Page 1

Celebrating NOMMA — past and present — in pictures, pg. 48

Ornamental and Miscellaneous Metal March/April 2008

The official publication of the National Ornamental & Miscellaneous Metals Association

$6.00 US

Job profile

A stunning, challenging, multilevel circular stair system page 43

Deconstruction recycling, page 30

Save money by recycling solvents, page 14

Shop Talk

NOMMA members talk scrap, pg. 18

Member Talk

Industrial/ornamental success , pg. 34

Biz Side

Will you ever be able to retire?, pg. 71

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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 on i s s i m Ad Wednesday, April 2, 4:30 p.m. – 8:00 p.m. – Trade Show Grand Opening/Reception

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

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

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

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

List three products you hope to purchase at METALfab 2008:

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

Name _____________________________________

Company __________________________________ Address ___________________________________

City _______________________________________

State ___________ Zip _______________________

Phone __________________ Fax ______________

Email _____________________________________


1) ________________________________________ 2) ________________________________________ 3) ________________________________________

Primary type of business: Fabricator General Supplier Contractor Other___________________

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

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

Job description: Owner Manager/Foreman Other_______________

Check here  if you are not involved in the business.

President’s Letter The benefits of peserverance 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

As I sit down to write my last letter as President of NOMMA, I really can’t think of anything to say. And I find that so embarrassing and frustrating that I almost don’t want to do it. There are times when finding the right motivation to do things that we know have to get done can be a real burden. Some of us just ignore it and hope it goes away, while others plow right through just to “get it over with.” Neither path tends to be enjoyable or very productive. However, I’ve learned that if we persevere through these times, much can be accomplished and great benefit can be had. An example of this recently came from my work place. We decided to review all work procedures and paper trails within the company. We met once a week with key managers and shop personnel to discuss all aspects of the business. I did not forward to this at all. Each of us had strong opinions and concerns when the discussion came around to “our” areas. Each of us had to set aside our pride while items of “interest” affecting us were discussed. Sometimes, the conversation did get off track but, fortunately, did not stay there for long. After several weeks we got through the process with some very surprising results. Opening up avenues of communication brought a mutual respect for each other and our areas of responsibility. For the shop, we created finishing and tolerance standards, and the installation crews have a complete job packet containing all up-to-date, pertinent information. We also reviewed the exact information our salesmen needed to provide to the estimator. The detailer even has a complete outline of what the shop needs on each drawing. The whole point of the review was to create a streamlined workflow, which would increase productivity while decreasing costs. I have to admit that, as much as I dreaded these meetings, the results have been well worth the time and trouble.

I can say the same for NOMMA. When a board meeting comes at a busy time or a letter needs to be written while a stack of paperwork has to be dealt with, it can all be a little overwhelming. But I can say that, over the six years that I have been privileged to serve on the board, the positive results have far outweighed any cost. I have truly gained far more than I have ever Breck Nelson is given. I will always president of cherish the friendthe National ships made, questions Ornamental and answered, and stories Miscellaneous shared by fellow Metals Association. NOMMA members. Joining with fellow shop owners and managers for the betterment of all has been a great learning experience for me. I’ve developed a deep respect for those I’ve served with over the years and truly believe we have accomplished much good for the membership of NOMMA and the industry as a whole. Having said this, I would like to challenge those of you who have yet to join or volunteer at NOMMA. There is still a lot of work to be done. Technical Affairs seems never able to rest, due to the ever-changing codes issues. There are future METALfabs to plan, complete with educational sessions answering today’s tough questions for the fabricator and small businessman. These are just two of the many challenges facing NOMMA today. Please consider taking an active part in NOMMA and make this association your association. I guarantee that the experience and wisdom gained will be worth more than any perceived cost. If you would like to know or hear more, just give me a call. It has been my privilege and honor to serve you as president of NOMMA, God Bless and have a great “08.


March/April 2008


March/April 2008 Vol. 49, No. 2

A coffee table is the inspiration for an ornamental fabrication business. See page 34.

Tips & Tactics

Biz Side

Job Profiles

Accurate measuring . . . . . . . . . . . . . 12 Easy and effective auto-measuring for spacing stops. Solvent recycling . . . . . . . . . . . 14 Save money while you go green by recycling your solvents. By Michael Robbins

Shop Talk

A stunning stairway ....................43 This three-level circular stair system wins Top Job Gold. By Lisa Bakewell

Modern zoo architecture ........48 A NOMMA member’s stainless steel mesh product creates a natural habitat.

Time is money . . . . . . . . . . . . . . . . . . . . 68 Stop wasting this precious resource. By Glenn Shepard

Will you be able to retire? . . . . . 71 Plan for tomorrow’s financial needs. By William J. Lynott

Project juggling school . . . . . . . . . 75 Prioritize your company’s objectives. By Rudolf Melik

Look before you scrap it . . . . . . . 18 Learn how some NOMMA members are recycling scrap. By Peter Hildebrandt

Member Talk Charitable recycling . . . . . . . . . . . . . 30 A community partnership creates a win-win situation for all. Ornamental success . . . . . . . . . . . . . 34 Industrial shop embraces ornamental. By Sheila Phinazee

President’s Letter . . .6 Persevering through challenges has many benefits.

Special Feature 2008 Trade Show Report. . . . . 54 METALfab 2008 exhibitors recap their products and services. METALfab 2008, celebrating NOMMA’s 50th anniversary, takes place in Memphis, TN, home to the Metal Museum (right).

Editor’s Letter 8 Recycling was once known as “thriftiness.”

What’s Hot! New Members . . . . . . . . . . . . . . . . . . . . 80 Nationwide Suppliers . . . . . . . . . . 80 Biz Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Chapter News . . . . . . . . . . . . . . . . . . . . 84 Literature . . . . . . . . . . . . . . . . . . . . . . . . . 86 People . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 New Products . . . . . . . . . . . . . . . . . . . . . 91 Classifieds . . . . . . . . . . . . . . . . . . . . . . . . 96

Reader’s Letters . . . 10 Plasma cutting software, brass plating, and more.

Biz Perspectives . . . 94 Plan today for a better business tomorrow.

Cover photo: NOMMA member Construction Services Inc., Decatur, AL, received a Gold award in the 2007 Top Job contest for this three-level circular stair system installed on the University of Michigan campus. March/April 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:


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


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


1-35 words: $50 member, $65 nonmember; 36-50 words: $75 member, $90 nonmember; 51-70 words: $100 member, $115 nonmember; 71-100 words, $130 member, $145 nonmember. Send items to: Fabricator, at address above, or E-mail: Ads may be faxed with credit card information to: (770) 288-2006. Deadline: 2nd Friday of the month prior to publication.


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

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

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

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

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


December as a separate for all advertising materials info, contact Todd Daniel at or

For a quote, contact NOMMA at (770) 2882004 or

Opinions expressed in Fabricator are not necessarily those of the editors or NOMMA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA. Circulation: 9,000.


Editor’s Letter Everything old is new... again I remember sitting in my grandmoth-

er’s kitchen as a child, watching her wash aluminum foil that had previously covered a casserole (or three), to be used again later. She also typed family letters (multiple copies with well-used carbon paper inserted between the sheets of paper) on the backs of solicitation letters she’d received in the mail. Birthday and Christmas presents were wrapped in newspaper and tied with twine — and the card on top was the cover torn from a greeting card from the past. At the time, it was one of those family jokes that we grandchildren rolled our eyes and laughed over. But later, I realized that Grandmama was a true recycler. She would have called it “being thrifty.” Today, I practice being thrifty, too, although I’m not nearly as good at it as she was. While I don’t actually scrub used aluminum foil, I do have a bin for newspapers, magazines, and plastic that gets picked up each week, and I make sure appliances and electronics go to places where they can be refurbished for continued use. Many of you NOMMA members are pretty thrifty, yourselves. In this issue of Fabricator, you’ll see a recurring theme — recycling. Our Shop Talk feature focuses on what some of you are actually doing with scrap materials — selling, buying, reusing. In Member Talk, Dirk Brown of Blue Mountain Metalworks tells us about a unique community partnership that involves deconstruction and recycling. One of our Tips and Tactics articles covers the topic of solvent recycling — how it works, and how it can be environmentally and financially beneficial to both large and small shops. Also in this issue, our second Member Talk article features James Minter and Imagine Ironworks. Believe it or not, a coffee table was the

catalyst for this ornamental fabrication business. We have two very interesting Job Profiles for you. First, you’ll read about Construction Services Inc.’s three-level circular staircase and the challenges in fabricating and assembling it. And second, NOMMA member Carl Stahl helped provide a more natural habitat for the Diana monkeys at London Zoo with stainless steel mesh. Helen Kelley is editor In Biz Side, of Ornamental & Glenn Shepard Miscellaneous Metal addresses one of Fabricator. everyone’s biggest nemeses: time wasters. (Glenn, a very popular speaker at last year’s METALfab, will be making a return appearance at this year’s convention.) Learn how to anticipate and head off these time “leeches” so that your workday is more productive. Also in Biz Side, William Lynott’s article, “Will You Ever Be Able to Retire?” will help you make a plan to allow you to stop working when you’re ready. The time draws near for NOMMA’s 50th anniversary celebration at METALfab 2008 in Memphis, April 15. As always, our convention will be packed with educational and networking opportunities, the annual Top Job competition, entertainment, and more. Details can be found on our website, I hope you enjoy reading this issue of Fabricator as much as I enjoyed putting it together. And when you’re finished (if you don’t save your back copies), be sure to recycle it!


March/April 2008

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



March/April 2008

March/April 2008 



Accurate measuring

Tips & Tactics

Measuring spacing stops by hand can be laborious and time-consuming. Is there a better way? The question of auto-measuring was recently discussed on NOMMA’s ListServ. Here, we highlight one system that can solve the issue of measuring between multiple stops.

The initial question on ListServ:

We have a Pirana p-50 Ironworker, and 2000’ of 2” x 1” aluminum channel that we need to punch holes for pickets. Anyone have any ideas or pictures of a stop of some kind to set for your spacing between pickets, so we don’t have to mark each one by hand. we bought this machine used and didn’t receive much tooling with it. Wade Ranck Eagle Machine & Welding John Groll, Groll Ornamental Iron, responded that he’d had success with Scotchman’s Advanced Measuring System, a series of cutting and punching stops, with his cold saw. “We have the single stop model on our cold saw, which allows cutting multiple pieces to the exact same length without measuring,” explains Groll. “The size can be changed in sec12

onds. They also offer a multiple-stop model that could be used for punching or drilling at different increments. We use our AMS for any job that has more than two same size pieces.” Fabricator asked Scotchman to supply some information about their AMS that could explain in detail the equipment and its capabilities. Here’s what they told us: The Advanced Measuring System (AMS) makes setting your length easy and accurate, the first time. Its versaility allows it to be used with a variety of equipment and applications, such as cut-off saws, radial arm saws, cold saws, punching, shearing, drilling, ironworkers, presses, and woodworking tasks. The systems are available to feed your material left to right or right to

For your information Here’s how the AMS works:

 Simply move the stop to the correct setting and let go. The gauge aligns itself to the dimension you selected. It’s as easy as picking up & pressing down the Multi-Loc or sliding the Quick-Loc to the setting.  Once set, the teeth guarantee the stop will never slip or move, eliminating miss-measures and waste.

 The same dimension can be repeated again and again, different operators, different operations, even on different days.

 Either permanently mounted at your work station or installed on a portable work table for use in the field, they quickly attach to any flat surface with common tools. For more information, log on to or Fabricator 

March/April 2008

left from 4’ to 24’ lengths. These patented state-of-the-art Loc Stop and Multi-Loc systems are manufactured using stainless steel investment casting and are guaranteed not to slip. They can be mounted on almost any metal or wood working machinery. The patented AMS Loc-Stop System is an industrial measuring device that helps produce greater efficiency, higher productivity, and lower business cost. Multi-Loc The Multi-Loc Stops allow you to set stops at various lengths, thereby maximizing your raw stock without changing your set up each time. These Multi-Loc versions of the AMS Gauging Systems allow you to place multiple stops on the rail as close as 1 inch apart on the Standard System, and 11/2 inches apart on the Heavy Duty System. Three stops come with each assembly and either system is available in left-hand and right-hand models. To operate, simply set the stops to your cut list dimensions. Slide the material past the stops you do not want to use, right to the desired setting. Press the material against the fence and the flippers on the stops not used will move away. Multi-Loc Systems are available in 1/16inch increments and in standard lengths of 4, 6, 8, 10, and 12 feet. Longer lengths can be achieved by joining rails together. Quick-Loc Simply squeeze the handle on the Quick-Loc Stop System, slide it into position, and release it. The teeth on the stainless steel stop align themselves to the teeth on the rail to give you exactly the dimension you set. Once in place, the stop cannot slip. The Quick-Loc version is available in left-hand and right-hand models. Numerous accessories have been designed to customize this system to your special needs. It is available in increments of 1/16inch, and in standard lengths of 4, 6, 8, 10, and 12 feet. Longer lengths can be achieved by joining rails together. The teeth feature allows you to quickly set the Quick-Loc Stop using the built in measure. In seconds, your work station is set up and locked in.

March/April 2008 


The AMS QL in use with a cold saw.

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Solvent recycling

Tips & Tactics

Recycling solvents not only helps the environment, but can also result in substantial savings.

Have you been thinking of purchasing a solvent recycler for your shop? Here are some ways to determine if it’s right for your business.

By Michael Robbins NexGen Enviro Systems Inc. Editor’s note: Since prehistoric times, the process of distillation has been used to produce alcohol for human consumption. This same process is now being used for many other purposes, including the recycling of solvents used in industrial or small business environments. Here, recycler supplier Mike Robbins describes this process and explains its potential benefit for the bottom line as well as the environment.

Distillation is the simple process of heating a mixture of ingredients until a solvent material evaporates-then cooling and condensing that vapor into a pure liquid. Alcohol has been produced this way since time immemorial, and today the process is being used by large and small organizations to recy14

cle materials from manufacturing, painting and cleaning operations. The ability to recycle solvents on a small scale has emerged in the past 30 years with the development of “batch” stills. Auto-body shops began using these small recyclers in the mid 1980’s, and now they’re catching on with more and more organizations that wish to control their own destiny and re-use their waste solvents thus saving on disposal cost. These recyclers save money in two ways: by recycling used solvents so they can be used again and by eliminating most (and some times all) of the expense of disposing the hazardous waste. Although even the smallest recyclers cost several thousand dollars, they can easily pay for themselves in a year or two if the company generates any volume of solvent waste. It also must be said that recyclers are good for the environment. They make it possi-

For your information Solvent recycling or solvent distillation is the preferred technology for recovery and reuse of waste chemicals from varied industrial applications such as paint cleanup, parts cleaning, printing, etc. Here are some of the benefits gleaned from solvent recycling:

 Save money on both new solvent purchases and waste solvent disposal costs  Reduce liabilities associated with solvent storage and waste disposal

 Make the workplace safer and cleaner

 Lower EPA generator status, thereby reducing paperwork and fees associated with waste accumulation and disposal  Reduce onsite hazardous waste storage

 Increase productivity of solvent cleaning operation

 Lower labor costs associated with storage and transport of solvent waste


March/April 2008

Iron and steel prices are going up.

Our prices are going down.


Lawler Foundry Corporation 75 years OF EXCELLENCE 1933-2008 FOR OUR NEW CATALOG 19

FAX 205-595-0599



Solvent recyclers come in a variety of sizes to fit the needs of both large and small shops.


ble to use the same material over and over again. Breaking it down There are two types of recyclers: continuous and batch. Continuous recyclers use inline or auto-fill technology â&#x20AC;&#x201D; that is, dirty solvent flows into one end and clean solvent comes out the other. These large recyclers are used in large-scale industrial applications by major generators of solvent waste. By contrast, batch recyclers distill one load of solvent at a time over a period of several hours. The principal components in a batch recycler are a tank in which the waste is deposited, a heating system for turning the liquid part of the waste into vapor, and a condenser to cool the vapor back into a liquid. The size of the tank determines the size of the recycler. Methods of heating include

steam, direct heat, and indirect heat. Indirect heat is usually the preferred approach because the heating is more uniform. The condenser is most often a series of looped copper or stainless steel coils (resembling a car radiator) that are cooled by a built-in fan or surrounded by water to chill the vapor into a liquid. Recyclers are fairly unique among the tools in most businesses in that they do almost all of the work on their own. About the only things you have to do are fill the tank, turn on the machine, and remove the solid material that collects in the bottom. Purchase options Here is a way to determine the degree to which you will benefit from owning a recycler: First, figure what youâ&#x20AC;&#x2122;re paying per year to have dirty solvent hauled off per drum. Add this


March/April 2008

number to the cost of purchasing replacement solvent. Then, weigh this figure against the price of a recycler and determine how long it will take for your savings to pay for it. If a recycler is of interest to you, the next step in the process is finding one that suits your particular needs. Here are some questions you should ask:  Is the capacity of the recycler adequate for your needs?  Is the tank heated by steam, hot oil, or by a directly attached heat element? (Hot oil is widely regarded as the best option for most units.)  Is the solvent vapor cooled and condensed by water, fan, or coolant? A fan is generally sufficient for smaller units.  Is the recycler designed to shut down safely if the maximum operating temperature is reached – or, in the case of a water-cooled unit, if the water is cut off?  Does the supplier offer a service for testing samples of your residue? This will ensure the viability of using a recycler. With society’s increasing concern for protecting the environment, it only makes sense (both for the sake of the environment and for the cost savings) to recycle your used solvents. Small batch recyclers are designed to do this at an affordable price. For larger organizations, medium, large, and more complex units are available to provide the same solution.

About NexGen: Michael Robbins is owner and president of NexGen Environ Systems Inc., a supplier of recyclers, from 2.6-gallon batch to 200-gallon continuous operation. Two of NexGen’s customers have been awarded the Governor’s Trophy for pollution reduction in their respective states. One was Rogers Body Shop in Minnesota, which reduced their solvent usage from 100 drums per year to just three by use of two 16-gallon recyclers. The second was a major northeastern Navy ship builder, which reduced their waste solvent stream dramatically by use of four systems in various areas of their production yard. Contact: NexGen Enviro Systems Inc., Ph: (800) 842-1630; Web:

March/April 2008 


Push-Lock™ fittings make cable railings easy to install. Push-Lock™ and new Pull-Lock™ fittings are attached to your cables by hand, totally eliminating field swaging. Made of attractive stainless steel, they are economical and easy to install. Use them with wood or metal framed railings, indoors or outside. Contact us today to learn how easy it is to fabricate a cable railing that you and your client will be proud of.

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Shop Talk

Before you scrap it... take another look  NOMMA

members — thinking both locally and globally — recycle their materials in a variety of ways for a number of reasons. By Peter Hildebrandt The reuse of metal is as old as, well,

the Iron or Bronze Ages. But, with the possible exception of inaccessible scrap metal from the Titanic, there truly is no end to the life of metal when it comes to direct use. Just because a ship has a 25-year life span does not mean its iron or steel cannot eventually be reused in computers, automobiles, skyscrapers, eggbeaters, or ornamental dolphins or railings — all of which, in turn, have life spans of their own. Scrap metal differs from ordinary trash or refuse in that the person who picks up our residential garbage is paid to send it to its final destination, the landfill. For the scrap metal owner, the situation is reversed. Those with scrap metal in yards or storage bins have material that is 18

basically inventory and has a value or monetary price per pound linked to events happening globally — including the world’s stock markets. For better or for worse, our scrapped metal infrastructure is now going to such places as China or India, and is returned to us as material goods we buy – resulting in a boost to their economies. The following NOMMA members discuss their relationship to scrap — how they reuse it, sell it, or feel about the possibility of our being on the wrong track with scrap metal, the reusable manmade substance nearly as old as the creativity of our species.

For your information

Scrap for some small change Chantal Francisco, daughter of Marcel Latulippe, owner and CFO with Palm Springs Welding Inc., says any scrap metal their company gener-

 Our scrap is exported to more than 140 countries

Scrap recycling industry facts:

 Scrap has been an important export commodity from the U.S. for more than a century  It was a $65 billion industry in 2006

 150 million tons of scrap materials are recycled annually including 81.4 million tons of iron and steel, 4.5 million tons of aluminum, 1.8 million tons of copper, and 1.4 million tons of stainless steel

 In 2006, scrap was the country’s second largest export to China in dollar value

 In 2006, 34 million tons of scrap were exported from the U.S., including: 13,540 iron and steel; 1,481 aluminum; 1,396 nickel and stainless; 803 copper; 121 lead; and 84 zinc

Source: Institute of Scrap Recycling Industries Inc.,


March/April 2008

Palm Springs Welding collects their waste metal in a bin that’s hauled away when full.

ates will not simply go into the garbage. In business for 40 years, Palm Springs Welding produces half-andhalf ornamental iron shop and structural steel. “We figure the scrap metal has got to go somewhere, so we have a big bin that a hauler takes away when it’s full. It gives us some ‘play’ money,” says Francisco. “It’s not a huge amount of money, as we only work with steel. The amount of money involved is probably only enough to cover the labor expense of moving the scrap to the bin on our shop floor; it’s negligible.”

“I think our industry, as a

whole, recycles throughout the process...” But Palm Springs Welding mainly likes being a good neighbor. They like the idea of keeping scrap out of the waste stream and placing it where it should be. “I think our industry, as a whole, recycles throughout the process,” adds Francisco. “I don’t think our business is alone in saving remnants to keep using until they’re unusable. We hang on to gates or fence panels that, for whatever reason, didn’t work, and keep them around to either sell to ‘Joe Schmoe,’ who comes in off the street, or to someone who happens to have an appropriate opening that those parts would suit. “We recently reused scrap jetcote plate as a donation to a church golf tournament for the tee sponsor signs (although we did use our new CNC plasma cutting machine to carve the text). We’d also love to reuse/recycle the ancient welding machines that take up space and hold dust on the side of our yard.” Scrap for a small customer bonus There are four different bins at Cape Cod Fabrications in East Falmouth, MA, a company incorporated in March, 2001. These bins include one for stainless steel, one each for brass and bronze, and one for carbon 20


March/April 2008

A long history with scrap Laurel Machine & Foundry Co. (LMF Co.) in Laurel, MS, is actually several smaller businesses rolled into one — a steel fabricator, machine shop, mill supplier of industrial hardware, a steel service center, and a foundry. “Not only do we create a lot of scrap due to the fact that we cut a lot of material to length, but we also purchase a great deal of scrap for our foundry,” says Gene Mulloy, CEO of the company. “This buying of scrap is done because the scrap we generate does not work well in our iron foundries. Though we sell all different grades of metal, we “I don’t think our business is alone in saving remnants to keep using until they’re unusable. We need to have one grade going hang on to gates or fence panels that, for whatever reason, didn’t work, and keep them around into our foundry that will to either sell to ‘Joe Schmoe,’ who comes in off the street, or to someone who happens to have work — and one grade only. an appropriate opening that those parts would suit.” That’s something we can’t —Chantal Francisco mix.” The company is very parsteel. And when these get filled, there this is one way to give our clients a litticular about what they buy. But, as are several salvage companies in the tle bit of a discount on what they’ve Mulloy points out, they pay a premiarea that will pay the by the pound of paid for their project.” um for that better quality metal. “I scrap, pick it up, and give them a Corner has noticed the demand for pay a lot more for my scrap than I check. recycled metal has definitely been receive for it,” adds Mulloy. “We prob“That’s basically the only recycling higher in the last three or four years. ably sell close to 40,000 pounds of that we do,” says Rich Corner, owner. “It is economics driving things now scrap per month, though we’ll also “We don’t necessarily try to recycle it from what I can see,” he says. “I used buy three to four times that much ourselves. We do large residential to have someone pay to remove the each month.” metal projects such as railings, gates, scrap. Now, they pay me if they can That scrap material comes from a and fences. We don’t have any sort of come and pick it up.” supplier in north Mississippi who, in facilities for melting down scrap metal and placing the melted product in forms.” LMF Co. On some of the larger projects, the actually customer will actually ask for the probuys ceeds from the recycled waste scrap. three-to“Most recently for a big project, we four times as scaled down some big metal stairs,” much as adds Corner. “The client then asked the for a check for the salvaged scrap 40,000 waste, which, at that time, amounted lbs. of scrap it to approximately one dollar per generpound for the stainless steel. ates and “Obviously at different times and sells with different market cycles, the scrap each month. is more or less valuable. The trick is to contact a few different companies, see which one is paying the most, and then you take it from there. We figure 22


March/April 2008

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“NOMMA members need to understand that scrap material is

vital in this industry, especially when it comes to the purchase of copper alloys.”

turn, receives it from an outfit using the same plating. Mulloy describes it as good quality, dense scrap with no rust or paint present. “I’ve been with the company 43 years now (the company itself is 106 years old), and this is basically the way we’ve always operated when it comes

to scrap metal,” says Mulloy. Hurricane Katrina, which hit Laurel in 2005, impacted LMF Co., but did not generate any more scrap business. Katrina tore the roof off the fabrication shop, blew out many doors at their operation, and caused Mulloy to spend a year repairing his house.

“A new scrap yard here in town, close to our operations, has definitely helped us out quite a bit,” says Mulloy. “Having one closer saves us the expense of selling and hauling 100 miles north to Jackson, MS.” Scrap vital for brass mill Mark Sisson, sales manager of Mac Metals Inc., Kearny, NJ, procures scrap and different copper alloys to cast primarily architectural bronze at this brass mill. Though the terms bronze and brass are somewhat interchange-

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Cape Cod Fabrications has designated bins for stainless steel, brass, bronze, and carbon steel. When they’re full, one of the several local salvage companies picks up the scrap, paying for it by the pound.

able, they are both copper alloys, with copper being the largest element in any brass or bronze. Mac Metals’ architectural bronze ends up going into such things as handrails, hardware, window and doorframes, and elevator sills. It is all made from recycled material. “Everyone in the brass mill industry uses recycled copper in different forms in order to make their melt stock,” says Sisson. “We use either boring, clips, stampings, or flashings, so everything we make is coming from recycled material. “Copper benefits from a well-developed recycling infrastructure and, 26

because copper has such a high value, the economics are there to recover, recycle, and reuse it,” says Sisson. “China has thrown a thorn into the supply side, though. It’s even harder for brass mills as an industry to obtain high quality scrap streams.” In the brass mill industry, things tie into commercial and residential construction being green, because one of the critical standards of new construction is the recycled content, according to Sisson. Copper alloys, which include brass, bronze, and nickel-silver, contain a great deal of recycled content; these three alloys contain 60 percent or more copper content.

“This is somewhat of a ‘hot button’ issue for architects or anybody trying to join in the green building battle cry,” adds Sisson. “With the LEED guidelines for commercial and residential construction, there is an emphasis on the value of copper alloys. I suspect many NOMMA members are now working very hard to maximize the value they get from their scrap by keeping a lot of scrap dealers busy — and many mills anxious to take that scrap back. “In our particular niche, we really enjoy taking our own scrap back because we know what’s in it. Many of our customers return scrap, and we pay them directly.” Mac Metals Inc. is a small specialty mill, but, typically, most products sold from brass mills to end users are sold with the understanding that the brass mill will buy the scrap back. “This arrangement is pretty much built into the equation. Most brass mills service machining industries and, as a result, there is much scrap generated, either in the form of rod ends or saw scrap or machining kerf,” says Sisson. “When a product is quoted, it’s sort of understood in many respects that the mill will be purchasing the scrap back. In fact, many mills give two prices — the price of the raw material and the scrap buy-back price. “On the architectural end of things, that’s not quite so clear because architectural brass and bronze is used in such a way that it doesn’t generate that much scrap. There’s not a lot of machining that goes on there. It’s cut to length and then assembled. In fact, when we cast material, it is cast primarily from scrap that we buy on the open market and buy from our customers.” Mac Metals only uses a very small amount of virgin material just to ‘sweeten the recipe,’ according to Sisson. Therefore, domestic scrap is their lifeblood. “The growth of trade in scrap with China and India is something a lot of us don’t quite fully understand, but it certainly is making scrap copper a scarcer commodity – and more valuable. Fabricator 

March/April 2008

“NOMMA members need to understand that scrap material is vital in this industry, especially when it comes to the purchase of copper alloys. Frankly, if they generate enough scrap to make it pay, they should make sure they’re shopping around for the best price they can get. We’re happy to get into that scenario; however, the one setback is the transportation costs. “If there’s enough scrap generated or shops are willing to sit on it long enough to generate enough to make it pay for the transportation, the mills are happy to accommodate the end users directly rather than going through a scrap dealer.” Passionate about scrap Fine Architectural Metalsmiths, Chester, NY, is basically a blacksmithing shop working in both ferrous and non-ferrous materials. They also have a school where blacksmithing is taught.

LMF Co. pays a premium for the higher grade of scrap it purchases for its foundry operation.

“In our little realm we’re trying to recycle in a different way,” says owner Ed Mack. “I wouldn’t hesitate to simply share the scrap I produce if someone needed it.” Mack feels that, when it comes to used steel, we should share it, give it

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away, or do anything but sell for scrap. “The selling off of steel as scrap, I feel, represents the death of our industry, along with others, brought to their knees in this country by short-sightedness — gaining a few cents per pound for something such as scrap.



“China has been very vigorously purchasing our scrap steel. When we make steel, we use coke to make the steel — and nearly 90 percent of the coke we use to make our steel is produced in China. However, the amount of coke they’ve been supplying us has decreased exponentially. What’s also interesting, and something that’s been happening for over a decade, is what the imports from China have been doing to our economy. Therefore, if

our raw materials, which we’re having trouble producing in our country, must come from China, we must also absorb the high cost of shipping.” Now, our inventories are decreasing in the production of the steel we use for making autos or anything else we’re doing, according to Mack. They’re also not selling us the amount of coke we need and, because the dollar is so low, we’re paying a fortune for it. In addition to this, the high

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demand for steel produced in China is driving the prices even higher. “Add to all that the fact that, because of NAFTA, we’re now allowing Canadian and Mexican steel into this country without tariff. So, you can see, overall we’ve done nothing to protect our resources,” he explains. “The large steel mills that have always guaranteed generations of workers a living are now closed down. There was an attempt to change the structure and reopen with the workers purchasing the mills and becoming the owners, because steel production is all they know. But those efforts failed due to lack of support from this country. In the end, our real estate becomes an attractive investment for foreign countries, in particular, China. One has to be aware of the larger picture.” Mack points out that if he wants to do a job with silicon bronze now, it’s just about impossible. It’s gone up some 200-300 percent in price. He harkens back to the idea that if we don’t fully understand what’s going on out there, we’re in trouble. “Also, it’s not too much of a stretch to add other things to the equation.

“...when it comes to scrap metal, that’s where we’re going to have to change and change quickly.”

Home and commercial building is at an all-time low, it’s bottoming out. Now, because it costs so much to transport building materials into our country, that’s something else which doesn’t bode well for our country. If you go to the lumberyard, they’ll tell you about it. “The average person may say, ‘Well, what the heck am I supposed to do with this scrap’? But I say, too, if you truly begin to understand this predicament we’re in, you’ll realize when it comes to scrap metal, that’s where we’re going to have to change and change quickly.”


March/April 2008

Member Talk

Charitable recycling  One NOMMA

member shop’s recycling efforts have expanded beyond its own walls to include a unique community partnership. Blue Mountain Metalworks often uses salvaged metals to build furniture items that can be sold not only to clients, but also in Habitat for Humanity’s local ReStore. These gates were fabricated into a queensized headboard.

NOMMA member Blue Mountain

Metalworks Inc. in Banner Elk, NC, has been recycling metals for several years now. In addition, the company has worked out a partnership with Habitat for Humanity that benefits both parties. Fabricator asked Blue Mountain’s owner, Dirk Brown, to share some information about his company’s recycling efforts and this unique philanthropic partnership.

stainless we keep for fun projects, etc.

send the materials, QandWherewhodousesyouthem? DB: We take them to a recycler, but actually don’t know their final destination.

Please tell us about your partnership with Habitat for Humanity. Q How often does that occur? What


types of recovered materials are they seeking?

DB: Since we opened, seven years ago.

DB: We have been fortunate to establish this connection. When they are on a site that will allow us, or their team, to remove metal items, they will call us to help them assess the amount and way in which things can be removed and transported. We get the “pick of the litter.” In the past, we have used some of the materials to build items for Habitat’s Re-store for resale and for clients. The majority of the recycled items

How long has your company been recycling?

What kinds of materials do you recycle? And what kind of volume Q are you talking about? DB: We recycle copper, aluminum, and stainless steel. The steel is about 5,000 lbs. every six months, the copper is less than 50 lbs., the aluminum ranges between 400-1000 lbs. The 30

For your information Habitat ReStores are retail outlets where quality used and surplus building materials are sold at a fraction of normal prices.

 Proceeds from ReStores help local affiliates fund the construction of Habitat houses within the community.

 Many affiliates across the United States and Canada operate successful ReStores—some of which raise enough funds to build an additional 10 or more houses per year.

 Materials sold by Habitat ReStores are usually donated from building supply stores, contractors, demolition crews or from individuals who wish to show their support for Habitat.  In addition to raising funds, ReStores help the environment by rechanneling good, usable materials into use.

To learn more about how your company can donate materials to a Habitat ReStore and to see a list of ReStores by state, log on to:


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congratulates NOMMA on 50 years of service to the industry.

A 1940s casting made into a railing.

Happy Anniversary NOMMA!

are of the structural nature and are usually hauled to the scrap yard. Some, however, can be resold for chain link fence posts, support posts, pipe rail, and other various uses. We have used a good deal of bargrateing for drainage grates and the like. Weâ&#x20AC;&#x2122;ve made a few furniture items. The local Habitat ReStore sponsored a raffle, and the prize was to have a room â&#x20AC;&#x153;ReStored.â&#x20AC;? A student at Appalachian State University won the raffle â&#x20AC;&#x201C; and that meant that the room to be â&#x20AC;&#x153;ReStoredâ&#x20AC;? was in a rental home. Everything created for the project was required to be modular and, therefore, removable (and moveable) at the end of the school year. So, with another volunteer, we made a shelf and desk system using the old stainless steel pipe recovered from a pool building that was torn down. Even the drain grates from the deep end of the pool found a use as shoe racks in the shelving. We received great press, and a couple folks still give us referrals based on that article! About once a year, we participate in some sort of ReStore project that comes up.

Is recycling a lucrative venture for you? Or is it more Q of a clean-out-the-shop thing, or a contribution to the green effort?



DB: Our recycling is always based on the green effort, but does it allow us to cover several types of bills â&#x20AC;&#x201D; mainly the fuel and wages to get the materials to the scrap yard, with a bonus of a few hundred bucks to spread around the crew! As far as keeping the shop clean, we always strive to keep our shop really, really clean in an effort to increase production and keep things safe.

Do you purchase any scrap or reusable materials for QBlue Mountainâ&#x20AC;&#x2122;s projects? DB: Any time we can! We also check with other shops to see if they have any overstock we have unique need for, before we make a special order. Fabricator 

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Beautiful Railings Begin With

Member Talk

Industrial machine and welding shop enjoys ornamental success

 NOMMA members James and Sue Minter know the

value of diversification in their business. By Sheila Phinazee

It all started with a coffee table. Or, at least, a new facet of a business began that way. In 1979, James Minter’s father (James Minter, Sr.) purchased B & O Machine and Welding in Brookhaven, MS. James joined his father in the business in 1980, when the shop’s original offerings did not include ornamental fabrication. However, 10 years later, James’ wife, Sue, decided she needed a coffee table — and she had faith that her husband could create it, 34

even though he had never fabricated one before. She was right. The coffee table turned out so well that things took off from there — the seeds of an additional fabrication business had been planted. B & O Machine and Welding was already a diverse company prior to the coffee table incident. Originally, the focus of the business was oil field work, but it later grew into a job shop. “We still do oil field work, gravel pit, saw mill work, and construction,” explains Minter. “But we also have an industrial machine shop and a welding shop, we do ornamental work, we have a crane service, and we offer material

For your information For nearly 30 years, B&O Machine and Welding and Imagine Ironworks have been serving the Gulf Coast area. Shop: Imagine Ironworks; B&O Machine & Welding 1380 HIghway 51 Brookhaven, MS 39602-0533 Contact: James W. Minter, Jr. Ph: (601) 833-3000 E-mail: imagine


March/April 2008

sales. We’ve got five different businesses and operations.” Once the decision was made to take on more ornamental ironwork, though, a new name was in order. “I thought we needed a name to get away from the more industrial sounding B & O Welding,” Minter recalls. “That’s how we came up with Imagine Ironworks.” The company grew steadily since its inception. Today, it has 22 employees —there are 12 in the shop, two supervisors, and two part-time clean-up guys (one of these is the Minter’s son, Walker), plus office staff. The NOMMA connection is important Minter is a big fan of his NOMMA network and NOMMA membership in general. “There are things I’ve learned at NOMMA conventions that have helped me in all the businesses that we have. There are not just tricks about ornamental work, there are tips about business,” he explains. “Some people think this Association is just for guys who make scrolls — but this is an organization about business. All of us in NOMMA are small businessmen first; we happen to be ornamental workers, but we’re all trying to run a business.”

Imagine Ironworks consists of an ornamental ironwork shop, plus four other businesses — an industrial machine shop, a welding shop, a crane service, and material sales.

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“We joined NOMMA so we could

attend the METALfab convention in Galveston in 2002. Since then, our ornamental business has almost tripled.” One example of something Minter learned at a METALfab convention that has translated to his other businesses came from one of the speakers, Michael Stone. In 2003, Stone, an author and consultant for building trades, stressed the need for making a profit by charging enough for your work. “All of a sudden a light went off in my head. ‘That it’s not how much you bill, but how much you keep,’” recalls March/April 2008 


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When ornamental fabrication became a staple in James Minter’s business, the company changed its name to Imagine Ironworks.

Minter. “It’s what’s at the bottom of the income statement that counts, not how much revenue you’ve got coming in.” The speaker also stressed the need for continual education, reading or listening to audio books while you’re traveling. “This doesn’t pertain just to iron workers; it’s good advice for anyone,” says Minter. “Since then, I’ve amassed quite a collection of books and CDs and tapes. I’ve been able to glean something that is beneficial to our business from each one of them.” Obviously, education is one of Minter’s passions. He is president of the Gulf Coast NOMMA Network, where his wife, Sue, serves as secretary. Minter is also the current chair for the NOMMA Education Foundation (NEF). Minter has also read that the average American spends 500 to 1000 hours per year in a vehicle. “That’s 12 weeks of 40 hours, on the low end, spent on the road,” says Minter. “Think of the education you can get, March/April 2008 


just by listening to audio books!” NOMMA membership has not only provided much-appreciated educational opportunities for the Minters, but has also helped increase their business by quite a bit. “We joined NOMMA so we could attend the METALfab convention in Galveston in 2002. Since then, our ornamental business has almost tripled,” notes Minter. He emphasizes that the learning opportunities provided by the association in the form of classes, conventions, education sessions, networking, and chapter meetings have helped all their businesses—the machine shop, welding shop, the crane service, material sales, and the ornamental division. “I’m a better businessman now because I’ve taken advantage of the opportunities to learn through NOMMA,” he says. Minter also partners with fellow NOMMA businesses on various projects. “Other NOMMA members might do something better than we do, so we outsource to them,” he

states. “And who better to outsource to than other NOMMA members?” Gulf Coast Network gets off the ground Minter and another NOMMA member, Scott Colson, were instrumental in starting their local NOMMA chapter, the Gulf Coast Network. “Scott and I originally talked about it five years ago. Then, about two years ago we decided to get started,”

The next Gulf Coast chapter

meeting will be in Slidell, LA at Charles Perez’s shop, North Shore Steel, on Saturday May 10, 2008. The event will feature a crawfish boil, a band, and a shop tour, and Top Job winner Roger Carlsen from Chicago will be on hand to demonstrate white metal casting.


A whimsical mailbox demonstrates Imagine Ironworks’ sense of fun and creativity.

recalls Minter. “We had our first official meeting at Scott’s shop, Iron Innovations (Clinton, MS). There were six people at that first meeting, which was enough interest to start a chapter.” Minter enjoys being a part of NOMMA on both the local and national level: “It’s a lot fun meeting other people in the same business. Nobody is very secretive about what they do. People are willing to share. It’s amazing.” “Chapter meetings are a lot of fun. It’s an opportunity to touch base with other fabricators and present them with new ideas and things they haven’t seen before,” says Minter. “Fabricators are a fun bunch.” Imagine Ironworks gains local recognition In 2006, the Brookhaven-Lincoln County Chamber of Commerce and the Industrial Development Foundation named Minter’s company Industry of the Year based on its years of service, community involvement, and relationships to other businesses. Most of the company’s ironwork is residential, with some commercial work. “This last year we did light structural for residential, frames for 38

garages, stairwells, balconies, and driveway gates,” says Minter. “And nearly 27 percent of our revenue last year came from ornamental jobs.” Minter has found that doing ornamental work includes its challenges. “There are a couple jobs in the shop now with bronze cap rail — working with bronze was real scary the first time because you can’t hide any mistakes on it. It all shows,” says Minter. “But our guys have become more comfortable working with it.” Imagine Ironworks keeps busy with Gulf Coast area projects. “Our work is not all high end work, some is pretty pedestrian, but it keeps our shop busy. We work within a 50-100 mile radius of Brookhaven; we go to Jackson, Hattiesburg, Baton Rouge, and north Mississippi.” Minter and his team have done several interesting ornamental jobs. One involved creating a seven-foot Celtic cross for a church’s memorial garden. Another ongoing project is taking place in downtown Brookhaven, a charming area that draws locals and visitors alike.

“...if you want to establish a

good relationship, you have to listen more than you talk.”

A couple of years ago, a local CPA contacted Minter. The CPA’s downtown office had an apartment space above it — which came in handy for nights when he had to work late, so that he didn’t have to drive all the way to his home in the country. The client wanted a covered balcony added to the front of the building so that he could enjoy drinking his coffee there in the morning, or for watching events like the Christmas parade. “We built the structure and it was nice looking,” says Minter. The idea took off and Minter and his team have put up even more balconies on downtown buildings, five this past year alone. “The downtown area has started to get the flavor of Natchez or New Orleans,” he adds. “People give us the credit, but I am impressed how people have bought these buildings and have restored and renovated them.”

Covered balconies have become popular in downtown Brookhaven, MS, thanks to Imagine Ironworks. Fabricator 

March/April 2008

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The balconies and other jobs have gained admiration from the locals, and have resulted in more business. Minter says that, although he advertises, most of his company’s business comes from word of mouth. He also works for several builders and architects, and believes working with them has given his business greater credibility. Returning customers are an asset as well, according to Minter. “What surprises me about ornamental work is the repeat business. You might do a piece for someone, then, five years later they call you again when they’re remodeling their house,” he explains. “We just went over a list of people we’ve worked for over the past several years and there are Most of the company’s ironwork is residential, with projects such as stairwells, balconies, driveabout 400 names on that list.” way gates, and frames for garages. Last year, nearly 27 percent of its revenue came from ornaSo, how has the experience mental jobs. been working with architects, in particular? “Typically architects believe anything can be built. In a way this optimism is good. Sometimes you can get them the look they want but you’ve got to approach it in a different way,” says For A Great Piece Every Time Minter. “And, sometimes you’ve got to Model 400-VSUADJ w/ Adjustable Height Vise Shown put your ego in your pocket.” Notches from Minter has had ongoing working 3/4” to 2-1/2” OD relationships with several architects in Jackson, MS for a number of years. “Some are better than others at listening to clients and guiding them along, but they are all very talented,” he states. 1-1/2HP He makes it a practice to provide architects with catalogs, information from METALfab, the NAAMM/ NOMMA Metal Finishes Manual, subPerfect for Thin or Thick Walled Tubing scriptions to O&MM Fabricator, and Perfect Weld Fit Every Time Calibrated Swivel Vise books from steel service centers, so that Allows Almost Any Angle Fast Metal Removal they know what material sizes are avail208/220/230 Volt Variable Speed able. 115 volt Single Speed Available “It’s like with anything — if you CALL OR CLICK In Use by Over 80 NOMMA Shops want to establish a good relationship, for Free Catalog you have to listen more than you talk,” Ideal for Prototype or Production Work says Minter. “God gave us two ears and 1-800-467-2464 one mouth for a reason.”

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NEF strives to keep fabricators in business James Minter is chair of the NOMMA Education Foundation. Here, he addresses why NEF is so important to the association and outlines some of the challenges facing NEF: I think that the NEF is very important to our industry because we have to realize that education is not just for NOMMA members. Anyone who comes in contact with railings or guards or whatever we make can benefit from education about our industry and our products. Representation Let’s recall Doug Bracken’s mention of the situation in Ontario, Canada, where ornamental railing has been outlawed because of climbability issues and the effect of Draconian code issues. (Note: NOMMA members may remember reading NOMMA Past President Doug Bracken’s letter, “Death of Ornamental Railings,” in the Jan/Feb 2006 issue of Fabricator. Canadian codes outlawed all ornamental railings except vertical picket design to protect unattended little ones from 0 to 24 months old.) “I can assure you that without strong representation, NOMMA members’ products could easily become endangered or extinct,” Doug stated in his letter. The same thing will happen here, if we don’t address the misinformation provided by those who oppose what we do. If code bodies are misinformed, and then act on it, before you know it, we’re in the same boat as Ontario. March/April 2008 


Recognition One of the challenges facing the NEF is gaining acceptance and awareness among NOMMA members. Offering books and DVDs is only part of what we do. We want NEF to be the premiere source for education for our industry. It’s been slow to take off, as some haven’t seen the need to fund it yet. Granted, many members are one-man shops, but paying dues alone won’t be enough. One action I would like our members to take is to put the NOMMA logo on their business cards and stationery. Having the NOMMA logo in place offers a fantastic opportunity to educate consumers about who we are and what we do, and it also brands the members who display it as someone who is serious about the metalworking business. There are members who have been gracious and generous, like Stan Lawler who gave $100,000 over five years then gave another $50,000 over the next five years to support NEF. However, generating consistent donations for NEF programs has not been easy. Research The NEF Lawler research pro-

gram, which just helped fund a study by the NAHB Research Center, not only benefited NOMMA members, but also educated the members of the Code Advisory Committee about climbability. In a clear way, this education has helped CAC members to make fully informed decisions about our products and industry. With the NEF and its fundraising mechanism in place, NOMMA had the money and was able to pay for this study. But there are going to be other issues that come before us, too, and there will be other opponents. Right now, there’s a threat to cable rail systems based on some flimsy engineering. We can’t afford to put our heads in the sand and ignore it, hoping it will go away. We need to address it and to do so takes money. So, in addition to putting out the DVDs, tapes, and books, there’s a whole sphere of things we can do to educate those who are uninformed and misinformed. We need to include them, as well as our own members, in our education efforts. More information on NEF can be found on page 79 of this issue and in past issues of Fabricator, as well as on the association’s web site,


Join NOMMA Today Increase your knowledge â&#x20AC;˘ Network and learn from peers â&#x20AC;˘ Enhance your companyâ&#x20AC;&#x2122;s exposure Join the National Ornamental & Miscellaneous Metals Association and youâ&#x20AC;&#x2122;ll receive.... Introductory Package - Upon joining you will receive a kit containing the Membership Directory, Buyerâ&#x20AC;&#x2122;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&#x20AC;&#x153;members onlyâ&#x20AC;? 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&#x20AC;&#x2122;s Journal, our bimonthly â&#x20AC;&#x153;how toâ&#x20AC;? publication. Youâ&#x20AC;&#x2122;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&#x2DC;? 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&#x20AC;&#x2122;s immediate agent or contractor. â&#x2DC;? 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. AďŹ&#x192;liation 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&#x20AC;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&#x2DC;? Regional Supplier $455 - Firms that sell supplies, raw materials, equipment, machinery, or services only within a 500-mile radius. â&#x2DC;? Local Supplier $365.00 - Firms that sell supplies, raw materials, equipment, machinery, or services only within a 150-mile radius. â&#x2DC;? AďŹ&#x192;liate $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&#x20AC;&#x2122;s Bylaws and Code of Ethics upon acceptance. Checks should be made payable to NOMMA.


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Job Profile

Dedication to quality, efficiency leads to the top  This stunning

three-level circular stair system garnered a Gold award in the 2007 Top Job competition.

By Lisa Bakewell Tom Place, president of Construction Services Inc. (CSI) in Decatur, AL, calls himself the “new guy on the block” — even though he’s been with the company since 1994, when he started out as a project manager. That’s because CSI has an enviable record of personnel longevity.

Staff dedication is crucial to fulfilling mission statement “Most of our shop personnel have been with us for many years,” notes Place. “In some cases, it is the only place they have ever worked. We are a specialized trade, which means we can’t just hire someone off the street.” He feels fortunate to work with an award winning team of professionals March/April 2008 


at CSI like David Archer, Benard Chasteen, D.L. St. John, Tim Proctor, and the Bates family (James, Joe, and Robert), who are some of the longterm shop employees. “Harry Knop, who is arguably the best ornamental metal guy in the U.S., if not the world,” says Place, “clearly deserves a large chunk of the credit too.” Longevity doesn’t just apply to CSI’s shop guys, he adds. “Scotty Prater, who heads up Sales and Estimating, has worked here since 1975 and is extremely important to the company,” he says. As is Roy Johnson, in Estimating, who’s been with CSI for 29 years, and Linda Thompson in Accounting, who’s been with the company for 20 years. “This is the type of commitment from people that you need to be successful in

For your information Computer-aided design (CAD) was used by CSI to create their award-winning circular stair system. Current CAD packages range from 2D-vector base drafting systems to 3D solid and surface modelers. Learn more about CAD with these resources:

 Moving from 2D to 3D CAD for Engineering Design: Challenges and Opportunities, by Louis Gary Lamit. Available on

 3DCADForums — A Design World Resource. This site feature over 50,000 CAD and graphics tips, tutorials, 3D models, freeware, and more.

 3D CAD Resources. This site offers tutorials for beginners and 3D CAD resources for several programs.


this industry,” states Place. And because of dedicated employees like these, CSI is proud to say that it has fulfilled all of its contractual obligations for more than 40 years, since its inception and incorporation by founder Mike Scroggins in 1967. Additionally, employee dedication to carrying out the company’s mission statement — to provide a quality product in a timely manner — has led to numerous industry awards, including a Gold Award in Category L (Stairs Complete) of NOMMA’s 2007 Top Job competition. Foresight and planning keep major problems at bay The Top Job award-winning piece is a three-level circular stair system, consisting of three separate stair flights, located at the University of Michigan. CSI custom fabricated the circular stair system with a built-in glass receiver, low iron glass guardrail

system, and a cast aluminum bracket support for a wood handrail. The stair system is self-supported from floor to floor, having a stainless steel soffit system. The stair and soffit were fully constructed in CSI’s fabrication facility in Alabama. This was done in order to ensure proper fit, which then allowed for an uneventful field installation process, according to Place. And looking ahead, anticipating problems and planning how to prevent them, paid off. “In the engineering phases, it was the development of the 3-D CAD engineering model that allowed us to identify and resolve potential problems in the beginning,” Place says. “Doing this prep work eliminates negative cost and time impacts when issues are resolved during the engineering stage, rather than if they are discovered later in the fabrication or installation phases.” Place adds that it was a challenge to

The stair and soffit were constructed at CSI’s facility before being transported to the University of Michigan.

maintain material and fabrication tolerances associated with blending all the different types of materials during the fabrication state. “Each type of material,” he says, “has its own set of special requirements that must be adapted to this particular situation. Having skilled craftsmen in the fabrication stage was essential to achieving this unique engineering concept.” And when it came time to install

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the stair system, the details became critical. “The main challenge in the installation phase,” says Place, “was achieving the proper fit of all the different parts and pieces taking into consideration you had two fixed points, top and bottom, that couldn’t change. As mentioned, each type of material has its own fabrication tolerances. To make them all work out in a spiraled condition, with two fixed work points is extremely difficult!”

No small feat There were more than 25 people involved in the University of Michigan project, including engineers, draftsmen, procurement personnel, expeditors, fitters, welders, material prep folks, project managers, a foreman, iron workers, glass and glaziers, and carpenters. “We expended over 5,000 shop hours in the fabrication process,” says Place. “And after the piece was fabricated, each flight was transported by

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truck on a wide load permit, which restricted travel times.” The travel time consisted of three days for each load and, upon delivery, the installation of the circular stair system took another six to seven weeks. State-of-the-art facility and equipment make jobs of any scale possible Located on seven acres, CSI’s 53,000 square-foot fabrication building is joined by an 8,000 square-foot administrative building. The facility is equipped with the most innovative machinery and workspaces available, such as an exterior fabrication area with its own overhead crane system — which comes in handy for extra-large fabrication pieces like their 2007 Top Job Award winner. Having evolved into a specialized metals fabricator since its inception, CSI employs a core group of about 40 professionals who offer their customers quality products. These products include rail systems, monumental and radiused/spiral stairs, and a wide variety of architectural metalwork like wall panels, torcheres, gazebos, column covers, and decorative art designs. Much of CSI’s state-of-the-art equipment has been custom designed and built for the company’s unique needs, and is capable of producing


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The main challenge in the installation phase was achieving proper fit of all the sections between the two fixed work points at the top and bottom. Fabricator 

March/April 2008

product to exact requirements and tight tolerances. Their equipment can handle unique shapes, sizes, multiple blends, precise joinery, and exact duplication of parts. CSI also has cranes and fork trucks capable of loading, unloading, and handling all of their materials. Though CSI has expanded its capabilities with experts in the field and top-of-the-line equipment, it is the simple knowledge of a job well done that brings the most satisfaction. “Our favorite part of the job is seeing the finished product after it has been incorporated into the permanent works,” says Tom. “Most of the time, our product contributes tremendously to the aesthetic appearance of the facility. People notice our work.” And that makes everyone at CSI very proud! NOMMA membership an asset CSI has been a member of NOMMA for more than 17 years. “NOMMA is the trade association for metalworking,” says Place. “Through their website and publications, NOMMA provides an unlimited, continuous flow of information ranging from the latest in ornamental metal fabrication techniques to operating and managing a business. The NOMMA Technical Affairs Division and the NOMMA Education Foundation are a tremendous asset for all members.”

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Job Profile

Modern zoo architecture features NOMMA member’s product

Photos: Hans-Georg Esch, Hennef/Sieg

 A transparent, yet durable stainless steel mesh enclosure

allows the Diana monkeys at London Zoo to live in a more natural habitat. The exotic appeal of wild animals has

been attracting people to Europe’s zoological gardens for more than 150 years. The reason for going to a zoo is the same today as it was then, but our general ideas about viewing animals have changed in the last few decades. Whereas these wild creatures used to simply arouse our curiosity, we now see them far more as living organisms that we want to treat with sensitivity and the respect they deserve. In increasing numbers, zoos all over the world are recognizing this change in the relationship between man and animal. As a result, many 48

facilities are commissioning new enclosures that are carefully created to reflect the natural habitat of the animals inside them. The animals are not the only beneficiaries of these new-style landscapes. The modern enclosures also allow zoo visitors to view the animals enjoying their exotic habitats live, thereby opening up an exciting new world of adventure. One of the most recent examples of contemporary zoo design is found at London Zoo. Rich in tradition, London Zoo has been committed to conservation and the protection of

For your information Project: London Zoo, Zoological Society London Architecture: Officium Design Engineering, Stuttgart, Germany Stainless steel mesh: Fabricated by Carl Stahl, Süssen

 The timeline for project, start to finish, was four months.

 The project required 500m² of X-TEND mesh width 50mm with cable diameter 1.5mm.

 Installation required four fitters over the course of three weeks.


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species for decades now, and it is partly because of this that one of its top priorities is providing its animals with a near-natural life in a natural environment. Surrounded by beautiful gardens and the buildings of Regent’s Park, the zoo is working to create modern enclosures that will give the animals more freedom and the visitors closer proximity to the inhabitants and their habitats. The architecture of the new Diana monkey enclosure is an excellent illustration of this concept. A closely meshed, but transparent net covers the extensive monkey complex and gives these small primates lots of space to climb. The delicate mesh — X-TEND net, manufactured by NOMMA member Carl Stah DécorCable — guarantees that zoo visitors can view the entire enclosure without obstruction, while preventing the animals from “going walkabout.“ Carl Stahl’s planning office — Officium — experts in the field of zoo enclosure architecture, developed the strategies for the steelworks (pylons, pylon heads and foots, insertion parts into concrete foundation, etc.), in addiFabricator 

March/April 2008


tion to the design and engineering for the mesh and cable structure. The innovative X-TEND net’s construction gives the monkeys amazing freedom because of its height. For humans, it is also an attractive architectural feature. Strung out like tents, the system’s nets, cables, and pylons provide a visually appealing interplay of straight lines and organic undulations. At the same time, the intelligently constructed net fulfills static functions as well as important financial criteria: the top-quality mesh needs no maintenance and possesses an extremely long life expectancy. “With the London Zoo, Carl Stahl came up with a very economic solution,” notes Thomas Ferwagner, CEO at Officium. “Pylons were brought into the interior of the enclosure and we actually used less steelworks than originally anticipated. This was all due to the efficient use of the three-dimensional characteristics of X-TEND as well as the experience in light struc-


The innovative X-TEND net’s construction gives the monkeys amazing freedom because of its height.

ture building, which Carl Stahl and Officium represent and have proven during the last 15 years in modern sophisticated zoo enclosure construction.“

Best of all, the stainless steel mesh allows the Diana monkeys to show off, performing their “song and dance routines“ for an adoring public.


March/April 2008

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Special Feature

2008 Trade Show Report METALfab 2008, celebrating NOMMAâ&#x20AC;&#x2122;s 50th anniversary, takes place in Memphis, TN, home to the Metal Museum (pictured at right) and birthplace of the association. As always, attendees will pack the exhibit hall to view the many products and demonstrations on display at the annual trade show.

 METALfab 2008 exhibitors recap their products and services in

this special feature. For a complete listing of these exhibitors, log on to: Auciello Iron Works Inc. Auciello exhibited the EZ Sleeve, a removable plastic sleeve for forming quick, accurate, clean postholes in concrete. The sleeve is 54

All-O-Matic Inc. removed after the concrete has set to leave a tapered hole. The sleeve is 1/6 inch thick plastic tapered tube with a pull-out tab on the closed top and a snap-on base. Color is safety orange. EZ Sleeve is the ideal way to form quick and clean post holes in concrete for installing railings, fence, or other posts. Ph: (978) 568-8382 Web:

All-O-Matic Inc. has been building gate operators since 1992. Our operaFabricator 

March/April 2008

tors carry a 5-year commercial and a 7-year residential warranty. This warranty covers the complete operator, from the control board to the frame. Troubleshooting has been simplified by using the same control board for all models. All-O-Matic’s slide gate operator models include the standard slider, SL100, and the heavy duty slider, SL150. Swing gate operator models include the standard swing, SW300, and the heavy duty swing, SW350. The company’s newest addition is its DC lineup, SL100DC and SW300DC, available mid-2008. Ph: (818) 982-1987 Web:

paint that adheres directly to hotdipped galvanized ironwork and also non-galvanized steel. It is available in satin black, bronze tone, white, graphite grey, and custom colors. Vinylast can be creatively combined with Architectural Iron Designs’ patinas to produce antique and highlighted finishes. Ph: (800) 784-7444 Web: http://www.archiron

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The American College of the Building Arts in Charleston, SC, offers a bachelor’s degree with a major in forged ornamental ironwork. The curriculum emphasizes a foundation of traditional skills and thorough schooling in modern shop production. In addition to 16 shop hours per week, students receive an academic education oriented to the building trades. The photo illustrates first-year students studying traditional joinery projects completed by college juniors. Ph: (877) 283-5245 Web: Architectural Iron Designs Architectural Iron Designs offers a variety of resources for ornamental iron projects, including Vinylast — a high performance paint for quality ironwork. Vinylast is a rapid drying March/April 2008 



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Big Blu Hammer Mfg. Co. Big Blu Hammer Mfg. features The Big BLU MAX with QC™ Quick Change die system. The Original “Big BLU” Power Hammer was conceived, engineered, and produced by an artist blacksmith for artist blacksmiths. Its innovative yet simplistic design allows the power hammer to be compact; easily approachable-front, right, and left; versatile and cost-effective. The Big BLU Power Hammer continues to become the workhorse and center of activity in hundreds of shops across the United States and in many foreign countries around the world. Made in USA. Ph: (828) 437-5348 Web: C.R. Laurence Co. Inc. The easy-toinstall CRS Component Railing System from C.R. Laurence Co. Inc. (CRL) is designed and manufactured by CRL for use with 3/8” or 1⁄2” tempered glass infill panels. This system makes it easy to design and build custom post railings from stock parts. A step above aluminum, this system features non-welded mechanical connections that can be assembled on the job site. Several post mounting options are available. Ph: (800) 421-6144 Web: The Cable Connection New Push-Lock™ fittings from Ultra-tec® Cable Railings Systems make installing cables in railings easier than ever. Cables can be cut to length on the job site and the fittings attached to the cables by hand, eliminating entirely any need for swaging in the field. Made of stainless steel, Push-Lock™ fittings are attractive, economical, 56


March/April 2008

and easy to install. Ultra-tec® cable railing products are manufactured by The Cable Connection. Ph: (800) 851-2961 Web: Carl Stahl DécorCable Innovations LLC

Carl Stahl DécorCable features XTEND® Flexible Stainless Cable Mesh — perfect for railing infill, plantscapes, tensile structures, and visual displays. X-TEND® is manufactured from AISI 316 stainless steel

March/April 2008 


components to ensure high durability, low maintenance, and easy recyclability. Many sizes of X-TEND are climb resistant and code compliant. “NEO,” the newest version of X-TEND, uses patented, self-locking stainless steel mini-ferrules that maximize transparency. Field installation and adjustment of “NEO” is quick and easy requiring only common hand tools. Ph: (312) 474-1100 Web: Carell Corp. Carell Corp. introduces its new T-2 Economical Ornamental Bar Working Machine complete with tools for scrolls, bar twisting, folding, and bending. The T-2 offers the high 3⁄4” bar capacity and speed of our T-

20. Quick set electric limits control bend degree. The UGFT-20 Embossing Device for fast and easy production of cold hammered edges and embossed designs can be quickly added to the company’s T-2, T-20, and T-40 Ornamental Bar Working Machines. We offer production quality at a lower cost. Ph: (251) 937-0948 Web: CML USA Ercolina Ercolina’s CE40MR3 angle roll is capable of bending a wide range of tube, pipe and profiles to CLR as small as four times diameter of the work piece. Operates


in vertical or horizontal position. Universal tooling set included with each machine. Forged roll shafts precision ground and fitted for maximum performance and minimal deflection. Heavy duty structure and rigid components for high section modulus ratings. Optional anti-twist correction system available for angle iron “leg in” applications. Ph: (563) 391-7700 Web: Colorado Waterjet Custom panels and components waterjet cut with your design from any material (steel, aluminum, stainless, bronze, etc.). This cold cutting process is slagfree, HAZ-free, and distortion-free. It eliminates the need for welding and grinding, and the chance of joints rusting. Endless possibilities for design: “If you can draw it, we can cut it!” Ph: (970) 532-5404 Web:



Ornamental Hardware • Custom Metal Parts Art Objects • Custom Grills • Signs and Letters Custom Bending and Fabrication


D.J.A. Imports Ltd. D.J.A. Imports Ltd., with decades of experience and creativity, introduces additions to an extensive, quality driven product line. The unique design of DJA 102, along with its beveled build partner DJA 103, offers clients unique designs meeting the 4” code. Please visit the company web site for specific dimensions. Ph: (718) 324-6871 Web: DoorKing Inc. DoorKing, Inc. introduces the model 6500 swing gate operator, designed for residential, commercial, and industrial applications. It is available with a ½ or 1 HP motor. The 6500 includes unique features such as adjustable magnetic limit switches, a two-piece housing that allows access to the operator without having to remove the arm, and a break-away hub designed to protect the gear box if the gate is struck by a vehicle. Ph: 800-826-7493 Web: Eagle Bending Machines Inc. Eagle will demonstrate the new Z-402 and the new CP30PR-E Roll Benders as economical alternatives to fabricators demanding Eagle quality and service. Z402’s have 2” capacity, LED readout and are available with hydraulic (h) or manual (m) bend roll adjustment. Eagle’s new, economical CP30PR-E has 11/2” capacity and uses a linear scale for roll positioning. These machines all feature foot pedal rotation control, horizontal and vertical operation, universal tooling, and numerous safety features. Ph: (251) 937-0947 Web:


117 DAVID BIDDLE TRAIL, WEAVERVILLE, NC 28787 • FAX: 828-645-2128 TOLL FREE: 800-635-2596 58

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Forjas2000 Located in Spain, Forjas 2000 is a young company that embraces European traditions in its ornamental iron production. The company’s products symbolize a blending of creativity, design, and Old Worls customs. Its catalogue features forged scrolls, rosettes, panels, balusters, spearheads, finials, handrails, rings, leaves, and more, including a wide range of stainless steel articles. Ph: (011) 34 925 80 46 14 Web:

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: hebo Maschinenfabrik, Am Berg 2, 35285 Gemunden-Grusen, Germany. Phone ++49 6453 91330 Fax 49 6453 913355 Email:



March/April 2008


DESIGN BOOK Choose from over 400 designs


CAD DRAWINGS Over 1,000 CAD renderings to work with


COMPONENTS Over 2,000 quality components for every need



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Frank Morrow Co.

F8552, 2 3⁄4”-wide is one of several recent additions to the Frank Morrow Co. line of over 3,000 embossed and perforated ornamental metal trims, 3,000+ decorative metal stampings (leaves, flowers, animals, husks, rosettes, motifs, etc.), and a diverse collection of more than 300 grey iron castings. Ph: (800) 556-7688 Web:

Hebo system can: twist, endforge, scroll, emboss, texture, hammer tube, and press belly pickets. The Hebo is designed and built by German blacksmiths for the ornamental iron industry. The Hebo system will bring new levels of production and creativity to the ornamental iron fabricator. Ph: (503) 722-7700 Web:

Hebo/Stratford Gate Systems, Inc. Hebo invented the modern wrought iron machine and is the worldwide leader in this field. The multi-functional 62

Laser Precision Cutting Inc.

Industry Ornamental Iron

Hartford Standard Co. Hartford Standard Co. introduces a line of round post caps. With this additional product line, the company now has one of the most complete offerings of both square and round post caps manufactured in the United States. Hartford Standard’s caps are primarily manufactured from steel and G90 galvanized; the company also offers caps in aluminum, brass, copper, and stainless steel. Square sizes range from 5/8” up to 8”. Round sizes range from 1 3/8” up to 4”, with additional sizes possible. Ph: (270) 298-3227 Web:

closed on the discreetly located truck assemblies beneath the track and gate frame. Ph: (800) 557-4283 Web:

Established in 1977, Industry Ornamental Iron (IOI) is a custom fabricator of gates, selling only to gate, fence, and ornamental iron companies. The company can produce gates from drawings, sketches, photos, or blueprints. IOI is pleased to be an exhibitor at NOMMA’s 50th anniversary celebration at METALfab 2008. Ph: (800) 915-6011 Web: International Gate Devices

International Gate Devices unveils its new E/Z Slide Bottom Track System, which adds an aesthetically pleasing design to any ornamental sliding cantilever gates. With this proven design track system, integrated into the bottom rail of any ornamental sliding frame, the gate seems to float in the air as it glides open and

Laser Precision Cutting Inc. (LPC) has been a leader in the metal cutting services industry since 1989. LPC utilizes laser cutters, a water jet, a press brake, and welding equipment to produce parts to customer specifications. LPC stands above all competition with their attention to detail, dedication to achieving customer satisfaction, and fast turnaround time. LPC’s job is the customer’s satisfaction. Ph: (828) 658-0644 Lavi Industries Lavi Industries is proud to introduce its 1inch fittings and tubing line. Lavi’s full line of 1” fittings — flush center and end posts, flanges, radius ell’s, perpendicular collars, end caps, glass clips, and tubing — are meticulously crafted from stainless steel or solid brass and are finished in-house to maintain the company’s strict quality standards. Ph: (800) 624-6225 Web: Fabricator 

March/April 2008

Marks USA Marks USA Ornamental Iron Locksets are available in US 26D, US 3, and US 15 finishes. This lockset features a 9 Series mortise lockbody, thru-bolted solid brass trim assemblies, and spring loaded captivated spindles. Marks USA locksets are backed by a lifetime mechanical and electronic warranty. Ph: (631) 225-5400 Web:

OGI Architectural Metal Solutions

then powder coated to your specifications. Ph: (800) 321-9800 Web: Paxton & Thau Artistic Supply The Skyport system from Paxton &

OGI Architectural Metal Solutions is proud to offer its new carbon steel PressLock fence for multi use applications in 8 stock configurations. The product is strong, yet lightweight for steel, and is an economical alternative to other steel products. The manufacturing flexibility also offers custom designs for special requirements. This product is typically galvanized and

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Thau Artistic Supply is a component stainless steel tube system that can be configured into unlimited designs for beautiful commercial and residential applications. Bar rails, hand rails, glass railing, cable rail, solid stainless steel bar and tube combinations, stainless steel balustrades, and railings… the possibilities are endless. The Skyport component system offers a no-weld solution and a sleek modern design. Whether you’re a custom builder, commercial contractor, or metal fabricator, you will find the system to be easy to work with and flexible for a variety of applications. Ph: (866) 629-2790 Web: www.paxtonthauartistic Rockite Div. of Hartline Products Co. Inc. Rockite is a powder-like compound that mixes with water to a pouring or pliable consistency for the quick and permanent repair of cracks, holes, or breaks in concrete. Anchors bolts and similar items in concrete with more than twice the holding power of fully cured concrete alone. Develops compression strength of 4500 lbs. per square inch within one hour. Adhesion is due to expansion and, when fully set, it grips metal to concrete permanently. Ph: (216) 291-2303 Fabricator 

March/April 2008

â&#x20AC;&#x153;FabCADÂŽ paid for itself within a month of purchase â&#x20AC;Ś It is easy to use even for someone like me who is not heavy into computers.â&#x20AC;? TERRY PRICE s 1UALITY /RNAMENTAL )RON s +ANSAS #ITY +3

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â&#x20AC;&#x153;I sold a huge condo ornamental gate contract two days after loading the software using FabCADâ&#x20AC;&#x2122;sÂŽ existing designs.â&#x20AC;? CRAIG POULSON s $ESIGNER $OORS s 0HOENIX !:

Are you experiencing a â&#x20AC;&#x153;bottle-neckâ&#x20AC;? at the drawing/design phase?


Do you think, â&#x20AC;&#x153;I donâ&#x20AC;&#x2122;t have time to learn thisâ&#x20AC;?? â&#x20AC;&#x153;I needed to come up to speed quickly on design and fabrication. FabCADÂŽ has allowed us to fabricate our products quickly and efficiently. The program works very well and the tech support is outstanding.â&#x20AC;? MIKE CROW s 6ARIS 7ELDING s 0ILOT 0OINT 48

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Includes: s Customized CAD system powered by AutoDeskÂŽ s Contains AutoRailâ&#x201E;˘ automatic railing, fence and gate drawing system s OrnaCADÂŽ Design Library (10,000 parts from 9 suppliers) s Rail Calculator (spreadsheet layout program) s On-line training movies s Free technical support


Recommended system requirements: Microsoft XP and 2000; 512 MB ram; 700 MB disk space; Pentium IV 800mh; 1024 x 768 VGA; Internet Explorer 6.0 or higher.

s For those who already have AutoCAD.ÂŽ AutoRailâ&#x201E;˘ instantly draws rails, fences and gates. (see sample drawing below) s Program includes finial and spindle drawings from the OrnaCADÂŽ Design Library.

FabCadâ&#x20AC;&#x2122;s design library has a collection of driveway and walk gates and over 10,000 castings and forgings drawn to scale from these catalogs:

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FABCADÂŽ CLASSIC s All items in the Premium package except for AutoRailâ&#x201E;˘, the automated drawing program. (See details about AutoRail below.) Recommended system requirements: Microsoft XP and 2000; 512 MB ram; 700 MB disk space; Pentium IV 800mh; 1024 x 768 VGA; Internet Explorer 6.0 or higher.


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System requirements: AutoCAD 2004+

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Royal Forge PTE Ltd. Royal Forge has, since its inception in 1986, produced exclusive wrought iron ornament components of superb quality and craftsmanship. Its designs are mainly inspired by the traditional works of the 18th and19th centuries and thus are able to fulfill the need for fine, classic, and artistic forging. Wrought ironwork has both the functions of security and ornamentation and, together with Royal Forge’s team of highly skilled professionals, continues to produce designs for railings, gates, grills, fencing , balconies, and much more. Ph: 65-235-9893 (Singapore) Web: Rutland Professional Gate Opening Systems Rutland Professional Gate Opening Systems are designed with the installer in mind. Made

in the USA, our commercial-rated swing and slide gate operators offer unique features not found anywhere else, including versatile mounting options, common control board for all models, quick-install, out-of-the-box settings, battery back-up is standard, fast opening speeds, and quiet operation. Ph: (800) 707-6599 Web: Scotchman Industries Inc. Scotchman Industries features the American-made Scotchman 5014TM Ironworker, which has 50 tons of punching pressure (13/16” hole in 3/4” plate). Standard features include: keyed punch ram, three-station revolving turret punch (which accepts up to three pieces of tooling, rectangular notcher (2-1/2” x 3” in 5/16”), angle shear (4” x 4” x 3 /8”), and flat bar shear (1/2” x 8”). The component tool table options include: 12” press brake, rod shear, square tube shear, picket tools and pipe notcher. Ph: (800) 843-8844 Web: Sharpe Products In addition to Sharpe Products’ already great pricing on stock handrail fittings, its custom bending and rolling services are also an excellent value. By utilizing Sharpe’s custom bending services, you can reduce the cutting, welding, and grinding times of your job, which will reduce project costs. The railings shown here saved one of the company’s customers 7 cuts, 12 welds, and 12 grinds! (Sharpe Products is ISO 9001:2000 registered.) Ph: 800-879-4418 Web: Sumter Coatings Sumter Coatings featured paints, primers, and topcoats especially for ornamental and miscellaneous metal. The firm’s popular Satin Shield Enamel was a featured product. Satin Shield is a fast drying direct-to-metal paint offered in assorted colors. Ph: (888) 471-3400 Web:



March/April 2008

TaurinGroup USA Practical yet versatile; the DS60HV machine is the ideal machine for the ornamental industry. This machine has been designed to fit attachments such as the staircase device, scrolling device, and bar twisting device. This 3 drive roll, 2 speed machine is perfect for any job, big or small, with models ranging from the most basic digital read-outs to the high end CNC controls for multi-radii bends. Call to speak with a helpful and friendly sales staff member to see how TaurinGroup can make your bending requirements trouble-free. Ph: (909) 476-8007 Web: Tennessee Fabricating Co. Lots of new goodies are here from your trusted friends at Tennessee Fabricating Co.: Drastic price reductions on hammered steel (solid/tube/flat) – “better than bundle” prices guaranteed. Be unique with the help of the company’s new Skyport cable rail system with a breakthrough look that also takes the hassle out of installation. Tennessee Fabricating has also unveiled a new wood/metal integrated rail system that you’re not going to find in any of the houses next door. You won’t break the bank, either! It’s time to separate yourself from the pack. Ph: (800) 258-4766 Web: Texas Metal Industries

Texas Metal Industries has specialized in the architectural and ornamental metals business for over 25 years. Rooted in the business originally as an aluminum foundry, TMI now serves customers from three strategic locations nationwide. The company supplies everything from access controls and gate operators, balusters, forgings, March/April 2008 


hardware, and furniture to welding supplies and miscellaneous hardware used by fabricators. TMI has become the source for everything ornamental. Call today for your catalog or CAD disc. Ph: (800) 222-6033 Web: The Wagner Companies The Wagner PanelGrip™ System is a patent-pending locking assembly of high strength aluminum, two PVC isolators and a specially designed aluminum shoe moulding. PanelGrip™ requires no special tools and provides an easy, clean and cost effective alternative for the installation of tempered glass panels. PanelGrip™ is for use with nominal ½” (12mm) tempered glass or other ½” thick panel material and allows for a .450” to .515” variation in glass thickness. For information, visit Ph: (888) 243-6914 Web: www.wagnercompanies. com

need a Porta-Bender to make final adjustments in the field. Don’t leave the shop without it! Ph: (865) 932-2636 Web: www.weaversiron West Tennessee Ornamental Door West Tennessee Ornamental Door offers a line of gate operators, access control products, and hardware for door, fence, gate, and rail fabricators. We will have working displays of low voltage operators on swing and slide gates in our booth. We displayed commercial operators, safety devices, intercoms, telephone systems, Ornamental doors, fence, gates and all the hardware. Ph: (866) 790-3667

Weaver’s Iron Works Porta-Bender was created by a fabricator for other metal fabricators. The Porta-Bender will bend 2-1/4” cap rail, channel up to 2” tubing and 1-1/2 schedule 40 pipe. The PortaBender weighs only 18 lbs. It adjusts instantly for inside or outside curves. The hydraulic cylinder delivers 5 ton pressure. If you have a pyramid bender, you 67

Biz Side

Time is money. Are you wasting your most precious resource?  Answer these six questions and learn what the

biggest “time leeches” are for your business — and how to stop them from sucking you dry.

By Glenn Shepard sounds familiar. You own a small metal fabrication business. Saying that you have your irons in a lot of fires would be an understatement. It’s more like you’re an octopus that has eight arms and still needs two more. You have a reliable estimator who can work up bids, but you still have to go over everything with a fine-toothed comb to make sure he hasn’t missed anything. You have a great bookkeeper, but still have to review every check written to make sure no more of your hard earned money than necessary is walking out the door. You have a great office manager, but still catch her making mistakes that she really shouldn’t be making after all the years she’s been with you. You’re in charge of hiring, firing, purchasing, accounts payable, accounts receivable, maintenance, sales, bidding, manufacturing, quality control, customer service, payroll, taxes, tech supSee if this


port, and all the other “fun” things that people who’ve never owned a business can’t imagine. You often work 12-hour days, haven’t taken a vacation in years, and still don’t have enough time to get everything done. You’re starting to feel like George Jetson on that treadmill gone wild, and want to scream “Jane, get me off this crazy thing!” If this sounds familiar, I’ve got good news and bad news for you. The bad news is that there is no Jane Jetson coming to rescue you. The good news is that if this all sounds hauntingly familiar, you’re not alone. More importantly, it can be remedied. Start by answering three questions:

have enough money to who wants some 1of it?Dogiveyouto everyone

For your information According to a study conducted by Pace Productivity, the following are the top 15 time wasters on the job:  Paperwork / administrative tasks

 Customer requests: service / problems / complaints  Phone calls / phone interruptions / inquiries

 Computer / system / equipment problems

 No internal support / other departments' inefficiency  Unspecified interruptions  Traffic / travel

 Meetings — too many / too long / unnecessary

 Volume of work / not enough time  Staffing issues / people absent

 Requests from peers / other departments

 Changing priorities / unplanned projects  Fire fighting / emergencies  Doing other people's jobs Fabricator 

March/April 2008

If not, who gets your hard earned and who doesn’t? 2money, 3 How do you decide who gets it? Unless you’re living on another planet, I bet your answer to the Question 1 is a big emphatic “No!” And I bet you have good answers to Questions 2 and 3. Now answer these three questions:

there enough hours in your 4timedayAreto toeveryone give a little piece of your who wants some?

other jobs, planning personal events, and arriving late or leaving early). If you have only three employees in your office, that’s an average of about 2½ hours per week they’re goofing off on the Internet. The next time you come into the office on a Saturday to catch up, ask yourself how much of what you’re doing should have been done by them while they were goofing off. Then there’s the time your employees waste socializing with co-workers (23.4 percent). Although the study didn’t specify, I bet a substantial part of that time is wasted hanging out in your office.

Want to know how I can guess this? Because chances are that your office is the only one that has chairs for visitors. You might as well put up a sign on your office door that reads “Sit a spell, Take your shoes off. Y’all come back now, ya hear?” and sign it, Jed Clampett. Even if you remove the chairs (which I did in my own office 10 years ago, and highly recommend) so that visitors have to stand, there’s still that employee who’s great at what he does in your shop, but couldn’t make a decision if his life depended on it. At least once a day, he runs to you for advice on every little speed bump he

gets your precious time, 5andIf not,whowhodoesn’t? 6How do you decide who gets it? I bet your answer to Question 4 is another big emphatic “No.” But if you’re like most people, you probably don’t have a good answer to Questions 5 and 6. It’s probably more of a firstcome, first-served basis than anything, and that’s a big problem. It allows the “Time Leeches” to latch on to you throughout the day and suck you dry, one minute at a time. The worst part is that so many of the things that were supposed to save you time actually waste it. So, where is all this wasted time going? Take the Internet, for example. According to a 2005 survey by America Online and, the average worker admits to wasting 2.09 hours per day, not including lunch and scheduled break-time. The biggest distraction was personal use of the Internet by over 44 percent of the more than 10,000 people polled. That’s more than the next eight categories of time wasters combined (socializing with co-workers, conducting personal business, spacing out, running errands off-premises, making personal phone calls, applying for March/April 2008 


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

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


encounters. Want to know why? Because you let him! By solving his problems for him instead of teaching him to how to solve them himself, you’re conditioning him to dump the monkey in your lap at every opportunity — which wastes even more of your precious time. And let’s not forget the phone. Alexander Graham Bell, the man credited with inventing it, despised its intrusion so much that he ripped a phone off his own wall. Imagine what he’d think about cell phones. And heaven forbid if you make the deadly mistake of checking your e-mail first thing in the day. You can kiss at least half your morning goodbye. Guard your time as a precious commodity Just as you wouldn’t hand over a blank check to everyone who asked for money, you shouldn’t hand over a blank check for your time. If you’re going accomplish everything you need to accomplish each day and keep your sanity, you have to place limits on how much time you’re willing to allocate to everyone and everything. The people who always get things done and still have time left over are dogmatic – some might even say obsessive – about who gets pieces of their time, and how much. In fact, they safeguard their time even more than their money. That’s because they understand that, while it’s true that time is money, that’s just the half of it. When you spend money, it’s gone forever. When you invest money (wisely), it grows and continues to grow indef-

initely. When you spend time, it, too, is gone forever. But no matter how wisely you invest your time, it will never grow. So if you really think about it, time is far MORE valuable than money. It’s more limited than real estate, and none of us know how much we have. If you’re ready to get off that treadmill, start by becoming dogmatic and yes, even obsessive, about guarding your time. Treat it as the most precious and limited resource you have, to be invested only in the ways most likely to yield the biggest returns. And if I may humbly suggest, one of the smartest ways for you to invest your valuable time is to attend METALfab 2008 in Memphis, April 1-5. I’ll be holding four sessions on April 3 and will tell you how to manage those young, Generation Y employees who need lots of handholding; how to find good employees and keep from getting fooled by slick-talking job applicants in the interview; how to handle difficult customers; and how to keep those Time Leeches from sucking you dry. I’ll see you there. P.S. Did I mention that procrastination is a huge Time Leech? If you haven’t registered yet, do it now at . Space is limited and you really don’t want to miss this. It’s NOMMA’s 50th anniversary, and this is going to be big.

Glenn Shepard is a professional speaker, consultant and best-selling author of books on management and career success. He will be a featured speaker at METALfab 2008.

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

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



March/April 2008

Biz Side

Will you ever be able to retire?  With proper planning, you can calculate your

financial needs for retirement. By William J. Lynott Many of the old rules for retirement

planning are under siege these days. Determining how much money you’ll need to maintain the lifestyle to which you’ve become accustomed — and how to save it — has never been an easy task. Retirement planning experts offer a variety of conflicting ideas on just how to arrive at that elusive figure. Now, the gut-wrenching changes in today’s volatile economy are making that job tougher than ever. Millions of business owners and employees who thought they were on the right path to a financially secure retirement are discovering that their goals may now be beyond reach. Longer life spans and the relentless pressures of inflation have combined to March/April 2008 


complicate one of life’s toughest challenges: how to make your money last longer than you do. Whether your planned retirement is years away or just around the corner, inflation is destined to exert a major influence on your future economic well-being. Ignore it at your own peril. Inflation never lets up As the chart on page 72 illustrates, inflation can vary wildly from one year to the next. Whatever the rate, it continues its work relentlessly year-afteryear. Even that harmless-seeming inflation rate of recent years takes a significant toll over time. After 10 years of a modest 2 percent inflation, that dollar bill in your pocket now will be worth only 82 cents in today’s dollars.

For your information When planning for retirement, you can use the following calculators to crunch the numbers:  Savings calculator: index.html

 401k calculator: retirement/401k_retirement_calculator. asp  Life expectancy: investor/calcs/n_expect/main.asp

 4-step retirement planner: index.html If you’re over 50 and need to jumpstart your retirement planning or boost your nest egg, log on to


Biz Side

Data from U.S. Bureau of Labor Statistics

How inflation will affect your retirement Here’s an example of how inflation affects your personal life right now: If you paid $60 for a week’s groceries in 1985, you’re paying about $109.67 for those same items today. If you paid $18,000 for a new car in 1985, it will cost you approximately $34,522 to replace it with a similar 2008 model. Ten years from now, a comparable new car will cost you about $44,191 (assuming a 2.5 percent inflation rate).

Obviously, you can’t predict the exact inflation rate in advance; all you can do is estimate.

Calculating inflation’s effects over a period of two or more years can be dauntingly complex. That’s why it’s difficult to make simple dollar-to-dollar comparisons from one year to another. If you’d like an easy way to gauge inflation’s effects on some of your personal or business expenses, log on to This easy-to-use inflation calculator 72

adjusts any given amount of money for inflation, according to the Consumer Price Index, from 1800 to 2006. How much income will you need in retirement? You’ve probably read several variations on how much income you’ll need during your retirement. Many financial planners estimate that you will need 80 percent of your preretirement income to maintain your current lifestyle in retirement. If your earnings are, say, $90,000 per year just before you retire, you will need $72,000 to maintain your lifestyle. If your annual income is $200,000, you’ll need $160,000 per year to retire in the style to which you have become accustomed, according to the most popular school of thought. However, Walt Woerheide, Ph.D., VP of Academic Affairs, The American College, Bryn Mawr, PA, believes that most people experience a significant drop in expenses when they retire. “Chances are your mortgage will be paid off, you’ll no longer need to put aside money for savings or college tuition, and you’ll have the time to do chores that you may have been paying other people to do,” he says.

Certified Financial Planner (CFP) Carl J. Kunhardt, Dallas, TX, says his experience is different: “We’re finding that clients are spending essentially the same in retirement as before. It’s what they are spending on that changes in retirement.” Obviously, experts don’t agree on a single model for estimating financial needs in retirement. More problematic, perhaps, is the fact that some of the popular formulas for estimating required retirement income fail to consider inflation. That’s why you must. The Charles Schwab brokerage recently published a retirement planning rule-of-thumb that takes clear notice of inflation’s effects. It suggests that you will need $230,000 in retirement savings in today’s dollars to provide $1,000 in monthly income during retirement. For example, if you want to add $4,000 per month to your Social Security income, you would need $920,000 in retirement savings and investments –- in today’s dollars. The key phrase in the Schwab formula is “in today’s dollars.” If, say, your retirement is 10 years off, you will need to increase the $920,000 mentioned above to allow for the effects of 10 years’ inflation. Fabricator 

March/April 2008

How to compensate for retirement’s effects

Obviously, you can’t predict the exact inflation rate in advance; all you can do is estimate. Even if you assume that today’s inflation rate will remain about the same over the next 10 years, that $920,000 in today’s dollars will be about $1,110,528 in 2018 dollars. Since the current low rate of inflation may not continue for much longer, you should adjust your estimate of required retirement income to compensate for the latest rates.

Financial consultant, Ingrid K. Lamb, CPA/PFS, CFS, Chesapeake Beach, MD, points out that Social Security and some private pensions are adjusted to help counteract the harmful effects of inflation. However, retirees who depend on investments for a significant part of their income may find that’s not enough. “One way of compensating for inflation,” she says, “is to invest part of

your portfolio in dividend paying stocks that have a long payment history and a record of steady dividend increases.” Maury Randall, Professor of Finance at Rider University in Lawrenceville, NJ, agrees that every retirement portfolio should contain some stocks as a hedge against inflation. “Another method of protecting yourself is investment in inflationindexed treasury securities (TIPS). These Treasury bonds provide a




In addition to Sharpe Products already great pricing on stock handrail fittings, our custom bending and rolling services are also an excellent value. By utilizing Sharpe’s custom bending services, you can reduce the cutting, welding and grinding times of your job, which will reduce project costs. Contact one of our team members for more informations. By thinking SHARPE, you SAVE!

Sharpe also offers custom rolling services for large radius bends.

STOP & SEE US AT THE NOMMA SHOW, BOOTH 512! • Largest Selection of Stock Formed & Mandrel Bent Elbows, Many Sizes & Radii Available • Stock Fittings Available in Stainless Steel, Steel, & Aluminum • On-line Ordering & Same Day Shipping

The railings pictured above were bent in one piece. By doing this our customer saved themselves 7 cuts, 12 welds, and 12 grinds!

• Become a “Sharpe Thinker” Member & Receive Additional Discounts • Fast Turn Around on Custom Bending

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return based on the current rate of inflation,” he says. “So, when inflation rises, you’ll get a higher interest rate.” You can get more information on TIPS from any broker or at The U.S. Treasury’s web site: Regardless of the method you use for retirement planning, you must take inflation into account. “If you hope to enjoy a comfortable retirement, you’ll have to arrange for it yourself,” says Kunhardt. “No one else is going to worry about your financial health in retirement. If you don’t take care of it yourself, it won’t happen.” The way to make it happen, says G. Mike Crawford, CEO of Lifeplan Financial Group, Dayton, OH, is to maintain a detailed financial plan for your retirement. “Without a roadmap, it’s difficult, if not impossible, to see where you’ve been and where you’re heading,” he explains. Understandably, Crawford believes that a retirement plan prepared by a CFP is the best choice for most people. Still, he recognizes that many people prefer to do their own planning. “That’s fine,” he says, “for those who have a good feel for personal finance and how to handle money. Whether you call on a financial professional or prepare it yourself, it’s important that your plan stay active and flexible.” Whatever form your final plan takes, make certain that you take the inevitable effects of inflation into account.

Beating inflation’s effects Use these tips to help meet your retirement goals:  Prepare a detailed and flexible plan for your retirement and keep it up to date as your circumstances change.  Maximize your contributions. Contribute as much as you can as early as you can to your tax-deferred retirement plan. Allow the magic of compound interest to help counter inflation’s effects.  Resist the temptation to use your retirement portfolio as an emergency funding source. Cashing out a portion of your tax–deferred retirement plan will result in taxes and penalties that will put a serious dent in future growth.  Include some equities in your retirement portfolio. Most experts agree that stocks historically offer the best opportunity to achieve a rate of return on investment that will outpace inflation.  Invest in dividend-paying stocks that have a long payment history and a record of steady dividend increases.  Invest a portion of your retirement portfolio in inflation-indexed treasury securities (TIPS).


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March/April 2008

Biz Side

Juggling school for project managers  Having trouble prioritizing your company’s objectives? Here

are seven reasons why you should overhaul your project management system.

By Rudolf Melik If you can’t prioritize the projects you

already have and make good decisions on selecting new ones, your organization will be in serious trouble. Read on to learn how to transform your project management “three ring circus” into a sane, smart, successful system. If you work in a project-based environment, you probably feel like one of those juggling clowns at the circus: trying to keep your ball, your baton, and your flaming torch in the air at the same time, all while maneuvering your unicycle around the ring. Focus too much on one object and you risk dropping one of the others—or even taking a tumble. Project management can be a lot like this. Neglect to give one project the attention or funding it needs and March/April 2008 


the consequences of doing so can be much more serious than a dropped ball, especially when your higher-ups find out money has been wasted on an unimportant or failed project. Great news: it’s time to send out the clowns. Organizations don’t have to manage their projects in such a circuslike manner. A dearth of facts and unbiased analysis lead executives to make poor decisions when selecting new projects or assigning resources to existing ones. The result? Unmet business goals and lost opportunities. Bad project management decisions not only cause the misuse of valuable funds, but also create an environment where strategic projects take a backseat while certain “pet” projects are given higher priority. Under a poorly managed project system, managers have no way to know

For your information Read more about project-based management in Rudolf Melik’s book, The Rise of the Project Workforce: Managing People and Projects in a Flat World (Wiley, 2007, ISBN: 978-0470-12430-7, $34.95), available at bookstores nationwide, major online booksellers, or direct from the publisher by calling 800-225-5945. Other books on the topic of projectbased management include:

 A Guide to the Project Management Body of Knowledge, Third Edition, from the Project Management Institute  The Handbook of Project-Based Management by J. Rodney Turner

 Project-Based Organization in the Knowledge-Based Society by Kodama Mitsuru


Ultimately, having the right information at the

right time will improve your company’s odds of creating tremendous value.

what percentage of their projects are high-risk, resulting in money spent simply to keep things going rather than completing value-creating projects. Successful executives have to make the right decisions not only at the project level but also at the business level, where there can be dozens, and possibly hundreds, of projects to evaluate at any given time. It’s a tall order, especially when you consider that all of these projects rely on the same enterprise resource pool and obtain funding from the same global budget. Project prioritization and selection — part of Project Workforce Management — is the clear solution. By using this methodology, you can organize and manage projects as a group, or a portfolio at a business or departmental level. Project prioritization and selection requires involvement at all levels of the organization, including executives, the project management office, project managers, and other stakeholders. The information is collected, shared, and presented for analysis in a systematic and easy-to-use manner. Project prioritization and selection involves a five-step process:

 Step One involves selecting project-ranking criteria. For example, in this step you’ll consider whether a project aimed at cost reduction or one aimed at staff retention is more important at a given moment.  Step Two allows you to rank the projects. The top 20 percent of projects will deliver 80 percent of the value to a business. This step helps you figure out what that top 20 percent is. You’ll use your criteria to weight your projects and then rank them accordingly.  Step Three balances your portfolio, providing you with the right mix of projects. This helps to increase the priority of those projects that offer high reward for low risk.  Step Four balances capacity/resources, helps you ensure that there is adequate resource availability, and assesses the organization’s capacity to deliver a given project.  Finally, Step Five helps you prioritize your overall portfolio by marking lower-ranked projects or those that cannot be funded immediately as inactive. Your efforts to prioritize and carefully select your projects will pay off tremendously. Here are just a few advantages to implementing this system at your organization: It allows you to organize your company’s best interests. Think of it as a Google Calendar or an iTunes playlist for your projects. The project portfolio that you create when you prioritize your projects helps you put all of the projects that are the most valuable to your organization right there in one place. Much like your Google Calendar organizes your meetings or your playlist allows you to put your favorite (think “most valuable” in business speak) songs in an easily-accessible list, the project portfolio organizes projects that share a combination of common objectives, cost centers, resources, risks, or other associations, and allows management to make funding decisions, and to report on and analyze a collection of projects in one entity. You can simply look at your portfolio and decide which projects are strategic, which require additional funding, and which ones are not reaching the expected end results. It consolidates your project information so that no matter what department employees or managers might be working in they know what projects are the most important and can devote their time and resources accordingly.


It takes the guesswork out of project management. Sometimes, managers might want to see certain projects take priority simply because the results will benefit their department or act as an easy win. And other times, well-intentioned managers may mistakenly assign more resources to what seems like an important project, when in reality another project should get the attention. Implementing project prioritization and selection processes




March/April 2008

elevates decision-making to a more strategic viewpoint by aligning and assigning projects with business priorities. It also helps optimize resource allocation. Managers can decide which projects are the most important, based on hard information. They no longer have to guess at what project deserves the most money and attention. It ensures that your company is always working toward the goals that will create the most valuable results for the organization. It provides guidance for new projects. In a perfect world, only new projects that create value for the business and its customers would be implemented at an organization. Unfortunately, we live in the imperfect real world. Once they’re up and running, new projects aren’t always given the attention needed to be successful. Or, conversely, they are given too much attention and their success isn’t helpful for the company. Project prioritization and selection helps you add new projects to your queue without misallocating more important resources to them. At the same time, it helps you allocate enough time and manpower to ensure quality results. It’s a balancing act. Project prioritization and selection provides a framework to evaluate new project requests or opportunities in a systematic matter. Each opportunity is considered against the current priorities and resource availability. If it’s determined that the new project isn’t a priority, it can be rejected or archived for future consideration.


Risks are assessed from a global perspective on their overall impact. Ask your managers; it’s likely that avoiding unnecessary risks is at the top of their concerns. But if they’re focused only on avoiding risks with respect to the projects already in the pipeline, then their risk assessments won’t do the company much good. With project prioritization and selection, new risks can be assessed more thoroughly and with respect to how they will affect the company as a whole. The steps you’ll use to organize your project portfolio, specifically in Step Three when you balance your portfolio, will help you weed out those projects that contain too much risk to pursue. Naturally, if projects are prioritized and selected properly, risk is greatly reduced and the business operates at an optimal capacity with a higher number of successful projects.


It helps you know when you have the resources and when you don’t. In project planning, resource availability is key. It is also equally important to understand the organization’s capacity to deliver and its ability to develop internal capabilities. Resources are allocated to high-priority projects, and this process is repeated until the resources are exhausted. Once all resources are allocated or reassigned, the remaining projects are put on hold or additional resources are added to the pool. Your project portfolio will help you see if you are over-allocated or close to capacity and in which months resources will be available for


March/April 2008 


projects. Simply put, the system allows you to balance your resources. Your ranking system will help you see when resources need to be reallocated, and everyone will understand the reasons behind the decision because the weighting and ranking is there for everyone to see. It is less time-consuming than juggling projects. When you hear about project prioritization and selection, you may think, “Oh, great! Something else to take up my time.” The reality is that once you have the system in place, you’ll spend less time trying to figure out


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what happened to all of those failed projects or spent resources and more time actually managing the projects that matter most. The management of your project portfolio, once set up, is an ongoing exercise performed with the help of project managers and, in some cases, project sponsors and executives. The great thing about this system is that it doesn’t need to be constantly poked and prodded. In fact, it is important not to upset the portfolio too frequently by constant prioritization and resource balancing. It is recommended that you have a minor review each month and a major portfolio review once every quarter. It makes people more accountable. Without a clear report of how and why projects are approved or rejected, no one can be held accountable when a project fails or is not funded when it should have been. The project prioritization and selection system fosters accountability. Resources are allocated based on specific criteria, so if a project doesn’t receive the funding or manpower it needs to be successful, or if it fails for some other reason, leaders will know what went wrong where and can address those issues with the appropriate employees. As a result, managers can analyze past decisions with respect to project prioritization and selection and use this knowledge to improve their decision-making and forecasting abilities. But remember: you should establish a framework for continued process improvement so that lessons learned and metrics obtained may be used to improve future project selection, estimation, and ranking decisions. Project prioritization and selection is just one more step in providing your employees with what will be the backbone of their success in project execution—timely and accurate information. This critical ingredient allows them to make fact-based decisions regarding project priorities and new project selection that align projects and resource utilization with the company’s goals. Ultimately, having the right information at the right time will improve your company’s odds of creating tremendous value—which, of course, is the reason for the juggling act in the first place.


About the Author... Rudolf Melik is one of the founders of Tenrox and currently serves as its CEO. He has more than 15 years of experience in software engineering and the project workforce management industry. Melik has extensive knowledge of, and speaks regularly about, software solutions that support compliance initiatives such as Sarbanes-Oxley, DCAA, GAAP project cost accounting, revenue recognition, and labor laws such as FMLA and FLSA. He was also the principal author of the first book on professional services automation. 78


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NEF Todd

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New NOMMA members As of February 8, 2008. Asterisk denotes returning members.

Berry Services Inc.* Ft. Wayne, IN Fred Berry, Fabricator Cacciola Iron Works Paterson, NJ Sal Cacciola, Fabricator Heritage Industries Inc.* Pittsburgh, PA Rob Gladu, Fabricator Kensington Gate Ltd. Phoenix, AZ Cara Holland, Fabricator Lost City Ironworks Inc.* Los Angeles, CA Philip Rohan, Fabricator New Age Ironworks Inc. Bellerose, NY Yair Tapia, Fabricator Point of View Design Memphis, TN David Gilliland, Fabricator Rincon Ironworks Carpinteria, CA Rick Sanchez, Fabricator WLN International Encinitas, CA William Napier, Fabricator

NOMMA Nationwide Supplier Members A Cut Above Distributing (800) 444-2999

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Allen Architectural Metals Inc. (800) 204-3858

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

Albina Pipe Bending Co. Inc. (503) 692-6010 Alloy Casting Co. Inc. (972) 286-2368 American Punch Co. (216) 731-4501

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

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

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Carl Stahl DecorCable Innovations (800) 444-6271 Classic Iron Supply (800) 367-2639

Cleveland Steel Tool Co. (800) 446-4402 CML USA Inc. (563) 391-7700

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Feeney Architectural Products, CableRailâ&#x201E;˘ (800) 888-2418 Geo. Bezdan Sales Ltd. (604) 299-5264

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McKey Perforating (262) 786-2700

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

Industrial Coverage Corp. (631) 736-7500

Multi Sales Inc. (800) 421-3575

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Industrial Metal Supply Co. (818) 729-3333

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Frank Morrow Co. (401) 941-3900 Mylen Stairs Inc. (914) 739-8486 NC Tool Co. (336) 674-5654

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Rockite, Div. of Hartline Products Co. Inc. (216) 291-2303 Rogers Mfg. Inc. (940) 325-7806

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Stephens Pipe & Steel LLC (800) 451-2612

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Biz Briefs


Cleveland Steel Tool marks 100th anniversary The Cleveland Steel Tool Company is celebrating its 100th anniversary. Founded in 1908, the company has spent the past century supplying steel tooling to the ornamental and miscellaneous metalworking trade, as well as many other industries. In 1908, The Cleveland Steel Tool Company was founded as a producer of patented punches for the automotive leaf spring industry. Cleveland Steel Tool was incorporated under President J. F. Doolittle, in downtown Cleveland, while Teddy Roosevelt was in the White House. “It’s an honor to be part of a milestone event like this” said Mark Dawson, president. “And it’s even more remarkable to look back and see how we have been able to stay true to the original vision of the company, while developing new markets and new products.” The engineering team at Cleveland Steel Tool has worked diligently throughout the years to bring innovative solutions to the metalworking industry. It is the mission of the engineering team to simplify designs and processes, increase tool life, and ensure compatibility throughout the tooling system. After many years as a tooling manufacturer, Cleveland Steel Tool increased its value in the marketplace by adding a complete line of ironworker machines, from 25 ton to 120 ton capacity. With the more recent addition of magnetic drills and annular cutters, the company is now positioned to provide its customers with a broad line of hole making tools and equipment. Working to ISO 9002 standards, CST runs its own in-house heat-treating facility for optimal quality control. Product testing is done in real time ensuring minimal time to market. The company also uses computer-based technology to accurately perform repeat manufacturing processes to achieve consistent results. “We are grateful to our customers for their support over the last 100 years, and we pledge that the next 100 years will feature the same outstanding quality and unparalleled service you have come to expect from us,” said Dawson. Cleveland Steel Tool is the world leader in tooling for ironworkers, and also offers a broad line of ironworkers, mag drills and cutters. For more info, contact The Cleveland Steel Tool Company, Ph: (216) 681.7400, Fax: (216) 681-7009, Web:


Biz Briefs . . . . . . . . . . .82 Chapter News . . . . . . .84 Literature . . . . . . . . . . .86 People . . . . . . . . . . . . .88

Events . . . . . . . . . . . . .90 New Products . . . . . . .91 Classifieds . . . . . . . . . .96

AWS Foundation receives $100K donation The American Welding Society (AWS) has received a $100,000 donation from OKI Bering to help relieve nationwide shortage of welders. AWS estimates a shortage of at least 200,000 welders by 2010. AWS is the world’s largest organization dedicated to advancing the science, technology, and application of welding. OKI Bering is a wholesaler of welding, safety, and industrial supplies headquartered in Cincinnati, OH. The donation was granted to the AWS Foundation Welder Workforce Development Program, which was launched in 2006 to address the need for recruitment and specialized training of entry level welders while supporting welding workforce needs for selected companies. Contact: AWS, Ph: (800) 443-9353; Web:

EMMA offers expanded metal services The Expanded Metal Manufacturers Association (EMMA) members offer expanded metal services such as finishes, forming, coatings, shearing, die-cutting, parts fabrication, expanding to size, edging, welding, and inventory management. These services are designed to help lower customer costs and save time. Contact EMMA, Ph: (630) 942-6591; Web:

Chamberlain acquires Digitech The Chamberlain Group Inc., Elmhurst, IL has acquired Digitech International Inc. of Asheville, NC as part of its ongoing growth plans in the integrated access control industry. “Digitech’s security products, talented employees, and customer base complement Chamberlain’s business and enhance our ability to deliver compelling integrated access control solutions,” said J. David Rolls, Chamberlain Chief Executive Officer. For more than 20 years, Digitech International has been a leader in developing and marketing access control and security systems for the worldwide self-storage industry. Contact: The Chamberlain Group, Inc., Ph: (800) 2826225; Web:


March/April 2008

Biz Briefs

What’s Hot

Court rules on insurance coverage for construction defects

Trends push green building to the forefront of industry

Florida subcontractors won an important legal victory as the state Supreme Court ruled that unexpected and unintended property damage arising out of the work of a subcontractor constitutes a covered occurrence of property damage under the general contractor’s commercial general liability (CGL) policy. The legal victory was the result of the court’s consolidated decision on two disputes that dealt with the extent of coverage afforded by standard-form CGL policies, under Florida law, regarding construction defects. In their Aug. 4, 2006, brief, ASA and ASAF argued that excluding coverage in the case J.S.U.B. Inc. v. United States Fire Insurance Co. would render the provisions of a standard CGL policy superfluous and effectively defraud a contractor that relied on the plain meaning of the policy language. Agreeing with ASA, the court concluded that defective work that is neither intended nor expected from the standpoint of the contractor can constitute an “occurrence” under a standard-form CGL policy and that physical injury to the completed project that occurs as a result of a subcontractor’s defective work can constitute “property damage” as defined in a CGL policy. For more information, log onto and click on “Subcontractor Advocacy.”

According to FMI’s 2008 U.S. Construction Overview, construction industry stakeholders are increasingly recognizing green building capabilities as “good” and being a necessary part of a firm’s best practices. According to the report, the growth in green construction has created a shift in perception among owners and the architectural and engineering communities. Three major trends are pushing green building to the forefront of the construction industry’s consciousness: 1) an unprecedented level of government initiatives; 2) heightened residential demand for green construction; and 3) improvements in sustainable materials. Contact: FMI Corporation, Ph: 919-785-9359; Web:

March/April 2008 


BlueScope acquires IMSA BlueScope Steel Ltd. has acquired IMSA Steel Corp. The purchase includes four subsidiaries of IMSA Steel Corp, including Varco Pruden Buildings, Steelscape, ASC Profiles, and Metl Span. Upon closure of the transaction, the company will welcome 2,500 employees to the BlueScope Steel family and add 23 manufacturing sites to its portfolio, totaling 33 operating sites in North America. Contact: BlueScope Steel Limited, Web:


Chapter News

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March/April 2008

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928-422-1000 March/April 2008 



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Literature components. This catalog also includes seismic mounts, Uniload™ Constant Natural Frequency mounts, circular cable, air springs, shear mounts, wedge levelers, bell shape stud and insert, bumpers and feet, and Sorbothane® pads. In addition, AAC offers thermal conductive silicone products to resolve heat problems associated with electronic components. Many are suitable for use in extreme environmental conditions.

New vibration mount catalog

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Informational packets on hot-dip galvanized steel

American Galvanizers Association The American Galvanizers Association has released two new, comprehensive informational packets intended to educate city/county and university officials on the benefits of using hot-dip galvanized steel in municipal and university projects. “Galvanize Your Community” and “Galvanize Your University” are free and address sustainability, cost, aesthetics, and sector specific information. Contact: American Galvanizers Association, Ph: (720) 554-0900; Web:

New welding handbooks and career guide

American Welding Society (AWS) The American Welding Society (AWS) has updated and expanded the Brazing Handbook that provides a survey of the basics of brazing processes and applications. Knowledge of the ancient art of brazing is supplemented by additional technical information. The AWS Welding Handbook 9th Edition, Vol. 3, introduces friction stir welding and recent developments in Fabricator 

March/April 2008

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beam technology. The new publication is available in print and electronic format and includes chapters on resistance spot and seam welding, projection welding, flash and upset welding, and high-frequency welding. According to AWS, with nearly half of the North American welder workforce due to retire soon, this country faces a potential shortage of more than 200,000 skilled welders by 2010. Several U.S. construction and manufacturing companies continue to report significant problems due to the shortage. To help combat this problem, AWS has published a new welding career guide, Your Career in Welding, which is available free to students, teachers, guidance counselors and parents. The guide features success stories, scholarship and local AWS chapter information, and career profiles. Order your free copy on AWS’ website. Contact: AWS, Ph: (888) WELDING; Web:

2008 full-line welding catalog

Miller Miller’s new catalog provides specifications on Miller MIG welders, TIG welders, stick welders, plasma cutters, welding generators, and safety gear.

The catalog also provides product selection charts and product information for Bernard, Hobart Brothers, Smith Equipment, Tregaskiss, and Weldcraft. Contact: Miller, Ph: (800) 4-A-MILLER; Web: www.millerwelds. com.

New catalog for mold makers, die makers, engravers, and die sinkers

Falcon Tool Falcon Tool’s illustrated catalog includes more than 15,000 tools and accessories such as Swiss precision and American pattern files, polishing stones, and carbide and high speed steel (HSS) burs. Contact: Falcon Tool Co. Inc., Ph: (216) 328-0300; Web: www.falcontool. com.

Celebrate NOMMA’s 50th anniversary at METALfab 2008! Memphis, TN April 1-5, 2008

March/April 2008 



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Wager announces promotions, new hires

preparing customer quotes, as well as training current estimators and customer service representatives. Patrick Hutchinson has been promoted to director of engineering services, where he will be responsible for estimating and Patrick Hutchinson product/ process engineering. He will oversee the positions of estimating manager, senior process engineer, process documentation technician, and team leaders for the tool and die operations. Justin Wesser has been promoted to the position of manager of quality services. He will be responsible for the quali-

The Wagner Companies announces that Debra A. Emmer has joined the company as a quality superDebra A. Emmer visor. She will oversee internal auditing, quality feedback and metrics, document control, nonconforming material, and corrective action. Emmer brings with her 30 years of experience in the metal forming industry. Jeff Wissbroecker has been promoted to estimator/customer service representative. He will be responsible for Jeff Wissbroecker

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ty assurance efforts of The Wagner Companies, as well as continuous oversight of the pipe bending department’s operations. Contact: The Wagner Companies, Ph: (888) 243-6914; Web:

Barnes receives award Thermadyne Industries Inc. recently announced that Lynn Barnes was a recipient of the 2007 Chairman’s Award. She is one of six award winners for the calenLynn Barnes dar year 2007. Barnes began her career at Thermadyne in 1994 as a Senior Programmer Analyst and served in several other positions before being promoted to her current role as director of business intelligence. Contact: Thermadyne, Ph: (636)728-3000; Web:

Hypertherm makes changes to support distributors Hypertherm has appointed John Brennan to the newly created position of North American distribution director. Brennan most recently served as the company’s national distribution John Brennan manager and will now oversee the North American sales team. Randy McMurtry was appointed the company’s new national distribution development manager. Randy McMurtry He most recently Fabricator 

March/April 2008

What’s Hot


served as a divisional manager for Hypertherm and will now support the national distribution network’s sales and marketing programs that sell Hypertherm plasma cutting systems and consumables. Contact: Hypertherm, Ph: (800) 737-2978; Web: www.hypertherm. com.

Martin named product manager Jergens Inc. has appointed Jeff Martin as product manager for KwikLok™ pins, inserts, and spring loaded devices in the company’s Jeff Martin tooling components division. Martin has experience in sales, marketing, and manufacturing engineering. Contact: Jergens, Inc., Ph: (800) 537-4367; Web:

Foundation board of directors. Howell has a broad background in the welding industry. He also brings to the board domestic and international experience in operations, human resources, and sales and marketing. AWS student member Chance Pollo was ranked seventh best welder in the world at the 39th WorldSkills competition on November 14-21, 2007, in Shizouka, Japan. Pollo competed Chance Pollo, holding the American flag. with 26 other countries and also received a Best of Nation Award for Contact: AWS, Ph: (888) WELDTeam USA. ING; Web:

AWS staff changes; student achievements The American Welding Society (AWS) has appointed John Filippi as new managing director to support AWS’ global expanJohn Filippi sion strategy. He will manage the overall development and technical content of the Society’s certification programs. Filippi is a 20year veteran with expertise in operations management. Robb F. Howell has been named as a trustee to the AWS Robb E. Howell

March/April 2008 



T h e Be s t W i r e M e s h P r o d u c t s Ava i l a b l e • Family owned & operated since 1928 • NOMMA member since 1976 • Exclusive manufacturer of: Sure-Guard™ • Tartan Weave™ Rod-Guard™ • Mesh-Guard™

web: email:

Call us first for: Railing infill panels, partitions, window guards, stairway enclosures & detention equipment






7920 Stansbury Rd., Baltimore, MD 21222 Ph: (410) 284-9549 • Fx: (410) 282-6499. 89

What’s Hot

Regional METALFORM Birmingham, AL, April 1-3, 2008 This event is sponsored by the Precision Metalforming Association (PMA) and will take place at the BirminghamJefferson Convention Complex. The educational presentations will range from fundamentals for beginners to advanced concepts for experienced metalformers. Contact: PMA, Ph: (216) 901-8800; Web:

EMMA Spring 2008 Conference April 25-27, 2008 The Expanded Metal Manufacturers Association (EMMA) will host its annual event at the Kiawah Island Golf Resort, Kiawah Island, SC. Contact: EMMA, Ph: (630) 942-6591; Web:

Peters Valley Craft Center blacksmithing workshops May-September 2008 Peters Valley Craft Center will offer courses in curved stairs, Damascus Steel, bladesmithing, power hammer forging, forged steel art, and more. The classes, held from May through September, will last two-to-five days and will fea-

Events ture nationally recognized instructors like Zack Noble, Dick Sargent, and Top Job Winner Dan Nauman. The school is located in a rural and wooded setting in northwest New Jersey. For more information and class schedule, visit Ph: (973) 948-5200.

Call for nominations, 6th Annual Image of Welding Awards June 15, 2008 Deadline for Submissions The American Welding Society (AWS) and the Welding Equipment Manufacturers Committee (WEMCO), a standing committee of AWS, is seeking nominations for its Sixth Annual Image of Welding Awards. The awards are issued in seven categories and the winners will be announced at the Image of Welding Awards Ceremony during FABTECH, October 6-8, 2008, at the Las Vegas Convention Center in Las Vegas, NV. Contact: AWS, Ph: (800) 443-9353; Web:

Upcoming Events May 2-3, 2008 Americas Glass Showcase

The annual trade show, convention, and golf tournament — sponsored by Americas Glass Association, Independent Glass Association, and International Window Film Association — will take place at the Cashman Convention Center, Las Vegas, NV. The Golden Nugget is the host hotel. Contact: Americas Glass Association, Ph: (877) 2752421; Web:; Email: June 2-5, 2008 NFPA’s World Safety Conference & Exposition

The National Fire Protection Association (NFPA) annual convention will be held in Las Vegas, NV. The conference will feature education sessions, new products and services, and NFPA code experts for the “Ask the Experts” session. Registrants save $100 by registering by April 10, 2008. Contact: NFPA, Ph: (617) 770-3000; Web: September 8-13, 2008 The International Manufacturing Technology Show (IMTS) 2008

IMTS, “Connecting Global Technology,” will be held at McCormick Place Chicago, IL. There will be trade shows, exhibits, and networking opportunities. Contact: IMTS, Ph: (301) 694-5243; Web:



March/April 2008

What’s Hot

New Products

Custom plasma cutting service

Gate operator

King King Architectural Metals announces the addition of their new Hi-Def CNC Plasma Cutting machine at their Dallas headquarters. Also, the company has released its 2008 product catalogue including more than 9,000 total items, ranging from finials and I-beams, to gate operators and hand forged railing panels. Contact: King Architectural Metals, Ph: (214) 388-9834; Web:

Byan The Byan Systems Inc. model 600A is geared for residential and light commercial applications. The product has an internal slow down feature and can handle larger gates without damage to the mounting hardware or gate. No positive stops are required; the operator automatically slows at the last five to 10 degrees of travel. Byan offers a four-year manufacturer warranty on all products. Contact: Byan Systems, Inc., Ph: (800) 223-2926; Web:

Hand Rails Online

CRL C.R. Laurence Co. Inc. (CRL) presents Hand Rails Online, a web-based design program for material sizing. Hand Rails Online is design and layout software for professionals working with handrails, guard rails, glass balustrades, stair rails, and windscreens. The program generates information such as railing layouts, parts lists, quote sheets, and material cut sizes. Contact: CRL, Ph: (800) 421-6144; Web:

Miller offers rebates

Miller Electric Mfg. Co. is offering rebates of up to $150 to customers who purchase select Millermatic all-in-one MIG welders and Spoolmate spool guns before April 15, 2008. The promotion is designed to call attention to new aluminum welding solutions, such as the Miller Spoolmate 100 Series and Spoolmate 3035 spool guns, and new Millermatic Passport Plus and Millermatic 180 with AutoSet™ MIG welders. Submissions should be mailed no later than April 30, 2008. Complete rebate details can be found at your local welding distributor or by visiting

CNC part finishing; antique brown solution process

Birchwood Casey CNC part finishing with the TRU TEMP process is possible for large or small jobs. This new system by Birchwood Casey automatically processes finished parts in 28 minutes using a low temperature, non-polluting finishing process. The TRU TEMP CNC line is designed to operate as a self-controlled unit and can be configured to accommodate a variety of production needs. Birchwood Casey’s antique brown® M38 solution or gel process can be brushed on or applied by immersion. This new product produces oil-rubbed bronze, leather brown, and chocolate brown finishes, and may be used for lighting, cabinet hardware, locks, window/door frames, sculpture, and other metal items. Contact: Birchwood Casey, Ph: (952) 937-7931; Web:

March/April 2008 


Diamond Mesh

Rectangular Mesh

We will custom fabricate infill panels to meet your specific requirements. Available in diamond, rectangular and square mesh with or without standoffs.

Square Mesh

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

New Products

CS Unitec The PTX Eco Smart finishing machine by CS Unitec has balanced straight line handling, high torque, and electronic speed control. It produces matte, satin, and other surfaces up to a mirror finish on steel, stainless steel, and nonferrous metals. The PTX is also suitable for coarse grinding jobs such as removing welds, deep scratches, oxidation, rust, and paint, and can also polish inside corners. Contact: CS Unitec, Ph: (800) 700-5919; Web:

50 Ton Turret Ironworker

SCOTCHMAN® Scotchman® Industries features the 5014 TM Ironworker in their “Metal Fabricating Solutions.” The 5014-TM has 50 tons of pressure and the ability to punch a 13/16” hole in a 3/4” plate. The 5014 TM features a three-station revolving turret that accepts up to three pieces



of tooling. The product includes an angle shear and a rectangle notcher. Contact: Scotchman Industries Inc., Ph: (800) 843-8844; Web:

Universal remote control and wireless keyless entry

Chamberlain® Chamberlain Professional Products introduces the Liftmaster® Universal Remote Control (Model 375LM) and Liftmaster® Universal Wireless Keyless Entry (Model 387LM), designed to operate most manufacturers’ garage door openers. The two-button LiftMaster Universal Remote Control can be programmed to operate up to two different manufacturers’ garage door openers, and mounts to a car’s visor. Consumers can set their own private four-digit PIN, and the product features a backlit keypad for nighttime use. Contact: The Chamberlain Group, Inc., Ph: (800) 282-6225; Web:

GET IT CLOSE. HIT YOUR MARK. LOCK IT DOWN. DRILL. THE NEW HMD904S SWIVEL BASE DRILL. It’s tough to line up precise center points especially in horizontal or upside down positions with a magnetic drill. But not with our new swivel base model. Get it close and engage the magnet. Release the swivel’s quick unlock handle. Line up the pilot over the center point and lock the swivel. It’s that simple and only takes seconds. Hougen makes the tough holes easy, again. 1-1/8" Patent Pending


WOODWARD-FAB.COM 800-391-5419 92


Surface finisher

800-426-7818 • Fabricator 

March/April 2008

What’s Hot

New Products Kwik-Lok™ Pins

Fortis lift trucks

Jergens Jergens Kwik-Lok™ Pins are designed for various construction applications including cranes, scaffolding equipment, mining equipment, drilling equipment, lifting equipment including hoists,

Hyster The Hyster Company’s new Fortis Line of lift trucks is customizable; each lift truck is offered with multiple power train configurations to meet specific application requirements. The Fortis family of lift trucks, which covers a capacity range of 2,000 lb. to 15,500 lb., offers both cushion and pneumatic tire classes, with multiple engine choices consisting of gas, LP, and diesel. Contact: Hyster, Ph: (800) HYSTER; Web:

slings, and cables, and in trailer beds. Pins may be used for any application requiring frequent connecting and disconnecting, lifting, changing, or securing objects without using tools. Contact: Jergens, Ph: (800) 537-4367; Web: Heavy-duty demolition hammers DeWALT

DeWALT’s new heavy-duty demolition hammers (D25899K, D25901K, D25941K) are designed to provide users with durability, performance, comfort, and reduced vibration with in-line design. The hammers’ spring-loaded dust seals keep contaminants from entering the tool, helping to extend the tool-life. Contact: DeWALT, Ph: (800) 4-DEWALT; Web:

Die cast model collection

JLG JLF Industries has introduced five new die-cast models, including JLG model E33MJ mast boom lift, JLG Toucan model 1210, JLG electric scissor lift model 2646ES, and two versions of the Atlas II military telehandler. Each has fully operable components including movable booms, adjustable steering, and detailed controls. A variable height-locking feature on all models allows the booms and scissors to be raised to any height without loss of elevation over time. Contact: JLG, Ph: (702) 294-1730; Web:

New England School of Metalwork 2007-08 Winter Session Coal Forge Building Pattern Welded Steel Basic Bladesmithing

2008 Summer Session

Lucian Avery—Door Hardware Dereck Glaser—Traditional Joinery Caleb Kullman—Fireplace Accessories P e t e r R oss— To ol F or g i ng Clay Spencer—Tire Hammer Building Marla Stelk—Copper Weather Vanes Don Fogg— Japanese Bladesmithing Bob Alexander—Forged Flowers Wendell Broussard and Doug Wilson (Special team taught class)

Plus several other workshops !!!!!!!!

Summer Workshop Registration is now Open!! 1-888-753-7502 March/April 2008 



What’s Hot Hand-truck cold water pressure washers

Kärcher Kärcher has introduced a commercial line of cold-water pressure washers using a handtruck design for maneuvering. The four models deliver cleaning power of up to 3,600 PSI of pressure with a flow rate of up to 4 gallons per minute. All come with Kärcher’s patented, professional-grade axial pump integrated with a Honda engine. Contact: Kärcher, Ph: (800) 4654980; Web:

Automated excavation system

Leica The Leica Geosystems PowerDigger features a large, color screen that displays information on the depth and position of the excavator bucket. Operators can dig in “blind cut” situations. Multiple job settings let the user switch between different digging profiles and custom profiles can be created on the machine to continue from existing ground profiles.

New Products Contact: Leica Geosystems Inc., Ph: (770) 326-9557; Web:

XMT™ Tool System expanded

Mate Mate Precision Tooling announces expansion of its XMT™ tooling system with the addition of the XMT 12.7 mm punch, stripper and Slug Free® die to suit the new XMTE10 multi tool. Designed for use in the new 10-station Euromac XMTE10 Multi Tool, this XMT 12.7 mm tooling will accommodate round and shaped tools with a diagonal dimension up to 0.500 inch (12.70 mm). The Mate Enumerator™ Sequential Numbering Tool is designed to stamp sequential serial numbers, dates, and codes on fabricated parts. The tool produces sequential numbering up to six digits long in one operation. Contact: Mate, Ph: (800) 328-4492; Web:

Night-vision security cameras

Zonet Zonet’s two new night-vision IP security cameras with two-way audio capabilities are suited for small businesses, offices, and builders. The cameras allow use in dark or sensitive areas such as entryways, hallways, outdoor areas, and storage locations. Contact: Zonet, Ph: (909) 594-3338; Web:

CNC router


Techno introduces the PanelMaster Pro Series CNC Router. Designed specifically to meet the demands of nested-based manufacturing, the PanelMaster Pro is constructed of large heavy tubing that is welded and stress-relieved with Techno’s precision drive system. The router features precision ball screw drives on all three axes, THK rails and bearings, and high-speed closed-loop servomotor and drives. Contact: Techno Inc., Ph: (800) 819-3366; Web:

HYDRAULIC IRONWORKERS Model BENDICROP 55 Ton Punch 3" x 3" x 5/16" Angle 14" x 1/2" Plate Shear

Rounds & Squares standard. Channel & Beam optional. A unique "built-in" bending section with a maximum ECRCEKV[ QH  Z  ƀCV RNCVG is standard equipment.

WWW.COMEQ.COM Phone: 410-933-8500 E-mail: 94

Enhanced website

OMAX® OMAX® Corporation recently announced the launch of an enhanced corporate website featuring customer focus links, live chat, and products to suit various abrasivejet machining needs. Contact: OMAX, Ph: (800) 8380343; Web: Fabricator 

March/April 2008

What’s Hot

New Products

Modular stacking system

Waterjet cutting system


Bystronic Inc. Brystronic Inc. has introduced the Byjet L, an abrasive waterjet cutting system optimized for the processing of large sheet sizes. The machine is ideal for steel service centers and other companies that need to process large volumes of waterjet parts or large sheets. The base frame of the machine is a modular construction that can be expanded in 6.5’ increments based upon the end-user’s needs. Models offered range from Byjet L 2030 with a 6.5’ x 10’ cutting area, up to the Byjet L 16030 with a 52.5’ x 10’ cutting area. All models include two High Precision Technology (HPT) abrasive waterjet cutting heads with automatic head

The HF Stacking Cradle System from Schmidt Structural Products is a modular system for storing long goods, coils, and flat stock. The system is transportable and adaptable, and consists of a spreader beam unit and stacking cradles. The spreader beam unit attaches to an existing facility crane with builtin hooks. Contact: Schmidt, Ph: (800) 5236719; Web:

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


spacing, height sensing and collision protection on each cutting head. Optional third and fourth cutting heads are available for even higher productivity. Contact: Bystronic Inc., Web: 631-4343330. S56 VMC Machining

Makino The Makino S56 utilizes a 40 taper, 13,000-rpm spindle with the rigidity required for hard cutting applications and the speed necessary to provide surface quality for die and mold applications. As an option, the S56 can be equipped with a 20,000-rpm spindle. The product has heavy cast construction and an axis configuration with no overhangs. Contact: Makino, Ph: (800) 5523288; Web:


Magnum Hand Tube Bender Rolls:


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



PO Box 3425 Knoxville, TN 37927 865.546.7733

UNIQUE ROLLING SYSTEM Works with both hand tubing benders

Cap Rails



! Flat Bar (on edge hard way)

$UWLVW%ODFNVPLWK–V Association of North America, Inc.

R&D Hydraulics, Mfg. and Machine Co. 1431 West 5th St. Chico, CA 95928 March/April 2008 




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

Classified ad rates and information

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



March/April 2008

Advertiser’s index Fabrication

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

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

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

Colorado Waterjet Co. Tornado Supply

59 94 32 40 58

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

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

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

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

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

March/April 2008 


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

Software 04 89 87

FabCAD Inc. MB Software Solutions Red Pup Productions

Stairs & Treads 100 28 43 74 79

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

Glass Services 78 91

K Dahl Glass Studios Lindblade Metal Works

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


Business Perspectives

Build a better business tomorrow... by planning ahead today  Anticipate and head off Running a small business is no small

task. Between sales and marketing, customers’ requests, vendor issues, employees needs, facility needs, paying taxes, balancing the books, insurance negotiations, and more, there is little time left for planning ahead — which is necessary for those who want to get ahead in business. Planning ahead requires a commitment of time and resources that, in turn, will provide a return on investment again and again. If you choose to avoid the planning milestones listed below, you place your future squarely in the hands of the Fates… leaving little for you to do but hope for the best when the worst happens. For example, let’s take a look at John and Sue, owners of a small metalworking business with five employees. Sue handles the books and the customers, while John oversees the shop. Sound familiar? Now, for the problem: One of John and Sue’s bigger customers has experienced a downturn and is unable to pay their bills for a longer-thanexpected period. The easiest solution is for John and Sue to visit their bank and get a short-term working capital loan showing the receivable as some kind of collateral, right? Well, yes and no. The good news is they have been banking at the same institution for several years and are known there. However, on the down side, they’ve never borrowed much money and haven’t established a relationship with a banker who really knows their business. Paperwork ensues; the bank wants financial data for the last three years, plus some of the company’s 98

problems before they begin.

equipment as collateral. Meanwhile, John and Sue’s payroll is coming up short and financing is still days away. What is the solution? Well, if John and Sue had gone to the bank after last year’s record sales, introduced themselves to their banker, and asked for a line of credit, they would have been easily approved in due course. Then, they could have advanced on the credit line when they needed it. All too often, however, the scenario goes more like this. John and Sue’s business took a downturn overall and, while they had a receivable to take to the bank, it was of dubious quality. They simply need some cash to see them through a rough spot while they sell the next round of orders and buy materials to fulfill them. Most small business owners and managers wait until this scenario happens to ask the bank for a loan. The end result is usually negative or on such difficult terms that no one wants to borrow the money anyway. Sadly, in many cases the small, hard-earned business fails under these circumstances. There are many proactive things you can do to improve your business security and build a safety net to catch you WHEN — not IF — you ever have to face one or more of these problems. Remember:  The best time to find a good attorney is when you don’t need one.  The best time to borrow money and meet your banker is when you don’t need to.  The best time to find a good insurance company/agent is BEFORE the accident or catastrophe occurs.  The best time to hire a good

employee is when he/she walks in the door.  The best time to hold a performance review is BEFORE the employee creates a disruption to your business.  The best time to relocate your business is when you have seriously planned the move, have a lot of earned cash in the bank, and a lot of work on the books.  The best time to fire a problem employee is yesterday.  The best time to settle differences within the business leadership is as they happen.  The best time to plan ahead is a quarterly board meeting attended by all of the primary shareholders. These meetings should focus on strategy as much or more so than operations.  The best time to add an outsider to the family-run business board of directors is now. So, if you want to advance your business, you first have to get on top of the day-to-day management long enough to pursue the items listed above. Without meeting these planning milestones, the future of your enterprise will be forever uncertain, subject to the whims of the economy served by your particular business. In other words, the best time to secure your future is now, by planning ahead. Doug Bracken is a past president of NOMMA.


March/April 2008





Metal Spirals from



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

We make installing a spiral straightforward.

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

Oak Spirals from



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

Victorian One ® from



Installation Video featuring “The Furniture Guys”

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

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

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

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


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

2008 03 fab  
2008 03 fab