Page 1

NOMMA members collaborate on fence project at Metal Museum, pg. 40

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

May/June 2008 $6.00 US

Tips & Tactics

Shop Talk

Biz Side

Railings for curved stairs, pg. 17

Efficiencies lead to quality, pg. 20

The upside in a tough economy, pg. 71

Job Profile

A salute to Top Job 2007

page 43

METALfab recap — NOMMA’s 50th anniversary convention, pg. 54

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May/June 2008 Vol. 49, No. 3

NOMMA member Web Metal Fabricators Ltd. specializes in solving construction problems, such as this project involving beams and columns to support a restaurant roof. See page 30.

Tips & Tactics

Biz Side

Job Profiles

Gate operators . . . . . . . . . . . . . . . . . . . 12 Certified installers can give you a winning edge over the competition. By Todd Daniel

Stair theory . . . . . . . . . . . . . . . 17 Here’s how to build a railing that actually fits a curved stair. By Dick Sargent

NOMMA service project ..........40 NOMMA members create a fence “collage” for the Metal Museum. By Todd Daniel

Top Job gallery....................................43 A look back at some of the entries in the 2007 Top Job competition.

The upside to the downturn . . . 71 You can strengthen your company, even in a tough economy, with these tips. Under the microscope . . . . . . . . . . 76 Prepare your company for a possible visit from a regulatory agency. By Ron Flexon

What’s Hot!

Shop Talk Systemize it . . . . . . . . . . . . . . . . . . . . . . . 20 NOMMA members Roger and Lee Flynn know the value of organization. By Peter Hildebrandt

Special Feature METALfab 2008 recap . . . . . . . 54 NOMMA’s 50th anniversary convention is a grand success.

New Members . . . . . . . . . . . . . . . . . . . . 82 Nationwide Suppliers . . . . . . . . . . . 82 Biz Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . 84 People . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Member Talk Beyond boundaries . . . . . . . . . . . . . 30 A member spotlight on Western Canada’s Web Metal Fabricators Ltd. By Sheila Phinazee

From oil to metal . . . . . . . . . . . . . . . . 37 Hendrick Mfg. Co. has served the industry for 132 years.

President’s Letter . . .6 NOMMA members, your input is needed!

It was a week of celebration — remembering NOMMA’s past, marking achievements, and looking toward the future.

Editor’s Letter . . . . . .8 When you love what you do, it shows.

Chapter News Literature

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

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

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

. . . . . . . . . . . . . . . . . . . . . . . . 96

Ad Index . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Reader’s Letters . . . . 9 Kozik and Top Job winners express their thanks.

Metal Moment . . . . 98 There’s simply no substitute for old-fashioned ingenuity.

Cover photo: This beautiful gate, featuring hand-forged scrolls, was an entry in the 2007 Top Job competition. It was crafted by Herndon & Merry, Nashville, TN. May/June 2008 



President’s Letter Your role, as I see it For those of you who may have missed

Dedicated to the success of our members and industry. NOMMA OFFICERS President Terry Barrett Royal Iron Creations West Palm Beach, FL President-elect Bob Foust Bob’s Ornamental Iron Studio Kansas City, KS

Vice President/ Treasurer Bruce Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA Immediate Past President Breck Nelson Kelley Ornamental Iron LLC Peoria, IL

FABRICATOR DIRECTORS Frank Finelli Finelli Ornamental Iron Co. Solon, OH

J.R. Molina Big D Metalworks Dallas, TX

Will Keeler Keeler Iron Works Memphis, TN

Mark O’Malley O’Malley Welding & Fabricating Inc. Yorkville, IL

James Minter, Jr. Imagine Ironworks Brookhaven, MS

Greg Terrill Division 5 Metalworks Kalamazoo, MI

SUPPLIER DIRECTORS Wayne Haas Cleveland Steel Tool Co. Cleveland, OH

Cathee Speaks King Architectural Metals Dallas, TX

Gina Pietrocola D.J.A. Imports Brooklyn, 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

2008 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

it, we just returned from a very successful convention in Memphis, the birthplace of NOMMA, some 50 years ago. The education sessions were outstanding, as usual. Keeler Iron Works, Tennessee Fabricating, and the Metal Museum were gracious hosts for the Saturday tours. Speaking of the Metal Museum, if you ever find yourself in the Memphis vicinity, do not miss this treasure on the banks of the Mississippi. The demonstrations, donated artwork, and new library are all testaments to our industry and its past, and the bridge to our future. It is phenomenal that NOMMA was founded by a handful of pioneers 50 years ago, and that dedicated presidents and boards since that time have guided the association to what it is today. I feel especially privileged for the opportunity to begin the work of the next 50 years, and I thank you for that. My task, as I see it, is to continue a process of improvement started many years ago and provide additional momentum to ensure that this association will not be just very good, but to help lead us to the path of being a remarkable association. In the early years, the pioneers that started the association knew full well what they needed to benefit themselves, what would excite them, and what would help grow the organization. Today, however, it is much more difficult with a larger membership to know these answers. At NOMMA, how do we identify and develop the programs and services that best benefit our members, in order to keep our current membership excited and attract new members for the future years? This is forever our task. In that regard, we have been working with outside resources and researching what other remarkable associations have done to discover the secret. We found that they all have a common thread in that they were exceptional in gathering information and devising their product offerings on the knowledge of the infor-

mation and not on whims, wishes, and small amounts of data. They also were very good at looking into the future to be ready before the members even knew they had a need. These remarkable associations have a process that is a living, breathing thing and that is ingrained within their organizations. We, too, can gain the information we need, and we can make good decisions as to what programs/services we need to develop to effectively meet or exceed the expectations of our common self- interest. As the Terry Barrett is stewards of the associ- president of ation, our role for this the National Ornamental and year is to define and Miscellaneous develop this process. Metals Association. Our feelings are, that if we are successful in understanding the needs and developing programs/ services for our current members, others will want to join our association. Your role in the process is to provide us with information! We need communication and feedback from all of you, all the time. As stated before, we are in the development stages of the process. So when a future intern calls you with a questionnaire, or we contact you to sit in a focus group or whatever the process is going to be, please take the few minutes from your busy day to help us, and thus yourself. In order to jump start this initiative, Todd Daniel has added a new contact point on the NOMMA website. If you look for the area that says, “Contact us,” you will see an additional option for board feedback. This goes directly to my email address for dissemination to the others. So give it a try, we can handle it! Together we will build an association so remarkable that we will honor all the work that has gone before. And in the words of the movie, The Field of Dreams, “If we build it, they will come.” Fabricator 

May/June 2008


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


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

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 For the love of it Do what you love; love what you do. This sounds so simple. But the reality

is that many people are never able to truthfully say this about their jobs. I’m one of the fortunate ones. I love words and I love people (everyone has a story!) — and luckily for me, I’ve been able to combine the two into a career as a journalist. Even better, I’m working for your association (and associations are all about their people) and editing your magazine. I couldn’t ask for a better job. It was evident to me during the week of METALfab 2008 that so many of you seem to have the same good fortune with your work. One of my most vivid impressions from this year’s convention is of how many NOMMA members are doing what they love — and loving what they do. Your enthusiasm, commitment, and pride definitely show! So, I’m going to ask you to share some of that positive energy and enthusiasm — in a new way. In his President’s Letter (p. 6), Terry Barrett is calling on all of you for communication and feedback about your association. Every member’s input is crucial to the bigger picture of making NOMMA not simply a good association, but a remarkable one. Read Terry’s letter and commit yourselves to being active voices and participants on this road to NOMMA’s continued success. Speaking of success, we have several articles in this issue that address that topic. In Member Talk, we feature two members who have achieved success by filling specific needs. Web Metal Fabricators Ltd. specializes in solving construction problems, while Hendrick Mfg. Co. evolved from its roots as an oil refinery to become a manufacturer of perforated metal. Roger Flynn and his son, Lee, of R & F Metals have found that imple-

menting certain technologies has helped organize their diversified production and make it more efficient. They also feel that they produce a higher quality product, while keeping costs as low as possible. You can successfully create a railing for a curved stair, if you follow a simple theory. Read about it in our Tips and Tactics article, “Stair Theory,” on p. 17. Helen Kelley is editor We had a very of Ornamental & successful conven- Miscellaneous Metal tion this year, cele- Fabricator. brating NOMMA’s 50th anniversary at METALfab 2008 in Memphis. Todd Daniel has chronicled a special NOMMA service project — just prior to the convention, several NOMMA members built sections of, and assembled, a metal fence that replaced an old wooden fence on the grounds of the National Ornamental Metal Museum. Read about this extraordinary volunteer effort on p. 40. We also have highlights of the convention in our METALfab recap, beginning on p. 54. Rounding out this issue are a photo gallery featuring some of the entries from the 2007 Top Job competition, timely business articles on keeping your company strong during an economic downturn and how to be prepared for a regulatory inspection, and more. As always, I look forward to sharing more of your stories in future issues of Fabricator. Keep those suggestions coming!

P.S. — Yes, I’m behind bars at METALfab in this month’s photo. I was pleading with Todd Daniel to put down the camera and unlock the gate; I was successful. Eventually. Fabricator 

May/June 2008

Letters An open letter from Frank Kozik award recipient Tom Zuzik To my fellow NOMMA members: In the mid to late 90â&#x20AC;&#x2122;s my

familyâ&#x20AC;&#x2122;s company joined NOMMA because we were looking for answers to building code issues. When we first joined, I gravitated toward the then-named Technical Committee, looking for answers as to where the heavy design restrictions came from. What amazed my brother and me was the open exchange of information that long-time members provided. At one conference in Nashville, my brother and I were talking to another member about proposals. From out of nowhere, a voice said, â&#x20AC;&#x153;Youâ&#x20AC;&#x2122;re crazy for writing proposals.â&#x20AC;? Stunned, I turned to see Ernest Wiemann, who said, â&#x20AC;&#x153;Son, you never write a proposal, you only write contracts.â&#x20AC;? When I returned to the shop, we implemented this time-saving practice and it worked. Had that simple suggestion not been given as openly as it was, I donâ&#x20AC;&#x2122;t know what I would be doing today. However, I can tell you it made me always want to try and help my fellow NOMMA members, having discovered that the more we helped fellow members, the more information was exchanged with us and the more friends we made. In the 1990s I learned that there was an important building code proposal coming and that NOMMA needed to be at the ICC meetings. As a wise man once said, â&#x20AC;&#x153;If you are not at the table you are probably the meal.â&#x20AC;? Having had experience with being the meal with the term â&#x20AC;&#x153;ladder effectâ&#x20AC;? in New Jersey, I was determined to see that it would never affect us again. You might ask, â&#x20AC;&#x153;Tom, where are you going with this?â&#x20AC;? Itâ&#x20AC;&#x2122;s simple â&#x20AC;&#x201D; I never considered what I did as â&#x20AC;&#x153;volunteering my time.â&#x20AC;? I always looked at it as what I could contribute to other NOMMA members. As members of NOMMA we all must look at not only what NOMMA is doing for us, but also what we can do for NOMMA. This organization needs each and every one of us to help not only with paying dues, but also by sharing our knowledge and time. Those of you who might think you donâ&#x20AC;&#x2122;t have something to contribute are just wrong. I can say this because I never felt I had something to contribute to this organization. So when I was called during the awards banquet at METALfab, I was completely blown away hearing that I had won the Frank A. Kozik Award for outstanding volunteerism. It is now weeks later, and I am still humbled and honored that such an award was presented to me. Looking back at what the Technical Committee â&#x20AC;&#x201D; now called the Code Advisory Council â&#x20AC;&#x201D; has accomplished over the past decade, I want to thank all of you for your commitment to NOMMA because without your membership this committee would not exist and the work this committee does would not be possible. Tom Zuzik Jr. Artistic Railings Inc. Garfield, NJ May/June 2008  Fabricator

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Letters Top Job winners express gratitude for 2008 awards Thank you to NOMMA for a very successful 50th convention! We were saddened that we were unable to attend because of scheduling conflicts, and we particularly regretted missing the event after learning we had won

Tell us what you think Letters are welcomed and encouraged. Please note that letters may be edited for clarity, grammar, and length. Send to: Mail: Letters to the Editor, c/o Fabricator, 1535 Pennsylvania Ave., McDonough, GA 30253. E-mail: Fax: (770) 2882006; Ph: (888) 516-8585. Please include your name, company, address, telephone number, and e-mail on all submissions.

three Top Job Awards. The Top Job contest is very important to us. The increasing quality of projects submitted pushes us to try new things and to strive for perfection in all that we do. To get that vote of confidence from our peers is certainly rewarding. The NOMMA organization itself, the convention classes and trade shows, the ListServ, and the help of fellow members are still the most valuable resources in our quest to master our trade. It is also rewarding as a parent now that my children are giving back to NOMMA by sharing the knowledge that we as parents and you as NOMMA members have shared with them. This knowledge assures the perpetuation of our organization and our trade. ~ Betsy Rodrigue Virginia Architectural Metals Fredericksburg, VA

To my fellow NOMMA members, I thank you for the honor of receiving a Top Job award. I wish to also thank everyone who entered the Top Job competition, and everyone who made METALfab 2008 a success. In addition, a thank you goes to all the hard working folks who keep NOMMA strong. ~ Dan Nauman Bighorn Forge Inc. Kewaskum, WI We wish to thank the NOMMA membership for our 2008 Top Job award. It is a great honor to be recognized in such a high standard of competition. ~ Karoly Sz端cs Artisan Metal Works Grand Cayman, Cayman Islands Top Job winners can be viewed online at



Fabricator  May/June 2008

In Memory

NOMMA’s first woman president passes Evelyn York, 79, a past NOMMA president and longtime volunteer, died April 17, 2008. Evelyn and her late husband Leon joined NOMMA in 1966, three years after founding York Metal Fabricators in 1963. She served as president in 1988 and was awarded the Julius Blum Award in 1991. During her decades of service to NOMMA she sat on many committees and was highly involved with longrange planning. She also played a key role in founding the former Oklahoma Chapter of NOMMA, and was a founding benefactor of the National Ornamental Metal Museum. In her free time, Evelyn had a passion for quilting and was a member of the Edmond Quilt Guild. In remembering Ms. York, Tycee Grice, a long-time NOMMA member, said, “Being on committees during her term of office was fun for Jerry and me. I still have her handpainted t-shirt that was her gift to her committee chairs.” According to fellow NOMMA member Lloyd Hughes,

May/June 2008  Fabricator

“Evelyn and Leon felt very strong about NOMMA and voluntered a great deal of time to the organization. I can’t help but recall the countless hours many of us spent in the Long-Range Planning Committee, which Evelyn chaired.” Her company, York Metal Fabricators, is known nationwide for their expertise in nonEvelyn York, shown with ferrous, glass, and complex her late husband, Leon. handrail systems. The firm will continue to be run by two of her children, David York and Dedra Runyan. Evelyn is preceded in death by Leon, another NOMMA president, who passed away in 2004. In addition to David and Dedra, she is survived by a third child, Deborah Pickens, and seven grandchildren and numerous great-grandchildren.


Gate Operators

Tips & Tactics

A new certification program for installers provides great promise for both business owners and consumers.

Contact: IDEA P.O. Box 236 West Milton, OH 45383 Ph: (937) 698-1027 Fax: (937) 698-6153 Web:

Attempts by Texas legislators to regulate installers prompts the Vehicular Gate Ad Hoc Coalition to create an excellent testing and certification program for industry.

By Todd Daniel NOMMA Communications Mgr.

& RIGHT: The certification program tests students on a variety of gate operator systems and configurations.


Does your shop install gate operators?

Are you looking for ways to promote safety and professionalism? If so, the new Gate Operator Installer Certification may be just for you. Officially rolled out in January, the program provides a way for you and your employees to earn the title of Certified Gate Operator Installer. Top Job file photos

Why become certified?

For your shop, certification means more technical expertise. The certification ensures that your installers are familiar with the latest safety standards — UL 325 and ASTM F2200. For the front office, you now have a valuable sales tool that can give you an advantage over competitors. You also have a better defense should an unthinkable lawsuit occur. And for the industry there is a huge plus — when our industry self-regulates it is less likely that a state or federal body will come in and do the regulating for us. Imagine the nightmare we would face if various states and federal agencies all began hitting us with different requirements. Robert Rayson of Stratford Gates Systems Inc. in Clackamas, OR presented a class on the new certification program at the recent METALfab convention. “I think it’s a good thing,” he says. “It adds credibility to professionals.” He adds that certification is a way to weed out unqualified people who should not be installing access control systems. “I’m encouraging everyone to do it,” he said. 12

FABRICATORS: LEFT — Christopher Metal Fabricating Inc., Grand Rapids, MI. TOP – Shanghai Loyal Orn. Wrought Iron, Shanghai, China.

Who created the program?

The certification program is the latest project of the Vehicular Gate Ad Hoc Coalition, which was formed in 1996 to address safety and regulatory issues. In the late 1990s the coalition played a key role in updating the UL 325 standard. In 2002 the coalition accomplished another milestone by releasing the ASTM F2200 gate construction standard. In 2006 the coalition began exploring the need for an industry certification program. The coalition then came up with testing criteria and began talking to the Institute of Door Dealers Education and Accreditation (IDEA) about administering the test. The coalition continues to meet twice a year to maintain the F2200 standard, review the progress of the testing program, and handle other

business. The group is made up of the American Fence Association (AFA), the Door & Access Systems Manufacturers Association (DASMA), the International Door Association (IDA) and the National Ornamental & Miscellaneous Metals Association (NOMMA). IDEA is now a member of the coalition as well. NOMMA’s longtime representative on the coalition is Brent Nichols of Picasso Gate Inc., Cheyenne, WY. What is the first step?

The test is administered by IDEA, which is a respected authority that provides accreditation services for the door industry. The first step is to visit the IDEA website ( and either download an application form or apply online. The Fabricator  May/June 2008

cost is $250 per person, and at least $50 must be included with the application (the rest can be paid prior to testing). Once the application and fee is received you will receive a self-study guide on CD-ROM. According to coalition member Buck Buchanan of B&B Controls, Shrewsbury, PA, â&#x20AC;&#x153;Once [your employees] receive the 10-chapter manual on CD, they should be reading and studying it as soon as they can. They are welcome to take the test at any time they feel ready.â&#x20AC;? Once your employees are registered for the test they will be automatically notified if any exams are scheduled for their area, Buchanan said.

congratulates NOMMA on 50 years of service to the industry.

What are the qualifications?

Of course, your employee must pass the test. According to Todd Thomas, IDEAâ&#x20AC;&#x2122;s managing director, a score of 80 percent or higher is required to pass. The second requirement is that you must provide documentation to show that the applicant has at least two years of field experience in installing and servicing gate operators. If your employee gained some experience at a prior job, you can provide this information in a notarized written statement. If you have a new employee, Buchanan recommends that you go ahead and get them through the testing phase, even if they donâ&#x20AC;&#x2122;t have the two years of experience. â&#x20AC;&#x153;You donâ&#x20AC;&#x2122;t want them doing it wrong,â&#x20AC;? Buchanan says. â&#x20AC;&#x153;Get the manual and let them study. A brand new employee can do that and gain at least 10 years of practical experience by having gone through the manual. We want a brand new guy to get that manual and learn the correct way from the very beginning.â&#x20AC;? Buchanan adds that if a student fails the exam, he or she can retake it as many times as needed at no Dates announced for the Gate Operator Installer School Ready to attend gate operator school? The American Fence Association (AFA) is holding its second school at the Tulsa Technology Center in Tulsa, OK, October 5â&#x20AC;&#x201C;11. The week-long class covers gate operator installation, wiring, electrical components, and troubleshooting. At the end of the course students may take the IDEA certification exam. For details and a downloadable registration form, visit: gateopschool or call Sara Wilson at (800) 822-4342.

May/June 2008  Fabricator

Courtesy of AFA

Students learn about gate operator electronics at the AFA gate operator installer school. The instructor shown at center is Buck Buchanan of B&B Controls.

Happy Anniversary NOMMA!



The IDEA website provides an extensive support area for the Gate Operator Installer Certification program. Visit the site at: www.

additional cost. A certification is good for three years. After that time, the employee must submit a renewal application and fee. In addition, certified installers must either earn continuing education units (CEU) or submit descriptions of 18 jobs completed during the three-year period. The time and location for CEU courses will come later. What does the study guide and test cover?

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Where do I take the test?

The first test already took place during the AFA FenceTech show in Las Vegas, earlier this year. According to Hinds, “Thirty-eight people passed the test at FenceTech 08.” Hinds, who chairs the coalition and serves as a representative for AFA, said the test will be given again in October at the AFA Operator Installer School in Tulsa, OK. He said there’s also a chance that some AFA chapters may give the test prior to October. In addition to all of the above options, the test can be taken during IDEA testing events, which are held at various locations throughout the year. Testing schedules will regularly appear in Fabricator and in TechNotes, NOMMA’s bimonthly technical bulletin. An important clarification is that the IDEA test and the

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The study guide and test cover virtually everything related to automated gate systems, including UL 325, ASTM F2200, safety practices, types of gates and operators, accessories, installation, electronics, troubleshooting, timers, and vehicle detectors. According to coalition chair Frank Hinds of Palmetto Southern Inc., Lexington, SC, “There is a wealth of knowledge in the study guide that will help anyone, even if you are already a professional in this industry. All the material is compiled by many people who had many years of experience in various fields.” Hinds added that the coalition spent about two years designing the program and compiling the data.

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“If the states start certifying, we’ve got everything in place to adopt our program.” — Brent Nichols, NOMMA’s longtime representative to the Vehicular Gate Ad Hoc Coalition

Fabricator  May/June 2008

AFA gate operator field school are completely separate, although the test is being given at the AFA school. In other words, the test is not a required part of the field school, and the field school is not required for certification. “It’s totally optional,” Hinds said. My employees passed!

What prompted this program?

In 2004 the gate operator industry was thrown into a difficult situation when the Texas legislature passed a law requiring the licensing of alarm installers. The law was worded in such a way that it also included gate operator installers. Fortunately, members of the industry worked hard to have the legislation corrected the following year, and the licensing requirement was removed. As a result of the Texas experience, the Vehicular Gate Ad Hoc Coalition began exploring the need for self-regulation and certification. “We felt it was far better to have the training program and test be done by those in the industry that know our technical requirements rather than some outside entity that has no knowledge of our business,” Buchanan said. According to NOMMA’s Brent Nichols, “If the states start certifying, we’ve got everything in place to adopt our program. Everyone can have the same criteria for certification.” Questions?

For more information, visit the IDEA website at: and click on “Certification and Accreditation.” Or, call the IDEA at (937) 698-1027. Buchanan said the gate operator training manual is intended to be a “living document” and ideas and input are always welcome. If you are an ornamental gate installer, feel free to contact NOMMA’s representative to the coalition: Brent Nichols of Picasso Gate Inc. Ph: (307) 632-1710. May/June 2008  Fabricator

Top Job file photos

Once your employees meet the twoyear experience criterion and pass the test, they receive a certificate, shirt patch, and ID card. They’ll also have their names published on the IDEA website.

The 10-chapter study course also covers slide gate systems, such as this one. FABRICATOR: Custom Lights & Iron, National City, CA


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Stair theory

Tips & Tactics

Working on the curve? It isn’t so difficult when you follow the steps of this simple theory. Build a railing that actually fits a curved stair — rather than one that was “tweaked” to work.

By Dick Sargent Peters Valley Craft Center There is much skill and experience lav-

ished on many objects built by ironworkers and blacksmiths. These may include estate gates, balconies, door hardware, etc., but none reaches the pinnacle of the ironworker’s art as closely as the curved stair rail. Often the focal point of the home, the curved stair demands adornment with railings made to the highest standards May/June 2008 


we can muster. It’s perhaps these high standards and the uncertainty of working with a curve that give us a feeling of trepidation when working on these stairs. These concerns can be reduced by having a full understanding of stair theory and good information about the stair our railing needs to fit. Figuring it out Stair theory is not rocket science. All stairs are based on a right triangle.

For your information Those of you who participate in NOMMA’s ListServ know its value in providing answers to your questions about procedures, equipment, personnel, and more. But did you know you can search the ListServ archives by subject, author, and date? There are several discussions in the archives about curved and spiral stairs and railings. You can access the ListServ archives by logging into the Members Only area of NOMMA’s website, 17

The curved stair demands adornment with railings made to the highest standards — the pinnacle of the ironworker’s art.

 The vertical distance from floor to floor = the total rise  The horizontal distance along the floor = the total run  The hypotenuse (diagonal) of these two = the stringer What has to be remembered here is that a curved stair — no matter if it’s a simple arc or an “S” turn — is still a right triangle. It simply has been bent into a curved form. This immediately puts us in a different place when it comes to doing our layout for our curved rail. Most of us are accustomed to drawing the stair profile on our bench or using an adjustable jig when building straight rails. This gives us the ability to check the run, rise, and stringer length with ease at any point along our railing simply by referring to such things as tread length, riser height, or nose-to-nose measurements. On a curved railing, at first glance, all of these measurements seem to be of little use in layout except for the total rise. The curve of the stair and the developed arc that is formed as the stair rises confound our effort to make a flat plan or elevation drawing of our staircase to build the rail upon. Good information Obtaining the measurements we need and how to use them is not difficult and will ensure that we can be certain our railing will fit accurately.

of light material is bent accurately to follow curve and helix of the stair. All nosing locations 1shouldtheA template be marked on this template.


A curved stair — no matter whether it’s a simple arc or an “S” turn — is still a right triangle. Fabricator 

May/June 2008

or rosin paper is placed on the floor at the of the stair and cut to fit the curve accurately. 2baseBuilding plumb, bob and line points are dropped from 3pointeachUsing nosing down to the rosin paper on the floor. Each is recorded along with the distance from nosing to floor. On open stringers, a square may be necessary to transpose the nosing locations. With this information, back at the shop, we first bend the actual railing members, i.e. top and/or bottom rails, to match our template. Next, either on the bench or the floor we lay out the curve of the stair from our paper pattern and align our railing above it using plumb bob, level, and tape measure. Now, we have an accurate means of measuring any point on our railing as it ascends the stair. All nosing heights can be checked simply by matching their reference points against the paper template. This is a very simple and short explanation of how to get an accurate start on building a curved stair — without being overcome by the nervous jitters. With this method, we can eliminate the use of all but simple shop math, the building of bucks, or even the replication of a stair in the shop to work from. In addition, problems such as “crowns” or “swales” in stringers are lessened or eliminated because we have measurements that represent the actual stair from which to build. Using this information, it is hoped that you will, with a little thought and patience, be able to build a railing that you feel actually fits the stair rather than one that was “tweaked” to work. Dick Sargent is head of the Blacksmithing department at Peters Valley Craft Center, Layton, NJ. Peters Valley, located in the picturesque Delaware Water Gap National Recreation Area, was established as a craft education center in 1970, providing education in blacksmithing, weaving, surface design, woodworking, photography, and fine metals. The goal of its founders was to provide a center of education, promoting contemporary crafts. Now in its 38th year, Peters Valley has been welcoming students of all ages and walks of life to its facility and has provided a place for the beginner to learn a craft, as well as providing craft artists with a place to learn new techniques and enhance their skills. The Center utilizes many of the historic buildings, which are part of the “valley.” From mid-fall to early spring, Peters Valley is home to a artists-in-residence, furthering their own craft, and working in their assigned studios away from the hustle and bustle of everyday life, while enjoying the camaraderie, knowledge, and skills of those who head the studios there. Contact: Peters Vally Craft Center, Ph: 973-9485200; Web: May/June 2008 



Shop Talk

Getting it down to a system  Maximized

output and lowered costs, plus quality products, are the results of this NOMMA member’s attention to technologies, organization, and efficiency. Iron stock posts stand ready for use in production railings.

By Peter Hildebrandt For Roger Flynn, founder and owner

of R & F Metals Inc., Clinton, MD, metalworking has always been a part of his life. Roger was born and raised in Maryland. While in school, Roger would work in his brother-in-law’s iron shop; he learned how to weld at age 14. Flynn started his own business in 1976, with one other employee. Over the years, that number would grow to as many as 95 employees at his shop. The time and dedication of both Roger and his son, Lee, is evident in every aspect of their business. Diversity in production mode R & F has always catered to the 20

new residential construction market, preferring to work directly for the builder or contractor rather than for the homeowners themselves. About half of their business is comprised of fabricating and installing ornamental railing; the other half is supplying structural steel. Most of the ornamental railings that R & F fabricates and installs are required by the builders or contractors so that their homes meet local building codes. These rails are normally exterior rails that often include front porch rails, welled exit rails at basement egresses, and hand rails going down stairwells. They are typically builder-grade, and although they are custom fabricated, they utilize stock components. The company

For your information The NAHB Research Center’s National Housing Quality (NHQ) Trade Contractor Certification program (mentioned in this article) emphasizes “building it right the first time, every time,” rather than wasting time and money having problems inspected out of jobs. The certification process can take as little as 90 days. Benefits of achieving this certification include:  Reduced defects

 Reduced callbacks

 Increased customer satisfaction  Improved profitability

Find out more about how consistent quality can equal increased profitability for your company. For details, log on to: contractor.aspx. Fabricator 

May/June 2008

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Roger L. Flynn, Sr., owner (left), and his son, Roger L. “Lee” Flynn, Jr. are dedicated to making sure every aspect of their business operates efficiently.

occasionally does interior rails, as well, which are installed in custom homes. These rails require custom fabrication and are sold at a much higher price point. Roger notes the importance of flexibility and market changes in his business. “Since the housing downturn, we’re taking more calls for homeowner work than we have in the past,” he explains, “whereas, we used to refer these customers to other fabricators because we were so busy with the contractors.”

at the beginning of construction, while the railing fabrication and installation comes during the last third of the construction process. In between delivering the steel and installing the railings, the company also welds and bolts the column and steel connections. Steel delivery occurs once the foundation is poured. When the framers deliver the lumber package, framing of the home takes place. R & F returns to weld the connections after all the steel is set, the framing is done, and

Successful synergy The structural steel side of the business consists of fabricating, painting, and delivering steel beams and columns. Because most of the houses in R & F’s area are built with basements, rather than on slabs or crawl spaces, almost all of them require some type of structural steel. There is synergy between the two halves of the business, which keeps R & F involved throughout a home’s construction. The structural steel fabrication and delivery typically comes

Motivational signs hang in several production areas at R & F. This message is the result of an employee’s suggestion in the late 1990s.


everything’s tied together. Later, they’ll return to do the railing work. R & F Metals is less of an ironwork craft business than a metalwork manufacturing operation. The employees work out of two buildings, each 5,000 square feet. One building is dedicated to iron railing; the other houses fabrication of miscellaneous items, including stairs, balconies, and aluminum railings, which have become increasingly popular because they require less maintenance than iron rails. “We’ve struggled over the years with our limited size,” says Roger. “But by adding the miscellaneous shop, we feel we’re doing a much better job of utilizing our spaces.” Clearly, what R & F does best is quality production. Over the years, they have worked hard to leverage technologies and increase efficiency. This has allowed them to maximize their output and keep costs low. They are in a very competitive market and margins are small. Their business has always been predicated on volume. “At our peak in 2005, we did almost 15,000 houses,” says Lee Flynn, who serves as R & F’s sales and marketing manager. “But in this year’s depressed market, we’re forecasting that our volume will only be about half that.” Certification is a valuable tool The company has lots of opportunities to interact with other subcontractors, mostly steel companies willing to share with them. Roger sits on the quality council of one particular builder, enabling him to have relationships with other subcontractors. The


May/June 2008

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company has recently completed the National Housing Quality (NHQ) Trade Contractor Certification program administered by the NAHB Research Center. The program emphasizes the philosophy: “building it right the first time, every time.” R & F is the first ornamental fabricator to receive certification through the NHQ program. This process took about a year, and going through it enabled R & F to bring outsiders into their organization, allowing them to comment on different aspects of the operation. “I think they were quite surprised about the level of sophistication we have from a technology standpoint,” says Lee. “We brought in a consultant, who reviewed our operation from top to bottom, and then we wrote a quality manual, which was a fairly significant document. Because we were the first company like ours to do this, we R & F’s Miscellaneous & Specialty Production Shop opened in March, 2006. didn’t really have a template or blueprint to follow from another comthe fact that this certification process want it to go — it gave us good insight pany going before us.” forced us to stop and take the time to of our corporate structure and why we As part of the process, auditors evaluate our entire operation,” says were in business, and it also involved evaluate different aspects of the busiLee. “From that you cannot help but all the employees on an in-depth basis. ness to ensure that the company’s improve as an organization. Lengthy This was a very positive experience for doing what they say they are, and, interviews were done with all of our us all. Even simple things, such as most importantly, following the qualiemployees as well as many of our cuswho should be accountable to whom, ty manual processes that were develtomers. Normally, during the course revealed some interesting takes on oped during the initial certification of a business day, it’s simply impossithings.” process. The certification means that ble to take the time to get that type of An important facet of the business it can be used in marketing. When R insight.” discovered during the process was that & F approaches contractors and As part of the certification process, workers tend to grow into a position builders, they are sure to mention that R & F undergoes an annual audit in based more upon their skills rather they have received the quality certifiorder to renew their certification. than what the skill set of that position cation. Builders, many of whom are This will keep them in constant touch should actually be. This allowed R & also in the process of getting certified, with how their operation is run and F Metals to redefine just what a understand the value of the certificahow processes are maintained when it billing, sales, or production person tion and are seeking vendors that have comes to quality. The process also should do and what their responsibiliachieved it. requires the business involved to have ties should be. When global marketing informaa mission statement, a vision stateTechnology developed in-house tion firm J.D. Powers and Associates ment, and an organizational chart. boosts production came into the housing market and “When you have a business, these started ranking homebuilders, the things grow organically,” says Lee. R & F has patented its own rail fabhomebuilders had to start taking “When Roger started the business, it rication software, RailWizard, which notice of the quality of the product was just himself and one other they developed beginning in the they were putting out, according to employee. You grow by necessity and 1990s. The purpose of the software is, Lee. That’s when the emphasis on don’t often take a 30,000-foot view.” basically, to draw a picture of the railquality and the importance of the cer“This certification program ing. Then it gives details of the railing tification program became apparent. requires you to have a more strategic as well as fabrication instructions for “Another added benefit for us was view of your company and where you it, including all the lengths and sizes of 24


May/June 2008

the materials that will go into the construction of the railing and a cutting list of that material, such as where to place all of the holes so the railing can be assembled. The company has gone from the point of doing an actual chalk drawing of a project on a table to one where a couple of field measurements can be entered into the computer, a picture of the rail drawn, and the cutting list printed out that yields the dimensions needed to set up the square for the rail. Once those dimensions are set, the components of the unit are welded together. They’ve also embarked on another software program called TakeOff, which handles their ordering and scheduling needs. This software allows them to enter job information into the computer just once, replacing the separate estimating, scheduling, and accounting programs previously used. It’s a “one-write” system that rolls all the various processes of a particular job or project together. R & F’s bidding process on a job allows for four or five different house types, including four or five different elevations for each type. The houses will then be optioned in perhaps 10 different ways, each of which affects the type of steel or railings the house will receive, such as an optional morning room, or side garage or bonus room above the garage. For each house type that they are contracted to do, R & F prepares a material requirements takeoff and enters it into the computer using their software. This allows them to check the options that each customer

Stock aluminum railing components are ready for use in the Miscellaneous & Specialty Shop. May/June 2008 



has selected on each house and then processes a list of the materials needed. The job is then sent to their yard or to the fabrication shop, and from there, it gets scheduled. “Builders have consolidated the number of houses they build in recent years,” notes Lee. “So, once we have all of their house types entered into the computer, it is a lot less time consuming to send bids for new projects.” Roger agrees that computerization

of details has simplified the process. “Some builders will build the same product in many different areas and some of the more popular houses can be built hundreds of times in one year,” he adds. “Having to only enter the material and fabrication details once into the computer has been a tremendous time saver. But not only does it save time, it also helps us ensure that orders are consistent and accurate. Basically the only thing we

have to add repeatedly is the actual addresses of the lots of the homes.” Implementation of remote application access is another thing that has proved very helpful to R & F. All employees have access to the network including a virtualization technology application and data via a Citrix Presentation server. Jose Frontanes, R & F’s human resources manager, works part of his time in Winchester, VA. When he leaves the shop, he can sign off of his applications on his work computer, then log onto his home computer later and pull up the same applications. The shop now has a number of employees who work in West Virginia, North Carolina and southern Maryland.

“This is all about exceeding

our customer’s expectations.”

“This has been a huge help, as the D.C. area is fairly transient — having to replace good employees is not easy and involves considerable expense,” says Lee. “Even when I’m at various companies in the middle of negotiations, I can simply use the customer’s computer and Internet browser to access anything I need from our network.” The company also has a document management system, which includes all of their contractual documents and all of the documents related to particular homes, whether they come in by e-mail or regular mail. The documents are searchable in the network by characters. Documents go through an optical character recognition engine, enabling searches to be done on any document on the server. All of R & F’s employees have access to every document. Documents can also be tagged with any particular metadata someone might want to use to make them even more searchable. This system has made the company virtually paperless. And should the server go down, the network has a number of backup systems. 26


May/June 2008


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LEFT: railing is staged for loading on trucks for installation. BELOW: Stock columns for steel deliveries.

Additionally, R & F has recently upgraded their phone system to an IP-based system. Remote employees now have Internet-connected phones that allow them to work just as if they are in the office. The phone system includes features such as auto attendant and voice mail, unified messaging, and automatic call distribution (ACD). The ACD feature has proved particularly valuable as increasing numbers of employees work remotely. Call distribution allows R & F to assign call groups to different types of phone queries so that calls about sales are sent to the sales group and calls about scheduling are sent to the scheduling group. Employees are assigned a code, and once they are signed into a particular group, calls are routed to them automatically by the system. “The ACD has allowed us to make sure that our customers get the answers they need and that the phones are being answered by a live person regardless of where that person may be,” says Lee. “This is all about exceeding our customer’s expectations,” he adds. “The business we’re in is very competitive and the easier that we can make the project manager’s job the better off we are. It’s this added value that can be the difference between getting the contract or not.” However, one trend that R & F has witnessed recently is that the decision-maker for a particular project may not have had any prior field experience or may have not worked with them before. This person often does not understand the value that R & F’s processes may add or the cost of missed deliveries or backorders, and is only awarding the contract based on price. But R & F remains committed to service and quality, and 28

according to Lee, “Indications are that builders are seeing more and more the value of hiring quality subcontractors.” For fabricating the rails and cutting the materials, the company is still using Scotchman saws, which are automatic and powered pneumatically. Due to the fact that this is a production shop, R & F works hard to minimize the number of different materials they use, as well as the different rail styles they offer. They also try to use the same components. So, what they can do — because of their proprietary software — is to actually build the rail to fit a stock component by changing dimensions in the railing. For example, the bottom channel on the bottom of the rail provides fabrication flexibility. The software allows them to build the rail, but then “float” the distance under the channel. This allows them to cut most of their pickets or balusters, as well as their posts, to the same lengths and then build the rail around them. “We’re not custom-cutting all the material going into the rail, such as the pickets and posts; instead when we cut them, we do hundreds or thousands at a time. So, what’s really custom are the horizontal members of the rail,” explains Lee. “Being able to build the rail with stock components is a tremendous time saver.” Hoping for the best Like many other companies, R & F is hoping for an economic turnaround in 2009. They’ve been hit on both ends, according to Lee, who says that the builders’ volumes are down while R & F’s costs are up, thereby making a difficult situation. “Right now, the builders don’t want to hear about price increases; they only want to hear about decreases because they’re under a lot of pressure to sell homes,” says Lee. “Most of the builders we work for are national or regional builders. Many of those that are being reported about in the news as having issues are in this area of the country.” R & F has recently been forced to reduce the number of its employees due to the decreased volume of work, and they have worked hard to reduce costs so that they can be as lean as possible during the current downturn. The huge number of unsold homes on the market at the moment is not going to improve until the backlog finally diminishes. R & F has found that builders are no longer going to build “speculative” homes or homes without a buyer when construction begins. “We’ve always tried to find the opportunity in every situation,” says Lee. “Even though times are pretty tough right now, we still feel there’s an opportunity to do something; we’ve just got to find it and do it. Currently, one of these opportunities is for us to, once again, take a look at how we do business and refine our processes so that when things do break loose we’re ready to go. That’s the most important thing for us right now. We have some downtime now to catch up a bit. “One thing Roger’s always taught me is that you have to find the opportunity in everything that comes your way — as well as be careful what you wish for.” Fabricator 

May/June 2008

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Member Talk

Beyond boundaries  Western

Canadian NOMMA member provides architectural metal products, engineering, and drafting services. This project involved erecting beams and columns to support the curved wood roof beams at Hooded Merganser Restaurant in Penticton, British Columbia.

By Sheila Phinazee Web Metal Fabricators Ltd., founded

in 1991 by NOMMA Member Rob Webster, specializes in structural and architectural metal products for the construction industry. Services offered include fabricating, welding, machining, and erecting — primarily in carbon steel but also aluminum, stainless steel, and bronze. Just one-half mile north of the Canada/USA boundary, Web Metal Fabricators is located in the resort community of Osoyoos in the Okanagan valley of south central British Columbia, three and one-half hours northwest of Spokane, WA. “Our expertise is in solving construction problems,” says Webster. “Quite often, architects, designers, engineers, and contractors will consult with us on how to build their concepts. We work with them on a continuous basis.” Webster and his team suggest mate30

rials and their sizes, fabrication methods, and techniques to attach components. One reason for Web Metal’s success is the varied years of experience each employee brings to the business. As a team, they have the ability to fabricate and weld, but also know how to put the entire building together. “We know the metal work, but we also know how it relates to the rest of the building and the other parts that attach to it,” says Webster. A “metal carpenter” Growing up, Webster had dreams of becoming an architect or carpenter — “I was definitely oriented toward working in the construction of buildings,” he says. He got his start at age 15 when he took a summer job at a local machine shop by chance. There, Webster did general fabrication and welding, repaired farm equipment, and built wrought iron railings for homes.

For your information Rob Webster of Web Metal Fabricators Ltd. is adamant about the importance of welding skills and certification to our industry. The American Welding Society (AWS) provides a welding certification program for companies that use welding as a joining process. The requirements for The Certified Welding Fabricator program are set forth in an American National Standard, AWS B5.17, Specification for the Qualification of Welding Fabricators. This specification defines the requirement for a company's compliance with welding-related functions and assures, through third party assessment, that the Welding Fabricator has the personnel, organization, experience, procedures, knowledge, equipment, capability, and commitment to conduct proper weldments. To learn more about this and other certification programs offered by AWS, visit the Society’s website:


May/June 2008

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After high school, he started an apprenticeship (which he completed in 1987) that gave him the opportunity to work for various companies in heavy industry and construction. “I traveled and did work for the saw milling and natural gas processing industries in northern British Columbia. I fabricated structural steel for the buildings, also fabricated and welded on the machinery and equipment,” recalls Webster. He also worked in the installation and maintenance of those same types of plants in the millwrighting trade. Then, in 1991, Webster started his own business. Webster has designed and constructed several of his own buildings including their new 6000 square-foot shop. Since he is working with designing and providing metal products for the construction industry he believes that, in an unexpected way, he has still managed to follow his dream. Although Webster thought he would be doing more wood construction

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Solid Edge 3D CAD modeling software and have a full-time detailer/CAD technician. “We’re finding that it is a difficult program to learn but has a number of features that make changes very simple,” says Webster.

related work, he’s not far from his initial goals. “I became more of a steel carpenter instead,” he says. “That’s basically what a metal fabricator is—you’re a carpenter that works with metal.” Webster’s background in heavy industry and construction makes it a natural transition for him to also offer engineering and drafting services in his business. “We have structural engineers that review our designs and stamp our drawings on a continuous basis,” says Webster. Web also has a welding and metallurgical engineer on retainer. They have used AutoCAD for a number of years, but have recently switched to

Business matters Like fellow fabricators in the U.S., Web Metal has to deal with codes and standards requirements. “Most building codes in the U.S. and Canada are very similar in a lot of respects,” says Webster. “But we don’t have the same design freedom as you do in the States particularly on nonclimbability of artistic railings. There are other areas, however, where we can be more creative like the architectural stuff.” According to Webster, the Canadian Standards Association (CSA) standard for welding is the equivalent to the American Welding Society (AWS) standard. Web Metal is certified to CSA Standard 47.1 for welding.





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people will keep coming back because they can trust you, and you treat them well,” says Webster. “Why would they go with an unknown when they know you will deliver? The architects we work with know our work and at the end of the day, we all look good.”

A Web Metal crew works on erecting a commercial building.

“It is a requirement of building codes here,” says Webster. “The fact that we’re certified allows us to weld, fabricate, and erect structural steel. It puts us on a different playing field than other potential competitors.” Web basically has two sides to its business, the structural side and the architectural side. The structural side includes beams, columns, joists, stairs, miscellaneous metals, and the fabrication and site erection of those items. The architectural side includes decorative guardrails, stairs, decorative features, lamps, and other things. “Last year we got a forge and power hammer. We’re trying to incorporate more forged work into the railing work, which is something new to this area,” says Webster. “We’re learning and trying unique ideas and other materials that we’ve seen through NOMMA.” About 80 percent of Web Metal’s business is commercial, industrial, and institutional, and 20 percent is residential. Some of the company’s projects include work for gas compressor stations, industrial plants, lots of commercial buildings, and recently, a 14story high rise. “With the establishment of several new subdivisions, we are now entering the higher end residential market,” 34

says Webster. “Sixty to seventy percent of our business includes repeat customers. We’ve never found advertising to be an effective use of our money; we do some to maintain our profile in the community, but we rely very little on advertising. We don’t even have a sign on our building.” Web has found completing quality jobs in high profile areas and establishing good relationships with general contractors to be important for good business. “Treat people fairly. Don’t nickel and dime your customers. Don’t let them take advantage of you, but give them a little something extra once in a while and they will remember that. Even if your services are not cheap,

Welding skills are crucial to success According to Webster, Canada is facing a shortage of labor in general. Workers are being recruited by the Alberta oil industry to work in the trades with large salaries; many are offered large incentives. Because of this, Western Canadian businesses like Web Metal have had a hard time attracting the right people. Webster has found that providing in-shop welding training in the evenings to be successful. Several times a year they provide mini crash courses, usually six coaching sessions lasting two-to-three hours, plus a session on practical experience put on by their welding engineer. Webster has found this to make a big difference in the quality of welding. “I would highly recommend this because workers pick up skills and apply it in their day to day work; they’re learning as they’re working and don’t lose time,” says Webster. “We’ve found that kids coming from welding school can’t weld. We have to take them from scratch and teach them how to do it.” The Canadian Welding Bureau provides the in-house welder testing. When Web Metal requests one, the

This shaft vent cover was erected at a mine reclamation site located above Osoyoos, British Coloumbia.


May/June 2008

Bureau sends a representative to witness the welder filling the test coupons and the preparation and bending of the same. The test coupons are bent under the representative’s supervision and Webster knows if the welder passes on the spot. The representative then issues the welding ticket for each process and position performed. “The Canadian Welding Bureau has become an invaluable partner to our operation,” says Webster. “I would highly recommend our American friends to look into certification with the AWS if your business warrants it.” In 2002, one Web Metal apprentice, David Heyduck, won first place in a steel fabrication competition against other young tradesmen across Canada. He finished first in the regional competitions and then first in the provincial. Heyduck continued on to become the Canadian Champion. He started working for Web at the age of 14 and continued until he was 21. “David was one of the youngest apprentices accepted at our local technical institute and also ended up having some of the highest marks,” says Webster. “It was a team effort to help get him there. He learned something from every person in our organization and put it all together. He is a very intelligent and hard working young man; we are very proud of him. He is going to go a long way in this trade.” Community connections Like many fellow NOMMA members, Webster is active not only in his business, but also in his community. He has served as a director for the economic development organization of the Town of Osoyoos for four years. He has also served on an advisory board for the Regional district of Okanagan-Similkameen, a level of rural government, for more than two years, and has been involved with the Boy Scouts as well. NOMMA membership has many benefits Webster first found out about NOMMA through one of his employees. “My apprentice at the time handed me a copy of Fabricator magaMay/June 2008 


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zine—I looked through it and thought, ‘Wow, this is about us,’” he says. “We had no idea that there was an organization out there that catered to and represented our interests.” He attended his first METALfab in

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Metal Museum. “Joining NOMMA was probably one of the best decisions we’ve made regarding the advancement of our business,” Webster acknowledges. In addition to building relationships with NOMMA members and suppliers, Webster is also an active participant on NOMMA’s ListServ, which is an email discussion list for members.. “The ListServ is a great resource for getting quick answers when problems arise,” says Webster. “When I first attended a NOMMA conference, I was amazed — almost shocked — at how open people were in sharing their techniques and ideas. It’s like having an extended metalwork family who want to help you out. That’s a rare commodity in any trade industry.” Webster was impressed by the level of quality and the variety of skills NOMMA members demonstrated. The annual Top Job Contest at METALfab also made a strong first impression. “The Top Job contest blew me away when I attended the first conference,” notes Webster. “To actually see the quality of workmanship of other firms and metalworkers is humbling, considering the level of design and the number of hours it takes to create these items.” Webster is interested in getting a NOMMA chapter going that would include both the Pacific Northwest and Western Canada, since members are widely spread out. “I’d love to hear from other NOMMA members in the area, even including Idaho and Montana,” he says. “Perhaps we can get together and maybe meet in Spokane.” Interested members can contact him by email at “At the end of the day it doesn’t matter what country you’re in — the basic principles around metalwork are all the same. We’re all trying to put out the best product we can, be proud of it, and make a living,” says Webster. “This trade has no boundaries. Regardless of where you are located we all face the same issues.” Fabricator 

May/June 2008

Member Talk

From oil to metal  A NOMMA

supplier member racks up 132 years of service to the industry. Hendrick Mfg. Co. is a perforated metal manufacturer founded in 1876 and located in Carbondale, PA. Over the years, additional manufacturing locations were established in Kentucky and Illinois. Today, Hendrick produces perforated metal sheets and coils for use by fabricators all across North America, including many fellow NOMMA members. Pursuing the American Dream Eli Hendrick started out with a dream to produce a particular product — and ended up in an entirely different business altogether. Born in 1832, Hendrick apprenticed as a wood turner in his native Michigan. He later served a tour of duty as a U.S. Pony Express mail carrier in Iowa. He also practiced his craft as a turner of ornamental wooden porch pillars during the early years of the 19th century before moving east to Franklin, PA in the 1850s. A confidence man from Toronto, Canada sold Hendrick a formula for the manufacture of oil for the thenMay/June 2008 


considerable sum of $10. The formula turned out to be worthless, but it sparked Hendrick’s interest in the refining of oil. He quickly developed a worthwhile formula and process of his own, producing quality lubricating products mainly for the railroads. And thus, the Hendrick Company was born. Sensing that a refinery would be most profitable if it were located near its customers, Hendrick relocated his company to Carbondale, PA in 1860. Carbondale was an ideal location due to its proximity to several large railroads. For the next dozen years, the company flourished, developing new products such as “Galena Signal Oil,” an extra-fine kerosene, for railway lighting. The company also developed “Plumboleum”, a gear box lubricant that remained a basic ingredient of automotive lubricants for 75 years. The filter presses used in the refining process consisted of mats of woven wire and canvas. In constant use, the wire eventually was abraded to the

point where it pierced the canvas, thereby reducing the efficiency of the filter. Hendrick reasoned that a metal sheet, properly perforated, could replace the canvas-and-wire filter, giv-

For your information Perforated metal — sheet metal usually having a regular pattern of perforations — is a very diverse product, available in many designs. Perforated metal is produced by punching holes in flat-rolled steel, aluminum, copper and other substrates — the shape of the hole is determined by the shape of the die. (Expanded metal differs from perforated in that it is made by slitting and stretching the metal sheets, rather than punching holes in them.) Some applications for perforated metal include:  Screening

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ing it a longer life. Several attempts at drilling holes, first individually, then in a multiple drill-press, proved Hendrick’s idea to be sound, but the production process was too costly. He then came up with the idea of punching holes simultaneously in the sheet metal. The metalpunching machine Hendrick’s developed was a pilot for the modern perforating press and the foundation upon which Hendrick Manufacturing Co. was built in 1876. Over the next 100 years, the company steadily expanded its technology and its product lines, branching out from the original oil and coal industries into aggregate, iron, steel, paper, material handling, construction, and other industries where perforated or slotted sheets of material are required. Hendrick Manufacturing today Today, Hendrick Manufacturing is an industry leader in ornamental uses of perforated metal. The company works with fabricators to achieve the

neat, clean look architects hope for when creating their original designs. Hendrick still manufactures punch plate for the mining industry in the same shop that turns out material to be used in architectural projects. As in most shops, it is a balancing act to produce products that require no special handling or care, yet are aesthetically attractive at the same time. Over the years, Hendrick has developed inhouse systems for assigning the appropriate amount of care to a product without increasing its costs unnecessarily. Hendrick processes tens of millions of pounds of metal per year. If the project requires stainless, carbon, galvanized, aluminum, copper, titanium, plastics, or other materials, Hendrick has probably punched it. If it is a unique product, the company is willing to try and determine its perforatability. Today, Hendrick’s all-across perforating machines can take a 20,000 lb. coil of metal and punch several rows

Hendrick Manufacturing provided the perforated metal for this stairway on the U.S.S. Intrepid.


of holes across the width of that coil (up to 60”) at speeds of hundreds of strokes per minute. This far exceeds what is possible with a CNC Turret press, and creates an efficiency that inhouse punching cannot match. Additional services While Hendrick also fabricates complete parts for its customers, it only involves itself in a project as far as the customer allows. In addition to perforation and fabrication, the company’s services include degreasing sheets to remove process oils and deburring sheets that may be used as tactile surfaces. In fact, Hendrick worked with 3M Corp. to develop one of the most sophisticated deburring/polishing machines in the metal industry. Additionally, Hendrick is involved in the renovations to the U.S.S. Intrepid. The company also has assisted in the design of signage unlike typical perforated metal uses. Hendrick Manufacturing is just like any other NOMMA member — perhaps a little older, but still handling every customer job as a unique project.

Hendrick Manufacturing provides full service material perforating solutions for a variety of markets including mining, automotive, aggregate, architectural, industrial, and more. The company manufactures perforated metal screens, sheets, coil, diffusers, guards, shields, strainers, and metal filters, and perforates all types of materials including stainless steel, aluminum, carbon steel, galvanized, brass, copper, plastic, and foil. In addition, Hendrick can provide cleaning/degreasing and deburring/polishing services. The company also has the capability to fabricate its perforated metal to the customer’s design using various other techniques including welding, bending, shearing, and rolling. Contact: Hendrick Manufacturing: Ph: 800-225-7373; Web: Fabricator 

May/June 2008

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Job Profiles

NOMMA Service Project NOMMA members join together to create a “collage” of fence sections for the National Ornamental Metal Museum

Volunteers put one of the many fence sections in place.

On an overcast Monday before METALfab 2008, a

group of NOMMA members spent the day installing fencing and gates at the National Ornamental Metal Museum in Memphis, TN. The ornamental sections were produced by 12 NOMMA members from around the country. The goal for the day was to replace an old, wooden picket fence that separated a private residential building from the main museum grounds. In creating the fence and gate sections, NOMMA shops were given basic specs but had complete design freedom. Once completed, members then shipped their work to Memphis prior to installation. Rob Keeler of Keeler Iron Works served as project manager, and he and his shop did the initial sitework and handled logistics. In the days prior to the installation, the various sections began arriving at the Keeler shop. Designs range from traditional pickets to highly ornate and modernistic designs. According to Rob, “I’m happy with the flow of the fence.” A thanks goes to the approximately 12 volunteers who came on Monday to assist with installation. Thanks to this NOMMA service project, thousands of museum visitors will now see a showcase of our industry’s products and the various design options available. “On our 50th anniversary, the project allowed NOMMA to restablish its roots with the Metal Museum,” Rob said. “It has dressed up the museum quite a bit.” 40

Bob Mueller double checks a piece during assembly.

Gene and JR lift a fence section in place. Fabricator  May/June 2008


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 Anderson Ironworks  Big D Metalworks  Boyler's Ornamental Iron Inc.  Christopher Metal Fabricating Inc.  Finelli Architectural Ironwork  Grizzly Iron Inc.  L & L Ornamental Iron  Master Metal Services Inc.  Northshore Steel Fab LLC  West Tennessee Orn. Door  Wiemann Ironworks  Wilson Railing & Metal Fab. Inc.

& RIGHT: Volunteers unpack the fence sections and prepare them for installation.


Photos courtesy of Curt Witter, Big D Metalworks

0HPEHU May/June 2008  Fabricator


Job Profile

Looking back at Top Job ‘07  Every year, NOMMA

members submit their best works for judging in the annual Top Job competition. Here are just a few highlights from last year’s contest. Look for our upcoming Job Profiles of 2008 winners in future issues of Fabricator. RIGHT: Big D Metalworks, Dallas, TX, crafted this circular monumental stair, which is the centerpiece of the children's building of a local hospital.

The stair was fabricated from rolled HSS sections, taken into the building at ground level, and lowered into place. The railing system was fabricated from stainless steel with no visible welds and incorporated curved tempered glass infill panels. Attachments for the top rail, horizontal bars, handrails, infill panels, etc., were custom fabricated or machined. The entire project required more than 2,000+ hours of labor.

LEFT: Sunmaster of Naples Inc., Naples, FL, submitted this all-316L grade stainless steel free-standing structure, which serves as the main entry protection from sun and rain, at an exclusive beachfront condominium. The entire piece is 64’-0 in width, and has 46’-0 projections with a 28’-0 cantilever. Schedule 40 Pipe was used to connect all the trusses together, with 4” square tube as the glass support members. Each Truss weighed in at 6,600 pounds, for a total combined weight of over 40,000 pounds, not including the tempered glass. Fabrication and installation required about 3,800 hours of labor.

May/June 2008 



LEFT: McLellan Blacksmithing, Loomis, CA, submitted this baldachi.

This was a very difficult project, as the architect had designed an I-beam ring weighing over 5000 lbs. and measuring over 14’ in diameter to be suspended from the ceiling — which was estimated to hold only 1,500 pounds. In addition, the cross that the ring was to hold weighed 500 pounds alone, and the church wanted a solid-ring look. Using tubing and sheet metal, the ring was fabricated to appear solid, yet weigh within the limits the ceiling could support. This structure allowed for lights to illuminate the crucifix to be hidden inside. The ring is suspended from the ceiling by stainless cable sheathed in decorative tubing with gold-leafed balls every 6 feet. The decorative ironwork was all forged, and the lettering is all gold leaf.

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The all-steel gate stands just less than 16 ft tall in the center, and 18 ft across. Initially, the customers wanted the gates to be only 6-1⁄2 ft. tall. Knowing that a taller gate would look better with the massive existing piers, Anderson Welding made a sample of the arch and held it in place at a few heights for the clients, who immediately changed their minds about the height. With a satin black finish highlighted with a copper patina, the focal point of the gates design is the two hand-painted flower panels. The style and look of the gate fit in very well with the surrounding ironwork, which was done in the 1920s. Fabricator 

May/June 2008

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LEFT: Entitled “Eagle in Flight,” this gate/sculpture was designed by Dynasty International Creation Inc., Orangeville, Ontario.

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ABOVE: This gate from MH Engineering, Horseshoe Bay, TX, was fabricated for an entryway to a garden area for exotic plants and shrubs.

The vine design was laid out in a switchback arrangement to give the gate a focal point near the top third of the length. The vertical framework is 1⁄2” square rod, and the vines are 1⁄2” rounds near the bottom and are blended to 1⁄4” rounds near the top to give the vines a more natural look. Cast steel leaves were attached to the vines so that the pattern could be seen from either side. German gold leaf (23-3⁄4 carat) was applied, front and back, to each of the steel leaves using the traditional oil gilding techniques. Oil based hand applied paints complete the surface of the non gilded areas and contrast the leaves of gold that make this gate a centerpiece. Fabricator 

May/June 2008

RIGHT: This stair railing was crafted by Builders Ironworks Inc., Crete, IL. The forged scroll panels in this 120 linear feet rail job were chosen to match crown molding and a chandelier in the residency. It used two 1 1⁄4” x 3/8” horizontal rails and forged panels with similar scrolls to comply with 4” spacing codes. The finish is black satin paint with gold paint faux finish on the leaves. This job took approximately 180 hours to complete.

LEFT: Sleeper Welding, Belmont, NH, submitted this repoussé in the Art/Sculpture category. The design for the peacock on the copper repousse was taken from a thank-you note written by the shop owner’s sister-in-law. The design on the brass sheet was modified from a Dover Book On French Designs.

RIGHT: Richard R. Pucci & Associates Inc., Ivyland, PA, crafted this copper-frame fire screen.

The frame is TIG welded and hammered on three sides. The gussets, hinges, and feature panels are silver soldered. The handles were hammered out of 3/4" round stock. Stainless steel machine screws are silver soldered on the rear of the copper frame to accept the steal framed screen. The steel mesh was sandwiched between 18 gauge steel panels that are screwed together with sheet metal screws. The screen frame was offset from the copper frame 1/16 of an inch with washers to insulate the copper from the heat. The finish was left natural to age on its own.



May/June 2008

LEFT: This entrance gate was submitted by Herndon & Merry Inc., Nashville, TN.

The gate was designed for the 12’ x 10’ arched opening by a member Herndon & Merry’s sales staff. Each leaf weighs 900 pounds and opens at the touch of a finger on split journal (top) and flange bearings (bottom). The bearings are bolted or welded to arms/plates extending through the stone from a steel beam which is anchored to the wood stud wall. The gate frame is 2" square, 2" x 4" rectangular tube, and 1"x 2" flat bar. The hand forged scrolls are 1” square solid and 3/4" x 1" flat bar. The frieze is composed of 3/4" square solid x 6" o.d. forged rings and 3/ 4" square, twisted and forged to a point. Cast iron rosettes on 1/ 4" plates accent the corners, front and back. Additional clearance was required under this gate because the cobblestone driveway rises as it enters the property. The job site was located 980 miles from the fabricator’s shop.

BELOW: This Mediterranean-inspired residential railing job was submitted by Coast Welding Co., Wilmington, CA.

The project includes 120 linear feet of completely curved interior railings featuring a double stair layout with a horseshoe-shaped top balcony. The upper railings were hand forged from 1/4" x 3/4" flat mild steel bar and the bottom railing was forged from 3/8" x 1 1/4" mild steel bar; 2-1/4" molded cap railing was heat formed to match the railing contours. The finish is flat black powdercoating. The fabricator’s biggest challenge was developing smooth design transition between the convex and concave curved railing sections at top of staircase. This project was part of larger scope of work that included front entry doors, a large round window, and a wine cellar door. It took approximately 420 hours to complete.

ABOVE: These gun cabinet door grills were designed and fabricated by Carnahan-White Inc., Springfield, MO.

The design concept was based on the theme of hunting and hunting dogs. RepousseNtechnique was used to raise the shapes. The barrel type hinges seem to float with no visible connections. Every piece in these doors were hammered and pinned, with as small amount of MIG welding as possible. All pieces were made from mild steel with light wire brushing and a clear coat finish. The job took about 120 hours to complete.



May/June 2008

LEFT: Neiweem Industries Inc., Oakwood Hills, IL, fashioned these curved iron railings.

There were four stairways in the home, two of which required iron railings — all of the stairs required the same hammered bronze baluster and toe ornaments, and bronze riser ornaments. The job included 110 feet of railing, 85 toe ornaments and riser ornaments, 18 post ornaments, and 250 hammered baluster ornaments. The baluster panels are fabricated from 1-1/4" x 1/2" flat stock. Fabrication challenges included curving each panel to the radius of the stair and ensuring there were no visible welds or grinder marks. The rail was finished with two coats of sandable primer and a final coat of deep bronze tone enamel mixed with gold leaf enamel. All of the bronze ornaments were crafted from 1/4" flat stock. Each piece was hammered for texture, given a routed edge and dark patina, polished, highlighted, and clearcoated.

ABOVE: This chandelier was submitted by Ephraim Forge Inc., Frankfort, IL.

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The client requested a twig light fixture — and sent a photo of a large branch with no leaves, a drawing with dimensions, and the instructions to make it light in appearance. After a meeting with the designer and a number of study pieces, the basics were laid out. The individual branches and twigs were hand forged at Ephraim Forge. There are 10 main branches that taper from roughly 3/4" to a point, which form the rough shape of the fixture. "Branching" off these main pieces are many smaller branches and twigs; there are 500-600 pieces in total. Each of the 10 main branches was assembled flat and then shaped with a torch and a pair of scroll tongs. The job was not only difficult because of its many pieces, but also because of the tight spacing and sharp points. The piece took about 50 hours to complete. Fabricator 

May/June 2008

RIGHT: This arbor was crafted by Wrought Iron Art Ltd., Oakville, Ontario, Canada.

One of three arbors that compose united composition for a condominium building entrance, this design was inspired by the image of two trees with interlaced branches where bobcat is hiding. The bobcat is made from solid steel, hollow balls, and metal mesh. This â&#x20AC;&#x153;arbor,â&#x20AC;? designed by the fabricator, was recognized as the best among eight other compositions that were competing to perform the project. The arbor is all hand forged by both hands and power hammer, and was installed using a boom truck. Approximately 450 hours of labor were required to complete the job.

ABOVE: This formed and fabricated railing was submitted by Wiemann Ironworks, Tulsa, OK.

The railing is made up of textured 1/2-inch square bar, laser cut 1/2-inch plate for the Greek Key, custom cast bronze ball, and finial feature with formed bronze collars. Designed by the fabricator, there are five separate pitches in this design, making the layout for such a tight stair very difficult. The finish is patinated and waxed. The approximate length of the railing is 48 linear feet. The railing took about 1100 hours of labor time to complete.

May/June 2008 



METALfab 2008

Looking back on METALfab 2008  Marking NOMMA’s 50th anniversary,

METALfab 2008 returned to the city where it all began — Memphis, TN. It was a week full of educational opportunities, networking, sharing, and recognition of achievements. We remembered our roots, and looked forward to the future with anticipation. RIGHT: One of the beautiful scrolled gates at the entrance to the National Ornamental Metal Museum.

The National Ornamental and Miscellaneous Metals Association (NOMMA) celebrated “50 Years of Taking Care of Business” at its annual trade show and convention in the city where it was founded, Memphis, TN, April 1-5, 2008. The week’s main events kicked off on Tuesday with registration and the opening night Welcome Reception. The following morning, convention attendees joined the NOMMA Board of Directors for breakfast and the annual business meeting, which included the election of new officers and directors, as well as special recognitions. Several long-time NOMMA members shared their memories from past years, including Mel Peterson, who attended NOMMA’s very first convention. After breakfast, an orientation was held for first time attendees, followed by the first of the week’s non-stop educational sessions, which addressed topics such as gate installation, curved stair measuring, shop layout, and more. Excitement was in the air late in the afternoon when the doors to the annual Trade Show opened. On Thursday, there were more edu54

cation sessions, including four presentations by popular motivational speaker Glenn Shepard — he even provided the solution to the age-old dilemma of how to handle difficult customers and “hard-to-please” people! Other sessions addressed insurance issues, restoration of ornamental metalwork, and a code update by NOMMA’s Technical Affairs committee. The Trade Show was again open in the evening, where everyone enjoyed a delicious reception and visiting the exhibitors’ booths. On Friday, the Trade Show was open in the morning for its final hours. The afternoon featured education sessions on finishing ornamental ironwork and regulatory requirements, as well as the Top Job Jamboree, highlighting this year’s entries in the contest. The Awards Banquet was held in the evening, during which new officers and directors were installed, outstanding NOMMA members were recognized, and the Ernest Wiemann Top Job Awards winners were announced, including the winner of the Mitch Heitler Award for Excellence, which is selected from the gold level award winners.

Bright and early Saturday morning, NOMMA members boarded buses for tours of the National Ornamental Metal Museum, Keeler Iron Works, and Tennessee Fabricating. The grand finale of the convention was the theme dinner that evening, which included live entertainment, dancing, and the annual NEF auctions. METALfab is a week of unrivaled opportunities and fun for our industry. It’s not too early to mark your calendar now for METALfab 2009, to be held in Long Beach, CA, April 22-24, 2009. See you there!

For your information  METALfab is NOMMA’s annual convention and trade show.  METALfab is open to members of

NOMMA as well as nonmembers. Read Fabricator magazine and visit NOMMA’s web site for event and registration details on METALfab 2009. Ph: (770) 288-2004; Web:

 To exhibit at the 2009 METALfab trade show, contact Martha Pennington via Email:, or log on to


May/June 2008

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Thanks to all of our Exhibitors ABANA 865-546-7733 Blacksmith organization. All-O-Matic 818-982-1987 Gate operators. Alloy Casting 800-527-1318 Aluminum castings and aluminum hardware. Alro Steel Corp. 517-788-3254 Metals, plastic, industrial suppliers. American College of the Building Arts 843-266-7836 Education. Apollo Gate Operators 210-545-2900 Gate operators and accessories. Architectural Iron Designs Inc. 800-784-7444 Ornamental iron forgings, castings, balusters, vinylast paint. Atlas Metal Sales (Div. AMIC) 303-623-0143 Silicon bronze. Auciello Iron Works Inc. 978-568-8382 E-Z sleeves. BFT U.S. Inc. 561-995-8155 Hydraulic electromechanical gate operators. Big Blu Hammer Mfg. Co. 828-437-5348 Big Blu air hammer. Blue Moon Press 866-627-6922 Metalworking books. Julius Blum & Co. Inc. 201-438-4600 Stock components for architectural metalwork. 56

Byan Systems Inc. 800-223-2926 Hydraulic gate operators and access control products.

DoorKing Inc. 340-645-0023 Access control.

International Gate Devices 610-461-0811 Patented internal slide track system for cantilever gate.

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

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

Iron World 301-776-7448

Carell Corporation 351-937-0947 Ornamental bar working machines, tube/pipe benders.

Elite Architectural Metal Supply LLC 847-636-1233 www.elitearchitecturalmetal. com Distributor of component parts.

Carl Stahl DecorCable 312-474-1100 Custom cable and metallic assemblies, cable mesh, tension products.

FabCAD Inc. 800-255-9032 FabCAD速 premium package that automatically draws railings, fences, and gates.

King Architectural Metals 214-876-0696 Balusters, forgings, hardware. Laser Precision Cutting 828-658-0644 Laser cutting and waterjet cutting. C.R. Laurence Co. Inc. 800-421-6144 Architectural hardware, railings.

Cleveland Steel Tool Co. 800-446-4402 Ironworkers, magnetic drills, portable punching, and related tooling.

Forjas 2000 SL 011-34-925-80-4614 Wrought iron products and stainless steel products.

CML USA Inc. Ercolina 563-391-7700 Tube, pipe, and profile bending and metalworking machinery.

GTO Access Control Systems 800-543-4283 Full line of automatic gate operators and accessories.

Colorado Waterjet Co. 970-532-5404 Waterjet cutting services, job shop.

Hartford Standard Company Inc. 270-298-3227 Heavy duty post caps in a variety of metal alloys.

Complex Industries Inc. 901-547-1198 Iron entry doors, iron castings, balusters, ornamental fencing, drive gates, mailbox stands.

Hebo/Stratford Gate Systems Inc. 503-722-7700 Hebo wrought iron machines.

Mittler Bros. Machine & Tool 636-745-7757 Upgraded ultimate tubing notcher.

Crescent City Iron Supply Inc. 708-345-6660 Supplier of ornamental components for railings, fencing, furniture, and artistic endeavors.

ITW Ransburg 419-470-2000 Liquid electrostatic spray equipment.

Frank Morrow Co. 401-941-3900 Decorative metal stampings, trims, and grey iron motif castings.

Custom Orn. Iron Works Ltd. 866-464-4766 Wrought iron components.

Industrial Coverage Corp. 800-242-9872 Insurance programs designed for NOMMA members.

D.J.A. Imports Ltd. 718-324-6871 Ornamental components, gate hardware, and more.

Industry Ornamental Iron Inc. 800-915-6011 Iron gates.

Lavi Industries 661-257-7800 Brass & stainless railing, architectural metal. Lawler Foundry Corp. 205-595-0596 Ornamental metal components and accessories. Marks USA 631-225-5400 Ornamental iron locksets.

National Ornamental Metal Museum 901-774-6380 Metal museum. NC Tool Co. Inc. 336-674-5654 Gas forges. List continues on page 58 Fabricator 

May/June 2008

2008 METALfab Trade Show RIGHT: King Architectural Metals displayed its balusters, forgings, and hardware.

ABOVE: The annual Trade Show was, as always, a popular part of METALfab. Attendees learned about exhibitors’ products and services, and were treated to a delicious buffet during Trade Show hours. Here, Stan Lawler of Lawler Foundry Corp., greets a convention-goer.

Exhibitors, continued National Ornamental & Miscellaneous Metals Association (NOMMA); NOMMA Education Foundation (NEF); NOMMA Chapters 888-516-8585 NOMMA is the industry’s trade association. The NOMMA Education Foundation is a charitable education foundation. New Metals Inc. 956-729-1184 Expanded metal, expanded metal fencing, and wrought iron forgings. Ohio Gratings Inc. 800-321-9800 Aluminum, carbon, and stainless steel bar grating products. P & J Mfg. Co. 419-227-8741 Textured metals, custom bends, custom scrolls.


LEFT AND ABOVE: Equipment demonstrations were held on the Trade Show floor.

Paxton & Thau Artistic Supply 205-290-2790 Forgings, rail panels, stainless steel, brass.

Scotchman Industries 605-859-2542 Ironworkers, cold saws, band saws, advanced measuring and stop systems.

Premium Home & Garden Co. Ltd. Xiamen 361004 P.R. China Wrougt iron gates, iron fences, iron railings, hand-forged, hot dipped galvanized.

Sharpe Products 262-754-0369 Architectural pipe and tube handrail fittings.

Regency Railings Inc. 214-742-9408 Forged iron stair components.

Sumter Coatings 803-481-3400 Paints and coatings for ornamental and miscellaneous metals.

Rockite Div. of Hartline Products Co. 216-291-2303 Rockite cement and Kwixset exterior cement.

Taco Metals Inc. 800-226-8201 Stainless railing components for mechanical, glass, and cable rail systems.

Royal Forge PTE LTD 011-656-235-9893 Wrought iron components, balusters, scroll, and curls.

Taurin Group USA 909-476-8007 Roll bending machines for the ornamental industry.

Rutland Professional Products 800-707-6599 Automatic gate openers.

Tamithia Designs Handmade jewelry.

Tennessee Fabricating Co. 901-725-1548 Decorative metals & hardware. Texas Metal Industries Inc. 800-222-6035 Aluminum castings, hardware, furniture, forgings, and more. Tracker CNC 519-472-1793 CNC shape cutting machine. The Wagner Companies 414-214-0444 Handrail components and systems, lighted rail, cable rail, glass rail, extrusions – brass, bronze, aluminum; pipe, and tube. Weaver’s Iron Works 865-932-2636 Porta-Bender. West Tennessee Ornamental Door 901-346-0662 Ornamental doors, fences, gates, gate operators, and access control systems.


May/June 2008

Education Sessions An invaluable part of METALfab, the informative education sessions are popular with conventiongoers.

METALfab 2008’s education sessions cov-

ered a wide variety of topics, from technology to human resources. And, attendees could observe how fellow NOMMA members’ shops operate via videotaped shop tours.

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ABOVE: Speaker Glenn Shepard animatedly points out the reasons “Why You Never Seem to Have Enough Hours in the Day,” and gave solutions. He also addressed the issues of handling diferent generation in the workplace, how and where to find good employees, and how to handle difficult customers and hard to please people.

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Be a star at MetalFAB 2009! Think of how much you enjoy learning about your fellow NOMMA members and their work. They are just as curious about you! Volunteer to be a part of Video Shop Tours at METALfab 2009. It’s easy to do, and it’s informative for all of NOMMA’s members. These virtual shop tours were a popular education session at this year’s convention. For more information on how you can participate, contact: James Minter Jr. Imagine Ironworks 1380 Highway 51 North Brookhaven, MS 39601 Ph: 601-833-3000 Email: imagineironworks@bellsouth. net

(800) 589-5545 Fabricator 

May/June 2008

2008 Top Job Award Winners The annual Ernest Wiemann Top Job

Competition is open to all NOMMA members. Entrants provide photos and descriptions of their work, and entries are displayed during METALfab. NOMMA members are given the opportunity to peruse the gallery of pictures and cast their votes in various categories. Once the winners are determined, a committee then reviews the gold winners in all of the categories and selects one job that merits additional recognition. This special job is presented with the Mitch Heitler Award for Excellence, and is considered the “best of the best.” The following awards were presented during the annual awards banquet during METALfab 2008:

Mitch Heitler Award for Excellence Art’s Work Unlimited Miami, FL

Category A (Driveway Gates) GOLD: Artisan Metal Works Ltd. Cayman Islands SILVER: A.Y.’s Designs in Iron San Diego, CA BRONZE: Art’s Work Unlimited Miami, FL Category B (Driveway Gates - Forged) GOLD: Art’s Work Unlimited Miami, FL SILVER: Bighorn Forge Inc. Kewaskum, WI BRONZE: Wonderland Products Inc. Jacksonville, FL

Category C (Interior Railings Ferrous) GOLD: Creative Metal Works Gulf Breeze, FL SILVER: Lipko Iron Work Canton, GA BRONZE: Accent Ornamental Iron Co. New Smyrna Beach, FL Category D (Interior Railings Nonferrous) GOLD: Artistic Railings Inc. Garfield, NJ SILVER: Sunmaster of Naples Inc. Naples, FL BRONZE: Strampe Metalcraft Eden Prairie, MN Category E (Interior Railings - Forged) GOLD: Big Blu Hammer Mfg. Morganton, NC SILVER: Virginia Architectural Metals Fredericksburg, VA BRONZE: Royal Iron Creations West Palm Beach, FL Category F (Exterior Railings & Fences) GOLD: Artistic Railings Inc. Garfield, NJ SILVER: Mueller Ornamental Iron Works Inc. Elk Grove Village, IL BRONZE: Pro-Fusion Ornamental Iron Inc. San Carlos, CA Category G (Exterior Railings & Fences - Forged) GOLD: Wonderland Products Inc. Jacksonville, FL

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


Phil Hermance of Art’s Work Unlimited is pictured holding the Mitch Heitler Award for Excellence. Art’s Work received the award for its entry in the Driveway Gates Forged category.

SILVER: Lipko Iron Work Canton, GA BRONZE: Big Blu Hammer Mfg. Morganton, NC Category I (Furniture & Accessory Fabrication - Forged) GOLD: Wiemann Ironworks Tulsa, OK SILVER: Wonderland Products Inc. Jacksonville, FL BRONZE: Big Blu Hammer Mfg. Morganton, NC Category K (Gates/Doors - Forged) GOLD: Shanghai Loyal Orn. Wrought Iron Works Co. Ltd. Shanghai, China SILVER: Wonderland Products Inc. Jacksonville, FL BRONZE: Aladdin Door & Gate Co. Indio, CA Category L (Stairs Complete) GOLD: Finelli Ornamental Iron Co. Solon, OH SILVER: Modern Iron Concepts Inc. Nashville, TN BRONZE: Virginia Architectural Metals Fredericksburg, VA Category N (Unusual Ornamental Fabrication) GOLD: Virginia Architectural Metals Fredericksburg, VA SILVER: Art’s Work Unlimited Miami, FL BRONZE: Fine Architectural Metalsmiths Chester, NY


May/June 2008

Julius Blum Award

Top Job Awards, continued

Curt Witter of Big D Metalworks was

Category O (Restoration) GOLD: Fine Architectural Metalsmiths Chester, NY SILVER: Superior Fence & Orn. Iron Cottage Hills, IL BRONZE: Flaherty Iron Works Inc. Alexandria, VA

given the Julius Blum Award for his longtime commitment to strategic planning and his willingness to share his planning skills with NOMMA. Also he was recognized for his work with NOMMA’s technical team. Upon receiving the award, Witter (pictured at right) said, “I encourage everyone to give — it’s worth it!” The Julius Blum Award, named after the late founder of Julius Blum & Co. Inc., recognizes those who make outstanding contributions to the industry.

Category P (Art/Sculpture) GOLD: Fine Architectural Metalsmiths Chester, NY SILVER: Precision Custom Metals Inc. Tucker, GA BRONZE: Art’s Work Unlimited Miami, FL

Frank A. Kozik Award Thomas B. Zuzik Jr. of Artistic Railings

Inc., Garfield, NJ, received the Frank A. Kozik Award for his outstanding work on the NOMMA Technical Affairs team and for his work in educating NOMMA members on important code issues. During his years of service, he has attended countless code hearings and represented NOMMA interests on proposals that affect the industry. Zuzik could not be present for the ceremony, but accepted the award via phone. The award is named in honor of Frank A. Kozik, who served as the association’s first president in 1958-59.

Clifford H. Brown Award


Jim Wallace, the

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™

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recently retired director of the National Ornamental Metal Museum, received the Clifford H. Brown Award. Wallace, a master blacksmith, served as the director of the National Ornamental Metal Museum for nearly 30 years. During that time, he helped to transform a handful of abandoned military buildings into a world class museum that is internationally known and respected. Wallace was also honored for his contributions to the NOMMA Education Foundation (NEF). Fabricator 

May/June 2008


Theme Party The final evening of METALfab was a

time for celebration. NOMMA members were invited to dress in clothes from their favorite era, in keeping with the convention’s theme, “50 Years of Taking Care of Business.” Greasers, bobby-soxers, hippies, disco dancers, and even some “regular” folks enjoyed a Southern buffet-style dinner, live entertainment by the Rock Williams Group (featuring a guest appearance by NOMMA’s own George Bandarra on the mouth harp), dancing, and the annual NEF silent and live auctions. A great time was had by all. Here’s to 50 more years!



May/June 2008

Thank you, METALfab 2008 Sponsors! Platinum    

Industrial Coverage Corp. King Architectural Metals Lawler Foundry Corp. The Wagner Companies


Julius Blum & Co. Inc. Carell Corp.



Colorado Waterjet Co. D.J.A. Imports Ltd. Eagle Bending Machines Inc. FabCac Inc. Innovative Hinge Products Inc. Lavi Industries Mittler Bros. Machine & Tool Ohio Gratings Inc. Regency Railings Inc. Tennessee Fabricating Co.

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

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May/June 2008 



The National Ornamental Metal Museum, located in a picturesque setting on the banks of the Mississippi River, is a true treasure. Visitors can tour various buildings, including the museum, library, and foundry, where demonstrations of repair and blacksmithing techniques are given.

Shop Tours & Demos On the last day of METALfab, NOMMA

members and staff boarded tour buses for three very special shop tours. The first stop was the National Ornamental Metal Museum. Guests enjoyed pastries and coffee, and toured the grounds, the museum and gift shop, library, and foundry, where they observed demonstrations of blacksmithing techniques and metal repair. Next, it was on to Keeler Iron Works, where guests were welcomed by Rob and Will Keeler and staff, and then given a tour of the facility. An authentic Memphis-style barbecue lunch was served, followed by a demonstration by Rob Keeler on making Damascus steel and another by Big Blu Hammer on power hammering techniques. The final stop on the shop tours was Tennessee Fabricating Co., a firm that played a key role in founding NOMMA in 1958. During their visit, guests got to see the company’s showroom and warehouse, and were treated to delicious snacks.

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May/June 2008

LEFT: Metalsmiths from around the world contributed samples of their work to the Anniversary Gates. The rosettes, typically about the size of a doorknob, show an incredible range of personal statements about the individual artist's interests, national pastimes and sometimes whimsical design motifs.

RIGHT: Whimsical metal works of art on the grounds of the Metal Museum delight visitors of all ages.

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UPPER LEFT: Rob Keeler (center) explains techniques for making Damascus steel. UPPER RIGHT: Dean Curfman of Big Blu Hammer demonstrates various power hammering techniques. LEFT: James Minter and Charles Perez enjoy a visit to Tennessee Fabricating’s showroom.

BELOW: An authentic Memphis-style barbecue lunch served up by the famous Neely’s BBQ.

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METALfab 2009 April 21-25, 2009 Long Beach, CA Details to come: Fabricator 

May/June 2008

Biz Side

The upside to the downturn  Strengthen your

business during economic tough times with these seven tips.

The financial news of the past few

weeks has left many a business owner panicked, anxious, and mentally writing their company’s obituary. Chin up, says David Giannetto. You can actually use the economic downturn to create a better organization. If you’re a business owner, it’s likely that some of your recent workdays have gone something like this: You bolt awake (probably after a sleepless night!), grab the financial section of the paper, and turn on your TV to get the latest worrisome financial news. Then, once you make it to work, you lock yourself in your office to carefully examine your company’s financial projections for the next few months, wringing your hands as you fret over every possible worst case scenario. May/June 2008 


Sound familiar? If so, David Giannetto says it’s time for the hand wringing to stop—and the smart thinking to begin. “The word ‘recession’ by itself has been known to send business owners into a panic,” says Giannetto, coauthor along with Anthony Zecca of The Performance Power Grid: The Proven Method to Create and Sustain Superior Organizational Performance. “Add in all of the economic postulating by the media, and you might find it easy to convince yourself it’s time to start counting down the days until your business’s demise. But all of that worrying is counterproductive. You can’t get anything done when you’re in panic mode.” Giannetto says the business owners

For your information Can your business survive an economic slowdown? The answer is yes — if your operation is solidly run. Here are some best practices that can help your company make it through tough times:

 Have a business plan that adapts to changes in the market  Embrace technological advances

 Treat your customers well, and expand your relationships with them

 Build a network of trusted advisors and supporters  Diversify your offerings, if possible

The U.S. Small Business Administration’s SCORE advisors have a wealth of business advice to share on facing an economic downturn. Log on to:


who use their time to improve their business and seize every possible opportunity—rather than wasting it on constant worrying—are the ones who will make it through the economic downturn. Play your cards right and you may even come out of these financial hard times with an even more prosperous business than you had before. “Making it through this economic slowdown won’t be a piece of cake for anyone,” admits Giannetto. “But if you

know the best steps to take, you will be able to come out on the other side of this recession with a very sound business in place.” Here are a few of his tips for steering your business through the economic downturn:


In business, only the strong survive. During an economic downturn, many business owners overlook the fact that their competitors are suffering too—and that

what results from the slowdown is still an even playing field. “The problems your organization struggles with due to the downturn also plague your competitors,” says Giannetto. “Therefore, your strategy for not only surviving the slowdown but prospering during it remains the same as it should be in good economic times: Build the strongest business you possibly can. And that means having a strong value proposition, managing in a fiscally responsible manner, and providing great service to get and keep important customers. Don’t let all the hype surrounding the slowdown distract you from keeping these basic tenets in the forefront of your mind. If you’re successful, you’ll come out on the other side of the economic downturn, miles ahead of your competition.”

“The death of your

competition actually creates holes in your market—ones that your organization can fill...”


Use the hype to focus your employees. One positive thing about all of the fear-inducing hype scaring business owners, executives, and managers everywhere is that in the right hands it can be a great motivational tool for employees. “The slowdown creates what I like to call a ‘momentary unifying factor’—something that allows each employee to set aside their individual concerns and rally around a greater common cause,” says Giannetto. “Use the economy to drive home the fact that providing quality service to customers and creating greater effectiveness and efficiency are the absolute best ways for your employees to help the business through the recession. Fear and the desire to keep your business up and running will unify your organization in ways you likely haven’t seen before. The challenge is for you, as the leader, to resist being overcome by the same fear, and to present a vision and path toward greater pros-



May/June 2008


perity that everyone in your organization will rally around.” Expand; don’t contract. It seems counterintuitive, but great companies expand during slowdowns; they don’t pull back. Remember, all competitors within an industry are dealing with the same challenges. As a result, the weakest of these organizations will be going out of business, losing critical funding and cutting operations, and/or letting go of critical but expensive assets and people. “All of these things open up holes in the market that a clear-thinking organization can fill,” says

May/June 2008 



Giannetto. “As these businesses fail, the market you are competing in may very well contract, and the death of your competition actually creates holes in your market—ones that your organization can fill—so you can actually expand through the slowdown. When this happens, you will want to be there to snatch up the customers of your failed competition. Be prepared to increase your sales, marketing, and advertising efforts during


the slowdown to make sure that newly ‘available’ customers reach out to you first.” Figure out what these tough times mean for your customers. You aren’t the only one suffering as a result of the slowdown. Your customers are too. The faster you realize that the quicker you will be able to better meet their needs. “Just like you, your customers are

making tough decisions on what they should spend their limited funds on, and what they can afford to give up,” says Giannetto. “And you don’t want to end up on the latter list! Look at your organization from their perspective and make sure that every portion of your organization, not just its product or primary service, is treating your customers right. Go the extra mile— even if that means spending extra money—to reach out to your biggest and best customers. Make sure you are meeting their expectations and keep the lines of communication open. That way if you find out they’re planning to break off relations, you can do something about it before it’s too late.”

“The words ‘economic downturn’ don’t have to mean


only bad news to your business.” Know the difference between profit and revenue. It sounds like something every executive should understand, but in many organizations which customers, products, services, or geographic locations provide the most profit for the organization are actually very difficult to determine. “All organizations can produce financial statements of gain and loss, but these do nothing to help managers make hard decisions about where they should be cutting specific, unprofitable customers or segments, and where they shouldn’t,” says Giannetto. “During a slowdown, you should apply greater scrutiny in these areas. It’s likely that at some point you will need to cut costs, and the first places to cut should be those areas where you are already losing money.”


Stay current and creative. A better tomorrow will come, and you must be ready for it. Too often during a slowdown companies cut back on the new products or services that represent the future of their business. Once the slowdown turns around—as it inevitably will—they find that they can not catch back up to



May/June 2008

with a stronger business than the one you had before.” About the authors of The Performance Power Grid: The Proven Method to Create and Sustain Superior Organizational Performance.: David F. Giannetto is the director of Cohn Consulting Group’s Enterprise Performance Management Practice. He is responsible for helping client organizations improve opera-

market demands and expectations. “Too many businesses fail while the market is actually turning around rather than during the dip because they are left with only outdated products and services,” says Giannetto. “That’s why you must avoid falling into this trap. Even during the downturn, keep your creative juices flowing. Always be thinking about new ways to satisfy your customers and which new products will enable you to better meet their needs.”


If you are a public company, be transparent and realistic. We have seen time and again that the market actually does respect firms that deliver realistic growth projects. “Even if these projections were lower than expected or desired, the market will not react as badly as it would have if you stated higher earnings than you actually came in at,” says Giannetto. “If you know you are going to fall short of your projected earnings because of the slowdown, tell the market. The value of your organization may take a hit, but it will be much less than it would be if you surprise the market with previously unstated losses at the last minute.”

tion efficiency, management effectiveness, customer satisfaction, and systems integration through the implementation of the latest performance management methodologies. Anthony Zecca is the partner-incharge of Cohn Consulting Group. He is a financial and management professional and a seasoned strategist focused on helping clients develop and implement growth and profit strategies.

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“The point of all of this is that the words ‘economic downturn’ don’t have to mean only bad news to your business,” says Giannetto. “If you manage business during the downturn correctly—taking care to address the needs of your employees and customers—it is possible to make it through all of this May/June 2008 



Biz Side

Under the microscope  For a company owner, there are

few things that inspire fear and loathing more than the words “regulatory inspection.” There are some things you can do now to prepare in case your company ever receives a visit from OSHA, the EPA, or a state agency.

By Ron Flexon The Flexon Group Editor’s note: Ron Flexon of The Flexon Group, a regulatory engineering consulting firm that helps companies with their environmental health and safety needs, provides this example, which outlines how his company assists clients who have undergone regulatory inspections.

Why is my company being Q:inspected? The most likely reason that your company could be inspected is that your facility appeared on a computergenerated list that randomly triggers inspections, community complaints, 76

employee complaints, and odor complaints from the community. Other possible reasons for a visit are complaints made to OSHA by employees, insurance carriers, or serious or frequent accidents and injuries. Advance warning is usually not given, and sometimes a warrant is required for the inspector to enter your facility.

What happens if my company is after inspection? Q:penalized About 28 percent of our clients (including some NOMMA members) have asked for our assistance due to a regulatory inspection from the Occupational Safety and Health Administration (OSHA) or their state’s Department of Environmental

For your information The Occupational Safety and Health (OSH) Act requires employers to comply with safety and health standards issued by OSHA, as well as with other regulations issued by OSHA. In addition, the Act includes a "general duty clause," which applies to hazards not addressed by any specific OSHA standard. The general duty clause requires employers to provide their employees with a workplace that is free from recognized hazards that are causing or likely to cause death or serious physical harm. OSHA’s website has helpful information on issues such as:  laws and regulations

 compliance assistance  field inspections

For more information, visit Fabricator 

May/June 2008

Protection Agency (DEP), resulting in severe penalties. Upon the client’s request, an Environmental Health and Safety (EHS) expert from our company will arrive onsite and conduct a comprehensive EHS audit of the entire facility, as well as audit the process and recordkeeping practices that are governed by regulatory state and federal requirements. Directly after the EHS audit is complete, we design a Corrective Action Plan for the client, which could include DEP/EPA permitting for process elements, engineering control recommendations, health and safety program development, record keeping implementation, and required training per OSHA, DEP, and EPA requirements. Once the company has paid the penalty to the penalizing agency, the company’s regulatory requirements for the facility must be implemented. Many of our clients have questioned, ‘If we pay the fine do we still have to implement these requirements?’ The answer is yes. The state and federal regulatory requirements will need to be reviewed, both administratively and technically by the agency, then implemented and managed by the company. Preparation for an inspection There are several steps you can take in advance to prepare for a state or federal regulatory inspection. Designate your company representative prior to the inspector’s arrival. Instruct the reception area to inform the representative when the inspector arrives. Your company representative should check the inspector’s credentials bearing a photograph, badge, and serial number with the nearest regional office. Your representative should accompany the inspector at all times. The representative should be the same person throughout the inspection

“Passing through a

regulatory inspection is like being awarded a large job in our industry.” — Keith Majka May/June 2008 


(two or more representatives could provide conflicting information). If, at any time, the representative has difficulty responding to a question, he/she should telephone for advice from an attorney or trusted knowledgeable source like an EHS consultant. Once the inspector is in, the compliance inspector’s protocol that is usually followed will consist of:  Facility walkthrough

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 Visual observation of hazardous materials used in the process

As our business has grown through the years and we add more specialized

processes to our manufacturing line, we have learned how complex regulatory requirements for our state can be. Passing through a regulatory inspection is like being awarded a large job in our industry; it’s a great assurance that we are doing something right.

 MSDS review  Request to review annual chemical inventory

— Keith Majka, Majka Railing Co. Inc.

 Request to review utility bills for gas and water usage.

issues penalties the same day while the Department of Environmental Protection issues your company by mail a Notice of Violation (NOV). Upon receiving the penalty, the company must act immediately to address and correct the non-compliance status. Showing good faith and a corrective action plan to the penalizing agency may help in reducing the dollar amount of the fine at the closing conference.

 Request to review applicable permits  Review of recordkeeping  Request to review regulatory policies and procedures  Verification of training records  Employee interviews

A NOMMA member’s story A few years ago, NOMMA member Majka Railing Co. Inc. of Paterson, NJ contacted our company, stating that they received several penalties from OSHA during an inspection of their facility. Directly afterwards, we visited

Once the compliance inspector has completed his/her inspection and, depending on the state in which your company operates, it is possible you will receive an immediate penalty or notice of violation. OSHA usually

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the manufacturing facility and conducted and comprehensive EHS audit — from the stacks on their rooftop to every electrical connection in their process. Once the audit was complete, the owners reviewed each and every non-compliant item and asked if we would design a Corrective Action Plan that would help them meet their requirements, including development of each and every environmental permit, required procedures, policies, and programs as required by federal and state agencies.

Showing good faith and a

corrective action plan to the penalizing agency may help in reducing the dollar amount of the fine.

Unfortunately, this was not the end of Majka Railing Co.’s regulatory problems. In the state of New Jersey, their initial inspection conducted by OSHA threw many black flags out to various departments within the New Jersey Department of Environmental Protection Agency. Phone calls and multiple onsite regulatory inspections were occurring on a monthly basis that would intimidate any size company and possibly affect their reputation and future business. During these inspections, The Flexon Group Inc. was already contracted to address every non-compliant item that was identified on the Corrective Action Plan and consulted with each compliance officer from various departments within the NJDEP to satisfy their state requirements resulting in an EPA compliance certificate for their Paterson, NJ manufacturing facility. Fabricator 

May/June 2008

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.


Join onlin online ne a at: t: w

Join NOMMA Today!

To join online:

Introducing NOMMA’s Newest Member Benefit:

Enhanced Member Locator

Potential clients can now find NOMMA members in their area just by entering their address.

Let local customers come to you via the NOMMA website

Homeowners, contractors, and architects can now quickly find a NOMMA member in their area by using our new Enhanced Member Locator. Unlike other systems that rely on ZIP Codes, the NOMMA Locator uses latitude and longitude for greater accuracy. Members are invited to enhance their listing by providing a logo, company description, and photos of their work.

Increase your company’s exposure by enhancing your listing on the NOMMA Member Locator. If you are a member, we encourage you to send the following items:

 Digital logo  200-Word Company Description  Up to 5 Images of Your Work  Up to 5 Keywords (see choices below)

Please send material to: To see the system, visit: and click on “Member Locator” The goal is for the new locator to be well known throughout the construction industry and become a place where owners, contractors, designers, and architects can quickly find a local fabricator.

Keywords: Choose up to five from the choices below.

Work Type: Residential, Commercial, Industrial, Restoration, Forging/Blacksmithing.

Products: Art/Sculpture, Doors, Fencing, Furniture & Accessories, Gates, Driveway, Gates, Walkway, Miscellaneous, Architectural, Miscellaneous, Industrial, Railings/Guards, Stair Systems, Structural.

Nonferrous: Aluminum, Brass/Bronze, Copper, Stainless Steel.

National Ornamental & Miscellaneous Metals Association 1535 Pennsylvania Ave. McDonough, GA 30253 (888) 516-8585 • Fax (770) 288-2006

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

NEF Auction A Big Success! The grand finale of NOMMA’s 50th anniversary convention was the silent and live auctions, which took place during the Saturday theme dinner On the last night of METALfab 2008, attendees took part

in the annual NEF silent and live auctions, which raised $23,446 for the foundation! Items featured in the auction included tools, equipment from suppliers, and beautiful sculpture. Serving as auctioneers for the evening were Carl Grainger and Roger Carlsen, who both did a great job of keeping the auction lively and fun.

A special thanks goes to everyone who helped make the auction a success, including the volunteers, donors, and buyers. Proceeds from the auction help support the educational and research work of the NOMMA Education Foundation.

Members of the auction team prepare for the silent auction. RIGHT: Inspecting items in the silent auction. BOTTOM LEFT: Mark Koenke displays a sculpture. BOTTOM RIGHT: Roger Carlsen auctions off an item. LEFT:

NEF Wishes To Thank Two Outstanding Donors

The trustees of the NOMMA Education Foundation would like to thank two outstanding supplier members who have made generous commitments to the foundation:  King Architectural Metals has pledged $5,000 a year for three years to support the programs of the NOMMA Education Foundation.  The Wagner Companies has pledged an annual scholarship of $5,000. The Wagner Promise Scholarship Fund is to help promising individuals who want to work in the metals trade and participate in the future of our industry.

For your information

May/June 2008  Fabricator

Contact: NOMMA / NEF 1535 Pennsylvania Ave. McDonough, GA 30253 Ph: (888) 516-8585 Fax: (770) 288-2006 Web: Email:

METALfab 2009 Date & Location: Join us for NOMMA’s 51st annual convention and trade show. The event takes place April 21–25, 2009 in Long Beach, CA. Details for the next convention are available online. Visit:


New NOMMA members As of April 18, 2008. Asterisk denotes returning members.

Abarca’s Metal Design Denham Springs, LA Raul Abarca, Fabricator Architectural Metalworks Inc. Boise, ID Garry Tolley, Fabricator C.T. and S. Inc. Irving, TX Bruce Witter, Fabricator Campbell’s Ornamental Ironworks Inc.* Chattanooga, TN Melvin Campbell, Fabricator Capitol City Iron Works Inc.* Indianapolis, IN Kip Gootee, Fabricator Covering the Bases Nashville, TN Keith Herndon, Fabricator DeVols LLC Lebanon, IN Alice Devol, Fabricator Equus Metals Inc. Tulsa, OK Timothy Morris, Fabricator Integrity Ironworks Inc. Sayreville, NJ Jim Zagata, Fabricator Iron World Laurel, MD Dan Mongello, Nationwide Supplier MDI Solutions Inc. DeBary, FL Jeffrey D. Meyer, Fabricator

NOMMA Nationwide Supplier Members A Cut Above Distributing (800) 444-2999 Albina Pipe Bending Co. Inc. (503) 692-6010 Allen Architectural Metals Inc. (800) 204-3858 Alloy Casting Co. Inc. (972) 286-2368 American Punch Co. (216) 731-4501 American Stair Corp. (800) 872-7824 Ameristar Fence Products (918) 835-0898 Apollo Gate Operators (210) 545-2900 Architectural Iron Designs Inc. (908) 757-2323 Argent Ornamental Iron & Steel (678) 377-6788 Atlas Metal Sales (800) 662-0143 Auciello Iron Works Inc. (978) 568-8382 Bavarian Iron Works Co. (800) 522-4766 Big Blu Hammer Mfg. (828) 437-5348 Julius Blum & Co. Inc. (800) 526-6293 Builders Fence Co. Inc. (800) 767-0367 Byan Systems Inc. (800) 223-2926 The Cable Connection (800) 851-2961 Carell Corp. (251) 937-0948 Carl Stahl DecorCable Innovations (800) 444-6271 Classic Iron Supply (800) 367-2639 Cleveland Steel Tool Co. (800) 446-4402 CML USA Inc. (563) 391-7700 Colorado Waterjet Co. (866) 532-5404 CompLex Industries Inc. (901) 547-1198 Crescent City Iron Supply Inc. (800) 535-9842 Custom Orn. Iron Works Ltd. (866) 464-4766 D & D Technologies (USA) Inc. (714) 677-1300 D.J.A. Imports Ltd. (718) 324-6871 DAC Industries Inc. (616) 235-0140 Decorative Iron (888) 380-9278

DKS, DoorKing Systems (800) 826-7493 Robert J. Donaldson Co. (856) 629-2737 Eagle Bending Machines Inc. (251) 937-0947 Eastern Metal Supply (800) 343-8154 Eastern Ornamental Supply Inc. (800) 590-7111 Elegant Aluminum Products Inc. (800) 546-3362 Elite Architectural Metal Supply LLC (847) 636-1233 Encon Electronics (800) 782-5598 Euro Forgings Inc. (905) 265-1093 EURO-FER SRL. (011) 39-044-544-0033 FabCad Inc. (800) 255-9032 FabTrol Systems Inc. (541) 485-4719 Feeney Architectural Products, CableRail™ (800) 888-2418 The G-S Co. (410) 284-9549 Geo. Bezdan Sales Ltd. (604) 299-5264 Gerhard Glaser GmbH & Co. (011) 49-607-893-7137 Glasswerks LA Inc. (323) 789-7800 GTO Inc. (800) 543-4283 Hartford Standard Co. Inc. (270) 298-3227 Hayn Enterprises LLC (860) 257-0680 Hebo/Stratford Gate Systems Inc. (503) 722-7700 Hendrick Mfg., Perforated Metals Div. (570) 282-1010 House of Forgings (281) 443-4848 Illinois Engineered Products Inc. (312) 850-3710 Indiana Gratings Inc. (800) 634-1988 Industrial Coverage Corp. (631) 736-7500 Industrial Metal Supply Co. (818) 729-3333 Industry Ornamental Iron Inc. (800) 915-6011 Innovative Hinge Products Inc. (817) 598-4846 Interstate Mfg. Associates Inc. (800) 667-9101 The Iron Shop (800) 523-7427

NOMMA Nationwide Supplier Members Iron World (301) 776-7448 ITW Industrial Finishing (630) 237-5169 ITW Ransburg (419) 470-2000 Jansen Ornamental Supply Co. Inc. (800) 4-JANSEN Justin R.P.G. Corp. (310) 532-3441 King Architectural Metals (800) 542-2379 Laser Precision Cutting (828) 658-0644 C.R. Laurence Co. Inc. (800) 421-6144 Lavi Industries (800) 624-6225 Lawler Foundry Corp. (800) 624-9512 Lewis Brass & Copper Co. Inc. (718) 894-1442 Liberty Brass Turning Co. (718) 784-2911 Logical Decisions Inc. (800) 676-5537 Mac Metals Inc. (800) 631-9510 Marks U.S.A. (631) 225-5400 Master Halco (714) 385-0091 McKey Perforating (262) 786-2700 Mittler Bros. Machine & Tool (800) 467-2464 Frank Morrow Co. (401) 941-3900 Multi Sales Inc. (800) 421-3575 Mylen Stairs Inc. (914) 739-8486 NC Tool Co. (336) 674-5654 New Metals Inc. (956) 729-1184 Ohio Gratings Inc. (330) 477-6707 Overseas Supply Inc. (281) 776-9885 Paxton & Thau Artistic Supply (205) 290-2790 Precision Glass Bending Corp. (800) 543-8796 Premium Home & Garden Co. Ltd. Xiamen (011) 86-592-588-7573 Procounsel (214) 741-3014 RedPup LLC (928) 422-1000 Regency Railings Inc. (214) 742-9408

Riata Mfg. (915) 533-9929 Robertson Grating Products Inc. (877) 638-6365 Robinson Iron Corp. (800) 824-2157 Rockite, Div. of Hartline Products Co. Inc. (216) 291-2303 Rogers Mfg. Inc. (940) 325-7806 Royal Forge Pte Ltd (011) 656-235-9893 L.E. Sauer Machine Co. (636) 225-5358 Scotchman Industries Inc. (605) 859-2542 Sculpt Nouveau (760) 432-8242 SECO South (888) 535-SECO Sharpe Products (800) 879-4418 Stairways Inc. (713) 680-3110 Steel Masters Inc. (602) 243-5245 Stephens Pipe & Steel LLC (800) 451-2612 Striker Tool Co. (USA) Inc. (866) 290-1263 Sumter Coatings Inc. (888) 471-3400 Taco Metals (800) 743-3803 Taurin Group USA (909) 476-8007 Tennessee Fabricating Co. (901) 725-1548 Texas Metal Industries (972) 427-9999 Transpacific Industrial Supply Inc. (909) 581-3058 Triple-S Chemical Products (800) 862-5958 Tri-State Shearing & Bending (718) 485-2200 TS Distributors Inc. (832) 467-5400 Universal Entry Systems Inc. (800) 837-4283 Vogel Tool & Die, Div. of TES Tube Equipment Inc. (630) 562-1400 The Wagner Companies (888) 243-6914 Wasatch Steel Inc. (888) 496-4463 Michael Wentworth Architectural Metalwork (925) 216-1004 West Tennessee Ornamental Door (901) 346-0662 Wrought Iron Concepts Inc. (877) 370-8000

New NOMMA members continued . . . MJ Snyder Ironworks* Marshall, IL Mark Snyder, Fabricator Paradise Ironworks & Construction* College Park, MD Ron Brown, Fabricator Premium Home & Garden Co. Ltd. Xiamen Xiamen, PR, China Alice Li, Nationwide Supplier Progressive Building Supply LLC Middlefield, OH Mark Pollari, Fabricator Salt Lake Valley Forge Lehi, UT Paul L. Venema, Fabricator San Gabriel Ornamental Leander, TX Charles V. Cate, Fabricator Security Iron Co.* New Orleans, LA William Winterfield, Fabricator Southwest Steel Henderson, NV Thomas R Collins, Fabricator Spirit Ironworks Bayport, NY Rachel Miller, Fabricator Towable Utility Gear LLC Dublin, GA Jeff Wells, Fabricator

What’s Hot

Apollo Gate Operators announces partnership

Inside Biz Briefs . . . . . . . . . . .84 People . . . . . . . . . . . . .85 Chapter News . . . . . . .86 Literature . . . . . . . . . . .88

Biz Briefs

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

CRL acquires Sommer & Maca Industries Los Angeles-based C.R. Laurence Co. Inc. (CRL), a supplier to the glazing, architectural, construction, industrial, and automotive industries, announces the acquisition of Sommer & Maca Industries (Somaca). Somaca also supplies the stone industry, and CRL will continue to carry the products for the stone and granite industries. Donald E. Friese, CRL’s Chairman and CEO, said, “With more than 40,000 products now available from CRL, and the expanded product lines this acquisition brings, we feel that all our customers and the industry as a whole will benefit greatly. We want to earn the respect and confidence of our new Somaca customers, and to thank our existing customers for the support that made this acquisition possible.” Contact: CRL, Ph: (800) 421-6144; Web:

OGI expands by adding Texas bar grating facility

Apollo Gate Operators Inc., headquartered in San Antonio, TX, has announced a partnership has been reached with Nice SpA, with headquarters in Oderzo, Italy. Apollo Gate Operators Inc. will be a subsidiary of Nice USA. Frank Felicella, formerly CEO and chairman of Apollo Gate, will become CEO of Apollo Gate Operators Inc. “The partnership with Nice brings additional liquidity, design, engineering, and a worldwide market to Apollo Gate,” said Felicella. “This combination of technology will allow both companies the distribution that is key to growth in the Americas. The recognition of the niche for Apollo Gate in the United States for its product quality in 12 volt and solar, customer service, and distribution will be an important asset to Nice.” Nice SpA will own the majority of the company. Apollo Gate operations will remain and increase its headquarters size in the San Antonio market. Contact: Apollo Gate Operators Inc., Ph: (800) 226-0178; Web:

AWS cautions about unauthorized translations The American Welding Society (AWS) issued a caution about the use of unauthorized translations of AWS standards and other AWS publications in Chinese, Spanish, and other languages. Because AWS has not sanctioned these translations, AWS cannot attest to their accuracy. Users of AWS standards should be aware that serious technical errors may exist in unauthorized translated material. Currently, AWS has authorized only the translation of AWS D1.1/D1.1M:2004 and 2006 Structural Welding Code – Steel into Japanese. Contact: AWS, Ph: (800) 443-9353; Web:

Rising steel prices help fuel soaring construction costs

Ohio Gratings Inc. (OGI) headquartered in Canton, OH, is expanding by opening a new 31,000 sq. ft. facility, OGiHouston, in Houston, TX. OGI offers various bar grating applications, custom fabrication, engineering support, budget estimate projects, and shop drawings. Contact: OGI, Ph: (888) 321-9800; Web: 84

“Red-hot steel prices, combined with record diesel fuel costs, are making construction unaffordable,” Ken Simonson, Chief Economist for The Associated General Contractors of America (AGC), recently stated. Simonson was commenting on the producer price indexes (PPIs) for March reported by the Bureau of Labor Statistics (BLS). “Unfortunately, there is worse to come,” Simonson asserted. “Steel suppliers have been burning up the fax wires announcing huge price increases and canceling previous quotes. Simonson warned that public agencies as well as private owners need to adjust to these realities. For more information, log on to ppi for the March PPI tables. Fabricator 

May/June 2008

What’ s Hot


Flaherty honored by AHS

Bocchi resigns

NOMMA member Francis X. Flaherty is one of 13 outstanding members of the horticultural community who will be honored by the American Horticultural Society (AHS) during its Great American Gardeners Awards Ceremony and Banquet on June 6, 2008. Flaherty is this year’s recipient Francis Flaherty of the AHS’s Meritorious Service Award, which recognizes a past Board member or friend of the American Horticultural Society for outstanding service in support of the Society’s goals, mission, and activities. Flaherty owns and operates Flaherty Iron Works in Alexandria, VA. In 2004, Flaherty assisted the AHS in the restoration of a set of 19th-century White House gates that were discovered at the AHS’s River Farm headquarters. The restored gates were featured at the 2005 Philadelphia Flower Show, after which Flaherty Iron Works installed the gates at River Farm. Additionally, Flaherty hand-forged a unique metal design piece for the AHS’s Green Garage® exhibit, which is being displayed around the United States, and he continues to provide quality craftsmanship and support to the AHS.

After more than 24 years of dedicated service to The Powder Coating Institute (PCI) and the coatings industry, Greg Bocchi resigned from the position of Executive Director, effective April 30th. Bocchi has accepted the position of President of The Vinyl Institute in Arlington, VA. The Vinyl Institute represents manufacturers of vinyl resin and vinyl systems additives. Contact: PCI, Ph: (800) 988-COAT; Web: www.powder

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Novaro joins GTO Jon Luis Novaro joins GTO Inc. as Florida and Ohio territory sales manager, representing the GTO access systems commercial and residential line. He will be responsible for sales, distribution, dealer development, marketing, and other sales related activities for GTO’s comJon Novaro plete line of residential, commercial, and industrial lines of retail and professional gate operators and accessories in those two states. Contact: GTO/PRO, Ph: (800) 543-GATE; Web:

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What’s Hot

Chapter News

Northeast Chapter hosts CAD demonstration The Northeast Chapter enjoyed a special CAD demonstration at their April 26 meeting. Presenting the program was Dave Filippi of FabCad Inc., who gave a program titled, “Using CAD as a Sales & Management Tool.” During the program Dave showed how a CAD system can improve sales, work quality, and cashflow. Over 20 people attended the event, which was hosted by Majka Railing Co. in Paterson, NJ. During the business portion of the meeting, it was announced that elections will take place at the next chapter

meeting. The group also discussed plans to create an item for the next NEF auction. In addition, members agreed to continue their President Keith Majka leads the business session during the Northeast Chapter’s well-attended April meeting. presence at the Ironworks in Bayport (Long Island), spring AIA conference. NY. The chapter wishes to thank memThe chapter’s next meeting takes bers of the former New York Chapter place May 17 at Artistic Iron Works for making a donation to the NorthLLC in Norwalk, CT. Following that, east Chapter treasury. the group will meet June 28 at Spirit

Gulf Coast attendees enjoy white metal casting demonstration Members of the Gulf Coast NOMMA Network were treated to a casting demo during their May 10 meeting at Northshore Steel Fab in Slidell, LA. Leading the main demo was Roger Carlsen of Ephraim Forge Inc. The presentation served as a pilot

for the new NEF Education Resource Program. The idea of the new program is to provide turnkey and traveling demonstrations that can be presented at various chapter meetings. In addition to the main event, there was a program on anodizing. Members

New England School of Metalwork 2 0 0 8 S u m m e r S e s s io n Lucian Avery—Door Hardware Dereck Glaser—Traditional Joinery Caleb Kullman—Fireplace Accessories Clay Spencer—Tire Hammer Building M a r l a S t e l k— C o p p e r W e a t h e r V a n e s Don Fogg— Japanese Bladesmithing Bob Alexander—Forged Flowers John Rais—New Forms in Steel Peter Ross—18 Cen. Tool Forging Bob Jordan—Beginners Blacksmithing Muh Tsyr Yee—Japanese Laminated Cutlery Jonathan Nedbor—Proficient Forging Techniques Josh Dow and Lauren Holmgren—Cast Iron Sculpture Wendell Broussard and Doug Wilson—Leaf and Scrollwork (Two Special team taught classes)

Summer Workshop Registration is now Open!! 1-888-753-7502 86

were also treated to a display of welding equipment and consumables, which were provided by a local supplier. The group’s last meeting took place in October at the Drapery Makery and Canvas Workshop in Fairhope, AL.


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Fabricator  May/June 2008

What’s Hot

Chapter News

Upper Midwest Chapter focuses on galvanizing The Upper Midwest Chapter featured presentations on hot dip galvanizing and exposed architectural steel at their May 10 meeting, which took place at Germantown Iron & Steel in Jackson, WI. Germantown Iron and Dean Derge Ornamental Ironworks in Kewaskum, WI served as hosts for the event. In the evening, the chapter held its annual evening social at The Safe House in downtown Milwaukee, which featured an evening of magic, music, and fun. In other news, the chapter still has some of their “retro” bowling shirts available, which commemorate NOMMA’s 50th anniversary. These were worn by chapter members at METALfab, during the Saturday theme dinner. To obtain Members of the Upper Midwest Chapter were well represented at METALfab 2008. During the Saturday night theme dinner members a shirt, contact wore a special commemorative shirt that recognized NOMMA’s 50th Heidi Bischmann anniversary. UMWC Shirts (414-214-8383, Still Available The Upper Midwest Chapter The chapter typically meets three times a year in May, September, and December. still has some commemorative Meetings are held at the shops or businesses of NOMMA members in Illinois, Wiscon50th anniversary bowling sin, Indiana, Michigan, Missouri, and Iowa. The chapter is currently looking for a shop shirts. You can order them dito host their September meeting. If you are interested, please contact Tina Tennikait or rect by contacting Heidi BisHeidi Bischmann. chmann (hbischmann@ For more information on the chapter, contact Tina Tennikait (618-259-4184,, You can also obtain information by visiting the Upper Midwest 8383. Chapter website:

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1-800-423-4494 May/June 2008  Fabricator 87

What’ s Hot Updated full-line fastener products catalog

Jergens Inc. introduces the latest edition of its full-line Specialty Fasteners Catalog for its Kwik-Lok™ pins, SpinnerGrip™ flange lock nuts, spring-loaded devices, threaded inserts, and threaded components and washers. New products in this year’s edition include: alloy steel pull dowels in spiral groove, flat vent, and standard round (un-vented) versions; fine threaded spring plungers; Kwik-Lok lifting pins, and more. Contact: Jergens Inc., Ph: (800) 537-4367; Web: 3rd edition of Strategic Planning for Contractors

FMI’s 3rd edition of Strategic Planning for Contractors: The Guide to Superior Management Performance is now available to readers in the building and construction industry. Written by Hank Harris, president and managing director of FMI, the 209-page guide covers a variety of business management topics. It provides examples of strategic plan-


Literature ning models, real case summaries, and a Sample Situational Analysis Checklist. Contact: Candace Robertson at FMI Corp., Ph: (919) 785-9359, Web: Line card highlights power products and services

Staco Energy Products Co.’s new full-color brochure details Staco’s power products and services. In addition to voltage regulators and harmonic filters, the company provides uninterruptible power supplies in both single and three phase configurations suitable for aerospace, manufacturing, testing, and other industries. Contact: Staco Energy Products Company, Ph: (888) 2611191; Web: 2008 Products DVD

CML USA Inc. presents a new informational 2008 Products DVD that gives you a front row seat to view Ercolina’s® innovative mandrel and non-mandrel rotary draw benders and angle rolls capable of bending a wide variety of material and profiles. CML USA Inc. inventories a wide variety of Ercolina® tube and pipe benders and tooling for round or square tube. Contact: CML USA Inc. Ercolina; Ph: (563) 391-7700; Web:


May/June 2008

Whatâ&#x20AC;&#x2122; s Hot

Education AWS launches online welding school locator

The American Welding Societyâ&#x20AC;&#x2122;s (AWS) online, searchable database lists nearly 3,500 U.S. and international welding schools and is designed to boost recruitment industrywide to help relieve the shortage of welders. AWS estimates a shortage of at least 200,000 skilled welders by 2010. The welding school locator is available free to students, parents, teachers, and others in the welding community. Many schools featured on the website list specific welding program information, such as class capacity, internship availability, career paths, number of classroom shifts, and types of qualifications received at completion. Contact: AWS, Ph: (800) 443-9353; Web: FMA Foundation Scholarships

The Fabricators & Manufacturers Association (FMA) Foundation is accepting scholarship applications for trade school-bound high school seniors who seek careers in manufacturing. These applications are accepted at any time during the year and are determined on a quarterly basis. To be eligible, applicants must be full-time students with a minimum 2.0 GPA, enrolled in an engineering or manufacturing-related course of study, or a trade or technical program that may lead to a career in manufacturing. Students will be responsible for submitting academic records and an engineering or manufacturing-related program description with each application. Trade school scholarships up to $2,000 per school year

May/June 2008 


require membership. Students may apply for membership at the time of scholarship application. Contact: FMA Foundation, Ph: (815) 381-1338; Web: Lincoln supports AWS welder shortage campaign

The Lincoln Electric Company will donate $300,000 to the AWS Foundation to help relieve a nationwide shortage of welders. Lincoln will donate the funds over a two-year period beginning in 2008. Lincoln will also contribute marketing support and partner with AWS to produce a promotional welding career video to be used online, in classrooms and throughout industry. The video will feature several well-known personalities who have sponsorship agreements with Lincoln. Contact: AWS, Ph: (800) 443-9353; Web: SNAG raises $20K at conference

The Society of North American Goldsmiths (SNAG), the association of jewelers, designers, and metalsmiths, raised $20,032 to promote SNAG scholarships and educational programming at its recent annual conference. SNAG grants educational endowment scholarships to undergraduate and graduate students, sponsors annual conference scholarships, and features ongoing educational programming. Contact: SNAG, Ph: (541) 345-5689; Web:


What’ s Hot


New England School of Metalwork Summer Workshops May – August 2008 The New England School of Metalwork features classes in door hardware, traditional joinery, copper weather vanes, Japanese bladesmithing, 18th century tool forging, and other techniques for various skill levels. Contact: The New England School of Metalwork, Ph: (888) 753-7502; Web:

Atlantic Coast Blacksmiths Conference Olivebridge, NY, September 4-7, 2008 This conference, held at The Ashokan Center in the foothills of hte Catskills, features forging demos by internationally recognized blacksmiths, a gallery show of ironwork, lectures, workshops, teaching station, trade show, tailgate sales, and open forge time. Contact: Tim Neu, Ph: (845) 657-8333; Web:

The Philadelphia Buyers Market of American Craft Summer Show

Upcoming Events

Philadelphia, PA, August 2-4, 2008

NFPA’s World Safety Conference & Exposition

The biannual, wholesale-only tradeshow of handcrafts made by American and Canadian artists, will be held at the Pennsylvania Convention Center in Philadelphia, PA. The show attracts thousands of retail gift shops, museum stores, and galleries that sell handcrafted jewelry, glass art, furniture, ceramics, and art made from recycled goods, and more. Contact: American Craft, Ph: (800) 432-7238, ext. 211; Web:


June 2-5, 2008 This annual expo will be held in Las Vegas, NV, featuring education sessions, new products and services. 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:

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May/June 2008

What’ s Hot

New Products

2008 products DVD

CML CML USA Inc.’s 2008 products DVD highlights Ercolina’s® mandrel and nonmandrel rotary draw benders and angle rolls that bend a variety of material and profiles. Ercolina® products are marketed through a network of local distributors and representatives. Contact: CML USA Inc. Ercolina, Ph: (563) 391-7700; Web: Circular cold saw

Scotchman® Scotchman® Industries presents the CPO 350 Circular Cold Saw. This machine features a double clamping and self-centering vise that provides burr-free,

volume parts. The product has 135° mitering ability and a miter-locking device that automatically stops at 45° left, 90º straight, and 45° right, giving it the ability to slot and notch. Additional machine features include a double reduction gearbox and a twospeed motor. Contact: Scotchman Industries, Ph: (800) 843-8844; Web: Legacy Series air-cooled TIG torch

Weldcraft Weldcraft’s new LS17 Legacy Series TIG torch features remote fingertip amperage control and is rated at 150 amps DC and 125 amps AC, both at 60% duty cycle. The LS17 air-cooled torch includes an interchangeable fingertip switch that can be replaced without any tools and a flexible knuckle joint at the base of the torch handle. The torch is available

Air boa pipe sander

CS Unitec The LRP 1503 air boa pipe sander from CS Unitec polishes hand rails, pipe, and tubing. It has a 1HP motor, with 20 CFM air consumption at 90 PSI and is lightweight. The sanding arm snakes up to 270° around the radius of the pipe. The operator rotates the boa slightly to achieve a 360° finish. An additional side handle can be rotated 180° in narrow spaces such as handrails that are fixed close to walls. Contact: CS Unitec, Ph: (800) 7005919; Web:



with a 121/2 or 25-ft. single-piece rubber cable assembly. Contact: Weldcraft, Ph: (800) 7527620; Web:

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" 1-3/8"

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800-426-7818 • May/June 2008 



What’ s Hot CD-ROM addresses die design and troubleshooting

PMA Precision Metalforming Association’s (PMA) MetalForming Magazine presents Metal Stamping by Design, a CDROM focusing on tooling issues that concern metal stampers, tool-maintenance personnel, tool designers, and builders. More than 50 articles from former MetalForming columnist and tooling expert Larry Crainich cover tooling, from basic die design to troubleshooting forming problems. Topics include die components, burrs, stampings, design, and tips to help stamping-tool users succeed. Contact: MetalForming Magazine, Ph: (216) 901-8800, ext. 127; Web:

New Products New line of hardmilling endmills

SST Consumables SST Consumables has released a new line of hardmilling end mills from PokolmVoha, the Future Generation Tool (FGT) line. This line features ball nose, corner radius, and Toric end mills with corner radius geometry, a radius tolerance of +/- 0.005 microns, and a shank-recess system for transition curves between the shank and cutting edge. The tools are made of ultra-micrograin carbide, designed to hardmill materials up to 58 HRc. Contact: SST Consumables, Ph: (248) 232-6260; Web: Extended reach safety air guns

Guardair Guardair Corp. introduces the new Lazer Series Safety Air Guns in extended reach versions ranging from

6” to 72”. The safety guns feature aircraft aluminum extension with an OSHA compliant venturi nozzle, lightweight power, and comfort-grip design. Contact: Guardair, Ph: (800) 4827324; Web: Online quotes for transaction windows and security hardware

CRL CRL has expanded the company’s Web Quote Request Information Center to include transaction window and security hardware quotations. Customers can request a quotation for projects by entering the job specifications online. Users can also e-mail or fax drawings and/or specifications. Contact: CRL, Ph: (800) 421-6144; Web:


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


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May/June 2008

What’ s Hot

New Products

Toggle clamps and flange locking bolt

Jergens Featuring common sizes for heavy or light workloads, Jergens’ toggle clamps fit a variety of applications. The clamps have mounting hole patterns and toggle action and there is no minimum quantity requirements on stock items. Jergens’ standard clamp line includes horizontal and vertical hold-down, pull action, squeeze-action, flush mount, and heavy-duty toggle clamp products. A range of replacement pieces and accessories is also available. Jergens also introduces the customized Spinner-Grip™ Flange Locking Bolt with a conical flange design that

locks the bolt to the part without the need for a lock washer. Spinner-Grip bolts do not have serrations that will mar the surface or plating of parts. In addition, the Spinner-Grip Locking Bolt can be uninstalled and reused without reapplication of locking patches or additional hardware. Bolts can be customized for harsh environmental conditions or various applications. Contact: Jergens Inc., Ph: (800) 537-4367; Web: “MIG Welding Made Easy” DVD

Miller Electric Miller Electric Mfg. Co.’s new DVD is designed to teach entry-level hobbyists MIG welding skills and help more advanced welders improve their skills. Featuring developer and metalworking expert Ron Covell, this 70-min. instructional program covers the basic processes used for successful MIG welding such as proper machine setup, joint preparation, wire selection, gun angles, travel speed, what to check

MARKS USA • 631-225-5400 • 800-526-0233 • FAX: 631-225-6136 • May/June 2008 


when things go wrong, and an introduction to plasma cutting. Contact: Miller, Ph: (800)4-AMILLER; Web: Ergonomic rolling carts

IAC IAC Industries introduces a new color line up for its Dimension 4 Rolling Carts family for moving raw materials, manufacturing supplies, and finished products. These rolling carts and storage carts complement Dimension 4 Workstations and are constructed of D4 aluminum extrusion uprights, a welded tubular frame, support beams, and a 11/4” laminated work surface with “T” mold edges, and radiused corners. Carts are available in standard and ESD laminates. Contact: IAC Industries, Ph: (714) 990-8997; Web: www.iacindustries. com.



What’ s Hot Waterjet cutting system, Bypump 50 APC, and compact material handling system

Bystronic Bystronic Inc. introduces the Byjet L, an abrasive waterjet cutting system suitable 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. All models include two abrasive waterjet cutting heads with automatic head spacing, height sensing, and collision protection on each cutting head. Optional third and fourth cutting heads are available. A CAD/CAM software package is included. Bystronic’s Bypump 50 APC intensifier pump cuts quickly with a dual cylinder intensifier design. With CNC control for each of the cylinders, Bypump 50 APC is able to maintain a constant pressure without the need for a large pressure accumulator and outputs 1.3 gallons per minute of water. The product allows one- or two-head cutting. Bystronic’s ByTrans compact material handling system expands user operations up to three shifts. Loading and unloading takes sixty seconds and its cycle time, which is independent of the thickness of the metal sheet, increases


New Products overall throughput. The ByTrans has a compact 15’ x 10’ inline footprint and handles sheet thickness up to one-inch plate. ByTrans integrates into any ByVision controlled machine. Contact: Bystronic Inc., Ph: (631) 231-1212; Web: Updated S56 and V33i for hardmilling 50+ HRc

Makino The Makino S56 vertical machining center has been upgraded and features Makino’s Pro5 control with SGI.4, a dual spiral chip set, and other features for heavy-duty cutting and continuous operation. The newly added Makino Pro5 retains the same features as the previous control software with updated graphical interface, configurable 12inch touch screen monitor, and a ‘floating’ function for access to key information. Makino’s V33i is a hardmilling vertical machining center suitable for surface finishing and long hours of continuous, unattended operation. The V33i features a stiffer, shorter spindle to operate vibration free over a range of spindle RPMs to reduce chatter and improve surface finish and tool life. Contact: Makino, Ph: (800) 552-3288; Web:


May/June 2008

What’ s Hot

New Products

UniStar P Single-Phase UPS

Staco Staco Energy Products Co. introduces the UniStar P series single-phase online Uninterruptible Power Supply (UPS) which features protection over an input voltage range. This double-conversion UPS is available in 6, 8, and 10-kVA models, to protect from outages and irregularities in incoming line voltages from 160 to 280 VA at 45 – 65 Hz. Contact: Staco Energy Products Company, Ph: (888) 2611191; Web: Sol-gel technology

HALOX® HALOX® releases its first sol-gel technology, HALOX® 550. This liquid inorganic-organic hybrid is suitable for replacing hexavalent chromium in coatings as well as in metal pretreatments. HALOX® 550 provides corrosion protection in thin film coatings (< 25 microns): waterborne and solvent-borne finishes, gloss DTM, conventional primers, acrylic clear coats,

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fast drying lacquers, wash primers, anti-fingerprint, and conversion coatings. HALOX® 550 forms a clear network and a non-porous, hydrophobic, dense barrier at the metal surface for anti-corrosive protection or to maintain high gloss coatings. Contact: HALOX®, Ph: (219) 933-1560; Web: Press brake and laser cutting center

CI The MAXFORM hydraulic press brake from Cincinnati Inc. combines forming speeds and part processing with PC-based programming. MAXFORM uses industrial PC-based touch screen control, Windows® software, hydraulics, and control technologies to deliver speeds up to 700 ipm. Simulation software enables offline part programming with “see and do” 3D graphics. Providing laser cutting for a range of flat stock applications, the Cincinnati CL-850 laser cutting center handles thick and thin material with a 5000W GE Fanuc laser resonator, cutting head, optics, and linear-motor-drive system. Contact: Cincinnati Incorporated, Ph: (513) 367-7100; Web:


To request a free catalog or register for a class, or call 1.800.FOLK.SCH



Blacksmithing (Beginning to Advanced)

Bladesmithing Traditional Blacksmithing photo by Paul Garrett

Toolmaking Design Process & many more!

May/June 2008 


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Classifieds Estimator/Project mgr. wanted


Collins & Hermann has an available opening for the following position: Estimator/Project Manager (Kansas City, MO location) is to develop new business clients, schedule and manage multiple steel fabrication projects, estimate cost to completion of management, oversee progress of projects through quality control inspections and documentation; while interacting professionally with staff and clients in this highly competitive field. Required Skills: • Individuals must have 3-5 years of experience in steel fabrication (including installation). • Strong knowledge in AutoCad and Fabtrol. • A proven track record in estimating. • Ability to travel to project sites. • Capability to work independently, as well as part of a team. • Good oral and written communication skills. • Excellent time management, strategic planning, and forecasting skills. • Qualified applicants must have excellent computer software knowledge including: Microsoft Excel, Word, Outlook, Timberline software, or other equivalent software programs. Collins & Hermann Inc. offers comprehensive benefits to include medical, dental, optical, life insurance, LTD, optional 401k, and profit-sharing. Relocation will be considered. Collins and Hermann Inc. is an equal opportunity employer and strong supporter of workplace diversity. EOE. Please fax resumes to (314) 868-4982 or email:

Employment nationwide in structural/miscellaneous steel fabrication. ProCounsel is in communication with over 3,000 structural/ miscellaneous and ornamental steel fabricators. We can market your skills (estimator, project manager, detailer, shop manager) to the city or state of your choice without identifying you. Employer pays fee. The right location, the right job, at the right money. ProCounsel: Buzz Taylor. Call toll free (800) 545-5900, or (214) 741-3014. Fax: (214) 741-3019.

NOMMA Forums

In addition to the Career Center, you’ll find a wealth of other resources in the NOMMA Forums, including our free Buy/Sell/Trade section and discussion areas for AutoCAD and Welding. To access this area visit and click on “Career Center & Forums.” 96

Help wanted

AutoCAD Drafter, Estimator, Field Measurer, Project Manager & Shop Supervisor. Railing fabricator specializing in aluminum, stainless, and glass railings in central New Jersey looking to expand and grow. Company is 22 years old, with 45 employees in 30,000 sq. ft. facility in Middlesex County, NJ. Architectural metal, miscellaneous iron or storefront experience helpful. We will reimburse relocation expenses and offer excellent pay commensurate with experience and or responsibilities. Full benefits including medical, dental, life, and disability insurance as well as a 401k match, profit sharing and bonuses. Fax resume and salary to (732) 332-1924 or email to Sales agent/reps wanted

Sumter Coatings is seeking independent sales agents/representatives

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

East Coast shop looking for quality stair and rail builders to fabricate misc. metal and small structural steel jobs. We will furnish shop drawings. Please send pictures or web site info. Contact John at Craft Metals. Fax: (215) 2813014. Please try us. Metal fabricator wanter

Five years experience: mig & tig, blueprints, installation, work independently & teamwork. Solve creative situations for stair railings & furniture. Website: Salary commensurate with experience. Submit resumes: NO PHONE CALLS PLEASE! Classified ad rates & information

Classified ads promote a one-time sale or offer or employment-related opportunities. Rates are as follows: 1–35 words = $65 ($50 member) 36–50 words = $90 ($75 member) 51–70 words = $115 ($100 member) 71-100 word = $145 ($130 member) Next classified deadline: Jun. 6

Need an employee right away?

If time is of the essence, consider posting your “help wanted” ad online by using the NOMMA Career Center. A free service to the industry, this is a great way to advertise your job posting. There are also sections for “Seeking Employment” and “Buy/Sell /Trade.” To access this area, visit and click on “Career Center.” Fabricator  May/June 2008

Advertiser’s index A thanks to the following advertisers for their support of O&MM Fabricator magazine ... Pg. 95 21 11 4 27 90 19 89 13 95 36 14 61 94 29 77 69 31 33 70 39 52 61 78 36 35 45 41 64 68 67 91 7 49 44 100 47 26 87 85

Company ............................................................................Website Apollo Gate Architectural Iron Architectural Iron Architectural Iron Designs Atlas Metal Sales Big Blu Hammer Mfg. Blacksmiths Depot Julius Blum & Co. Inc. John C. Campbell Folk COMEQ Inc. The Cable Connection Carell Classic Iron Supply Cleveland Steel Tool Colorado Waterjet Co. CompLex Industries Inc. D & D Technologies (USA) Inc. D.J.A. Imports DAC Industries Inc. DKS, DoorKing Systems Decorative Iron Eagle Bending Machines Eberl Iron Works Encon Electronics FAAC International FabCAD Inc. Feeney Architectural The G-S Co. Hawke Industries ......................................................(909) 928-9453 Hebo - Stratford Gate Hougen Mfg. Hypertherm Inc. Industry Ornamental Iron International Gate The Iron Shop Iron Work Gallery Ironwood LLC/Brian Russell Jansen Ornamental Jesco Industries Inc.

65 99 92 23 2 74 91 93 79 77 15 86 26 86 51 85 16 3 68 63 90 10 57 55 73 64 59 44 53 60 72 89 25 75 92 32 88 88 9 46 42

KAS Direct Building King Architectural Metals Laser Precision Cutting Lawler Foundry Lewis Brass & Copper Co. Liberty Brass Turning Lindblade Metal Works Marks U.S.A. Membership Ad Mittler Bros. Machine & Multi Sales Inc. NC Tool Company National Bronze & Metals Inc. N.E. School Metal P & J Mfg. Co. ..............................................................(419) 227-8742 Pat Mooney Inc. Paxton & Thou Artistic Supply Paxton & Thou Artistic Supply Peters Valley Craft Education Center Production Machinery R & D Hydraulics Mfg. & Machine Red Pup Regency Railings Salter Industries Sharpe Simsolve........................................................................(909) 737-2480 Stairways Steptoe & Wife Antiques Ltd. Striker Tool Co. (USA) Inc. Sumter Coatings Sur-Fin Chemical Corp. TS Distributors Inc. Texas Metal Industries Tiger Stop LLC Traditional Building Tri-State Shearing & Bending..................................(718) 485-2200 Universal Entry Systems Inc. ..................................(800) 837-4283 Vogel Tool & Die Corp. The Wagner Companies Weaver's Iron Works YAC Equipment &

Companies in bold are first-time advertisers.

Advertise in NOMMA’s annual Buyer’s Guide Note: Closing Date for the 2009 NOMMA Buyer’s Guide is August 30, 2008

Advertise in the July/August 2008 O&MM Fabricator! The July/August issue of Fabricator will focus on computer technology. In addition, we will have our ever-popular regular features including job profiles, shop talks, tips & tactics, front office articles, and more. Don’t miss out! To place an ad, contact Todd Daniel (, 888-516-8585, ext. 102).

Deadline: May 30, 2008 May/June 2008  Fabricator

(Sep/Oct deadline: Jul. 25)

Want your company’s name listed in the Buyer’s Guide? Call Todd Daniel at NOMMA. Ph: (888) 5168585, ext. 102. Check out our online Buyer’s Guide to find detailed listings of supplier products. Visit: and click on “Buyer’s Guide.”

Getting Duplicates? No Longer Wish To Receive Fabricator? Please help us reduce waste by reporting unneeded issues. To remove an issue from our list, simply fax the mailing label to: (770) 288-2006. Or, send an email to: You may also send a drop request by visiting the “Fabricator” area of the NOMMA website. 97

Metal Moment

Adapt and overcome: A shop owner’s credo  Sometimes it takes

a little old-fashioned ingenuity to create “optimal efficiency.” LEFT: Rollers on wheels can be moved out of the way easily.

By Tom McDonough Master Metal Services Inc. There are very few shops with so much

space that they are set up to operate at optimal efficiency. Optimal efficiency as in perfect work flow, ample space for the workers, room for material storage and forklift traffic. Well, I don’t have one of those shops. When I started Master Metal I was in an 800 sq. ft. shop; I quickly expanded to the bays on either side of my shop, increasing my floor space to 2.400 square feet. “What was I going to do with all that space?” I wondered. A year later, I bought out an existing sheet metal company with a total of 6,000 square feet of shop space and 1,000 square feet of office space. I thought I’d died and gone to heaven… until I combined my equipment with theirs. Suddenly, I realized I could have used a few more thousand square feet. I had to find a place for a new saw I’d just purchased, and the only logical place was close to my bay door. This happened to be where we stored all of 98

move it side to side with v-groove gate our sheet material and where the forkwheels — so, we can adjust the roller lift constantly comes in and out. We all system to any position. He also made put our heads together, and I felt we attachment brackets to support angles came up with a great solution. when sheared. When we are not using We modified the sheet rack so that the ironworker, we push the roller up the saw material would fit on the lower against the rack out of the way to give sections of the rack. Then, we cut the us more floor space. rollers into sections so that the middle In this industry, we are like the was open and the fork lift could pick Marines. We adapt ... and we overup material in the center. However, come. there still was a problem — the back roller was interfering with the fork lift Tom McDonough is Vice President of traffic. To solve that, we ended up putMaster Metal Services Inc. in Fort ting the rollers on wheels so they could Lauderdale, FL. be moved out of the way when necessary. After driving sleeves into the slab, we secured the rollers in place with cane bolts. When I bought out the sheet metal company, the owner had an ironworker with the coolest roller system. This particular ironworker has multiple heights, which makes it hard to feed the material into it. The previous owner had made a roller system that could When the ironworker is not in use, the roller is raise and lower with a hydraulic pushed up against the rack, out of the way, to piston. He also made tracks to provide more floor space.


May/June 2008





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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

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“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 05 fab  
2008 05 fab