Celebrating NOMMA â€” past and present â€” in pictures, pg. 48
Ornamental and Miscellaneous Metal The official publication of the National Ornamental & Miscellaneous Metals Association
January/February 2008 $6.00 US
Portable drilling: ensure fast, accurate hole cutting, pg. 18
Preserving the shine with finishes, pg. 23
Sculptures inspired by nature, pg. 38
Filing your tax return electronically, pg. 66
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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 www.nomma.org/metalfab for exhibitor contact
information and demo schedules. If you would like to participate in the education program, social activities, etc. visit www.nomma.org/metalfab 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: www.nomma.org/metalfab/registration.html. 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: www.nomma.org/metalfab/registration.html 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.
Company __________________________________ Address ___________________________________
State ___________ Zip _______________________
Phone __________________ Fax ______________
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 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
Giving has its own rewards Question: What do a nurse, lumberyard owner, ironworker, farmer, computer geek, electrician, retired doctor, school teacher and metal shop owner have in common? Answer: Absolutely nothing…or so I thought. The above question describes the makeup of the group I recently had the privilege of traveliing with to Haiti. The objective of our trip was to put a new roof on a church/school in a remote mountain top village. After meeting everyone and spending the night at the airport, we arrived the next day in Haiti. We immediately took another short flight and, after collecting my luggage (everyone else’s arrived a day later), we climbed into the back of a truck and road 1½ hours up the mountain to the village. We were greeted enthusiastically and treated to a gourmet Haitian meal. Not sure what it was, but it tasted good and I was hungry. Over the next three days we worked side-by-side with the Haitians, raising the steel trusses, welding purloins, and sheeting the roof. Men, women, and children gathered ever day to sit and watch the structure coming together. Working 40+ feet off the ground with someone you can barely communicate with was a little scary at times, but together we were able to complete the project on time. Our reward for the hard work was swimming in a tropical lagoon with a 60-foot water fall — absolutely beautiful! We came home exhausted but we realized that we had received far more than what we left with. No, we were paid nothing monetarily, but what we
came home with was worth more than gold. Nine acquaintances had become close friends. We now share a common bond, knowing we were able to help those who truly could not help themselves. Breck Nelson is I also came home president of with a renewed out- the National look on the life I Ornamental and have been so greatly Miscellaneous blessed with. I guess Metals Association. Mr. Brad Tuttle was correct when he said, “Work is what we do for a living, but giving is what we do for a life worth living.” Giving is one of the basic principles on which NOMMA is built. I have written in the past about the sacrificial giving of others that has helped build this association into what it is today. NOMMA can only continue to operate as long as this continues. Please join us this April at Metal Fab 2008 in Memphis, TN, where NOMMA will celebrate its 50 birthday. Learn new techniques first-hand from fellow experts with live demonstrations, classroom talks, and shop tours. Then, see how you can help in this tradition of sharing and volunteering for the benefit of all. I wish everyone a bountiful year in 2008.
January/February 2008 Vol. 49, No. 1
NOMMA member Flaherty Iron Works teaches metalworking techniques to local Boy Scouts, page 44.
Tips & Tactics Case study . . . . . . . . . . . . . . . . . . . . . . . . 12 Measuring levels of hexavalent chromium in the shop. By Rob Rolves
Portable drilling . . . . . . . . . . . 18 Twist drilling vs. annular cutting — which is right for your job? By Tom Carroll
Sculpture and the sea . . . . . . . . . . 38 Merging dual loves for art and nature.
Paperless possibilities . . . . . . . . . 66 The benefits of electronic tax filing.
By Lisa Bakewell
By Mark E. Battersby
Lending a helping hand . . . . . . . . 44 Scouts earn their metalworking badges.
Taking it to the top . . . . . . . . . . . . . . 72 Get ahead of the pack... and stay there.
By Helen K. Kelley
By Richard Lepsinger
Special Feature NOMMA, past and present . . . 48 A retrospective in photos.
Shop Talk Preserving the shine . . . . . . . . . . . . 23 Protective coatings enhance beauty, prevent corrosion. By John L. Campbell
Little Giant anniversary . . . . . . . . 32 The indispensable 25 lb. Little Giant Power Hammer turns 100. By Sheila Phinazee
New Members . . . . . . . . . . . . . . . . . . . . 80 Nationwide Suppliers
A beautiful balustrade ..............55 This award-winning three-story balustrade was a weighty matter. A textured vine railing ..............62 This Top Job award winning rail was part of a client’s landscape makeover.
Editor’s Letter NOMMA members are making a difference.
. . . . . . . . . . 80
Biz Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . 82
By Peter Hildebrandt
President’s Letter . . .6 The giving spirit reaps its own rewards.
Chapter News Literature
. . . . . . . . . . . . . . . . . . . . 84
. . . . . . . . . . . . . . . . . . . . . . . . . 86
People . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87 Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 New Products Classifieds
Reader’s Letters . . . 10 A new scholarship fund; displaying the NOMMA logo.
. . . . . . . . . . . . . . . . . . . . 89
. . . . . . . . . . . . . . . . . . . . . . . . 96
Biz Perspectives . . . 94 Everything trickles down from the top.
Cover photo: NOMMA member Eureka Forge, House Springs, MO, placed first in the Interior Railings - Forged category of the 2007 Top Job competition with this Nouveau-style balustrade. January/February 2008
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: firstname.lastname@example.org.
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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.
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December as a separate for all advertising materials info, contact Todd Daniel at or firstname.lastname@example.org.
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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 Shine your light There is a marvelous community newspaper, the Beacon, that arrives in my mailbox (free of charge!) every week. It provides fresh perspectives and shines a light on local issues that should not be kept hidden, and for that, I love this home-grown paper. A few days before Christmas, I pulled the current issue of the Beacon from my stack of mail. There, on the front page — where I expected to find a story on something related to holiday cheer — was a gritty exposé on homelessness in my community. The reporter had accompanied one of our city policemen, making the rounds of various camps and other known dwelling sites for the homeless, and he wrote of the various circumstances that had brought some of these people to their current plight. The article was sad and shocking. But it was also a blessing, for it called a desperate situation to the forefront. It must have taken some courage on the part of that reporter to go into a somewhat scary, depressing, and relatively unknown situation...and then write about it objectively and with brutal honesty. But I think he knew that, sometimes, you have to shine a light on things, bring them out into the open, so that they can be made better or even flourish. Quite often, I am reminded of how generous and giving the NOMMA membership is and how many of your lights shine. We have several examples in this issue of the magazine. In his President’s Letter on page 6, Breck Nelson writes about a recent trip he made with a group of very dissimilar people who all had a similar goal — putting a new roof on a church and school in Haiti. These nine diverse personalities became close friends as they worked together to provide a much-needed structure for a less fortunate community. Francis Flaherty, Flaherty Iron Works Inc., recently signed on as a counselor to help four local Boy
Scouts earn their metalworking merit badge. Over the course of two months, Francis and his employees taught the Scouts about safety practices, how to use various tools and equipment, and many metalworking techniques. When all was said and done, the four boys had earned their badges and were proud of the work they’d done. See the story on page 44. We continue to highlight NOMMA’s history, leading up to our 50th anniversary celebration at METALfab 2008. This time, we’re telling the story Helen Kelley is editor mostly in pictures of Ornamental & (starting on page Miscellaneous Metal 48), but we also Fabricator. have more comments to share from some of our long-time members. Read what they have to say about the caring and cooperative spirit of NOMMA on page 54. Also in this issue of Fabricator, we have profiles of two Top Job award winning projects — Eureka Forge’s three-story balustrade (page 55) and Iron Touch LLC’s textured vine railing (page 62). Our second Member Talk feature spotlights Carl Glowienke’s work at Sealife Sculpture. In Shop Talk, John Campbell tells you all about protective coatings on page 23, and we celebrate the 100th anniversary of the 25-lb. Little Giant Power Hammer on page 32. We round things out with two excellent Tips and Tactics articles, plus sound business advice in Biz Side and Doug Bracken’s Business Perspectives. Please keep in mind that items are needed for our annual NEF auction, which will take place at METALfab ‘08, April 1-5 in Memphis, TN. Information is found on pages 78-79. I wish you all a happy, peaceful, prosperous — and light-filled — New Year!
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Readersâ€™ Letters Tell us what you think We need to hear from you. Please send us your article suggestions, editorial corrections, tips youâ€™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: firstname.lastname@example.org 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.
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Tips & Tactics
A NOMMA member decides to measure hexavalent chromium exposure in his shop. The big question: does continuous welding on stainless steel put you at risk for hexavalent chromium exposure?
By Rob Rolves Foreman Fabricators In May 2006, Tony Leto of R & B
Wagner sent a message out on NOMMA’s ListServ about new OSHA rules regarding hexavalent chromium with a compliance deadline for the end of the month. Since our company regularly works with alloy 304 stainless steel, I realized I needed more information to see if and how this new rule would affect us. Fortunately, Tony made that simple by attaching a basic information sheet and references to the Specialty Steel Industry of North America (www.ssina.com). Should I be alarmed? I quickly located a local testing facil12
ity, explained my concerns, and asked their opinion about the matter. The gentleman I spoke with told me that the new ruling had created an uproar, but that fabricating stainless steel wouldn’t release the hexavalent chromium and that it was only a concern for plating. Theoretically speaking, the chrome shouldn’t be released and should still be part of the stainless steel. I was mollified, but decided to keep abreast of new developments regarding the ruling. Within a couple of weeks, there was more information available on the NOMMA website, and it was detailed. To my dismay, this information indicated that welding stainless steel creates the most exposure to hexavalent chromium, and links to more information were included. I also
For your information Industrial uses of hexavalent chromium compounds include chromate pigments in dyes, paints, inks, and plastics; chromates added as anticorrosive agents to paints, primers, and other surface coatings; and chromic acid electroplated onto metal parts to provide a decorative or protective coating.
Hexavalent chromium can also be formed when performing "hot work" such as welding on stainless steel or melting chromium metal. In these situations the chromium is not originally hexavalent, but the high temperatures involved in the process result in oxidation that converts the chromium to a hexavalent state. OSHA has more facts about hexavalent chromium and regulatory standards posted on its web site: www.osha.gov/ SLTC/hexavalentchromium/index.html Fabricator
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The testing equipment consisted of a unit that hung from the welder’s belt, which connected to a filter attached to his collar. The collar unit tested for hexavalent chromium under the welder’s hood.
reviewed the SSINA site again and contacted Joseph Green there, who explained that we could have issues with cutting, welding, and even polishing stainless steel. The relief I had felt a couple of weeks before was long gone by this point. With the looming compliance date, I knew I’d have to stay on this task. Finding the appropriate resources The deadline approached, and then passed, while I continued my research. My next step was to try to find someone to do some testing to determine 14
what the hexavalent chromium levels were in our shop. I began searching for local companies to do the work, traded many phone calls, and tracked down referrals with little luck. Eventually, I learned of an organization called Industrial Hygiene. I wasn’t familiar with the discipline, but industrial hygienists have an association with the sensible name of American Industrial Hygiene Association (www.aiha.org); and luckily, they have a St Louis chapter. After several months of frustrating research, I found them just days before they were offering a scheduled seminar on
the very topic I was studying: hexavalent chromium. My fellow seminar attendees were mostly people whose sole responsibility at their companies was safety. Very large companies in our area that employed a staff just to contend with workers’ safety issues were there to learn more about the new rules and how to comply with them. Still, I was welcomed in spite of my relatively small stature in the business community. The seminar gave basic information, and several people talked of equipment that could help protect workers. I also learned that the cutting and polishing aren’t problems, but rather, just the welding, which creates hexavalent chromium particulates in the smoke. We were shown different types of filters, which could fit under a welding hood, as well as small pressure systems that would push air under the welder’s hood to prevent smoke from entering their breathing space. I followed up with one of the presenters of the program and asked his opinion of our situation. He suggested that we first get someone to inspect the overall airflow in our shop — if the airflow is good enough, it eliminates some sustained exposure to weld smoke and reduces the danger to employees. The regulations are concerned with the cumulative effect of a day in the fabricating environment, so if you have workers exposed to the smoke — even if they aren’t welders themselves — you need to be concerned about their exposure. Because of the space available and the ceiling height in our 16,000 square-foot shop, it was unlikely that anyone was endangered other than the welder themselves, and then only through the smoke immediately produced at the weld and not residual smoke lingering afterwards. The consensus was that we would likely have no problems with any level of hexavalent chromium being dangerous, which helped take some of the urgency out of the project. However, we felt that we certainly wanted to finish the task to make sure our guys Fabricator
An additional testing unit was set up about six feet away from the welding site. After the test weld was complete, both units were retrieved by a technician for evaluation. Results were mailed a few weeks later.
were safe and also to be proactive in the event OSHA made a visit. In that instance, we would be able to show that we had already tested ourselves, and were aware of the issue and taking steps to correct it. Test time Last, came the air sampling at the welder’s station. I contacted another person from the seminar who could provide the equipment and give an accredited report. We decided to wait and do this testing on a day when we would have a considerable amount of continuous stainless steel welding to do. We were looking for a “worst case” scenario that would reflect our workers’ highest exposure to hexavalent chromium, and even though we always have stainless welding happening at our shop, we never had a project I felt was over and above a “normal” day. So, after a long delay of waiting for the right day, it was time to just pick a task and finish the job. We chose a small countertop with about six feet of continuous weld that would give us as much welding in a short time frame as any other job. It would only last about an hour, but the results could be extrapolated to determine the equivalent level of hexavalent chromium exposure for an eight-hour day. The test consisted of a unit that hung from our welder’s belt, which attached to a filter attached to his collar; the collar unit allows for testing under the hood where the operator breathes. There was also an additional unit set up about six feet away from the weld. At the end of the job, the technician took all the equipment with him, and within a couple of weeks we received a report in the mail telling us what we already suspected: no actionable amount of hexavalent chromium was detected. Not only was it not an amount requiring more January/February 2008
action, but it barely registered at all. The TIG process put out so little smoke that only minute amounts of hexavalent chromium were released. Essentially, the more smoke that is produced when welding stainless steel, the better chance you will have of more hexavalent chromium exposure.
the actual test. The rest of the cost was the time I spent on learning about the regulation, and scheduling and attending meetings. A very rough estimate of that would be about 10-15 hours; hopefully, this article could shorten that time for you. My advice would be to run the test, and if there is an actionable amount being released, then speak with ventilation experts about how to mitigate the problem.
Was it worth it? Our outside costs on the project were $25 for the seminar and $850 for
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Although I was initially aggravated to have another task put on my desk, I thank Tony Leto for alerting the ListServ members about the regulation, and thank the SSINA for their help and for keeping their website updated with information. It’s good to know our men are not in danger and good to know we can prove it to any regulatory body that asks.
New white paper details fume collection solutions for hexavalent chromium exposure A new white paper from the United Air Specialists (UAS) provides specific guidance on how to comply with OSHA specifications on hexavalent chromium and minimize harmful exposure through air filtration. Hexavalent chromium (CrVI) compounds are used as corrosion inhibitors and present an occupational hazard to workers that weld, cut, torch cut, or grind chromium-containing metals such as stainless steel. Exposure to hexavalent chromium through inhalation or touch can pose significant health risks to workers, including lung cancer, skin and membrane ulcerations, allergies, and skin irritation. Welding environments can vary in a number of ways, including the welding process in use, the amount of hexavalent chromium fumes generated, and the welding location. In this paper, UAS experts explain why a source capture system combined with a cartridge collector is the only viable way to deal with stainless weld fumes in each of these scenarios. Entitled “Fume Collection Solutions for Hexavalent Chromium Exposure,” the white paper can be downloaded in PDF format on the UAS web site: www.uasinc.com. United Air Specialists Inc. designs and manufactures technologically innovative, high-performance custom air filtration equipment for a wide range of industrial applications. Fabricator
Tips & Tactics
Become an expert at cutting holes in various metals when you understand the differences between twist drilling and annular cutting. Ensure fast, accurate hole cutting on the job site or in the shop when you choose the right tools.
By Tom Carroll CS Unitec Portable drilling in applications such
as construction, steel fabrication, and more poses many challenges – the method of hole creation is just one of them. Understanding the difference between twist drilling and annular cutting, and the equipment, power, and time required, will have you efficiently and expertly cutting holes in steel, stainless steel, and other metals. The methods Twist drilling, the creation of holes in metal with a drill bit, is probably the most recognized method of hole making. But, with only two cutting edges, twist drills require more time, power, and slower feed rates because the complete area of the hole is removed and turned into chips. Annular cutting, the cutting of 18
metal with a hollow-core bit, is an efficient way to create holes 7/16” to 5” diameter (up to 3” deep) with an accuracy of +0.004”, -0.000” in steel, stainless steel, etc. Multiple cutting teeth cut only the material around the periphery of the hole, forming a solid metal slug. In fact, the wall thickness of the cutter is approximately ¼” thick, meaning that no matter what size hole you are cutting, you are only removing a small amount of material around the edge of the hole. Because the cutting surface of annular cutters is spread out over multiple cutting edges (teeth), they remain sharper longer and can create five to 10 times more holes than traditional twist drills. Final holes are smooth and burr-free – no reaming is required. Additionally, hole cutting with annular cutters requires no predrilling or step drilling. Annular cutters are commonly used to do on-site repair and to make
For your information Safety Safety, as always, is an important part of the drilling process. For some excellent safety tips on drilling metal, log on to: workcover.tas.gov.au/attach/sa009597met.pdf. Drilling concrete and more
Cutting holes in tile, concrete, reinforced concrete, asphalt, brick, block and natural stone is most often handled with concrete core drilling machines. Handheld diamond core drilling machines and stand-mounted rigs are ideal for drilling holes in floors, walls, ceilings, roads, and more. Cutting can be handled either dry or wet, and models with dust extraction capabilities are available. Applications include holes for pipes, plumbing, fence posts, monuments, manholes, rebar installation, and concrete anchoring systems. For more information, visit: http://en.wikipedia.org/wiki/Diamond_ core_drill or http://www.csunitec.com/ drills/coredrill.html Fabricator
mechanical openings and pipe thru holes. The annular cutter creates the hole in a 3step process: The pilot pin accurately centers the cutter over the area to be drilled. During drilling, the pilot pin retracts and allows the internal lubrication to reach the cutting teeth. When the hole is complete, the slug is automatically ejected from the cutter, leaving an accurate, finished hole. Another unique feature of annular cutters is their tapered inner wall. On highquality precision-engineered cutters, the tapered wall design serves two functions. Primarily, it accommodates for the effect of frictional heat, which causes the expansion of both the cutter and the internal metal slug (coupon). Secondly, it facilitates the smooth, easy ejection of the slug. When preparing to drill holes on-site or in the shop, it is important to consider the method of drilling as well as the equipment, power, and time required to complete the project. These factors will help you determine the best method to complete your hole-making project.
Twist drilling – Bringing the workpiece to the machine Both annular cutting and twist drilling require a drill press or machine to turn the cutting tool. Due to the physical design of the drill bit, twist drilling requires a machine with more horsepower – most often a bulky, bench-mounted machine that is traditionally vertically configured and less portable. To explain, the speed of the twist drill, at its center, is zero. A large amount of force is needed to “push” the mate-
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rial from directly under the tip of the bit outward, where the two cutting edges can bite and convert the solid material into chips. The larger the hole, the more time and horsepower are required to evacuate the material. Annular Cutting – Bringing the machine to the workpiece Alternatively, annular cutters can cut at higher feed rates with lower horsepower consumption, meaning they can run on smaller machines and drill 3x to 4x faster. For instance, holes that used to be made with conventional twist drills on heavy, bulky, 70-80 lb. machines can now be made on smaller, lighter (approximately 24 lb.) portable machines. A wide variety of portable magnetic-mounted drills exist to drill holes, on-site, for repair or construction on structural steel. These newer, lightweight machines can also be used in manufacturing or fabrication shops. Configurable in both horizontal and vertical positions, magnetic drills are also available with pneumatic or hydraulic power for underwater/hazardous locations. Application considerations Hole Size: Twist drilling, generally, is ideal only for holes up to ½” diameter. Holes over ½” are best handled by annular cutters. Twist drills are available in more precise diameters –
Annular cutters remove metal from around the periphery of a hole, leaving a solid metal slug that is easily ejected.
annular cutters increase by 1/16”, whereas twist drills are available in increments of 1/32”.
Applications involving overlapping holes are also more easily managed with annular cutters.
Hole Type: Twist drills are ideal for blind holes in applications where the hole does not need to go completely through the material. Additionally, they are good candidates for creating starter holes when tapping, as twist drills are available in more exact fractional sizes. Less chatter and drift is experienced when annular cutting through holes, leaving a more symmetrical and accurate hole.
Hole Location: In addition to the aforementioned drilling capabilities afforded by portable drills and annular cutters, another consideration is hole location and finish. Annular cutters drill holes that are otherwise difficult or impossible with twist drills – there is no predrilling or step drilling required. Annular cutters are also ideal candidates for applications where a finished, burr-free hole is needed. This includes drilling pipe or tubing where special tools or manual scraping are not feasible or possible in the middle of a difficult-to-access cylinder.
Twist drill vs. annular cutter: A comparison of metal removal. 20
The conclusion Unless you’re making blind holes or holes less than ½” diameter, annular cutting is worthy of serious consideration, especially if your application is not under controlled shop conditions. TiAlN-coated annular cutters are available for applications where the use of lubrication or coolant is not practical – i.e. horizontal drilling or where material or environmental contamination is a concern. One final benefit of annular cutting is evident after the job is complete – Fabricator
cleanup and recycling. When twist drilling, many sharp chips are intermingled with the lubricant. Separating the two for environmental and recycling purposes is difficult, time consuming and costly. Scrap from annular cutters consists of a minimal amount of swarf and a solid slug. Separating a solid chunk of metal is easier, plus it will generate more profit when selling back the scrap.
CS Unitec specializes in electric, hydraulic, and pneumatic power tools for construction and industry. In 1991 the company invented the first pneumatic portable band saw. In subsequent years the company has added to its list of industry firsts with a wide range of portable magnetic drills, hand-held hydraulic, pneumatic, and electric concrete core drills, core bits, air concrete saws, hydraulic, electric and pneumatic band saws, air chain saws, air hack saws, pipe saws, reciprocating saws, saw blades, concrete grinders, sanders, polishers, surface finishing tools, corner drills, nut runners, portable nibblers, drills and drive units, air torque wrenches, rolling motors, rotary hammers, drill motors, dust extraction tools, vacuum systems, and metal finishing tools. Contact: CS Unitec, Ph: 1-800700-5919; Web: www.csunitec.com.
Celebrate NOMMAâ€™s 50th anniversary celebration at METALfab 2008! April 1-5, 2008 in Memphis, TN, where it all began.
Details are available at www.nomma.org January/February 2008
ALL THE USUAL SUSPECTS
PLUS A WHOLE NEW LINEUP
Call For a Catalog Today. 1.800.258.4766
Tennessee Fabricating Company 2993 Fleetbrook Dr. Memphis, TN 38116 901.725.1548 fax: 901.725.5954 www.tnfab.com email@example.com
Preserving the shine The right protective
coating not only helps prevent corrosion, but also can enhance the aesthetic value of your project.
This rail, an entry in the 2007 Top Job competition from Wonderland Products Inc., contains a multitude of details. The bronze cap-rail was antiqued and waxed to preserve its luster.
By John L. Campbell Remember those older bank build-
ings? Someone’s daily job was to polish the bronze hardware — the revolving doors, the bank’s name plate, the indoor handrails, the trim on the elevators. Some banks, the older ones, still do that today. A finished bronze handrail is like a bride on her wedding day. She’s beautiful — the best she’ll ever look — unless there’s a way to keep her from aging and handling. With the bare bronze handrail there’s the aging from oils and moisture from human hands, and nicks and scratches from rings, bracelets, and car keys. Without some type of protective coating, bronze and brass, as well as iron and steel, will start tarnishing and discoloring, especially if exposed to outdoor environments. March/April 2007
The discoloration of brightly polished bronze is so noticeable, and the upkeep so labor intensive, that the first thoughts are to apply some type of coating. The question is: what should you use? The pros and cons of clear lacquer One way to preserve the finish on copper base alloys is to apply a clear lacquer, a film-forming polymer dissolved in a liquid solvent. The solvent evaporates, leaving behind a clear film. Recognizing the need for a coating to protect copper base alloys, the International Copper Research Organization developed a product called Incralac™. The solvent-based product can be thinned or removed with xylene. The lacquer contains 15 percent Acryloid 44 solids, plus ben-
For your information The NAAMMNOMMA Metal Finishes Manual is a valuable resource for information related to architectural metal finishes. The 116-page manual also includes a section devoted to applied coatings. NOMMA members can purchase the manual on the association’s website, www.nomma.org. Additional valuable information about protective finishes can be found on the web sites of these organizations: NACE International www.nace.org/nace/index.asp
Society for Protective Coatings www.sspc.org/ 23
This bronze and stainless steel sign, submitted by Medwedeff Forge & Design in the 2007 Top Job contest, was created utilizing several processes: laser and plasma cutting, forging, carving, chasing, etching, machining, casting, welding and soldering. The finish includes a chemically induced patina, lacquer, and wax.
zotriazole for corrosion resistance and an ultra-violet stabilizer. There are several such products on the market, but not all of them are available in small quantities for the custom fabricator.
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The health hazards associated with volatile organic solvents like xylene led to the development of a water-based Incralac™ as well. The water-based Incralac™ is not suitable for coating surfaces with a patina. On the plus side, the water-based formula produces a harder finish, which can be removed with vinyl pyrrolidine (aka n.methyl. pyrrolidine). Incralac™ can be applied either by brush or spray. Three or four coats is recommended, allowing 15 minutes between coats. It hard-dries in about an hour. Pricing information is available at TalasOnline.com or from Seagrave Coating Corp. in New Jersey, (201) 933-1000. There are numerous polymers used for clear coatings, but only a few are suitable for outdoors. All of them are expensive. The thermosetting polymers have the best resistance to heat and abrasion. A chelating agent such as benzotriazole protects the surfaces under the coating from tarnishing. The thermosetting coatings are not easily stripped off for refinishing, which is a consideration when deciding what coating to use. The copper roof on the Sports Palace in Mexico City is coated with Incralac™, but that’s an application in which there’s little wear and abrasion to the surface finish. The acrylic base lacquers, even those modified, do not hold up well on bronze handrails. One of the problems with acrylic coatings is the undercutting of the coating by nicks and scratches. About eight years ago, Chris Reiling at Keystone Metals Inc. had a discoloration problem with a bronze railing at the University of Pittsburgh. The railing had been coated with Incralac™, but eventually the scratches allowed corrosion to undercut the coating. To take care of the problem, Keystone removed the coating and applied a spray-on beeswax. (For more information on this process, see the sidebar on natural wax finishes, page 30.) Fabricator
Join NOMMA Today Increase your knowledge â€˘ Network and learn from peers â€˘ Enhance your companyâ€™s exposure Join the National Ornamental & Miscellaneous Metals Association and youâ€™ll receive.... Introductory Package - Upon joining you will receive a kit containing the Membership Directory, Buyerâ€™s Guide, logo slicks, and a sampling of our educational booklets and sales aids. Technical support on issues related to codes and standards. Email discussion forum - the perfect place to get your questions answered. NOMMA eWeb - This â€œmembers onlyâ€? area of our website contains technical support information on ADA, driveway gates, building codes, and more. Subscriptions to TechNotes, our bimonthly technical bulletin and Fabricatorâ€™s Journal, our bimonthly â€œhow toâ€? publication. Youâ€™ll receive O&MM Fabricator as well. Subscription to NOMMA Newswire, our biweekly email newsletter. Discounts to METALfab, our annual convention, continuing education programs, and other events. Discounts to the training DVDs and various publications provided by the NOMMA Education Foundation. Membership Categories Please Check One: â˜? Fabricator $415 - Metal fabricating shops, blacksmiths, artists or other firms and individuals in the industry whose products or services are sold directly to the consumer or the consumerâ€™s immediate agent or contractor. â˜? Nationwide Supplier $585 - Firms that sell supplies, raw materials, equipment, machinery, or services on a nationwide or international basis.
Awards contest - A great way to get recognition for your work. Insurance program - participate in the NOMMA-endorsed insurance progam. Enjoy competitive rates and a unique program customized for our industry. AďŹƒliation and recognition - As a member you are encouraged to display the NOMMA logo on your company stationery, sales literature, building, vehicles, etc.. Industry support - Your dues advances the work of the NOMMA Technical AďŹ€airs Division, which represents industry interests with code bodies, government entities, and standards-setting organizations. This advocacy work is essential to ensure that our industry has a voice with organizations that can impact our industry and livelihoods. Member Locator - Obtain extra exposure with our online member locator. Our website receives over 15,000 visitors per month, including visits from architects, contractors, and consumers. Chapters - If there is a chapter in your area you can enjoy local education events, social activities, tours, and demos.
â˜? Regional Supplier $455 - Firms that sell supplies, raw materials, equipment, machinery, or services only within a 500-mile radius. â˜? Local Supplier $365.00 - Firms that sell supplies, raw materials, equipment, machinery, or services only within a 150-mile radius. â˜? AďŹƒliate $300 - Individuals, firms, & organizations which do not engage in the fabrication of ornamental or miscellaneous metal products and do not provide products or services to the industry but which have a
special interest in the industry. Please note: The membership year runs from July 1 to June 30. Membership dues payments are not deductible as a charitable contribution, but may be deducted as an ordinary and necessary business expense. By signing this application, you agree to abide by NOMMAâ€™s Bylaws and Code of Ethics upon acceptance. Checks should be made payable to NOMMA.
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Selecting the right coating In deciding whether or not a particular coating is suitable for the service conditions, the following questions should be asked: Is the coating going to be indoors or outside? Is the atmosphere dry or humid? What kind of wear and impact resistance is required? Can the coating be renewed from time to time? Is a highly reflective coating
objectionable? Both matte and glossy are often available. Who manufactures clear lacquer products? Those companies in the business whom we contacted have geared their marketing of clear lacquer materials to OEM (original equipment manufacturer) accounts. That’s where the volume lies. With some exceptions, availability of the products is often limited to five gallon sizes and larger.
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Inquire about water reducible Sure Grip (PFGA) (paint for galvanize and aluminum).
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Poor preparation prior to
coating is one of the main reasons most coatings fail. Seagrave Coatings Corp. in Carlstadt, NJ, produces both an airdrying, modified acrylic lacquer and a thermoset epoxy. The thermoset epoxy coating will withstand wear and abrasion better than the acrylic. Both these coatings are mixed with a thinner for spraying. The modified acrylic called Syncrylac™ dries to the touch in about five minutes. With no handling, the coating will last up to 10 years. Seagrave also produces Incrylac™, a modified acrylic coating, modified meaning other resins have been added to produce cross-linked systems with good mechanical strength, abrasion resistance, flexibility and adhesion. Durachem™ is the trade name for Seagrave’s baked epoxy. The cure time at 325F to 350F takes a minimum of 10 minutes, but depends on metal thickness and oven variations. According to the Copper Research Organization one of the best lacquer coatings for copper base alloys is a fluoropolymer lacquer. Fluoropolymer technology offers superior outdoor durability with excellent hardness to flexibility ratio. In our research, we found Sandstrom Products Company, which makes such a lacquer. Fluoropolymer lacquers offer the best scratch and chip resistance, compared with acrylics, acrylic urethanes, silicone alkyds, and silicone polyesters. However, the product has drawbacks. Like most thermosetting polymers, it’s a two-part mix with a pot life of about four hours, depending on ambient temperature. Price is a big factor. Limited shelf life of six months and availability are other limiting factors for the custom fabricator, one who is not producing the same every day product. Sandstrom Products Corp., located in Port Byron, IL, along the Mississippi River, produces a fluoropolymer lacquer called FEVER™. They sell 8gallon and 40-gallon units at a cost of $360 a gallon. According to Sandstrom’s Bob Sireno, they only Fabricator
Easy. Easy to install. Easy to maintain.
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line including CableTrellis™, DesignRail™ railing systems, StaLok® rod assemblies & Lightline® door canopies. See why Feeney is the easy choice among building professionals.
Photo: ©2004 Jay Graham
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produce this coating to order. For most custom fabricators the price alone would surely cure their “fever” for the product. One of Sandstrom’s OEM accounts uses the coating on stainless steel escalator panels. It’s a two part mix with a pot life of about four hours at room temperature. On the plus side, FEVER™ is a coating that will last 20 to 50 years, even with handling. It’s the type of finish you would like to have on your new pickup truck. Another clear coating for metal protection is a product manufactured by Peacock Laboratories in Philadelphia. It’s called Permalac™. The manufacturer states that the product is also used as a tile sealer, citing one successful application on swimming pool tiles, 2800 of them. The company claims that Permalac™ should give satisfactory exterior protection on architectural bronze for at least 10 years. The bronze statue of Kansas State’s mascot, the Jayhawk, at Lawrence, KS, has recently been refurbished and coated with Permalac™. Unlike Incralac™, Peacock’s product can be color tinted and applied over patinas. The solvent used in Permalac™ is toluene and the coating air dries to the touch in less than five minutes. Drying time can be delayed or made faster with the addition of thinners the company supplies. For maximum protection the coating should have a thickness of 0.5 to 0.75 mils (ASTM D1400). The pencil hardness test has a rating of “H” with a dried film flexibility that passes bending on a 3/16” diameter mandrel. For adhesion, the dried film should pass the crosshatching and Scotch tape test 100 percent. We don’t
This hand forged railing, entered in the 2007 Top Job competition by Flaherty Iron Works, has a wire brush natural finish with a bronze tone clear coat.
know anything about the chemistry of this product, information the manufacturer considers proprietary. However, we know it’s not a fluoropolymer or a thermosetting resin in a spray can. In doing the research for this article we learned that DuPont no longer produces a lacquer. Many of the lacquer manufacturers market to original equipment manufacturers, the large users like those in the automotive or furniture industry. They price their product in gallons, not like the 12-ounce aerosol cans in which you can purchase Permalac™ for less than $20. Available in both glossy and matte finishes, Permalac™ can be purchased in quarts, gallons, or 55-gallon drums. It can be brushed or sprayed on. Because of public concern over the potential hazards of volatile organic compounds, Peacock Laboratories has developed an environmentally friendly formula that is called Permalac EF™. The new formula is currently undergoing testing to make sure it meets all the standards of their existing product. For additional information about the product and its applications, go to their website at www.Permalac.com. Improving the coating’s chance of survival Poor preparation prior to coating is one of the main reasons most coatings fail. Surfaces to be coated must be clean, dry, and free of all dirt, grease, silicones, release agents, wax, loose or peeling paint, oil, and other contaminants. The spray operator and those mixing lacquers with xylene and toluene thinners should wear MESA/NIOSH approved self-contained breathing apparatus. Based on this limited research, one has to conclude that the custom fabricator’s options for more durable, clear lacquer finishes are limited; and those limitations present another entrepreneurial market for someone.
When is lacquer a varnish?
congratulates NOMMA on 50 years of service to the industry.
Happy Anniversary NOMMA!
0/ "OX #ARLSTADT .* FAX BLUMINFO JULIUSBLUMCOM WWWJULIUSBLUMCOM
A lacquer is a clear or colored coating that dries by solvent evaporation. The most widely used natural lacquers in the United States are nitrocellulose (pyroxylin). Fast-drying synthetic lacquers employ a type of polymer, a thermoplastic or thermosetting resin, dissolved in a fast-drying solvent like naphtha, xylene, toluene, or acetone. The word, â€œlacquer,â€? dates back centuries, when shellac was first manufactured in India using the secretions of the lac insect. The earliest known lacquers date back to 7000 B.C., when the Chinese and Japanese made finishes from the resin of a tree. The active ingredient of the resin is urushiol, a type of phenol suspended in water. These finishes were resistant to water, acids, alkali, and wear, but did not hold up to ultraviolet light. In the United Kingdom, if you spray it, itâ€™s a lacquer; if you brush it, itâ€™s a varnish.
Natural wax finishes For years, furniture polishes and wax finishes for automobiles have used carnauba wax, a brittle, high-melting wax extracted from the Brazilian carnauba palm leaves. Another natural protective finish is beeswax, which is used both for wood and metal finishes. When the acrylic finish on a bronze handrail chipped and showed ugly tarnishing marks for Keystone Metals Inc. in Pittsburgh, Chris Reiling discovered that using a coating of beeswax was more effective. The beeswax is available in an aerosol can. Brian Metzker, who does business as World Class Promotions, has been selling The Original Beeâ€™s Wax since 1974. He recommends it for wrought iron and stainless steel, as well as marble, granite, and painted surfaces like kitchen cabinets. One advantage is that the finish needs no buffing; and as it enhances the beauty of natural grained wood, beeâ€™s wax protects both wood and metal surfaces from the acidic moisture of finger prints. The companyâ€™s website is beeswaxpolish.com. Metzkerâ€™s phone number is (800) 568-1413.
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 two-year warranty.
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.
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Celebrating 100 years of the 25-lb. Little Giant The first and last
Little Giant hammers ever made are on display and at work in a Nebraska shop.
By Sheila Phinazee The Nebraska-based Little Giant
Company, owned by Sid and Mary Suedmeier and daughter Keri Hincker, will be throwing the indispensible hammer a birthday party in January. The first 25-lb. Little Giant hammer was made in January 1908. Amazingly, it has made its way back to the company that manufactured it. “It had never occurred to us to search for serial #1 of any size of Little Giant, since so many of them have been moved around and we have no idea how many have been scrapped,” says Hincker. “It really would be like 32
searching for a needle in a haystack. The discovery of serial #1 was very serendipitous.” Jim Carothers of Saltfork Craftsmen in Oklahoma came upon #1 from someone selling old blacksmithing equipment and notified Suedmeier. The machine turned up in Perry, OK, only 40 miles from where it was first shipped. “The original Little Giant [Company] kept thorough records, handwritten in large, leather bound ledgers. With a serial number, we can tell the sale date of a machine, and, in most cases, the wholesaler, individual purchaser, and location,” says Hincker.
For your information Still in use across the nation, the Little Giant Power Hammer remains a vital part of a reborn art form — the transformation of metal. Do you own a Little Giant and want to make it work harder than ever? Learn how at the 16th annual Little Giant Rebuilding Seminar, March 28-30, 2008, in Nebraska City, NE. An old-style 25-lb. machine will be rebuilt, and a new-style machine will demonstrate proper assembly and adjustment. Registration information is available online at www.littlegianthammer.com; by phone at (402) 873-6603; or by email, Sid@LittleGiantHammer.com. Fabricator
Tubular Balusters Available in steel or aluminum
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“That paper trail contributes to the historical mystique of Little Giants.” As the Little Giant celebrates 100 years of use, its popularity extends well beyond its NOMMA member following. “In a historical throwback activity like blacksmithing, it is only natural that antique machinery and tools appeal to people. Little Giants were the most widely purchased brand of power hammer, and that renders them iconic,” says Hincker. “People remember their dad or granddad using Little Giants, and they are sentimental about the machines.” Practically speaking, Sid Suedmeier attributes most of the Little Giant’s success to its size and its ability to do the job. “The 25-lb. size is good for most ornamental work. Due to its size, it is more desirable for most shops and it’s a good size for hobbyists,” he says. “The 25-lb. hammer weighs 900 lbs. The 50-lb. hammer, which is almost as popular as the 25-lb. hammer, weighs
1800 lbs. Bigger hammers are for more industrial use.” Family history Suedmeier purchased the remains of the Little Giant Company from Denny Dotson, owner of the Dotson Foundry in Mankato, MN, in 1991. Suedmeier had owned an auto parts business for 40 years before taking on Little Giant; he was also a knife maker on the side in the mid-80’s. “In the 90’s I started forging knives, and I picked up old hammers to shape and build them,” he explains. In 1991, Suedmeier worked out a deal with the Dotson family, who were ready to sell the Little Giant portion of their business. Suedmeier started a parts supply for Little Giants, working with foundries in Mississippi and Iowa and with Roger Rice, a local machinist. Then, in 1999 when he semiretired, Suedmeier sold the auto parts business and started selling and repairing Little Giant parts and rebuilding machines full-time.
Little Giant history According to Hincker, the original Little Giant Company was started by Louis and Lorenz Mayer in Mankato, MN. Their father was a blacksmith, and the boys established a foundry before patenting the first Little Giant in 1895. That business is still in operation as the Dotson Foundry. “Without the Mayers’ appreciation for the history of the Little Giant branch of the company, the blueprints, patterns, and records may have been lost, and our modern day supply of parts would not exist,” says Hincker. Little Giant has hammers come in five sizes: 25-lb., 50-lb., 100-lb., 250lb., and 500-lb. Little Giant started with the 50-lb. model in 1895. The other four sizes came along, beginning in 1905. The Suedmeiers now own 25 lb hammer #1, the first one made in 1908. According to Suedmeier, the agricultural industry brought about the need for the Little Hammer with the sharpening of plowshares. In the win-
Ads from days-gone-by declare the “ruggedness and efficiency of Little Giant Power Hammers. LEFT: appeared in The American Blacksmith, January 1910; CENTER: published in American Ironsmith, July 1993; ABOVE: published in Nebraska Blacksmiths, 1964.
ters, farmers sent their plowshares to blacksmiths, who would reshape and resharpen them. In the 1950s, they began to use throw-away plowshares. In the 1970s, no-till farming came into use, which cut down on the need for these unit until there was a resurgence of decorative blacksmithing and ironwork.
Cause for celebration A special “Hammer-In” and several other activities are planned for the January 11th- 12th, 2008 anniversary celebration. The event will feature demonstrations from blacksmiths, bladesmiths, vendors, and a horse shoer. There will also be a tinsmith on hand to display his handiwork.
Hammer #1, also known as “Alpha,” will join the more recent 25lb. #8876, also known as “Omega.” This hammer is the last 25-lb. frame ever cast and machined by Little Giant in Mankato, and had never been assembled until now. It was part of the remains of the company that the Suedmeiers purchased in 1991. Both
stration, since the agricultural industry brought about the need for the first hammers,” says Suedmeier. As a special tribute of appreciation, Suedmeier will give a plowshare sharpened on the “Alpha” to its previous owners, the Dotson family. Seminars and resources Each year in March since 1991, Little Giant sponsors rebuilding seminars to show people how to rebuild their hammers. Fred Sid Suedmeier attributes most of the Little Caylor helped the Suedmeiers Giant’s success to its size and its ability to do learn about hammers. They the job. worked together for 11 years until the “Alpha” and “Omega” will be up Caylor passed away in 2002. and working. Also, 15-18 other “We owe a lot to Fred; he made the brands of hammers purchased by learning curve a lot easier for us. He Suedmeier will be on display. was a good blacksmith and I was a Because of its historical signifigood machinist,” says Suedmeier. “We cance, the celebration will have made a good team. The last hammer renowned blacksmith Bob Bergman Fred and I rebuilt together belonged from Wisconsin on hand to demonto Francis Whitaker, the well-known strate how plowshares are sharpened. blacksmith, for the school he started “I am excited to have this demonin Carbondale, CO,” says Suedmeier.
According to Suedmeier, the seminars continue to be successful. “We’ve had about 25 seminars with participants from all over North America,” he notes. “Some people have returned two or three times because they had so much fun.” Seminars are also good for those who do not own a hammer — they learn what to look for and what to stay away from when buying a hammer. Little Giant has taught the same seminar in other locations like Colorado, West Virginia, Minnesota, Indiana, and New Mexico. An additional resource for history and information is The Little Giant Company’s website, which features original foundation plans, dies, parts, instructions, lubrication guides, and a virtual museum. Visit it at www.littlegianthammer.com. “Little Giants can do the job, says Hincker, who is being groomed to carry on the business. “As early company advertising says, a Little Giant is ‘a time saver and money maker.’ That is still true today.”
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Sculpture and the sea
A NOMMA member’s ideal vocation merges
his loves of art and nature. By Lisa Bakewell Carl Glowienke had no idea that his
life’s vocation was to become a worldrenowned sculptor. Although he’d always had an affinity for art, his first love was music and he was educated as a musician — a composer, to be exact. But, for more than 16 years now (since 1991), Carl Glowienke has owned and operated Sealife Sculpture Studio in Lakeside, CA (a far cry from his native Chicago), just 20 minutes from the ocean that gives him so much inspiration. Take one look at Glowienke’s port38
folio and it’s plain to see that he loves nature and garners his ideas from the animals, fish, trees, and landscape surrounding him. Dolphins, sharks, sea turtles, and stingrays are sculptural inspirations from the sea; his gates depict the flora, trees, and sea life of the San Diego area; his fireplace screens, balcony railings, and tables follow suit. Virtually everything that Glowienke creates has its roots in nature — just the way that he likes it. A calculated leap of faith Determined, but unsure of whether or not the market would support his
For your information NOMMA member: Sealife Sculpture, Lemon Grove, CA Ph: (619) 469-1340 Web: www.sealifesculpture.com Contact: Carl Glowienke Specialization: Gates, sculpture, fireplace screens, home furnishings Problem solving method: Allowing the mind to work subconsciously Recommended reading: An Alchemy of Mind by Diane Ackerman Fabricator
work, Glowienke began his sculpting career on a part-time basis. To supplement his income, he worked as a waiter. “It takes a long time to develop the skills to be a sculptor and the reputation to where you’ll be trusted with a large-budget project,” he notes. “So, I supplemented my income from sculpture sales by working in restaurants. At a certain point it became clear that there was enough demand for the work, and if I just worked full time, then I could stop working at restau-
rants. It was something that I wanted to do for a long time.” When Glowienke got to the point that he was working 25 hours at each job per week, he decided it might be time to take the plunge into full-time sculpting. “It’s kind of like having one foot on the dock and one foot into the boat,” he says. “At some point you just have to take the leap.” Finding inspiration in all experiences Glowienke feels very fortunate to
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have had excellent training as an apprentice. “I’ve had the benefit of studying with several great teachers and that’s really the only way to do it,” he explains. “Because you can’t read about it and do it. You have to actually do the work.” Glowienke was fortunate enough to study with one of the greatest living sculptors in Mexico, master sculptor Guillermo Castano Ramirez, whom he met through a mutual friend. Castano taught Glowienke “bronze casting and,
basically, just about everything,” he says. “I was very privileged that he took me on as a student. He’s the kind of teacher that would allow me to make mistakes — even if they were expensive mistakes — and then say, ‘Well you won’t do that again, will you?’” Glowienke spent a total of five years working with Castano, traveling back and forth to Mexico, where he’d work for several days a week before returning home again. Prior to and during the time that Glowienke worked with Castano, he
also had the privilege of researching with Dr. Stephen Leatherwood at Hubbs Sea World Research Institute from 1985-90. There, he learned all about the sea creatures that he would be depicting in his art — an education that allows him to create sculptures that are so realistic and lifelike. When asked what his favorite part of his job is, Glowienke says he loves solving the problems that come up in developing his pieces. He is also very interested in how the mind works, too, and marvels that his fabrication problems can be solved even when he
doesn’t think he’s thinking about them. “I’ll come up with a solution to a structural or engineering project in yoga class,” he laughs. He also shares that one of his favorite authors is Diane Ackerman and says that reading An Alchemy of Mind was very inspirational and enlightening in learning how the mind works. Projects, processes, and methods Glowienke creates his sculptures, gates, and home furnishings for residential and commercial clients in his 1500 square-foot studio that’s just a “down-the-hill walk” from his house on a small horse property that he and his wife own. His work is split 60/40 between residential and commercial work, and his institutional work constitutes about 15-20 percent of his commissions. Today, all of his pieces are commissioned.
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Though Glowienke creates beautiful gates, fireplace screens, and other furniture (made of steel, stainless steel, and bronze), his favorite pieces to create are his sculptures, which are made of bronze. His smallest pieces measure about 12” and take about 40-50 hours to create, with a delivery time of about eight weeks. Glowienke’s larger and institutional pieces, which might measure over 12’ by 12’, take hundreds of hours to create. Commercial pieces take about 12-15 weeks to complete, and the institutional pieces can take up to 18 months from start to finish. Glowienke’s sculpting process begins with sketches and a steel armature of the piece. Clay is then put over the armature and molds are taken of the work in plaster, urethane, or silicone, depending on the piece. Next, a small sculpture is cast in wax and taken to the foundry where another Fabricator
Almost all of Carl Glowienke’s work reflects his love of nature, especially the coastal environment.
mold is put around the piece — a ceramic shell — and is baked at high temperatures. Molten bronze is then poured into that shell and sent back to Glowienke for cleaning, polishing, and finishing. For larger pieces he uses a sandcasting method, where a fiberglass mold, a ¼” thick or less, is created. The pieces are then marked with grooves or hitches and cut into pieces to be used as templates for casting. Once the casting is done, the grooves and hitches are lined up on the bronze pieces and then put back together. They are assembled into an original mold like a jigsaw puzzle and cleaned, polished, and finished according to the specifications of the piece. Some of Glowienke’s larger pieces have permanent homes at the San Diego Natural History Museum, Cabrillo National Monument, and in Hong Kong and China. Glowienke uses a wide variety of finishes on his pieces that depend on whether the piece will be inside or outside or will get wear from the public — especially children. In cases where there’s going to be extreme wear, baked epoxy is used. His extensive experience and training have taught him what a piece will look like as it weathers and is handled, and he’s able to achieve different patinas on his pieces using chemicals and various copper finishes before they are lacquered and waxed. Glowienke sometimes uses his original molds to offer very small, limited edition series of his work. For the small pieces, no more than 25-30 pieces are recreated; for the larger pieces, no more than 10. His newest projects include a series of giant seashells, which started when a client ordered a giant conch shell. The response to these was so great that Glowienke was commissioned to sculpt other shells for décor or fountains. The shells are made of bronze for fountains or cast marble (resin bonded marble, similar to kitchen countertops) for decoration and are quite beautiful. Of people and paperwork Though Glowienke has had more employees in the January/February 2008
One of Glowienke’s newest projects is a series of giant seashells. The shells are made of either cast marble or bronze.
past than he does currently, it was cumbersome for him to employ too many people. “My favorite part of the job is creating new pieces, solving new challenges,” he says. “My least favorite is managing the business.” So, today he has only one assistant, Sean Ketchem, who has worked with him for three years. Ketchem, who studied painting at University of California – San Diego and is quite talented, wanted to broaden his horizons. At Sealife Sculptures, he helps with fabrication, welding, painting, and assembly. Glowienke is also not very fond of paperwork. Fortunately, he says he only has to spend about one day per week on it and is able to work the other five days on what he loves best — sculpting. Sunday is the artist’s chosen day off, which he tries to keep even when facing deadlines. When asked how he handles an unhappy client, Glowienke says it doesn’t happen very often, but if a customer doesn’t like something in a final product such as the finish or the particular positioning of a figure, it can be changed. “I can only think of two instances where that’s occurred in the last 16 years, though,” he adds. “Most clients hire me and say, ‘Well here’s what we had in mind. Come up with something — you’re the artist — we trust your judgement on this.’ And then I do sketches and a scale model before we ever start the full thing, so the customer has a pretty good idea of what the project is going to look like before it’s done.” “My main goal is to try to get people to appreciate the beauty all around them — and the beauty of nature. When I do my job right, it stops their internal dialogue just for a moment or two and they go, ‘Wow, look at that!’” And “Wow, look at that!” definitely sums up the work of Carl Glowienke.
Lending a helping hand Scouts earn their
metalworking badges with some assistance from NOMMA member Flaherty Iron Works.
By Helen K. Kelley, editor Some lucky boy scouts in Alexandria,
VA recently were able to earn their metalworking badges, courtesy of hands-on experience provided by longtime NOMMA member Francis Flaherty. The four members of Troop No. 680 visited Flaherty Iron Works over the course of a few months, where they received training to complete requirements for the blacksmithing category of the merit badge. The project came about when one of the troop leaders saw an advertisement for Flaherty Iron Works in a church bulletin and approached 44
Francis Flaherty about helping the scouts. An Eagle Scout himself, Flaherty was pleased to offer his guidance. He was required to fill out paperwork to be a “counselor” — once his application was approved, the time and dates were set for the scouts to complete their work. Of the 170 members in Troop 680, several expressed an interest in earning the metalworking badge. Four of the older boys — Patrick Martin, William Johnson, David Trimarchi, and Michael McCabe — ages 14-16, were selected to participate in the project. The Boy Scout metalworking badge handbook set out all of the require-
For your information Interested in becoming a merit badge counselor to a Scout Troop in your area? To qualify as a merit badge counselor, you must:
at least 18 years old proficient in the merit badge subject by vocation or avocation. Be able to work with Scout-age boys Be registered with the Boy Scouts of America There is no fee to become a merit badge counselor, but you must submit the appropriate paperwork, which can be found online at: www.scouting.org/forms/34405.pdf Fabricator
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ments or steps that the scouts needed to complete to receive their badges. There are four different categories under the metalworking badge; however, all four boys elected to follow the blacksmithing track. Over the course of two months, the Scouts spent a few hours once a week at Flaherty Iron Works, where lead blacksmith Hong Le demonstrated various techniques, according to the guidelines set forth by the handbook. The first class — which both the handbook and Flaherty considered the most important — was safety. The boys learned about what kind of gear to wear when performing metalworking tasks as well as basic safety practices around the shop. They were very conscientious about following these guidelines throughout the class. In addition to safety practices, the scouts learned: After first learning safety rules, the Scouts were taught a variety of blacksmithing and metalworking techniques, such as working with anvils, tongs, power hammers and punches.
About the forge, parts of the anvil, tools used in the shop How to use the forge and anvil to draw out pieces of iron Making circles and bends with the horn of the anvil Making twists (hot forged) using a vice Making rivets Upsetting Working with tools such as tongs, power hammer, and punch MIG and TIG welding Tempering metal and annealing The differences in working with different metals — ferrous and nonferrous How to apply wax, turpentine, and linseed oil rubbed finish By the end of the class, the scouts had each made a skewer with circular twisted handle, a punch, and a sword. Flaherty says that the class was not only beneficial to the scouts, but also to his employees. “Some of our laborers were not familiar with the blacksmithing aspect of ironwork, forging, etc., so they attended some of the classes, too,” he notes. “It was a great opportunity for them to learn.”
The classes adhered to the Scouts’ metalworking badge handbook requirements.
Although it involved quite a time commitment — and it’s sometimes difficult to make the time when you’re running a busy shop — Flaherty says the project was very worthwhile and he would offer assistance to scouts again. In fact, the troop hoped to send another small group to Flaherty Iron Works in the winter months to earn their metalworking badges. “I was really glad to see how enthusiastic the boys were about blacksmithing. We live in a very high-tech metropolitan area and it was good to see them take such an interest in the very old trade,” Flaherty says. “And they really enjoyed the work. Their parents told us about how these teenage boys — who sometimes don’t talk a lot — very enthusiastically described to their families and friends what they were doing at the iron works. Some of them even asked if they could come back and get summer jobs here. It was really encouraging to us to see them take such an interest.”
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Editor’s note: In honor of NOMMA’s upcoming 50th anniversary, we have been highlighting the association’s history and achievements in a series of articles in Fabricator. In this issue, we celebrate NOMMA — as it was and as it is now — in photos.
In NOMMA’s earlier days, members dressed pretty formally. Clockwise from upper right: members enjoy dinner at NOMMA’s very first convention in Memphis, 1957; ??? at the Roosevelt Hotel; the first Julius Blum award is given; snazzy sports coats were acceptable for shop tours; the first general session is well attended.
past & present Ainâ€™t we got fun? NOMMA members are light on their feet and have clever costume ideas.
Marilyn and Bob Mueller; LOWER LEFT: Leon York; TOP RIGHT: Howard and Mary Troxler; CENTER RIGHT: Ernest Wiemann; LOWER CENTER AND RIGHT: NOMMA members donned period garb and kicked up their heels at past conventions. TOP LEFT:
Celebrating NOMMA, Past and Present
Winning a coveted award in the annual Top Job competition has always been a thrill. ABOVE: Jerry Grice presents Dave Ponsler with a Top Job plaque. RIGHT: Jim and Bob Foust smile with their awards.
Members of NOMMA’s Board of Directors, past and present, have always shared the same dedication to ensuring that the association’s mission and guiding principles remain intact.
Jim Wallace’s trademark moustache is something else that hasn’t changed over the years.
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Celebrating NOMMA, Past and Present
Today, the annual auction and silent auction, held at METALfab, are an important fundraising effort for NOMMA’s Educational Fund.
LEFT AND ABOVE:
LEFT: Voting in the annual Top Job competition is a highly anticipated event at NOMMA’s annual convention.
LEFT: METALfab attendees always look forward to an opportunity to tour a NOMMA member’s shop. In 2007, they were treated to a tour, lunch and demos at Eagle Bending Machines & Carell Corp.
above: Jack Klahm demonstrates techniques for working with aluminum during METALfab 2007. below: George Bandarra discusses working with stainless steel.
We remember... Ed. note: In our last issue, 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 more of their comments, as promised.
The first METALfab Sue and I attended was Galveston, TX in 2002. We were familiar with the organization, and even some of the leadership and membership, as we were long-time subscribers of The O&MM Fabricator. We thought our business had grown to the point where we could afford to join NOMMA and go to the convention. We hoped that NOMMA membership and convention attendance would provide ideas to better our business. We were blown away by what we encountered! What we found was, indeed, a wealth of information to use in our business, but better than that was the openness and generosity of the NOMMA members who welcomed us into the fold. Now, I have to admit that I was a bit star-struck. Having read about Belk Null and Jan Allen Smith in The O&MM Fabricator, it was incredible to talk with them in the hotel hallway! Sitting in an education session conducted by Lloyd Hughes, and having him answer a question – wow! Having Mike Boyler as a table companion at the theme party and having him spend the time to encourage us to get involved in the Association — awesome! Rubbing shoulders with the likes of Ed and Sally Powell, Doug Bracken, Jerry and Tycee Grice, Dave Filippi, Jack Klahm, and Chris Maitner – I felt like I was in the presence of metalworking royalty. Other members who may not have been in the magazine pages – Joseph Koppers, Bob Paxton, Allen Guidry, Bill Peck, and Steve Engebegtsen are just a few – made us feel welcome. It didn’t take long to realize what a generous and giving bunch the members and staff of NOMMA were, as they were all willing to share their time with a first-time convention attendee. Our goal in attending that convention was to make our business better, and that is what happened. And like that first year, each year since we have learned or seen something that has improved our business. But what will always stick with me is what a fabulous and giving group of people we have in our Association. — James Minter, Jr., Imagine Ironworks
I attended my first NOMMA convention in Atlanta in 1975. That experience changed life because I saw the tremendous potential that existed in the ornamental metal business. Being exposed to industry greats like Bill Merry, Cliff Brown, Carl Newman and others gave me the insight I needed to improve the way I did business. — David G. Filippi, Team FabCad 54
It has been intriguing to watch the progress of NOMMA as we have grown together. My first awareness of NOMMA was as a 10-year-old child in 1960, from the details our father told us when he returned from the conventions. As we got older, he told us about the great people he met, how impressed he was with their knowledge, and, of course, all the fun that they had when they got together. We grew up hearing the names Mitch Heitler, Mel Petersen, Cliff Brown, Frank Kosik, Ernie Wiemann, Howard Troxler, Carl Neuman, Bill Gasperini, Bob Mueller, Brooks Davis, Barney Lazarone, and many others. In 1970, my brother Bruce and I started taking turns going to convention. We finally got to meet these people and discover what our Dad was talking about. The great thing about many of these originators and early members was their commitment to what they believed in. They would spend hours discussing their opposing views, sometimes in heated debate, but when the meetings were over, they went out together, socialized, and enjoyed each other’s company. This is where the “NOMMA Family” atmosphere was born. It has always been a part of NOMMA’s fabric. Our founders were very far-sighted as to what our organization should be about and why it needs to exist. They were also wise in planting the seeds of cooperation and sharing that flourish today. —Mike Boyler, Boyler’s Ornamental Iron Inc. I remember meeting Jerry Grice for the first time at the 1990 NOMMA convention in Boston. I had a problem with a project I was working on at the time; it was a three-line pipe railing inside a home, and the customer wanted the gate to look like an “E.” I mentioned it to someone, who directed me to Jerry for help. He explained his solution, which involved putting a mechanism inside the pipe with a spring and handle. I wrote it all down, and when I got home, used Jerry’s suggestion in building the gate. It worked beautifully, and the customer was very impressed. I don’t think I saw Jerry again until about 10 years later at another METALfab convention, but he remembered me! Also, I do business with another NOMMA shop, Majka Railing Co. in New Jersey. I happened to visit Keith’s shop for a NOMMA Northeast Chapter meeting and saw the railings he mass produces. I thought, “Wow, I could sell those!” And I do. In fact, his railings have become one of my best sellers. Paul DeFrancesco of Lightning Forge in Utah has been very helpful to me as well. He told me that if I ever wanted to learn about forging railings to get on a plane, and he’d pick me up at the airport, give me a place to stay, and teach me in his shop. Eventually, I did go to out there with my family on vacation, and Paul spent a couple of days with me in his shop and touring around town. What makes NOMMA so great is its members, their willingness to help each other, and the long-standing friendships we form. — Paul Montalbano, Duke of Iron Fabricator
A beautiful balustrade
This 2007 Top Job
award winner reflects a unique departure from traditional scrollwork. Todd Kinnikin of Eureka Forge is no
stranger to success in NOMMA’s Top Job contest. Out of the three years he has entered work in the competition, Eureka Forge has won the Mitch Heitler Award for Excellence — the overall Top Job winner — twice. This year, his entry in the Interior Railings category was both the winner of its category as well as the Heitler award. Fabricator recently caught up with Kinnikin, where he shared some details about the planning, challenges, and completion of the project.
: How did this railing project come to Eureka Forge and what were the clients’ design wishes?
The clients contacted us because we January/February 2008
had previously done some work for the wife’s mother, and she had seen the quality of work we could offer. The client specified that she wanted a railing that was distinctive and “organic.” So, we created a sample for her, which essentially was a newel, and presented a theme incorporating cast birds (because they like birds).
: How did you go about merging the creative process with the actual Q fabrication? We created some cast bronze birds. The birds can be manipulated once you make the waxes from the mold. You can heat them, change the wings, etc. And you have an almost endless number of permutations for birds in
For your information NOMMA member: Eureka Forge, House Springs, MO Ph: (636) 938-4455 Web: www.eurekaforge.com Contact: Todd Kinnikin Project: An 83-foot, three-story balustrade with forged newels and handrails Style: Textured and twisted vines with floral details and bronze-cast birds inspired by the Nouveau style That’s a heavy load: The entire balustrade, forged to round from solid square stock, weighs nearly 4,000 pounds. It took eight men to heft the pieces — one of which weighed 1,000 pounds — upstairs for final assembly.
The castbronze birds (modeled on barn swallows) were created in a variety of poses.
flight, perched on a limb, and more. Once the client had approved our design ideas, we began fabrication. We built the newels and installed them in a rough condition. Then we tied them together with false work onsite to establish a relationship between the pieces. We made pieces of the railing in the shop with lap joints and mortise and tenon joints — then, we took those out, joined, and welded the ends in place. We loosened the mechanical fittings to take the railing apart to bring back to the shop. There, we did the rest of the forge work, fit, and finish.
: The client was inspired by Nouveau designs in another Q family member’s home. What are some of the intricacies of Nouveau? The Nouveau style was in vogue from 1890-1914. It spread from Europe to the U.S., and it died out about as quickly as it started. It was pretty much gone by WWI. Some of the characteristics are curvilinear designs incorporating floral and plant motifs. You’ll see it in items like Lalique lamps.
“They just had no idea of what
they were asking and the number of hours it would take...”
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: Who designed the railing? What Q are the floral details, birds, and bird houses modeled on? The client had conceptual input, and the piece was designed in our shop. I’m a firm believer that “the camel is a horse as designed by committee” — we usually put one lead artist in charge of something like that. All I do is critique, unless I am the lead artist. Currently, we have 10 employees, whose talents range from certified welding to traditional blacksmithing to masters of fine art. What they all have in common is a three-dimensional sense. The birds were modeled on barn swallows. The bird houses sprang from the mind of Claude Mette, who was the lead artist on this project.
: How long did the job take to Q complete, how many people worked on it, and how were they
: What were the biggest chalQlenges on this job?
assigned their tasks? The whole thing took about 2200 hours to complete. At some point, everyone in the shop worked on it. Each person was assigned a portion of the project according to strengths and skills. There was a crunch time; we did put in some 16+ hour days to complete the installation, for which we gave ourselves a deadline.
This Coming ! Spring
A celebration of the village blacksmith.
Textured and twisted vines formed 17 intertwined “rootwads,” which branch into stylized floral details and tendrils. They appear to “grow” out of floors and stair treads to wrap around the rails and posts in individually designed, yet harmonious panels.
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I suppose the biggest challenge was trying to read the minds of the clients, because they were very “sketchy” about what they wanted. They approved the concept, and they’d approve a model…but then wanted to make changes. I told them that it was art, and at some point I had to tell them they were paying for the artistry. Another challenge was the weight — one piece weighed about 1,000
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pounds and had to be carried in a door and up the steps. The whole project weighed approximately 4,000 pounds. Yes, that was a big challenge, getting eight people to carry over 1,000 pounds up steps. There were some uncomfortable moments. We were billing the clients monthly. In the first several months, they were glad to see me. But by the end of the job, the husband would start to twitch when I walked into the room. They just had no idea of what they were asking and the number of hours it would take — they realized they had to stop the micromanagement. They were thrilled with the piece when it was complete.
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We did change the flavor of it. In the lower levels, it’s more playful because it’s seen in the entertaining area of the house. As it went to the upper levels of the house, it became more formal. Each section was complete when we brought it in for installation. Fabricator
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the notch, which, of course, we needed for the newel. So, I just pretended I was a stair builder for a half hour; I “remodeled” a finished walnut stair tread with a cutoff wheel!
: Is there anything you would do differently Q if you had to do this particular project over again? Yes. I would allow for a longer lead time so that I didn’t have to tie up so many people in the shop. The way we did it was just too crunched up and prevented me from using key people in key positions on other projects. And I failed to anticipate the number of hours it would take to create the project. Forged newels and handrails were initially fitted and assembled at the job site, then returned to the shop to be infilled with sculptural elements prior to installation.
Q: Were there any panic moments? Yes. One of the stair treads had been notched to accept a newel. The homeowner had had carpenters in to do some other work — and for some reason, they decided to repair
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: How did you become interested in metalQworking?
It’s a story you’ve probably heard a thousand times before. My grandfather was a blacksmith. My father was an engineer. I’m educated as an engineer. I was in the construction industry my entire life until I had a heart attack and retired in 1991. Then, my grandfather’s influence started to kick in. I began making small art pieces. And I exhibited at five shows a year, one of which was in Paris. I was having a good time. Then, someone asked me to do a project I couldn’t handle by myself. So I asked Rod Roots, my labor foreman from construction days who happened to have blacksmithing skills, to help me for two weeks. Years later, he’s still here, as my shop foreman. I have no formal art training, but I have good sense of proportion. Eureka Forge was born when I started making pattern welded (Damascus steel) art knives in the early ‘90s. I had a millwork shop that was available — I owned the building and it was only 500 feet from my home. I had a forge and an anvil, but I had never really done much with them until after I got out of construction.
Q: Where is your client base? Our clients are coast to coast. We get them mostly by referrals. I don’t advertise. I’m afraid to, because we’re already backed up now — I’d need a bigger building! In fact, I guess I’m going to have to build a 12,000 square-foot building because I can’t find anything already built that’s not environmentally trashed. We’re in the process of acquiring an industrial property on which to build a bigger facility.
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A textured vine railing completes a landscaping makeover
to learning leads to a Top Job bronze award.
By Peter Hildebrandt For Sherman Blankenship, owner of
Iron Touch, LLC, Louisville, KY, time spent in school and an apprenticeship proved to be fertile ground for ornamental blacksmithing. His love of learning and dedication to continuing education have resulted in fine quality craftsmanship – fine enough to garner two awards in NOMMA’s Top Job Competition in the past two years. Making the most of learning opportunities First, Blankenship enrolled in Murray State University’s metal sculpture degree program involving metal casting in bronze and aluminum for those with an art background. Then, 62
he spent four months in a European exchange program in Regensburg, Germany (described as “Germany’s best-preserved medieval city”), where his enthusiasm for metalworking only grew stronger. While there, he visited many churches and studied their architecture for his own interest. “I fell in love with the iron outside and inside those churches,” he says. “There were lots of Old World-styles, with most of the churches being centuries-old. Even where the ironwork had been repaired or restored, the effort had been done expertly enough that you could hardly tell. I found it fascinating.” Back home in his campus studio at Murray State, Blankenship happened to have a chance encounter with
For your information NOMMA member: Iron Touch LLC, Louisville, KY Ph: (502) 491-0084 Web: www.irontouch.com Contact: Sherman Blankenship Project: Custom-designed and fabricated 41/2’ tall fence with handforged, hand-woven scrollwork Materials: 2” O.D. schedule 40 pipe; 5/8” and 3/8” round bar; 11 gauge sheet metal. Challenge: Making a die for an air hammer in order to achieve the vine’s delicate lifelike appearance. Solution: Drawing on nature’s inspiration for the design, then heat-treating and constructing dies. Fabricator
The client’s home received a landscaping makeover that called for 45 feet of custom designed and fabricated fence. The fence railing was set in post holes with concrete. The finish was a threestep primer base coat, black topcoat, and a green coating on the vine work.
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NOMMA member and sculpture artist George Bandarra, who offered him a job. Bandarra had a prominent oncampus presence, regularly producing work on structural hand railings and gates — he needed help, and Blankenship needed the guidance. “It was a natural match,” explains Blankenship. “George gave me an opportunity, and from there, I started working with him on some very interesting and challenging projects.” This work and relationship evolved into a three-and-a-half-year apprenticeship. Blankenship says that it gave him priceless knowledge. “Few get to train under someone like him [Bandarra], much less are able to pick somebody’s brain on blacksmithing techniques,” he notes. Blankenship feels that Bandarra’s great “teaching sense” and good rapport with people comes from the fact that he knows more about metal than most people. “George has a huge wealth of knowledge. He’s always out to help people, really easy to get along with and understanding of the fact that I was in school,” Blankenship says. “Now, I strive to match those qualities of temperament.” After receiving his degree in metal sculpture from Murray State, Blankenship stayed on for another year-and-a-half to fulfill his arrangement with Bandarra. Then, he decided to move back to Louisville, taking the love and skills he’d developed for working on railings and gates home with him. Blankenship soon started his own business. “I took a leap of faith, dove back into what I loved, and opened my own shop/studio doors,” he recalls. “It has worked out just fine.” Iron Touch, LLC has been operating for six years as of July, 2007. The 2,000 square foot shop is centrally located in Louisville. Blankenship likes the convenience of this leased space near interstate highways and many mom-and-pop shops. Two awards – same client Almost immediately, Blankenship’s Fabricator
work became noteworthy and he has already gained recognition in NOMMA’s Top Job competition. He received a Gold award in 2005 and a Bronze award in 2007. Ironically, both awards are for work done for the same person, but at two different houses in Louisville. The job for which the Bronze Award was awarded involved an entry gate for a courtyard and 45 feet of fence railing around the grounds and home. Blankenship was glad to have the opportunity to work again with his former client, who now needed some ironwork at her new house. “Basically, she gave me a roundabout idea of what she had in mind. And then she’s always just set me free on the design, with just a couple things she wanted to incorporate,” explains Blankenship. “I came back with the designs, she loved them, and we went ahead with it.” The job was inspired by a vine design that the client had sketched on a piece of paper during the first job that Blankenship had crafted for her. From that design, he crafted a sample leaf to show her. “She was impressed with how lifelike it appeared, and requested that style of leaf throughout the vine I was to construct. This simplified things,” says Blankenship. “This client is an easy person to work with, especially because she knows exactly what she wants when she sees it.” Prepared for fine handiwork Blankenship is appreciative of Bandarra’s mentoring, which helped him get much-needed experience prior to taking on a job with something as delicate as the leaves of an ivy vine. “George is good with just about anything,” says Blankenship. “He threw in all types of textures, proposed all sorts of jobs, and enjoyed the challenge of solving artistic problems associated with the form and function of his iron designs — and he always figured it out. This was great because it taught me how to do the same thing.” Bandarra had shown him what January/February 2008
“Art mimics nature. It was a real
test to discover what would work on hot metal that would look just right...”
needed to be done in order to make a leaf look real. Subsequently, Blankenship came up with his own texturing process in order to complete the ivy vine, his first noteworthy project. He considers the support posts on this same customer’s first job to be
one of his biggest achievements as far as textures are concerned. That job has served to launch several subsequent designs and constructions. Challenges and solutions When Blankenship began the design on this fence work, it was a task at which he was already proficient. The scrolling at the beginning of the railing coming off the brick was basically modeled after what he’d already crafted in the gate that enters into the client’s courtyard. “We simply continued that motif
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from the gate to help this work all flow onto the railing on the border of her property. Then I noticed some holes in her brick that I thought were really interesting and I wanted to use those,” he explains. “I ended up taking the vines up that wall, around a corner post and through the masonry hole, and wove across the railing itself several yards to the house. Instead of just stopping at that point, I decided we had to do something more, so I ran the vine two to three feet right up the wall of her house, just like living ivy would do.”
The greatest challenge on the project for Blankenship came in figuring out how to make a die to go in his air hammer in order to achieve the vine’s delicate lifelike appearance. He taught himself how to heat-treat and construct dies for the air hammer, and drew on his knowledge of wilderness shapes to design whatever textures and other processes were needed. “Art mimics nature. It was a real test to discover what would work on hot metal that would look just right, in addition to looking like a natural vine,” notes Blankenship. “I wanted to
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custom-make it, forge it in my shop. And the fact that the customer wanted the same thing did not hurt.” Although making up the dies was a challenge, as well as time-consuming, Blankenship truly enjoyed this part of the work. It gave him much time at his forge and with his air hammer. Blankenship made a few different pieces for attachment on his air hammer to do the big metal for texturing. He also has a little double-sided swage he made himself for smaller metals with the same type of texture. The method included making four-foot pieces in a series, and as he intertwined them through the work, he attached new ones on the end. Completion and installation The project was massive and detailed — there were roughly three ivy leaves per each two feet of vine. Forty-five and a half feet of vine contained close to 100 handmade leaves. With one other person in the shop helping Blankenship with the work, the job took about 360 hours over the course of approximately nine weeks to complete. The on-site installation of the vine and metal work was the least time-consuming part of the project; it took only two days (although they were 15-hour days), with workers. Blankenship says the job was not only massive, but also complicated by its deadline. “It was one of the larger jobs I’ve ever had go through my shop since it opened. And it was a challenge to complete the design process and install on the client’s schedule,” he states. “The client was in a rush to get it done before the Kentucky Derby, which is a big deal in this area. People do like to show off their homes at that time of year, as well as during the Christmas Holiday season – my two busiest times of year.” Challenging jobs like this inspire Blankenship to continue his focus on design and texture. A second project that he entered in the interior forged category of the 2007 Top Job competition involved 38 feet of work that included a balcony, a long straight piece, and one which descended some Fabricator
steps. Every centimeter of that work was textured — even when Blankenship ground down the welds, he had to re-texture them to make the metal work vine look like it had just grown up out of the floor. Blankenship credits his current success to his past learning opportunities, especially his friendship with (and mentoring by) George Bandarra. “George taught me how to scroll really well with all different shapes and sizes and to understand design as far as certain types of houses and likenesses,” says Blankenship. “I’ve been doing a lot of the texturing work. And I’ve just kind of run away with it now.”
The fence design features hand forged, textured scrollwork. The textured vine with veined leaveshad to be hand-woven throughout the length of the fence, through the brick wall, and up the side of the house.
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Paperless possibilities Electronic filing of
tax returns has benefits for everyone, from large corporations to individuals.
By Mark E. Battersby The Internal Revenue Service is trying very, very hard to convince everyone to file income tax returns electronically. The IRS is pushing electronic filing because of the time and money they save; can the same be said for the increasingly smaller sized businesses that are required to file electronically? And more importantly, what are the pros and cons for your fabrication business? In January 2005, the IRS began requiring large corporations to electronically file their Forms 1120 and 1120S, the basic tax returns for incorporated businesses and those operating as S corporations. Certain large and mid-size corporations — those that have assets of $10 million or more and file at least 250 returns annually — are currently required to electronically file their Forms 1120 and 1120-S. Surprisingly, record numbers of taxpayers (not only the very largest that are required to file electronically) are choosing to electronically file not only tax returns, but also other forms 68
required by the IRS and the Social Security Administration. Those inevitable payments can also be made electronically. The IRS made me do it Electronic filing is a method by which qualified filers transmit tax return information directly to an IRS Service Center over telephone lines in the format of the official IRS forms. The IRS e-file program allows taxpayers to file their tax returns through an electronic return originator or by using a personal computer, modem, and commercial tax preparation software. The individual’s or company’s tax advisor, CPA, or bookkeeper can also utilize the e-file program and electronically file tax returns. E-file is not limited to incorporated companies; all businesses, including S corporations and partnerships, may also elect to electronically file employing virtually all forms of magnetic media. “Magnetic media” encompasses electronic filing as well as filing on magnetic tape, cartridge, diskette, or other media. (Attention, those who
have “aging” computer: After January 1, 2007, the IRS will no longer accept 3-1/2” diskettes for filing information returns.)
For your information The number of electronic options available is increasing every year, helping reduce your burden and improve the timeliness and accuracy of tax returns. Within IRS.gov, you can accomplish many things electronically through one single source. The Electronic IRS is a gateway to the many IRS electronic options available. Visit the “Electronic IRS” and you’ll find links to helpful information, specifically for:
Individual taxpayers Large business taxpayers Small business taxpayers Tax professionals Software companies Tax-exempt organizations
For more information, log on to www.irs.gov/efile/article/0,,id=151880, 00.html.
companies report having a plan in place to meet the IRS’s electronic filing requirements. A whopping 35 percent of those surveyed by the accounting firm KPMG LLP in late December 2006 had not even started to prepare to meet the electronic filing deadline.
Jumping on board Just as electronic filing is not only for large corporations, it is not just for taxes. Electronic filing and payment options for businesses include employment taxes, information
returns, and partnership returns as well as returns from small corporations and S corporations. However, despite the IRS’s increased emphasis on electronic filing of returns, only 15 percent of eligible
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Going electronic Although many businesses and exempt organizations prepare their returns electronically, many continue to submit them in paper form to the IRS. So, why file electronically? It’s quick, there is a 99 percent accuracy rate and it is smart – the IRS acknowledges receipt of an electronically filed return within 48 hours. The popularity of e-filing cannot be underestimated. The IRS’s figures show that over half of all tax returns filed in 2006 — a whopping 73.3 million — were filed electronically. The IRS recently issued final regulations governing who is required to file electronically. Although a temporary rule excusing those large corporations claiming electronic filing posed a financial hardship has been left out, those final rules do provide for a waiver of the requirement in the event of hardship. The White House is pushing to expand the IRS’s authority to require more businesses and exempt organizations to file their returns electronically, in an effort to bring the IRS closer to achieving its goal of having 80 percent of all returns filed electronically. E-file In the meantime, although it is not yet mandatory for the majority of metal fabricating businesses, filing tax returns electronically is a relatively straightforward process. Using the IRS’s “e-file” is one option, and most commonly used business forms can be filed either directly under the IRS’s efile program, through tax professionals, or by utilizing the services of third-parties specializing in electronic filing. What’s more, according to the IRS, using e-file does not affect the chances of an IRS examination of the return. In most states, a company can Fabricator
file an electronic state tax return simultaneously with their federal return. Other state tax authorities actively encourage electronic filing of required state forms and reports although few require electronic filing.
Although that day has not
yet arrived, the IRS clearly wants every business to “go electronic,” at least for filing, and, in some cases, paying their taxes. Beyond the basic tax return Another electronic filing option for every business allows the filing of a limited number of Forms W-2 electronically. In fact, with the employee’s permission, it is also possible to set up a system to furnish Forms W-2 electronically to employees. Each employee participating must, of course, consent electronically, and the company must inform the employees of all hardware and software requirements necessary to receive the forms. Soon, businesses may be required to file information returns used to report certain types of payments made during the year. Form 1099-MISC, “Miscellaneous Income” is, for example, used to report payments of $600 or more to persons not treated as employees for services performed for the business. In fact, as of 2006, the SSA no longer accepts the filing of paper Forms W-2 and W-3. Paying electronically A business (or its owner) can e-file their Federal tax returns and, at the same time, authorize payment via electronic funds withdrawal from their checking or savings account. Electronic payment is available for the following types of taxes: Form 1040 series (Federal income tax); Form 4868 (extension for filing individual taxes); Form 940 (unemployment tax); Form 941 (quarterly employment taxes); Form 1041 (estates and trusts); Forms 1120, 1120S, and 1120 POL January/February 2008
(corporate taxes); and Form 7004 (extensions for corporate taxes). The IRS’s goal of eventually having all businesses file electronically coincides with the U.S. Treasury’s push to have both individuals and businesses make tax payments using their “Electronic Federal Tax Payment System” (EFTPS). The U.S. Government’s EFTPS, which has been available since 1996, processed 78 million payments worth $1.8 trillion during fiscal 2005. The
number of payments processed represented a seven percent increase from the previous year. The electronic filing program, IRS e-file, includes electronic payment options, including: (1) electronic funds withdrawal; (2) credit cards; and (3) the Electronic Federal Tax Payment System (EFTPS). Credit card payments As of January 1, 2006, businesses filing Form 940 (Employer’s Federal
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credit card. Naturally, using credit cards to make payments of taxes, any taxes, incurs fees and interest costs. Credit cards do, however, offer an option, albeit an expensive one, for payment of taxes.
Unemployment (FUTA) Tax Return) and Form 941 (Employer’s Quarterly Federal Tax Return) with a balance due can pay the amount owed on the return by credit card over the phone or via the Internet. Credit card payments can be made for the balance on the current return that is due. Electronic payments are made using either of the two third-party service providers offering credit authorization and providing a confirmation number as proof of payment. Since there is a convenience fee based on the amount of the payment, the IRS recommends that a metals fabricator consider this option only in emergencies. Regular Federal Tax Deposits (FTDs), i.e. monthly, semiweekly deposits, cannot be paid by
Sooner rather than later As the IRS moves closer to its goal of having 80 percent of taxpayers filing electronically for 2007, it continues to close the doors of a number of processing centers. The growing popularity of electronic filing reportedly forced the IRS to announce the closure of its Philadelphia Submission Processing Center this year. The IRS’s path to electronic filing has not been without its fair share of stumbling blocks. During the 2006 filing ‘season,’ the IRS experienced processing problems and was forced to offer temporary exemptions to large companies and tax-exempt organizations for which e-filing was mandatory. Of course, every large corporation can request a waiver from the mandatory filing requirements based on “technology constraints” or “undue
financial hardship.” Unfortunately, neither term has been defined by the IRS. However, the IRS claims that only 50 firms had taken advantage of the waiver process by the March 15 corporate filing deadline. The IRS will work carefully to assess waiver requests on a case-by-case basis, but the IRS intends to meet its stated goals on time. Although that day has not yet arrived, the IRS clearly wants every business to “go electronic,” at least for filing, and, in some cases, paying their taxes. Whether a company relies on a tax professional or handles its own taxes, the IRS offers convenient programs to make going electronic easier. Will your business reap the benefits of “going electronic?” NOTE: Although many fabricators and other businesses will purchase software or rely on the services of a tax professional, a list of e-file software and service providers is available on the IRS’s Web site, www.irs.gov. For additional information about EFTPS, visit www.eftps.gov, or phone EFPTS Customer Service, 1-800-555-4477.
The secrets of top performing companies Here’s how the
most successful companies get ahead of the pack... and stay there.
By Richard Lepsinger OnPoint Consulting Becoming a top performer means a)
adopting proven leader behaviors and b) creating the right organizational structure and systems. Here are some simple steps for achieving both. All leaders want to be part of a topperforming company. All employees do, too. And partners and customers seek out businesses that are at the top of their game, as well. It’s natural to want to spend our working hours engaged with dynamic organizations that flourish, not struggling ones that flounder. But have you ever wondered what makes a company a top performer? I have—and when my company did a research study on a related subject, we discovered some surprising answers. January/February 2008
Our research on how top-performing companies prepare for and manage change — and what they do to ensure they are able to execute plans and strategies effectively — reveals some interesting similarities and differences between the most and least successful companies. First, the similarities between the two groups are striking. Companies in both categories can point to visions that employees believe are clear and strategies that are perceived to be realistic. They have employees who understand that the “customer is king” and who are engaged and have the skills required to do their jobs. What, then, differentiates the very best companies from those that are less successful? Top-performing companies are characterized by cultures that are flexible, adaptive, participative, and
For your information A quick online search yields a large number of book titles on various topics related to business success: The 100 Absolutely Unbreakable Laws of Business Success by Brian Tracy
How to Succeed as a Small Business Owner ... and Still Have a Life by Bill Collier When the Little Things Count . . . and They Always Count: 601 Essential Things That Everyone In Business Needs to Know by Barbara Pachter How They Achieved: Stories of Personal Achievement and Business Success by Lucinda Watson
Business Orchestration: Strategic Leadership in the Era of Digital Convergence by Johan Wallin Source: www.amazon.com
...having the best leaders in
the world won’t matter if your organization isn’t set up in a way that allows them to use their skills.
innovative—and they operationalize these cultural attributes through leader behavior and organizational structure and systems.
Leader behavior: Four ways to lead your company into “TopPerformer” territory Leaders in top-performing companies are capable in four areas—managing paradoxes, leading change, participative leadership, and leading by example. If you’re a leader, you need to ensure that you’re comfortable in all four areas. If you’re a CEO, make sure all your leaders meet the following criteria:
Get comfortable with managing paradoxes. Leaders in top-performing companies are better at finding the right balance between what appears to be mutually exclusive outcomes: achieving short- and long-term goals, establishing control and providing autonomy, ensuring stability and managing change, and keeping costs low and quality high while growing the business. They are also better able to manage the sometimes contradictory needs of customers, employees, and stockholders/owners. Understand (and use) the five magic keys to managing change. OnPoint’s research identifies five behaviors that enhance the ability to lead and manage change effectively: Be forthright about the change and its impact. Sixty-four percent of the 655 participants in OnPoint’s survey said that open and honest communication from leaders, even when they don’t have all the answers, would make change easier. People want leaders to be accessible and to engage in “change talk.” What is change talk? It’s an open discussion of the pros and cons of making the change or maintaining the status quo, and of the behaviors required to support the change and boost people’s confidence in their ability to transition successfully to the new way of doing things.
Model behaviors that support the change. It is not enough to just say the right thing or even enthusiastically communicate the benefits and the business case for the change. Employees want to see those words backed up with behavior. That is how they judge how effectively someone is leading and managing a change.
Set realistic objectives and milestones. As employees reach realistic goals and milestones, they become more positive about the change and will see its benefits. Targeting unattainable goals will frustrate and demoralize employees dur-
ing the first few critical months, and the time and energy you’ve spent preparing for the change will have been a waste. Don’t underestimate the resources required. The over commitment of existing resources or underestimating what it takes to accomplish objectives is a primary cause of change initiatives’ failing to meet their intended outcomes. Keep in mind that your employees have commitments to annual performance goals in addition to the work they need to do to make the change a success.
trust or follow them if they are not willing to live by the same values and support the same priorities they require of others. Take, for example, two contrasting approaches to the “leadership by example” factor: Donald Carty, former president of American Airlines who offered gigantic “stay bonuses” to senior executives after asking employees to take significant pay and benefits cuts, and Carlos Ghosn, CEO of Nissan, who, when he took over the floundering com-
Maintain enthusiasm and excitement among your employees. During the first month of a change, managers meet with employees to get their support. After the first month, though, those managers return to their day-to-day jobs, and employees can lose focus. Leaders need to model behaviors that support the change for the duration of the initiative, not just at the kickoff.
Involve team members in the decisions that affect them. Participative leadership matters. In 2006 the NBA introduced a new basketball and never asked the players for input while it was in development. As a result, the players refused to use a new ball they felt was difficult to handle. Involving the players early on would have increased the quality of the ball and the acceptance of the “new ball” decision. Employees should be involved in critical decisions that affect them, and they should be able to freely share their thoughts and concerns. It gives employees a sense of ownership and nothing truly great can occur in the absence of that. Lead by example. Leaders in top-performing companies understand that people will not January/February 2008
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pany in 1999, pledged to step down if Nissan failed to show a profit in 2000. Carty lost credibility and had to step down, while Ghosn is celebrated as a “master of execution” and a “turnaround artist.”
allows them to use their skills. As our research revealed, your corporate structure and operational systems are just as important as your leader’s behavior. Here are some goals to shoot for:
Structure and systems: Three ways to change yours for the better Of course, having the best leaders in the world won’t matter if your organization isn’t set up in a way that
Strike a proper balance of centralized and decentralized responsibility and ensure that people at all levels have the freedom to take action to achieve results. This improves responsiveness and allows issues to be man-
aged right where they happen. When Mark Hurd took over as CEO of Hewlett-Packard, he understood that the key to success was to make the Compaq acquisition work. He did just that when he reorganized the company into three divisions, with each division having its own sales force, making the heads of the divisions responsible for sales. He also reorganized the IT function. Instead of having eighty-five data centers, he centralized them into three. Essentially, he decentralized the sales force and centralized the IT function of the company. This is the opposite of the way the company was organized before, and it ensured the organizational structure would be better aligned with the business strategy. One measure of HP’s success is that operating profit increased during 2006 by 31 percent.
Becoming a top performer
requires... a willingness to review and continuously improve products, services, and the business model itself. Excel at coordinating decisions and actions across organizational boundaries. In 2006 Ford demonstrated how difficult this is. When the company decided to update the Ford Focus the North American operation wanted to simply refresh the existing model, while the European operation wanted to develop a new version of the model. The two groups couldn’t come to an agreement, so they each did what they wanted to do. The North American group updated the existing model, and the European group developed a new model. As a result, Ford couldn’t share parts or take advantage of economies of scale and it cost the company money. Ensure that systems are aligned with strategic initiatives. For example, if your strategy calls for “innovation,” does the organization have systems in place to facilitate organizational learning and creative thinking? To encourage innovation, a company needs a 76
mechanism to screen and fund these ideas. Individuals shouldn’t have to struggle to find support and resources to help develop their ideas. People frequently cite the efforts of Art Fry and Spencer Silver, the 3M employees who invented Post-Its, as a shining success story of personal initiative and perseverance. We would ask, “Why did those guys have to work so hard? Wouldn’t it have been better for everyone if a support system had been in place?” The bottom line? Being a top-per-
forming company is a rigorous challenge—one not for the faint of heart. Indeed, recent events at Dell, Motorola, and Chrysler illustrate how difficult it is to execute effectively and maintain top performance year after year. Still, the results are worth the effort. Becoming a top performer requires constant attention to the differentiating factors discussed above and a willingness to review and continuously improve products, services, and the business model itself. But the alternative is settling for mediocrity, and in a
global economy mediocrity is the kiss of death. After you claw your way to the head of the pack, and after you realize how much fun you and your employees are having, you’ll be glad you didn’t settle. OnPoint Consulting is an organizational and leadership consulting firm that specializes in helping companies close the gap between the creation and communication of their vision and strategy and the achievement of their business objectives. For more information, visit www.onpointconsultingllc.
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.
HERE IS HOW YOUR BUSINESS WILL BENEFIT. • Own the same machinery world wide parts suppliers use • Labor cost go down, as your least expensive employees become the most productive • Computerized control makes for fast and consistent results • Create a profit center making custom components • Inventory can be reduced, no waiting for parts • Take your business to new levels of quality • Affordable: less than cost of one $10 hr employee
US Representative, Robert Rayson, Stratford Gate Systems Office 503.658.2881 Fax 503.658.2517 Cell 503.572.6500 Email: email@example.com www.drivewaygates.com hebo Maschinenfabrik, Am Berg 2, 35285 Gemunden-Grusen, Germany. Phone ++49 6453 91330 Fax 49 6453 913355 Email: firstname.lastname@example.org www.heboe.com January/February 2008
New NOMMA members As of December 21, 2007. Asterisk denotes returning members.
Capco Steel Providence, RI Michael Caparco, Sr., Fabricator Custom Steel Designs LLC Shipshewana, IN Paul Miller, Fabricator
Evans Metal Products Co.* Elkhart, IN Bruce Rienks, Fabricator Gelander Industries Inc. Tavares, FL Kim Sechler, Local Supplier
Kreissle Forge Sarasota, FL Martin Haas, Fabricator Liberty Designs Eidson, TN Jeff Stoltz Fabricator
MIW Corp. dba Malatos Iron Works Fall River, MA George Malatos, Fabricator Modern Iron Concepts Inc. Nashville, TN John Phillips, Fabricator
NC Tool Co. Inc. Pleasant Garden, NC Denise Jones, Nationwide Supplier
New England School of Metalwork Auburn, ME Derek Glaser, Affiliate Precision Custom Metals Inc. Tucker, GA Vincent Annaloro, Fabricator Renovatec Inc. Ft. Lauderdale, FL Michael Beaulieu, Fabricator
Shaw Mfg. Wrought Iron Works Inc. Hilton Head, SC Pete Shaw, Fabricator
South Shore Ornamental Iron* North Pembroke, MA Carl Peterson, Fabricator TS Distributors Inc. Houston, TX Brad Stein, Nationwide Supplier
NOMMA Nationwide Supplier Members
A Cut Above Distributing (800) 444-2999
Albina Pipe Bending Co. Inc. (503) 692-6010
Allen Architectural Metals Inc. (800) 204-3858 Alloy Casting Co. Inc. (972) 286-2368
Custom Orn. Iron Works Ltd. (866) 464-4766
D & D Technologies (USA) Inc. (714) 677-1300
D.J.A. Imports Ltd. (718) 324-6871
DAC Industries Inc. (616) 235-0140
American Punch Co. (216) 731-4501
Decorative Iron (888) 380-9278
Ameristar Fence Products (918) 835-0898
Eagle Bending Machines Inc. (251) 937-0947
American Stair Corp. (800) 872-7824
Apollo Gate Operators (210) 545-2900
Architectural Iron Designs Inc. (908) 757-2323
Argent Ornamental Iron & Steel (678) 377-6788 Atlas Metal Sales (800) 662-0143
Auciello Iron Works Inc. (978) 568-8382
Bavarian Iron Works Co. (800) 522-4766
Big Blu Hammer Mfg. (828) 437-5348
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
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 (847) 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, CableRailâ„˘ (800) 888-2418
Carl Stahl DecorCable Innovations (800) 444-6271
Frank Morrow Co. (401) 941-3900
Cleveland Steel Tool Co. (800) 446-4402
Gerhard Glaser GmbH & Co. (011) 49-607-893-7137
Classic Iron Supply (800) 367-2639 CML USA Inc. (563) 391-7700
Colorado Waterjet Company (866) 532-5404 CompLex Industries Inc. (901) 547-1198
Crescent City Iron Supply Inc. (800) 535-9842
Geo. Bezdan Sales Ltd. (604) 299-5264 Glasswerks LA Inc. (323) 789-7800 GTO Inc. (800) 543-4283
Hartford Standard Co. Inc. (270) 298-3227 Hayn Enterprises LLC (860) 257-0680
NOMMA Nationwide Supplier Members, continued Hebo/Stratford Gate Systems Inc. (503) 722-7700
Hendrick Mfg., Perforated Metals Div. (570) 282-1010 House of Forgings (281) 443-4848
Illinois Engineered Products Inc. (312) 850-3710
Marks U.S.A. (631) 225-5400
Sculpt Nouveau (760) 432-8242
McKey Perforating (262) 786-2700
Sharpe Products (800) 879-4418
Master Halco (714) 385-0091
Michael Wentworth Architectural Metalwork (925) 216-1004
Indiana Gratings Inc. (800) 634-1988
Mittler Bros. Machine & Tool (800) 467-2464
Industrial Metal Supply Co. (818) 729-3333
Mylen Stairs Inc. (914) 739-8486
Industrial Coverage Corp. (631) 736-7500
Industry Ornamental Iron Inc. (800) 915-6011
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 NC Tool Co. (336) 674-5654
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 Mac Metals Inc. (800) 631-9510
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
Royal Forge Pte Ltd (011) 656-235-9893
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
TS Distributors Inc. (832) 467-5400
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 . . . . . . . . . . .82 Chapter News . . . . . . .84 Literature . . . . . . . . . . .86 People . . . . . . . . . . . . .87
CML USA expands operations
Events . . . . . . . . . . . . .88 New Products . . . . . . .89 Classifieds . . . . . . . . . .96
PMA renews alliance with OSHA The Precision Metalforming Association (PMA) has renewed its alliance agreement with the Occupational Safety and Health Administration (OSHA) to improve worker safety and health in the metalforming industry. The agreement was originally signed on November 17, 2005 and was renewed on November 29, 2007. Through the alliance, PMA and OSHA are updating safety literature and training. Additional information about the PMA-OSHA alliance is available at www.pma.org/about/osha.
PMA business conditions report According to the November 2007 Precision Metalforming Association (PMA) Business Conditions Report, metalforming companies expect a significant decline in business conditions during the next three months. Conducted monthly, the report is an economic indicator for manufacturing, sampling 145 metalforming companies in the United States and Canada. When asked what general economic activity trends they expect over the next three months, only 15 percent of participants reported that conditions will, 47 percent anticipate activity will remain the same, and 38 percent forecast a decline in business conditions. “PMA members are growing increasingly cautious about the general economic health of the United States, according to our November Business Conditions Report,” observed William E. Gaskin, PMA president. “However, they are still reporting fairly strong current shipments which, according to PMA’s monthly orders and shipments report, were running an average of 10 percent higher than 2006 for the first nine months of 2007. Their outlook for incoming orders for the next three months is down, a typical year-end pattern that factors in lower business expectations for the December holidays.” Contact: Precision Metalforming Association, Ph: (216) 901-8800; Web: www.pma.org. 82
CML USA, Inc. has announced completion of a new 50,000 sq. ft. operations facility in Davenport, IA. Located in Eastern Iowa’s Industrial Center (EIIC), CML USA’s new headquarters will provide sales, technical support, and light manufacturing for Ercolina pipe, tube, and profile bending machinery. Future plans for new job creation include openings in customer sales, service, and light manufacturing positions. Contact: CML USA, Inc. Ercolina, Ph: (563) 391-7700; Web: www. ercolina-usa.com.
ASA report shows important trend Several states will benefit from powerful new laws that address business practices that, for decades, have created cash flow and other financial problems for construction subcontractors. American Subcontractors Association’s (ASA) members played an integral role in generating this “wave of change” by educating policymakers about the effects of business practices such as retainage, slow payment, pay-if-paid clauses, and inequitable risk transfer. ASA has documented these policy changes in its 2007 edition of The ASA Report: The Policy Environment in the States. The report scores each state in individual policy areas such as prompt payment and anti-“bid shopping” policies, and uses the scores to assign an overall score and grade to each state. The results showed a significant trend in new state laws limiting the practice of retainage, which is the withholding of an amount of progress payments (usually a percentage of the contract value or a specified dollar amount) owed to a contractor or subcontractor until its client determines that the funds should be released. In 2007, four states adopted laws affecting their scores in the “retainage limitation policies” category of ASA’s report: Kentucky, New Mexico, North Carolina, and Tennessee. Most significantly, New Mexico became the first state ever to effectively prohibit retainage. For more information, log on to www.asaonline.com and click on “Subcontractor Advocacy.” Fabricator
What’ s Hot
OSHA’s employerpaid PPE final rule The U.S. Department of Labor’s Occupational Safety and Health Administration (OSHA) has announced a final rule on employer-paid personal protective equipment (PPE). Under the rule, all PPE, with a few exceptions, will be provided at no cost to the employee. OSHA anticipates that related substantial safety benefits of the rule will result in more than 21,000 fewer occupational injuries per year. The rule contains a few exceptions for ordinary safetytoed footwear, ordinary prescription safety eyewear, logging boots, and ordinary clothing and weather-related gear. The rule also clarifies OSHA’s requirements regarding payment for employee-owned PPE and replacement PPE. While these clarifications have added several paragraphs to the regulatory text, the final rule provides employees no less protection than they would have received under the 1999 proposed standard. The rule also provides an enforcement deadline of six months from the date of publication (November 15, 2007) to allow employers time to change their existing PPE payment policies to accommodate the final rule. For more information, log on to www.osha.gov.
New ISO standard for sustainability
Triple-S Steel Supply creates new company
Triple-S Steel Supply introduces TS Distributors to 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 its doors in 2007 to its 80,000 square foot facility. Contact: TS Distributors, Ph: (800)392-3655; Web: www.tsdistributors.com.
A new ISO standard is established to help the global trend of urbanization to develop in an environmentally friendly manner. “ISO 21930:2007 Sustainability in building construction—Environmental declaration of building products, will be a very helpful tool for the designers of buildings, manufacturers of building products, users of buildings, owners of buildings, and others active in the building and construction sector who are increasingly demanding information that enables them to address environmental impacts of buildings and other construction works,” says Jacques Lair, leader of the team of ISO experts that developed the standard. For more information, log on to www.iso.org.
DoALL adds new distributors
DoALL band saw blades, sawing machines, material handling systems, and cutting fluids are now available to a limited group of industrial distributors and machinery dealers. The 16 new distributors are located in Texas, California, Michigan, Iowa, Massachusetts, Connecticut, Louisiana, Ohio, and Indiana. Contact: DoALL, Ph: (888) DOALLSAWS; Web: www.doallsawing.com. January/February 2008
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What’ s Hot An overview of the blacksmith’s craft
The ABC’s of Blacksmithing by Fridolin Wolf places its emphasis on the history and description of blacksmithing work processes in their logical sequences. The author uses a variety of examples to explain how a project goes from the original stock to the completed piece of work. The nearly-200-page book covers topics from materials, fuels, and tools to surface treatments and contrasting techniques, accompanied by supporting photographs and illustrations.
Literature Originally published as two separate books in the German, French, and Spanish languages in the 1970s, the book has now been translated into English and combined into one edition for this re-release. Contact: Blue Moon Press, Ph: (814) 6276000; Web: bluemoonpress.org.
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Deconstruction and reusing building materials
In Unbuilding: Salvaging the Architectural Tresures of Unwanted Houses by Bob Falk and Brad Guy, two of the country’s leading experts on salvaging unwanted houses explain in words and pictures the green art of “unbuilding” and take the reader on a fascinating tour of the proceess. Unbuilding provides little known information on outdated construction techniques and the methods used to determine the value of salvaged materials. It also covers a variety of topics, from simply dismantling a wall to completely unbuilding an entire house safely. Most importantly, the material salvaged, such as ornate hardware, is often of a quality that is unmatched by anythig available today. And, thanks to new tools and several decades of experience, deconstruction today is often as fast and affordable as conventional demolition, even without the tax benefits. The 256-page book contained 300 color photos and 20 drawings. Price: $30.00. Contact: The Taunton Press; Web: www.taunton.com. Fabricator
Foreman announces staff changes Foreman Fabricators Inc., a fabricator of specialty architectural metal, has promoted Nelson Vogt to the role of Senior Estimator. Vogt has been with the company Nelson Vogt since the mid ‘90’s, performing a variety of roles including job planning and development and project management. He will oversee job site visits and assess customer needs and project feasiJeremy Marquardt bility. Jeremy Marquardt has joined Foreman Fabricators as a Project Manager. Marquardt’s experience includes having spent almost 10 years with an architectural Tim Lovell firm focusing on project detailing and planning, CAD design and development, and general architectural support. Marquardt joins Tim Lovell on the Project Manager team. Lovell’s special expertise includes several years of onsite project consulting. Contact: Foreman Fabricators Inc., Ph: (314) 771-1717; Web: www.foremanfab.com.
Indalex names new CFO Indalex Holding Corp. has appointed Patrick Lawlor as Vice President and Chief Financial Officer. Lawlor joins Indalex from Norsk Hydro where January/February 2008
he was Vice president and General Manager, Midwest Division, Hydro Aluminum. Contact: Indalex, Ph: (416) 2345808; Web: www.indalex.com.
Chamberlain Group appoints Karasek The Chamberlain Group Inc. has appointed Mark Karasek to the newly created position of Executive Vice President Engineering & Chief Technology Officer (CTO). In his new role, Karasek will be responsible for developing and implementing plans to drive technology and product development-related best practices for Mark Karasek Chamberlain and parent company Duchossois Industries Inc.
Contact: Chamberlain, Ph: (800) 528-5880; Web: www.chamberlain. com.
Hardt Elected PMA 2008 Chairman Ralph Hardt, president of North American operations for Feintool Inc., Cincinnati, OH, has been named the Precision Metalforming Association’s (PMA) 2008 chairman of the board of directors. Hardt began his term by stressing the importance of metalforming companies’ participation in the global market. “As 2008 PMA Chairman, I will promote the importance of improving global competitiveness for U.S. metalforming companies, and the mission starts with promoting the 16th ICOSPA (International Council of Sheetmetal Presswork Associations) Congress, which occurs next September in Grand Rapids, MI.” Contact: Precision Metalforming Association, Ph: 216-901-9666; Web: www.pma.org.
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FENCETECHâ€™08 and DECKTECHâ€™08 The American Fence 0 Association (AFA) will hold its 46th annual convention and trade exhibition, FENCETECHâ€™08 side-by-side with DECKTECHâ€™08, February 5-7, 2008. The event will be held at the Mandalay Bay Resort and Convention Center in Las Vegas, NV. FENCETECHâ€™08 will showcase latest products, applications, and techniques while DECKTECHâ€™08 highlights deck, railing, and perimeter security products. Contact: AFA, Ph: (800) 822-4342, Web: www.fencetech.com. .EW 6EGAS 3ITE IN
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AWS Acquires Weldmex The American Welding Society (AWS) has purchased the largest welding trade show in Latin America and
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will continue under the name AWS Weldmex. The annual AWS Weldmex event, currently in its fifth year, is scheduled to take place on January 29-31, 2008, at the new Centro Banamex in Mexico City. Categories of equipment, processes, and accessories to be exhibited at AWS Weldmex 2008 include a variety of arc welding products, plus brazing, punching, bending, resistance welding, robotics, industrial gases, laser cutting and welding, soldering, tubing and piping, plasma cutting, and stamping. Contact: AWS, Ph: (800)443-9353; Web: www.aws.org.
Welders Competition award winners The American Welding Society (AWS) announces the winner and 11 finalists of the 2007 Professional Welders Competition, which took place on November 12-13 at the Combination
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FABTECH Int. and AWS Welding Show in Chicago, IL. After 188 welders from across the United States and Canada went head-to-head in the ultimate welding challenge, only one walked away with the $2,500 grand prize. The Professional Welders Competition is held every two years at the Fabtech Int. and AWS Welding Show. The next competition will take place in 2009 in Chicago, IL. The 2007 competition awarded cash prizes of $2,500, $1,000 or $500 to the top three finalists. The grand prize of $2,500 was awarded to Luis Aceves, welding instructor at the Manitowoc Crane Corporation in Manitowoc, WI. Contact: AWS, Ph: (800) 443-9353; Web: www.aws.org.
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May 2-3, 2008 Americas Glass Showcase
The annual trade show, convention, and golf tournament â€” sponsored by Americas Glass Association, Independent Glass Association, and International Window Film Association â€” 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: www.americasglassassn.org; Email: firstname.lastname@example.org.
What’ s Hot All-glass door hinges
CRL C.R. Laurence Co. Inc. (CRL) introduces the Atlas Series of all-glass door hinges that are suitable for large interior glass doors. With two of the double-acting Atlas Hinges installed, an all-glass door weighing up to 140 pounds (63.5 kilograms) with a maximum width of 39 inches (1000 millimeters) can be created. The Atlas Hinge’s automatic closing function with adjustable spring strength eliminates the need for a closer mechanism and will close the door from any position. When fully opened, the product will hold open at 90 degrees. Hinges are available in chrome, brass, oil-rubbed bronze, and
brushed nickel finishes, and accommodate 5/16” to ½” (8 to 12 mm) tempered glass. Brass and stainless steel components are suitable for saunas or areas with excess moisture. Contact: CRL, Ph: (800) 421-6144; Web: www.crlaurence.com. 50 Ton ironworker and advanced measuring systems
Scotchman® Scotchman® “Advanced Measuring Systems” are manufactured from stainless steel investment castings and can be adapted to almost any type of metal or wood working machinery. The “MultiLoc System” allows user to put several stop
blocks on the rail for multiple settings. The product’s design eliminates any tightening of nuts, bolts, or locking devices. Scotchman also offers the 5014 CM Ironworker in their “Metal Fabricating Solutions.” This machine has heavier capacities and more features than the previous model, including 50 tons of pressure. The 5014 can punch a 13/16” hole in 3 /4”, 1-1/4” in 1/2” material and up to a 21 /4” in 1/4” with a 4” x 6” die holder. Standard features include a keyed punch ram, adjustable stroke control, electrical box with emergency palm button and lock-out tagout accommodations, 230/460volt 3 phase electrics, all guards necessary to comply with ANSI B 11-5 standards, and forklift accommodations. Contact: Scotchman®, Ph: (800) 843-8844; Web: www.scotchman.com.
e g d E g y n i c t t a u r C
u c c A
Direct Drive Saws Combine the speed of an abrasive saw, the precision of a cold saw and the versatility of a band saw. • • • • •
Precision Mitre Cuts - 0º to 60º 8” to 20” Cutting Capacities Pull Down or Hydraulic Cutting Systems ACCU-CUT Blade Guide System Small Footprint
www.patmooneysaws.com email@example.com January/February 2008
We will custom fabricate infill panels to meet your specific requirements. Available in diamond, rectangular and square mesh with or without standoffs.
Diamond Mesh w/Standoff
Standard frame is 1" x ½" channel with or without banding or “U” edging. 10, 8 and 6 gauge steel. All types of finishes available. Division 5,8 and 10. Call us today and let us take care of your infill panel needs. Call toll free
1-800-609-8296 Visit Jesco Industries, Inc. 950 Anderson @ Fab Road Litchfield, MI 49252-0388 Phone: 1-517-542-2353 Fax: 1-517-542-2501
What’ s Hot Digital image verification system and CNC Routers
New Products tion system, to simplify cutting digital prints with a Techno CNC Router. The system is equipped with a digital camera that automatically locates reference markers on a print file, verifies the image, and adjusts it for linear and rotational distortion. The system integrates with traditional graphics programs and mounts on all Techno CNC Routers. Contact: Techno, Ph: (800) 8193366; Web: www.technocnc.com. Thermal imaging cameras
Techno Inc. introduces four new “Premium Class” CNC routers with welded and stress-relieved, all-steel construction, plus THK rails, bearings, and ball screws on all three axes. Routers also feature brushless closed loop servomotors and lock ahead high-speed contouring, and are suitable for heavy production. This series comes with a heavy T-slot table and is also available with a vacuum table option that allows the use of the Tslots. The “Premium Class” is available in four standard sizes of 59” x 50”, 59” x 96”, 59” x 120”, and 59” x 144”, with special sizes available by request. Techno also presents the new Techno Vision digital image verifica-
Wahl Wahl Instruments Inc. announces the addition of the Long Distance Model HSI3003 to its line of Wahl Heat Spy® Thermal Imaging Cameras. The HSI3003 offers narrow angle 9.1° x 6.8° field of view optics to enable detection and temperature measurement of small objects over long distances. Designed for hand-held use, the camera can also be used as a
detection and diagnostic tool for monitoring the condition of electrical and mechanical systems, building diagnostics, and energy audits. Standard accessories include software, waterproof carrying case, wrist strap, battery, AC adaptor, USB cable, SD card and SD card reader, user manual, operating software CD, and light shade. Wahl has also added the High Temperature Model HSI3002 which measures in the range of 392° to 1652°F (200° to 900°C), and is suited for use where high temperature measurement is required. This product is designed for hand-held use but includes a tripod mount for remote use and comes with standard accessories. Contact: Palmer Wahl, Ph: (800) 421-2853; Web: www.palmerwahl.com. JetMachining® Center
The 60120 JetMachining® Center is the latest addition to OMAX® Corporation’s line of precision abrasive waterjets. The large format machine cuts larger or multiple parts from stock up to 5’ x 10’ (1.5m x 3m). The system is suitable for harsh environments with a traction drive that enables faster traverse speeds. The 60120 cuts a variety of materials including ceramics, composites, plastic, glass, stone, aluminum, tool steel, stainless steel, mild steel, and titanium with an accuracy of motion up to .003”. Contact: OMAX, Ph: (800) 8380343; Web: www.omax.com. Water-based rust remover
Amazing One Amazing One is offering a new environmentally friendly product to the restoration trades. RUST CLEAN 90
New Products is a water-based, biodegradable rust remover that contains no acids, solvents, or other harmful chemicals. It is nontoxic, non-flammable, and non-corrosive — it contains no acids that eat away surface metal. Contact: Amazing One, Ph: (517) 546-2022; Web: www.rustclean.com. Pulsed MIG welding system
Miller Miller’s new aluminum welding system combines an enhanced Millermatic 350P MIG/Pulse MIG welder and XR-Aluma-Pro gun for aluminum welding and feeding. The system includes everything necessary to weld aluminum “out of the box,” and has series specific arc programs and gun tension settings for improved feeding, a more forgiving arc, and longer consumable life. Contact: MILLER, Ph: (800)426-4553; Web: www.MillerWelds.com.
“Product of the Year” finalist and new Powermax Consumable Kit
Hypertherm Hypertherm presents a new consumable kit for Powermax1000, 1250, or 1650. Consumables for all four types of cutting with a Powermax are included in the new kit. The consumables are: Shielded consumables for everyday drag cutting following a line or template; Unshielded consumables for cutting in tight places or better arc visibility; Gouging consumables for tough metal removal jobs; and FineCut consumables for more precise cuts on thinner plate. The kit also includes a reference guide. Hypertherm’s Powermax30 handheld plasma cutter is a judges’ award winner and finalist for “Product of the Year” in a competition sponsored by the New Hampshire High Technology Council. Introduced last year, the Powermax30 is a portable plasma cutter that weighs 20 pounds. The product can cut 3/8” thick metal and sever ½” thick metal. It is used in a variety of industries including automotive repair and restoration, residential construction, and metal arts. Contact: Hypertherm, Ph: (800) 737-2978; Web: www.Hypertherm.com.
What’ s Hot E/Z Slide bottom track system
(Photo by Gate Technology Services, NC)
International Gate Devices (IGD) introduces the “E/Z Slide Bottom Track” system for ornamental sliding track gates. The new bottom track is available in different lengths to accommodate various frame sizes. Contact: International Gate Devices, Ph: (800) 557-4283; Web: www.intlgate.com. Slitting tool system
Mate Fully OEM compatible, Mate Precision Tooling’s
Mate LongLife combines tool steel punch and die inserts with punch and die holders. The product’s punch inserts are available in two standard sizes, 5.00 x 56.00 mm rectangle and 5.00 x 76.20 mm rectangle with two punch holders. The die inserts suit up to 3.00 mm mild steel and are also available in two standard sizes. Contact: Mate, Ph: (800) 328-4492; Web: www.mate.com/longlife.
Oil repellent gloves with grip
Ansell New HYFLEX® 11-920 gloves from Ansell combine oil repellency and patent-pending Ansell Grip Technology™. The gloves prevent oil penetration and reduce the risk of dermatitis and need to double glove. They have an ergonomic design and are machine washable. Contact: Ansell, Ph: (800) 8000444; Web: www.ansellpro.com.
Cable stripper and commemorative items
Klein Klein Tools recently added the QTR-Turn™ NM cable stripper/cutter (Cat. No. K1412-3) with Klein-Kurve® handles to its line of strippers and cutters. The QTRTurn removes the outer jacket of nonmetallic (NM) cable and has springloaded action for self-opening. The multi-functional tool strips, cuts, and loops 12 and 14 AWG solid wire, and shears 6-32 and 8-32 screws. Continuing its 150th anniversary celebration, Klein Tools introduces three commemorative, limited edition products with the Klein Tools 150th anniversary logo. They include a ninepiece nut driver set, a contractor’s leather zipper portfolio with handles, and a lockback pocket knife. Contact: Klein Tools, Ph: (800) 5534676; Web: www.kleintools.com.
New England School of Metalwork 2007-08 Winter Session English Wheel Building Tool Forging for Smiths C o a l Fo rg e B u il din g Fo rg ed B o t a nic a l Fo rm s Pattern Welding Basic Bladesmithing
2008 Summer Session Instructors Lucian Avery Dereck Glaser Caleb Kullman Peter Ross John Rais Don Fogg
Doug Wilson Jonathan Nedbor Muh-Tysr Yee Clay Spencer Wendell Broussard And more !!!!
Summer Workshop Registration is now Open!!
www.newenglandschoolof metalwork.com 1-888-753-7502 92
What’ s Hot 1st Zinc
2-Flute micro grain ball endmills
Weld-Aid Weld-Aid presents 1st Zinc, a 95 percent zinc-rich coating designed to provide the highest level of corrosion protection for metal in cold-galvanizing applications. The product was developed for use on metal parts and assemblies as either a protective primer coat to be later topcoated or as a stand-alone coating. 1st Zinc is available in aerosol cans and bulk gallons. Contact: Weld-Aid, Ph: (800) WeldAid; Web: www.weldaid.com.
NS Tool A new tooling option is available to machinists tackling hardened steels in the 48-65 HRc range from Single Source Technologies’ NS Tool. The MSBH230 and MRBH230 twoflute micro grain carbide ball endmills are designed to improve chip removal and reduce chatter in hardened steel, and feature a Mugen coating for high oxidation temperatures. The new tooling is available in 0.05-3mm radiuses, longneck (MRBH230), and standard (MSBH230) version. Contact: Single Source Technologies, Ph: (248) 232-6232; Web: www.SingleSourceTech.
Magnetic activated ground
Metal and plastic knobs
Western Enterprises Western Enterprises announces the new magnetic activated ground for welding with built-in on/off switch. The product is lighter than alligator clamps or traditional style magnetic clamps without needing to tack a tab to the surface. The “Magnetic Activated Ground” can handle up to 450 amps continuously at 100% and up to 600 amps at a 20% duty cycle on a clean, flat surface The product has an ergonomic curved body which permits onehanded operation with or without gloves. Contact: Western Enterprises, Ph: (440) 871-2160; Web: www.WesternEnterprises.com.
Jergens Jergens offers an extensive line of metal knobs for clamping, fastening, operating control, and other applications. Metal knobs include cast iron, steel, and aluminum with reamed holes, tapped holes, blanks, or custom made. Jergens also offers plastic handles, knobs, and handwheels. Contact: Jergens, Ph: (800) 537-4367; Web: www.jergensinc.com.
What’ s Hot Compact material handling system and press brake
Bystronic’s new material handling system “ByTrans,” can expand user operations up to three shifts. The system’s short cycle time is independent of the thickness of the metal sheet and ensures greater overall throughput. Loading and unloading takes 60 seconds and the “ByTrans” has a small 15’ x 10’ inline footprint and handles all sheet thickness up to one inch plate. Bystronic introduces the new Beyeler Xpert press brake: a system that offers users simplified repetition accuracy. The Beyeler Xpert comes
equipped with a comprehensive database based on material bend allowances and empirical bending knowledge for use by experts or novices. The open control makes it possible to change all calculations individually. All major tooling styles are supported by the Xpert and its database. The press brake adjusts ram position and crowning during the bending process in response to material properties and introduces no angle errors with .00015” ram positioning repetition accuracy. Contact: Bystronic Inc., Ph: (631) 231-1212; Web: www.bystronicusa. com. Waste oil heater line
Landa Landa Cleaning Systems’ new waste oil heaters provide an economical alternative to disposing of
used oil. The four models feature BTU input ranging from 155,000 to 500,000 and an integrated air compressor that produces clean, dry air and eliminates the need for shop air plumbing. The products also have multi-direction air louvers to direct the heat where needed and swing-out removable burner for cleaning and maintenance. Contact: Landa Cleaning Systems, Ph: (800) 547-8672; Web: www.landa.com. Remote hour meter
Hyster Hyster Company’s remote hour meter automatically tracks lift truck run time to take the place of manual product checks. Through a customizable software interface, managers can use the network’s grouping capability to view the runtime of an entire fleet or specific units. Contact: Hyster, Ph: (800) HYSTER-1; Web: www.hysteramericas. com.
DEDQDRUJ DEDQD DRUJ ABANA A PO Bo Boxx 3425 25 Kno xville, TN 37927 27 Knoxville, 865.546.7733 33
$UWLVW%ODFNVPLWKV $UWLVW%ODF FNVPLWKV Association of North Norrth America, Inc. 94
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Contact Rachel Bailey at (423) 413-6436, or firstname.lastname@example.org. 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: 1–35 words = $25; 36–50 words = $38; 51–70 words = $50. Next closing date is Friday, June 9, 2006. For more information, contact Rachel Bailey, Ph: (423) 413-6436; E-mail: email@example.com.
Advertiser’ s index Fabrication
Access Control and Gate Operators/Hardware Pg 15 07 25 71 76 38 30 21 92
Company ......................................................................................Website Chamberlain ..........................................www.chamberlain.com D & D Technologies (USA) Inc. ..............www.ddtechusa.com DKS, DoorKing Systems..............................www.doorking.com Encon Electronics..........................www.enconelectronics.com International Gate Devices..................................www.intlgate.com Marks U.S.A. ................................................www.marksusa.com Master Halco ..........................................www.fenceonline.com Multi Sales Inc. ....................................www.multisalesinc.com Universal Entry Systems Inc. ............................(800) 837-4283
Metal Moment 90Striker Tool Co. (USA) Inc. www.strikertools.com 89 TP Tools......................................................................www.tptools.com 93 Vogel Tool & Die..................................................www.vogeltool.com Fabrication Services 78 94
Colorado Waterjet Co. ................www.coloradowaterjet.com Tornado Supply ........................................................www.owi-inc.net
59 94 32 40 58
Birchwood Casey ..................................www.birchwoodcasey.com Intercon ......................................................www.intercononline.com Sumter Coatings Inc. ......................www.sumtercoatings.com Sur-Fin Chemical Corp. ..........................www.surfinchemical.com Triple-S Chemical Products..................www.ssschemical.com
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 Inc.......www.archirondesign.com Architectural Products by Outwater ..............www.outwater.com Atlas Metal Sales ......................................www.atlasmetal.com Bavarian Iron WorksCo. ....................................www.ttbiw.com Julius Blum & Co. Inc. ..............................www.juliusblum.com The Cable Connection ............www.thecableconnection.com Cable Rail by Feeney ..................................www.cablerail.com Cable Rail by Feeney ..................................www.cablerail.com Complex Industries Inc.......................................(901) 547-1198 Crescent City Iron Supply..................................(800) 535-9842 D.J.A Imports Ltd. ....................................www.djaimports.com Decorative Iron ..................................www.decorativeiron.com FATIH PROFIL Inc..............................................www.fatih.com.tr The G-S Co. ..........................................................www.g-sco.com Jansen Ornamental Supply Co. ........www.jansensupply.com Jesco Industries Inc. WIPCO div.................www.jescoonline.com King Architectural Metals ......................www.kingmetals.com Lawler Foundry Corp. ........................www.lawlerfoundry.com Lawler Foundry Corp. ........................www.lawlerfoundry.com Lewis Brass & Copper Co. Inc. ..............www.lewisbrass.com National Bronze & Metals ........................www.nbmetals.com New Metals Inc.........................................www.newmetals.com Oakley Steel Products ........................................(888) 625-5392 Regency Railings ..............................www.regencyrailings.com Rik-Fer USA ..........................................................(630) 350-0900 Tennessee Fabricating Co. ................................www.tnfab.com Tennessee Fabricating Co. ................................www.tnfab.com Texas Metal Industries ..................................www.txmetal.com The Wagner Companies ............www.wagnercompanies.com The Wagner Companies ............www.wagnercompanies.com Wrought Iron Concepts ......www.wroughtironconcepts.com
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. Co.................www.bigbluhammer.com Blacksmiths Depot.............................www.blacksmithsdepot.com Carell Corporation......................................www.carellcorp.com Cleveland Steel Tool Co. ..........www.clevelandsteeltool.com Classic Iron Supply ......................www.classicirononline.com CML USA Inc. ..........................................www.ercolina-usa.com COMEQ Inc. ..............................................................www.comeq.com Eagle Bending ....................www.eaglebendingmachines.com Glaser USA ..................................................www.glaser-usa.com Hebo GmbH........................................................www.heboe.com Mittler Bros. Machine & Tool ................www.mittlerbros.com NC Tool Co. ..........................................................(800) 446-6498 Pat Mooney Inc. ....................................www.patmooneysaws.com PlasmaCAm ..............................................www.plasmacam.com Production Machinery Inc. ........................www.promaco.com R & D Hydraulics Mfg. & Machine Co. ..................www.rdhs.com Silver Mine Distribution ....www.silverminedistribution.com Striker Tool Co. (USA) Inc. ....................www.strikertools.com
Professional Development 84 86 84 16 53 88 86
ABANA............................................................................www.abana.org ARTMETAL ..............................................................www.artmetal.com Campbell Folk School ......................................www.folkschool.org NEF / NOMMA ..................................................www.nomma.org NOMMA ..............................................................www.nomma.org NOMMA ..............................................................www.nomma.org Traditional Building ........................www.traditional-building.com
Software 04 89 87
FabCAD Inc. ......................................................www.fabcad.com MB Software Solutions ......www.mbsoftwaresolutions.com Red Pup Productions ............................www.ornamentalpro.com
Stairs & Treads 100 28 43 74 79
The Iron Shop ........................................www.theironshop.com Salter Industries ......................................www.salterspiralstair.com Stairways Inc. ........................................www.stairwaysinc.com Steptoe & Wife Antiques Ltd. ....................www.steptoewife.com Tri-State Shearing & Bending............................(718) 485-2200
Glass Services 78 91
K Dahl Glass Studios ......................................www.kdahlglass.com Lindblade Metal Works ..............www.lindblademetalworks.com
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.
Trickle-down theory for small business management Everything — from work ethic
to business culture — filters down from the top. By Doug Bracken Wiemann Iron Works It is no wonder that the actions of the President of the United States of America are under a microscope — he is the announced and stated leader of this great nation and, as such, is expected to represent us at home and abroad. Our choice for this position, which is elected, says a lot about us as a nation and our values at the time of the election. In business, however, our leaders are often appointed more often than elected. But the role is still the same. The values and goals of the company are supposed to be set by the company’s leadership and followed daily by the employees. Trickle down theory — the idea that everything starts at the top and works its way down — works for business values, ethics, and culture. And it is a natural law in business and in politics. Sam Walton set the tone for his multinational billion dollar discount retail business with a number of simple decisions and mandates that are still in effect today, one of which was to keep overhead as low as possible. This is the reason that the Wal-Mart’s corporate headquarters is still in a small, unassuming single-story building in Bentonville, AR. The executive office is not any more elaborate than those found in a number of small machine shops and foundries I have visited, with cabinets that date to the last remodel in the 80’s. And when they travel, Wal-Mart’s executives share rooms at the sensibly priced 98
motels where they are staying. A “fat cat” executive has no place in a lean, cost-conscious corporation bent on saving money at every turn. While your business may not rival Fortune 500 companies in volume, it is interesting how few business leaders, whether running a five-person operation or a 5,000-person operation, neglect their leadership roles to spend their energy and time pursuing selfish interests, adopting a “do as I say not as I do” policy for their leadership mantra. It should be no surprise to anyone working in such a structure that the types of organizations these “leaders” create are fragmented and full of disenfranchised employees who also share the same self-centered vision. In other words, find a greedy, self centered business leader and you will find a group of like-minded employees. Take this simple example: Business owner Bob regularly takes office supplies home for personal use, and employee Susan knows this. Business owner Sally reimburses the company with a check or cash for the office supplies she takes home, and employee Greg knows this. Which employee do you think will hold company property to a higher value or standard, Greg or Susan? Which employee will think twice before taking office supplies home themselves? This is but one small example of how important consistent, ethical, and, certainly, sensible daily leadership is within an organization of any size. I have seen businesses with just a
handful of people who struggle dayto-day with a leader who is erratic or absent. And I have seen small companies struggle with two partners who want to take the firm in different directions or plunder the company profits for their personal use, ultimately leading the company to ruin. On the other hand, I have seen examples in which business leaders failed but learned from previous efforts, then tried and succeeded by following a clear and consistent, well adapted plan. Leaders who free themselves from petty self-interest can lead; leaders who cannot do that merely follow their own noses and find “success” by luck, more than skill or talent. Success starts at the top. So, for those of you in a position to advance the common cause for the better, please do so quickly. And, for those of you reading this who simply report to work every day, wondering what the future holds for you and your company, look to its leaders. If they are not leading, then there is no reason to follow. The author welcomes your comments, suggestions, and inquiries for reprinting rights at Douglas_Bracken @wiemanniron.com.
Doug Bracken is a past president of NOMMA.
King Architectural Metals "RIDGING THE DIVIDE BETWEEN OLD WORLD FORGING PROCESSES AND MODERN DESIGN STANDARDS TO PROVIDE LIMITLESS OPTIONS FOR CREATING DESIGNS THAT WILL LAST
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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 www.TheIronShop.com/FAB Main Plant & Showroom: Dept. FAB, P.O. Box 547, 400 Reed Road, Broomall, PA 19008 Showrooms / Warehouses: Ontario, CA • Venice, 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 ©2007 The Iron Shop
Circle 11 on Reader Service Card
Published on Nov 12, 2012