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Ornamental and Miscellaneous Metal


The official publication of the National Ornamental & Miscellaneous Metals Association

July/August 2009 $6.00 US

Get quick answers with the NOMMA ListServ, page 12

Job Profile

See entries from the 2009 Top Job contest page 44 Shop Talk

Choosing the right plasma cutter, page 19

Member Talk

Lay off results in a new venture, page 24

Biz Side

Leave your competitors in the dust, page 54

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July/August 2009 Vol. 50, No. 4

Crafted from scrap materials, this fence features coyotes and other wildlife, page 34.

Tips & Tactics

Job Profiles

NOMMA ListServ . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Learn about another great benefit of membership.

Longtime shoer of horses winds Top Job gold .........................34 One man’s scrap is another man’s treasure.

Leave your competitors in the dust . . . . . . . . . . . . . . . . . . . . . . . . . 54 Win the race by providing outstanding service to your customers.

By Pete Hildebrandt

By William J. Lynott

Fabricating a public restroom ............................39 A NOMMA firm fabricates Portland’s new public toilet.

Learn how to handle feedback . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Don’t be offended by negative feedback, instead, learn from it!

Shop Talk Architects get a ‘hands on’ education at a NOMMA shop . . . . . . . . . . . . . . . . . . 14 Architecture students receive a firsthand education on our trade.

Biz Side

By Greg Madden

By James Minter Jr.

Selecting the best plasma cutter for your shop . . . . . . . . . . . . . 19 For best results, it’s important to select a unit that’s the correct size and type. By Leon Drake

Member Talk A life challenge leads to a successful fabrication business A fabricator goes from sheet metal work to crafting highend designs. By Sheila Phinazee

What is your business worth? . . . . . . . . . . . . . . . . . 60 Don’t be offended by negative feedback. Instead, learn from it! By Lisa Bakewell

What’s Hot! The prototype “Portland Loo.”

PressLock fence proves an ideal solution ..............................41 Fencing system is ideal for both perimeter area and playground. Top Job Gallery .........................................................44 A sampling of entries from the 2009 Top Job competition. By Todd Daniel

Supplier Members . . . . . . . . . . . . . . . 70 Biz Briefs . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Events . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Chapters . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Products . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 Advertiser’s Index . . . . . . . . . . . . . . . 81

President’s Letter . . . . . . . 6 Director’s Letter . . . . . . . . . 8 Reader’s Letters . . . . . . . 10 Metal Moment . . . . . . . . . 82 Exciting changes Transition time Top Job award is featued in Plug into the resources of the ahead. at NOMMA. local newspaper. Metal Museum. Cover photo: These stunning gates at forged from Monel 400. They were darkened with Birchwood Casey M-21 and waxed. Approximate labor time was 400 hours. Fabricator: Wonderland Products Inc., Jacksonville, FL.

President’s Letter

Exciting changes ahead! Dedicated to the success of our members and industry. NOMMA OFFICERS President Bob Foust III Bob’s Ornamental Iron Studio Kansas City, KS

Vice President/ Treasurer James Minter, Jr. Imagine Ironworks Brookhaven, MS

President-Elect Bruce Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA

Immediate Past President Terry Barrett Royal Iron Creations West Palm Beach, FL

FABRICATOR DIRECTORS Frank Finelli Finelli Architectural Ironworks 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

Ray Michael R & F Metals Inc. Clinton, MD

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 Ltd. Brooklyn, NY

NOMMA STAFF Interim Executive Director John L. Fiegel, CAE Meetings & Exposition Manager Martha Pennington

Communications Mgr. J. Todd Daniel Administrative Assistant Liz Johnson

2009 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

Abraham Lincoln once said something

to this effect: “I’ll halt to a point of view just until someone shows me the value of another point of view.” During our week in Long Beach and just about every day since, your NOMMA staff and Board have spoken with exhibitors, past presidents, new and long-time fabricator members — and the one overwhelming “point of view” is that we must not eliminate our yearly convention and trade show. We understand that — more than ever — value is of great importance. That’s why I am pleased to announce that METALfab 2010 will be held in Tulsa, OK, for the first time in NOMMA history. Well, you asked for it, and now you have it. Multi-tier education! Hands-on training! Plenty of shop tours! As soon as the details are finalized, you will begin to see what’s in store for METALfab 2010. Recently, I spent two days in Tulsa, and was amazed and surprised — amazed at what Tulsa has to offer, and surprised to see that this mid-sized metropolis has a vibrant small town feel with big entertainment and many attractions. (Don’t let this get back to Kansas City, but the barbecue was excellent!) Why have we never been to Tulsa before? Doug Bracken and I visited with shop tour candidates and met with potential new exhibitors, and the reaction to what NOMMA is bringing to Tulsa next March was thrilling. Making METALfab 2010 more educational — with more products to view — and more affordable for everyone is at the heart of this plan. These improvements reflect our commitment to turning that philosophy into meaningful benefits for you and your shop. We were confronted with information that suggested there is a better path forward. We are at the beginning of a blueprint for an ambitious agenda, not just for 2009 and not just for future METALfabs, but also for the future of

NOMMA. Now, let me give you a quick Strategic Plan update. In late June, your NOMMA Board will meet in Atlanta for our board and strategic planning meeting. This is a critical time in the strategic plan process and that is why your immediate past president, Terry Barrett, will continue leading the strategic planning charge. Terry and the board will remain focused during the next few months on exeBob Foust III is prescuting this plan ident of NOMMA. and paving the way towards an updated NOMMA. In my previous letter, I asked for your help. Many of you have called to give ideas, all of them good. And that made me think how special this really is. I am getting advice from people in my industry, most of whom have been doing this a lot longer than I, and have experienced all of the same pains. This is a real resource that, for the most part, is untapped. As you come to decide your own level of NOMMA involvement, let me just repeat something Breck Nelson (Kelley Ornamental) said: “Once you get involved with NOMMA, you will get much more back than you could ever give.” NOMMA is vested in changing the future of your shops, and this is where it becomes easy for your Board and staff to become very committed and extremely focused on our partnership. In closing, for a little over two years, we have been hearing politicians using the word “change,” to the point that it has become tiresome with less meaning. Unfortunately, I must spout that same word, but please understand that we think the ability to change is critical to leadership. We can change. In the coming months, you will begin to see changes. Your NOMMA board is listening. Fabricator  July/August 2009

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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

Editorial - We love articles!

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

Advertise - Reach 8,500 fabricators

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

Membership - Join NOMMA!

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.


Classifieds may be placed on the NOMMA website at no charge. Visit and click on “Career Center.”

Exhibit in METALfab

Exhibit in METALfab, NOMMA’s annual convention and trade show. For more information, contact Martha Pennington at (888) 516-8585, ext. 104, or


Subscription questions? Call (888) 516-8585. Send subscription address changes to: Fabricator Subscriptions,1535 Pennsylvania Ave., McDonough, GA 30253. Fax: (770) 2882006, or E-mail:

1-year: U.S., Canada, Mexico — $30; 2-year: U.S., Canada, Mexico — $50; 1-year: all other countries — $44; 2-year: all other countries — $78.

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

Buyer’s Guide

Published each December as a separate issue. Deadline for all advertising materials is October 31. For info, contact Todd Daniel at (888) 516-8585 or


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

Opinions expressed in Fabricator are not necessarily those of the editors or NOMMA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA. Circulation: 8,500.


How to reach us

Executive Director’s Letter

Transition time at NOMMA As many readers recently learned, your

editor, Helen Kelley, and long-serving executive director, Barbara Cook, have left the organization. Todd Daniel, NOMMA communications manager, is reprising his role as editor. And I became interim executive director on June 25, 2009, following Barbara’s dismissal by a vote of the board of directors. The NOMMA board of directors has engaged Transition Management Consulting to assist it during this challenging period of change and transition for the organization. This time doesn't have to be stressful and rushed. By using a professional interim executive, NOMMA has the advantage of assessing the organization — what is working well, not working well, and what can be improved or changed. The interim provides a set of fresh eyes and an independence that only an outsider can. Executive transitions are an opportunity for organizational assessment and renewal, not simply as a crisis requiring an immediate solution or search. The hallmark of TMC’s executive transition services is its ability to integrate effective high-level association management skills with change management. The breadth of experience of its founders and consultants is unparalleled in the association field. Our work as professional interim executives is to prepare the organization for its next executive, so she or he can hit the ground running and take full advantage of the honeymoon phase. I have served as an association management leader for over 20 years following a 22-year military career, 15 of which were in the Pentagon with specialties in international affairs, planning, programming, and budgeting. I have provided interim executive leadership to a number of organizations in transition, including the Society for

Competitive Intelligence Professionals and Destination ImagiNation. Since 1988, I have served as executive director in over 15 professional societies, foundations, and trade associations, often simultaneously within association management companies, among them the Association for Unmanned Vehicle Systems, Society of Environmental John L. Fiegel, CAE Toxicology and is interim executive Chemistry, Inter- director of NOMMA. national District Energy Association, and World Airline Entertainment Association. I earned the Certified Association Executive (CAE) designation from the American Society of Association Executives in 1991 and have recertified every three years since. I hold a Masters of Science in International Affairs from Troy State University’s program in Germany and a Bachelors of Arts in Management from Texas A&M University. Over the next several weeks I hope to visit member firms to learn more about the industry as the staff and I assess an array of opportunities NOMMA has to continue to serve its members going forward.

Fabricator  July/August 2009

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Letters are welcomed and encouraged. Send to: Mail: Letters to the Editor, c/o Fabricator, 1535 Pennsylvania Ave., McDonough, GA 30253. E-mail: Fax: (770) 288-2006.

Reader’s Letters Award receives mention in the press We can’t thank you all enough for the incredible amount of planning, and hard work that you did for METALfab 2009. We came back exhausted, I’m sure you all were barely alive by the end of that week. We learned a lot and exchanged some good information with fellow members. I also want to thank you for the press release that was sent out to publicize our award. The release was featured two different times in our local newspaper. ~ Brandi Crumpler Gulf Coast Metal Works Inc. Cape Coral, FL Are handouts available from METALfab? Members of our staff attended METALfab 2009 and were impressed by the presentations given by Cynthia Paul. Would it be possible to obtain a copy of the handouts that were used during her classes? ~ Jay Flom Feeney Inc. Oakland, CA Editor’s Note: You’re in luck. The handouts from Cynthia Paul are posted on the NOMMA website. To download them, go to “METALfab” and then click on “Education.”

ADA grab bar placement The NOMMA office has received several inquiries about the placement of ADA grab bars in bathroom stalls. This information is available in the ADAAG guidelines (, in section 4.17.6. The following are the requirements for the rear and side grab bars:  Rear Grab Bar - The grab bar on the back wall shall be 36 inches minimum in length, extending from the wall toward the open side of the water closet, 33-36 inches above the finish floor (see Fig. 30c).  Side Grab Bar - The side grab bar shall be 40-42 inches in length, beginning 12 inches maximum from the rear wall, 33-36 inches above the finish floor (see Fig. 30d). Diagrams are available from the Access Board website, and the guidelines may also be downloaded and viewed from your PC.

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Fabricator  July/August 2009

NOMMA’s online support area offers goodies for all Have a question on a certain pare your work and how to provide topic? Often you will find the answer good instructions for the anodizer. on the NOMMA website. To access  Resource Guide: This is our our technical resources, go to continually growing list of schools, and click on “Suprelated associations, and for-profit port.” Here is a sampling of our popcompanies that provide free reular features: sources on their websites. To find on Joint Finish Guidelines: These line information that’s relevant to our guidelines are now regularly specified industry, we’ve made things easy by by specifiers and architects. You can providing links under the various oreither view them online or download ganization listings. For instance, go You can find answers to many common questhem. to the listing for Door & Access Systions in the “Support” area of the NOMMA  Metal Rail Manual: Last pub- website. tems Manufacturers Association and lished in 1986, this publication is click on “More Info.” You will then currently being revised, but much of the engineering data see links to 26 technical bulletins. is still useful. You can download either the entire manual  Literature Guide: This resource was born in 1997 or just the sections you need. when Ed Mack and Lloyd Hughes led an education session  Working With Bronze Cap Rail: Likely, the all-time on literature resources. The handout from the class was in most asked question is “How do I form a bronze or brass great demand, and eventually we put it online. Since that cap rail?” Download an excellent article on this topic. time we’ve continually improved and expanded the online  Anodizing Your Aluminum: You’ve never had to guide. The various books in the guide cover art, history, anodize a job before, so what do you do? Written by a suptechniques, business management, or more. Most of the tiplier, we provide a highly detailed article on how to pretles can be found online by doing a Web search.

July/August 2009  Fabricator


Tips& Tactics 

Member Benefits Contact: Todd Daniel NOMMA 1535 Pennsylvania Ave. McDonough, GA 30253 Ph: (888) 516-8585 Fax: (770) 288-2006 Web:

NOMMA ListServ - A great benefit of membership Since its launch in 2000, the ListServ has become a thriving, online community. If you are a NOMMA member and haven’t subscribed, we encourage you to join us. ommend this simple procedure: • Find someone who has already posted and hit “reply.” • If you are starting a new topic, simply replace the subject line and body text.

By Todd Daniel NOMMA Communications Mgr. Imagine a place where you can get a

quick answer to anything related to our industry. Picture an online world where you can share your triumps and challenges with fellow fabricators. Think of a place that is, well, almost like an online tavarn, filled with your NOMMA member colleagues. Such a place does exist — it’s called the NOMMA ListServ. Okay, so what is a ListServ?

In 2000, NOMMA launched an email discussion list for members. To participate in the ListServ, a subscriber simply sends an email, which is bounced to all other subscribers. Currently, about 25 percent of our membership is subscribed, and we would love to see ALL members subscribed. What do you talk about?

In regards to topic, the only rule is that it must relate to our industry. Both shop and front office issues are fair game. Most conversations on the ListServ fit into four categories: • Where do I find it? • How do I do it? • What is it? • How do I handle a business situation? Discussions on the ListServ cover every corner of our industry. If you follow the ListServ regularly, you will gain a tremendous amount of information. For example, the following are some of the conversations that were taking place in early June: 12

What can I expect?

• Armillary sphere - What is it and where can I find components to build one? • Nickel silver - Can anyone give me pointers? • Presentation photo - Need a photo of a 6-foot high sliding gate to show a client. Can anyone help? • Dry ice blasting - Looking for information. • Silicon bronze - Need a source for odd ball sizes. • Fusion welding - Need a quick education. How do I join?

Any NOMMA member is eligible to subscribe. There is no limit to how many employees may subscribe from one company. To join the list, simply send an email to Liz Johnson at the NOMMA office ( Once subscribed, you will receive two emails. These emails provide instructions on the ListServ commands and rules. Once subscribed, you will immediately begin to receive messages. If you’d like to post a question, we rec-

Right away, you’ll start receiving a lot of email. But don’t worry, the system has a daily limit on the number and length of posts that are sent out. Most email programs allow you to create a “rule” to better manage your email. For instance, you can make a rule to send all ListServ messages to a separate folder, or make them a certain color. If you prefer, we can set your subscription to “digest mode,” which means you only get one daily post that contains all the messages for the day. Participation is not necessary, but encouraged. If you can answer someone’s question, by all means, jump right in! Community

After a while, you’ll get to know many of your fellow subscribers, and you’ll start feeling at home in your online community. The relationships you create on the ListServ can carry over into the real world, and you may find a new fabricating partner, someone to subcontract work to, or even someone to exchange referrals with. ListServ Benefits

In addition to exchanging information, a lot of networking takes place on the ListServ. Some examples include: • A member needs another member to install a job in a distant location. Fabricator  July/August 2009

• For geographic and other reasons, a member may hand off a job to another shop. • A fabricator may not be able to find something stock, and can often find a fellow member who can produce the parts. In addition, any work request received by the NOMMA office is posted to the list, as well as other announcements and NOMMA news.

• Always identify yourself by name and company. • If you are starting a new topic, make sure you change the subject line. This not only makes the ListServ easier to follow, but it also helps with archiving. Common troubleshooting

The most common technical problem we see on the list is that a person is posting under a different email list. Your email is the only way the system knows you are a subscriber, so if you don’t use the same address, the system will reject your post.

ListServ Archives

One of the greatest benefits of the ListServ is that we now have nine years of discussions stored in the NOMMA Archives. This is a nice resource and is great for pulling up a past discussion. Instructions for using the archives are at the bottom of every post. Some helpful tips

A few tips can make your ListServ experience more enjoyable and useful for you and your fellow subscribers. Here are a few basic guidelines: • Take the time to read the instruction email that you receive. This email

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At the NOMMA convention in Long Beach, NEF trustee Roger Carlsen led an excellent and thorough presentation on the ListServ.

covers the rules, NOMMA’s code of ethics, antitrust laws, and netiquette. • The most important rule is to respect antitrust laws. To play it safe, and just for good taste, we ask that you never post any specific dollar figures on the list. However, you may use percentages in your question.



Safety & Security

Your email address is kept completely secure in the ListServ system and is not given or sold to others. All outgoing emails are scanned for viruses and other threats. The company we use, L-Soft International Inc., is the original ListServ provider and has been in business for 20 years. We are confident that the service is safe and secure for our members.

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Shop Talk

Architects get a ‘hands on’ education at a NOMMA shop architecture students visit Imagine Ironworks/B & O Machine and Welding to receive a first-hand education on the metalworking trade.

skills used in the building trades and construction industry, as well as some “old world” skills seldom employed nowadays. Not all of the fifth-year students could make the trip. “At this time of the year, there are only three weeks of school left in the semester — and four weeks of school projects still to finish,” explained Professor Callender. By James Minter Jr. While in the shop, the students got to try Imagine Ironworks their hand at cutting steel plate with a cutting torch, and MIG and TIG welding. Some of When opportunity knocks, open the door! them had welded before, and were anxious to And when it is a chance to entertain and edushow off for their classmates. Before begincate a group of architecture students about ning, all were briefed about safe work habits, metalworking, invite that opportunity in for a and the need to wear protective equipment. visit! “This is the first time I’ve ever cut metal That’s what happened recently, as Imagine with a tool,” said student Whitney Grant. “It Ironworks/B & O Machine and Welding in kind of feels like cutting butter with a hot Brookhaven, MS, entertained 16 knife.” fifth-year architecture students Of course, the art and skill of Consider from the Mississippi State Univerornamental metalworking goes hosting sity School of Architecture. The back much further than do welding architecture students spent an afternoon in machines and cutting torches. An students at Brookhaven learning about metaloverview of the art and artistry of your shop! Sponsoring a tour working, and also touring the ornamental ironwork was prefor a local university downtown area. sented, from grill panels from 12th helps architectural Professor Jassen Callender, century cathedrals, through restudents head of the School of Architecsplendent 18th century palace understand what ture’s fifth-year program in Jackgates, the work of 20th century arthey are specifying, son, MS, was delighted with the tisans Samuel Yellen, Antoni plus it’s great public offer to bring some of his students Gaudi, and Edgar Brandt, and on relations for our on a field trip. It offered them a to today’s metal artists. Although industry chance to experience some of the Tom Joyce and Albert Paley would



For your information

■ Fifth-year

What? A NOMMA member shop opens its doors to a group of architecture students James Minter and their professor. Where? Hosting the event was James Minter Jr. and the staff at Imagine Ironworks/B & O Machine and Welding in Brookhaven, MS. In addition to the tour, students also toured downtown Brookhaven. CO NTAC T

James W. Minter, Jr. Imagine Ironworks 1380 Highway 51, P.O. Box 533 Brookhaven, MS 396020533 Ph: (601) 833-3000 Fax: (601) 833-3580 E-mail: Web:

The tour group poses in front of the shop. Adam Haver working on a scroll.

Fabricator  July/August 2009

LEFT: Rachel Davis (assisted by Chuck Plaisance) setting a rivet. BOTTOM LEFT: Whitney Grant (assisted by James Schenk) cuts with a torch. RIGHT: Students get the chance to practice TIG welding.

Photos courtesy of James Minter Jr.




















Offering the only



probably be amused, the soon-to-be architects tried their hand at forging tapers, bending scrolls, and even some pre-welding assembly techniques, such as riveting, banding, and mortise and tenon joinery. Some of the other shop equipment was demonstrated, as steel plate was cut in the shear and then bent in the press brake. Those students who experienced and struggled with the cutting torch appreciated the ease with which a powerful hydraulic shear can slice through ¼” thick steel plate in seconds. The original idea for the field trip came from Jackson, MS architect Richard McNeel. When he was a student, a well-known window manufacturer hosted his class for a visit to their facility. The visit made such an impression on him that, for many years afterward, he specified their windows on Why buy from various companies when almost every job because they were the Encon offers all the products you need? window company he knew. Richard reaDial ONE number: 800-782-5598. soned that by entertaining and educating the architecture students of today, our shop can establish itself as either a reference source for metalworking, or better yet, the vendor of choice on many future projects.

technical team in the industry.

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The students were invited to draw upon metalworkers as resources for their practices. A story was told to them about a very unwieldy and impractical canopy, which was specified and drawn as ½” thick stainless steel plate, with the only support coming from ½” round suspension rods and a small angle secured by 3/8” anchors mounted to the face of a cast stone veneer. The 800 lb. weight of the stainless steel plate, plus undersized mounting arrangements, could make for a very dangerous overhead architectural feature. The group was told that, yes, the awning could be built as drawn, but the architect who designed it would have served his client better had he sought advice on fabrication and installation from a Fabricator  July/August 2009

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reputable and competent metalworker. After wrapping up the shop activities, the group toured downtown area. Brookhaven is the home of the Mississippi School of the Arts, a two-year residential arts-based high school (one of the current students, Jasmine Murray, made it to the top 13 on this season’s “American Idol”). One of the first graduates of the School of Architecture at Mississippi State, architect Larry Albert of Hattiesburg, MS, had the lead in designing the campus, along with its nine-story dormitory and the adjacent

Downtown developer Terry Pappas demonstrating the handoperated elevator in the renovated warehouse. RIGHT:

Student Life Center. Mr. Albert faced numerous challenges while trying to integrate old historic buildings with new state-of-the-art buildings on the campus of an abandoned women’s college. His answer to the contextual massing challenge provided by the site was appreciated by the group. Revitalizing Downtown

Downtown Brookhaven is seeing an influx of residents, as long-empty second floor areas have been converted to living spaces. The students toured two such recently renovated downtown buildings that now house businesses on the street level, and apartments on the second level. One building, a former mercantile warehouse, had been vacant for many years, and many wondered what could be done with the space. Now its two apartments are highly coveted. Terry Pappas, the developer of the former warehouse, proudly showed off the building and its focal point, a lovingly restored and operable hand-operated freight elevator in the building’s common area. With the rise of “green” architecture, what could be much greener than saving and restoring existing buildings? All of us who planned and put on the demonstrations and tour deemed it a success, and we enjoyed opening up our shop to the future architects. But how did we do in the eyes of the professor? We passed! While we didn’t get a letter grade, at the conclusion of the afternoon events, Professor Callender set up a tour for next year’s class. Mr. Minter is a trustee of the NOMMA Education Foundation and vice president/treasurer of NOMMA. 18

Fabricator  July/August 2009

Shop Talk

Selecting the best plasma cutter for your shop For best results, choose the plasma cutter that is the correct size and type for your needs.

By Leon Drake Dynatorch Inc.

More is better, right? Well, no — at

least, not as often as you would think. A larger plasma cutter costs more up front and more to operate, and may give poorer results. Select a unit based on your most common need, not the maximum you may one day need for one job. Start by using the most common material type and thickness you cut as a guide. You may never cut 1” material, so do not assume that you need that capacity at all times. Plasma systems are divided into two types: Air and mixed gases (also called mechanized). Air plasma systems generally use hand or machine torches and most have a contact start. These systems do

A sampling of plasma cutters includes (CLOCKWISE): Hypertherm Powermax 1000, Kalburn Spirit 275, and the Thermal Dynamics Cutmaster 83.

not generate high frequency at start and use only compressed air as the plasma gas. They generally are sized by amp ratings and run 40, 60, 80, 100, and possibly 120 amps. Cutting capacity is dependent largely on amperage. You can usually buy these with both torches as an option to allow use on a CNC machine and then quickly switch to the hand torch for manual cutting. Most consumables for these are interchangeable. Mixed gas systems allow using oxygen, air, nitrogen and special mixed gases. These are larger systems with amperages of 130 and up, and can cut faster and thicker materials. They are

always three-phase powered and only offer machine torches for CNC systems. They generally use high frequency pilot arc start and require CNC systems to be shielded to avoid damage or erratic operation. Be advised that hand torches are rated for much thicker materials than machine torches. On the same unit, you will see different capacities, such as recommended, maximum, severance, and machine torch (pierce). What does all this mean? “Recommended” is what you should plan on

For your information

major plasma system types are air and mixed gas. Determine what system best meets the needs of your shop.

What happens if my plasma system is too big? Imagine trying to cut aluminum foil with a blow torch!

Summary: When it comes to plasma cutters, more is not always better. In fact, a larger plasma cutter may actually give less satisfactory results.

Light cutting needs: If you’re only cutting by hand and using single-phase power, then air plama is your best option. The next step is to choose a system based on the thickness you want to cut.

What should I be aware of? You can’t just swap gases on a given unit. For instance, using oxygen on an air plasma unit will quickly eat up the electrode nozzle.

Plasma cutting types: The two July/August 2009  Fabricator


Leon Drake Dynatorch Inc. 3530 Starnes Dr. Paducah, KY 42003 Ph: 877-260-2390 Email: Web:


for a hand torch. “Maximum” is possible, but not a promise. “Severance” assumes an edge start and is going to be a poor cut — but it will cut. The reason these numbers are greater is that you can tilt a hand torch over on its side to start a cut, blowing the material away from the cut. Machine torches must operate pretty much perpendicular to the material (exception is a beveller or torch rotator). Machine torches have to blow straight down through the material (pierce) and will reduce the capacity. If using this on a CNC machine, use the machine torch number as a guide. Usually, you can push a plasma system a bit past its rated capacity, but the cut quality will not be as good and you have to account for piercing or start on the edge. If you are only using the torch as a hand-held operation and will be operating from single-phase power, then air plasma is your choice. Select the unit based on the recommended thickness. Be aware that when running at or near maximum amperages, the duty cycle

will be in the 5060% range. That means that at 50%, you can cut for five minutes and then must stop for five minutes to allow the unit to cool. In machine CNC operations, this can be a huge slowdown factor and should be considered when quoting jobs on a machine or selecting a plasma size. Mixed gas systems

& RIGHT: Samples of artwork made with plasma cutting. TOP

Mixed gas or “mechanized” systems are for use with CNC machines only. They allow the use of different gases from air or oxygen for steel to nitrogen or mixed gases for aluminum or stainless steel, resulting in faster cutting speeds, cleaner dross free cuts, and 100 percent duty cycle. They will require three-phase AC

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power and have closed loop watercooling to keep the torch running full time. These systems cost much more than an air plasma system and are much more complex. The high end of these systems are “Precision” or “High Definition” (Hyp) plasma that will give a fine cut with less bevel on the edge. Generally one gas is used for the plasma and a different gas for the shield. Ratings for capacity on mechanized systems are quite clear and less confusing. Selecting an oversize plasma system is like using a blowtorch on aluminum foil. Cuts will be wide with a lot of dross. Detail is not possible as the larger system cannot be turned down to low amperage and have the cut quality of a smaller unit on thin met20

Fabricator  July/August 2009


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als. It depends on the application and one size does not fit all. Also, keep in mind the material you’re cutting. If cutting primarily aluminum or stainless steel on a CNC, you will be much happier with a mechanized mixed gas type unit. If looking for high speed to cut parts quickly with less dross, get an oxygen capable unit. You cannot simply swap gases on a given unit, either. Consumables have to match the gas. Using oxygen on an air plasma system will quickly eat up the electrode and nozzle. Mixed gas

A Thermal Dynamics machine torch and hand torch.

systems require a change out of the whole consumable set when changing gasses, and are quite specific about

pressure settings. The pressures can be set manually or automatically, depending on the gas console you purchase. Automatic gas consoles are very nice but carry significant additional cost. What will you spend? Air type hand held plasma will start at around $1,200 for a 30-amp unit, reaching $5,200 for a 100-amp unit. Mechanized systems with 130 amps might start at $20,000 and go up quickly as options and amperage increases. Note: “High Definition” or “HyDefinition” are terms trademarked by Hypertherm Inc.

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Member Talk

A life challenge leads to a successful fabrication business ■ Now

creating contemporary ironwork and antique blacksmithing in historic Mt. Airy, MD, Antietam Iron Works began over 20 years ago, growing from union sheet metal work to crafting custom design.

For your information

About: Antietam Iron Works, LLC, a NOMMA member, has provided interior and exterior railings, gates, fences, and architectural designs for more than 20 years. Services: The company offers in-house powder coating and shot blast, featuring unlimited colors and textures. The firm has 20-foot ovens for processing large and small parts.

A railing with a meadow theme. A challenging job in North Virginia.



By Sheila Phinazee NOMMA shop members (Austin) Fred and

Kathleen Gunnell of Antietam Iron Works LLC specialize in interior and exterior railings, fences, gates, and architectural pieces using present-day fabrication for contemporary designs and historic blacksmithing methods for restorations and reproductions. Antietam consists of only six employees, including Fred and Kathleen. “It is a challenge to find creative, skilled workers even though our county has a 15 percent unemployment rate,” says Fred. “But we don’t really need many production welders. Most everything we do is custom.” With a recently acquired facility and new equipment, however, Antietam now takes on more production type jobs like product display racks, and commercial railings. This helps with cash flow and allows Fred and their son, James, to work on more ornate 24

pieces involving blacksmithing. Like many other businesses, Antietam began as a result of one of life’s challenges. Fred was a union sheet metal worker out of Washington, DC. Soon after he married, had his first child, and bought their first home, Fred was laid off. Out of necessity, he began doing various types of miscellaneous jobs and eventually narrowed it down to welding and fabrication of iron railings, gates, and fences. “Here I must give credit to Wally’s Iron Works, in Mt. Airy, MD,” says Fred. “I was making railings in my driveway with a buzz box, and would often go to Wally’s to buy material. They were so generous in sharing information and techniques with me, from laying out railings to punching the holes in my channel.” Fred enjoyed the sounds, and smells, and activity of the iron working going on in Wally’s shop. And he learned a lot. “They were NOMMA members and gave me a Fab-

Other Specialties: The company is proficient in restorations and has restored several historic gates. Memorable quote: “We feel blessed,” says Fred. “In the years we’ve been in business, we’ve never been this busy until now — even in light of the economy.” CO NTAC T

(Austin) Fred and Kathleen Gunnell Antietam Iron Works, LLC 201 Lincoln Way West, Suite 100 McConnellsburg, PA 17233-1304 Ph: (717) 485-5557 Web: www.antietamironworks. com Email: kathleen@

Fabricator  July/August 2009


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Ethan with one of the first railings that he fabricated in the Summer of 2007.

ricator magazine to read,” says Fred. “That opened up a whole world of information to us.” Setting down roots

In 1984, the Gunnells and their two sons moved to Keedysville, a small town near Sharpsburg, MD, where the name Antietam Iron Works was born. During the Civil War, the Antietam Battlefield was the site of the bloodiest one-day battle in American History. In 1989, the Gunnells found the perfect setting for their home and business, a 220-year-old limestone farm house on 13 acres, with a large barn and 3,000 sq. ft. implement shed, which — after renovations — became their shop. “When considering the purchase of the farm, I was concerned about keeping the name Antietam Iron Works. I was so excited to learn that the Antietam Creek flowed right through our property within a few feet of our new shop,” says Kathleen. “It was here in this beautiful historic setting that Fred’s love and talent for black-

Regan handpainting a staircase railing. The customer wanted a rustic look, with rust showing through the finish.

smithing grew.” The Gunnells added a Kuhn Air Hammer to their shop, and worked with coal and propane forges. Fred’s work then evolved to incorporate hand-forged scrollwork and historic details. “We have created railings, gates, and fences for residential and commercial customers in the Pennsylvania, Maryland, DC, and Virginia region, and as far west as Lake Charles, LA,” says Fred. “Our customers have included a cabinet member of the first President Bush, historic restorations in city parks, and historic homes.” Three years ago, the business had come to another crossroads. The Gunnels had to choose either to grow, or continue to turn away work due to the size of the shop and limited equipment. “We chose to expand and purchased a large abandoned warehouse on Main Street in McConnellsburg, PA,” says Kathleen. “We renovated the building in keeping with the historic character of the town, incorporating

antique brick and iron accents.” The front half of the building now houses eight office suites, which the Gunnells rent out to tenants, including the Fulton County Chamber of Commerce and State Senator John Eichelberger. The rear of the building houses Antietam’s 7,000 sq. ft. shop and an addition for the newly-added shot blast and powder coating operation. Antietam has patronized some NOMMA suppliers to help the business grow. “We have added FABCAD and Tracker CNC,” says Fred. “We aren’t using this new technology to the fullest yet; we just haven’t had time to learn all it can do for us.” Other equipment in the shop includes a shot blast machine for prepping material for powder coating and Eagle Bending equipment. “Our blacksmiths use many handmade tools and dies, antique anvils (one from colonial times), a 125-yearold wagon wheel roller, coal and propane forges, a Kuhn air hammer from Centaur Forge, and other equipment,” adds Fred. Family affair

Fred with sons James and Daniel in front of driveway entry gate which includes hand forged roses, vines, scrolls, etc. LEFT:


Recently, Fred discovered that his grandfather had been a blacksmith for 40 years in Beltsville, MD. This was quite a surprise to Fred, since he himself had worked many years in the metalworking business without this knowledge. “You won’t see me shoeing horses like he did, though,” adds Fred. The Gunnells’ three sons and one daughter have grown up with the business. Their sons started out playing in Fabricator  July/August 2009

the shop. As they grew older, they started cutting material, measuring things, and welding, and then gradually began blacksmithing. “Our oldest son, James (26), has become my right hand,” says Fred. “He is an accomplished blacksmith and helps run all aspects of the business. James urged us to enter the top job competition this year at METALfab, and attended the convention in Long Beach along with his new bride, Danelle, and his brother, Daniel (24).” The Gunnells’ youngest son, Ethan, was learning the skills of welding and blacksmithing as well. He was excited to begin working full-time during the summers. However, in October 2007, at age 15, Ethan passed away in a tragic car accident that also claimed the life of a dear friend. “During this time of unbelievable grief, James and Daniel were such a tremendous help in enabling us to carry on the business,” recalls Kathleen, with much gratitude. Although Daniel has recently returned to his career in the Criminal

Justice field, Kathleen has considered future business possibilities for James and Daniel. “We’ve often thought they would do well with their own line in the future,” says Kathleen. “They have made many things on the side as gifts for friends, like wine bottle holders, candle sconces, coffee tables, A new hairpin gate and fence. and fireplace screens. brochures and have done some local But we’re always so busy with big arbuilders’ shows,” says Kathleen. “Use chitectural things—we just need more of the Yellow Pages has been minimal, time.” along with an occasional fall festival or Marketing the business special event ad in the newspaper.” Experience and having a good repThe Gunnells also utilize the Interutation has its advantages as demonnet, where Antietam’s website menstrated by Antietam’s repeat customers. tions assisting businesses in ADA “Being in business as long as we have handicap accessibility requirements. has been the strongest asset,” says Fred. “We can provide railings for the re“That, and word of mouth.” quired handicap ramps to comply with The shop has also tried other marthe code,” says Fred. Often local cusketing strategies. “We’ve made up tomers or contractors are not familiar

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with the requirement, so Antietam employees explain the finer points to them. Although Antietam offers restorations, reproductions, and modern fabricating techniques, Fred acknowledges that blacksmithing is his favorite part of the business. “I love it when a customer gives me the freedom to run with it,” he says. Although they sometimes have to use components to meet a client’s budget, the Gunnells enjoy doing something that is creative without components. “We love hand forging

The staff restored the archway, took it down and brought it back to the shop in pieces, reproduced missing parts, blasted and powder coated the finished product and reinstalled it. RIGHT:

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Fabricator  July/August 2009

and making the scrolls,” says Kathleen. “And we can control the size and shapes,” adds Fred. Restoration, a key portion of Antietam’s business, has also been interesting. They have restored fences and archways around historic cemeteries and homes. “Often, after we have completed a restoration involving reproduction of entire fence sections or gates, old cast iron parts, and missing scrollwork, the customers have commented that they cannot tell the old from the new parts,” says Kathleen. “That’s rewarding.” One very memorable project was a grand staircase that Kathleen and their daughter hand-painted with a rustlooking finish. James oversaw the very challenging installation while Fred was in Honduras on a mission trip doing welding on the roof of an impoverished hospital. New business ventures

After Antietam started powder coating — just a year and a half ago — its powder coating business is starting to pick up. “We feel blessed,” says Fred. “In the years we’ve been in business, we’ve never been this busy until now — even in light of the economy.” The Gunnells decided to offer their own in-house powder coating to save time and money for their own projects — after having to send many projects to a shop 40 miles away — and they can also powder coat for others. “We have 20 ft. ovens and can coat large items like race car frames, patio furniture, etc.,” says Fred. “Our customers love it because we offer unlimited colors and textures with much less maintenance.” Other powder coating jobs include finishing racecar frames, display racks, motorcycle frames, and wheels for cars. “One of our ongoing projects involves fabricating sales display racks incorporating logos cut out on the Tracker then adding them,” Kathleen explains. “This has opened up a lot of new venues.” NOMMA support

The Gunnells have been NOMMA members on and off for 10 years. “We July/August 2009  Fabricator


still haven’t used all of NOMMA’s resources. We’re still just scratching the surface,” says Kathleen. “We need to set aside some time to utilize the ListServ and web connections, etc. I know they would be tremendously helpful.” Fred says, “I’m visual. I love to see the work of other people and the care and time they put into their work. Seeing the incredible skill of NOMMA workers raises the bar for us all.” The Gunnells say NOMMA has helped their business in so many different ways. “It keeps us up to date on code, we learn new products from the advertisers in the magazine, and we have purchased new technology as a result,” Fred notes.

A Piece of Iron Fred sees much correlation between his life’s work and his faith. About 15 years ago he wrote the following: I love to pick up an old, rusty, bent-up Piece of iron, and then give it new life by Cleaning it up, re-shaping it, and forging it into A unique and beautiful piece of work. When thinking of this, I am reminded of What Jesus has done in my life. Before I was saved, I was bent up, rusted and dirty. He has taken me through the fire Purified my heart, cleaned me up, Straightened me out, and given me new life! Even now, though, I still get banged up and rusty. That is why I need His mercy and forgiveness daily. I also know that He continues to take me Through the fire daily, shaping and forming Me into the servant that He wants me to be. Without his shaping and forming, what are we?

Fred hand-forges a part for a gate.

By Austin F. Gunnell III Antietam Iron Works

Constructing a walk-through gate for brick wall in customer’s garden. 32

Fabricator  July/August 2009

Job Profile

Longtime shoer of horses wins Top Job gold A lone cowboy is one of the many features created for a rural gated community.

 Scrap materials were skillfully incorporated into an artistic fence. The project netted Darling’s Blacksmithing a gold award in the 2009 Top Job contest.

For your information

By Pete Hildebrandt It’s not every day you get asked to make junk. At his shop in the hills outside of Fresno, CA, Reuel Darling took on the task of making a variety of pieces for a “junk gate and fence” in a gated community. The project won him a gold award in the Exterior Railings and Fencing category of NOMMA’s 2009 Top Job competition. According to Darling, it all began when two young people from Los Angeles welded some things they’d found in a junkyard onto the fence. Over time, the fence boasted airplanes, motorcycle riders, and all sorts of things crafted out of junk. But then, people started stealing things off the fence, such as the spiders from the spider web, the flowers, a horn player, and lots of other interesting adornments. “The thefts became easier due to the availability of battery-operated saws to remove them,” says Darling. “Before that, people would just bend the pieces back and forth a number of times until they broke right off. They hadn’t been welded on very well in the first place.” The thefts increased — other things stolen from the development included fireplace 34

screens, handrails, drawer pulls, and doorknobs. Residents of the gated community decided that the stolen fence items should be replaced, and that’s where Darling entered the picture. He ended up replacing many of the stolen decorations. His source of material — and inspiration for his work — was junk. Fortunately, junk was readily available. “We have a big junk pile onsite at our shop,” explains Darling. “It’s grown through the addition of pieces we’ve found over the years and put in the back of our truck to bring back here.” Fence features whimsical creations

For the gate and fence, Darling crafted a cowboy playing a guitar, snakes, coyotes, quail, and anything else that came to mind. His son-in-law, Kevin, makes small dogs, which he cuts out and sells as silhouettes. The two put some of those dogs (a little Dachshund and a Chihuahua) on the gate. Big fiveto six-inch pipe became snakes, complete with rattles that wiggled back and forth. Darling’s wife, Jodi, didn’t think it would be too big a hit with the homeowners to place mean-looking snakes on a fence gate. She suggested that they be made to look less threatening — so the snakes’ heads now have

Project: A fence addition made completely of scrap materials, and featuring various animal designs. Unique feature: Because of past problems with vandalism and scavaging, the cowboy was secured with anchors driven about 4” into the rock. Challenge: Making the horseshoes look like a human form. Designer: Fabricator. Safety Challenge: During installation it was necessary to have a water truck on standby in case of an accidental fire. CO NTAC T

Darling's Blacksmithing 30248 Watt Valley Rd. Tollhouse, CA 93667 Phone: (559) 855-2929 Primary Contact: Mr. Reuel Darling

Fabricator  July/August 2009




This fence section contains an amazing variety of scrap parts.

July/August 2009  Fabricator

©Fox Vance Photography, Reno, NV

a more cartoonish look. One intriguing section of the fence features a piece in which — using laser cuts —twisted bars became an arch crafted into a “Kilroy Was Here” face in the gate. Another piece of the gate and fence featured some multi-sided lamps with slit glass down the sides and layered tops that Darling’s crew managed to transform into flowers. In addition, Darling made some bows for the gate. Using extra “ribbon” left over from another blacksmithing job, he “tied” up the funny-looking flowers. Replacements for the spider web, which had been vandalized, were constructed. More spiders were made and rebuilt back into the spider web. Vandals had also stolen the “driver” and third wheel of a tractor built out of a variety of gears and old wheelbarrow wheels that had been on the fence. That missing wheel was rebuilt and a little horseshoe driver was crafted and placed back on the tractor. One of the new pieces Darling’s Blacksmithing created was a guitar-strumming cowboy made of horseshoes. Darling’s son-in-law cut the top and bottom of the musical instrument from the pattern of a real guitar, and then installed welding rod strings on it. The cowboy was welded onto some pins that were already in place on an adjacent rock, but had broken off to some degree. More heavy pieces of metal were welded down to the rock and under it, in an effort to make it much more difficult for vandals to remove the cowboy. Darling is already working on a complementary piece for the cowboy. “We’re now building a fiddle player to go on the other side of the gate opposite the cowboy playing the guitar,” says Darling. “He’ll go on another rock. We got part of his legs and the fiddle made but it will be another month or so before we get him on the gate.” Since the residential development where the fence resides is called Quail Oak, Darling also constructed a flock of cut-out quail, which were welded on the gate, to reflect the name. All of the new and replacement features were painstakingly attached to the fence and gate. “We’ve tried to weld the items onto the fence much better than the originals were,” says Darling. “Back when the symbols were first placed on the fence, they were tacked on pretty lightly

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Two coyotes sing along to the cowboy’s music.

and a lot of them were simply falling down anyway.” Fire and water

The job posed some special challenges. When work started on the fence and gates, the land where the project was located was green. As work progressed, dry grass had to be cut back with a weed eater and raked back so that welding could be done safely on the gate and fence, without setting the surrounding area on fire. Darling also got help from someone he works with — a horseshoer who owns a water tank that he uses to haul water to his horses. The horseshoer’s truck, its tank, and the pump on it were brought in as a backup “fire truck,” in case welding sparks might have escaped during work on the gate project. From horses to blacksmithing

Growing up, Darling’s dream was to be a horse jockey, but he grew a bit too

The fence is full of small, whimsical details.

big for that career — so he ended up as a horseshoer, horse trainer, and horseshoeing trainer. Darling began shoeing horses as a way to make a living, later becoming well-known as a farrier for Arabians, Morgans and Tennessee Walking horses in the Fresno area. He would sometimes travel as far as San Diego for his work. A local school eventually asked Darling to teach a vocational education horseshoeing class, which allowed him to stay much closer to home. He took care of his shoeing business in the mornings and taught the horseshoeing school in the afternoons for about 10 years or so. When Darling built a fireplace screen for a friend of a fellow horseshoer — crafting grapes on the screen that looked real enough to eat — other people noticed the work and decided they wanted such a screen too, but with a different kind of grape. Work on the first project occurred while Darling was still shoeing horses. But

after the grape screen, demand for his blacksmithing work took off. Next, a customer wanted a gazebo made for the middle of his flower shop, with his name written on it in his own handwriting. That customer, in turn, got Darling more customers. Darling has helped out a great deal with the American Farrier’s Association, the Western States Farriers Association, and the California Farrier’s Association. “I was in them all. I’m a firm believer in the importance of the associations,” says Darling. “We had the first horse-shoeing contest in Fresno, where I served as coordinator. I’ve also been added to the International Horseshoeing Hall of Fame in Louisville, KY.” A collaborative shop

Darling’s 10 acres includes a barn workshop-residence at one end of the property. These days he isn’t shoeing horses anymore — he can’t “pound” very long due to some long-term prob-

Two quail listen to the cowboy too. Designed by the fabricator, the entire project took about 160 hours. 36

Fabricator  July/August 2009

A bouquet of flowers. BELOW: A front view of the singing cowboy, which was one of the main elements of the project. RIGHT: The snakes and the spiders were made “not too scary.” LEFT:

lems with his back and neck, including recent neck surgery. But his helpers are all there watching out for him and they don’t let him lift (though he says he’s able to lift more than they will let him). Darling has three people working with him at his shop, including a horseshoer who comes out to help and learn when he isn’t shoeing horses. “I really don’t have what you might July/August 2009  Fabricator


call ‘employees,’” says Darling. “All those involved work on any project, and I divide up what comes out of it. They are my helpers and when we get paid, everyone gets their share.” As long as the scrap metal holds out

Darling is not sure what lies ahead for his business, nor which whimsical character will end up on the gates on the other side of the Quail Oak development, which is being revitalized after years of neglect. Darling has also done railing work and a stairway for a house there. “Our gate work will be an ongoing project,” he says. “I see it limited only by our imaginations – and the size of our scrap metal pile.”

A farmer plows his field, and no doubt enjoying the cowboy’s music.

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Fabricator  July/August 2009

Job Profile

For your information

Fabricating a public restroom ■A

NOMMA fabricator is chosen to help the City of Portland build its first public toilet. Dubbed the “Portland Loo,” the city now plans to market the unit to other municipalities. By Greg Madden Madden Fabrication

On December 8th, NOMMA member Madden Fabrication celebrated the “first flush” of Portland’s newly installed public toilet, officially named the “Portland Loo.” Commis-

sioner Randy Leonard and the City of Portland selected Madden Fabrication to fabricate the custom prototype, which was designed by the City and Curtis Banger with CB Designs. The single occupant unisex toilet contains more than 600 pieces and weighs in at nearly 7000 lbs. The majority of the weight comes from the 3/16” thick 304 stainless wall panels and ½” thick stainless louvers. The design incorporates angled lower louvers that allow privacy, yet police can view legs/feet from the outside to deter illicit activities from going on inside. A stainless half-round faucet is mounted outside to reduce the “hotel effect” and to keep loitering inside to a minimum. The Loo’s construction allows for complete fabrication and shipping of the structure to any site, where it can be plumbed to sewer and water as it is secured to the ground. The plumbing is insulated and wrapped with electrical heat trace powered by two deep cycle batteries. The batteries, which are charged by solar panels on the roof, heat the plumbing in winter and also power an interior light when occupied

Project: A prototype public Loo, which the City of Portland hopes to market to other cities. Fabricator: NOMMA member Madden Fabrication. Designer: Joint effort between the city and Curtis Banger of CB Designs. Features: The project includes a variety of fabricating processes, including laser cutting, rolling, forming, welding, machining, and different welding processes. CO NTAC T

Greg Madden Madden Fabrication 2550 Northwest 25th Pl. Portland, OR 97210 Ph: (877) 902-6424 Fax: (503) 242-2446 E-mail: Web:

TOP: Portland Commissioner Randy Leonard is shown at the grand opening event. RIGHT: The press and city leaders were on hand for the ceremonial first flush, which was made by mayor-elect Sam Adams.

July/August 2009  Fabricator


and an exterior light above the door when vacant. The exterior light guides pedestrians to the Loo at night. The lighting and heating allows for 24-

At the opening event, attendees examine the simple, but high-tech toilet.

hour, 365 day-a-year operation without external electrical utilities. “The ½” thick 45-degree angled louvers that wrap around the curved walls were the most challenging to build,” says Madden Fabrication owner Greg Madden. “The louvers were plasma cut flat and then rolled to fit the curve of the building. Each louver had to be fit precisely to reduce visibility into the Loo.” The prototype required 1,200+ hours in fabrication and involved several fabrication processes, including laser cutting, rolling, forming, welding, machining, and several different welding processes. The city of Portland has a patent pending on the design and hopes to offer the Loo for sale to other cities, using the The first prototype toilet took over 1,200 hours proceeds to offset water buto fabricate. reau costs. For more information about office, (503) 823-3001, or by e-mail at purchasing your own Portland You Loo, contact Anna DiBenedetto in may also view more information at Commissioner Randy Leonard's

Your one-stop source for 18 years! 888-380-9278 40

Fabricator  July/August 2009

Job Site

Job Profile

A PressLock Steel Fencing system was used for the recently-renovated All Wars Memorial in Atlantic City, NJ. In addition to being used along the perimeter, the fence material was also used as trellises in the children’s play area.

NOMMA supplier’s products featured in two unique jobs provided by OGi Architectural Metal Solutions are used for a unique fence project and a Florida condominium development.

Editor’s Note: We encourage submissions of completed work from both our suppliers and fabricator members. Please note that due to contest rules, jobs that you intend to enter in the Ernest Wiemann Top Job Competition cannot be published until after the event. By Carl Griffin Ohio Gratings Inc. OGi Architectural Metal Solutions, an Ohio Gratings, Inc. company (OGi) provided the galvanized and powder coated PressLock Steel Fencing for the All Wars Memorial in Atlantic City, NJ. The All Wars Memorial Building had its grand opening in April 2008 after an $11 million renovation and expansion which was jointly funded by Atlantic City and the CRDA. The new playJuly/August 2009  Fabricator

ground addition required a secure perimeter fence that was visually open yet strong and durable. For this purpose, our PressLock Urban steel fence configuration was used and installed between brick piers and as single and double swing gates with ornamental fabrication. The playground also had several areas for shade where the PressLock Urban fence material was used as a trellis system above. OGi manufactured and fabricated the fence materials and provided fence posts, gates, and hardware. Fence panels were 5'6" in height, 4'-2" in width with a mesh opening of 23/16" x 51/4". The in-line fence posts were 2" x 1/2" steel flat bar galvanized with powder coating to match the fence. Posts were core-drilled and embedded at 18" and gate assemblies had a 2" x 2" HSS

For your information

■ Products

Firm: OGi Architectural Metal Solutions, an Ohio Gratings Inc. company, is a long-time NOMMA Nationwide Supplier. Projects: A fencing system for a memorial in Atlantic City, NJ and aluminum louvers for a Florida condominium development. Products Used: PressLock Steel Fencing for the fence project and VisiScreen for the condo project. CO NTAC T

Ohio Gratings Inc. 5299 Southway St., NW Canton, OH 44706 Ph: (330) 477-6707 Fax: (330) 477-7872 E-mail: Web:


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welded steel tube miter cut. Gate posts were a 4" x 4" HSS steel tube embedded 24" in concrete. All fence material utilized the PressLock fence mounting system with a welded mounting bar at top and bottom. This bar had extended formed arms that met the posts and an aligned, slotted, hole to facilitate installation. The material has withstood the rigors of an inner-city playground and has allowed for a safe and secure outdoor area for the youth of the community.


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LEFT: A circular disc design adds visual interest to this gate. TOP: The project required a fencing material that was strong and durable, yet visually open.

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In Florida, Ohio Gratings, Inc. provided their aluminum louver (VisiScreen) product for the Artech Condominium project. The primary application for the material was a functional and decorative grille system on an 800 foot long 5-story parking garage designed to resemble a cruise ship. The VisiScreen material allowed for a 60% visual block and deflection of car headlights from adjacent condo buildings, while allowing the parking garage to be ventilated naturally with 65% open air flow provided by the louvers. With the versatility of this product, the VisiScreen was also utilized in the skywalk, the parking garage to the condo building, as well as an ornamental canopy for the car drop and the main entrance. At the penthouse level, the material was used as an ornamental handrail and cornice feature. OGi’s aluminum louver products Fabricator  July/August 2009

RIGHT: The VisiScreen material effectively blocks most of the light from car headlights, while also allowing for plenty of ventilation.

are manufactured from 6000 series aluminum extrusions and are lightweight, allowing for easy installment. These green products are corrosion resistant and can be supplied with various finishes including anodized and powder coated which help to increase the longevity of the products. These aluminum louvers are ideal for visual barriers where total or partial concealment are requirements, as well as security screens, privacy fences, sunshades, light diffusers and reflectors. About the company

OGi headquarters and 312,000 square foot manufacturing facility is in Canton, OH. Their other facilities are located in Ridgeland, SC, Houston, TX and Lindon, UT, which offer an array of grating products and services. Since 1970, Ohio Gratings, Inc. has manufactured quality bar grating from traditional industrial flooring to architectural applications, and offers design and custom fabrication services, engineering support, project budget estimates and shop drawings.




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The decorative grilles were used not only on the parking deck, but also the skywalk and entrance canopy. July/August 2009  Fabricator


â&#x2013; In this issue, we feature entries from the 2009 Ernest Wiemann Top Job Competition.

Allen Architectural Metals Inc. Talladega, AL LEFT: These gates were designed by the fabricator for a private residential estate. The design includes a combination of cast iron elements, steel tubing and forged elements. The challenges of this job were to install the gates on existing brick pillars that had been in place for many years and the hand applied painted finish. The idea was to hand apply the finish so that the gates looked as if they had been in place since the time the estate was established. The client wanted a vintage weathered look. Approx. labor time: 200 hrs. for design, fabrication, custom painting and installation.

Art's Work Unlimited Miami, FL RIGHT: These heavy aluminum gates were designed to look like wood with a plant design accent. This is a single slide gate made to look like a pair of swing gates. The main frames are 4 x 6 x Âź" tubing to which we hand routered all the edges. We used aluminum T & G extrusion for the wood panels and trimmed them with textured flat bar. The top trim was fabricated by laminating several pieces of aluminum together. We cut out faux hinges and then forged the fishtail ends and hammered the surface with a textured die that we made. The fern details at the top were all forged by hand, and then welded to a plate. Lastly we made door knockers by forging round loops and making the plates and ring to hold the loops. Approx. labor time: 620 hrs. (includes painting and installing). 44

Fabricator  July/August 2009

July/August 2009  Fabricator


Bob's Ornamental Iron Studio Kansas City, KS RIGHT: We had a homeowner visit our showroom and wanted us to build a cost effective, "free flowing", component rail, out of 3/4" solid bar. After talking him out of trying to "hodge podge" a rail together, and seeing the location, our firm designed this "free flowing" rail to meet the 4" ball code. There were three 3" square post left over from the old rail that we had to "fancy" up. We used 1" angle iron and 1" flat bars to give the appearance of a â&#x20AC;&#x153;sunkenâ&#x20AC;? panel, welded on a couple of plates with eased edges and added an aged, bronze finial. All scrollwork is formed from 1" x 1 /2" flat bar with forged and tapered ends. Top cap rail consist of 21/4" x 5/8", chamfered edge flat bar with a half oval bar, drilled and plugged welded from the bottom. Banding is a 1" fat bar, heated and wrapped. Finish: Industrial Benjamin Moore, Bronze tone. We aged the bronze finial with a Birchwood Casey product. Approx. labor time: 290 hrs.

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Oakwood Hills, IL TOP & BELOW: These glass shelving brackets were made of vendor supplied hammered steel and balusters. They were designed by the fabricator to show the texture of the glass edge. The challenge was the finish. The steel was colored with flame and heated. Then it was rubbed with copper wire for highlights. We used beeswax for the final treatment. Approx. labor time: 33 hrs.



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Fabricator  July/August 2009

Fine Architectural Metalsmiths Chester, NY LEFT: Forged 1” verticals are tapered down to ½” at the base, and wrapped in a continuous ½” round that created two undulating horizontals. The top terminates in an upset 11/2” button, with a hammerpeened surface and the base ends in a small upset. Interior railing is for a whimsical Gothic estate, and had to match the fanciful design of the house. Handrubbed waxed finish. Designed by the fabricator.

Klahm & Sons Inc. Ocala, FL RIGHT: This is all cast aluminum except the frame. The opening is 17 feet wide by 17 feet tall. Each leaf weighs approximately 300 pounds. The finish is a dark bronze color. Approx. labor time: 200 hrs.

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Kelley Ornamental Iron LLC Peoria, IL LEFT: This set of double drive gates were designed and fabricated for a client’s hunting club. The instructions given were, “I need a gate, please make me one.” We designed three gates with two being very simple in design, and the third as you see it here. One look at this third design and the client said, “build it.” The gate frame and structure is fabricated from steel stock hammered cold of various sizes. The ducks, turkeys and deer head were handformed from 14 ga. aluminum plate, and then mechanically fastened to the frame. The entire gate was powder coated deep bronze with the faux finish applied in our shop. Installation was completed with an automated opener and two fence sections. Approx. labor time: 200 hrs.

Lightning Forge Murray, UT RIGHT: Adapted from a picture in Historical Arts & Castings’ book of European ironwork, the landscape architect had us “reinvent the wheel” to make this gate. The lattice work was laser cut from ¼” plate with small rosettes attached on both sides with rivets made of 12 gauge copper wire. The rosettes were dipped in high temp primer prior to riveting to prevent rust. There are over 240 rosettes on a 38” wide gate. The chamfer on the hinge and latch posts was milled into solid bar. The square bronze medallions were bronze riveted after powder coating so that all iron surfaces are protected. In excess of 250 man hours were spent on three gates. A black textured powder coating was applied to all pieces and final assembly was done with bolts, pins, and rivets.

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Fabricator  July/August 2009

Mueller Orn. Iron Works Inc. Elk Grove Village, IL RIGHT: This steel gate unit was designed by the fabricator and customer for their home’s front foyer. Using ½” square bar with forged ball ends for the scrolls, 3/8” x ½” bar for the ovals and the forged tails, ½” x 11/2” channel for lower horizontal members with 3/16” steel plate welded between and ½” x 11/2” flat bar for the side bars and hinges. The hinge posts are 11/2” square tube with hidden attachments at the floor and ceiling. The side panels were attached to the wall through the top scroll and under the bottom horizontal member. The owner did not want to see a drop bolt so we constructed a drop latch that would hold the gates shut even if their dogs jumped against it. The most difficult part about this project was the installation – we had to notch the 6” high wood base around the bottom channel and plate. Approx. labor time: 45 hours shop and installation.

PORTA-BENDER Now Buy Direct From the Manufacturer DeAngelis Iron Work Inc. South Easton, MA TOP: This rail was fabricated using all nickel silver components. The top rail is a “half-oval” nickel silver molded cap from Julius Blum. ¾” x 1½” rectangular nickel silver tube was used for the sub rail and bottom rail material is 1/4” x 2” nickel silver flat bar. The oval infill was formed using ¾” x 1¼” solid nickel silver bar stock. Interlocking oval segments were formed hot and brazed to one another. Joints were painstakingly brazed, cleaned, filled, and polished out. Top and bottom of the ovals were drilled and mechanically attached to the sub rail and bottom rail. All countersunk holes were oversized to allow for screws to be recessed below the top plane of the material. Fasteners were concealed by brazing in nickel silver plugs to fill recesses above fasteners. All components received a #4 satin brush finish. Approx. labor time: 625 hrs. AWARD: GOLD. July/August 2009  Fabricator

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Steel Welding Freedom, PA RIGHT: This classic style driveway gate was designed to appear as if it was original to the property and in keeping with the 1920s tudor style home. The clients wanted a strong and simple design that would include the original 4’ piers, but asked for the gates to be 71/2’ tall. In order to accommodate their request, the added decorative scrolls mounted onto the piers helped blend the tall leaves of the gate with the short piers. The gates were hung from steel posts on heavy duty hinges so the gates could be opened in either direction. The lattice work on the bottom of the gate was added for strength and also to mimic the diamond shape leaded windows of the home. Sandy soil required extensive footings to support the gates. Approx. labor time: 238 hrs.

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Fredericksburg, VA LEFT & RIGHT: Designed by the fabricator, the double-leafed gates celebrated the country estate of the client and his Irish background. Each fixed side panel boasted a shamrock to celebrate his heritage. The laser-cut 'R's were gold-leafed and attached to the center panel after the gates were powder coated. ”x1” steel tubing formed the frames with ¾” square bar pickets. 45-3454-ACF-121807-V2





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Wonderland Products Inc. Jacksonville, FL LEFT: Forged from Monel 400, these drive gates serve as the main entryway to this home. Being flanked by curved scroll panels, also in Monel, they really set the stage for any would-be visitor to enjoy the plethora of Monel metalwork throughout the home. The architect seemed to go out of his way to create spaces for metalwork which we were happy to accommodate. Out of respect for the metal, we incorporated a stylized floral element with octagonal stems to pay tribute to the nouveau movement when Monel and other white metals were brought to the forefront of ornamental metalwork. The scrollwork is forged from 1/1/4” x ½” and the frames are 1” x 2”. They were darkened with Birchwood Casey M21 and waxed. Approx. labor time: 400 hrs.

Wiemann Ironworks Tulsa, OK RIGHT: Forged stair and balcony railing for private residence. Fabricated using 5/8” square solid infill, 11/2” x ½” solid horizontals. All material had eased corners and was fullered with power hammers. Antique bronze cap rail. Project consisted of approx. 75’ of total stair and balcony railing. Installation of lower bar tight against wooden curb system. Railing designed by architect. Cutting and splicing infill is always difficult but the fullered texture makes it even more challenging. This stair railing spanned three stories without any posts – it required a dozen welding and dressed joints on each of four splices in the field to install. Approx. labor time: 1,125 hrs.

Wrought Iron Art Ltd. Oakville, ON, CANADA RIGHT & BELOW: These 3-dimensional classical style gates are known as “Crown Gates” (operating gates with two leaves). The gates have austere classical central parts with scrollwork and a rich crown, decorated by flowers, leaves, ribbons and an enhancing pineapple atop. This estate has two identical gates at the same driveway. One hundred percent hand forged by both hands and power hammer. Hot dip zinc galva-

nizing, flat black finishing. Designed by the fabricator. Installed using boom truck. Size is approx. 22’-0” W by approx. 15’-0” H, and each leaf weighs 1,300 Kg. This was for a private residence. Approx. labor time: 500 hrs.

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Solon, OH RIGHT & BELOW: The portico entrance gate was designed in concept by the residential architect. He was looking for a very custom feel using a variety of component parts. The challenge was to take his hard line drawing and transform it into a detailed CAD drawing showing actual parts and pieces. The gateâ&#x20AC;&#x2122;s side panels and transom was then constructed using over 25 different components that needed to be cut and welded in to make them, at times, look like an original piece. The finish was then made to match the light fixture. We sandblasted, zinc metalized, and used a dark bronze base color and then applied a light dry brush of copper with a final clear coat. Approx. labor time: 230 hrs. (includes installation).


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Blue Mountain Metalwork Inc. Banner Elk, NC ABOVE & BELOW: Based on the clientâ&#x20AC;&#x2122;s desire to keep an open, funky feel for the space, these rails were designed with flow in mind. Each panel was designed for its particular opening and to keep the flow from one opening to the next. The main challenge was building the panels to meet maximum opening and structural codes while keeping the pattern. The pattern was derived from a grid layout that allowed the fabricator to keep up with the previous panelâ&#x20AC;&#x2122;s construction with transition and stair panels being more difficult to keep the flow. The arched bridge to a meditation platform was an added bonus to the job. It required structural engineering approval for loads and attachment to the structure. Panels are constructed of 1Âźâ&#x20AC;? x 3/8â&#x20AC;? flat bar and 1½â&#x20AC;? x Âźâ&#x20AC;? flat bar. Bridge 6â&#x20AC;? x 3 /8â&#x20AC;? x 1½â&#x20AC;? channel. Approx. labor time: 510 hrs.


Fabricator  July/August 2009

Cape Cod Fabrications East Falmouth, MA RIGHT: This stainless steel staircase and bridge system was designed by the architects with detailing and design input from our shop. The stair stringers and bridge supports were #304 stainless steel channel with 11/2” thick glass treads and floor planks. The guard rails were fabricated from built up stainless steel flat bars with glass infill panels. The entire system was built in our shop, then disassembled and shipped to the site. The greatest challenge was getting a consistent #4 finish on the insides of the heavy channel which we did with a stoke sander. This was very labor intensive. Approx. labor time: 180 hours fabrication and installation.

Christopher Metal Fabricating Inc. Grand Rapids, MI BELOW: We designed this aluminum arbor for an architect. It is made of a combination of 11/2” square tube ¼ wall, 11/2 x ½ channels, ¼ x 1 flat bars for the scrollwork and 3/16 x 5/8 bars for the banding. All scrolls were made from 6063 aluminum forged cold, ends eased by grinding. Many were formed in the Hossfeld scroll bender; some were formed in hand made patterns. The trellis is 10’ diameter; 8’ clear under the headers. The crown is 30” diameter 24” tall including the bronze finial. When we measured the area he wanted to surround (a round patio), the retaining walls were not in place yet. When we went to install the trellis, fortunately the roof was a separate piece because the retaining walls were not where they were supposed to be and interfered with the placement of the vertical legs of the trellis. That’s why Phone: (800) 285-3056 Fax: (716) 854-1184 there is a 2” offset between the left and the round top. The legs had to be i STAIR PANS i BENT PLATE moved in towards the center of the i TREADS i POUR STOP circle by 2” in order to remain centered on the patio. The finish is a mineral bronze powder coat. Approx. labor time: 148 hrs.

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Biz Side

Leave your competitors in the dust Win the race by providing outstanding service to your customers. The following are eight important steps to victory. ■

It’s no secret. Business is getting

tougher these days. It’s difficult if not impossible to raise prices enough to compensate for rising costs. As if that weren’t enough, today’s demanding customers will defect to a competitor at the slightest provocation. OK, the fabricating business isn’t all sweetness and light, but not to worry. Many (most, really) of your competitors have yet to recognize something that you don't ever want to forget: Metalworking is a people business. Metal fabricating professionals sell products to people, not to objects. Whether it’s a custom railing, an entire structure, or just a little design advice, success depends directly on the satisfaction of the person on the receiving


end of the transaction. All the business school expertise in the world is no substitute for an understanding of that basic business principle. Here are eight important ways to help you acknowledge the value of each of your customers, keep them coming back for more . . . and leave your competition in the dust: STEP Take action on those things


that most of your competitors only talk about.

It’s sad but true: The principles that separate successful and profitable shops from the also-rans have been well known for decades. There’s nothing magical about them. They’re easy to learn and even easier to put into effect. Still, they go largely ignored by the majority of shop owners. These days, it has become popular to bundle up some of those old business philosophies in new clothing and present them as original, innovative business techniques. Forty years ago, management consultants were exhorting business owners to excel in customer satisfaction, just as they are today. Then as now, only a small percentage heeded that valuable advice and went on to reap the rewards. The majority simply nodded in agreement while giving little more than lip service to the subject. Many of your competitors are making that same mistake today.

As you know from your own experience, it’s a pleasure to do business with a company that has made customer satisfaction its top priority. A pleasure because it’s fun to be around people who enjoy their work. Of course, it’s even more fun to look at an operating statement with a healthy bottom line. So, make sure that you take action on the following management techniques, things that most of your competitors only talk about.

For your information

By William J. Lynott

Tip of the Day: Socially engage your customers. Remember, people do business with people they like. Memorable Quote: “Keeping your name in front of your customers reminds them that you appreciate their business. That, in turn, is an effective and inexpensive way to keep them coming back.” About the author: Bill Lynott is a longtime business writer for Fabricator. Since 1957, he has written nearly 1,000 essays and columns, and is the author of three books. In addition to his career as a writer, Bill also has an extensive background in Bill Lynott management, consulting, marketing Fabricator  July/August 2009

STEP Take the time to listen

inexpensive way to keep in touch, and computers have made the job a lot easier than it was in Joe Girard’s day.


to your customers; make sure that you’re providing the satisfaction they expect.

Successful metalworking professionals take nothing for granted when it comes to their most valuable assets: their customers. There are a number of ways to find out how well you’re doing in that department. The best ones involve asking customers themselves how they feel about your work. Telephone or mail surveys of random samplings of customers are the easiest and most popular way to stay tuned in to their attitudes. Whatever satisfaction survey method you choose, stick with it. Once you establish a program for evaluating your customer satisfaction efforts, install that method as a permanent part of your shop’s operating procedures. STEP Remember that people do


business with people they like.

If you and your employees are highly skilled but working in a clinically detached manner, you are overlooking one of the easiest ways to keep your customers coming back for more. Worse, you are ensuring that you will have to replace many customers who

STEP Make full use of your


would otherwise keep coming back and generating new referrals. Many years ago, car salesman Joe Girard established a system for mailing what he called a “nice note” to each of his customers and prospects. Even when his mailing list grew into the thousands, Joe kept up with his mailing chores (and this was long before computers simplified the task). Did all this work pay off? It certainly did. Joe Girard is listed in the Guinness Book of World Records as the all time automobile sales champion. In one year alone, Joe sold 1,425 cars. That’s an average of about four cars per day for an entire year. Should you be sending postcards to your customers now and then? It’s an

customer database.

Are you capturing the full name and mailing address of each of your customers in a flexible database? If you aren’t, today is the day you should start. If you aren’t already using industry-specific software, setting up a database with inexpensive, off-the-shelf software such as Microsoft Excel, Access, or Lotus Approach is far easier than it was just a few years ago. User-friendly interfaces and intuitive menus have made these programs easy to learn and use even for computer beginners. If you don’t have the time or inclination to do the work, it’s not difficult to locate a person or firm specializing in mailing list maintenance. If you already have your own customer database, resolve to use the information it contains to help you with the critical job of staying in touch with your customers and identifying likely prospects for special promotions. Keeping your name in front of your customers reminds them that you appreciate their business. That, in turn, is an effective and inexpensive way to keep them coming back.

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July/August 2009  Fabricator


STEP Train every employee to be


an important member of the Customer Satisfaction Team.

Your own understanding of the importance of customer satisfaction will be for naught if even one of your employees remains mired in the dark ages. Every employee should be made aware and continually reminded that “fixing” the customer is just as important as fixing the customer’s problem. If you’ve been in business for a while, you’ve already seen your share of cases where the customer’s problem

was resolved, but the customer was still unhappy. The most common cause of this potentially fatal malady is employees (or owners) who have allowed themselves to become isolated from the customer’s concerns. It’s up to you to make certain that all of your employees understand that the ultimate goal of your combined efforts is a satisfied customer, not just a completed job.

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STEP When you make a mistake,


own up to it.

Perfect business operations are found only in textbooks. In that regard, your business is like all others. You and your employees will make mistakes, fail to satisfy a customer, or fall short in some other way. There is probably no way to avoid such incidents in a hectic business environment. What is important is not that things occasionally go wrong, but how these incidents are handled. That’s why you should look on every error that you or your employees make as a valuable learning experience. Above all, don’t try to make YOUR problems your customers’ problems. Independent studies clearly show that customers whose complaints are resolved to their satisfaction often become better customers than they were before the incident that triggered the complaint. On the other hand, you’re probably well aware of the consequences of unresolved complaints.


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Independent studies clearly show that customers whose complaints are resolved to their satisfaction often become better customers than they were before the incident that triggered the complaint. Fabricator  July/August 2009

STEP Make sure that you treat


the telephone as an important business tool.

Your customer's experience with your shop begins the moment that you or one of your employees answers the phone. Train everyone in your organization who answers the phone to understand the importance of treating every caller with courtesy and respect. In particular, make sure that your telephone is always answered promptly. Never allow it to ring more than three or four times, and make sure that everyone identifies himself or herself by name in a cheery voice. Never leave a customer on hold for more than a few moments. Customer Satisfaction Audits, a commercial survey method, consistently show that leaving a customer on hold for more than a minute is one of the most certain ways to alienate the caller. If you can't find the information you need within a minute or so, volunteer to call the customer back. And always, ALWAYS, call the customer back

July/August 2009  Fabricator

when you have promised to do so. Even if you haven’t been able to find all the information you need, don't force the customer to wait for a call that never comes. STEP Don’t overlook your


employees as a source of ideas to improve your operation.

No one is closer to your customers

and their opinions than are your own employees. Acknowledgement and recognition are astonishingly powerful tools for gaining maximum benefit from employees. Workers who feel that their opinions are respected by their bosses are far more likely to make positive contributions to the business than those who feel that they are being ignored or patronized. If yours is a small, independent operation, you don’t need a formal program. Just make it a point to ask your employees how they feel about things, how to improve the business, how to satisfy customers. So, what does it take for a metal fabricating business to stand out in the crowd — to eliminate competition as a worry? The answer to that question lies right here in these pages. Make customer satisfaction and employee cooperation the prime products in your inventory and your competitors will soon be sitting around wringing their hands and complaining about you.


Biz Side


Learn how to handle When confronted with negative opinions, many people go on the defense. Yet, getting feedback from others can be a great time for learning. ■

A colleague who just heard your pres-

entation at work is giving you some feedback that you were too quiet, didn’t get to the point quickly enough, and lacked a compelling example. Your breathing goes shallow and your body stiffens, your heart speeds up, and you look around to see if anyone is in earshot of this conversation. You worked for days trying to perfect this presentation—days! Faced with the often-difficult experience of feedback—in our work and personal lives—many of us respond in unproductive ways. But taking in feedback from others, both positive and negative, is imperative if we are to ex58

perience the satisfaction that comes with enhanced competence and improved relations. It is possible—and necessary—to think positively about feedback. Typical Reactions to Feedback

When given difficult feedback, most of us find that we do one or more of the following:  Pretend. We say little, disguise any hurt or humiliation, push the feelings way down and eventually act like it never happened. “Thank you so much for sharing that.”  Defend. We justify our actions, give explanations, and point out rea-

sons. “There was so much happening last week, I didn’t end up with nearly the time I needed to prepare. Oh, and the microphone wasn’t working so well today.”  Deny. Denial automatically makes the other person wrong. “I didn’t see a problem; I’m great at what I do.”  Interrogate. We ask for proof that there is any truth to the feedback. “Well, if you want me to understand what you’re trying to get at, I’ll need some specific examples.”  Lash out. Anger is the first reaction for some. “Get off my back, will you? How dare you criticize me, you of Fabricator  July/August 2009

all people! I thought you were my friend.”  Criticize. We go on the offensive through blame, innuendo, or other unsolicited comments. “I never believe anything those hotshots say. You know how it is in that department.”  Self-destruct. We turn all our negative reactions inward against ourselves. “I am such a loser. I’ll never get it right. I’m never doing another presentation.” All of these reactions serve to distract us from painful feelings of not being good enough, as well as the notion that we need to change in some way. But adapting to feedback—which inevitably asks us to change, and sometimes significantly—is critical if we are to succeed in our jobs, our marriages, and our family relationships. Turning “Feedback” into “Food for Thought”

Taking the dread out of receiving feedback can happen with as little as a simple twist of words (“I wonder what’s going to happen” instead of “I worry about what’s going to happen”) and a slight shift in beliefs (“All feedback is a gift”). Here are some guidelines that can help transform feedback into food for thought:  Track your own reactions. Recognize your emotions and responses. What body sensations, thoughts, emotions arise? Recognize that whatever arises in your mind is your own responsibility. It is not the other person’s fault you are responding as you are.

You get to choose how you think and how you respond. When we own our own reaction, it opens the way for genuine communication with the other person.  Get support. Though it may be difficult to identify, you may feel inhibited and ashamed upon hearing feedback that requires change. Ask trusted friends to listen, encourage, and offer suggestions. Work with a coach. Even in settings in which people are expected to be self-reliant (such as many jobs), it’s nearly impossible to make significant change without such encouragement.  Listen with an open mind and heart. Begin by acknowledging that the perception of the person giving feedback is the reality that needs to be looked at. Without confirming or denying the perception of that person, simply listen and take in what he or she has to say.  Change defensiveness to curiosity. Don’t explain or defend yourself. It may be appropriate to bring the subject up later, if explanations are appropriate. For now, though, say the three magic words: “Tell me more!” What has the person giving you feedback observed? What does that person expect or want you to do differently? Don’t assume you know what the other person means…ask questions to clarify your understanding.  Regard all feedback as an act of generosity. Feedback can help you rec-

ognize habitual styles that may need to change. It can help you reexamine how you are living your life. It is a wonderful gift. Consider offering sincere appreciation to the bearer of feedback, even acknowledging how difficult it may have been to deliver the news.  Focus on the message not the packaging. There may be times when feedback is given harshly or by someone with whom we struggle, or there is a mixture of truth and personal distortion in what we are told. Forget about what package the message comes in; what is the message? How can you penetrate to the truth contained in the feedback? What can you learn? Contemplation is a critical step to integrate the message.  Reframe the feedback. When we put feedback in a positive light, negative emotions and responses lose their grip. For example, you could see the feedback on your presentation as a way to improve your chances of promotion, leading you to improve your skills in various ways. Or, the feedback may point you to greater personal success in a position that does not require presentation skills. The bottom line: Taking feedback to heart puts you in control and takes you out of helplessness. It may require ruthless self-honesty and a little detective work, but the payoff is high. Author’s content used under license, © 2008 Claire Communications.

For your information

What: Your natural instinct is to react defensively to feedback. But the key is to take a positive approach. Memorable Quote: When we put feedback in a positive light, negative emotions and responses lose their grip. July/August 2009  Fabricator


Business Valuation

Biz Side

What is your business worth? There are several ways to value your business. The trick is to find the method that works best for you. ■

When you’re considering selling your

fabrication business — or buying out your partner or obtaining a small business loan — you need to know its value. Even if you’re not considering selling or obtaining a loan right away, experts in a variety of financial fields adamantly agree that knowing your business’ current value is essential. NOMMA member John McLellan, president of McLellan Blacksmithing, agrees with the experts. He feels that he should know the market value of his business — although he doesn’t. What’s holding him back, then? He just doesn’t feel that he knows enough about the process. When NOMMA asked McLellan what he’d like to know about the business valuation process to make him more comfortable, he told us that his 60

concerns were threefold. He wants to know the steps involved in valuing his business, the factors that determine what his business is worth, and how that information is used to come up with a value or sale price. “I know there are tangible things like equipment and real estate that are pretty straightforward,” says McLellan. “But it seems there are ‘other’ things a business appraiser takes into account, because most businesses sell for far more than what the equipment and property are worth.” And he’s right. In this article, you’ll get an insider’s view of business valuations from accountants, financial analysts, business brokers, investors, authors, and others. You’ll learn what a business valuation is, why you need one, where to get one, what they cost, how your business is valued, and which factors affect its value. In addition, experts will share their

For your information

By Lisa Bakewell

What: Need to sell your business? Are you wanting to buy out a partner? Do you need to refinance or to obtain a loan? Then it may be time to value your business. How: This article covers the three main types of business valuations. These include broker’s opinion of value, standard appraisal, and a business appraisal report. Memorable Quote: “In higher income areas, like Beverly Hills, the economy will have less of an effect on business than in lower income areas.”

Fabricator  July/August 2009

tips for making your business look its very best to potential buyers or lenders. What is a business valuation?

A business valuation is a report compiled by a professional appraiser, accountant, business broker, or other financial expert to estimate the economic value of your business or another personâ&#x20AC;&#x2122;s interest in your business. According to Andrew Rogerson, CBI, CBB, CMEA, CSBA of Murphy Business and Financial (and author of Successfully Sell Your Business: Expert Advice from a Business Broker;, there are essentially three types of business valuations. Brokerâ&#x20AC;&#x2122;s Opinion of Value

The first type of business valuation report is a Brokerâ&#x20AC;&#x2122;s Opinion of Value (BOV). This valuation report can be created by anyone as long as they disclose their training and experience. BOVs are:  Typically used to arrive at a selling price (or value) for a business by a business broker;  Can be created with limited access to financial information and a set of comparable sales (comps);  Do not conform to the Uniform Standards of Professional Appraisal Practice (USPAP);  Cannot be used in a court of law for divorce proceedings, to settle with the IRS, or to buy out a partner in your business; and  Cost between $500 and $1,000.

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The second type of business valuation is a Standard Appraisal. This type of appraisal:  Uses a limited set of valuation techniques;  Is Uniform Standards of Professional Appraisal Practice (USPAP) compliant;  Explains (in detail) how the appraiser reached the value of the business;  Does not include information such as the condition of the national economy, the history of the business, the outlook of the industry, or in-depth financial analysis; and  Costs between $2,500 to $4,000. Business Appraisal Report

The third type of business valuation is a Business Appraisal Report. This document is:  Also USPAP compliant;  Covers in-depth financial analysis and ratios of the business;  Discusses the economy and its impact on the business;  Discloses full details of the company, including its history analysis of certain metrics and financial material; and  Costs from $5,000 to $12,000, though costs can go as high as $30,000 for very complex companies. Itâ&#x20AC;&#x2122;s important to note that in order for Standard Appraisals or Business Appraisal Reports to meet USPAP standards, someone holding the correct certification must sign off on them. For proper certification, an appraiser must get



initial training, ongoing training, testing, and certification from an organization such as the American Society of Appraisers, the Institute of Business Appraisers, or the National Association of Certified Valuation Analysts. Why do I need a business valuation?

“The valuation game begins the day you start a business,” says Neil Ducoff, Founder and CEO of Strategies ( “And I hope owners remember this. Too many owners wait until they want to get out of their business to pay attention to the value of it.” Bryan Cook, MBA, CMEA, SBA, of Murphy Business Financial Corporation (, agrees. He says, “If a business owner wants to get the very best price for their business, they should employ a business broker to give them a valuation at least two years before they want to sell. If there are


major defects in the business operations or accounting practices, they can be repaired in that time.” “Also,” Cook adds, “an attorney and CPA should be consulted to minimize tax effects or any future liability from the sale of the business, and a good financial planner is helpful in transitioning the gains from sale into investments appropriate for the risk tolerance and life stage of the seller.” To break it down, Ducoff stresses that the importance of a business valuation professional is to provide unbiased opinions of a company’s value. “In

other words,” he says, “it’s to make sure the price is right when an owner is ready to divest him- or herself of all — or a portion — of their business.” Plus, Ducoff adds, the objectivity of a third-party valuation is crucial if others examine the results. For example, an appraisal may be examined by the IRS to determine if gift or estate taxes are due on a transaction, or by a judge if you are dissolving a partnership. No matter what the purpose, though, the end result should be a comprehensive statement of your business’ worth. It will ultimately save you time, money, and stress by ensuring that your goals are realistic from the outset. How should my business be valued?

There are several approaches used to value a business, and experts agree that using more than one approach is the best indicator of true market value. Bryan Kirchwehm, CA of Pacific Valu-

Fabricator  July/August 2009

ation Consultants (, says the three generally accepted approaches to valuation are Market Approach, Income Approach, and Cost Approach. “The Income Approach is the most commonly accepted,” he says, “as it places a value on the future cash flows expected to be received from an investor contemplating a purchase of that business.” David E. Coffman, CPA, ABV, CVA of Business Valuations & Strategies PC (, agrees, but says that established, profitable businesses should be valued using both market and income approaches. “Market methods look at sales of similar businesses, and income methods look at cash flow,” he says. “Both approaches have pros and cons, so both should be considered.” Michael Soon Lee, MBS, CRS of Realty Unlimited (, says that, from a Realtor’s standpoint, Return on Investment (ROI) is the most common method used by brokers when establishing the worth of your business. Your business value, Lee says, is affected by how much money a buyer will need to get the business going versus the expected cash flow from the business. Once a buyer knows how much money they need to put into the business, he says, then they can compare the return to other investments they might make. “A quick way to ballpark whether to even look further into a business is the Payback Method,” says Lee. “You simply subtract the annual income from expenses (disregarding owner salary or withdrawals) and divide that figure by the amount of money you must invest to buy and set up the business.” This will give you the number of years it will take the buyer to recoup his/her investment. “I like to see a payback under two years,” says Lee, “but other investors may be different.” What factors determine the value of my business?

“Most businesses are valued using industry comparables,” says Mike Handelsman, General Manager of BizBuyJuly/August 2009  Fabricator (an expert in buying and selling businesses). “For example, if there is a history of transactions in the industry and one can determine the average multiple of revenue and cash flow that similar businesses in the industry sell for, then that is a strong basis from which to value a business. The challenge is usually finding a set of comparables for the industry.” Another factor when valuing your business is your motive for selling, according to Neil Ducoff. “Believe it or not, your reason may raise red flags with prospective buyers,” he says. “Being ready to retire or move on to other things will likely not cause a second thought, but if the business is in trouble, you’d better try to fix the problems before putting it on the block. And for what it’s worth, if you

fix the problems, you may decide not to sell!” The economy also plays a big part in the business valuation. According to Chad J. Simmons, there is no time like the present state of the economy to illustrate that point. “I would expect that any type of business that is strongly linked to consumer discretionary income is likely to have a harder time competing for consumer dollars,” he says. David Gresen, CPA, ABV, CVA of Klein Liebman & Gresen, LLC (, agrees, but says the location of a business plays a big part in how the economy affects a business. “In higher income areas, like Beverly Hills,” he says, “the economy will have less of an effect on business than in lower income areas.” Ultimately, the final sale price of your fabrication business will depend on how badly the buyer wants to buy and how badly you want to sell. A valuation expert can help you meet in the middle, but buyer and seller must both be willing and excited about the transaction. That’s the bottom line. What’s included in the value of my business?

According to financial experts, many tangible and intangible assets make up the value of your business. “First,” says Robert J. Allen, CFA, of Bailes & Company, P.C. (, “there may be assets in place


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such as equipment, furniture, real estate and cash on hand,” which make up the tangible items included in the value of your business.

“In addition,” he notes, “there may be some other specifically identifiable assets such as a trade name, signage, employees, and staff in place,” which

Yes, I want to have my business valued! So the next question is: What types of documents do I need for a business valuation? According to the experts, these documents are commonly used for business valuations:  Adjusted Profit and Loss Statement. Because many small business owners deduct expenses — such as the use of their vehicle — and pay themselves salaries, you need to ‘add back’ these discretionary expenses. That way a buyer can see what it will truly cost him or her to run your business. Note: According to experts, depending on the buyer, you may need to have your financials audited as well.  Formal business appraisals, if available.  Accounts receivable and allowance for bad debts. These two accounts must be examined together, according to experts, because the buyer will want to make certain that the net receivables on the balance sheet are really collectible by examining the percentage of receivables and bad debts for the past three years.  Property, plant, and equipment. A professional appraisal of buildings and equipment is good, according to experts, but they warn not to forget that the value of used tangible items is usually very low.  Depreciation schedules. These schedules show tangible personal and real property.  Federal Tax Returns. These are important to show detail of income sources and expenses. Though banks require these, business brokers may use them to uncover hidden assets or cash streams that may have an effect on the true value of your business. As a final note: Fabricators should keep in mind that solid financials are essential. This includes keeping track of income, expenses, and profit for the business, which will provide you with the information needed to manage your business successfully — even before you think about selling or obtaining a loan. Small business software programs, such as QuickBooks, can help you keep track of this information.

are intangible items, but are very important when valuing your business. Other intangible considerations that add value to your business, according to Michael Soon Lee, might include:  Goodwill, which is the dollar value placed on your reputation, and adds a lot of value to your business;  A good location, unless there are a lot of similar vacancies nearby;  A below-market rent, as opposed to opening a brand new location (at market rent) and having to make tenant improvements;  A ready-to-go space needing minimal equipment and improvements; and  Seller financing, which adds value and increases your pool of available buyers. Another huge factor in how much a fabricator might command for her/his business is the amount of direct customer contact the owner has. Christopher Farrell, CPA, of Goldstein & Company LLP, says, “If an owner does most of the face-to-face interaction with clients, there could be substantial doubt as to the number of clients that would move over to the new owner. Just because they like the current owner does not mean that they will like the new one.” Brent Larlee, business consultant and entrepreneurial executive of WaiHaka Strategies LLC ( suggests that considering the number of competing businesses in a geographic area is also important. Too many fabrication shops in one area might decrease the value of your business. Who should I hire for my business valuation?

According to Chad J. Simmons, the key to a obtaining an accurate business

If an owner does most of the

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face-to-face interaction with clients, there could be substantial doubt as to the number of clients that would move over to the new owner. Fabricator  July/August 2009

valuation is to assemble a team around yourself to perform certain “mission-critical functions,” including a broker, a banker, a lawyer, etc. — and all for different reasons. Your banker and broker can both help

“A banker is helpful to qualify the business sale proposition before it is made available, so you know it can be financed to the right buyer at the asking price,” he explains. “You need a broker to create inquiries for the business and handle negotiations with professional objectivity, and a lawyer is needed to make sure you can get the contract written that effectively communicates your interests to a buyer.” “To accomplish this goal,” Neil Ducoff says, “you may decide to hire an individual or a full-service firm to conduct a business appraisal. Full-service firms should have access to information on current appraisal and legislative requirements, as well as the resources to properly value all of your assets. Individual appraisers should belong to a professional association such as the American Society of Appraisers (ASA).” Regarding the use of business brokers, Ducoff adds, “The main reason to use a business broker is the protection of your bottom line. Fundamentally, they are similar to residential real estate brokers and using one will result in more potential buyers, which will generate more competition in bidding. “A business broker will also know how to identify the right buyer—one who truly understands the value of your business. So you will leave the transaction confident that you got the best price and terms possible.” Not Ready to Hire a Professional?

Mike Handelsman, General Manager of (an expert in buying and selling businesses), suggests that a business owner might start the valuation process by using an online tool that provides an accurate value of a business based on compara-

July/August 2009  Fabricator

ble businesses, cash flow, and location. One example of this type of service is his company, which offers a valuation service using an inventory of 26,000 sold businesses and 50,000 businesses for sale to assess the value of any business in any location ( So, as we’ve discussed throughout PROOF - AB-48839-948


this article, knowing the current value of your fabrication business is imperative — whether you’re selling your business today or somewhere down the road. Knowing the existing financial facts will allow you to gauge your company’s growth and success, and plan for its future. NOMMA member Sean Hayes of Elsaforge Inc. said it best when he was asked why a business valuation is important. He said, “Business valuations let you know what you are working for. If you are not making money and growing the business, you only have a paying hobby.” And that’s really the key, right? You want to be assured that you’re not working for nada, zilch, zip. You want to assure yourself that when you are ready to sell, you can leave the transaction confident that you got the best price and terms possible — that you did the very best you could — and you were well prepared…ahead of time.

BENDING ROLLS $//7<3(6‡$//&$3$&,7,(6 $// 7<3(6‡$//&$3 &$3$&,7,(6 $&,7,(6

Postville Blacksmith Shop • Offering tools and equipment for ornamental ironwork. • We make custom tools for power hammer work. Make your own components! • We do subcontract forge work - parts to complete projects. • We offer in-house training at your shop in blacksmith work both hand and power hammer. N8126 Postville Rd Blanchardville WI 53516 Phone 608-527-2494 Fax 608-527-6908 We can provide recommendations from many NOMMA shops.


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Join NOMMA today! Own or Manage an Ornamental and Miscellaneous Metal Fab Shop? Then NOMMA is the organization for you! Tap into a goldmine of information by becoming a NOMMA member. Get quick access to information and resources by joining NOMMA. We offer educational tools, discounts, networking opportunities, and more... O&MM Fabricator Magazine NOMMA’s glossy magazine offers shop techniques, job profiles, business articles, and more.

Member Discounts Pay lower rates for our educational materials, sales aids, training DVDs, continuing education classes, and annual METALfab convention.

Members only Website Download technical bulletins and access information on ADA, building codes, driveway gates, etc.

Professional Resources Receive TechNotes, our bimonthly technical bulletin and Fabricator’s Journal, our members only “how to” publication.

Technical Support Get answers to your questions by posting them on the ListServ or contacting our staff.

Best of all, a NOMMA membership is only $425* per year! That’s less than $1.16 a day for one of the smartest choices you’ll ever make.

NOMMA & NEF Provide First-Class Education For the Industry LEFT: The NOMMA Education Foundation (NEF) provides professional education sessions during our annual METALfab convention and trade show. TOP RIGHT: NEF Continuing Education programs are regularly held in the fall and prior to METALfab. RIGHT: A highlight of METALfab is the shop tours, which typically feature various mini demos.

Other Member Benefits: Awards Contest, Insurance Program, Chapter Membership✝, Member Locator, Introductory Package, and MORE ...

National Ornamental & Miscellaneous Metals Association 1535 Pennsylvania Ave., McDonough, GA 30253 Call 888-516-8585, ext. 101 or visit *For fabricator membership. Memberships are also available for suppliers.✝Chapter membership is only available in regions serviced by a chapter.

NOMMA Education Foundation

A â&#x20AC;&#x2DC;Thank Youâ&#x20AC;&#x2122; To Our Donors In partnership with the National Ornamental & Miscellaneous Metals Association

A special thanks goes to members who made donations to the Foundation in the last twelve months. By supporting the efforts of NEF, the following individuals and companies are helping to build a stronger industry through education and research. Benefactor $4,000 - $9,999

Lawler Foundry Corp.

Imagine Ironworks

Partner $1,000 - $3,999

DeAngelis Iron Work Inc. Koppers Fabricators Inc. International Creative Metal Inc. Allen Iron Works & Supply Co. Royal Iron Creations

Hallmark Iron Works Inc. Keeler Iron Works The Valentines Boyler's Ornamental Iron Finelli Architectural Ironwork

Supporter $500 - $999

Wiemann Ironworks Kelley Ornamental Iron

Cleveland Steel Tool Co. Weldon Welding & Inspection Services Inc.

Backer $100 - $499 Sally Powell Big D Metalworks Christopher Metal Fabricating Northshore Steel Fab LLC Alliance Steel & Fabrications Inc. Hayn Enterprises LLC SRS Inc.

Builders Ironworks Inc. Artisan Metal Works Ltd. Flaherty Iron Works Ephraim Forge Inc. Atlantic Industrial & Mechanical Inc. La Forge de Style Tesko Enterprises Zion Metal Works

Ebinger Iron Works Inc. Bailey Metal Fabricators Mark O'Malley Accent Stair and Specialty Foreman Fabricators Inc. Republic Fence Co. Inc. Welding Works Inc.

Contributor Up To $100 Curt Witter Florissant Iron Works

West Tennessee Ornamental Door Bridgeton Drafting Co. LLC

Division 5 Metalworks Elm Grove Forge

A thank you to all who support the NOMMA Education Foundation 68

Fabricator  July/August 2009

Support the NOMMA Education Foundation!

 Yes, I want to support education, industry research, and the many programs of the NOMMA Education Foundation Iâ&#x20AC;&#x2122;ve enclosed my contribution of:  $100



Other ___________

If you are interested in joining other NOMMA members who have made commitments for ongoing support to the Foundation, please call Foundation chair Roger Carlsen at (815) 464-5656 or NEF Executive Director Barbara Cook at (888) 5168585, ext. 105. Contact ___________________________________________________________________________ Company _________________________________________________________________________ Address __________________________________________________________________________

City _____________________________________ State __________ Zip ______________________

Phone ____________________________________________________________________________ Fax _____________________________________________________________________________

Email _____________________________________________________________________________  Enclosed is a check payable to the NOMMA Education Foundation for my donation.  Please charge my:  AMEX

 Discover  MC  VISA

Card #__________________________________________ Exp _____________CVV____________

Name on card _____________________________________________________________________

Signature _________________________________________________________________________

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

You may also give online at:

Contributions are deductible as charitable contributions under section 501(c)3 of the Internal Revenue Code. July/August 2009  Fabricator


NOMMA Nationwide Supplier Members New NOMMA members As of June 19, 2009. Asterisk denotes returning members. Big C Steel Inc. Clearwater, FL Lou Ferrante, Fabricator Custom Metal Cutting & Fabricating Phoenix, AZ Karl Stone, Fabricator F & C Professional Aluminum Railings Corp. Plainfield, NJ Segundo A. Flores, Regional Supplier Irongate Inc.* White Post, VA Dennis Ridings, Fabricator Jackson-Cook LC Tallahassee, FL Jeff Lewis, Fabricator Jax Chemical Mt. Vernon, NY Anthony Nappi, Fabricator Lazo Designs Inc. Canoga Park, CA Octavio Lazo, Fabricator Metal Creations Inc.* Hooper, UT Milt Neeley, Fabricator Middleton & Company Insurance* Newton, NJ Richard Gaynor,Local Supplier Nova Scotia Community College* Sydney, NS Canada Gary Cameron, Affiliate Specialty Iron Works Port Allen, LA Jay Leblanc, Fabricator Stair Service Inc. San Jose, CA Howard Simmons, Nationwide Supplier 70

A Cut Above Distributing (800) 444-2999 Albina Pipe Bending Co. Inc. (866) 252-4628 Alku Group of Companies (800) 465-7143 Allen Architectural Metals Inc. (800) 204-3858 Allied Tube & Conduit (800) 882-5543 All-O-Matic (818) 678-1790 Alloy Casting Co. Inc. (800) 527-1318 American Punch Co. (800) 243-1492 Ameristar Fence Products (888) 333-3422 Anyang USA (940) 627-4529 Apollo Gate Operators (800) 226-0178 Architectural Iron Designs Inc. (800) 784-7444 Architectural Metal Sales (925) 216-1004 Atlas Metal Sales (800) 662-0143 Auciello Iron Works Inc. (978) 568-8382 Barnett Bates Corp. (800) 541-3912 Bavarian Iron Works Co. (800) 522-4766 BFT U.S. Inc. (877) 995-8155 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 Custom Orn. Iron Works Ltd. (866) 464-4766 D & D Technologies (USA) Inc. (800) 716-0888 D.J.A. Imports Ltd. (718) 324-6871 DAC Industries Inc. (800) 888-9768 Decorative Iron (888) 380-9278 DKS, DoorKing Systems (800) 826-7493 Eagle Bending Machines Inc. (251) 937-0947 Eastern Metal Supply (800) 343-8154 Elite Architectural Metal Supply LLC (847) 636-1233 Encon Electronics (800) 782-5598 EURO-FER SPA (011) 390-44-544-0033 Europa Stairways LLC (786) 845-9844 FabCad Inc. (866) 427-2454 FabTrol Systems Inc. (888) FAB-TROL Feeney Architectural Products, CableRailâ&#x201E;˘ (800) 888-2418 Frank Morrow Co. (800) 556-7688 Geo. Bezdan Sales Ltd. (800) 663-6356 Gerhard Glaser GmbH & Co. (011) 496-07-893-7137 Glasswerks LA Inc. (800) 350-4527 The G-S Co. (410) 284-9549 GTO Inc. (800) 543-4283 Fabricator  July/August 2009

NOMMA Nationwide Supplier Members Hartford Standard Co. Inc. (270) 298-3227 Hayn Enterprises LLC (800) 346-4296 Hebo/Stratford Gate Systems Inc. (503) 722-7700 Hendrick Mfg., Perforated Metals Div. (800) 225-7373 House of Forgings (281) 443-4848 Illinois Engineered Products Inc. (312) 850-3710 Indiana Gratings Inc. (800) 634-1988 Industrial Coverage Corp. (800) 242-9872 Industrial Metal Supply Co. (800) 371-4404 Innovative Hinge Products Inc. (817) 598-4846 Interstate Mfg. Associates Inc. (800) 667-9101 The Iron Shop (800) 523-7427 ITW Ransburg (800) 233-3366 Jansen Ornamental Supply Co. Inc. (800) 4-JANSEN King Architectural Metals (800) 542-2379 Laser Precision Cutting (800) 514-8065 C.R. Laurence Co. Inc. (800) 421-6144 Lavi Industries (800) 624-6225 Lawler Foundry Corp. (800) 624-9512 Lewis Brass & Copper Co. Inc. (800) 221-5579 Liberty Brass Turning Co. (800) 345-5939 Logical Decisions Inc. (800) 676-5537 Mac Metals Inc. (800) 631-9510 Marks U.S.A. (800) 526-0233 Master Halco (800) 883-8384 McKey Perforating (800) 345-7373 July/August 2009  Fabricator

Mittler Bros. Machine & Tool (800) 467-2464 Multi Sales Inc. (800) 421-3575 Mylen Stairs Inc. (877) 303-9422 NC Tool Co. (800) 446-6498 New Metals Inc. (888) 639-6382 Ohio Gratings Inc. (800) 321-9800 Overseas Supply Inc. (866) 985-9885 P & J Mfg. Co. (419) 227-8742 Paxton & Thau Artistic Supply (866) 629-2790 Precision Glass Bending Corp. (800) 543-8796 ProCounsel (866) 289-7833 Q-Railing USA Co. (714) 259-1372 RedPup LLC (928) 422-1000 Regency Railings Inc. (214) 742-9408 Riata Mfg. (915) 533-9929 Robert J. Donaldson Co. (856) 629-2737 Robertson Grating Products Inc. (877) 638-6365 Robinson Iron Corp. (800) 824-2157 Rockite, Div. of Hartline Products Co. Inc. (800) 841-8457 Rogers Mfg. Inc. (940) 325-7806 L.E. Sauer Machine Co. (800) 745-4107 Scotchman Industries Inc. (800) 843-8844 SECO South (888) 535-SECO Sharpe Products (800) 879-4418 Stair Service Inc. (800) 478-2477

Stairways Inc. (800) 231-0793 Steel Masters Inc. (602) 243-5245 Stephens Pipe & Steel LLC (800) 451-2612 Striker Tool Co. (USA) Inc. (866) 290-1263 Suhner Industrial Products Inc. (706) 235-8046 Sumter Coatings Inc. (888) 471-3400 Taco Metals (800) 743-3803 Taurin Group USA (909) 476-8007 Tennessee Fabricating Co. (800) 258-4766 Texas Metal Industries (800) 222-6033 Transpacific Industrial Supply Inc. (909) 581-3058 Triple-S Chemical Products (800) 862-5958 Tri-State Shearing & Bending (718) 485-2200 TS Distributors Inc. (800) 392-3655 Universal Entry Systems Inc. (800) 837-4283 Vogel Tool & Die, Div. of TES Tube Equipment Inc. (800) 272-8946 The Wagner Companies (888) 243-6914 Wasatch Steel Inc. (888) 486-4463 West Tennessee Ornamental Door (866) 790-3667 Xycorp Inc. (888) 745-0333


What’s Hot ? 

Inside Events . . . . . . . . . . . . . . . . . . .73 Chapters . . . . . . . . . . . . . . . . .74

Products . . . . . . . . . . . . . . . . .76 Literature . . . . . . . . . . . . . . .78

Biz Briefs

AGA’s scholarship essay winners

Industrial Metal Supply launches first retail storefront Industrial Metal Supply Company’s (IMS) Irvine, CA branch is being reconfigured as the first fullservice retail storefront facility. Once the conversion of the Irvine facility is complete, all commercial and industrial deliveries for Orange County customers will be handled by the IMS Riverside facility, which will expand its staff to meet the increased demand. IMS is positioning itself for future expansion to include additional retail storefront facilities throughout the region. The company stocks steel, aluminum, stainless, brass, copper, and silicon-bronze. Contact: Industrial Metal Supply Co, Ph: (800) 350-6768; Web:

The American Galvanizers Association (AGA) recently announced the winners of the 2009 Galvanize the Future: An Edgar K. Schutz Scholarship essay contest. Three students were selected from more than 40 applicants based in architecture, civil, or other engineering programs in North America. Securing the first place prize of a $2,500 scholarship is Anna Bruce, an 18-year-old student majoring in Mechanical Engineering at Texas Tech University in Lubbock, TX. Her essay, “The Galvanized Community,” was selected the winner by a panel of three industry experts that judged the essays on six criteria. The second place winner of a $1,500 scholarship is 21-year-old Stephanie Grannetino, Architecture major at Philadelphia University in Philadelphia, PA. Her essay, titled “What has the Steel Construction Industry Seeing Green?” examined the

Metal Museum announces new online store The Metal Museum’s signature American-made jewelry, sculpture, books, and home accessories are now available online. The online inventory changes weekly. All proceeds from the store support museum programming; donations are also accepted. Contact: National Ornamental Metal Museum Foundation Inc., Ph: (877) 8812326; Web: NYC adopts new codes New codes went into effect in the Big Apple on July 1. The city now follows the 2008 NYC Construction Codes. Contact: International Code Council, Web:


green qualities of hot-dip galvanized steel, as well as the financial benefits. The third place winner, 24-year-old Jenny Joe, was awarded a $1,000 scholarship. She tackled the second essay option, creating a course outline to teach students about corrosion management and the role of hot-dip galvanized steel. Joe will be attending Columbia University in New York, NY, in the fall to study Architecture and Urban Design. The scholarship opportunity is open to college students majoring in architecture, civil engineering, or structural engineering. Construction management, material science, or other approved engineering fields are now included. The student can be fullor part-time, and enrolled in either an undergraduate or graduate degree program at any four-year university in North America. Contact: AGA, Ph: (720) 554-0900; Web:

Encon presents Apollo technical seminar Encon Electronics collaborated with Apollo Gate Operators in May for a joint technical training seminar. The first day of the two-day workshop was held at the Encon Training Facility in Hayward, CA. The second day was

held at the Holiday Inn, Elk Grove, CA. Nearly 40 Encon dealers attended the two seminars conducted by Apollo technical support representative Ron Swartz and West Coast sales manager John Anderson. Topics included product demonstrations, troubleshooting techniques, and the Apollo 835/836 circuit board in detail. Additional Encon seminars are scheduled at the training facility in Hayward, CA. Customized training is also offered. Contact: Encon, Ph: (800) 782-5598; Web: Encon and Apollo teamed up for a joint training seminar. Fabricator  July/August 2009

What’s Hot?  Metalworking and CNC Machine Tool Show 2009

November 3-7, 2009 The Metalworking and CNC Machine Tool Show China will be held at the Shanghai New International Expo Center (SNIEC). Currently in its tenth year of existence, southeastern China’s trade fair for machine tools, metalworking, and metal processing is gearing up for exhibits, demonstrations, and generating business leads. The Aerospace and Aviation Technology Show will be held concurrently. Contact: Hannover Milano Fairs Shanghai Ltd., Ph: +49 511 89-31632; Web: 6th Annual Forge-In Blacksmith Festival

October 17, 2009 Artistic blacksmiths and vendors are invited to the Forge-In at Fitchburg


Fall ICC Code Hearings October 24 – November 11, 2009

NOMMA will be represented at the 2009 ICC code hearings, which take place in Baltimore, MD. Contact: International Code Council. Web: Riverfront Park in Fitchburg, MA. The event draws thousands of visitors each year and offers live blacksmith competitions and demonstrations for cash and prizes, children’s activities, entertainment, food, and works by artists. Contact: Discover Fitchburg, Ph: (978) 345-9596; Web: Metal Museum’s “Selections from the Permanent Collection”

June 26-August 23, 2009 The Metal Museum of Memphis,

TN is pleased to present “Selections from the Permanent Collection.” This show, comprised of four separate exhibitions, offers viewers an opportunity to experience historic and contemporary metalwork. Contact: The Metal Museum, Ph: (901) 774-6380; Web: Traditional Building Exhibition & Conference

October 21-24, 2009 The event will be held at the Baltimore Convention Center and will feature historic restoration, rehabilitation, and traditional building sessions. Approximately 5,000 participants are expected to take part in seminars, workshops, craftsmanship demonstrations, architectural tours, and social events. Contact: Restore Media, Ph: (866) 566-7840; Web:

• • • •

July/August 2009  Fabricator


What’s Hot? 

Chapter News

Upper Midwest Chapter enjoys finishing demos The Upper Midwest Chapter held their

summer meeting and annual social on June 13 in St. Louis, MO. Serving as host shop for the day was Foreman Fabricators Inc., which is celebrating its 50th anniversary this year. Activities for the day started with a business meeting, which was followed by a presentation on how to obtain a quality finish on radius tube corners and a concentric finish on round parts. The Foreman Fabricators staff showed some of the solutions they have come up with, and they demonstrated their techniques on various aluminum and stainless steel items. In addition, there was a discussion on polishing mediums. For lunch, Foreman Fabricators treated everyone to a wonderful meal provided by a nearby Italian restaurant. The lunch was followed by a

presentation from Rob Rolves on shop control software. After the meeting, the annual social festivities began! The first activity was a walking tour of the historic Soulard neighborhood. The community is one of the oldest parts of St. Louis and has homes that were built in Chapter members have fun with one of the exhibits at the City Museum. the mid-1800s. house, three-story slide, and other feaFor dinner, chapter members and tures. Throughout the evening attenguests dined at The Dubliner, which is dees and their families had a great a popular Irish Pub. From there, attentime exploring the museum and enjoydees went on the next leg of their ing the many exhibits. evening adventure, which was a visit to All in all, it was a wonderful day, City Museum. The museum, which is with an excellent attendance of 30 peohoused in a former shoe company ple. A thanks goes to Foreman Fabribuilding, had something for everyone, cators for their generous hospitality. including a children’s playground, fun-



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What’s Hot? 

Chapter News Mark Koenke, chapter president and Top Job chair, presented Todd Kinnikin from Eureka Forge with the 2009 Mitch Heitler Award for Excellence.


Scenes from the Upper Midwest Chapter’s summer meeting and annual social.


The polishing demo at Foreman Fabricators Inc.

Attendees enjoyed a walking tour of the historic Soulard neighborhood.


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Lubrication and rust protection

Pipe/tube notching tool

Birchwood Birchwood Casey Metal Finishes presents TRU TEMPÂŽ low temperature, black oxide for use on sprockets, universal joints, sheaves, and power transmission components. The TRU TEMP finish is designed to offer protection from galling and corrosion, without impairing fit. TRU TEMP solutions contain no EPA regulated chemicals. Contact: Birchwood Casey, Ph: (952) 937-7931; Web:

Woodward-Fab The new model WFN6 notcher by Woodward-Fab uses standard hole saw blades to create weld fit-up saddles in tubing up to 3" diameter. The notcher is designed for tube frames, roll bars, and frame connectors, and is constructed from CNC machined ž" steel plate. The angle can be adjusted from 0 to 90 degrees. Power is supplied by any ½" hand drill motor. Contact:




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Outwater Outwater Plastics Industries + Architectural Products by Outwater is pleased to introduce its updated line of powder coated wrought iron elements for use with wood railings. The elements are available in round and square formats, along with a line of smooth and forged edge or heavily hammered and ribbon twisted designs. Finishes include flat or satin black, copper or silver vein, antique bronze or nickel, and oil rubbed copper. The elements are suitable for both residential and commercial design applications. Contact: Outwater, Ph: (888) 772-1400; Web:

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What’s Hot? 


Lumenrail® LED light sticks

Wagner The Wagner Companies has introduced Lumenrail LED light sticks. The luminaries are ¾” wide and come in lengths from six to 60 inches. Wagner Lumenrail LED light sticks are designed to be installed indoors or out, in wet or dry locations, and may be mounted on the wall, ceiling, or under a cabinet. Contact: Wagner Lumenrail, Ph: (888) 243-6914; Web: or www.wagnercompanies. com.

tional threaded terminals, eliminating the need for in-line turnbuckles or threaded terminals with cap nuts. The product is available for ⅛”, 3/16”, and ¼” wire for machine swage, or ⅛” and 3/16” for hand crimp. Contact: C. Sherman Johnson Co. Inc., Ph: (860) 8738697; Web: Pro Series 4896 models

Techno CNC Routers is proud to release the first production run of the Model 4896 Pro Series. Introduced earlier this year,

Terminal Tuner turnbuckles

Johnson Johnson Architectural Hardware has recently introduced the “Terminal Tuner” turnbuckles line for architectural cable railings. The terminal tuners terminate cable with conven-

the Pro Series was designed for panel process manufacturing. The new heavyweight (3050 lbs.) 4896 model has a 4 ft. x 8 ft. process area and uses Finite Element Analysis (FEA) software. The 4896 has precision ball screw drives on all three axes, THK rails/bearings, and high-speed closedloop servomotors and drives. By design, the Pro Series can also be equipped with various spindle setups for high volume part production, multi-zone vacuum table, reverse engineering lasers, and 4th axis rotary tables. Contact: Techno, Ph: (800) 819-3366; Web: Locking chain plier with replaceable chains

Strong Hand Strong Hand Tools™ has designed a locking chain plier with extra length

Infill Panels

Rectangular Mesh

Diamond Mesh

We will custom fabricate infill panels to meet your specific requirements. Available in diamond, rectangular and square mesh with or without standoffs. Frames available in 1" x ½" channel or with a hemmed edge. Division 5,8 and 10.

Call us today and we'll take care of your infill panel needs.

Diamond Mesh w/Standoff

Square Mesh

"From the simplest to the complex, Jesco does it best!" Call toll free

96 1-800-609-82 View our complete catalog ate .com nlin www.JescoO Jesco Industries, Inc. 950 Anderson @ Fab Road Litchfield, MI 49252-0388

Phone: 1-517-542-2353 Fax: 1-517-542-2501

July/August 2009  Fabricator


What’s Hot? 


Literature Online literature for products and parts

Weldcraft To help customers choose TIG torches, consumables, and accessories, Weldcraft now offers downloadable PDFs of spec sheets, replacement parts data, and more on their website. The literature and manual web page helps customers find supporting documents for specific torch models and replacement parts. Other downloads include owner’s manuals for select TIG torches and connection diagrams for connecting both air- and watercooled torches to common power sources. Contact: Weldcraft; Ph: (800) 752-7620; Web:

for increased holding capacity. Locking chain pliers can be used for clamping unusual-shaped materials or a group of materials. The Xtra-Length locking chain plier comes standard with a 24” chain, which can be removed from the plier and replaced with a series of six chains, measuring from 16”-78” in length. Contact: Strong Hand Tools, Ph: (800) 9895244; Web: Universal milling machine

Knuth Knuth’s VHF 3 features vertical milling, drilling and tapping, and a horizontal arbor for horizontal milling, slotting, and keyway cutting. The machine’s vertical head swivels ± 45° and offers three axes with automatic feed and rapid feeds. Contact: KNUTH Machine Tools USA Inc., Ph: (847) 4153333; Web:

Wicked helmet design

Miller Miller Electric has just added the “Wicked” design to its Elite and Digital Elite Series of Arc Armor auto-darkening helmets. Elite and Digital Elite helmets are designed to offer welding comfort and safety with integrated auto-darkening and other technologies. Contact: Miller, Ph: (800) 426-4553; Web: T4 titanium machining

Makino Makino’s new T4 five-axis horizontal machining center is designed for titanium milling, combining manufacturing methods and metal removal rates for aerospace applications such as edge frames, pylons, and bulkheads. The T4 can be equipped with an automatic pallet changer system for continuous operations. Contact: Makino, Ph: (800) 5523288; Web: EasyView™ tooling carts


Anvils Hammers


Professional Quality Tools for the Blacksmith Wide Selection Spring Swages

See our work at


Kayne and Son 100 Daniel Ridge Road • Candler, NC 28715 U.S.A. Phone: 828 667-8868 Fax: 828 665-8303 78

Mate Precision Tooling announces introduction of Mate EasyView™ tooling carts for visual tool management on the shop floor. The carts can carry a 2800 lb. tooling load and can be configured as needed. EasyView carts are built from heavy-duty 14-gauge powder-coated steel and have four 700 lb. capacity casters. Contact: Mate, Ph: (800) 328-4492; Web: Fabricator  July/August 2009

What’s Hot?  Impact ready drill bits

DeWalt DeWalt is expanding its existing line of Impact Ready products with the launch of the new Impact Ready drill bits. DeWalt built the new Impact Ready drill bits with a one-piece shank design to reduce bit breakage and a patented tapered web design for hightorque applications. Contact: DeWalt, Ph: (800) 4DeWalt; Web:


Literature New catalog features 175 pages of components

D.J.A. Imports D.J.A. Imports is proud to announce the release of their 2009 catalog. The 175-page publication features a full range of components, including pickets, belly bars, panels, scrolls, hardware, and many other items. A color section in the rear of the catalog shows samples of completed projects in the field. Some items in the catalog are not available on the website. Fabricators may download a free copy from the company’s website, or the publication may be ordered by phone or email. Contact: D.J.A. Imports. Ph: (718) 324-6871. Email:

300 Ton Crimper

Wauseon Wauseon Machine is pleased to announce the O+P H80 300-ton hydraulic crimping press. The machine is designed for crimping hose up to 2” diameter - 6 wires. In addition, this machine is also used to swage tubing, crimp cables and component assembly, and is powered by a 7.5 HP motor. The

Online digital photo gallery

Vernon Tool Vernon Tool launches a new online digital photo gallery with more than 325 photos to demonstrate the range of Vernon Tool machines, industrial applications, and on-site projects. The gallery of application and product photos is available on the company’s website. Contact: Vernon Tool, Ph: (760) 433-5860; Web:

DON’T USE A TWIST DRILL TO DO AN ANNULAR CUTTER’S JOB. For materials up to 1/2" thick

48 diameters from 1/4" thru 1-1/2", 6 mm thru 25 mm

Precision ground hardened M2 H.S.S.

Patented tooth geometry provides smooth cutting action

Cut round, virtually burrfree holes in seconds

No surface scratching or dimpling

10 times the tool life of hole saws

Whether you’re making a few holes with hand-held tools or thousands of holes in production applications, only Hougen RotaCut ™ Sheet Metal Cutters give you clean, accurate and virtually burr-free holes 3X faster than twist drills or hole saws with longer tool life and no need for secondary operations. Available in two convenient kits... 5/16 thru 3/4" and 7/8 thru 1-1/2" diameters.

800-426-7818 • July/August 2009  Fabricator

Made in USA


What’s Hot? 


crimper can produce up to 470 operations per hour. Contact: Wauseon Machine, Ph: (419) 337-0940; Web:

thetic metal removal fluids for machining and grinding ferrous and nonferrous alloys. Multan® B 236™ is created for most water conditions and multi-metal applications. Additionally, the Multan® B 414™ contains more oil and extreme pressure additives for use on soft metals and alloys such as aluminum, stainless steel, titanium, inconel, brass, or copper. Contact: Henkel Corporation, Ph: (860) 228-8056; Web:

Metal removal lubricants

Henkel Henkel Corporation has introduced two new water-soluble Multan® metal removal lubricants formulated to resist bacteria and foaming. Henkel’s Multan® B 236™ and B 414™ are semi-syn-


New DVD package available


In its efforts to offer comprehensive educational materials to technical schools, students, trainers, and the larger manufacturing community, the Society of Manufacturing Engineers (SME) announces the release of a nine-DVD package based on the textbook, Fundamentals of Tool Design, 5th Edition. The package consists of the textbook and nine DVDs and features contributions by well-known industry representatives. Contact: SME, Ph: (800) 733-4763; Web:


Smart Solutions for a Challenging Market To register visit: Carolyn Walsh 781.779.1560 Exhibitor inquiries: Anita Delargy 866.566.7840 Speaker inquiries: Judy Hayward 802.674.6752

Baltimore, Maryland Oct. 21-24, 2009 Baltimore Convention Center 80

ABANA 15754 Widewater Drive Dumfries, VA 22025-1212 703-680-1632


Association of North America, Inc. Fabricator  July/August 2009

Advertiser’s index A thanks to the following advertisers for their support of O&MM Fabricator magazine ... Pg. 80 3 46 43 79 31 78 61 9 65 35 76 62 23 64 22 29 4 25 40 11 62 53 16 17 21 63 38 79 10 59 84 32 77 84 13 2 77 28 74 75

Company . . . . . . . . . . . . . . . . . .Website ABANA . . . . . . . . . . . . . . . . . . . . Apollo Gate Operators . . . . . . . Architectural Iron Designs . . . . Arteferro Miami . . . . . . . . . . . . Atlas Metal Sales . . . . . . . . . . . Big Blu Hammer Mfg. Co. . . . . Blacksmiths Depot . . . . . . . . . . Julius Blum & Co. Inc. . . . . . . . Byan Systems . . . . . . . . . . . . . . COLE-TUVE Inc. . . . . . . . . . . . . . The Cable Connection . . . . . . . John C. Campbell Folk School Carell Corp. . . . . . . . . . . . . . . . . Chicago Metal Rolled Products. Colorado Waterjet Co. . . . . . . . CompLex Industries Inc. . . . . . D & D Technologies (USA) Inc. D.J.A. Imports Ltd. . . . . . . . . . . DKS, DoorKing . . . . . . . . . . . . . Decorative Iron . . . . . . . . . . . . . DynaTorch . . . . . . . . . . . . . . . . Eagle Bending Machines . . . . . Eberl Iron Works Inc. . . . . . . . . Encon Electronics . . . . . . . . . . . FabCAD Inc. . . . . . . . . . . . . . . . Feeney Architectural . . . . . . . . . The G-S Co. . . . . . . . . . . . . . . . . Hebo - Stratford Gate . . . . . . . Hougen Mfg. Inc. . . . . . . . . . . . Industrial Metal Supply Co. . . . International Gate Devices . . . The Iron Shop . . . . . . . . . . . . . . Jansen Ornamental . . . . . . . . . Jesco Industries Inc. . . . . . . . . . King Architectural Metals . . . . . Lawler Foundry Corp. . . . . . . . . Lewis Brass & Copper Co. Inc. Lindblade Metal Works . . . . . . Marks U.S.A. . . . . . . . . . . . . . . . Pat Mooney Inc. . . . . . . . . . . . . NC Tool Company Inc. . . . . . . .

Attention Suppliers! Plug into the NOMMA Network Call (888) 516-8585, ext. 101

Advertise in Fabricator!

Help us celebrate our 50th anniversary by placing an ad in Fabricator. For more info, download our new media kit at

July/August 2009  Fabricator

76 47 15 52 65 33 7 74 27 73 30 55 66 45 57 42 37 48 56 73 80 50 75 18 49 20

National Custom Craft Inc. . . . Olin Wrought Iron Line . . . . . . P & J Mfg. Co . . . . . . . . . . . . . . . Paxton & Thou Artistic . . . . . . . Postville Blacksmith . . . . . . . . . Production Machinery Inc. . . . . Q-Railing . . . . . . . . . . . . . . . . . . R & D Hydraulics . . . . . . . . . . . . Regency Railings . . . . . . . . . . . Rod Iron Rod . . . . . . . . . . . . . . .432-582-2226 Sharpe Products . . . . . . . . . . . . Simsolve . . . . . . . . . . . . . . . . . . Society of Mfg. Engineers . . . . Stairways Inc. . . . . . . . . . . . . . . Striker Tool Co. (USA) Inc. . . . . Sumter Coatings Inc. . . . . . . . . Sur-Fin Chemical Corp. . . . . . . TACO Metals . . . . . . . . . . . . . . . Texas Metal Industries . . . . . . . Tiger Stop LLC . . . . . . . . . . . . . . Traditional Building . . . . . . . . . Tri-State Shearing & Bending . . .(718) 485-2200 Universal Entry Systems Inc. . . .(800) 837-4283 Wagner Companies, The . . . . . Weaver's Iron Works . . . . . . . . . YAC Equipment & Machinery .

Companies in bold are first-time advertisers.

Check out Fabricator Online Can’t find your current copy of Fabricator? Our new, online edition makes it easy to access the magazine from home or work. To see the online edition, visit www. and click on “Fabricator Online.”

As a supplier NOMMA offers many marketing opportunities to gain exposure for your company, including membership, advertising, exhibiting, and sponsorships.

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. 81

Metal Moment

Plug into the resources of the Metal Museum

The Metal Museum offers a variety of opportunities for learning metalsmithing skills. Itâ&#x20AC;&#x2122;s never too late to learn more about

your craft or refine your techniques! Did you know that The Metal Museum offers a variety of internships and residencies? Opportunities include the two-year Blacksmith and Museum Internship, general museum internships, 3-12 month artist-in-residents, and library research residencies.  Blacksmith and Museum Internship. This two-year intern program provides housing and studio facilities. The intern works in the blacksmith shop and assists with exhibit design and installation during regular business hours. The intern has unlimited access to the blacksmith shop and foundry. At the end of the two-year period, the intern has a body of his or her own work, as well as experience working on large-scale projects designed and produced by the museum. The next available internship is June 2010.  General Museum Internships. Participants learn about collections 82

management, exhibition design and installation, marketing, and much more. Internships are designed to meet the individual goals and needs of the participants.  Artist-in-Residence. This program affords artists the opportunity to live and work in a stimulating, supportive museum environment. With full access to the on-site smithy and foundry, artists are able to focus on their art and create a new body of work over the course of three, six, or 12 months. The program welcomes self-motivated, focused individuals working in various forms of metal arts including foundry, conservation/small metals, and blacksmithing work. Housing, health insurance, studio space, and some materials are provided. The residency does not include a living stipend. Applications may be submitted at any time. Residencies are awarded based on merit and availability.  Research Residencies. Artists

and art historians may apply for a research residency. Residencies include housing and access to the library collection. Interested applicants may apply at any time. Residencies are awarded based on merit and availability. Each residency and internship has its own application process and requirements. For more details, visit ml. Located on 3.2 acres on the Mississippi River in Memphis, TN, The National Ornamental Metal Museum is the only institution in the United States devoted exclusively to the preservation and promotion of fine metalwork. Unlike ordinary museums, it isnâ&#x20AC;&#x2122;t just a place where art is displayed; itâ&#x20AC;&#x2122;s a place where art is made. At the Metal Museum you can see works of art, see artists work, learn the craft, and craft the art. Contact: Carissa Hussong, The Metal Museum, Ph: (877) 881-2326; Email: Fabricator  July/August 2009


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King Architectural Metals L O S





Metal Spiral

Oak Spiral

Victorian One Spiral

Proud nationwide member of...

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1-800-523-7427 Ask for Ext. FAB or visit our Web Site at

2009 07 fab  
2009 07 fab