Situations or events that cause stress are called “stressors”.  A bad or detrimental stressor is called “distress”.“Di” means “two” in Greek. Think of double trouble. Distress is a disabling or crippling stress.  A good or beneficial stressor is called “eustress”.“Eu” means “good” in Greek. Think of joy and laughter. Eustress is a pleasant or a healing stress. — Courtesy May/June 2007 


Get the recognition you deserve! Enter your outstanding work in the Ernest Wiemann Top Job Contest

Open to all NOMMA members

Details and forms available from the NOMMA Member’s Only Area

Deadlines: December 14, 2007 Late Deadline: Jan. 4, 2008 National Ornamental & Miscellaneous Metals Association 77

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

Support the NOMMA Education Foundation!

Education • Videos • Publications Research • And More ... By supporting the work of the NOMMA Education Foundation (NEF) you are helping to build a better industry through education and research. ✂

 Yes, I want to support education, industry research, and the many programs of the NOMMA Education Foundation I’ve enclosed my contribution of:  $100



Other ___________

If you are interested in joining other NOMMA members who have made commitments for ongoing support to the Foundation, please call Foundation chairman James Minter, Jr. at (601) 833-3000 or NEF Executive Director Barbara Cook at (888) 516-8585, ext. 105. Contact _________________________________________________ Company _______________________________________________ Address ________________________________________________

Return To: NOMMA Education Foundation 1535 Pennsylvania Ave. McDonough, GA 30253 Ph: (888) 516-8585 Fax: (770) 288-2006

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Fabricator  May/June 2007

NOMMA Member Benefits and Application Form  Technical Affairs Division — By supporting NOMMA,

“bouncing” each person’s e-mail to all others on the list, and in that way conversations take place.

you promote the work of our technical team. Our volunteers and staff continually represent industry interests with ASTM, ANSI, ICC, NFPA, UL, and ADA. This advocacy work is essential to ensure that our industry has a voice in building codes, standards, and government regulations.

 Top Job Awards Competition — All members are eligi-

ble for the annual Ernest Wiemann Top Job Contest. Enter your best work in any of 16 categories that cover sculpture, gates, rails, furniture, structural, and more. All entries are displayed in a gallery during the METALfab convention and the winners are announced at a special awards banquet on the last night of the event. Winners receive a plaque and the “best of the best” winner is awarded the Mitch Heitler Award for Excellence.

 NOMMA Education Foundation — The NOMMA Education Foundation works to advance the educational mission of NOMMA. The Foundation provides resources ranging from training videos to continuing education programs. Plus, the Foundation continually evaluates innovative learning programs to keep pace with new industry technologies and trends.

 Member Discounts — Members receive discounts on all

publications, videos, educational seminars, METALfab (our annual convention and trade show), and on display advertising in Ornamental & Miscellaneous Metal Fabricator.

 E-Mail Discussion List — Get quick answers to your

question by joining our on-line "ListServ." The systems connects you to a community of fellow NOMMA members around the world via e-mail. The ListServ works by

Membership Categories

 Affiliate $300 - Individuals, firms, & organizations which do not engage in the fabrication of ornamental or miscellaneous metal products and do not provide products or services to the industry but which have a special interest in the industry.

Please Check One:  Fabricator $415 - Metal fabricating shops, blacksmiths, artists or other firms and individuals in the industry whose products or services are sold directly to the consumer or the consumer's immediate agent or contractor.  Nationwide Supplier $585 - Firms that sell supplies, raw materials, equipment, machinery, or services on a nationwide or international basis.  Regional Supplier $455 - Firms that sell supplies, raw materials, equipment, machinery, or services only within a 500-mile radius.  Local Supplier $365.00 - Firms that sell supplies, raw materials, equipment, machinery, or services only within a 150-mile radius.

Company Name

Please note: The membership year runs from July 1 to June 30.  Membership dues payments are not deductible as a charitable contribution, 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.  Checks should be made payable to NOMMA (U.S. dollars, check drawn on U.S. bank). 

Your Name

Address City


Phone E-mail Company Specialty/Description Signature


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Return to: NOMMA, 1535 Pennsylvania Ave., McDonough, GA 30253 (888) 516-8585 Fax: (770) 288-2006 Or join online at

New NOMMA members

NOMMA Nationwide Supplier Members

2-a-T Metal Works Inc. Avon Park, FL Bill Temples Fabricator

A Cut Above Distributing (800) 444-2999 Allen Architectural Metals Inc. (800) 204-3858 Alloy Casting Co. Inc. (972) 286-2368 American Punch Co. (216) 731-4501 American Stair Corp. (800) 872-7824 Ameristar Fence Products (918) 835-0898 Apollo Gate Operators (210) 545-2900 Architectural Iron Designs Inc. (908) 757-2323 Argent Ornamental Iron & Steel (678) 377-6788 Atlas Metal Sales (800) 662-0143 Auciello Iron Works Inc. (978) 568-8382 Bavarian Iron Works Co. (800) 522-4766 Big Blu Hammer Mfg. (828) 437-5348 Julius Blum & Co. Inc. (800) 526-6293 Builders Fence Co. Inc. (800) 767-0367 Byan Systems Inc. (800) 223-2926 The Cable Connection (800) 851-2961 Carell Corp. (251) 937-0948 Carl Stahl DecorCable Innovations (800) 444-6271 Classic Iron Supply (800) 367-2639 Cleveland Steel Tool Co. (800) 446-4402 CML USA Inc. (563) 391-7700 Colorado Waterjet Company (866) 532-5404 CompLex Industries Inc. (901) 547-1198 Crescent City Iron Supply Inc. (800) 535-9842 Custom Orn. Iron Works Ltd. (866) 464-4766

As of April 6, 2007. Asterisk denotes returning members.

Aladdin Door & Gate Co. Indio, CA Brian Tremblay Fabricator

Argent Ornamental Iron & Steel Lawrenceville, GA Andy Penick Nationwide Supplier Berryhill Ornamental Iron Broken Arrow, OK Darin Berryhill Fabricator

Custom Ornamental Iron Waynesboro, VA Randy Teter Fabricator Daniel Goldsmith Riverside, CA Daniel Goldsmith Fabricator

Home Expressions El Paso, TX Alejandro Miranda Fabricator Link Exclusives Owings, MD Robert Link Fabricator

Procounsel Dallas, TX Buzz Taylor Nationwide Supplier

Rens Welding & Fabricating Inc. Taunton, MA Rens Hayes Fabricator Riata Mfg. El Paso, TX Brian Haltley Nationwide Supplier

White’s Steel Inc. Indio, CA Ed Neumeyer Fabricator

D & D Technologies (USA) Inc. (714) 677-1300 D.J.A. Imports Ltd. (888) 933-5993 DAC Industries Inc. (616) 235-0140 Dashmesh Ornamentals (011) 911-61-250-2574 Decorative Iron (888) 380-9278 Decorative Ironworks Inc. (817) 236-6151 DKS, DoorKing Systems (800) 826-7493 Robert J. Donaldson Co. (856) 629-2737 Eagle Bending Machines Inc. (251) 937-0947 Eastern Metal Supply (800) 343-8154 Eastern Ornamental Supply Inc. (800) 590-7111 Elegant Aluminum Products Inc. (800) 546-3362 Encon Electronics (800) 782-5598 Euro Forgings Inc. (800) 465-7143 EURO-FER SRL. (011) 390-44-544-0033 FabCad.Inc (800) 255-9032 FabTrol Systems Inc. (541) 485-4719 Fatih Profil San. Tic. AS (011) 902-58-269-1664 Feeney Architectural Products, CableRail™ (800) 888-2418 Geo. Bezdan Sales Ltd. (604) 299-5264 Glaser USA (888) 668-8427 Glasswerks LA Inc. (323) 789-7800 Grande Forge (Asia) Sdn Bhd 011-656-235-9893 The G-S Co. (410) 284-9549 GTO Inc. (800) 543-4283

NOMMA Nationwide Supplier Members Hartford Standard Co. Inc. (270) 298-3227 Hayn Enterprises LLC (860) 257-0680 Hebo/Stratford Gate Systems Inc. (503) 722-7700 Hendrick Mfg., Perforated Metals Div. (570) 267-1922 House of Forgings (281) 443-4848 Illinois Engineered Products Inc. (312) 850-3710 Indiana Gratings Inc. (800) 634-1988 Industrial Coverage Corp. (631) 736-7500 Industrial Metal Supply Co. (818) 729-3333 Innovative Hinge Products Inc. (817) 598-4846 Interstate Mfg. Associates Inc. (800) 667-9101 The Iron Shop (800) 523-7427 ITW Industrial Finishing (630) 237-5169 ITW Ransburg (419) 470-2000 Jansen Ornamental Supply Co. Inc. (800) 4-JANSEN C. Sherman Johnson Co. Inc. (860) 873-8697 Justin R.P.G. Corp. (310) 532-3441 King Architectural Metals (800) 542-2379 King of the Ring (305) 819-2256 Laser Precision Cutting (828) 658-0644 C.R. Laurence Co. Inc. (800) 421-6144 Lavi Industries (800) 624-6225 Lawler Foundry Corp. (800) 624-9512 Lewis Brass & Copper Co. Inc. (718) 894-1442 Liberty Brass Turning Co. (718) 784-2911

Logical Decisions Inc. (800) 676-5537 Mac Metals Inc. (800) 631-9510 Marks U.S.A. (631) 225-5400 Master Halco (714) 385-0091 MB Software Solutions LLC (717) 350-2759 McKey Perforating (262) 786-2700 Metalform - Bulgaria (703) 516-9756 Mittler Bros. Machine & Tool (800) 467-2464 Frank Morrow Co. (401) 941-3900 Multi Sales Inc. (800) 421-3575 Mylen Stairs Inc. (914) 739-8486 New Metals Inc. (956) 729-1184 Ohio Gratings Inc. (330) 477-6707 Overseas Supply Inc. (281) 776-9885 Paxton & Thau Artistic Supply (205) 290-2790 Precision Glass Bending Corp. (800) 543-8796 Procounsel (214) 741-3014 RedPup LLC (928) 422-1000 Regency Railings Inc. (214) 742-9408 Riata Mfg. (915) 533-9929 Rik-Fer USA (305) 406-1577 Robertson Grating Products Inc. (877) 638-6365 Robinson Iron Corp. (800) 824-2157 Rockite, Div. of Hartline Products Co. Inc. (216) 291-2303 Rogers Mfg. Inc. (940) 325-7806

L.E. Sauer Machine Co. (636) 225-5358 Scotchman Industries Inc. (605) 859-2542 Sculpt Nouveau (760) 432-8242 SECO South (888) 535-SECO Sharpe Products (800) 879-4418 Stairways Inc. (713) 680-3110 Steel Masters Inc. (602) 243-5245 Stephens Pipe and Steel LLC (800) 451-2612 Striker Tool Co. (USA) Inc. (866) 290-1263 Sumter Coatings Inc. (888) 471-3400 Taco Metals (800) 743-3803 Taurin Group USA (909) 476-8007 Tennessee Fabricating Co. (901) 725-1548 Texas Metal Industries (972) 427-9999 Transpacific Industrial Supply Inc. (909) 581-3058 Tri-State Shearing & Bending (718) 485-2200 Universal Entry Systems Inc. (800) 837-4283 Universal Mfg. Co. Inc. (901) 458-5881 Valley Bronze of Oregon Inc. (541) 432-7551 Vogel Tool & Die, Div. of TES Tube Equipment Inc. (630) 562-1400 The Wagner Companies (800) 786-2111 Wasatch Steel Inc. (888) 496-4463 West Tennessee Ornamental Door (901) 346-0662 Wrought Iron Concepts Inc. (877) 370-8000 YAC Equipment & Machinery (305) 633-0700

What’ s Hot Inside Biz Briefs . . . . . . . . . . .82 Chapter News . . . . . . .84 Events . . . . . . . . . . . . .86 People . . . . . . . . . . . . .87

Literature . . . . . . . . . . .88 New Products . . . . . . .89 Fab Spotlight . . . . . . . .98

Software news...

New release of AutoCAD 2008 The new version of AutoCAD 2008 software has been refined with the drafter in mind and includes features to increase speed and accuracy while saving time. Annotation scaling and layer properties per viewport minimize workarounds, while text and table enhancements and multiple leaders help deliver precision and professionalism. AutoCAD LT 2008 software, the world’s number-oneselling 2D drafting and detailing product proposes to be simpler thanks to drafter that minimizes workarounds and features annotation scaling and layer properties per viewport, text and table enhancements, and multiple leaders. AutoCAD Architecture software is more geared for architects. According to its developers, creating and sharing accurate drafting and construction documents is more efficient with the system’s familiar environment, flexible implementation options, and easy-to-use architectural drawing and design tools. The DWG file format enables coordinated collaboration between engineers and design professionals. Contact:, Ph: (800) 874-9001; Web:

Vista OScompatible laser nesting and bend simulation software Cincinnati Incorporated has developed new Vista-compatible versions of its laser nesting and press brake bend simulation software, making it available for purchase in April, three months after Microsoft’s introduction of the Vista operating system. The new software responds to requests from customers switching to the new OS. 82

Biz Briefs

The Vista-compatible software versions are Laser Nesting v. 4.5X and Bend Simulation 4.5X . The laser and press brake software allow off-line programming and simulation to maximize machine run-time and enable right-the-firsttime part processing. Advanced graphics simplify creating programs from CAD files. The Bend Simulation Software uses OpenGL accelerator. Users need to be aware that Vista does not have full support from all graphic board manufacturers, cautions Cincinnati. Customers should take appropriate steps to ensure their hardware works with Vista before upgrading their PCs. Also according to Cincinnati, newly purchased PCs with the appropriate OpenGL accelerator should not be a problem. Contact: Cincinnati Incorporated; Ph: (513) 367-7100; Web:

Chamberlain Group acquires Edko’s gate operator business The Chamberlain Group Inc., of Elmhurst, IL, has acquired the assets associated with the design and manufacturing of gate operators of Edko Inc., located in Sugar Grove, Ill. The announcement was made by Chamberlain’s CEO, J. David Rolls and Edko’s President, Donald Parrin. Edko has been privately owned and operated for more than 50 years. The company has manufactured and distributed commercial and residential gate operators and related gate and access control products. Edko’s former owners will continue to distribute and sell gate operators and other products under the name, Pro Access Systems. Under this agreement, Edko’s locations that do business under the name of Pro Access Systems will continue to function as independent companies, separate from Chamberlain. Pro Access, acquired by Edko in 2003, will continue to manufacture gate operators during a transition period and will support its customer base with spare or replacement parts for a seamless transition. Pro Access will increase their portfolio of Chamberlain products in addition to the other products they sell and distribute. Operational locations will remain in Atlanta, Tampa, Denver, and Chicago with a continued focus on distribution and customer support. In addition to the Chamberlain products now offered, Pro Access will continue to manufacture and distribute security gates, hardware, and other manufacturers’ products. Contact: Chamberlain, Ph: (800) 282-6225; Web:


May/June 2007

What’ s Hot

Biz Briefs

Klein Tools renews Le Mans sponsorship Klein Tools, Lincolnshire, IL, has announced its return as a sponsor of the 2007 American Le Mans Series (ALMS). As a part of its sponsorship, Klein Tools is the official hand tool of ALMS. The company’s sponsorship will again include the Klein Tools Pit Crew Challenge. As in 2005 and 2006, the contest consists of 20 cars and teams who will vie for the championship with the grand prize winner receiving $20,000 and preliminary and semifinal winners earning $10,000. The Challenge will take place at four Series venues: Salt Lake City, Lime Rock, CT, Detroit, and Monterey, CA for the final round. The Pit Crew Challenge involves a driver change, changing four wheels/tires, and simulated refueling. At the end of the tire change and refueling, the new driver will be required to start the engine and drive forward breaking the laser beam, ending the competition for that car. New to the 2007 season, Lowe’s Home Improvement and Klein Tools have partnered for select Series events to feature demonstrations of the Klein Tools Pit Crew Challenge

May/June 2007 


throughout the race season. The demonstrations will feature ALMS teams and drivers in simulations of the actual challenge at Lowe’s stores in Florida, Georgia, Ohio, and Wisconsin. Contact: Klein Tools, Ph: (800) 553-4676; Web:

GTO/PRO introduces technical services To meet the needs of dealers and distributors, GTO/PRO has added a number of factory and Electronics Technicians Association certified technicians to its staff and has expanded services to include: Expanded hours - Technical services is now open from 8 a.m. to 7 p.m. EST. Pro Priority Phone Service - GTO has upgraded and added a new Pro Call Distribution System to its phone system. GTO/PRO dealer calls are now prioritized and routed to PRO technicians, reducing hold times. Online Product Troubleshooting - available 24 hours, seven days a week, dealers and distributors can log on and access online product troubleshooting and installation guides. Contact: GTO/PRO, Ph: 800-543-4283; Web:


What’s Hot

Chapter News

Upper Midwest Chapter features aluminum forging The Upper Midwest Chapter held their May 5 meeting at Christopher Metal Fabricating in Grand Rapids, MI. The main demos for the day were on aluminum forging and repoussé. Other highlights included a shop tour, business meeting, delicious lunch, and roundtable discussions. Afterwards, many attendees attended an optional evening dinner and show, which served as a fundraiser for the NOMMA Education Foundation. During the evening, attendees were treated to a performance of “The Judy Show,”a musical and comedy performance that took place at the Ship ‘n Shore Hotel. During the show, Michael Holmes, a noted female impersonator, gave stunning renditions of Judy Garland, Pearl Bailey, Carol Channing, Billie Holiday, Bette Davis, and other famous celebrities.

Members of the Upper Midwest Chapter were well represented at the recent METALfab convention in Destin, FL. During the Friday “beach party” event, members took time out for a group shot.

Northeast Chapter exhibits at regional architectural event In April the Northeast Chapter exhibited at an AIA seminar and tabletop show. The event was hosted by the Architects League of Northern New Jersey. About 400 people attended the gathering, which took place in Tea-

neck, NJ. During the show, chapter members passed out copies of Fabricator, sold copies of the NAAMM/ NOMMA Finishes Manual, and answered questions. According to chapter president Keith Majka, participation in

the event helped to get NOMMA’s name out to architects and designers. A thanks goes to the tabling team, NOMMA suppliers, and members who worked “behind-the-scenes” to make the event a success.


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Fabricator  March/April 2007

What’s Hot

Chapter News

SoCal Chapter meets at King Arch. Metals

Chapter Contacts Florida Chapter

The SoCal Chapter held their spring meeting on April 28 at the new location of King Architectural Metals in Buena Park, CA. Events for the day included a general meeting and discussion, the election of new officers, and a planning session for future meetings. Afterwards, the group spent time browsing a special parking lot sale hosted by King Architectural. A special thanks to King for hosting the event and providing refreshments.

At the chapter’s last meeting in December, members gathered at the shop of Hans Duus blacksmith Inc. to produce a project for the NEF auction, which was held during METALfab. In January, the group’s president, Sami Dahdal of Sam’s Iron Works and chapter member Juan Almanza of Almanza’s Iron Works, helped support NOMMA’s code work by attending a meeting of the ICC Code Technology Committee in Irvine, CA.

President: Pedro Vasquez Discount Ornamental Iron Ph: (813) 248-3348 Gulf Coast NOMMA Network

President: James Minter Jr. Imagine Ironworks Ph: (601) 833-3000 Northeast Chapter

President: Keith Majka Majka Railing Co. Inc. Ph: (973) 247-7603 Southern California Chapter

Gulf Coast group to meet in Birmingham The Gulf Coast NOMMA Network’s January meeting was cancelled due to an unforeseen event. The group’s next meeting takes place Saturday, May 19, 2007 at Lawler Foundry Corp., 4908 Powell Ave.,

Birmingham, AL. Registration starts at 9 a.m. and the program begins at 9:30 a.m. All NOMMA members are invited. For details, check the “Chapter” section of the NOMMA website or call James Minter Jr. at (601) 833-3000.

President: Sami Dahdal Sam’s Iron Works Ph: (818) 982-5343 Upper Midwest Chapter

President: Tina Tennikait Superior Fence & Orn. Iron Ph: (618) 259-4184 For more chapter info, see the NOMMA website.

To view photo of past chapter events, visit the NOMMA website.

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EMMA to hold fall conference The Expanded Metal Manufacturers Association (EMMA) invites all North American Expanded Metal Manufacturers to its Fall Conference at The Radisson Hotel, Chicago, IL, November 3-5, 2007. Expanded metal industry experts will present opportunities for press conferences, group advertising, press releases, web site exposure, trade shows, and

exchanging information with peers. Contact: NAAMM Headquarters, Ph: (630) 942-6591; Web:

SNAG 2007 Conference to be held in Memphis The Society of North American Goldsmiths (SNAG) will hold its 36th

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annual conference, June 13-16, 2007 at the historic Peabody Hotel in Memphis, TN. The event, themed “Directions Unknown: Looking Forward, Learning form History,” will be hosted by The Metal Museum. In addition to demonstrations, the conference will feature internationally recognized artists as guest speakers, including Korean metalsmith Hyewon Lee, knifemaker Phillip Baldwin, Dutch artist Felieke van der Leest, and blacksmiths Elizabeth Brim and Tom Joyce. An array of exhibitions, including “Modernism in American Silver: 20th Century Design,” a restrospective of the work of Earl Pardon, and “Modern Art Knives: Beyond the Samurai Sword,” will run concurrently with the conference. Registration and conference details are available online. Contact: Society of North American Goldsmiths, Ph: (541) 3455690; Web:

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July 24-26, 2007 America’s Fire & Security Expo

If you are involved with fire protection systems and equipment, special hazards, chemical and hazardous material storage and handling, building fire protection, life safety, electrical installations, or security products, systems and services NFPA’s Americas’ Fire & Security Expo is the event for you. Miami Beach Convention Center, Miami, FL. Contact: National Fire Protection Association, Ph: (800) 593-6372; Web:

October 12-13, 2007 Florida Artist Blacksmith (FABA) Conference

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May/June 2007


C.R. Laurence promotes Friese

Standard Tinsmith Supply appoints Fishkind as new chairman

C.R. Laurence Co. Inc., (CRL), a leading supplier to the glazing, architectural, construction, industrial, and automotive industries based in Los Angeles, CA, recently announced the executive appointment of DJ Friese. Friese will also be responsible for managing and DJ Friese directing the Technical Sales Division, which consists of five distinct Business Groups/Brands; Commercial Hardware, Architectural Hardware, Shower Hardware, Transaction/Hospitality Hardware, and Key Accounts. Friese joined the company in 1992 and has since served as Sales Representative, Regional Sales Manager, VicePresident of Customer Service, and Vice-President of Sales and Service. He is also a Corporate Officer of the Executive Committee. Contact: CRL, Ph: (800) 421-6144; Web:

Standard Tinsmith Supply, based in Brooklyn, NY, has appointed Scott Fishkind as new Chairman of the Board of Trustees. Fishkind brings years of experience to the company, market knowledge, and established working relationships with large building developers such as Burman Properties, BRT Realty, and Pinewood Developments.. Through these relationships, the company has been able to gather valuable ideas, material, and market analysis. A graduate of Hofstra University (Cum Laude), Fishkind has also volunteered his time at the Garden City Park Fire Department since 1999. He visits local elementary schools in his area to teach fire safety to young children. Standard Tinsmith Supply has been serving the sheet metal and HVAC industries since 1914. The company is in its fourth generation of family ownership. In addition to tin supplies, the company also stocks stainless steel, aluminum, aluminum diamond plate, hot and cold roll steel, and galvanized steel. Contact: Standard Tinsmith Supply, Ph: (917) 417-6313; Web:

May/June 2007 




What’ s Hot

Klein Tools introduces pocket-size product catalog Klein Tools has developed a smallsized catalog that can be stored in a shirt pocket, tool box, or glove compartment and is indexed for easy reference even while on the jobsite. The new, full-color 192-page mini catalog features 800 products. Contact: Klein Tools; Ph: (800) 553-4676; Web:

2007 Rex-Cut® specialty abrasives datalog Rex-Cut Products Inc.’s new 26-page catalog provides an index, application photos, and specs and features a range of products for cutting, grinding,


blending, and finishing stainless steel, aluminum, exotic metals, and mild steel. New products include: Fusion™ interleaf flap discs that combine a premium coated abrasive layer and surface conditioning layer for one-step finishing; Sigma Screen™ multipurpose discs, Type 27 unitized wheels, and Type 27 finishing flap discs. Contact: Rex-Cut, Ph: (800) 225-8182; Web:

Wagner releases master catalog The Wagner Companies’ 2007 Catalog is its largest and most comprehensive to date. This 280page edition, features 7,800 items and includes all railing systems, products, and services from the R&B Wagner railing component product line and the J.G. Braun ornamental metal line. The updated catalog includes an expanded technical information section with installation instructions and current code summaries. New products introduced include the Wagnerail™ Railing System with aluminum and stainless steel components and assemblies that are unique to Wagner and multiple infill options of glass, Ultratec® cable railing, 3form Ecoresin™ panels or Archimesh™ Stainless Steel Wire Woven Mesh Panels. Contact: Wagner, Ph: (888) 243-6914; Web:


May/June 2007

New Products

What’ s Hot

New total job software package MBSS MB Software Solutions of Pine Grove, PA now offers FabMate Total Shop Solution Software, a package designed to assist with the total job process – from creating estimates, managing the shop floor, to out-the-door, and helps produce more accurate estimates in less time. MB Software offers hardware, software, and networking solutions with purchase plans or leasing options. Contact: FabMate, Ph: 717-3502758; Web:

Auto-darkening helmets Miller Electric Miller recently introduced two new lines of auto-darkening helmets for professional welders and hobbyists. The new Performance Series, which replaces the previous Xli and Xlix helmet lines, is designed for those who weld for extended periods nearly everyday and feature three arc sensors that darken the lens between shade #8Ñ13 in 1/20,000 of a second. The Performance line also has Miller’s Auto-On/Auto-Off feature, which activates the lens shade without having to manually turn the helmet on, and grind mode, which stops the lens from darkening while grinding. New features to the Performance Series, not previously available on the Xli Series and Xlix Series, are the combined features of a magnifying lens holder and a quick release front lens cover. Miller Auto-Darkening Helmets are covered by a two-year warranty. Contact: Miller Electric, Ph: (800) 426-4553; Web: May/June 2007 


16-ton pneumatic press AIM Joraco A new, compact 16-ton pneumatic toggle press adapts to various applications including assembling bearings and bushings, punching, bending, and forming. The Toggle-Aire® 16-Ton Pneumatic Press is a benchtop unit that employs a mechanical advantage to create increasing ram forces as it completes its 1.5” stroke; with 0.001” accuracy and repeatability. The product can be a cost-effective alternative to a hydraulic press in applications where high ram forces up to 36,960 lbs. are required. Featuring a 10-in. x 18-in. footprint and 4.75-in. deep throat, the Toggle-Aire® 16-Ton Pneumatic Press accommodates a variety of tooling, operates on 80-100 psi air, and only consumes 0.91 CF @80 psi. This low-maintenance press has a one-shot lubrication system, Syncro-sig™ antitie down actuators, and an adjustable shut height. Contact: AIM Joraco, Ph: (888) 889-4287; Web:



(951) 737-2480 89

What’ s Hot

New Products

Dri Touch® Amber Birchwood Casey This product blocks rust and corrosion on all metals without affecting part operation by producing a colorless, odorless barrier film that is dry to the touch and highly resistant to humidity and corrosion. An alternative to oil-based products, Dri Touch® Amber will not drain off parts or wick off into packaging materials. Dri Touch® Amber combats corrosion several ways. The liquid product is thin enough to penetrate recessed areas and displace moisture out of the

part. According to the manufacturer, once the moisture is gone, the Dri Touch® film dries quickly, leaving a nonoily, colorless film that resists moisture and prevents corrosion before it starts. The film has a flexible,

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Barclay Spiral Staircase • Distinctive historic design • Modular components in a 5 ft. diameter • Rugged cast iron construction • Brass or steel handrail • Easy assembly • Complete catalog featuring this and other staircases 1 0 0 y e a r s b e h i n d t h e t i m e s™

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self-healing property, to re-flow and re-coat areas that are scratched or damaged during handling. Any subsequent contact with water will cause the water to simply bead up and drain off the part. The product can be applied to wet or dry surfaces and is absorbed by the part itself, enhancing part color and becoming an effective barrier against atmospheric humidity and corrosion. This property is especially useful on porous materials, such as powdered metals, cast/ductile iron, or subassemblies and parts with blind holes or other “problem” parts that need better protection. The corrosion barrier is long lasting because the protective film will not drain off the part or wick off into packaging materials. Dri Touch is a high-grade solventbased formulation with a light amber color and minimal odor that is safe and easy to apply in any factory or tool assembly area. It is compatible with all lubricants, cutting oils, and hydraulic oils and acts as an ideal topcoat over black oxide and phosphate conversion coatings to seal out corrosion. Application is made by dipping, brushing, or low-pressure spraying. Dipping followed by short spin drying to reclaim the excess can efficiently coat bulk handled parts. The product is rated for 100+ hours salt spray and 600+ hours humidity protection. It meets water displacement test Mil-C-16173 and stain test Mil-C-22235A. Contact: Birchwood Casey; Ph: (952) 937-7931; Web: Fabricator 

May/June 2007

New Products

Wagner introduces New Bikerail™ and imports Pure Iron from Europe Galvanized Steel Bikerail™

Pure Iron

The Wagner Companies of Milwaukee, WI has developed the BikeRail™ component system for bike racks. Made of 2-in. galvanized pipe, system is available in one, three, and five loop configurations, unpainted or painted black. The BikeRail™ system uses an aluminum mechanical splice connector for a non-weld assembly and installation. The mechanical splice connector permits BikeRail™ to be angled to custom configurations. BikeRail™ is available as an embedded or surface mount kit. Drive-in spikes are included with all surface mount BikeRail™ kits for easy installation into concrete. In embed applications where frost is a concern, extensions are available to set BikeRail™ below the frost line. Racks can be made to meet specific requirements, with other pipe and tube sizes, with decorative infill panels, and with custom finishes like powder-coat colors. Industrial strength bike racks are also available. Kits are packaged for UPS shipment.

The Wagner Companies imports Pure Iron from Europe for distribution in the United States. Wagner has Pure Iron in stock in a variety of shapes and sizes and available for same day shipment. Pure Iron is a high-purity iron that is ductile and is a preferred material for forging and decorative metal work. While very popular in the first half of the 20th century, its use was reduced by the development of new steel alloys and high production costs. Eventually, there was no domestic source for this material. Pure Iron is chosen for art and forged metal work due to its superior malleability and excellent weldability. It is corrosion resistant and holds heat about 40 percent longer than mild steel. Wagner stocks Pure Iron in two, four, and sixfoot lengths. Random lengths are also available. Contact Wagner, Ph: (888) 243-6914; Web:

Impact drivers and drilling accessories DeWALT As part of its new Impact Ready™ line of impact driver qualified power tool accessories, DeWALT has developed pivoting bit tip holder and doubleended bit tips. One of the first products in the line is the DW2169—a 38-piece accessory set that includes the Impact Ready™ 6point deep sockets (in the most common sizes) rated for performance in impact drivers up to 2000 in lb. of torque. The set also includes nutsetters, socket adapters, and screw driving bits. Each bit is qualified and manufactured for optimal performance with impact drivers. Additionally, the set includes new items, such as an impact rated pivoting bit tip holder (DWPVTHLD) offering a 20-degree pivot, and new double-ended 1” bit tips (DW2002DE) featuring two usable ends. DeWALT’s tools have increased power up to 2000 in lb. of torque that enable contractors to drive lag bolts into wood, fasten anchors into concrete, and/or tighten couplings. Cobalt Pilot Point® Drill Bits provide users with a range of applications and increased bit longevity. The new bits are May/June 2007 


for stainless steel and other hard metals and are ideal for professional contractors, metalworkers, residential electricians, residential plumbers, framers, and other professional construction users. Bits are designed with the patented Pilot Point® tip design for faster drilling speeds, and produce accurate and clean round holes in metals. Each bit (3/16” and up) is designed with a pilot tip on top of a split point with four cutting edges. This reduces walking on material and enables the bit to start on contact. Each bit also has three flats on the shank in order to prevent bit slippage in the tool. To ensure easy identification and prevent the markings from wearing off, bit dimensions are laser-etched above the flats on the shank. According to DeWALT, for increased durability, the patented web design provides a thicker web at the base of the shank for a stronger bit core, which results in less breakage. Also, Pilot Point® bits have a no-spin shank with three flats that provide a positive lock on the chuck, which keeps the bit from spinning. Each bit is made from cobalt steel, which creates a more wear resistant bit ideal for drilling into stainless steel and other high-end metals. Contact: DeWALT; Ph: (800) 4-DEWALT ; Web: 91

New Products

What’ s Hot

Modular perimeter guarding system North American Safety Products

including end-user manufacturers, warehousing OEMs, and automation line builders. SATECH perimeter guarding options include four individual specifications designed to suit different applications and budgets. Comprehensive choices of hinged, sliding, and rise and fall access gate designs are available to fulfill machine access requirements to suit each post and panel specification North American Safety Products will provide a detailed CAD drawing with plan, 3-D views from the customer’s guarding layout, a list of all guard components, and a fixed price quotation for the supply and delivery of all parts. Contact: Versa-Guard, Ph: (800) 475-6946; Web:

Newly designed website Architectural Iron Designs Inc. North American Safety Products, Inc. of Frankfort, IL has entered into an exclusive distribution agreement with SATECH Safety Technology S.p.A. of Milan, Italy to supply their modular perimeter guarding system to customers in the United Sates, Canada, and Mexico. The SATECH system includes a comprehensive range of panels, posts, access doors, brackets, and accessories. The versatile and economical system will appeal to anyone using perimeter guarding,

e g d E g y n i c t t a u r C

Architectural Iron Designs’ recently launched website features new products, educational articles, and product brochures. Additional features include: the Edition 6 Catalog whose pages can be “flipped” online, a design collection of hundreds of designs that users can customize, and a showcase of customer projects using the company’s components. The website also serves as a professional resource center with links to other sites. Contact: Architectural Iron Designs, Ph: (800) 784-7444; Web:

u c c A

Direct Drive Saws Combine the speed of an abrasive saw, the precision of a cold saw and the versatility of a band saw. • • • • •

Precision Mitre Cuts - 0º to 60º 8” to 20” Cutting Capacities Pull Down or Hydraulic Cutting Systems ACCU-CUT Blade Guide System Small Footprint

800-323-7503 92


May/June 2007

New Products

What’ s Hot

Journeyman™ gloves and Lockback pocket knives Klein Tools Klein Tools recently added work gloves to its Journeyman™ line that already includes pliers, cutters, and other hand tools. The new Utility (Cat. No. 4005254), Framer (Cat. No. 40057-59), Heavy-Duty Protection (Cat. No. 40062-64) and Leather Work (Cat. No. 40067-69) gloves provide comfort and durability. All glove styles are available in medium, large, and extra-large sizes. Journeyman™ Framer Gloves feature a fingerless design on the thumb, index, and middle finger for increased sensitivity when handling wire connectors, screws, nails, and small parts. The gloves have synthetic leather palms and non-slip rubberized finger grippers. They also offer panels between each finger for ventilation, easy-entry Neoprene cuffs, and rubber cuff straps with a hook and loop closure for convenient storage. Heavy-Duty Protection Gloves have a streamlined, accordion knuckle panel with impact-absorbing molded rubber for protection. Gloves also have non-slip rubberized grippers on the forefinger, ring finger, thumb, and the heel of the palm for grip control and longer wear, as well as breath-

Hypertherm’s Centricut Brand

able mesh on the finger panels. A two-ply synthetic leather palm with a die-cut foam pad (for high impact zones) and Neoprene cuff provide protection. Leather Work Gloves are constructed of professionalgrade, genuine goatskin leather with form-fitting spandex for fit and ventilation. The back of the hand and fingers has rubber ribs for extra protection with a lightly padded palm to increase grip. Also, Klein has added six new lightweight lockback pocketknives to its line of knives. These compact fit in a pocket, and open quickly and safely with one hand because of a textured thumb stud. The corrosion-resistant, multiple style blades are made from AUS 8 stainless steel and hardened to 58-59 Rc, providing long life. Lockback pocket knives (Cat. Nos. 4400-BLK and 40001BLK) have 2-1/4” and 2-1/2” drop point blades, respectively. Black chrome blades and black anodized-aluminum handle provide resistance to corrosion. Additional lockback pocketknife styles have anodized aluminum handles for corrosion resistance. A removable pocket/belt clip is included with all models, except for Model No. 44000-BLK, for easy access. Contact: Klein Tools; Ph: (800) 553-4676; Web:

Stair Pan-Type Risers • High Quality Products


Tread & Riser

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Stair Pans With Nosing

• Family Owned Since 1923 Hypertherm has launched a new logo for their Centricut brand of consumables. It incorporates the tag line, “Innovation. Integrity. Hypertherm,” to emphasize key aspects of the brand and the endorsement by Hypertherm. Hypertherm’s Centricut brand of consumables is available for a broad range of mechanized plasma and CO2 laser cutting systems. The product line utilizes advanced consumable technology and is backed by technical support. As part of the Hypertherm family, Centricut products are available through authorized Hypertherm partners worldwide. Contact: Hypertherm, Ph: (800) 643-0030; Web: May/June 2007 


• Friendly Customer Service • Custom-Formed Shapes Floor Plate Stair Treads

• Competitive Prices • Prompt Delivery Throughout North America

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New Products

What’ s Hot

CPO 350 circular cold saw Scotchman This American-made machine features a double clamping and self-centering vise that provides burr-free, high quality, volume parts. The saw has 135° mitering ability and a miter-locking device that automatically stops at 45° left, 90° straight, and 45° right giving it the ability to slot and notch. Additional features include a double reduction gearbox and a two-speed motor. Machine utilizes up to a 14-in. diameter blade giving it a 47/8-in. OD round capacity. Contact: Scotchman, Ph: (800) 843-8844; Web:

Specialized square for objects with protrusions InventHelp InventHelp, Pittsburgh, PA has announced that one of its clients has designed a modified square for trade profession-

als and do-it-yourselfers. The inventor has created a prototype, The Redesigning A Square, to help users square objects with vertical protrusions where a standard square could not give a true reading. This tool would give accurate readings for base plates, poles, flanges, and pipes and it is reproducible in variations that would work like a regular square. The original design is currently available for licensing or sale to manufacturers. Contact: InventHelp, Ph: (412) 288-1300 ext. 1368; Web:

Online job board expands SellingCrossing SellingCrossing, an organization dedicated to finding employment positions in sales, has expanded its website to include jobs in the marketing, advertising, and public-relations sectors. The company’s system obtains job information from all over the country. The user is then given a list of positions that fit his or her search criteria. Website’s services are offered for free to employers, while candidates looking for work are charged a fee. Contact: SellingCrossing, Web:

DEDQDRUJ DEDQD DRUJ ABANA A PO Bo Boxx 816 6 Farmington,, GA 30838 8 Farmington,

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May/June 2007

New Products

What’ s Hot

Extended warranty program; compact wire welders Lincoln Electric The Lincoln Electric Company has introduced a two-year extended warranty program that extends Lincoln’s factory three-year warranty to five full years for its welding machines, wire feeders, and plasma cutters. This patent pending program, supported by the company’s industrial distributor network, is a first in the welding industry. New and existing customers that have purchased qualifying products in the past year can enroll in the program. They will have no out-of-pocket costs for repairs for the life of the extended warranty. Parts and labor costs will be fully covered, including nationwide coverage for all repair work. Products available for extended warranty coverage include stick welders, TIG welders, MIG (CV) welders, multiprocess (CC/CV) welders, engine-driven welders, wirefeeder welders, semiautomatic wirefeeders, automatic wirefeeders, robotic/automatic systems, and plasma cutting systems. The extended warranty program excludes any parts not manufactured by Lincoln Electric such as engines and engine components and accessories, air compressors, and batteries. The warranty is not available for welding or cutting accessories, consumables, guns, torches, or replacement parts.

Lincoln’s four new Power MIG® 140 and 180 models serve as compact welding solutions for professional welders and home hobbyists alike. Each model features Lincoln Diamond Core Technology® and the rugged drive system aid arc performance for MIG welding on thin gauge steel, stainless, and aluminum or on gasless flux-cored welding for deep penetration on thicker steel, even outdoors. Power MIG 140 models are designed to run on common 120 volt household current with an amperage range of 30140 amps to MIG weld single pass up to 10 ga. (.135”) with self-shielded flux-cored multiple pass welds up to 5/16”. Power MIG 180 models run on 208-230 volt input power and, with an amperage range of 25-180 amps, to MIG weld single pass up to 3/16” and perform self-shielded flux-cored multiple pass up to ½”. The new Power MIG 140 and 180 feature Lincoln’s arc enhancement innovation, Diamond Core Technology™ – ensuring superior arc starting, reduced spatter, a wider performance sweet spot, and enhanced aluminum and stainless steel performance. The welder’s rigid cast aluminum drive delivers precise wire alignment for improved wire feeding. The tool-less, quick-lock drive roll system makes changeovers fast. Contact: Lincoln, Ph: (888) 355-3213; Web:

John C. Campbell Folk School Since 1925 • Brasstown, North Carolina

Weeklong and weekend classes • Nationally-known instructors Friendly, supportive environment • On-campus housing Delicious meals served three times a day

To receive a free catalog, call or visit May/June 2007 


1.800.FOLK.SCH 95

Classifieds 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 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. Business opportunity

Manufacturer, fabricator, and installer of high-end customized and artistic works in metal for commercial clients in U.S. and abroad. Company is located in Southeast Florida. Jobs include work in wrought iron, steel, stainless steel, aluminum and bronze for major hotels, shopping centers, resorts, office towers, and condominiums, etc. Products include balcony and stair railings, furniture, and sculptures. Revenue is approximately $1M. Offered at $1,150,000. Warehouse building in industrial/commercial area offered separately. Contact: J.G. Montes at (786) 251-0034 or at Sales agent/reps wanted

Sumter Coatings is seeking independent sales agents/representatives

for the eastern U.S. to represent our Metal Master Brand Paints. Qualifications would include someone currently selling other type products to ornamental and steel suppliers. Call, fax, or email Chet Dinkins at the number below for more information. Any emails should be preempted with a phone call to Chet before sending. Ph: 888-471-3400. Fax: 803-481-3776. Email: Estimator needed in sunny Calif.

Established structural/miscellaneous steel fabricator in Los Angeles, CA area is seeking a self-motivated professional with a desire to grow with our 25 years old company. Estimator must be experienced with industrial and commercial structures and capable of dealing professionally with customers as well as subcontractors. Computer skills are necessary. Competitive salary and benefits. Relocation cost will be discussed. Ironman Inc., (818) 341-0980, fax: (818) 341-348, email: Fab./artist/blacksmith wanted

Sierra Forge & Fire, an artisan school and ironworks studio in central California, is offering a unique opportunity for a fabricator/metal artist/blacksmith. We are seeking someone who can be a key part of a studio environment, a developing school, and a strong community of craftsmen. You will be joining a committed effort to develop this project—

Need an employee right away? If time is of the essence, consider posting your “help wanted” ad online by using the NOMMA Career Center. A free service to industry, this service is a great way to advertise your job posting. There are also sections for “Seeking Employment” and “Buy/Sell /Trade.” To access this area, simply visit and click on “Career Center.”


this is NOT your typical job. If you are self-motivated, mature, skilled with iron and people, send letter to: Lead fabricator wanted

Lead fabricator needed for ornamental iron shop in Minnesota. Excellent working environment in a brand new shop; 30 years in business. Must be able to fabricate curved rails, spiral rails, and curved stairs in aluminum, stainless steel, and wrought iron. Excellent pay and benefits. Call Joshua at (612) 207-8998. Shop equipment and tools for sale

Seventy-four year old machinist is ready to retire. Most machines are only 4 years old – too many pieces of equipment, hand tools, and accessories to list here. For information, call Bob Martin at (239) 287-6286 or Mike Roy at (239) 992-2222. Employment Opportunities

See NOMMA’s website for listing of NOMMA member shops offering employment opportunities: Classified ad rates & information

Classified ads promote a one-time sale or offer or employment-related opportunities. Rates are as follows: 1–35 words = $65 ($50 member) 36–50 words = $90 ($75 member) 51–70 words = $115 ($100 member) 71-100 word = $145 ($130 member)

Need an employee? Do you have excess equipment? Selling your business?

Consider placing an ad in the Fabricator Classifieds section. Next closing date:

Friday, June 8

Fabricator  May/June 2007

Advertiser’ s index Fabrication

Access Control and Gate Operators/Hardware Pg 15 07 25 71 76 38 30 21 92

Company ......................................................................................Website Chamberlain D & D Technologies (USA) Inc. DKS, DoorKing Encon International Gate Marks U.S.A. Master Halco Multi Sales Inc. Universal Entry Systems Inc. ............................(800) 837-4283

Metal Moment 90Striker Tool Co. (USA) Inc. 89 TP 93 Vogel Tool & Fabrication Services 78 94

Colorado Waterjet Co. Tornado Supply

59 94 32 40 58

Birchwood Casey Intercon Sumter Coatings Inc. Sur-Fin Chemical Corp. Triple-S Chemical

Components, Panels, Hardware, Extrusions 33 31 90 70 68 24 03 27 79 60 39 44 35 76 10 75 36 37 93 02 59 29 13 09 83 49 73 45 42 69 19

Architectural Iron Designs Architectural Products by Outwater Atlas Metal Sales Bavarian Iron WorksCo. Julius Blum & Co. Inc. The Cable Connection Cable Rail by Feeney Cable Rail by Feeney Complex Industries Inc.......................................(901) 547-1198 Crescent City Iron Supply..................................(800) 535-9842 D.J.A Imports Ltd. Decorative Iron FATIH PROFIL The G-S Co. Jansen Ornamental Supply Co. Jesco Industries Inc. WIPCO King Architectural Metals Lawler Foundry Corp. Lawler Foundry Corp. Lewis Brass & Copper Co. Inc. National Bronze & Metals New Metals Oakley Steel Products ........................................(888) 625-5392 Regency Railings Rik-Fer USA ..........................................................(630) 350-0900 Tennessee Fabricating Co. Tennessee Fabricating Co. Texas Metal Industries The Wagner Companies The Wagner Companies Wrought Iron Concepts

Fabrication Equipment & Tools 51 65 61 17 85 69 74 61 58 23 78 65 75 11 41 92 99 26

Big Blu Hammer Mfg. Blacksmiths Carell Cleveland Steel Tool Co. Classic Iron Supply CML USA Inc. COMEQ Inc. Eagle Bending Glaser USA Hebo Mittler Bros. Machine & Tool NC Tool Co. ..........................................................(800) 446-6498 Pat Mooney Inc. PlasmaCAm Production Machinery Inc. R & D Hydraulics Mfg. & Machine Co. Silver Mine Distribution Striker Tool Co. (USA) Inc.

May/June 2007 


Professional Development 84 86 84 16 53 88 86 ARTMETAL Campbell Folk School NEF / NOMMA NOMMA NOMMA Traditional Building

Software 04 89 87

FabCAD Inc. MB Software Solutions Red Pup Productions

Stairs & Treads 100 28 43 74 79

The Iron Shop Salter Industries Stairways Inc. Steptoe & Wife Antiques Ltd. Tri-State Shearing & Bending............................(718) 485-2200

Glass Services 78 91

K Dahl Glass Studios Lindblade Metal Works

Some suppliers listed here may offer products in more than one category. Check ads and websites (or phone numbers) for details. Bold denotes NOMMA Supplier Members. Want your company’s name listed here? Call Rachel Bailey (423) 413-6436.


Metal Moment

Metal on the side...

The lifesize Steinway piano, made of bronze and stainless steel, under construction. ABOVE LEFT:


Checking the fit of the piano’s lid.

Clyde and Ryan of Indy Art Forge show off their current work. The piano will be part of a sculpture entitled “Hoagy,” a tribute to pianist/songwriter Hoagy Carmichael. LEFT:

five years now, designing and building all of our pieces.

Ed. note: Clyde Pennington and his friend, Ryan Feeney, are partners in Indy Art Forge, Indianapolis, IN. However, this is actually their “side” career. Read our Q&A with Clyde about his business and his current project below:

: You have two careers. Tell us Qabout them. Indy Art Forge consists of two artists/blacksmiths, myself and Ryan Feeney. We are both career firefighters for the city of Indianapolis (IFD), and have been firefighter/EMT's for about seven years now.

: How did you get into metalworking?


We began doing metalwork on our days away from the firehouse. Our prior work experience included handrail fabrication and various types of construction. We’ve been in business for about 98

us about “Hoagy,” your curQ:rentTellproject (pictured above). The piano commission is part of a larger sculpture by artist Michael Mcauley. The Steinway piano we’re building will eventually be attached to a bronze likeness of pianist/songwriter Hoagy Carmichael. Hoagy will be sitting at the piano with his right hand on the keys and his left arm on the lid. His jacket will be draped over the curved side. The exceptional Hoagy likeness is being cast at a foundry in Ohio. Upon completion, the piano will be sent to Ohio to begin the joining process. After the sculpture is completed, it will come back to Indianapolis to be unveiled at the Indy Jazz Festival. It will then travel to Chicago and New York for more unveilings. The piece will then be sent to its final resting place at Indiana University. The piano is made almost entirely from cda 655 silicon bronze and stainless steel. All visible surfaces are

bronze, while the under-structure is primarily stainless steel. The entire piano was built without casting anything. Every layer of trim and every curve was formed by hand. The primary tools being used are a plasma cutter, T.I.G. and M.I.G. welders, and a lot of templates and jigs. The project will be finished in June. We estimate it will take about 300 hours to complete. There are still several components that need to be finished. The keys and trim below are not in place. We are also still working on the foot pedals and lid.

How did you find out about our Q:magazine and NOMMA? We found out about Fabricator magazine by accident. I saw a copy sitting on the desk of one of our vendors. When I asked him about it, he simply gave it to me. I had a subscription by the end of the day. I plan on being a lifetime reader. To see more of Clyde’s and Ryan’s work, log on to Fabricator 

May/June 2007

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King Metals has just published its 2007 product catalog. Volume 33 presents over 8000 products, with 900+ new items. Explore the wide range of architectural and decorative metal products that King Metals offers in this new comprehensive catalog. As always, every order is shipped the same day it is placed from one of our three 60,000+ square foot fully stocked distribution centers.


Call Today For Your FREE CD and/or Book!


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)RU WKH Ă&#x20AC;UVW WLPH King Metals has compiled its Auto&$' Ă&#x20AC;OHV DQG WKH\ DUH QRZ DYDLODEOH WR RXU FXVWRPHUV 7KHVH Ă&#x20AC;OHV FRYHU D wide range of our products from castings to hand forged components. Another indispensable tool for the architect, designer, fabricator and metal smith.


King Metalsâ&#x20AC;&#x2122; Design Concepts Volume II is now available. Volume II contains over 600 new designs and photos of railings, staircases, fences, gates, doors, ZLQGRZ JULOOV FROXPQV DQG Ă&#x20AC;UHSODFH VFUHHQV <RX ZLOO Ă&#x20AC;QG 'HVLJQ &RQFHSWV DQ LQVSLUDWLRQDO DQG LQYDOXDEOH tool when designing and producing architectural or decorative iron and aluminum projects.


Metal Spirals from



Features: •Steel Construction •Landing & Rails •All Required Hardware •Install Manual & Video

We make installing a spiral straightforward.

Options: •Any Floor-to-Floor Height •Diameters 3'6" to 7'0" •BOCA/UBC Code Models •Custom Welded Units •Aluminum Construction •Hot Dipped Galvanizing -- Many More Available --

Oak Spirals from



Features: •All Red Oak Construction •Landing & Rails •All Required Hardware •Install Manual & Video Options: •Any Floor-to-Floor Height •Diameters 4'0" to 6'0" •BOCA/UBC Code Models •Turned Spindles •Solid Oak Handrails •Finger Groove Rails -- Many More Available --

Victorian One ® from



Installation Video featuring “The Furniture Guys”

Features: •Cast Aluminum Construction •Landing & Rails •All Required Hardware •Installation Manual

Options: •Any Floor-to-Floor Height •Diameters 4'0" to 6'0" •BOCA/UBC Code Models •Brass Handrails •Cast Scroll Tread Ends •“Antique” Baked Finish -- Many More Available --

The best selection, quality, and prices! Since 1931, The Iron Shop has enjoyed a reputation for outstanding design and fabrication of custom built spiral stairs. Today, we utilize computer-aided technology throughout our production process to guarantee that each stair meets exacting standards—successfully mixing state-of-the-art manufacturing with Old World quality. Offering the largest selection, highest quality, and lowest prices in spiral stairs—we make sure that you get the right spiral to meet your needs. This has made The Iron Shop the

leading manufacturer of spiral stair kits, with over 100,000 satisfied customers worldwide. And our spirals are still made with pride in the U.S.A. Call for the FREE color Catalog & Price List:


Ask for Ext. FAB or visit our Web Site at Main Plant & Showroom: Dept. FAB, P.O. Box 547, 400 Reed Road, Broomall, PA 19008 Showrooms / Warehouses: Ontario, CA • Sarasota, FL • Houston, TX • Chicago, IL • Stamford, CT

Proud nationwide member of... “The Furniture Guys” is a registered trademark belonging to Ed Feldman and Joe L’Erario ©2003 The Iron Shop

Circle 11 on Reader Service Card

2007 05 fab  
2007 05 fab