Page 1

Marking 50 years of NOMMA’s Technical Affairs achievements, pg. 42

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

November/December 2007 $6.00 US

Job Profile

Restoring a landmark building in our nation’s capital page 58

Energy efficient glass fibre optics technology, pg. 18

Shop Talk

Youth has its advantages, pg. 26

Member Talk

Custom ironwork and tailored fabrics, pg. 34

Biz Side

Will you be a lord... or a serf?, pg. 71

In loving memory of one of our founders, the heart and soul of our company and our family...

To the Wife who lives on in memories To the Mom who guided us along the paths of our lives To the Boss who taught us that service was our only real product To the Friend who was compassionate to the best and the worst of us To the Customer who understood that both the buyer and seller had to win To the Vendor who cared for her customers for more than their business

Lynn White 1938 - 2006 We miss you and we love you still... 2033 N. 17th Ave. • Melrose Park, IL 60160 LOCAL TOLL-FREE FAX TOLL-FREE FAX

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504.467.7444 504.466.0316

Our 2007 Catalog 14 is now available




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Join Us For

April 2–4, 2008

NOMMA’s 50 Anniversary Celebration at METALfab 2008

Trade Show and Exhibitor Appointments/Demos rade Free T Show East Hall – Memphis Cook Convention Center, Memphis, TN sion s i m d A Wednesday, April 2, 4:30 p.m. – 8:00 p.m. – Trade Show Grand Opening/Reception

Thursday, April 3, 8:30 a.m. – 11:30 a.m. – Exhibitor appointments/demos on show floor 1:00 p.m. – 3:00 p.m. – Exhibitor appointments/demos on show floor 4:30 p.m. – 8:00 p.m. – NOMMA’s 50th Anniversary Celebration/Trade Show Open Friday, April 4, 8:30 a.m. – 12:00 p.m. – Trade Show Open/Breakfast on show floor

METALfab is the only trade show for the ornamental and miscellaneous metals industry. Join the METALfab 2008 exhibitors for a display of their products and services. Also enjoy great food and beverage while you visit with the exhibitors and other attendees. With the return of the full trade show you will see machinery demos on the show floor. To give trade show attendees a greater opportunity to spend time with individual suppliers, we have established time Thurs., April 3, for appointments with exhibitors. Exhibitors will also have the opportunity to schedule demos of their equipment or you can contact an exhibitor and make a request for a specific demo. Go to for exhibitor contact

information and demo schedules. If you would like to participate in the education program, social activities, etc. visit for additional information about a full registration for METALfab 2008. Complete the information below for free admission to the the activities listed above, or register online at: If you have questions call (888) 516-8585, ext. 101. You will not receive a confirmation for this free ticket – your badge will be at the METALfab registration desk in the lobby of the East Hall – Memphis Cook Convention Center. METALfab 2008 is sponsored by the National Ornamental & Miscellaneous Metals Association.

F REE Ti c k e t f o r M ETAL fa b 2 0 0 8 Trade S how and E xhibi tor A ppoi ntments

List three products you hope to purchase at METALfab 2008:

Memphis Cook Convention Center – East Hall, 255 N. Main St., Memphis, TN Register online: Complete this form and mail to: METALfab, 535 Lakemont Ct., Ste 200, Roswell, GA 30075 or fax to (770) 518-1292. You can also bring this form to the registration desk outside – East Hall - Memphis Cook Convention Center.

Name _____________________________________

Company __________________________________ Address ___________________________________

City _______________________________________

State ___________ Zip _______________________

Phone __________________ Fax ______________

Email _____________________________________


1) ________________________________________ 2) ________________________________________ 3) ________________________________________

Primary type of business: Fabricator General Supplier Contractor Other___________________

2) Annual gross sales  Below $1 million  $1 - $2.5 million  $2.5 - $5 million  Over $5 million

3) Your role in purchasing:  Final Say  Recommend  Specify 4)   

Job description: Owner Manager/Foreman Other_______________

Check here  if you are not involved in the business.

President’s Letter “Over the top” service 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 Bruce Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA Douglas Bracken Wiemann Ironworks Tulsa, OK

James Minter, Jr. Imagine Ironworks Brookhaven, MS Curt Witter Big D Metalworks Dallas, TX

Frank Finelli Finelli Ornamental Iron Co. Solon, OH

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

Wayne Haas Cleveland Steel Tool Co. Cleveland, OH

Gina Pietrocola D.J.A. Imports Ltd. Bronx, NY

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

A few weeks ago, my wife and I took our teenage daughter to the Mayo Clinic in Rochester, MN. She had seen local specialists and was taking the prescribed medicine, which didn’t seem to be helping her. Frustrated that we might not be getting the best attention or proper care, we decided to go to Mayo Clinic, which has a world renowned staff. The care and treatment we received from the day we contacted Mayo Clinic was “over the top.” I’d like to share just a few of the insights I came home with and how, if we apply them to our businesses, our customers would leave feeling the same as we did after our Mayo experience.

Insight 1: Keep your appointments and arrive on time. If possible, make a courtesy call the day before. After our appointment was set, we received in the mail a complete schedule of when and where we were to be. A personal follow-up call came two days before our appointment, asking if we understood the instructions, had a place to stay, if we had any questions, and how they could help in any other way. I have to say, not only were they ready on time, but the nurses were ready and waiting for us! Insight 2: Be kind and considerate of your clients’ needs. Dr. William J. Mayo said: “The best interest of the patient is the only interest to be considered ...” This is not just a statement written for a brochure; it IS Mayo Clinic. The care we received made us feel as though we were their only patient. Insight 3: After reviewing the project and doing your homework, present the best possible solution. Back up your recommendation with facts that support why it’s the best solution. If there are other options, present them — but articulate why you feel the solution you chose is the best.

The Mayo specialists we saw after we completed the required test sat down with us for 1½ hrs. He asked why we came to Mayo and what we hoped to find out. He wanted to know our concerns and answer all our questions. He then proceeded to tell us their findings and go over the treatment options. He was sure to explain the pros and cons of Breck Nelson is each option. After president of some more discusthe National sion, he gave the Ornamental and Miscellaneous recommendation that he and his col- Metals Association. leagues agreed upon. We left feeling we had made the best possible decision. Insight 4: Follow up with your client. After arriving home, we received in the mail a complete written diagnosis explaining everything again. Any doubts that may have come up later completely vanished. I can honestly say that the experience we had at Mayo was one I will never forget. Today, my daughter is doing well, and is back to her old self. My wife and I are grateful to the staff and doctors that took such wonderful care of my daughter in her time of need. If we ever face any uncertain health issues in the future, you can be sure where we will go. Maybe it’s time our companies had a check-up. We hear a lot about marketing, sales, and customer service, but I think it can all be summed up in one statement: Do unto others as you would have them do unto you. Who knows, maybe some day someone will write an article about their great experience with your company.


November/December 2007


November/December 2007 Vol. 48, No. 6

These exotic entrance gates for a new residential community in the Cayman Islands are a perfect melding of architectural and natural themes. See the story, page 62.

Biz Side

Special Feature

Tips & Tactics Third-party gate options . . . . . . . 14 Free up shop time and widen your company’s product line.

Technical achievements . . . . . 42 The work of these volunteers has always been an invaluable benefit.

By Todd Jackson

By Todd Daniel

Energy efficient lighting . . . . . 18 Glass fibre optics offer an efficient, powerful, and beautiful lighting option. By Gersil N. Kay

Shop Talk Youth has its advantages . . . . . . 26 Creativity, ingenuity, and low turnover are the payoffs when you hire young. By Helen K. Kelley

President’s Letter . . .6 Going the extra mile in customer service.

The new feudal society . . . . . . . . . 71 Will you be a lord or a serf? By Sanford Kahn

Sculpture brought to life ........51 This massive water feature is a feat of both engineering and design.

New Members . . . . . . . . . . . . . . . . . . . . 76

By Lisa Bakewell

Nationwide Suppliers . . . . . . . . . . . 76

Jefferson at Penn Quarter ......58 An historic landmark in our nation’s capital gets a facelift.

Member Talk

By Sheila Phinazee

By Martin Seidenfeld, PhD

Job Profiles

By W. Wayne Fuller

Silk and iron . . . . . . . . . . . . . . . . . . . . . . 34 An Alabama business creates custom ironwork and tailored fabrics to match.

Rules for new managers . . . . . . . 66 Here’s how to be effective on the job.

Entrancing entrance gates ....62 Integrating architectural and natural themes makes a bold style statement. By Karoly Szücs and Christopher Anco

Editor’s Letter . . . . . . 8 The road less traveled makes life more interesting.

What’s Hot!

Biz Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Chapter News

. . . . . . . . . . . . . . . . . . . . 82

Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 People

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86


. . . . . . . . . . . . . . . . . . . . . . . . . 88

New Products Classifieds

Reader’s Letters . . . 10 A technical affairs update, plus member requests.

. . . . . . . . . . . . . . . . . . . . 89

. . . . . . . . . . . . . . . . . . . . . . . . 92

Metal Moment . . . . 94 Fabricator magazine is used as a teaching tool.

Cover photo: NOMMA member Robinson Iron Corp., Alexander City, AL, was called in to help restore an historic four-story cast iron façade in downtown Washington, D.C. November/December 2007 



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:

1-year: 2-year: 1-year: 2-year:

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

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

Buyer’s Guide Published each issue. Deadline is Sept. 30. For (888) 516-8585


December as a separate for all advertising materials info, contact Todd Daniel at 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 Off the beaten path When you travel, do you stick to the

Interstates or do you like taking the back roads? I’m more of a back roads person. I love traveling through small towns and rural farm country, as well as coastal and mountain scenery. You miss a lot when you stay on the road more traveled. For example, on our way to the coast this summer for vacation, my husband and I avoided I95 like the plague and opted to drive on roads that went by shady pecan groves, green cotton and soybean fields, small-town schoolyards, and local businesses with priceless names. We passed by Fat Boys Camo Supply, Eunice Crop Insurance, and Ann’s Livestock Trailer Washout. Barbecue, of course, is a Southern staple and the smell wafting from the smoke pit of Swine & Dine BBQ was divine. Fried chicken is also popular in small towns and can be exciting or possibly alarming (Extreme! Fried Chicken), as well as international (Omar’s Chic-King). We also noted that armadillos are more prevalent than possums and raccoons on the roadsides in south Georgia these days. Well, you get my drift. Had we not gotten off the beaten path, we wouldn't have had nearly as much fun on that five-hour drive. I’ve been editing Fabricator for a year now, and I’ve learned that a lot of you have taken “back roads” on the way to where you are today. Many of you did not start out in metal working, nor did you have any idea that you would end up owning a fabricating shop. In this issue, you’ll read about two NOMMA members who took some winding roads to success. In Shop Talk, we feature Charles Calhoun of Calhoun Metalworks, who actually planned to go into theater direction. After working in film for a short while, he began welding coffee tables in his backyard as a hobby... and the rest is history. Our Member Spotlight shines on Joe and Mona Strange of

The Drapery Makery & Canvas Workshop Inc. (and its Ornamental Steel Division) in Fairhope, AL. When they married, Mona had a homebased business and Joe was teaching at a local junior college. But that all changed when the pair teamed up on the job, too. What began as Mona’s custom sewing business managed to evolve into a company with diverse offerings, including awnings, custom iron curtain rods, wrought iron tables, credenzas and more. Also in this issue, we have three outstanding Job Profiles. Learn how Cape Cod Fabrications made Helen Kelley is editor of Ornamental & an artist’s vision Miscellaneous Metal come to life on p. Fabricator. 51, and read about Robinson Iron’s challenges in restoring the facade of an historic building on p. 58. Karoly Szücs of Artisan Metal Works crafted entrance gates for a new community in the Cayman Islands that were a perfect melding of architectural and natural themes; read about it beginning on p. 62. We continue our series on NOMMA’s 50-year history with Todd Daniel’s article on the association’s Technical Affairs achievements, p. 42. And some of our long-time members share their reminiscences on p. 50. As you know, we’ll celebrate NOMMA’s 50th anniversary at METALfab 2008 in Memphis, TN, April 1-5. Items are needed for the annual NEF auction, which takes place during the convention — please consider donating items for this special event, which raises funds for the educational and research work of the NOMMA Education Foundation. Until next time, be well and happy... and I hope you stray from the beaten path a little.


November/December 2007

Why choose Wagner? Our Products . . .

• 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

Readers’ Letters Tell us what you think We need to hear from you. Please send us your article suggestions, editorial corrections, tips you’d like to share with other readers, and comments on new products and services. Your input makes our industry, association, and publications stronger. Mail: Letters to the Editor, c/o Fabricator, 1535 Pennsylvania Ave., McDonough, GA 30253. E-mail: Fax: (770) 288-2006. Ph: (423) 413-6436 Please include your name, company, address, telephone number, and e-mail. Letters are subject to editing for clarity, grammar, and length.

6KDSH 8S <RXU 3UR¿WV Bug-o Systems Programmable Shape Cutting Machine.

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November/December 2007

November/December 2007 



3500ETL · · · · ·

Post-mounted swing gate operator Continuous duty/heavy duty commercial New arm design Adjustable limits and extension arm 1,100 inch-lbs. of torque

· Operates swing gates up to 20 ft. and 1,000 lbs. · Available as 3600ETL dual gate operator with

Dual Gate Synchronization · Meets UL 325 standard

7000ETL · · · · ·

Post-mounted slide gate operator Residential and light commercial Fully systems capable Timer to close option Operates slide gates up to 20 ft. and 600 lbs.

· Includes 25 ft. of #40 roller chain · Available in dual gate model with

Dual Gate Synchronization · Meets UL 325 standard

7200ETL · · · ·

Post-mounted slide gate operator Continuous duty/heavy duty commercial Fully systems capable Operates slide gates up to 30 ft. and 1,000 lbs.

7100ETL · · · · · ·

Pad-mounted residential gate operator Light commercial and residential Fully systems capable Operates gates up to 20 ft. and 600 lbs. Available in dual gate model with Dual Gate Synchronization Meets UL 325 standard

· Available in dual gate model with

Dual Gate Synchronization · Meets UL 325 standard

7300ETL · · · · · · ·

Pad-mounted commercial gate operator Continuous duty/heavy duty commercial Fully systems capable Operates gates up to 30 ft. and 1,000 lbs. 12V DC motor generates more than 1/2 HP Available in dual gate model with Dual Gate Synchronization Meets UL 325 standard

· · · · ·

Fully systems capable Post-mounted or pad-mounted (with additional fabrication) Operates slide gates up to 30 ft. and 1,000 lbs. Available in dual gate model with Dual Gate Synchronization Meets UL 325 standard

7500ETL · · · · ·

Designed and built according to customer input Continuous duty/heavy duty commercial Compact design–all components in a single box Fully adjustable internal limits Lockable externally activated quick release

1500 · · · · ·

Swing gate operator Residential Push to open or pull to open application Easily adjustable limit switches Operates swing gates up to 16 ft. and 600 lbs.

1600 · · · · ·

Dual swing gate operator Farm and light residential Push to open or pull to open application Easily adjustable limit switches Operates swing gates up to 16 ft. and 600 lbs.

1550ETL · · · · · · ·

Swing gate operator Residential Push to open or pull to open application Easily adjustable limit switches Operates swing gates up to 16 ft. and 600 lbs. Soft start/soft stop feature Meets UL 325 standard

1650ETL · · · · · · · ·

Dual swing gate operator Residential Push to open or pull to open application Easily adjustable limit switches Operates swing gates up to 16 ft. and 600 lbs. Soft start/soft stop feature Dual Gate Synchronization Meets UL 325 standard

AGO-BA12 · · · · · · ·

Wireless Solar Stand-alone Runs on 12 volts DC Operates arms up to 12 feet in length Replacement arms are low cost and easy to change Continuous operation

· Battery (not included) rechargeable with solar or · · · · ·

electrical battery chargers Cover is key lock secured All internal steel parts are zinced Cover and pedestal are powder coated Smooth mechanical soft start and stop operation Two-year warranty

Security–it’s the watchword in the gate operator industry. Which explains why a growing number of people are turning to Apollo Gate Operators. Of course, we offer the security of our full line of gate operators. Apollo gate operators are precisely engineered and solidly constructed to meet all commercial and residential needs, requiring only a 12 volt DC battery rechargeable by either solar or AC power. All Apollo gate operators are available in models that meet UL 325 standards. And all come backed by a twoyear warranty.

The only source for a full line of solar powered gate operators.

But there’s also security in Apollo’s customer service department. Our customer service department is staffed entirely by skilled technicians, each with a comprehensive grasp of all Apollo products at all stages of product life, ensuring prompt and precise repair turnaround. And these same technicians can be contacted directly Monday through Friday, from 8 a.m. to 5 p.m. Real people, real time. So it’s no wonder Apollo is quickly becoming a favorite in the industry. We provide security you can depend on. Visit for a free catalog and to locate the nearest distributor. Or visit us in person at Fencetech Booth 2340. | 800.226.0178 12902 Delivery Drive | San Antonio, TX 78247

Tips & Tactics



November/December 2007



November/December 2007

StaLok® Rods

Easy. Easy to install. CableTrellis™

Easy to maintain. Easy on the eyes. Our stainless steel cables are simple to assemble, effortless to maintain, and virtually transparent. And with our special DesignRail ™

QuickConnect-SS fittings, they’re easier than ever to install. Additional ideas? Learn about the complete Feeney Architectural Products line including CableTrellis™, DesignRail™ railing systems, and StaLok® rods. See why Feeney is the easy choice among building professionals.

Scott/Edwards Architecture Portland, OR

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For our full catalog call us at 1·800·888·2418 or visit us online or

Tips & Tactics

Energy efficient lighting Beautifully crafted metalwork should not be left in the dark.

Glass fibre optics functional lighting is the most energyefficient technology known today.

This Vango Chandelier, featuring glass fibre optics, is lit with multi colors.

By Gersil N. Kay, IESNA Conservation Lighting International Ltd.

With global warming, depleting natu-

ral resources, and the uncertain international conditions, energy conservation has become a prime factor in construction and illumination. Although light is essential to see or do anything and enhances all design, artificial lighting could consume up to 45 percent of a buildingâ&#x20AC;&#x2122;s energy and also guzzle electricity outdoors. Of the three disciplines now regulated under national mandates, state/local codes and restrictions, 18

lighting has made the most strides in approaching practical savings. The Building Envelope and Heating/ Ventilating/Air Conditioning (HVAC) are the other two categories named in the national ASHRAE/IESNA1 Standard 90.1 (energy conservation for other than low-rise residential buildings, which have their own standard). Standard 90.1 is the basis for the national EPAct 2005, LEED, IECC and sections of every stateâ&#x20AC;&#x2122;s building codes. Both new and existing buildings, and their alterations and additions, are now regulated. Note that all standards represent only the barest minimum. If followed slav-

For your information  An optical fiber (or fibre) is a glass or plastic fiber designed to guide light along its length. Fiber optics is the overlap of applied science and engineering concerned with the design and application of optical fibers. Optical fibers are widely used in fiber-optic communication, which permits transmission over longer distances and at higher data rates than other forms of wired and wireless communications.  The light-guiding principle behind optical fibers was first demonstrated by Daniel Colladon and Jaques Babinet in the 1840s, with Irish inventor John Tyndall offering public displays using water-fountains several years later. â&#x20AC;&#x201D; Source: Wikipedia Fabricator 

November/December 2007

D&D’s quality qu uality ty & value vaalue luee Eliminate expensive callbacks before they happen! #



• Safe, durable, sturdy, r reliable • Meets swimming ppool barrier codes v • Key lockable convenience • Operates from both t sides of the gate a • Proven D&D self-latching magnetic technology • Tested to 400,000 open & close cycles

The future in gate hinges is here!

D&D Gate Hardware: the finishing touch • Will NOT rust, bind or stain • Maintenance free • Vertical & horizontal adjustments, during and after installation • Made of super-strong engineering polymers and stainless steel • Easy to install – no welding or special tools • Limited LIFETIME WARRANTY


Gate hardware for vinyl, y , wood,, metal and chain link fencing. g Call, e-mail or write us for a free catalog:


• Self-closing hinges with stainless steel spring • Patented internal design tension adjustment • Models with horizontal and vertical adjustment to fit gates up to 1,000 lbs


Ideal for picket-style gates

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st ed Co l l a t s In an ess th l % 0 5 k Box a L oc Not recommended for use on pool gates. Use Magna•Latch® for child safety gates.

• Locks and operates from both sides • Rekeyable, 6-pin security locks • Installs in minutes (no milling or welding) • Eliminates the need for costly lock boxes • No welding, painting or special tools

GATE LATCH • Stylish design fits 1” to 6” posts • Simplified installation (saves time & $$$) • One size fits metal, wood & vinyl • Adjustable vertically & horizontally • Locks & operates from either side Not recommended for use on pool gates. Use Magna•Latch® for child safety gates.

ishly, there will be only minimum results. However, it is possible to create sophisticated and affordable illumination within the increasing energy conservation restrictions if the most energy-efficient technology best suited for the particular application is chosen. There are many viable solutions besides the usual incandescent bulbs, halogen, or fluorescent lamps that have been used abroad for decades. In fact, our foreign colleagues consider the United States at least 10 years behind them in lighting. Some of the reasons for this are lack of practical education in alternate lighting systems and terminal inertia to change to newer procedures and products. Consider the alternate lighting tools most appropriate for your work. Good lighting increases productivity, safety, personal comfort, energy conservation, and profits. Anyone can recognize bad lighting, even without training. It may be hot, glaring, or too dim or off focus, and certainly wastes energy. Theatrical and architectural techniques can be combined for the best way to highlight material, texture and details. What are these unconventional systems? Some are mentioned below: Glass fibre optics functional architectural lighting Glass fibre optics functional (as

A harness of custom-assembled glass light “tails” or guides, each composed of hundreds of glass strands.

opposed to decorative) lighting is the most energy-efficient technology known today. It is not the same as glass fibre optics for communication — it is not interchangeable. It has long been used in other countries as an additional lighting tool for task, display, and architectural features. Components:  A light source (called projector or illuminator) is a metal container



Send For Free Brochure

• 2 FREE COVERS with purchase of 4 roller set • Available in 4” & 65⁄8” round or square design

E/Z SLIDE™ • For Wrought Iron, Wood, Metal, Picket And Chain Link Gates • UL 325 Compliant • Patented

IGD 20


10” round fence plier with “hog ring grooves” PADDED NON-SLIP HANDLES $17.90 EACH • 12+ ARE $15.80 EACH FOUR DOZEN OR MORE CALL FOR PRICING

INTERNATIONAL GATE DEVICES, INC. 101 Sycamore Avenue, Folsom, Pennsylvania 19033 (610) 461-0811 • 1-800-557 GATE (4283) • FAX (610) 534-9682 e-mail: • website:

Celebrating Our 25th Anniversary

the size of a large shoebox. Manual or automated special effects are possible.  A harness of fully custom-assembled glass light guides (tails), each composed of multiples of 400 strands of glass the size of a human hair. Diameters of various size tails range from only 0.1 mm to 10 mm (less than ½”). The octopus-like combination of very thin, flexible tails is secured at one end by the common end. This is simply inserted into the boss (opening) of the light source. The tails are fished through interstitial spaces just like copper wire. Fittings need only a ½” to 1” opening. Linear spaces of at least 90’ can be covered with one lamp over a throw distance of up to 100’, depending upon tail size. Since power and control wiring are done conventionally, installation is just another lighting job.  End-emitting tails are for functional uses. Side-emitting tails are a substitute for neon and are only decorative.  Miniaturized fittings (optional) just screw onto the threaded metal ferrules at the end of each tail. These control the lighting in intensity, performance, and size of footprint, from narrow spotlight to diffused, even Fabricator 

November/December 2007

From a full line of ironworker and related tooling, to the machines that use them, we have what you need for fast, efficient metal fabricating. For nearly 100 years, The Cleveland Steel Tool Company has served the metal fabricating industry by providing high quality products for fast, efficient metalworking. We have more tooling ready for immediate shipment than any other tooling manufacturer. Our line of versatile, affordable, hard-working ironworkers will give your shop the competitive edge you need.

For hole making on the go, you canâ&#x20AC;&#x2122;t go wrong with The Porta-Punch, a 35-ton portable punching machine. Several magnetic drilling machines and a full line of cutters are also available. Whatever your fabricating needs may be, count on The Cleveland Steel Tool Company for the best products available, friendly and fast service, and expert technical support.

800.446.4402 â&#x20AC;˘ â&#x20AC;˘

Buildings may also be investigated, where applicable.  Enhances environment — Provides sophisticated, affordable illumination within the energy restrictions. Good lighting enhances all design while conserving energy. Increased energy conservation without increased productivity will inevitably fail.

Miniaturized fittings screw onto the threaded metal ferrules at the end of each tail. These control the lighting in intensity, performance, and more.

light, downlights, adjustable eyeballs, etc. Properties:  Safe — No electricity flows through the tails, only light rays. No harmful heat or ultraviolet rays dry out or irreversibly fade “fugitive organic materials” (anything that once grew).Indispensable for high, inaccessible, electromagnetic, or hazardous locations; vibration, water features, historic décor, retrofitting fixtures, or constantly changing exhibits.  Very energy efficient — One cool-burning lamp powers multiple (as many as 32) points of high level

light, complying with current energy conservation mandates. Air conditioning loads are not increased by heat from the lighting.  Affordable — Long-lasting and reusable. The system lasts decades just by relamping. Substantial savings in installation, maintenance, and operation make for prompt payback on initial investment and continuing economies thereafter for the long life of the system. There may be financial incentives offered by utilities and municipal, state, and federal agencies for upgrading to more efficient lighting. The federal Investment Tax Credit for Rehabilitation of Historic


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November/December 2007

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The light sources were fitted with nine custom dichroic1 color filters, plus white. After the 10 projectors were programmed for individual solid colors and combinations for Christmas, Fourth of July, Easter, etc., they were lifted into the ceiling position and connected to the DMX512 theatrical computer. A simple push button control activates the light show. Similar techniques could be used to light metal staircases, fixtures, etc. CFLs Compact fluorescents (CFLs) are another innovation, but care must be taken for proper disposal because of their mercury content. CFLs may not fit into all existing fixtures. Unless ordered instant start, they could present a safety hazard. Since there are a great many colors of white, the CFLsâ&#x20AC;&#x2122; Kelvin color temperature may not be acceptable for some uses. Kelvin temperatures go from 2500K (yellowish) to 5000K (sky

blue). The lower Kelvin range looks best with the warm colors, yellow/orange/red, while the higher temperatures enhance the cool blue/green ones. CFLs are not directional. The big question is, who will manufacture the masses of quality products needed immediately for replacement? LEDs Light Emitting Diodes (LEDs) are also inventive, but still require some energy to dissipate the heat created by this solid-state lighting (SSL). They are vulnerable to vibration, moisture, temperature and voltage drops. Experienced and expensive consultants are needed to maneuver through the complicated compromises that must be considered in installation. The 100,000-hour lamp life that was first promised is now down to 50,000 hours, which is about 10 years before the system has to be completely renewed. If as much money and effort were

spent in research on making incandescents more energy efficient as has been lavished on LEDs, the urge to eliminate incandescents might not be so strong. The best lighting advice is to engage professionals who can best showcase your efforts. Donâ&#x20AC;&#x2122;t be like the man who acted as his own brain surgeon, and in reading the book while slicing, died of a misprint. Conservation Lighting International Ltd., Philadelphia, PA, is a pioneer American lighting design firm conserving energy and materials with glass fiber optics. For more information, log on to: Note: 1 American Society of Heating, Refrigerating, Air Conditioning Engineers/Illuminating Engineering Society of North America, along with the U. S. Department of Energy.




November/December 2007


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Shop Talk

Youth has its advantages

All but one of Calhoun Design and Metalworks’ employees are between the ages of 20 and 29.

 Creativity, ingenuity, and low turnover are the payoffs. By Helen K. Kelley, Editor Step into the main office of Calhoun Design and Metalworks and you’re likely to hear an old Led Zeppelin tune blasting alongside the banging of tools in the metal shop beyond. Push through the swinging doors to the shop and you’ll see a number of employees working away on various projects. And then it strikes you — they’re not children of the ‘60s. These guys are young. Remarkably, all but one of Charles Calhoun’s employees are under the age of 29. And that’s totally by design. 26

Strategic-yet-untraditional hiring Charles Calhoun has something of an unusual policy when it comes to selecting employees. Experience is not a critical factor here. “My philosophy is to hire employees truly from the ground up,” he explains. “I’ve found that if you can hire young employees with little experience, but with a strong desire to do the work, it’s beneficial. They learn our processes while always feeling like they are moving forward within the company, and that, in turn, lowers our employee turnover rate.” Calhoun probably comes by this

For your information Employee stats for Calhoun Design and Metalworks: Total employees: 10 Ages: 20-29 Backgrounds: Various. Most have art school educations— five are graduates of the Atlanta College of Art. Two have trade school educations. One is a graduate of Georgia Institute of Technology. Shop foreman/manager: Graduated from Atlanta College of Art as a sculpture major; started as a grinder/finisher with the company and worked his way up through the ranks. Fabricator 

November/December 2007


The employees of Calhoun Design and Metalworks are not required to have a lot of experience. They just need a desire to express their creativity and learn new skills.

non-traditional hiring strategy naturally. A theater studies major in college, his plan was to go into film production. He did work in the film industry for a few years before he got sidetracked by a hobby — welding coffee tables in his backyard. Soon, Calhoun was designing and building furniture in his garage; not long after that, he was fabricating railings and other architectural elements. “I actually never worked a day in the theater. But the degree gave me skills and insights that I could apply in areas like design, fabrication, and finishes,” says Calhoun, when asked if he ever regretted his career choices. “And it’s turned into a real business. I get plenty of artistic satisfaction from designing projects and client relationships.” His business prospered and Calhoun built a studio to accommodate the increasing workload. But within a few years, Calhoun Design and Metalworks outgrew that location, too, and moved to its present 20,000 square-foot location in a warehouse district on Atlanta’s southside. Not only did the business require successively larger locations, it also needed more and more employees. And what Calhoun has sought in those employees is creative thought along with a desire to learn and grow. Over the years, it’s proven to be a very successful hiring strategy. “We often hire inexperienced people with artistic or engineering talent, cultivate their skills, and encourage them to work their way up,” Calhoun says. “The great thing about this strategy is that whenever someone higher up in the chain moves on for whatever reason, it opens doors for employees who are ready to take on more responsibility. It might require more time to train that person in the beginning, but we don’t have the issue of people moving in and out of our company as often, because we have invested in each other.”

“I truly believe that my

employees are my greatest asset.” 28


November/December 2007




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Charles Calhoun (foreground) gets an update on a current project from a member of the shop staff.

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Creative collaboration and good communication are effective Most of Calhoun Design and Metalworks’ clients are seeking innovative designs and solutions. Therefore, all employees of the company are encouraged to bring their ideas to the table. “We’re very lucky that we’re allowed so much creative license by our clients,” acknowledges Calhoun. “As a company, we try to collaborate as much as possible. My employees have come up with some great design ideas.” Calhoun meets with clients first and talks with them until he has a strong idea of what they want, making rough sketches as he goes. He turns those notes and sketches over to his associate designer, who refines the sketches and creates shop drawings in AutoCAD. Although Calhoun makes the final decisions about the materials to be used on various projects, he often collaborates with his employees first. Not just allowing, but in fact, actively seeking out this kind of input, has gained a loyalty and dedication from employees — and a low turnover rate. Fabricator 

November/December 2007



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“We have created a high level of trust among our management to oversee the execution of the designs. By the time someone is in a management position here, they already know exactly how something should look,” explains Calhoun. “I truly believe that my employees are my greatest asset.”

Some of Calhoun Design and Metalworks’ beautifully creative designs.

Forged iron driveway gates in Atlanta, GA.


Bronze entry canopy in Greenwich, CT. UPPER RIGHT:

LEFT: Hand forged iron pear tree espalier, Atlanta, GA residence.


About Calhoun Design and Metalworks... Established in 1994, Calhoun Design and Metalworks, located in Atlanta, GA, works primarily as a custom shop, specializing in hand forged ironwork, but also working with stainless steel and aluminum. The company can tackle a variety of projects, from commercial jobs requiring cranes and engineers to custom creations for private residences. Contact: Calhoun Design and Metalworks, Ph: (404) 755-6155; Web: www.calhounmetalworks. com.


November/December 2007

Member Spotlight

Selling silk out the front door... and iron out the back

 A coastal Alabama business

creates custom ironwork and tailored fabrics to match. By Sheila Phinazee NOMMA business owners Joe and

Mona Strange make quite a team at The Drapery Makery in Fairhope, AL, selling customized ironwork, drapery, bedding, awnings, design, and blinds— they’re a favorite one-stop shop for local decorators. No two jobs are alike, and, as the duo’s website says, “If you can imagine it, we can make it.” Joining Forces Mona, a professional seamstress, started a drapery-making business in 1986. At the time Joe met Mona, she 34

was a widow with a home-based business and he was teaching business and computer science classes at a local junior college. Sometime after they married, one of Mona’s clients complained that his curtain rod was too long for a window. Joe fixed the problem by cutting the rod to the correct size. Previously, Mona used a local vendor and a second vendor in Maine to do custom rods, but before long, Joe was twisting and shortening store-bought rods, making sure they were just right for Mona’s clients. At the end of 2000, Joe’s teaching grant at the junior college ended.

For your information Company: The Drapery Makery & Canvas Workshop Inc. (Ornamental Steel Division) Location: Fairhope, AL Total employees: 11 Specialization: Custom sewing and custom iron Key to success: Diversification of services offered Contact info: Email: Ph: (251) 990-8789 Web: Fabricator 

November/December 2007

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However, by this time, both he and Mona were very busy with her drapery venture. So, Joe was officially in business. He enrolled in an evening adult education class to learn welding, and began making curtain rods. Next, the business expanded into making canvas awnings — Mona sewing them and Joe making the metal frames. “If it wasn’t for Joe, we wouldn’t be in business,” says Mona. “Thanks to him, we’re doing more than 10 times the work we had before!” Eventually, at the request of customers, Joe tried his hand at making metal furniture... and then handrails. In 2003, Drapery Makery began supplying handrails to builders, starting on a small scale, while creating drapery for interior designers. Not long after, the company branched into related industries and the iron portion of their business took off. Drapery Makery began building handrails, table bases, pot racks, benches, and more metalwork. Selling iron to other welders became another offering when the company bought out the inventory of another welder going out of business. “It was an easy transition into ironwork,” says Mona. “Accessories and metal components are a natural part of interior design.” Today, the Drapery Makery’s main products are draperies, ironwork, awnings, curtain rods, furniture, and handrails. Or as Joe says, “We sell silk out the front door and iron out the back.” The shop employs 11 workers, including Mona and Joe, three seamstresses, and six metalworkers. The couple demonstrates effective teamwork. “Joe knows more about iron and welding, and I know more about sewing and drapery, but we work together to manage both sides of the business,” explains Mona. “We each have input in both sides.” The shop’s workers also know what’s happening on both sides. Sometimes, the ladies are sewing the drapes while the guys in the back are working on the rods for the same job. Although Joe and Mona have their hands full with their broad range of products and services, there are benefits to this kind of diversification. “The cool thing is that if we happen to have a slow month in draperies, iron or awnings will pull us through and keep things moving,” says Joe.



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Shop talk When Joe’s teaching grant expired at the end of 2000, he and Mona decided to rent commercial space — formerly a chicken barn — and made extensive renovations to accommodate their growing business. “Since our clientele includes designers and ladies shopping for Fabricator 

November/December 2007

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LEFT: Joe Strange in The Drapery Makery’s metal shop.

draperies, we had to make sure the space looked nice,” says Joe. Their shop includes a showroom, iron shop, and other amenities. Shop machinery includes: one TIG, two MIG machines, one gas operated machine for grinding, one Eagle bender, one Phoenix band saw, nine sewing machines, and various hand tools. High-end customer base About 60 percent of Joe and Mona’s business comes from decorators and builders. The shop’s clientele includes contracts with interior design companies, furniture stores, other vendors, and national chains. The other 40 percent of their business involves working with home owners, creating custom sewing under their own Drapery Makery label. Specialty finishes Although Joe and Mona originally began painting in small batches for faux finishes on curtain rods and railings, they now offer a wide variety of finishes. Joe recalls one particular job that involved creating a bed’s headboard, footboard, frame, and legs. The customer that placed the order wanted a distressed black finish. “It involved a lot of hand rubbing, the guys working on it were real busy,” Joe says. By the time the job was done, though, the 38

customer had a complete ensemble with the headboard, footboard, frame, iron vanity, window seat, throw pillows, seat cover, bedding, and drapery. Location, location, location The shop owes some of its success to its great location. Fairhope, on Mobile Bay, is a bedroom community to Mobile. The shop’s upscale clientele includes owners of condos on the nearby beach and their decorators. “Because of the decorators and ‘artsy’ nature of our location, we are

fortunate to catch odd jobs,” says Joe. Drapery Makery gains additional business by word of mouth and repeat customers, some of which are on job seven or eight. Some of the shop’s work has reached as far as California and St. Croix, with customers who have additional properties there. However, most of the company’s business is in the Gulf area. “The region we cover includes Louisiana, Mississippi, and the Florida panhandle,” says Mona. Planning for the future The couple has plans for streamlining their business practices for greater efficiency, learning more about welding, and updating their machinery. The business is currently housed in a 4000 sq. ft. rented building. Mona and Joe have purchased a 1.5-acre property off the main road and plan to be in a larger building that they own; since space is an issue, they will be able to expand as necessary. The business is currently working with the Alabama Technology Network “Lean Manufacturer’s Program,” which encourages continuing education among other things. All of Drapery Makery’s metal shop employees attend a six-week welding


Much of The Drapery Makery’s upscale clientele request custom-made window treatments and hardware. Fabricator 

November/December 2007

“METALfab was a great

opportunity for networking, and especially seeing how others manage their shops.” class, two nights per week. Mona and Joe also took them to NOMMA’s METALfab convention this year in Destin. The shop’s seamstresses attend industrial fabric trade shows, too. “With the young people in the

shop, our intent is to keep them,” says Joe. The company pays a fair wage, gives paid holidays, pays half their health care coverage, and offers a 3 percent matching 40l plan. Once they learn to weld, some of the shop’s employees leave to work in the local ship yard. Fabrication, though, is harder to teach, according to Joe. He has used NOMMA videos to train some of his employees. “We watched the how-to-videos

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NOMMA connection This is Joe and Mona’s third year of membership with NOMMA, and they have experienced several related benefits. “METALfab was a great opportunity for meeting other people in the industry, networking, and especially seeing how others manage their shops,” says Mona. Joe feels that fellow NOMMA members are a great business resource. “We’re blessed with a lot of business, but we’re learning as we go,” he says. “We would like to get a better handle on things like pricing and building up our business.” He adds that NOMMA members Jan Allen in Birmingham and Jim Minter in Mississippi have been very helpful by giving advice and suggestions. The Drapery Makery hosted the Gulf Coast Regional NOMMA meeting in October, featuring an Alabama shrimp boil. A few days before the event, a local television morning show crew came out with their cameras to film Joe and the guys demonstrating forging and plasma cutting techniques.

Drapery Makery’s main products:  Custom sewing, draperies, bedding.  Blinds and Roman shades. (They install them and act as warranty dealer with Hunter-Douglas, Levolor, Graber, and Kirsch.)  Awnings — Weld frames in the metal shop, seamstresses cover them with canvas, and workers install them.


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for laying out steps and building curved handrails. It was important for us to make the curve meet code and be pretty and consistent,” says Joe.

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November/December 2007


An awning under construction. Custom iron work is one of The Drapery Makery’s specialties.


Community involvement Joe and Mona are also active in local organizations. They have hosted after-hours receptions for the Chamber of Commerce and have been nominated three times for the Chamber’s Small Business of the Year award. In addition, Mona is a member of the youth leadership program, which

November/December 2007 


encourages young people to visit local businesses and gain skills in leadership and conflict resolution. Joe is an officer in the Rotary Club and serves as secretary for the local blacksmith guild. Family ties Joe and Mona have three children— a daughter, who attends the

University of Wisconsin, and two sons, one a chemical engineering major who is an excellent TIG welder, and another who is great with hand tools and installing drapery. Their sons have worked in the shop over the summers. This business truly is a family affair.


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November/December 2007



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November/December 2007

Special Feature

We remember... Ed. note: As part of our continuing series on NOMMA’s 50-year history leading up to METALfab ‘08, we asked some long-time members to share their memories and insights. Here are some of their comments; we’ll share more in our next issue. I remember my very first convention in Dallas back in 1995. I was relatively new to the industry and attended the Top Job Jamboree. The work on display at the Jamboree was, as usual, incredible and I remember being truly inspired—as well as a little bit intimidated. I have used that experience as motivation over and over through the years and those memories continue to push me to accept new challenges and try new things in order to improve the way we do business. —Chris Connelly, DeAngelis Iron Work, Inc.

I attended the very first meeting of NOMMA in Memphis. Abe Sauer of Tennessee Fabricating Co. sponsored it. About 40 of us were there at the first meeting, including our first president, Frank Kozik. There was a lot of lively discussion. I had to drop out of the organization for a while in order to spend time with my sons, who both had polio. It was several years before I attended my next convention in 1972. I’ve attended 30+ consecutive conventions since then, and I’m planning to be at the 2008 convention in Memphis! I think making the entries in the Top Job Competition anonymous was a significant change for NOMMA. It made the voting system more fair. Also, the Top Job Jamboree has become an important part of METALfab. — Ernest Wiemann, Wiemann Iron Works

Every time I prepare a shop drawing for a spiral stair, I remember back in the late 70’s when I attended a NOMMA convention. I met with a person who, sometime after midnight, sat down and took the time to teach me how to figure and build my own custom spiral staircases — tread size, degree of turn, and the proper diameter to roll the handrail. I know we have built over 200 of these since then with very nice margins. I can’t express enough gratitude on just this one experience. I wish I could remember who the person was! Thanks to all of you who have helped and encouraged us to become better at what we do. — Frank M. Finelli, FInelli Architectural Iron & Stairs 50

I’ve traveled along most of NOMMA’s 50 years and have been asked to share some remembrances — random and maybe inappropriate at best, and with humble apologies to hundreds of unmentioned friends and invaluable contributors for any factual/omissive slights. Memory fades when your favorite shoes are older than the average NOMMA member. So, here goes . . .  Blanche Blackwell, the first executive director, was a crown jewel (as is our present staff); a smart, dedicated, eloquent lady who more than once reminded us to act professionally.  Going to California with a group to organize Western chapters with a side trip to Tijuana — the bus breaking down and the immigration officer asking me, “Where is Alabama?”  Leon York (’74 Louisville) riding his aluminum-spangled horse (and himself resplendent) into the Grand Hall, and Evelyn York elected as our first woman president (’85)  Cliff Brown and others (always others) pressing the membership to be more technical and willing/able to teach us how.  Ernest Wiemann, after accepting his “nth” consecutive Top Job award, saying to the audience: “When you’re gute — you’re gute!” What a guy for the ages.  Jim Wallace (’78) hired as the first and only director to date of the National Ornamental Metal Museum — 30 years later retiring. The museum is now an acknowledged and accredited institution.  National Education Foundation: volunteers sharing their expertise, information, and money. Another tribute to strategic thought and action by NOMMA men and women. Another platform to maintain the NOMMA organization as the most viable and progressive leader in our industry.  Newer products, tools, and techniques, provided by suppliers that are promoting and selling, and creating an ever expanding market for ornamental and architectural metals. — Stan Lawler, Lawler Foundry Corporation

There have been so many positive experiences through NOMMA that it is hard to single any one out, from the friends I have made over the years to the opportunities that have arisen. It was because of NOMMA that 25 years ago I got to spend time at Bill Valerius’ shop in Chicago. Bill wanted to help the next generation of metalworkers just as he had been helped early in his career. Angelo Finelli, Kevin Merry, and I spent six intense weeks learning from one of NOMMA’s finest craftsmen. Despite the hard work it was a very enjoyable experience and one that has had a profound impact on my career. — Lloyd Hughes, Lloyd K. Hughes Metalsmithing Fabricator 

November/December 2007

Job Profile

Massive water feature sculptures come to life  This 2007

Top Job award winner is a combined feat of engineering and design.

By Lisa Bakewell “My favorite part of all of our projects is when they’re completed and I get to take photographs of them and see the final work,” laughs Rich Corner, principal at Cape Cod Fabrications in East Falmouth, MA. “The end result is always very satisfying, but the process of completing a project can sometimes be nothing short of excruciating.” This is especially true, he adds, when he and his crew are trying to meet nearly impossible deadlines and solve extreme engineering challenges. One of Cape Cod Fabrications’ most recent challenges — complete with impossible deadlines, engineering challenges, and significant paperwork — won them a Top Job Gold award in November/December 2007 


the Art/Sculpture category in NOMMA’s 2007 Top Job Competition. The winning entry came in the form of three water feature sculptures designed by a famous artist, Mikyong Kim, who heard about Cape Cod Fabrications from a landscape architect they had previously worked with on another project. Kim, who was commissioned by Southern Connecticut State University (SCSU) to create the three water features, hired Cape Cod Fabrications to work with her on all aspects of the project including the design development, budgeting, paperwork, fabrication, and installation of the unique water feature pieces she had envisioned. Kim knew it wouldn’t be an easy project to complete and hired

For your information Project: Three 16’ high x 30’ long sculptural water features designed for a university campus by an artist. Shop: Cape Cod Fabrications, East Falmouth, MA Ph: (508) 564-5777 Web: Contact: Rich Corner Method: Perforated #316 stainless steel channels were compound rolled using fixtures and full-scale drawings to ensure accuracy. Greatest challenge: The coordination and rigging for transporting the sculpture to the job site...which was 400 miles away.


Cape Cod Fabrications based on their previous experience with challenging and complicated works of art. Though Cape Cod Fabrications did have previous experience with difficult and unusual pieces, they knew, going into the project, that this was possibly one of their biggest, most challenging jobs yet. Kim’s proposed work of art would consist of three massive (16’ high and 30’ long) water feature sculptures and all three were to be slightly different from the other. Corner knew, though, that he and his crew were up to the challenge.

“... the end result is that this

project got us more work, gained us more recognition, and won us a Top Job award.” A feat of engineering, design, and patience The project was designed around several perforated stainless steel water channels and angel hair patterned stainless steel sheets that were designed to collect rainwater in small pools, allowing the water to trickle down the sculpture and bring the water features to life. In the wintertime, the perforations would cause ice dams, creating beautiful icicles and turning the pieces into dramatic ice sculptures. These art pieces, conceived by Kim and fabricated by Cape Cod Fabrications, were to become landmarks of the university. “This was a very complex project,” said Corner. “And it was extremely challenging to get everything correct and to make this project work from an engineering standpoint while still making the piece aesthetically perfect based on the artist’s vision.” Working from life-size drawings, Cape Cod Fabrications was able to complete the project and successfully grasp that vision, making this one of their most successful projects to date. The basic fabrication of the pieces consisted of putting a special angel hair finish on 30 3/16” stainless steel sheets, measuring 4’x12’, and sending the sheets to be laser cut and formed into channels. The channels were then cut into miscellaneous sized strands; were ground, then polished; 52


November/December 2007

CNC ring rolled to the desired radius and helix, and welded together into a custom fixture. After each subassembly was produced, the pieces were ground and polished again. At one point, Corner says the piece looked like a bunch of spaghetti noodles all going in different directions—and this is where the life-sized drawings really came in handy! The three pieces were originally supposed to take about six months to finish, but the process lasted about twice as long, according to Corner. And, in addition to dealing with the sheer size and engineering of the project, working with the university proved to have its own challenges.

RIGHT: This close-up shot shows the intricate angel hair pattern stainless steel sheets.




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The channels lined up and ready to go. complete the installation of the sculptures.

“Every step of the process needed to be approved by a Board of Directors,” explained Corner. “If every ‘T’ wasn’t crossed and every ‘I’ dotted, payment wasn’t made.” Corner thanks his business manager, Steve Wuthrich, for keeping the project on course by completing all of the necessary paperwork and doing a great job of following up on necessary permits. “We had to be bonded for this project because we were dealing with a university and the project was considered a piece of artwork,” shares Corner, adding that the company’s attention to detail paid off. “My management staff is so good at following up, and the end result is that this project got us more work, gained us more recognition, and won us a Top Job award, of which I’m very proud. But it was a lot of work.” When asked about other challenges of the project, Corner just laughed and said, “One of the biggest challenges was that we had all three structures going on at once. We were in a 5,000 square foot facility at the time and we basically built the structures in our parking lot. Spring turned into summer, and summer into fall, and we went well into the winter before we were done. We had to build a 54


It took a crew of three installers and a project manager five days to

makeshift shed around these things and bring in some portable heaters just so the guys could get out of the elements!” Professional (installation) help needed The entire project required approximately 1,350 labor hours and took the better part of a year to finish, but once fabrication was completed, one of Cape Cod Fabrication’s greatest challenges still lay ahead. The installation site at the university was 400 miles away from their shop. The coordination and rigging for transporting the sculptures was going to be an awesome and somewhat delicate task, and Cape Cod was going to need some help to accomplish it. Some professional help. To do the job, the company hired Mariano Brothers Specialty Moving, a rigging company with previous experience in transporting large fabricated items. The sculptures were to be transported on a flatbed truck by cradling them in a sling and taking them one by one to the installation site. “This cost more money,” said Corner, “but allowed the sculptures to stay virtually intact during the shipping process.” Transporting the items in this manner made the installation

process of the project easier and much cleaner. Once the sculptures were delivered, the installation took three installers and a senior project manager approximately five days to complete. “My crew had to rig the sculptures with a crane and nylon strings, lower the pieces into place, weld up attachment points to embedded stainless steel plates, and then do a final concrete pour,” explained Corner. “Once all that was done, the pieces still needed touch-up, polishing and cleaning to make the project perfect.” It takes teamwork Corner acknowledges that it took the work and input of many people to complete the award-winning project. “I really need to thank everyone who worked on this project,” said Corner. “The AutoCAD detailers that worked on the approval and fabrication drawings were Mike Chase and Doug Hefler. There were nine fabricators in all, including Bill Callahan, Dennis Frezza, Jim Caramanica, Derek Riley, Walter Whalen, Alain Paradis, Jeremye Graham, Andrew Rieckenberg, Rick Perez and José Cordon. The installers, Joshua Craig and Darryl Clymer, worked with senior project manager, Chad Allen, on Fabricator 

November/December 2007

is very familiar with complicated pieces such as the three water features. “This is a typical project for us,” says Corner, “something that has not come before; that’s not just a one-off. We don’t do a lot of one-offs. We’re a heavy designbuilt metal fabrication studio— heavy on the front-end design. Architects like to deal with us because they want input from people that have experience.”

installation at the site, and René Paradise was the general manager overseeing all aspects of the shop work. As you can see, it takes a whole team to accomplish a project like this one and I have a great crew!” Cape Cod Fabrications has become well known for its work in modern residential and clean line projects and

White elephant… or touchdown Cape Cod Fabrications is a 10year-old company that began as a small metal shop doing welding and fabrication work. After a few years, Corner and his crew started getting into more challenging architectural railings, barricades, fences and sculptures. Today, the shop occupies 20,000 square feet of space and employs 26 people including designers, AutoCAD detailers, fabricators, installers, an in-

house graphic designer, and a nineperson management staff. As the leader of the bunch, Corner sees himself as the shepherd, putting together a team of skilled individuals and being willing, as the company owner, to take on large risks such as the water features sculpture. The rewards are in the final results of each project. “Our work is usually something that some artist, architect, landscape architect or designer just thought up in their mind,” says Corner, “and we are just, basically, handed a napkin sketch and told to run with it and take it to the end zone for a touchdown. Sometimes we get a white elephant, but fortunately, most of the time we make the touchdown!” And Corner likes scoring the touchdown. He considers receiving a Top Job Gold award a win for his team. “It’s exciting for us as a company to win an award like this one,” he notes. “It’s the icing on the cake.”




November/December 2007


Job Profile

An historic landmark gets a facelift  Stored away for

decades, a cast iron façade is lovingly restored and reassembled on its original site.

By W. Wayne Fuller Robinson Iron Corp. Turning around urban decay is not an

easy thing especially when it involves the heart of the nation’s capital, 13 historic properties, and the desire to create significant urban amenities. However, all of this has been accomplished brilliantly at The Jefferson at Penn Quarter in downtown Washington, D.C. The project, as conceived by the architect, Mary Oehrlein & Associates, is a mixed-use development that respects the history of the site (Clara 58

Barton’s offices were located there during the Civil War). One important facet of this plan required the restoration and installation of an historic four-story cast iron façade that had been previously removed and saved by the Pennsylvania Avenue Development Corporation during the 1970s and stored at Andrews Air Force Base. The builder, JPI Construction, engaged the metals restoration experts at Robinson Iron, one of the country’s foremost experts in the manufacture and restoration of cast iron, to do the job.

For your information  The Jefferson at Penn Quarter in downtown Washington, D.C., made use of historic facades to create a mixed-use block that respects the history of its site while providing urban amenities.  The project included the restoration of the original 1885 facade and entrance of one of the buildings on the site; the restoration and reuse of the building that served as Clara Barton’s Civil War headquarters; and the restoration of eight additional facades.  The site was one of the last remaining eyesores in the East End/Penn Quarter neighborhood. Fabricator 

November/December 2007

Assembling the “puzzle” All of the façade’s components were loaded onto trucks and sent to Robinson’s facilities in Alabama. There, the enormous jigsaw puzzle of pieces presented quite a challenge. First, the position and dimension of each cataloged piece had to be confirmed. Then, each casting had to be cleaned, repaired, or recast. And finally, new methods of attachment had to be devised and an entirely new support structure engineered. Cleaning involved a lead abatement procedure, with an application of Pretox to encapsulate any lead coatings and ren- Robinson Iron was faced with the challenge of assembling an enormous “jigsaw” puzzle of pieces in order to faithfully recreate the façade. der them non-leachable. This The original structure had been material was removed by needle scalRepairs were made in a variety of attached to cast iron brackets embeding the surface by personnel wearing ways. The primary method was welding with Nichol electrodes and then ded in a masonry bearing wall. the prescribed safety gear. Samples reinforcing with stainless steel plate However, the restored façade would were sent periodically to a lab to require more modern methods of attached with stainless fasteners where determine the efficacy of the proceattachment and a new support strucneeded. dures.

November/December 2007 



LEFT: Painstaking effort was given to replicating each piece of the original cast iron façade.

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ture that could withstand the harsh winter elements. J. Scott Howell, vice president and general manager of Robinson Iron, and Bobby Patterson, Robinson’s engineer, engineered these details, along with Joseph P. Callaghan, P.E., who provided structural calculations for the wind and snow loads. The restored cast iron was fastened with ASTM 325 bolts and anchors to stainless steel angle clips that were attached to CNC cut steel brackets. These brackets, in turn, were welded to structural steel beams or attached to masonry with chemical anchors. Bond breaker tape was used at critical connections to allow for thermal expansion and contraction of the assembly. Because the original building belonging to the façade had been razed, the restored façade was erected on the front of an entirely new building – what some would call a “façadectomy.” The restored façade, once again part of the streetscape, is a tribute to the craftsmanship of early ironmongers, the architects/preservationists who saved it, and the ingenuity of Robinson Iron. Combining old and new makes restoration fun “One of the unique qualities of The Jefferson at Penn Quarter project was that it required a combination of historic and new cast iron,” explains Scott Howell. “We were able to reuse some of the original turn-of-the-century materials, along with new cast iron that we provided. That’s what made it so interesting and fun.” Robinson Iron Corp., now operated by a third generation of the Robinson family, continues to cement its reputation as an expert in cast iron restoration. “We see this kind of work as a big part of the company’s future because there are so many of these projects out there, particularly in cities in the Northeast, which are rich in cast iron façades,” says Howell. “We hope to be recognized as a leader in this field of restoration, as well as the manufacture of new cast iron.” Fabricator 

November/December 2007

The restored four-story cast iron façade was erected on the front of an entirely new building.

NOMMA member Robinson Iron employs more than 300 skilled craftspeople with specialties in design, engineering, patternmaking, casting, finishing, and installation. Every discipline related to the art of metalworking is represented. Best known for historic reproduction, Robinson possesses an extensive library of 19th century antique cast iron patterns. The company’s distinguished project list includes some of the nation’s most cherished landmarks. i.e. The Lincoln Cottage, The Library of Congress, and the Executive White House. This family owned firm is now operated by a third generation of Robinsons who understand and respect the skills and traditions passed down to them by their grandfather, Mr. Joseph H. Robinson, Sr. Contact: Robinson Iron Corp., Ph: (800) 824-2157; Web: November/December 2007 



Job Profile

Entrance gates make a bold statement  This project,

integrating both architectural and natural themes representative of a new island community, garnered a bronze Top Job award. Photo by Justin Uzzell

By Karoly Szücs, Artisan Metal Works Ltd., and Christopher Anco Karoly Szücs is the managing partner

of NOMMA member Artisan Metal Works in the Cayman Islands. A certified welder and experienced fabricator by trade, Karoly has combined his natural artistic talent with his fabrication knowledge and skills to create for his client’s unique and custom functional art pieces for either residential or commercial use. Karoly’s inspiration 62

comes from the natural surroundings of this tiny Caribbean island, and his artistic creations are mainly contemporary in nature. His talent is in incorporating a harmonious relationship between the required functional aspect of the work and the aesthetics and themes of the works surroundings. In most cases, people seeking out Karoly’s talents are looking for that special one of a kind project which will make a distinct statement about their project. The custom gates for the

For your information Dimensions of gates: 25’ wide; 8’ tall at the columns; 12’ tall in the center Special touch: The center element on the gate represents a bird in flight. Approximate labor time: 200 hours Shop: Artisan Metal Works Ltd., Grand Cayman, Cayman Islands Owner: Karoly Szüchs Ph: (345) 949-1591 Email:


November/December 2007

Salt Creek Community on Grand Cayman Island — which garnered a bronze award in the 2007 Top Job Competition — are just one of the many distinct functional projects the staff of Artisan Metal Works has created under the guidance of Karoly. The design parameters for the project were straightforward:  Design and fabricate a set of functional gates for the new community that not only would provide security for the residents, but also make a bold statement for anyone entering the community.  At the same time, the gates must incorporate the architectural and natural themes used throughout the community.  The goal was to create the operational entry gates to represent the grandeur of the upscale community while at the same time reflect the tranquility and serenity of the surroundings without creating the illusion of exclusivity.

Each gate-leaf, based on the community’s logo design, measures about 13’ tall x 14’ wide.

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The Salt Creek community logo, etched on this boulder, was the inspiration for the entrance gates.


Using the community’s corporate logo as a starting point, the final gate design incorporated two large arched gate leafs, each approximately 14 feet wide and 13 feet tall at the centerline of the entryway.

2 Materials

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In order to deal with the tropical marine environment, the gate would be fabricated from marine grade aluminum, the base and hinge sides of the frame consisting of 2” x 4” square tubing while the top and center frames where fabricated from 2” x 2” aluminum tubing. The decorative elements of the gate leafs, representing blades of grass gently blowing in the breeze and a center element representing a soaring bird were cut on a CNC plasma table from ¼” aluminum plate.

3 Environmental considerations

The island community is located within the hurricane belt; therefore, it was decided to increase the structural strength of the gates by incorporating 2” x 2” square tubing stringers formed to follow the shape of the grass elements and welded in between each opposing element and to the top and bottom frames.

Marine grade aluminum was chosen for its ability to withstand the salt air environment. 64


November/December 2007

Excellence in Traditional Components


The gates near completion outside the shop at Artisan Metal Works. LOWER: The finished gates are installed at Salt Creek.





The gate was finished using an etching primer followed by a brass based top coat accented with a gold wash which was then chemically initiated to patina in two different tones of green and blue.

5 Installation

Installed, the gates operate between two large stone pillars and act as the welcoming feature to the Salt Creek Community.

Karoly credits his shop crew of five â&#x20AC;&#x201D; Richard Kentish, Desmond Graham, SzĂścs GyĂśrgy, Herculand Rodrigues, and Dante Pommels â&#x20AC;&#x201D; for the quality work, such as the Salt Creek project, produced by Artisan Metal Works. â&#x20AC;&#x153;They are doing a great job. Without their hard work, this company would not be successful,â&#x20AC;? he says. November/December 2007 







Biz Side

Promoted to management? Learn the three crucial rules  You’re a talented,

proficient worker. Here’s how to make the transition to managerial excellence. By Martin Seidenfeld, Ph.D. When employees in the metalworking

industry are very good at what they do, chances are they’ll get promoted into management positions. But that produces a dilemma, for while they probably have had many years of practice to become good at metalworking, they probably had had very little, if any, training in how to manage others. Learning to be a manager – the hard way As a psychologist in a mental health center, I was generally considered competent and effective. So, when an opening arose for the Chief Psychologist position, I was urged to apply and eventually got the job. Not only was I was pleased and excited about my new status and the increased pay, but I felt this would be my chance to be something special, a really, really good “boss.” Was I ever mistaken! Even with the best intentions, I proceeded to make mistake after mistake. In a fairly short time I found myself isolated, alienated from my staff, frustrated, angry, and terribly unhappy. I had fallen into the traps that many first-time managers do, whether they are in high-level professions, skilled trades, or business. 66

Eventually, I did become a reasonably competent manager. But as a psychologist, while serving in a businessoriented psychological consulting firm, I noticed how my experiences were similar to those of many other people, in many different fields. The best nurses became nursing administrators, the best lawyers became managing partners, and so on. I reflected on my experience and did some research, and came to understand the process of how people develop from worker proficiency to managerial excellence.

giants speak a foreign language — you can’t really understand what they’re saying, and they can’t understand you. Furthermore, in this world of giants, everything is built to their scale, so you are completely dependent on them. For example, you are thirsty and see a sink. But the taps are way up out of your reach and the glasses are too large for you to grasp. Fortunately, some of those giants sense your needs and get you some water. Mostly, though, they just ignore

The psychology of manageremployee relations The most important thing I learned was that, at a profound psychological level, managers are not seen as “normal” human beings — and, therefore, cannot be treated as such. The reasons for this are complex and rooted in our very nature as human beings. To better understand this, let’s go on an imaginary trip. Imagine that you live in a world of giants. Close your eyes and visualize a world in which everyone around you is a giant, perhaps 18 to 20 feet tall. You have to crane your neck to see their heads. You can walk through their legs without crouching. These

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you . . . which is okay. Of course, your big worry is that the giants might become angry with you. In that case, you’d be in serious trouble. Pretty intimidating, isn’t it? Perhaps you recognize this world. It’s where you lived when you were two or three years old and only came up to your parents’ mid-thighs. Consider this important fact about our species, homo sapiens. As infants, we are just about the most helpless of all newborns. Unlike a baby fish that can swim and provide

for its own nutritional needs from birth, we are dependent for nutrition on adults. A common songbird might be fed in the nest for a few months and most large mammals can get along and feed themselves within a year of their birth. Now, think about humans. How old must a human be in order to be able to survive on its own? Certainly, we’re talking about many

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years. So, we must ask: having lived for many years in a state of total inferiority, total inadequacy, and dependent on friendly giants in a life-or death way, do we ever get completely over it? Perhaps not. Supervisors are giants I believe we retain some vague memory-sense of that early condition so that, when we must interact with “giants,” such as parents — or parental figures, like our supervisors — we again feel some of that sense of smallness and, yes, fearfulness. Such unconscious memories continue to affect us. So, when your supervisor, who is probably a perfectly decent, normal human being, asks you to “please step into my office,” something happens. We don’t simply accept his invitation as one normal adult talking to another. An element of anxiety creeps in. Now, you are the giant Most people recognize that they feel some unease when dealing with their supervisors. It is much harder to accept that your employees react to you, the new manager, as the giant and, at some level, fear you. Your employees have a special regard for you, and it isn’t always positive. You are always watched very closely because you are perceived as powerful. In fact, you do have some significant power over them: you determine their work assignments, conduct their performance assessments, and could significantly affect their careers. But your power tends to be vastly exaggerated. This exaggerated concern about you has both positive and negative consequences. Keeping in mind that you will always be perceived, to some extent, as a “giant,” we can now examine the three crucial principles new managers must appreciate and accept.

Supervisors’ behavior and 1.attitudes will be emulated. 10600 Telephone Rd., Houston, TX 77075 Phone 713-991-7600 Fax 713-991-0022 Toll Free 1 (888) 380 - 9278

On the positive side is the fact that if you are enthusiastic, show enthusiasm for your products, work hard, demonstrate belief in your company’s high standards, and generally show a Fabricator 

November/December 2007

strong work ethic, you are miles ahead toward building an effective work force. Your work ethic will be the ones adopted by your employees. On the negative side is the fact that every behavior of yours is observed and studied and tends to be overinterpreted, not always desirably. For example, if you take off early, or take an extra long lunch break (and your employees do not know that it is for a good, solid business-related purpose), they will assume that goofing off is okay. If you keep a messy work station, it will be assumed that neatness doesn’t really count. You are the model and set the standards, and how you behave will become the organization’s norms.

2. Supervisors cannot be buddies with their employees.

The single biggest complaint about managers is that they are not fair, or have pet employees. This pitfall can be avoided by remembering this second crucial management principle. As a normal human being, you will feel closer to some of your employees than to others, because of your common backgrounds or interests or life styles or personalities. Naturally, you would tend to befriend them as you would if they were merely coworkers. But because you are their supervisor this would be extremely unwise. Because you work closely together, relationships inevitably develop. The trick is to be friendly, sympathetic, interested in each of your employees as unique individuals — and yet retain carefully structured “formal” relationships with each of them.

. Supervisors must organize and lead others to per3themselves. form specific tasks, rather than always perform them A manager’s job is to get things done through others. Your energy must shift from focusing on specific tasks to focusing on leadership tasks. As an employee, your performance is assessed on the basis of how productive you are. But as a manager of others you are assessed on the basis of how well your work unit performs. Therefore, it makes sense to help your workers to become more proficient and productive, rather than to focus on your personal productivity. Let’s say you head a department of five employees — four workers and yourself. If, by dint of tremendous effort you were able to increase your personal productivity by 20 percent, which would be an amazing leap forward, you would have increased your five-person unit’s overall productivity by 4 percent. But suppose, instead, you worked with each of your employees so that, on the average, they each increased their productivity by just 5 percent. In that case you would have increased your department’s overall productivity by 20 percent! It’s not hard to see which is the better strategy. November/December 2007 


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familiar tasks becomes your security blanket. You also well might be tempted to avoid exercising leadership, a skill with which you have had little experience and about which you feel you have little expertise. Nonetheless your essential focus must shift from doing the work yourself to managing the work of others: organizing, planning, motivating, and leading them. Realistically, first line supervisors, and even higher level managers, are often expected to do some of the


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hands-on, basic work. But all too frequently, new managers use this fact as a cop-out and rationalization to continue doing basic tasks and largely ignore their managerial responsibilities. To the extent that a manager does the basic work he or she is not truly functioning as a manager since, by definition, a manager is someone who gets things done through others. As a manager you need to realize that your future career growth almost certainly will depend on your ability to manage others effectively. This is the skill set which will lead you to be promoted into higher management levels. If you merely remain a proficient worker, you will continue to be a worker, even though you have the management title. One interesting manifestation of mangers hanging onto their basic skills, to the detriment of their career development, is their reaction when a new person is hired who is even more technically proficient than they are. As time goes on, this is quite likely to happen, since new hires may be more up-to-date on the latest ideas and techniques. Instead of feeling threatened, and perhaps trying to outdo the new employee, wise managers will count their blessings and see how the new team member will help the department move ahead — to the manager’s credit. The bottom line Becoming a manager is not easy, and most don’t make the cut to move into higher levels of management. By remembering and using the three crucial principles outlined here you can increase your chances to be a truly successful manager.

Martin Seidenfeld is a Boise, IDbased psychologist with over 30 years experience as an organizational consultant, clinician, professor, trainer, and author. His book, Talk About Stress, was published in 2000, and his articles have appeared in several national publications. Visit his web site, Fabricator 

November/December 2007

Biz Side

The new feudal society  Here’s how to prosper in the coming age of

poverty and privilege. By Sanford Kahn There is an old saying that goes something like this — what goes around comes around. This saying is plausible, but not entirely correct. What goes around does come around, but in a different shape and form. To more fully appreciate this new “feudal society” we will be entering, we must first examine where we have been and the consequences flowing from that time and place. The period from about 1995 to 2000 was a very unique interval in our economic/business history. The economic events that occurred in this time period happen, at most, twice in a century. This period of time is called a “founders economy,” and the years l995 to 2000 comprised the first stage of this founders economy. It is a time of fundamental and rapid technological and economic transformation of society. The transformation is permanent, and it seems to defy the laws of economic gravity. The last such period occurred in the l920’s. This resulted from the conNovember/December 2007 


fluence of the rapid electrification of the U.S. along with the mass introduction of the automobile. The first stage of a founders economy ends in a bubble... and it does pop. When it does, the second stage is called the “blood in the streets” phase. We are in that phase now and it will dictate our new social and economic environment. The term “blood in the streets” does not necessarily imply actual corporal fighting. Rather, it means an intense period of business competition. This second stage can easily last 15 to 20 years. It continues until the weak business enterprises are filtered out. The difference now, compared to the previous founders economy, is that not only do you have intense business competition within our national borders but also internationally. The Internet, along with inexpensive communication and transportation costs, has helped to transform the international marketplace. In this second phase, how companies compete and price their goods and services will give rise to the new

business “serfs” and “lords” — the new feudal society. From the end of World War II till the late l990’s, companies generally used the cost-driven model to price their product or service. In this model, a company added up all their

For your information Free Cash Flow (FTCF):

 is what a company has left over at the after paying for all the salaries, bills, interest on debt, and taxes and after making capital expenditures to expand the business.

 gives an investor the insight as to how heavy or light a company's business model is and how clearly it shows a company's ability to reward investors.  is not perfect, but it is more difficult to manipulate than net income or earnings per share.  is simple to caculate; just subtract capital expenditures from cash flow from operations. Source: The Motley Fool;


costs to produce a product or service and then tacked-on a competitive profit margin. This determined the price at which to sell their product or service. Most of the time, it worked. It is in this second stage of intense business competition that the traditional cost driven model breaks down. Competition is intense because dramatic worldwide increases in productivity have led to too many goods chasing too little demand. Companies

now have very little pricing power and must use a price driven model of pricing. This model answers the question: what price will cause my firm’s product or service to clear the market, give me a competitive advantage? It is usually a lower price than the cost driven price, but with that comes less competition. Once you determine the price of your product or service with the price driven model, you do everything in

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your power to slash all costs. This includes labor, medical, inventory, material, and any other expense than can be cut. No cost is sacred — you have to reduce all expenses to stay competitive.

The future belongs to those

individuals (lords) that have the intellectual acumen to anticipate and the wherewithal and flexibility to take advantage of developing opportunities.

It is this second phase of the founders economy that will give rise to the new business “lords” and “serfs.” The new lords will be those business people who can quickly discern, adapt to, and exploit the unpredictable movement in the turbulent flow of life. The new lords will be those business people who have as their target the goal of growing the free cash flow of their business. This cash flow represents the means, the wherewithal, for those shrewd business people to take advantage of opportunities and events that present themselves. By growing the free cash flow of a business, not only do you increase its value, but also you provide it with the means to maintain its market share and possibly increase it. On the other hand, the new “serfs” are those businesses that are mired in debt and illiquidity. If they stay this way, they will travel down the road to extinction. You could be the smartest business manager alive, but without the free cash flow (the financial means), it will be difficult to capitalize on opportunities in this second phase. Having an ample free cash flow allows you the opportunity to take business risks and survive the possibility of failure. It also allows you to hire the talent necessary to grow your business and expand your market share. In the old feudal society (circa 1200 AD), everything was rather constant. Fabricator 

November/December 2007

If you were born a serf, that is where you stayed. If you were born a lord, that is where you belonged. In the new feudal society nothing is constant. Through luck, change of management focus, and acquisitions it is very possible that business serfs can become lords. Conversely, if business lords should lose their focus and become complacent in this extremely competitive phase, they could stumble down the path toward serfdom. Lastly, one must keep in mind that the novel conditions with which busi-

nesses now have to deal to remain viable entities in the coming decades will have a seismic impact on the social order and the expectations prevailing among the individuals who make it up. The future belongs to those individuals (lords) that have the intellectual acumen to anticipate and the wherewithal and flexibility to take advantage of developing opportunities. The serfs are maladroit and floundering in debt. It will be difficult for them to seize opportunities. The second phase of the founders

economy will be more turbulent than that which preceded it. But, therein lies the opportunity for those who can and wish to be lords. Out of turbulence comes the potential for growth. To paraphrase Mel Brooks — it is good to be a business lord. Sanford Kahn is a business author and speaker. For more information on his programs please e-mail:, or visit his web page at

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

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November/December 2007

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New NOMMA members As of October 5, 2007. Asterisk denotes returning members.

Abel Engineering Fabrications Ltd.* Midlothian, United Kingdom Derek Glasgow, Fabricator AST Waterjet* Irving, TX Tony Woodall, Regional Supplier

Blue Ridge Welding & Forge LLC Rixeyville, VA Terrence F. Gooding, Fabricator

Dave’s Welding & Metal Fab. Inc. West Fargo, ND Dave Lynnes, Fabricator Delta Fabrication Inc. West Monroe, LA Steve Eyre, Fabricator

First Impression Security Doors Inc. Gilbert, AZ Tim Cornelius, Fabricator Loyal Wrought Iron Co. Ltd.* Guangzhou, PR China James Yan Xiaojin, Fabricator Mandos Metals Corp. Ft. Myers, FL Bill Mandos, Fabricator

Michael Wentworth Architectural Metalwork Berkeley, CA Michael Wentworth, Nationwide Supplier

Midwest Stairs & Iron Inc. Saint Francis, WI Howard Wurgler, Fabricator

Northstar Steel & Orn. Supply Inc. Gilbert, AZ Jimmy Lindblom, Regional Supplier Pendragon Specialties LLC Elkhorn, WI John Bashaw, Fabricator

Shickel Corp.* Bridgewater, VA Mark Shickel, Fabricator

Silver State Steel Distribution & Supply Las Vegas, NV Justin Alexander, Regional Supplier Tacoma Iron Work Tacoma, WA John Leskajan, Fabricator

Wheeler Ornamental Metals Dothan, AL Henry Wheeler, Fabricator

NOMMA Nationwide Supplier Members A Cut Above Distributing (800) 444-2999 Alloy Casting Co. Inc. (972) 286-2368 American Punch Co. (216) 731-4501

D & D Technologies (USA) Inc. (714) 677-1300

D.J.A. Imports Ltd. (718) 324-6871

DAC Industries Inc. (616) 235-0140

American Stair Corp. (800) 872-7824

Decorative Iron (888) 380-9278

Apollo Gate Operators (210) 545-2900

Eagle Bending Machines Inc. (251) 937-0947

Ameristar Fence Products (918) 835-0898 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

Builders Fence Co. Inc. (800) 767-0367 Byan Systems Inc. (800) 223-2926

C.R. Laurence Co. Inc. (800) 421-6144 Carell Corp. (251) 937-0948

Carl Stahl DecorCable Innovations (800) 444-6271

DKS, DoorKing Systems (800) 826-7493 Eastern Metal Supply (800) 343-8154

Eastern Ornamental Supply Inc. (800) 590-7111

Elegant Aluminum Products Inc. (800) 546-3362 Elite Architectural Metal Supply LLC (547) 636-1233 Encon Electronics (800) 782-5598

Euro Forgings Inc. (905) 265-1093

EURO-FER SRL. (011) 39-044-544-0033

FabCad Inc. (800) 255-9032

FabTrol Systems Inc. (541) 485-4719

Feeney Architectural Products, CableRail™ (800) 888-2418

Classic Iron Supply (800) 367-2639

Frank Morrow Co. (401) 941-3900

CML USA Inc. (563) 391-7700

Gerhard Glaser GmbH & Co. (011) 49-607-893-7137

Cleveland Steel Tool Co. (800) 446-4402 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

Geo. Bezdan Sales Ltd. (604) 299-5264 Glasswerks LA Inc. (323) 789-7800

Grande Forge (Asia) Sdn Bhd (011) 65-6-235-9893 GTO Inc. (800) 543-4283

Hartford Standard Co. Inc. (270) 298-3227

NOMMA Nationwide Supplier Members, continued Hayn Enterprises LLC (860) 257-0680

Mac Metals Inc. (800) 631-9510

Sculpt Nouveau (760) 432-8242

Hendrick Mfg., Perforated Metals Div. (570) 282-1010

Master Halco (714) 385-0091

Sharpe Products (800) 879-4418

Hebo/Stratford Gate Systems Inc. (503) 722-7700

House of Forgings (281) 443-4848

Illinois Engineered Products Inc. (312) 850-3710

Marks U.S.A. (631) 225-5400

McKey Perforating (262) 786-2700

Michael Wentworth Architectural Metalwork (925) 216-1004

Industrial Coverage Corp. (631) 736-7500

Mittler Bros. Machine & Tool (800) 467-2464

Industry Ornamental Iron Inc. (800) 915-6011

Mylen Stairs Inc. (914) 739-8486

Industrial Metal Supply Co. (818) 729-3333

Innovative Hinge Products Inc. (817) 598-4846 Interstate Mfg. Associates Inc. (800) 667-9101 ITW Industrial Finishing (630) 237-5169

Multi Sales Inc. (800) 421-3575

New Metals Inc. (956) 729-1184

Ohio Gratings Inc. (330) 477-6707

Overseas Supply Inc. (281) 776-9885

ITW Ransburg (419) 470-2000

Paxton & Thau Artistic Supply (205) 290-2790

Julius Blum & Co. Inc. (800) 526-6293

Procounsel (214) 741-3014

Jansen Ornamental Supply Co. Inc. (800) 4-JANSEN Justin R.P.G. Corp. (310) 532-3441

King Architectural Metals (800) 542-2379 King of the Ring (305) 819-2256

L.E. Sauer Machine Co. (636) 225-5358

Laser Precision Cutting (828) 658-0644 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

Precision Glass Bending Corp. (800) 543-8796 RedPup LLC (928) 422-1000

Regency Railings Inc. (214) 742-9408

Riata Mfg. (915) 533-9929

Robert J. Donaldson Co. (856) 629-2737

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

Scotchman Industries Inc. (605) 859-2542

SECO South (888) 535-SECO Stairways Inc. (713) 680-3110

Steel Masters Inc. (602) 243-5245

Stephens Pipe & 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 The Cable Connection (800) 851-2961 The G-S Co. (410) 284-9549

The Iron Shop (800) 523-7427

The Wagner Companies (888) 243-6914

Transpacific Industrial Supply Inc. (909) 581-3058 Triple-S Chemical Products (800) 862-5958

Tri-State Shearing & Bending (718) 485-2200 Universal Entry Systems Inc. (800) 837-4283

Vogel Tool & Die, Div. of TES Tube Equipment Inc. (630) 562-1400 Wasatch Steel Inc. (888) 496-4463

West Tennessee Ornamental Door (901) 346-0662

Wrought Iron Concepts Inc. (877) 370-8000

What’ s Hot Inside Biz Briefs . . . . . . . . . . .78 Chapter News . . . . . . .82 Events . . . . . . . . . . . . .84 People . . . . . . . . . . . . .86

Literature . . . . . . . . . . .87 New Products . . . . . . .88 Classifieds . . . . . . . . . .92

The Chamberlain Group, Elmhurst, IL has upgraded its dealer extranet Web site to include new and enhanced features. The new site gives dealers additional tools to run more efficient and profitable businesses. The dealer extranet is full-service and passwordA celebration of the village blacksmith.

9” x 11”, 765 pgs., 3000+ drawings $124.00 plus $6.50 s&h

protected to allow Chamberlain’s professional dealers to stay connected to important account information. Contact: Chamberlain, Ph: (800)528-5880; Web:

Wagner implements laser scanning system Laser Design Inc., supplier of 3D laser scanners announces the sale of a Surveyor DM-1620 3D laser scanning system to Wagner Spray Tech, Inc., a Minneapolisbased company that specializes in spray paint technology. Wagner will use the system to improve the quality inspection process for the injection-molded plastic parts they manufacture. “Laser Design has hundreds of system installations around the world that are instrumental in supporting engineering, manufacturing, and engineering applications in many industry sectors, such as aerospace, automotive, and telecommunications, just to mention a few,” according to C. Martin Schuster, President of Laser Design. “We are very proud of our leadership role in the industry, helping our customers streamline and improve their manufacturing and inspection processes.” Contact: Wagner, Ph: (888) 243-6914; Web:

Chamberlain launches enhanced dealer extranet site

This Coming ! g in r p S

Biz Briefs

A ‘must have’ for every blacksmith’s library - Tal Harris


8” x 10”, 199 pgs., 532 photos/drawings $45.00 plus $3.50 s&h

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November/December 2007

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Biz Briefs

Coalition encourages code officials to improve public safety The “Raise the Profile” Coalition, a national coalition, will undertake the goal to educate the public, industry, and elected officials about the critical role code officials play in improving the level of safety in the built environment. The coalition, committed to creating awareness about the important role code officials play in making everyday life safer, is made up of building safety professionals, trade associations, manufacturers, consumers, and other stakeholders committed to improving public safety by raising awareness of code officials’ roles. The application of contemporary codes has dramatically improved the level of safety in buildings and their environs. To maintain and enhance the level of safety America has today, the “Raise the Profile” Coalition advocates raising the profile of code officials. Coalition also promotes continuing improvements to codes, standards (building, electrical, fire, HVAC, plumbing, property maintenance, zoning, environmental, etc.), and the regulatory system to administer them. Contact: International Code Council, Ph: (888) ICCSAFE; Web:

unchallenged, subcontractors, home builders, and other builders would have been left to defend themselves against lawsuits for accidental injuries and property damage that they thought were covered by their CGL policies. For more information, log onto and click on “Subcontractor Advocacy.”

CML has new location CML USA Inc., manufacturer of tube, pipe and profile bending machinery, has moved. The new address is 3100 Research Pkwy., Davenport, IA 52804. Ph: (563) 391-7700; Web:

Industry Ornamental switches to Metal Master Finishes

ASA prevents insurers from denying accidental damage coverage The Texas Supreme Court handed subcontractors, home builders, and others in the construction industry a precedent-setting victory in an Aug. 31, 2007, decision concerning the coverage provided by a common type of commercial general liability (CGL) insurance policy. The decision denies an insurer’s argument that a home builder’s CGL policy does not cover accidental property damage caused by a subcontractor’s allegedly defective work. The American Subcontractors Association Inc. (ASA) and ASA of Texas Inc. (ASAT) joined other construction trade associations in the state in filing two “friends of the court” briefs in the case in 2005 and 2006. “If the Texas Supreme Court had decided in favor of the insurer, a lot of subcontractors and other businesses would have been looking at their CGL policies and wondering exactly what it is they bought,” said 2007-08 ASA President David H. Bradbury, Precision Concrete Construction Inc., Alpharetta, Ga. “ASA and ASA of Texas presented subcontractors’ view that insurance should be applied fairly and with common sense. One of the points we made was that if damage is accidentally caused where there’s a construction defect, that alone isn’t a reason for denying coverage. The insurance policy didn’t contain that exclusion, so ASA believes the Texas Supreme Court came to the right conclusion.” Had the district court’s decision remained successfully November/December 2007 


Industry Ornamental Iron Inc., a provider of high-end gates for the industry, has switched its finishing system from powder coating to the Metal Master finish system, which is sold by Sumter Coatings Inc. The Metal Master product meets the demands of the most corrosive environments. According to a company spokesperson, the new finish product now allows Industry Ornamental to compete for the southeastern coastal business, which was formerly the domain of aluminum products. Metal Master is a durable epoxy primer/acrylic urethane top-coat system that is comparable to a baked on factory finish. Industry Ornamental is also using another Sumter product, NuCharge It Epoxy Rust Inhibitive Primer, which contains zinc in the dried film giving the surface added protection. Once cured this product has a durable impervious film that makes it a great rust inhibitive primer. A third Sumter product that is being used, NuCharge A-Thane, is a two-component acrylic urethane that combines superb corrosion and UV protection resulting in exceptional gloss retention and weathering ability. Contact: Industry Ornamental Iron Inc., Ph: 800-9156011 ext 701; Web: 79

Biz Briefs

Whatâ&#x20AC;&#x2122; s Hot

Whatâ&#x20AC;&#x2122;s your fluid dynamics IQ?

oped a Fluids IQ Test. The test consists of 17 questions and, on the average, requires 10 minutes to complete. Upon completing the Fluids IQ Test, participants will be able to see their score and how it compares against their peers who have also taken the test. The test is available online at

A recent Flomerics survey investigating the opinions of mechanical design engineers on Computational Fluid Dynamics (CFD) analysis revealed that the vast majority (75 percent) of mechanical designers have heard of CFD. However, the same survey revealed that 80 percent of mechanical design engineers are not currently using CFD. Many have a working knowledge of the basic principles of fluid flow and heat transfer, but may not be aware of that fact. To help design engineers test their understanding, Flomerics has devel-

PMA Business Conditions Report According to the September 2007 Precision Metalforming Association (PMA) Business Conditions Report, metalforming companies expect business conditions to remain fairly steady during the next three months. The report is an economic indicator for manufacturing, sampling 159 metalforming companies in the United States and Canada. When asked what they expect the trend in general economic activity to be over the next three months, 28 per-

cent of participants reported that conditions will improve, 53 percent predict activity will remain the same, and 19 percent anticipate a decline in business conditions. Metalforming companies expect incoming orders to dip slightly during the next three months. Just 36 percent of respondents forecast an increase in orders, 44 percent expect no change, and 20 percent anticipate a decrease in orders. However, current average daily shipping levels compared to the past three months improved in September. Thirty-two percent of companies reported that shipping levels are above those of three months ago, 39 percent reported no change, and 29 percent reported that September levels are below those of three months ago. The number of companies with a portion of their workforce on short time or layoff decreased to 11 percent in September, down from 13 percent in August. Contact: PMA, Ph: (216) 901-8800; Web:

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Biz Briefs

New wholesale hardware and access controls company

panels and Italian-designed stair components. TSD ships nationwide. Contact: TS Distributors; Ph: 800392-3655; Web: www.tsdistributors. com.

ASM joins global community information network

Triple-S Steel Supply has created TS Distributors (TSD), a company which will focus on delivering ornamental metals, access controls, fabrication supplies, tools, and accessories to metal fabricators, contractors, and welding shops across the nation. Located in Houston, TX, TS Distributors opened the doors to its 80,000 sq. ft. facility earlier this year. TSD has one of the largest, most complete inventories in the industry, including ornamental metal basics, hard-to-find parts, and new exclusive products such as prefabricated fence

Don’t miss out on NOMMA’s 50th anniversary celebration at METALfab 2008!

Join us where it all began... in Memphis, TN April 1-5, 2008. Highlights include the annual Top Job Competition, educational sessions, trade show, shop tours, and more. Details are available on NOMMA’s website:

November/December 2007 


ASM International unveiled an interactive and customizable website for members of the Heat Treating Society (HTS). The website for HTS, an ASM affiliate society, is the third of many new community websites being launched during an 18-month period as ASM, its affiliate societies and chapters work to create a global community information network. The launch was announced during ASM’s 25th Conference & Exposition. “The mission of HTS is to be the leading global source for heat treating information and networking, and with this new community website, we are

providing unprecedented content and capabilities to heat treating professionals worldwide,” said HTS Past President Bill Bernard. Contact: ASM International, Ph: (800) 336-5152; Web:

KUKA donates robots to Steel Fun Factory KUKA Robotics Corporation has donated two KUKA 6-axis robots the States Steel Fun Factory exhibit located at the Detroit Science Center. The new exhibit features hands-on exhibits for all ages where visitors can learn how a variety of manufacturing processes turn an idea into reality with the help of computer design, prototypes, simulations, conveyors, robots, statistics, and more. The Detroit Science Center features 110,000 square feet of scientific exploration. Contact: Detroit Science Center, Ph: (313) 577-8400; Web: www.detroit

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November/December 2007

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Miller’s Ultimate Workshop Giveaway Ongoing through December 31, 2007 Miller will be giving away the Ultimate Weldshop valued at more than $17,000. The Ultimate Weldshop Giveaway includes a welder/generator, welding and plasma cutting power sources, auto-darkening helmet, safety gear, welding accessories, and personalized expert training. The Giveaway runs October 1 through December 31, 2007, and offers participants the opportunity to win more than 1,300 Instant Win prizes, including welding and plasma cutting equipment along with related accessories and gear.

For more information and online registration, log on to

ASA Business Convention and Forum

RAPID 2008 makes a move to Florida SME Conference Call for Speakers Open The Society of Manufacturing Engineers’ (SME) RAPID Conference

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and Exposition heads to Disney’s Coronado Springs Resort and Convention Center in Lake Buena Vista, Fla. on May 20-22, 2008. This rapid technologies and additive manufacturing event highlights the latest advances and provides an opportunity for industry experts to reach manufacturing professionals involved in product design and development. Contact: SME, Ph: (800) 733-4763; Web:

The American Subcontractors Association (ASA) will hold its Business Convention and Forum, March 6-8, 2008 at the Francis Marion Hotel in Charleston, SC. The event is open to subcontractors, suppliers, and service providers in the construction industry. Contact: ASA, Ph: (703) 684-3450 Web:



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IMTS 2008

Upcoming Events November 3-5, 2007 Expanded Metal Manufacturers Association (EMMA) Fall Conference

The Association for Manufacturing Technology (AMIT) will hold its annual IMTS (International Manufacturing Technology) September 8-13, 2008 at McCormick Place in Chicago, IL. This is the 27th anniversary of the annual event. IMTS brings together the worldwide manufacturing community to showcase the latest innovative technologies in metalworking equipment and services. More than 1,200 exhibiting companies will occupy 1.2 million net square feet of exhibit space. Buyers and sellers from over 100 counties will exchange business and technical knowledge. The show attracts more 90,000 buyers and sellers from 119 countries. Contact: Association for Manufacturing Technology, Ph: (703) 827-5252, Web:

EMMA will hold its Fall Conference at The Radisson Hotel, Chicago, IL. There will be trade shows as well as networking opportunities. Contact: NAAMM Headquarters, Ph: (630) 942-6591 Web: February 5-7, 2008 FENCETECH and DECKTECH 2008

FENCETECH ‘08, the American Fence Association’s annual convention and trade exhibition, will take place alongside AFA’s DECKTECH trade show at the Mandalay Bay Convention Center, Las Vegas, NV. More details and registration information can be found on AFA’s Web site. Contact: American Fence Association, Web: www.american May 2-3, 2008 Americas Glass Showcase

The annual trade show, convention, and golf tournament — sponsored by Americas Glass Association, Independent Glass Association, and International Window Film Association — will take place at the Cashman Convention Center, Las Vegas, NV. The Golden Nugget is the host hotel. Contact: Americas Glass Association, Ph: (877) 275-2421; Web:; Email:



WOODWARD-FAB.COM 800-391-5419 November/December 2007 



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Wagner announces staff changes

Chamberlain hired Hegedus LEFT: Christine Heiden RIGHT:

Jeni Kultgen

The Wagner Companies has promoted Christine Heiden to the position of Estimator/Customer Service Representative for the Systems team. She will be responsible for estimating Wagnerail™ projects and serving the needs of Railing Systems customers. In addition, Heiden will be involved with order entry and maintenance to support Wagner railing systems business. Jeni Kultgen has joined the com-


pany as a Staff Accountant and will be responsible for maintenance of the general ledger, preparing financial statements, account reconciliation, and other general accounting duties. She will also supervise the daily activities of accounts payable, accounts receivable, billing, and accounting services. Contact: Wagner, Ph: (888) 2436914; Web: www.wagnercompanies. com.






Mike Hegedus has been hired as the vice president of supply chain management for The Chamberlain Group Inc. Prior to joining Chamberlain, Hegedus was employed at Elcoteq Inc. in Espoo, Finland as global director of supply chain management. “Mike brings significant technical, management, and leadership skills to this important position,” said Robert Durazo, executive vice president, operations, The Chamberlain Group, Inc. “His background and training makes him an ideal fit for this role, and we are looking forward to his contributions.” Contact: Chamberlain, Ph: (800)5285880; Web:

Ey Joins Makino

LEFT: Andrew Ey


AFA B Booth ooth 1315


MORE THAN PRODUCT 8 0 0 - 78 2 - 559 8


Andre Ey has joined the Die Mold Technologies Group at Makino, Auburn Hills, MI. “Ey’s position will focus on both the business execution and the strategic goals of our Die Mold Group,” said Don Lane, CEO of Makino. “His experience and abilities will serve Makino well.” Andre Ey has 18 years experience as a senior executive at global manufacturers, both in management and marketing. His leadership has shown an ability to create and execute strategic plans, drive business growth, and boost revenues and profitability. Contact: Makino, Ph: (800) 5523288; Web: Fabricator 

November/December 2007


Jim Wallace

November/December 2007 




What’ s Hot

Door and window hardware catalog

Dust collection capabilities brochure

The ‘CRL83’ Door and Window Hardware Catalog is the fifth in a current series of six hard cover Master Catalog publications, comprising a line of more than 38,000 products. It can be used as a stand-alone or in conjunction with CRL’s Online Catalog and web-based services at The six Master Catalogs present the company’s products in an easy, organized format, tailored to customers’ needs and the industries they serve. Contact: CRL, Ph: (800) 421-6144; Web:

A new 24-page brochure from Farr Air Pollution Control (APC) showcases the company’s extensive capabilities in the design and manufacture of dust collectors for a wide range of processes. It describes how Farr APC dust collection systems solve dust challenges for the following industries and applications: blasting, chemical processing, custom OEM, fiberglass and FRP, food processing, laser and plasma cutting, metal grinding, mining, paper scrap, pharmaceutical, rubber grinding, seed processing, thermal/flame spray, welding, and woodworking. The brochure also includes an overview of the popular Farr “Gold Series®” cartridge collector, which carries a 12-year warranty and comes equipped with award-winning HemiPleat® filter technology. Cartridge filters for retrofit solutions

TUBING BENDERS Hand Tube Bender Rolls: ! 1 1/2” Square Tubing ! 1 x 1 1/2” Rectangular Tubing ! Flat Bar (1/2 x 1 1/2” & smaller) ! Pipe & Tubing


„ „ „ „


New UNILOAD™ catalog from AAC Advanced Antivibration Components (AAC) of New Hyde Park, NY introduces a new vibration mount catalog, “UNILOAD™ Constant Natural Frequency Mounts, V105.” These new patented mounts automatically adjust their stiffness in response to load. CNF Uniload™ mounts can be used without any calibration for a wide range of loads. The catalog includes a nine-page technical article explaining the unique features of these mounts, and metric sizes as well as quantity pricing for these mounts. Contact: AAC, Ph: (516) 328-3662, Web:


Magnum Hand Tube Bender Rolls:

are also described. Contact Farr APC, Ph: (800) 4796801; Web:

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

# 2” Square Tubing 1 x 2” Rectangular Tubing Flat Bar (1/2 x 2” & smaller) " Pipe & Tubing Additional Rollers Available


Call for Free Catalog - 800/446-6498

Works with both hand tubing benders

Cap Rails



! Flat Bar (on edge hard way) R&D Hydraulics, Mfg. and Machine Co.

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

1431 West 5th St. Chico, CA 95928



November/December 2007

New Products

What’ s Hot 50-ton turret ironworker

SCOTCHMAN® Scotchman® Industries is pleased to feature the 5014 TM Ironworker in its “Metal Fabricating Solutions.. The 5014-TM has 50 tons of pressure and the ability to punch a 13 /16” hole in a 3/4” plate. The 5014 TM features a three-station revolving turret that accepts up to three pieces of tooling. Product includes an angle shear that can shear up to 4” x 4” x 3/8” angle iron and a flat bar shear that can shear 3/4” x 4” to 1/4” x 14”. The 5014 TM also features a rectangle notcher that will notch up to 21 /2” x 3” in 5/16” material. With its component tool table design, it has the ability to accept optional equipment, such as the 12” press brake, rod shear, square tube shear, picket tools, pipe notcher, and special tooling.

November/December 2007 


Contact: Scotchman® Industries, Ph: (800) 843-8844; Web: Mobile, fully-adjustable welding table

Strong Hand Tools™ The NOMAD™ Economy Welding Table by Strong Hand Tools™ is designed to move easily throughout the workplace — it folds for portability, serves a variety of applications, and weighs 44 lbs. The table height is adjustable and its steel tabletop tilts to three positions: horizontal, 30°, and folded. Three 1.1” (28mm) slots in the 30” W x 20” D tabletop allow clamps to be inserted at any point, for greater “reach.” Contact: Strong Hand Tools,™ Ph: (800) 989-5244 ; Web:

Fast cutting saw blades

Pat Mooney Inc. Pat Mooney’s Kanefusa Saw Blades allow material to be cut faster and with less material loss due to kerf. The tooth geometry of Kanefusa blades points to lower cutting forces, high blade RPM, high resistance to chipping, and good swarf curling. Consisting of cermet or tungsten carbide, these teeth have a longer edge life than metal or band saw blades. To ensure that plates are free from distortion and have uniform thickness, Kanefusa Saw Blades are precisionflattened and ground. Unique plate processing results in run out of less than 30 microns for enhanced cut quality and a longer blade life. A variety of Kanefusa Saw Blades are offered (ST-4, Ti-4 and TA-4SUS) for cutting bearing steel, drive shafts, rails, pipes, and more. Contact: Pat Mooney, Ph: (800) 323-7503; Web:


New Products

What’ s Hot Cast aluminum furniture legs

Outwater Plastics Industries & Architectural Products By Outwater Outwater offers its new designer series of cast aluminum furniture legs in an array of designs, sizes, and finishes to suit a broad range of aesthetic tastes and applications. Available in satin chrome, bright chrome, and matte nickel finishes, with heights ranging from 4” to 151/4”, furniture legs are designed with incorporated rubber foot bumpers to prevent furniture from sliding and protect floor surfaces.

Contact: Outwater, Ph: (888) 7721400; Web: Customizable extrusion table plates

Techno Techno’s new line of aluminum extrusion table plates are available in 1, 2, or 3 meter lengths and widths that range from 75mm to 375mm. The table makes fixturing easy and removes the


410-933-8500 WWW.COMEQ.COM 90 t yco s drive toronto, ontario m6b 1v9 tel: 1-800-461-0060 tel: (4 16) 780-1707 fax: (4 16) 780-1814 e-mail: www. steptoewife . com

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™


need to drill and tap. The T-slot design allows more space to change to new setups and the slots run the length of each table plate. A variety of competitor profiles and extrusions can be used with this product. Contact: Techno, Ph: (516) 3283970; Web: New brush-on blackener

Birchwood Casey

Birchwood Casey’s New PRESTO BLACK® BST4 brush-on liquid is a fast acting, cold blackener for all iron and non-stainless steels. When applied to any clean ferrous metal surface, the BST4 solution blackens within 30 seconds and forms a durable, black finish that can be top coated to form a protective black oxide finish. When properly sealed, finish will stand up to wear and corrosion as well as a paint finish, but has a more natural appearance that blends with surrounding architectural materials such as wood, stone or other metallic surfaces. The black finish can also be easily burnished to produce a distressed pewter finish. Contact: Birchwood Casey, Ph: (952) 937-7931; Web: New products for aluminum welding

Miller Miller’s Spoolmate 100 Series plugs directly into welders without the need for a separate control box. This product is designed primarily for the home hobbyist and othFabricator 

November/December 2007

New Products

What’ s Hot ers who do occasional aluminum welding. The Spoolmate 100 Series features a recessed contact tip and a clear spool cover to help reduce the number of burn backs. Dual V-knurled drive rolls ensure consistent feeding of aluminum, which lacks the column strength to reliably feed through a standard MIG gun. Users can also adjust drive roll tension to match the wire being used. Contact: Miller, Ph: (920 734-9821; Web: JetCutting Center for stone and metal cutting


waterjet addition designed specifically to support large format cutting in metal or stone fabrication shops. The versatile FABRICATOR easily accommodates standard metal sheets up to 6’ 8” wide by 14’ long and stone slabs. The FABRICATOR has the ability to add on any number of 6’ table extensions to increase its cutting length and enable the machining of even larger materials. Ideal for the metal fabrication and stone industries, the FABRICATOR excels in the rapid cutting of a variety of materials, including granite, stone, tile, and metal, that are up to 6 inches thick with a maximum table load of 250 lbs./sq. ft. Based on the Windows® XP operating system, the FABRICATOR provides user-friendly software to simplify the cutting process. Contact: OMAX, Ph: (800) 8380343; Web:

Cold-water pressure washer line

Kärcher Kärcher has introduced a new line of full-sized, electric-powered, cold-water pressure washers for indoor and outdoor cleaning. The four models deliver cleaning power of up to 3,200 PSI of pressure with a flow rate of up to 4.5 GPM. Each model has ergonomic design, pulsation dampener system, pressure-controlled auto start/stop, and Kärcher’s professional-grade axial pump with fourpole, water-cooled motor. Contact: Kärcher, Ph: (888) 8059852; Web: www.karchercommercial. com.

OMAX’s FABRICATOR JetCutting Center is the company’s latest abrasive

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

DEDQDRUJ DEDQD DRUJ ABANA A PO Bo Boxx 3425 25 Knoxville, TN 37927 27 Knoxville, 865.546.7733 33

To receive a free catalog, call or visit


November/December 2007 


$UWLVW%ODFNVPLWK–V $UWLVW%ODF FNVPLWK–V Association Associ iation tiion n of North Norrth h America, Amerrica, ca, Inc. 91


Contact Rachel Bailey at (423) 413-6436, or Please note, classified ads promote a one-time sale or offer, or an employment-related opportunity.

Classified ad rates and information

Classified ads promote a one-time sale or offer or employment-related opportunities. Rates are as follows: 1â&#x20AC;&#x201C;35 words = $25; 36â&#x20AC;&#x201C;50 words = $38; 51â&#x20AC;&#x201C;70 words = $50. Next closing date is Friday, June 9, 2006. For more information, contact Rachel Bailey, Ph: (423) 413-6436; E-mail:



November/December 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.

November/December 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

Fabricator goes to class

 NOMMA reaches a new generation

of future metal workers. Ed. note: Neil Mansfield, a metal fabrication/welding teacher, wrote to us recently to say that his school subscribes to Fabricator. Both faculty and students learn from our publication and from you, NOMMA members! Here are some excerpts from his letter, along with photos of his students in the shop. Our school has subscribed to Fabricator magazine for several years now. I read it from cover-to-cover and leave it out on our shop table for our students to read during their break. They always comment on how impressed they are with the uniquness of the metal projects featured. I was so pleased to read the recent articles on copper alloys, stainless steel finishes, and right angle grinders and 94

sanding discs. Finishing is an area where we all need a better understanding; after all, finishing is the final job. As a fabricator, you can have great designs, excellent craftsmanship, and beautiful welds, but if it’s not finished to a high level, your hard work is lost to the customer’s first impression. In the past, I purchased cheap, lowend right angle grinders and standing disc for our shop due to our limited budget. However, this proved to be a grave mistake. Students didn’t have the eye-hand skills necessary to use the equipment properly even after several instructional sessions on how to use a right angle grinder with flap disc, cut off wheels and grinding wheels. So, we have purchased higher-end grinding

backing pads, grinding disc, flap disc, and cutoff wheels. I can’t say enough about their durability — spending a little extra for these products pays off in the long run. As a shop teacher, I appreciate your publication as it helps me learn new techniques and expand my knowledge of ornamental iron work. I use your articles as reading and writing assignments for my students to research and learn about different aspects of our metal fabrication trade. Many thanks, and keep those fabulous articles coming. Neil Mansfield Metal Fabrication Teacher Assabet Valley Vocational High School, Marlborough, MA Fabricator 

November/December 2007




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 11 fab  
2007 11 fab