Page 1

Ornamental and Miscellaneous Metal


The official publication of the National Ornamental & Miscellaneous Metals Association

May / June 2011 $6.00 US

Photographic glimpse of METALfab 2011 page 36

2011 Mitch Heitler Winner: Wrought Iron Art Ltd. Category: Forged Driveway Gates

Shop Talk

In-house machining, page 16

Shop Talk

Injured eyes don’t lie, page 26

Member Profile

Keep ‘heavy arts’ alive, page 31

Biz Side

Energy retrofits save money now, page 45


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May / June 2011 Vol. 52, No. 3

Lots of fun and learning at METALfab 2011, page 36

NOMMA Network

Member Talk

Florida chapter holds demos and classes............................... 10

Also, service day at Metal Museum. By Todd Daniel Tips & Tactics Website marketing and optimization considerations....... 14

By Paul Barkley

Shop Talk In-house machining............................ 16

Saws, lathes, drill presses, and milling machines help machinists achieve the desired geometry. By Pete Hildebrandt

Injured eyes don’t lie......................... 26

Fabricators need properly selected eyewear and common sense to help prevent eye injuries. By Jeffrey Dean Fogel We never stop learning — unless we choose to.

Keep ‘heavy arts’ alive..................... 31

With a patent for an aluminum railing system, NOMMA member Bill Coleman’s Arc Angels features his aluminum, iron, steel artwork, from gates and railings to wine racks. By Molly A. Badgett METALfab 2011 METALfab 2011 trade show review.............................................. 36

Our photographic glimpse offers the action and educational opportunities that attendees enjoyed during METALfab. For non-attendees, we hope you see a reason to attend in 2012. Biz Side

Shop Talk

President’s Letter........... 6

Biz Side

Energy reducing retrofits you can do now...................................... 45

Several federal tax-saving incentives and funding program can help you go green. By Mark E. Battersby

Exec. Director’s Letter.... 8

The backbone of America.

Employee theft....................................... 48

Implementing a series of policies and paying close attention to your employees will help you deter theft and fraud. We provide you with a list of early warning signs and ideas to help you mitigate the problem. By William J. Lynott

Secure your business future........ 51

Proactive estate and succession planning help make a family company have successful transition to new generation. By Leon and Terrance Resnick What’s Hot!

Business Briefs................................. 58 Events.................................................... 58 Literature............................................. 60 New Products..................................... 61 Nationwide suppliers..................... 56 New members.................................... 57

NEF Chair Letter............ 12 What IS the NEF? And what is its relationship to NOMMA?

Metal Moment............... 66

How to give constructive criticism.

About the cover The 2011 Mitch Heitler Award, for the best of the best, went to Wrought Iron Art Ltd. for this residence gate/

fence system. The same job also won a gold award in the Gates, Driveway-Forged category. See list of winners on page 43. May / June 2011 n Fabricator


NOMMA O fficers President James Minter, Jr. Imagine Ironworks Brookhaven, MS

President-Elect Will Keeler Keeler Iron Works Memphis, TN

Vice President/ Treasurer J. R. Molina Big D Metalworks Dallas, TX

Immediate Past President Bruce Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA

F abricator D i rectors Todd Kinnikin Eureka Forge Pacific, MO

Ray Michael R & F Metals Inc. Clinton, MD

Mark Koenke Germantown Iron & Steel Corp. Jackson, WI

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

Keith Majka Majka Railing Co. Inc. Paterson, NJ

Greg Terrill Division 5 Metalworks Kalamazoo, MI

S u ppli er D i rectors Wayne Haas Cleveland Steel Tool Co. Cleveland, OH

Rick Ralston Feeney Inc. Eugene, OR

Treasurer Mike Boyler Boyler’s Ornamental Iron Inc. Bettendorf, IA

T rustees Heidi Bischmann The Wagner Companies Milwaukee, WI Carl Grainger Grainger Metal Works Nichols, SC James Minter, Jr. Imagine Ironworks Brookhaven, MS Lynn Parquette Mueller Orn. Iron Works Inc. Elk Grove Village, IL

NOMMA C hapters Florida Chapter Britt Gordy, President Liberty Aluminum Co. Fort Myers, FL (239) 369-3000

Northeast Chapter Keith Majka, President Majka Railing Co. Inc. Paterson, NJ (973) 247-7603

Gulf Coast Chapter Scott Colson, President Iron Innovations Inc. Clinton, MS (866) 924-0640

Upper Midwest Chapter Mark Koenke, President Germantown Iron & Steel Corp. Richfield, WI (262) 677-2530

NOMMA S taff Executive Director, Editor J. Todd Daniel Layout Editor Robin Sherman


We never stop learning — unless we choose to My mom, Maxine, is an 85-year-

If that yearly participation old amateur artist. She could sit can do that for me, a small back to paint what she already businessman in the rural Deep knows, painting in the styles South, it can do the same for with which she is most comforteach and every member of able. Who would blame her? NOMMA. But she simply cannot do If you did not take advanthat. She loves to paint and tage of METALfab 2011 in New James Minter, Jr., Orleans this year, pay some she always wants to improve Imagine her painting skills. She attends attention to the opportunities Ironworks, is workshops on pastels, oils, wa- president you are missing to make your tercolors, painting techniques, business better. of NOMMA. and takes other painting classes Please put METALfab 2012 to make her artworks better. She on your calendar now — just doesn’t quit looking for ways to February 29 through March 3, 2012. make her art better and better. What METALfab does for me

NOMMA E ducation F ou n dation O fficers

Vice Chair Christopher Maitner Christopher Metal Fabricating Grand Rapids, MI

President’s Letter

Is cost a challenge?

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

Chair Roger Carlsen Ephraim Forge Inc. Frankfort, IL


Dedicated to the success of our members and industry.

Meetings & Exposition Manager; NEF Executive Director Martha Pennington Member Care & Operations Manager Liz Johnson

METALfab gives me an opportunity to learn more about techniques and work practices to make my business better and more successful. Whether it is in finishes, design, understanding codes, or better business practices, METALfab always gives me something to bring home and make my “art” better and better. The yearly opportunity of participating NOMMA’s annual convention, with its education sessions, trade show, and chance individual conversations can improve our own businesses, along with those of our colleagues and friends. It also makes NOMMA a stronger organization for everyone. A win-win situation for us all, wouldn’t you agree? So why don’t more of our members take advantage of METALfab? Maybe we don’t get the word out well enough. Every METALfab that I’ve attended has given me ideas that: n make my company money, n save my company money, and n turn new customers into repeat customers. Participation in METALfab has contributed to our success at Imagine Ironworks in Brookhaven, MS.

I encourage you to begin a small savings program today; vow to save a little each month toward your expenses next year. This simple budgeting plan will help you to take advantage of one of the most valuable tools you have at your fingertips through your membership in NOMMA: METALfab 2012. My challenge to each of you who has taken advantage of METALfab over the years is to “talk it up.” Everywhere you go, every colleague you come into contact with, even the architects and contractors that you know, tell them what NOMMA and METALfab have done for you (and in turn, for them) by making you a successful businessperson/artist. Thank you all for your continued support of our wonderful organization. I look forward to seeing you all, if not during this next year, then at METALfab 2012 in Orlando, FL. And who knows, my by-then 86-year-old mother may also be there, perhaps working on a painting — using some new technique she just recently learned to improve her skill.

Fabricator n May / June 2011



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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 805 South Glynn St., Ste. 127, #311 Fayetteville, GA 30214 Editorial We love articles! Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph/Fax: (888) 516-8585. E-mail: Advertise Reach 8,000 fabricators For information, call Jim Gorzek, Ph: (815) 227-8269. Email: Ads are due on the first Friday of the month preceding the cover date. Send ads to: Fabricator at address above. E-mail ads to: (max. 5 megs by e-mail). Or upload ads to our website where a downloadable media kit is available: 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. Exhibit in METALfab Exhibit at METALfab, NOMMA’s annual convention and trade show. For more information, contact Martha Pennington at (888) 516-8585, ext. 104, or Subscriptions Subscription questions? Call (888) 516-8585. Send subscription address changes to: Fabricator Subscriptions, 805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214. Fax: (888) 5168585, 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. NOMMA 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 2011 Editorial Advisory Council Doug Bracken.......... Wiemann Metalcraft Nancy Hayden......... Tesko Enterprises Tom McDonough.... Master Metal Services Rob Rolves................ Foreman Fabricators Inc. 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. © 2011 National Ornamental & Miscellaneous Metals Association 8


How to reach us

Executive Director’s Letter

The backbone of America As I visit NOMMA shops, and

and delivers an exceptional get to know our membership product, so please pay us on better, I am in awe of the “spirit” time. Listen to our opinions on of our industry. The vast majorhow to make a project better. ity of our membership is made And if you give us extra paup of small businesses, and perwork to fill out, understand many of these are family run. that we must account for this Fueling the spirit of our time in our price. Todd Daniel trade is passion, creativity, and is executive director of the love for a challenge. Education and knowledge NOMMA. Even shops that don’t do While it is important for all ornamental work are creative of us to be respectful and have as they discover clever ways to reasonable requirements, we in build incredible miscellaneous the industry can increase effiand structural metal products. ciency through education. When you combine this creativity with I encourage you to read the busithe savvy that running a business reness articles in each issue of O&MM quires, you end up with a remarkable Fabricator, attend the business sesgroup of craftspersons. sions at METALfab, and participate in our email discussion list, which is now Government called the “NOMMA Problem Solving In short, ornamental and miscelNetwork.” laneous metal shops represent the Finally, I’d like to put in a plug for very best of what our country is about: two organizations that look out for Small businesses that give people our interests. The American Subcongood jobs, enhance the beauty of the tractors Association (ASA) does a built environment, and provide a solid good job with protecting the rights of foundation for our economy. subcontractors, both with government But small businesses are also disand general contractors. proportionately taxed and regulated. If I’m hoping that NOMMA will we want to rebuild our economy and rejoin this organization and get increate a healthy, sustainable marketvolved when finances permit. You can place, we need a tax system that is fair also join as an individual at www. and government regulations that are streamlined with limited intrusion. Another organization that deserves Small businesses are the bedrock a “shout out” is the National Federaof our communities and nation, and tion of Independent Business (NFIB), anything we can do to foster their which gives small businesses a voice success is a win-win for all. I am not in Washington. The group is active on advocating libertarianism or any kind the state and national levels in all 50 of political philosophy, I just want states. government to make life easier for Most recently, they won a great vicsmall companies and not burden them tory by getting the Senate to repeal to death with frivolous paperwork and the new and excessive IRS Form 1099 requirements. reporting requirements. Look them up at Customers

To our customers, I only ask that you respect us. Our trade is made of skilled craftspersons and business professionals. Our industry works hard Fabricator n May / June 2011



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The NOMMA Network Florida chapter holds demos and classes

Phil Heermance, right, gives a treadle hammer demo. The orchids, below, were among the plant items created during the forging demos.

Art Ballard, above (left), talks about the tools and techniques used in his shop. A representative from Metabo Corp., left, gave a demo on finishing and polishing.

Service Day at Metal Museum NOMMA volunteers completed a variety of jobs at the Metal Museum in Memphis, TN during the first annual volunteer day on April 30. Throughout the day, members worked on handrails, the gazebo, and other projects. There was plenty of scraping and painting going on. As an added bonus, the NOMMA Education Foundation hosted a class on scratch casting. In the evening, the Keeler family held a dinner gathering. A thanks to all members who attended. Plans are to make the service day an annual event. James Minter Jr. positions a handrail for the library access ramp.

The Florida Chapter enjoyed an exciting day of education and demonstrations at their April 30 meeting in Miami, FL. Art’s Work Unlimited served as host shop and about 35 attendees came to enjoy a variety of demos. Art Ballard began the meeting by sharing the history of the company and his association with Phil Heermance. He spoke of the slow economy over the past two years and how the company responded with both marketing and by expanding into new product lines, such as stainless steel stairs and cable rails. Art showed an example of a tenth scale stair they used as a model for a full stainless steel stair they recently built. He then gave a tour of his shop and discussed the tools they used, paint processes, and installation. Phil Heermance provided a variety of demonstrations throughout the day, including stainless steel techniques, repoussÊ techniques (including the use of a treadle hammer), paint techniques to provide a faux bronze finish, forging with angle to provide a variety of leaf shapes and flower petals (such as the orchid), and forging with tube. Metabo Corp., a NOMMA supplier member, provided a demonstration of stainless steel finishing and polishing tools and techniques. The American Welding Society, which is based in Miami, provided a safety demonstration, and Jay Mudge gave a demo on creating bamboo from aluminum tube. The day of fun and learning included a barbecue lunch and plenty of time for networking and socializing.

Our apologies A few ads were improperly placed in the last issue, which caused some confusion for readers. It is our policy to separate direct competitors and to not place ads in articles with related subject matter. O&MM Fabricator magazine regrets the errors. 10

Fabricator n May / June 2011

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NOMMA Educational Foundation

In partnership with the National Ornamental & Miscellaneous Metals Association

What IS the NEF? And what is its relationship to NOMMA? By Roger Carlsen, NEF Chair

ible contributions, grants, and matching gifts. n Is restricted in the amount of political and legislative (lobbying) activities it conducts. n Must limit the organization’s purpose to its specified cause, and may not expressly engage in activities that are not in furtherance of its specified purpose.

In the past I have addressed what NEF does, but I

have recently realized that I had neglected to explain what the foundation is, its relationship to NOMMA, and even why we need a foundation. As one of my last acts as Chair of NEF, I will correct this omission. Both NOMMA and NEF are not-for-profit charitable corporations, referred to as 501(c) corporations. There are several types of 501(c) corporations. NOMMA is classified as a “nonprofit business league” and thereby a 501(c)(6), according to the IRS code. And, as NEF’s middle name states, it is an “education” foundation, and therefore classified by Internal Revenue Code, as a 501(c)(3) corporation.

Update from NEF Chair Roger Carlsen, Ephraim Forge Inc.

How they are alike

There are similarities between a (3) and a (6): n Both are tax exempt. n Neither has specific ownership. n No part of net earnings may inure to the benefit of an individual. n All profits are reinvested in each organization (respectively). n They may not organize for profit or to engage in for-profit activities.

How they are different

501(c)(6) n Primarily supported by dues and other income from activities substantially related to its exempt purpose. n May not accept grants. n Individual contributions are not tax deductible, although businesses can deduct contributions as a business expense. n May engage in any amount of legislative activity germane to the common business interest. 501(c)(3) n Has income from individual and business tax deduct-

Why both NOMMA and NEF exist

There are many nuances that make it necessary for both NOMMA and NEF to exist. For example: n If an individual makes a donation to NEF (for example, in the form of an item for the auction or money), it may be tax deductible, whereas if the same donation were given by an individual to NOMMA, it would NOT be tax deductible. n NEF’s primary focus is on education, to fund educational programs for the industry and for the public that are far reaching; whereas NOMMA has more than one primary directive to benefit our industry. n NOMMA may not receive grants or other funding from government agencies; NEF may. NEF is established through the bylaws of NOMMA. NEF’s trustees are appointed by the NOMMA Board of Directors. Even though NOMMA may give money to the foundation, the foundation cannot give money to NOMMA, except for reimbursement of services rendered, such as a management contract. Funds may NOT be co-mingled at any time for any reason. NOMMA expects responsible stewardship

As appointed NEF Trustees, we understand that when we are appointed by the NOMMA board they do not expect us to be under their thumb and merely do whatever they request. Rather they have bestowed upon us a charge, more specifically a “trust” (a sometimes overwhelming responsibility). NOMMA expects (requires) of us, as trustees, to be responsible keepers of the NEF mission and purpose, i.e., to ensure that the educational needs of our industry is at the forefront of all of our decisions and that we are good stewards of the funds that we administer. As good stewards of finances it would be unwise of us


For more information on donating to the NOMMA Education Foundation Contact Martha Pennington, (888) 516-8585 x 104, 12

Fabricator n May / June 2011

to spend all of our funds by the end of each year (as many governmental agencies must do) with no thought for the future. A few years back, I was the treasurer of a smaller not-for-profit corporation and was advised by one of the board directors that as a sound management program we should have two to three years of our annual budget in reserve in the event that things got bad. I really did not understand, at that time, why we should have such a reserve; I never anticipated being in such a recession as we are presently. Today, we are in a time “when things got bad” and I am pleased to tell you that NEF is, at least for the present, in that safe reserve position. However, we do not want to eat the seed corn for sustenance. We have some exciting programs in the planning stages and do have budget requirements for the near term to meet. The auction at METALfab was a relative success. It was a relative success because while we did take in money for our education programs, due to the down economy only 50% of what we received last year was received this year (the auction is usually a substantial portion of NEF’s

May / June 2011 n Fabricator

[NOMMA has] bestowed upon us a charge, more specifically a “trust”

(a sometimes overwhelming responsibility). NOMMA expects (requires) of us, as trustees, to be responsible keepers of the NEF mission and purpose, i.e., to ensure that the educational needs of our industry is at the forefront of all of our decisions and that we are good stewards of the funds that we administer. Please help NEF to continue to help you, your colleagues, and posterity with a contribution (tax deductible, of course). Contact NEF Chair Roger Carlsen, any of your NEF trustees, or executive director Martha Pennington at with a pledge or any questions.

income). So, as you can see we are already falling behind what we need to meet current budget and are starting to encroach into our reserves. With no further income we will be eating into our reserves more. Wikipedia tells us that education “in the largest sense is any act or experience that has a formative effect on the mind, character, or physical ability of an individual. In its technical sense, education is the process by which society deliberately transmits its accumulated knowledge, skills and values from one generation to another.” Education is what will help us to survive our current economic challenges, and education is what will see us through to the second half of the 21st century. This is why NEF exists. Thank you.


Tips& Tactics n Website marketing and optimization considerations Editor’s note: A longer NOMMA white paper by the author is available in the member’s area at http://tinyurl. com/3muevou By Paul Barkley These days you need a strong market-

ing plan more than ever. Your website is just one component of an overall strategy. And getting found is a neverending process. Marketing strategy

You can’t just put up a website and announce you’ve done all your marketing. Consider how the site content fits in with your other marketing materials. Typically, a website provides more complete information that you can’t conveniently put in an ad or brochure. The idea is to drive traffic to your website through your other marketing vehicles, including, for example, on your trucks and email signatures. Place the address everywhere. Ideally, your website address should be short, easy to remember, and easy to spell. Since everyone wants an address like that, too, it can be difficult to get a good domain name. Simple names like are already taken. If you feel it’s worth the money, you can buy names on the secondary market through brokers. They can run a few hundred dollars up to thousands. The best name is your own company name assuming it isn’t hard to spell or remember. In your marketing materials, if you are “My Great Welding Company,” capitalize the first letter of

each word to make your domain name stand out: While long, this name is easy to remember, easy to spell, and is the actual name of the company. If your company name is difficult, consider getting a new domain name, which cost about $20 a year. Your hosting company, which runs the computer that has your website on it, often can sign you up. Search engine optimization

Many people think that the only purpose of a website is to attract new business. Our attitude is that if you make your website a part of your marketing strategy, any prospects that you attract directly through the website are a bonus. You also want to get noticed by people who use search engines. Search engines try to return the most relevant results to people who search, not to vendors as such. They use secret algorithms so people don’t trick them. Getting ranked high in search engines requires some effort. One method is to have a lot of incoming links from other “authoritative” websites. But it’s hard to get other people to point to you — you need compelling content that their viewers might want. Getting listed in a directory helps, but writing an original article on your website that readers refer to is better. Don’t fall for scams that offer to link to your website if you’ll link to theirs; if you get caught, you’ll be severely penalized by the search engines. Keywords, the terms that you think someone will use to search for a com-

pany like yours, are important too. These words should appear on your website without “stuffing” them all over. You can’t just say, “Hey, we repair iron, iron, iron, iron railings!” Find ways to talk about what you do and use synonyms for your keywords to reinforce the message. Make sure your content is well edited and readable. Your developer will also use keyword “meta tags,” but these are deemphasized by search engines today. Still, do insert them. Ask your website developer about search engine optimization (SEO) work. Your developer will build some SEO features into your basic website. But it is usually extra because the developer has to work with you to identify search terms that you’re interested in, and then actually search for those terms and see how you rank. Then an analysis about why your competitors are ranking better than you are and what you can do about it is necessary. Keep in mind that it often takes months to see the results of SEO because even when invited, the search engines won’t return for weeks to index your new material. This can be frustrating. And of course your competitors are probably secretly plotting to raise their SEO rank at your expense! Paul Barkley is the CEO of Reflexion Information System, LLC, a software and web development company in the Washington, DC area. He specializes in websites for small to mid-size businesses. Contact him at


Fabricator would like to publish your step-by-step tutorial or problem/solution case study. Please contact the Editor at (888) 516-8585 or e-mail: 14

Fabricator n May / June 2011

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Shop Talk

In-house machining When material needs to be cut, saws, lathes, drill presses, and milling machines help machinists achieve the desired geometry. For fabricators, geometry is where it’s at. n

Axles and wheels for railcar equipment to work on the New Orleans streetcar line. The axles on the floor are for standard gauge track, while the new axles (with wheels) fit the wider gauge New Orleans tracks.

Repairing and boring holes to fit new pins to restore a piece of construction equipment. The worn holes have been built up with weld, and the holes are machined to a specific diameter. 16

By Peter Hildebrandt Sometimes in-house machining is necessary for a

part that either doesn’t yet exist, would take too long to order, or would be too costly to buy. Fabricator spoke to some NOMMA members who are doing machining either as the largest portion of their business or on the side to learn about the services they offer and the equipment they’re using. B&O Machine and Welding Company, Imagine Ironworks

James Minter, Brookhaven, MS, is owner of two businesses under the same roof. B&O Machine and Welding Company accounts for two-thirds of his work with in-house machining. His ornamental metalwork business with Imagine Ironworks accounts for the rest. Over the years, Minter has done a lot of machine work for sawmills, gravel pits, and the oilfield. Sawmills are B&O’s larger industry segment, thus much of the equipment they have is geared toward that work. “We do not have any CNC equipment, although CNC equipment salesmen tell us we are missing the boat,” says Minter. “We also don’t have any fancy computerized torch/plasma cutting equipment, as we get very good service from Sol’s Pipe and Steel, Inc., in Monroe, LA. They supply and deliver cut steel, stainless steel, and aluminum pieces. They process steel, cut it, and drill or do some forming. We use that service a lot. They maintain the inventory and get us cut-to-shape pieces in about three days, so why invest in a complicated piece of equipment?” B&O has two Wellsaw 1118 horizontal bandsaws. “This will cut a piece of metal 11" tall by 18" wide, although we have been known to use it on use it on larger pieces, cut halfway through, and then turn it over to cut the other half. We cut shafts, structural steel, pipe & tube, angles, flat bar, on these. However, if we have a job that requires many pieces of material the same length, we have our steel service center do the cutting for us.” They have a good selection of lathes including: a Summit 21" x 80" (swing x bed length); Cincinnati Hydroshift 21" x 120"; and a Summit 14" x 40". They use four other lathes, and several others were acquired from a local community college that closed their machine shop program. The company’s Hansford (Davis) keycutter cuts keyways in the bores of sprockets mostly for sawmills and gravel pits. It can also cut slots in thick pieces of metal, so they also make clevis yokes, also for sawmills. Minter says their Wilton (made by Arboga of Sweden) U-50 drill press is a workhorse. “This can drill a hole up to about 11/2" diameter. It has an automatic feed, so the guys really like using it. We also have Fabricator n May / June 2011


A sawmill sprocket being bored in a lathe. When this picture was taken, the lathe and sprocket were rotating at 220 RPM (the camera made it look like it was not moving).




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several small drill presses scattered around the shop so that there are small drill presses very close to individual work stations (a tip learned from NOMMA member Berger Ironworks) he says.” “Our Cincinnati Milacron Verci Power mill weighs 22,000 pounds, so it is solid as a rock. It has a pivoting head, and we use it to bore things both horizontally and vertically. “Some recent jobs we used it for were to bore pump pieces for a paper mill, and cut gear teeth for a company that makes a cornstarch-based additive for consumer products. We have smaller mills, too, and most of our work on them is cutting keyseats in shafts,” Minter says. They have a five-ton overhead hoist from DeShazo Crane, which is one of three that cover most of their shop floor. They are used to unload and load trucks, load jobs into machines, and even straighten bent and twisted items when combined with tie-down points in the floor. “These are really nice to have.” says Minter. A Milwaukee port-a-band saw is rigged up as a vertical bandsaw. “I forget where we got the conversion kit but it was from eBay. This gets a lot of use,” says Minter. “Our HTC hydraulic plate shear can cut up to (and including) ½ thick steel plate. Watch those fingers! And our HTC hydraulic press brake is used for bending plates. “We also have an American 9" x 36" (column diameter x arm length) drill press. Big, heavy items that can’t fit in the Wilton drill press fit easily into this. Some of these are not specifically used for machining, like the shear, press brake, and overhead cranes, but they help make us ‘us’. ” Their machine shop is also used for ornamental parts. “There is a cast iron post (part 8304) that is made by Lawler Foundry, that doesn’t have a base or any kind of mounting plate on the bottom of it,” says Minter. “We can weld a square piece on it, which we’ve already drilled some holes in, and then put it in a lathe and turn it around so it makes for a nice finishedlooking piece.” Machine work has helped the ornamental side. On one of his ornamental Fabricator n May / June 2011

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L.E. Sauer Machine Company does some laser cutting and CNC machining, including turning, milling, and drilling. Their CNC machines are old Brown & Sharpe with table travels of up to 30 by 80 inches.

projects, the client picked out a large tapered cast iron finial to use on a fence. The piece was 11/4" square by 13" long, with about 9" of the finial length tapered down to 7/8" square. The lead time for the project was four weeks, and the lead time from the foundry was six to eight weeks. “We decided to make something close in appearance, so we used 11/4" square stock and milled a 3/16" flat taper on all four sides of the thirty pieces we needed. It took about two and a half days to make the finials, and ‘home-made’ finials came in at about 18% of the cost of what the foundry wanted. The whole job was installed on time, and we kept some money in-house,” says Minter. “Our machine shop clients are a completely different category from our ornamental/structural iron customers. We do use our machining capabilities for ornamental items from time to time, but the machine shop could not exist just to serve our ornamental/ structural customers,” Minter says. “I view life here at our shop as working with a big model kit — except there are no instructions,” he says. “For example, one couple had an antique bed they wanted made into queen-size. We had to make the pieces to fit the antique hardware on the bed. It took me two months to figure out how to do this. But all of a sudden there’s that inspiration, the pieces are made, and you’ve given them exactly what they want.” L.E. Sauer Machine Company

A job shop, a machine shop, and more recently a fabricator, L.E. Sauer Machine Company, St. Louis, MO, has 60–70 employees in an 80,000 sq ft shop. Owner Warren Sauer is the third generation with the company, which will have its 85th anniversary this year. Sauer became a NOMMA member about three years ago, originally coming into NOMMA as a supplier. But the company also does fabrication, so they are now more concentrated on that end of the relationship with the group. The company still does some laser cutting for a couple of NOMMA 20

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members, and CNC machining, including turning, milling, and drilling. “We have some pretty good-sized equipment. For example, on our metalworking lathe we can turn work up to about 30 inches in diameter by 12 feet long. On our CNC we can work on items 30 inches in diameter by about five feet in length.”

They have a Mori Seiki lathe for working with diameters in the nine to 12-inch vicinity. Their CNC machines are old Brown & Sharpe with table travels of up to 30 by 80 inches. “We’re not like a big contract shop that’s got a bunch of defense or automotive contracts. We do some artwork and sculpture, renovation and that

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kind of work, too — someone can come in with a sketch on a napkin and we can work with it.” About the only thing they outsource is some painting or powdercoating and some plating, but they’re basically a full-function shop. Sauer has a product line which makes up about 50% of their work. They make equipment or tooling for corrugated box-making machines. The other half consists of whatever job shop work or other work that comes up. Sauer has websites for the different facets of their business: n; n; n; and n The different sites help avoid confusion: Clients are able to see one specific site for the type of work they’re interested in learning about, without having to wade through one general site to find what they are looking for. Interstate Manufacturing Associates

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This job machine shop, Interstate Manufacturing Associates, Newport, NH, makes a line of ornamental, specialty hinges called the Boss Hinge. Owner Craig Jennison saw a trade magazine ad years ago from a person in Kansas City who was selling his product line. “At the time I thought it would be neat to get into making my own product because most of what we do here is contract machining; someone will send us a print of something and ask ‘how much to make 20 of them?’ “Historically, the bulk of our business has been for people who make spare parts for land-based gas and oil-fueled turbines. There are a lot of people out there doing that. We make nuts, bolts, and other things for other industries too.” Their hinges are mostly for steel and aluminum gates or doors, some for wood, come in three sizes. They’ve added a few models and sizes since buying the line, still with the same basic design that the original developer had. Jennison also kept the original Fabricator n May / June 2011

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Craig Jennison President Interstate Manufacturing Associates, Inc. 169 Sunapee St. Newport, NH 03773 (603) 863-4855

James Minter, Jr. President B & O Machine and Welding Co./ Imagine Ironworks 1380 Highway 51 N, Brookhaven, Mississippi 39601 (601) 833-3000 bomachinewelding@ imagineironworks@

name of the line to help with the customer transition. He moved the existing inventory to NH and has been making them as a small part of his business ever since. “We have a way of making the hinges that sets us apart from most of the rest of the people in the industry who do them,” adds Jennison. Interstate has CNC and manual equipment. All their hinges are made from standard off-the-shelf aluminum stainless steel cold-rolled products. “We do make specialty items, bigger or smaller hinges if someone wants them. If they need them a little more elaborate, we can do that too,” says Jennison. Colorado WaterJet Company

Colorado WaterJet Company, Berthound, CO, uses a Flow Waterjet machine at their job shop. They typically work from machined plates. Most of their work is for manufacturers. The company has been a NOMMA member since 1998, and they also do a fair amount of work for NOMMA members, typically cutting out panels or railing components of various shapes and sizes. These can range from simple S-curves to hinge plate blanks to full-paneled sectioned scrollwork. 24

Warren Sauer President L. E. Sauer Machine Co. 3535 Tree Court Industrial Blvd. St. Louis, Missouri 63122 sales@sauermachine. com (636) 225-5358

Dan Nibbelink President Colorado WaterJet Company 5186 Longs Peak Rd, Unit F Berthoud, CO 80513 (970) 532-5404 (970) 532-5405 fax www.coloradowaterjet. com dn@coloradowaterjet. com

About the author Peter Hildebrandt has been a contributing writer for Fabricator magazine since 2005. He writes about science, technology, industry, and history for a variety of trade publications.

week or two depending on shop load. Any design that you can draw, we can cut,” says Nibbelink. Nibbelink has a small shop with four people running two machines. The whole cutting process is computer-controlled; operators put the design in the computer Interstate Manufacturing hinges. Top left, and tell it to go. H10 model hinge for small garden gates has Their machines cut bronze alloy pivot pins. Bottom left, H17 steel, aluminum, stainless model hinge with 3/4" diameter barrel with 3/8" stainless steel diameter pins. steel, abrasion-resistant steel, plastic, wood, glass, Colorado Waterjet. Above, 1" aluminum, and stone. Although they arched fence/railing crown, approx 15" high, prefer CAD files, CWJ customer design. can work from drawings and sketches. They have one cutting Company president Dan Nibbelink head on each machine, which is acexplains that home pressure washers curate to within ten thousandths of an run at about 2,000 psi, while the presinch, yielding good clean edges. This sure in their waterjet cutters runs from is a cold-cutting process. Unlike laser, 55,000–60,000 psi. A pound per minplasma, or flame-cutting, it does not ute of sand is mixed in with the water. heat the edge, doesn’t warp the part. “The sand is what actually does the And there is no slag. cutting,” he says. Their process uses only one galColorado WaterJet Company has lon of water per minute (a low-flow been in business 13 years, the process shower head uses two and a half galhas been commercially viable for 20 lons of water per minute). It is also a years, and the technology has been clean process, one using no solvents or around for about 30 years. anything harmful or polluting, accord“Turnaround times for us depend ing to Nibbelink. on how good the information is that The abrasive sand used is garnet the customer provides. For those ussand, silicon-free and because they ing CAD files, we can usually return don’t cut anything hazardous, the a quote within a couple of days and waste is toxin-free. then return a job from our shop in a Fabricator n May / June 2011

Injured eyes don’t lıe Shop Talk

By Jeffrey Dean Fogel


Whatever type of fabrication you’re doing, properly selected eyewear plus a modicum of common sense equals fewer eye injuries.

*This figure encompasses all manufacturing workers. But there remains a significant number among fabricators who are injured despite safety glasses. 26

On November 2, 1880, one P. Johnson was granted a patent for a pair A foreign of glasses that would protect the eyes. It was hastily assigned a value body. Tiny on the scale of social approval, right next to the spot reserved for the flying objects can surround plastic pocket protector. a fabricator, It took another century’s worth of eye injuries for people to a common grudgingly admit that safety glasses only work when you wear them. reason for eye injuries. Even today, Bureau of Labor Statistics numbers show that the majority of eye injuries occur to workers who were not wearing safety eyewear. Fabricators should take the BLS numbers personally. Metal workers garner the lion’s share of work related eye injuries. The good news is that most eye injuries are preventable by simply wearing P. Johnson’s beneficent invention. The bad news is that oddly 40 percent of workers with eye injuries were wearing some form of protective eyewear at the time.* So, short of sporting hermetically sealed Kevlar-polycarbonate goggles skingrafted to our mugs, what’s it take to get some reasonable eye protection? You have to be wearing the right kind of protective eyewear. Truth be known, there aren’t really many ways fabricators can injure their eyes — essentially three: 1) Abrasion, 2) Foreign object, or 3) Flash burn. But first, let’s brush up on eye anatomy. The eye is a hollow globe with a movie screen at the back and a lens at the Fabricator n May / June 2011

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front. The lens is covered by a protective bubble called the cornea, a tough, transparent dome about 0.5 inches in diameter and 0.04 inches thick. It attaches, at its periphery, to the sclera (the “white” of the eye). Looking inward through the cornea, you can clearly see the black pupil and variably colored iris beneath. It is the cornea that mostly suffers the slings and arrows of workplace misfortune. Abrasion

By far, the most common insult to the cornea is the corneal abrasion. It’s usually caused by flying debris from grinding, or chipping slag. When a tiny metal fragment glances off the cornea, it leaves a scrape. The cornea, rife with nerve endings, is extremely sensitive. You don’t think you have a corneal abrasion — you know it. A scratch or scrape in the epithelium (surface skin cells) of the cornea will produce a minor agony and a

After a few hours in the salty, liquid environment of an eyeball, a metal object

will do the predictable thing. Once removed, it can leave a rust ring. This isn’t serious, but it is more complicated. Occasionally, one can hit your cornea with enough velocity to puncture it, introducing a risk of infection.

Corneal lacerations quite often are the result of a foreign body striking the cornea.


tsunami of tears. Happily, most corneal abrasions heal overnight — or at most, a few days — leaving the eye unaffected. Foreign bodies

Fabrication tends to fill the air with clouds of tiny flying objects. Particularly, grinding, which puts you at the epicenter of a Lilliputian metallic asteroid belt, and has an affinity for eyes. So how do you get said object out of your eye? You don’t. An ophthalmologist does. Don’t worry. They usually numb your eye with a topical anesthetic before digging around in there. But it’s important to get the foreign body out quickly. After a few hours in the salty, liquid environment of an eyeball, a metal object will do the predictable thing. Thus, once removed, it can leave a rust ring. This isn’t serious, but it is more complicated. And in medicine, more complicated is more expensive. Given prompt ophthalmologic care, foreign bodies are not serious. Unless they are. Occasionally, one can hit your cornea with enough velocity to puncture it. This introduces the risk of infection. And if the projectile has enough oomph, it can pierce the cornea, lens, and everything beneath. This introduces the risk of blindness. A hole in the eyeball itself, referred to as an open globe, can let all the vitreous humor (referred to as the goo inside the eye) leak out. With an eye, that’s as bad as it gets. The prognosis is poor. Safety glasses.

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A bewildering array of safety glasses can be immediately narrowed down by the criteria issued by the American National Standards Institute. Glasses labeled ANSI Z87.1 meet the standard. Just look for the tag. Prescription lenses will have a tiny trademark sandblasted into a corner to indicate ANSI conformity. Typically, manufacturers use one of four materials for safety lenses, which must be a minimum of 3 mm thick at their thinnest point. Glass. This has the advantage of good optics and scratch resistance. It Fabricator n May / June 2011

must meet a ball drop As for style, more test of a 3/8" steel ball coverage is better. And from a height of 60 if you spend a lot of inches. time near a grinding References Welding CR39. Glass is wheel, side shields are a “Radiation and the effects on eyes good, particularly for good idea. Eye injuries and skin,” Canadian Centre for prescription lenses. United States Department of Labor, Occupational Health and Safety, But we’re in the 21st Flash burn Fact Sheet No. OSHA 93-03, www. century. Better is A third way you can Safety lens materials CR39, the basic plastic Todd Nighswonger, “How much eye injure eyes in fabricaEsslor of America, Verilux lenses lens that is 10 times tion, so different from protection is enough,” Occupational more shatterproof the other two in both Hazards, Feb. 2002. About the author Jeff Fogel began writing as a journalthan tempered glass. risk and remedy, it gets Ted Braun, “Preventing Eye Injuries It’s also lighter and can when welding,” Occupational Health & ist with the New York Daily News. He its own category: Photo:tri-state-quarter page.qxd 12/19/07 9:44 AM Page 1 has been a copywriter and associate be made very scratch keratitis, a form of snow Safety, Feb. 01, 2007. creative director for Ogilvy & Mather, as resistant. blindness. But unless well as several other major advertisThe Merck Manual, 16th edition, Polycarbonate. you’re an Inuit or Shering agencies. Jeff now lives in New Ophthalmologic disorders, tab 17. Working our way up pa, welding is your only Hampshire where the weather’s bad, Roger Timmons, “Fabrication and the price ladder, polyrisk for photokeratitis. the skiing’s better, and blacksmithing’s Welding Engineering,” Elsevier Ltd, a respectable way to keep warm. carbonate is lighter Also known as arc 2008, pg 17. than CR39 and abeye, flash burn, or ultrasurdly shatterproof. violet keratitis, it’s techOne hundred times the strength of ate is not strong enough for you, try nically a severe sunburn of the cornea. tempered glass, it can stop a .22 caliber high index plastic Trivex. Stronger, The surface epithelia, having suffered bullet. So it’s safe to assume it’ll also lighter, and pricier than polycarbona mild radiation burn, slough off, stop most foreign bodies flung from a ate, it’s excellent for high prescriptions leaving bare nerve endings exposed. grinding wheel. whose thicker lenses can be made As you might have guessed, it’s very PROOF -lighter. 45-3454-ACF-121807-V2painful. High index plastic. If polycarbon- AD somewhat

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Aside from hurting like all get out, ment for standing around, doing nothother symptoms include light sensiing, while someone else works. Dark tivity, blurred vision, and watery or curtains can eliminate this problem. bloodshot eyes. Patients often describe Arc welding involves heat in the a continued sensation as feeling like 6,000 degree F range. Heat of this there’s sand in their eye. magnitude emits a goodly amount of The only comfort is the knowledge infrared waves, which occupy the 300 that the condition typically only lasts a GHz to 400 THz range on the elecday or two at the most. tromagnetic spectrum. That’s enough Interestingly, a significant numenergy to scorch the surface of your ber of people get photokeratitis from cornea. simply watching another work. 1 1/28/11 Then the ultraviolet light. CSU-201103-NOMMA Fabperson Hlf Ad_Layout 2:55there’s PM Page 1 This is most likely some divine punishAn arc emits UV light, and plenty of

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your personal little sun. UV light is classified as having a wavelength shorter than violet but longer than an x-ray. It not only can produce a radiation burn (sunburn) but also wreak more insidious damage in the way of cataracts. Welder’s helmet

Your best ticket to prevent the infelicities of radiation burns is a welder’s helmet. And there are plenty to choose from. Too many, in fact. It’s confusing. As with safety glasses, ANSI criteria can simplify your buying decision. At the very least, an ANSI approved helmet must be able to thwart high velocity projectiles, filter out 100 percent of UV and IR light at any lens shade setting, and live up to advertised lens darkening speeds in auto-darkening helmets, in temperatures from 23 degrees F to 131 degrees F. This leaves you at a crossroad: a) passive lens helmet versus b) auto-darkening helmet. Passive lens helmets are cheaper. But you have to flip them up to get a gander at your work piece and flip them down just before striking an arc. Two problems with that. 1) It’s hard on your neck. 2) It increases the chance of forgetting to flip the shade down. Refer back to photokeratosis. Auto-darkening helmet. If you decide on this you’re now faced with another choice. You can get a fixed shade, which darkens to a single setting of, say, #10. Or you can splurge a little and get a variable shade helmet. This allows you to set the amount of darkening. The range is typically from #9 to #13. The obvious advantage is versatility. It allows you to use the helmet for a wide range of welding types and amperages. Splurge some more to get sensitivity control, light sensors, and delay control (setting the length of time the lens stays dark after the weld). Finally, there’s helmet weight. Lighter is better. Your neck will thank you. Your chiropractor, orthopedic surgeon, and massage therapist will miss you. If you’ve got ’em, wear ’em.

Fabricator n May / June 2011

Keep ‘heavy arts’ alıve Member Profile

By Molly A. Badgett


With a patent for an aluminum railing system, NOMMA member Bill Coleman’s Arc Angels features his aluminum, iron, steel artwork, from gates and railings to wine racks.

May / June 2011 n Fabricator

It probably wasn’t considered art in the days of the

horse and buggy. The work of blacksmiths, no doubt, was a dime for every dozen orders, and a blacksmith was as easy to track down as the local barber. Delve back into medieval times, the skill of a blacksmith stood between the average warrior’s good day — and a particularly bad one. Today, keeping the ancient work of the blacksmith and other metal artists alive is the goal of NOMMA member Bill Coleman of Arc Angels Inc., Dunedin FL. He’s doing this and more with a new educational co-op focused on past-time pastimes at the Institute for Creative Arts (ICA) in Dunedin. The ICA is a 6,000-square-foot building that’s the professional home to a half-dozen artists with room for each to reap rewards from his or her wares in a show-and-sell retail environment. The Institute pro-

Owner and craftsman Bill Coleman personally inspects, signs and numbers each finished decorative metal art piece as it comes out of the Arc Angels studio. Pictured here is a candle sconce.


vides a showcase for bygone-era arts — metalworking, stained-glass making, mural painting, and glass blowing among them — as well as a learning environment. Artistic types interested in learning more about metalworking, blacksmithing, and welding can come to the Institute for classes and apprenticeships. “Part of our vision is to develop the artist co-op into a tourist attraction,” Coleman said, “to bring visitors from the surrounding areas to take classes, shop, eat, and stay in our wonderful little town. It’s certainly an exciting challenge and worthwhile project. “Training and apprenticeships will be of paramount importance,” he added, “and perpetuating our craft and skills to younger generations is a major goal.” Operations in the arts are plentiful in Dunedin and in nearby Clearwater, but none offers the type of art or art education that Coleman and his co-op represent. Some of the Institute’s classes are offered in conjunction with the Dunedin Fine Arts Center. The

Bill Coleman studies blueprints for one of the commercial railing projects lined up for his metal art company, Arc Angels. Coleman grew up around metal. His father owned a metal shop, and as a high-school student he often apprenticed at his father’s shop as a welder and fabricator.

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Bill Coleman says he hopes his and others’ work at the Institute for Creative Arts, as well as their community-outreach plans for the artist co-op, will inspire other artists to follow their own dreams.

DFAC is heavily committed to education in the arts and cultural programming, but because of zoning or other issues, it doesn’t offer classes in industrial arts. “Our city is a very unique city with a very artsy environment,” Coleman said, “One of our goals is to enhance and expand on the accomplishments of the Dunedin Fine Art Center. We definitely can complement each other and work in concert to benefit the art community of Dunedin. “It’s exciting; the city is thrilled with us,” he said of the ICA project. “They’re 100 percent behind what’s happening here.” Having a major glass-blowing exhibition at the ICA, adding to what Coleman describes as a full-scale “hot shop,” also will serve as a tourist attraction for the city as well as a teaching center for that trade. One could say that Coleman’s vision for his blacksmithing shop goes from art to entertainment. He and business associate J.R. Lodico (himself an accomplished blacksmith who worked for three years as an apprentice at the Metal Museum in Memphis, Tenn.) are developing their shop to resemble an Old World blacksmith smithy. “We are designing the area to look as if you just went back in time to the late 1800’s,” explained Coleman. From a visual perspective alone, that’s probably not a hard thing to do when outfitting the facility contents. As for the building in which the arts are housed, a bit of nostalgia is readily reachable with the mind’s eye. It’s an old abandoned cement plant located in the core downtown district of Dunedin, one of the only properties in the area May / June 2011 n Fabricator

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At ICA, you have Metalmorphosis, a copper-arts studio run by artist Don Decker, and Liquid Sol, a customartwork studio featuring murals, paintings, sculptures, and specialty surfaces. In Studio A is Dirt Path Studio, whose “cathedral-quality” stained-glass work, including restorative work, fits well into the ICA’s mission. And, Jim Goins specializes in commercial photography. He uses the latest digital methods, but he’s honed his detail-attentive commercial product and on-site photography since the 1970s. Coleman’s own gallery and sales office, Arc Angels, features his iron, steel, and aluminum artwork of all sizes and shapes, from gates and railings to wine racks. His 30-year history and accomplishments in cast and wrought ornamental metalwork earned him clientele worldwide, from the Russian government to MGM Studios in Orlando a little more than 100 miles away. It also has earned him a U.S. patent for one brainchild, a unique Pedestal table. aluminum railing system. A member of NOMMA for several years, Coleman grew up around metal. His father owned a metal shop, and as a high-school student he often apprenticed at his father’s shop as a welder and fabricator. Despite having mastered critical skills while working after school and during his summer breaks, Coleman moved on to study at Florida State University. After graduation from FSU, however, he returned to work with the layouts, designs, engineering, and special finishes of his old love, architectural metalwork. In 1970, he moved to Clearwater to start his own company. He now works exclusively in Dunedin. His latest endeavor in his metalworking beyond that of a craft for craft’s sake appears as much nostalgic as it does educational. “Our interest now is training a new generation of metalworker and filling the artistic desires of our seniors,” he said, noting also a twist on things from a gender perspective. “Not that this is too surprising, but we have had more inquiries for welding instruction from women than men,” Coleman said. He identifies some nostalgia there, namely, a “Rosie the Riveter” World War II influence, where women filled factories and foundries while their Fabricator n May / June 2011

“We have been offered help and guidance from members of NOMMA,”

Coleman said. One example: materials donations have been made by national metals supplier, King Architectural Metals. men were in battle. A case in point, Coleman offered, is that his newest welding and metalworking instructor is Dominice Gilbert, who studied at the Art Institute of Chicago and worked as an artist in residence at the National Ornamental Metal Museum in Memphis. Along the way toward his new endeavor to recreate an artistic past with intensely authentic expressions, Coleman has been especially thankful of help from NOMMA members. “We have been offered help and guidance from members of NOMMA,” he said. One example: materials donations have been made by national metals supplier, King Architectural Metals. Coleman is hopeful that the example set and determination shown by him and others at the Institute for Creative Arts will inspire other artists. “Excitement, fear, and challenge are all part of the big adventure,” he said. “The idea is to reach out and go for your dreams.”

For your information



Bill Coleman 1431 Hagen Ave. Dunedin, FL 34698 Phone: (727) 433-2300 Fax: (727) 441-9566 About the author Molly A. Badgett is a freelance writer based in Atlanta, GA. She often covers issues related to U.S. manufacturing. May / June 2011 n Fabricator

Tenant artists plan to turn the 6,000-square-foot ICA facility into a showplace and education center for heavy arts that can be demonstrated in their historical context. Success, they say, could turn Ad_2011:Layout 1 2/7/11 10:09 AM Page 1 the city of Dunedin, FL, into a tourist destination.

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METALfab 2011 Annual Conference Review NOMMA held its 53rd annual trade show and confer-

Incoming president James Minter Jr. gives his acceptance speech during the Saturday evening banquet.

For your information


View the 2011 Top Job Winners View candids from METALfab 2011


ence in New Orleans, LA, March 16–19. The week of fun and learning started with a trade show grand opening reception on Wednesday night and ended with the annual awards banquet on Saturday evening. This year’s conference was packed with education sessions that covered everything from grand stair layout to employee safety. Highlights of the week included the Thursday St. Patrick’s Day party, the annual awards contest, and the Saturday shop tours. One thing that made METALfab 2011 unique was the large number of volunteers who made the event a success. All total, we had 73 members who volunteered for a variety of jobs, such as presenting, front desk help, assisting with the auction, staffing the Top Job and chapter booths, and bus monitors. We’re also proud that our annual awards contest enjoyed strong participation with 55 companies entering, including 20 first-timers. On the following pages we offer a glimpse of the action and energy that we all enjoyed during METALfab. A thanks to the NOMMA Education Foundation and the Convention Committee for a job well done!

Fabricator n May / June 2011

Upper Midwest Chapter, as in previous years, had a tremendous showing at METALfab.

Attendees enjoyed seeing the latest products and services at the trade show.

Sally Nibblelink gets into the spirit of St. Patrick’s Day. May / June 2011 n Fabricator


METALfab 2011 Around the Show The 2011-2012 NOMMA board installation Saturday evening.

The St. Louis delegation! Terry Spatz Coleman and Todd Kinnkin.

Paul Di Francesco, middle, presented a hand-forged grill to Jack and Becky Klahm during Thursday’s auction.


Fabricator n May / June 2011

METALfab 2011 Copper Development Association Award

ard New Aw

Allen Architectural Metals Inc., Talladega, AL, won the Copper Development Association Award for the fabrication of a bronze baptismal font, left. Larry E. Peters, above, project manager & architectural applications specialist for the association, shows the award. The award, given out at the awards banquet, is given to a Top Job entrant who shows the best mastery and display of copper and copper alloys. The job also received a bronze award in the 2011 Top Job competition.

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 Flat Bar (on edge hard way) Roger Carlsen, chair of the Certification Task Force, leads an education session on certification. May / June 2011 n Fabricator

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METALfab 2011 Show Floor Demos, Shop Tours, and Trade Show

Enjoying the Saturday shop tours.


Fabricator n May / June 2011

METALfab 2011 Frank A. Kozik Award Long-time volunteer Dave Filippi helped lay foundation for Technical Affairs Division Former NOMMA board member Dave

Filippi of FabCad Inc. has received the Frank A. Kozik award for outstanding volunteer service. Dave has been a tireless industry volunteer throughout his career and has served NOMMA since the early 1990s. In addition to serving for years on the board, he reorganized the Standards Committee in 1992 and helped to lay the groundwork for today’s Technical Affairs Division. He has also served on numerous committees, including Education, Convention, and Membership. Even after rotating off the board in the mid-1990s, his volunteerism did not slow down one bit. Over the years, he led numerous education sessions and continuing education classes, and he has presented at chapter meetings. He also regularly leads the orientation class at METALfab events and helps out in many other small ways. Just in the past year, he helped with the NOMMA booth at the ABANA and Fabtech conferences, and he currently serves on NOMMA’s METALfab Review Task Force. The Kozik award was presented during NOMMA’s 53rd annual conference in New Orleans, LA, March 19. The Frank A. Kozik Award is a special recognition that is given to a member “who keeps on giving.” The award’s namesake, Frank Kozik, was NOMMA’s first president, and set an example by continuing to volunteer even after he was off the board.

May / June 2011 n Fabricator

Dave Filippi, right, is the recipient of the Frank A. Kozik Award, which is given for outstanding volunteerism. Presenting the award was Doug Bracken, who received the award in 2009.

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METALfab 2011 Clifford H. Brown Award Education is a serious misson for The Wagner Companies For its outstanding contributions to

Members of The Wagner Companies team are shown with the Cliff Brown Award. Accepting the award on behalf of the company was Bob Wagner, right.

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industry education, The Wagner Companies, Butler, WI, is the recipient of the 2011 Clifford H. Brown Award. The award, presented annually by the NOMMA Education Foundation (NEF), was given during the Partners in Education Reception at METALfab on March 18. The Wagner Companies has a long history, corporate culture, and strong commitment to employee volunteerism in the industry. Employees regularly lead classes at METALfab and local chapter meetings and are active in helping members on the NOMMA ListServ. They also serve on various NOMMA committees and task forces, attend code hearings, help to raise funds for NEF, and provide grants for attending METALfab. NEF Chair Roger Carlsen presented the award to Bob Wagner. The award is named for the late Cliff Brown, Hallmark Ironworks, who was a NOMMA past president, author, and long-time advocate for industry education.

Roger Carlsen served as one of the auctioneers during the NEF benefit auction, which was held during the St. Patrick’s Day theme party.

Fabricator n May / June 2011

METALfab 2011 2011 Ernest Wiemann Top Job Competition Congratulations to the 2011

Top Job contest winners. This year, 55 companies submitted 130 entries and 321 photos. Twenty participants entered for the first time. Note that category J did not open because the 5-entry minimum was not reached. A. Gates, Driveway 1 Art’s Work Unlimited A-4 2 A.G. Welding A-3 3 Custom Iron by Josh A-2 B. Gates, Driveway, Forged 1 Wrought Iron Art Ltd. B-7 2 Schulte Studios Inc. B-1 3 Art’s Work Unlimited B-6 Tie 3 ATFAB B-5 C. Interior Railings, Ferrous 1 M. Cohen & Sons Inc. C-2 2 Iron Décor C-1 3 Vasquez Custom Metals C-6 D. Interior Railings, Nonferrous 1 Innovative Metal Design D-2 2 Big D Metalworks D-4 3 Allen Architectural Metals Inc. D-5 E. Interior Railings, Forged 1 Eureka Forge E-5 2 M. Cohen & Sons Inc. E-4 3 Heirloom Stair & Iron Inc. E-8 F. Exterior Railings & Fences 1 Heirloom Stair & Iron Inc. F-6 2 Allen Iron Works & Supply Inc. F-3 3 Wiemann Metalcraft F-8

G. Exterior Railings & Fences, Forged 1 Wrought Iron Art Ltd. G-1 2 Grizzly Iron Inc. G-4 3 Vasquez Custom Metals G-2 H. Furniture and Accessory Fabrication 1 Design Metals H-2 2 Foreman May / June 2011 n Fabricator

Mitch Heitler Award recipient, Oleg Shyshkin, Wrought Iron Art Ltd., accepts the award with his son Nickolas.

Fabricators Inc. H-1 3 Grainger Metal Works H-12 I. Furniture and Accessory Fabrication, Forged 1 Vasquez Custom Metals I-1 2 Virginia Architectural Metals I-10 3 Heirloom Stair & Iron Inc. I-9 K. Gates/Doors, Forged 1 Duerst Custom Metalwork K-1 2 DeAngelis Iron Work Inc. K-4 3 Wrought Iron Art Ltd. K-2 L. Stairs Complete 1 Wrought Iron Art Ltd. L-9 2 Construction Services Inc. L-5 3 SRS Inc. L-4 M. Structural Fabrication 1 Columbia Wire & Iron Works Inc. M-3 2 Custom Iron by Josh M-4 3 Innovative Metal Design M-5

Ray, Vicki, and Henry work a shift at the Top Job Gallery.

P. Art/Sculpture 1 Wrought Iron Art Ltd. P-3 2 Christopher Metal Fabricating Inc. P-2 3 Artisan Metal Works Ltd. P-1 Mitch Heitler Award (Chosen from among the gold award winners). Wrought Iron Art Ltd. B-7

Copper Development Association Award (A new award given to an entrant who shows excellence in mastery and display of copper and copper alloys). Allen Architectural Metals Inc. D-3


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N. Unusual Ornamental Fabrication 1 Eureka Forge N-7 2 M. Cohen & Sons Inc. N-4 3 Big D Metalworks N-1 O. Restoration 1 DeAngelis Iron Work Inc. O-1 2 Elegant Iron Studios O-3 3 Virginia Architectural Metals O-2

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METALfab 2011 Exhibitor List Alloy Casting Co. Inc.

D.J.A. Imports Ltd.

Illinois Engineered Products

American Fabricator Supply

Eagle Bending Machines Inc.

Industrial Coverage Corp.

Julius Blum & Co. Inc.

EPi, Electrochemical Products Inc.

The Cable Connection

Elite Architectural Metal Supply LLC

ITW Finishing Equipment Americas

Carell Corp. Century Group Colorado Waterjet Co. Complex Industries CS Unitec Custom Mfg. & Polishing Inc. Custom Orn. Iron Works Ltd.

Etemplate Systems (Tri-Tech Solutions Inc.) FabCAD Inc. Genova Imports LLC HE&M Inc. Hebo/Stratford Gate Systems Inc. Hypertherm Inc. & Airgas Inc.

King Architectural Metals Lavi Industries Lawler Foundry Corp. Lewis Brass & Copper Co. Locinox USA Logical Decision Inc. Marks USA Metabo Corp. Mittler Bros. Machine & Tool Morse Industries NOMMA/NOMMA Chapters NOMMA Education Foundation Regency Railings Inc. Rockite Div. of Hartline Products Co. Inc. Scotchman Industries Sharpe Products Sumter Coatings The Wagner Companies Weaver’s Iron Works West Tennessee Ornamental Door


Fabricator n May / June 2011

Biz Side

Energyreducıng retrofits you can do now n

Several federal tax-saving incentives and funding program can help you go green. By Mark E. Battersby

For your information


About the Author For over 25 years, Mark E. Battersby has been providing professionally prepared editorial features, columns, White Papers, and reports for magazines, journals, newsletters, and websites on the news and developments within the everchanging tax and financial arenas that impact small businesses.

May / June 2011 n Fabricator

To improve energy efficiency in commercial

buildings, the White House recently proposed a series of initiatives including “new” tax incentives for building efficiency, more financing opportunities for commercial retrofits, and a streamlining of state and municipal regulations. Fortunately, you have no reason to wait for these proposals to become a reality. What may surprise the owners and managers of many ornamental and miscellaneous metals businesses that own the buildings housing their operations — and the Administration — is that current tax incentives already substantially reduce the cost of making commercial buildings more energy-efficient.

A number of funding programs are also available. Although our tax rules have long treated commercial property less favorably than residential property, today tax breaks are available for commercial buildings, creating significant incentives to make those properties more energy efficient. The Energy Efficient Commercial Building Deduction currently permits fabricators to claim tax write-offs for new or renovated buildings that save 50% or more of projected annual energy costs for heating, cooling and lighting. Partial deductions are also available. Rather than deducting the actual cost of the equipment, or systems purchased to make commercial buildings more energy efficient, a flat tax deduction of up to $1.80 per square foot is available. The improvement must save at least 50% of the heating, cooling, ventilation, water heating, and interior lighting energy cost. A partial deduction of $0.60 per square foot can be taken for improvements made to one of three building systems: 1) The building envelope. 2) Lighting or heating. 3) Cooling system. The deduction applies to “energy efficient commercial building property,” defined as depreciable property installed as part of a building’s n interior lighting systems, n heating, cooling, ventilation and hot water systems, or n the building’s envelope as part of a certified plan to reduce the total annual energy and power costs. The U.S. Department of Energy maintains a list of software that must be used for calculating power consumption and energy costs to certify the energy savings required to claim the deduction. With only buildings covered by the scope of the American Society of Heating, Refrigeration and Air Conditioning Engineers’ (ASHRAE) Standard 90-1-2001 eligible, seeking professional assistance is almost mandatory. 45

erty placed in service before 2017, the credit percentage is increased to 30% for: n Qualified fuel cell property n Equipment that uses solar energy to generate electricity to heat or cool a structure or provide solar process heat (except used to heat a swimming pool) n Equipment that uses solar energy to illuminate the inside of a structure using fiber-optic distributed sunlight; n And after October 3, 2008 — qualified wind energy property. That’s right, the cost of small wind turbines for home, farm, or business use, as well as the cost of installing geothermal heat pump systems, qualify for a tax credit. In addition to a fuel cell credit similar to that available to consumers, tax credits are available to businesses that install qualifying micro-turbines. These systems, which typically run on natural gas, are small powerproducing systems sized to run small to medium-size commercial buildings.

Saving taxes while saving energy

Increasing numbers of businesses already use solar heating or lighting, or are installing it. Not too surprisingly, many of them are eligible for tax credits. Every metals fabricating business, for example, is, eligible for tax credits for qualified solar water heating and photovoltaic systems and for certain solar lighting systems. Under the tax credit rules, qualifying equipment will either use solar energy to generate electricity, to heat/ cool or provide hot water to a structure, or will use solar energy to illuminate the inside of a building by means of fiber-optic distributed sunlight (tube systems and passive solar are not eligible). The credits are available for systems “placed in service” between January 1, 2006 and December 31, 2016. The business energy investment credit is generally equal to 10% of the taxpayer’s basis in qualified energy property placed in service during the tax year. However, effective for prop-

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In addition to the incentives provided by our tax laws, a number of local, state, and utility company programs provide advice on energyefficiency, grants, state and local tax breaks, and even financing. The American Council for an Energy-Efficient Economy ( energy/state) offers, as one example, the State Energy Efficiency Policy database. The database is searchable by either state or policy area. Another database, established in 1995 and funded by the U.S. Department of Energy, is the Database of State Incentives for Renewable Energy (, a project of the North Carolina Solar Center, and the Interstate Renewable Energy Council (IREC) provides a comprehensive gateway to detailed information of a variety of state energy policies. Other tax write-offs

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More mundane tax write-offs help reduce the bill for energy-efficiency. Thanks to the Tax Relief Act that became a reality in December 2010 many tax write-offs were extended. Now ornamental and miscellaneous metals businesses can write off 100% of equipment and machinery placed in service after September 8, 2010 and through December 31, 2011. For property placed in service in 2012, the new law provides for 50% additional first-year depreciation. Last fall’s Small Business Jobs Act also increased the Section 179, firstyear expensing dollar and investment limits to $500,000 and $2 million, respectively, for 2010 and 2011. The Tax Relief Act provides for a $125,000 limit and a $500,000 investment limit for tax years beginning in 2012 and “sunsets” after December 31, 2012. This means metals fabricating businesses may immediately write-off the full cost of some energy “propFabricator n May / June 2011

erty” this year and claim a Section 179 expensing deduction of as much as $500,000 for newly acquired business property, new or used, placed in service after December 31, 2011. The Section 179 expensing writeoff is reduced, dollar-for-dollar, by any property acquisitions in excess of the $2 million investment ceiling, limiting the write-off to smaller businesses. And a 15-year write-off is available for qualified improvements made to leased business property under which both leased equipment and the business premises qualify. Paying for energy savings

Today, access to capital for an energy-efficiency upgrade is no longer an issue for the majority of metals fabricators and businesses. Some upgrades require little funding. For those requiring investment, many traditional and non-traditional financial resources are available. Energy performance improvement projects may be different from many other business investments in that they provide an immediate and predictable positive cash flow resulting from lower energy bills. This feature allows them to be financed with both familiar and unconventional financing. Tax incentive programs offered by local, state, and the federal government have long helped overcome the relatively higher front-end costs associated with energy efficiency equipment. Today, tax incentives reduce the cost of acquiring and installing energy-efficient property — and significantly reduce the day-to-day costs of operating the business. The increased emphasis on energysavings has also spawned a number of programs to help finance the cost of “going green.” Last fall’s Small Business Jobs Act created the State Small Business Credit Initiative (SSBCI) funding it with $1.5 billion for state programs that support lending to small businesses, such as ornamental and miscellaneous metals fabricating operations (and small manufacturers). Participating states will use the May / June 2011 n Fabricator

federal funds for programs to leverage private lending to help finance small businesses, such as metalworking shops that are creditworthy but are not getting loans they need to expand and create jobs.

Last year’s “Jobs” act included other provisions designed to help small businesses obtain funding. Although not limited to energy funding, among the new programs providing financing are: n A Small Business Lending Fund to provide up to $30 billion in capital to financially sound small banks with less than $10 billion in assets to encourage them to lend money to small businesses. n Any metals fabricating businesses considering Small Business Administration loans stand to benefit from the extension of provisions that amped up SBA lending guarantee programs and fee reductions that recently expired. In addition, the bill increases the maximum loan size for the SBA’s 7(a), 504, and microloan programs. The 7(a) and 504 loan program maximums would bump from $2 million to $5 million and the microloans would increase from $35,000 to $50,000. Loans made under the SBA Express program would temporarily increase from $300,000 to $1 million. Phone: (800) 285-3056

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Inconsistent explanations Substance abuse Disgruntled employee

Secretive conversations Bad behavior Loitering

Unusual loyalties

Employee Theft n Know

the danger signals of employee theft and fraud. By William J. Lynott It’s only natural for you to place a great deal

of trust in your employees. “We’re like one big family,” is a refrain often heard in entrepreneurial ranks. That’s as it should be — but it’s important to keep your guard up. The unfortunate fact is that employee theft is a growing national problem, and our difficult economy isn’t making things easier. FBI statistics show employee theft is the fastest growing crime in America. “And metal fabrication shops are not immune,” says Greg Madden, owner of Madden Fabrication, Portland, OR, we’ve had our share.” To an employer, employee theft occurs when a worker steals merchandise, money, or property while on the job. Even wasted or stolen time is a form of employee theft. 48

From a strictly legal perspective, a theft is committed when an employee takes something with the intent of depriving the business owner of the stolen item’s value. Even more important than legal considerations is the devastating damage to the business that can result from employee dishonesty. “With metal prices constantly rising, theft of material is a constant threat,” says Madden. “We recently had $5,000 to $6,000 worth of stainless stolen from our yard. We’re not certain if it was an inside job, but the material is gone nevertheless.” Even if you’re confident that employee theft is not a problem in your shop, do recognize the telltale signs and know how to build and maintain an environment that will help your staff to avoid temptation. Minimizing the chances of employee theft begins with the hiring process, says Joseph T. Wells, founder and president of the Association of Certified Fraud Examiners. “Before hiring anyone,” he says, “you should conduct a background check to find out as much as you can about the employee’s previous experience with employers and law enforcement. “Background checks are always a good practice, but each employer must decide whether the time and expense is worth the return. At a minimum, you should check the background of any prospective employee who will have access to cash, checks, credit card numbers, or any other easily stolen items.” What to do

Before hiring, Wells says check as many of the following as possible: Past employment verification. Even though most employers will only verify position and dates of employment when you call to check a reference, you can sometimes tell by their tone of voice what they think of the employee. Also, ask whether the applicant is eligible for rehire. Criminal conviction checks. Most public records services (such as Nexis or ChoicePoint) have criminal conviction records for almost every large county in the U.S. If not, search the criminal conviction records in the criminal courts division of the employee’s county of residence (or other counties in which he or she previously resided). Drug screening. Many business owners screen for drugs — for both current and potential employees. Obviously, people who are frequent drug users can be more prone to theft or fraud. Fabricator n May / June 2011

Policies that help deter fraud

“Developing anti-fraud programs can be one of the most important things that you can do for your business,” says Wells. “Prevention, in the long run, is always cheaper than recovering your losses.” He suggests these precautions: Perception of detection. Employees who think they might get caught in occupational fraud are less likely to commit it. Increasing the perception might be the most effective method. Internal controls, for example, do little good in forestalling theft and fraud if their presence is not known by those tempted to steal. This means letting all employees and supervisors know that programs are in place for actively seeking out information concerning internal theft. Proactive programs. Becoming proactive in your anti-fraud efforts might be another effective step. Some useful programs cost little while others require a cost commitment. In most cases, anti-fraud programs will more than pay for themselves. “Tools would be easy things to steal,” says Greg Madden, so we use a wall-mounted shadow board to hold the shop’s tools. A spot for each tool with the outline of the tool on it makes May / June 2011 n Fabricator

it easy to quickly spot will aid in the prevention anything that’s missing.” of some frauds. Another proactive Job rotation. Some program at Madden Fabfrauds are detected durrication requires that all ing sickness or unexvendors be informed that pected absences of the T CO NTAC no order is to be filled, perpetrator because Association of Certified without a purchase order they require continuFraud Examiners, with number. “And I crossous intervention by the 55,000 members, is the check all purchase orders offender. That’s why it world’s largest anti-fraud and make all cash deposcan be helpful to rotate organization and a provider its myself.” potentially sensitive jobs of anti-fraud training and education. Many states Employee education. whenever possible. have local chapters. Every business should Split responsibility. some mechanism Wherever possible don’t Cohave 4/5/07 10:41 AM PageToll 1 Free: (800) 245-3321 designed to educate emallow the same person ployees about the serious who handles incoming About the Author consequences of internal cash and checks to do Bill Lynott is a long-time theft. One way is to make the paperwork accountbusiness writer for Fabricathe training part of orien- tor. Since 1957 he has writ- ing for that money. tation for new employees. ten nearly 1,000 essays and Trash control. Make columns and is the author Any education efforts random checks of dumpof three books. In addition should be positive and sters and trash bins for to his career as a writer, Bill non-accusatory. Remind goods that may have also has an extensive backemployees that illegal been placed there for latground in management, conduct in any form er pickup. Use clear trash consulting, and marketing. eventually costs everyone, bags for easy inspection including them, through lost profits, and keep outside dumpster lids locked adverse publicity, decreased morale, after business hours. and lower productivity. Conduct frequent inventories. Do Enforcement of mandatory vacamaterial inventories often and rantions. Many internal frauds require domly. Examine records of purchases constant personal, as opposed to autoand sales daily. Assigning inventory mated or computerized, intervention, control responsibilities to specific inand are often discovered when the dividuals helps to establish accountperpetrator is away on vacation. The ability, which in turn helps to discourenforcement of mandatory vacations age theft.

For your information


Reference checks. Surprisingly, few employers call the references a candidate provides, apparently assuming that an applicant wouldn’t provide a bad reference. However, many times applicants will list important-sounding individuals as references with the hope that you won’t call. And people often assume, incorrectly, that a former supervisor or co-worker will provide a good reference Always obtain the consent of the applicant. Numerous federal and state laws, such as the Fair Credit Reporting Act, govern the05 gathering and use05 of G-S 2007 g-s co:2007 information for pre-employment purposes. Many of these laws require that you obtain written consent from the applicant before gaining some of the information listed above. Consult with your attorney to ascertain the laws applicable to your business and to obtain the proper authorization forms.

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Consider insurance that covers employee theft. Greg Madden recalls a conversation he had with a shop owner. “She told me that her foreman stole a lot of her tools and equipment and that her insurance resisted covering her because her policy didn’t include employee theft. I checked with my insurance company, and they tell me that my plan would cover it, but reading through the fine print I found security measures that if not taken could cause issues with payment for a claim, such as how many employees have keys and alarm codes and how careful you are with access to your facility.” Reading the fine print on an insurance policy may not be your favorite activity, but it can pay big dividends. Consider video surveillance. Technological advancement has greatly reduced the cost of video surveillance putting it in the reach of even the smallest shops. Installing strategically placed cameras can be a strong deterrent. However, do emphasize the program in a positive light, pointing out that the cameras have been installed for the protection everyone including employees. Early warning signs

Despite the best of internal programs, Wells says be aware of early warning signals of employee dishonesty: Substance abuse. An employee with a substance abuse problem will need extra money to finance the habit. This is one of the most common scenarios. Disgruntled employee. Is someone belligerent, often complaining about management or his or her job? Bad behavior. A person with a temper or unpleasant behavior tends to discourage questions. Inconsistent explanations. This might occur when discussing discrepancies in paperwork or cash accountings. Loitering. Watch out for excessive loitering around the business by off duty employees, ex-employees, or friends. Secretive conversations. Do employees quickly stop phone conversations when you approach? Unusual loyalties. Do some employee relationships with other employees, customers, or vendors appear too friendly? Watch for customers who loiter or who meet with employees around closing hour. Lifestyle. Are any employees living an excessive lifestyle relative to what their salary could be expected to support? Forgot something? Do you have an employee who habitually returns to the work area after others have left to retrieve something supposedly left behind? Gifts to employees. Watch for gifts or favors to employees from vendors or customers. If you suspect theft

Although sensible precautions can greatly reduce the likelihood of theft by employees, no fool-proof ways to prevent it exist. A dishonest employee determined to steal is difficult to stop. If you suspect or have evidence of employee theft, call your local police department. Handling the matter on your own could lead to false or impossible-to-prove accusations which could expose you to serious legal liability. Fabricator n May / June 2011

Biz Side

Secure your busıness future n

Proactive estate and succession planning help make a family company have successful transition to new generation.

By Leon and Terrance Resnick For three generations, the 45-year-old Jay

For your information

With a two-out-of-three failure rate of first generation family businesses getting to a second generation, the Hawkins family will find that successfully transferring their family business to Nathan and Adam may be more challenging then anything they’ve faced.

Hawkins family business, ABC Metal, has been vital to their community. This close family has no intention of either they or their business leaving home. About the Authors Starting with two employees in 1966, they Transition challenges Leon Resnick and earned a few valued customers. Now ABC emn Do Jay and Rachel transfer the business ploys more than 100 in three locations. The hard Terrance Resnick are 1/3 each to each child even though only two of partners in Resnick Assowork has paid off and the family, with their $25 three are active? ciates, an estate, business million company, enjoys a comfortable lifestyle. n Combined with the $25 million company, succession and life insurNow 65, Jay is still closely involved with the Jay and Rachel’s estate is worth $30 million. ance planning firm with company and owns 100% of it. His wife Rachel They are presently faced with a correspondoffices in Kansas City and Harrisburg, PA. phased out of the business in 1968 when they ing federal estate of millions of dollars due The Resnicks have had the first of their three children. Two sons, and payable nine months after the death of the presented seminars for Nathan and Adam, are involved in the day-tosecond spouse. many business groups, day operations having worked their way up n Three employees are vital to the day-toincluding the Coca-Cola to management level hoping to take over the day success of ABC. What assurances do Bottlers Association, and business. Their sister Lauren, while close to her Nathan and Adam have that these key employwork with these groups’ brothers, never showed much interest in the ees will stay once Jay exits the business? members on an individual basis. business; she lives in the same town as her famThese are a few of the common yet often They may be reached ily, but has an unrelated career. overlooked challenges for a successful family The Hawkins are a classic example of a family at (913) 681-5454 or enterprise. If not addressed through estate and (717) 652-2929. business that took a chance, worked incredibly succession planning, then the Hawkins family hard, and made their company successful. The will be almost assured of losing the company. Hawkins want ABC to continue for Nathan and Adam, and Conversely, if proper planning is implemented and reif possible, for future generations of Hawkins. viewed annually, they have a good chance of seeing their Unfortunately, when it comes to a family business, intenbusiness thriving for many years. tions aren’t what make these goals happen. Proactive estate and succession planning are keys to driving a family compaIssue number 1 ny into and beyond the next generation. Actions speak loudWe generally recommend that only children who are acer then intentions, and poor planning combined with potentively working in the company receive business interests in a tial hefty federal estate taxes speak louder then anything. family held concern.


May / June 2011 n Fabricator


Typically, the company If the Hawkins family It is generally not in the best interest and related assets comprise doesn’t liquidate, how will the of the business or family for non-active family family get the millions of dol70% or more of a business owner’s estate. If one child lars in a short period of time members to have stock. Non-active family working in the company ultito satisfy the IRS? members may be “equalized” with non mately gets a 70% distribution The company should qualof the estate assets, without ify for a Section 6166 program business assets through the estate plan. proper planning that means (IRS 14 year installment plan), the other children will receive as Jay’s closely held stock an incredibly inequitable Issue number 2 makes up more than the redistribution. Insufficient liquidity, when it is quired minimum of 35% of the total of Properly structured life insurance needed most, often destroys family his and Rachel’s estate. can equalize the inheritance for chilbusinesses, since the federal estate tax Section 6166 is a problem, howdren of family business owners. No is due within nine months after the ever. Other then ABC being a busiother planning technique allows the date of death of the second spouse. In ness partner with the IRS for 14 years, immediate creation of wealth. the Hawkins case, Jay and Rachel may even with nominal interest rates the Caveat: The correct acquisition and have a $30 million estate but with $25 first four years of the 14 year plan, the implementation of life insurance for million of it being illiquid, how will Hawkins estate may still pay considestate and business planning is often the executor raise over millions of dolerably higher amounts out of pocket complex and sophisticated. lars in nine months? (through principal and interest) than As with legal and accounting/ Their solution, as it is for other what the original tax bill was. valuation work, experienced specialclosely held family businesses, is to Although many tax planning strateists should handle this part of the liquidate hard assets (i.e. ABC, land gies are available, when a tax bill is due planning. holdings), the last thing Jay Hawkins the options to pay the bill are few. Stories abound about business would ever want to do. He and his n Pay cash from the estate. If an owners having life insurance only to family have worked too hard to build estate is liquid, this will take care of see premiums unexpectedly skyrocket ABC not to see Jay’s and Rachel’s sons the obligation, but is obviously expenor their policies implode. continue the success of ABC. sive as a family is paying 100 cents on


Fabricator n May / June 2011

the dollar and losing the cash All life insurance policies are not the same. company. This is not always and future appreciation of the the case; properly designed There is a very real threat if you do not fully cash forever. deferred compensation prounderstand your contract design, ownership, grams often provide the same n Borrow money. If an estate qualifies, this route is result of retaining the emstructure, and language. Sufficient liquidity more expensive then selfployees, as would the transfer upon the death of an owner of a closely-held funding the tax because the of ownership. loan amount and interest Of course, other issues are or family business is a must. It provides capital involved. must be paid. But those referfor any taxes due, a cushion in lean teams, and enced in the article are critin Selling the company. The family doesn’t want to cal. Business owners should the fuel needed for expansion and growth. entertain this option to raise not minimize their imporcapital to pay their tax bill. tance. It can literally mean the difference between your n Life insurance. If acquired and structured propowners, what happens if another combusiness surviving or not. erly, this can save the Hawkins family pany lures away the three key people? millions of dollars compared to the Overnight, ABC can become a difLegislative Update: The Tax Relief, other methods. By positively leveragferent company — and not for the Unemployment Insurance Reauthoriing premium dollars into a tax-free better. In this instance, “golden handzation, and Job Creation Act of 2010, death benefit, the Hawkins family will: cuff ” programs can be implemented which provided taxpayers some to retain these three employees. The temporary relief, including a two-year n take care of their tax bill, “golden handcuff ” would be an asset to increased estate and gift tax exemption n save millions of dollars, and ABC and the employees would have an is set to expire December 31, 2012. As n succeed in keeping ABC in the family. attractive retirement program should of this writing, many advisors suspect they stay with ABC until retirement. that any additional relief from federal Issue number 3 Many business owners believe the estate taxes is unlikely. There is also no If the tax bill is paid and Nathan only way to retain key executives is to guarantee this tax relief will be and Adam now have ABC as 50/50 give away ownership interests in their extended past the two years.

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May / June 2011 n Fabricator

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18 Great Reasons To Join NOMMA

A NOMMA membership provides a great value for your dues — you’ll get a wide array of benefits and tools that help your business. Four Easy Ways To Join: 1) Call Liz Johnson, our member care manager, at (888) 516-8585, ext. 101. 2) Email: 3) Download an application form from our website (click “Join Now!”) and fax to: (888) 516-8585. 4) Join online (click “Join Now!”) - Benefits of Membership NOMMA provides an excellent value for your membership investment — 18 benefits!

☛ Knowledgebase - Access hundreds of documents, including back issues of Fabricator, TechNotes, and Fabricator’s Journal.

☛ Member Kit - Upon joining, you’ll receive a kit containing a sampling of NEF publications and sales aides.

☛ Chapters - If you live in an area covered by a chapter, your dues also cover chapter membership. Chapter meetings feature demos, shop tours, and time for networking.

☛ Subscriptions - Receive a free subscription to O&MM Fabricator and NOMMA Newswire, our monthly email newsletter. ☛ Free monthly webinars - Focusing on business, shop, and technical issues. ☛ Vendor Discount Program - Receive discounts from a growing number of participating vendors. ☛ Awards Contest - As a member you’re eligible to compete in our annual Top Job competition, which recognizes outstanding industry work. ☛ Free Smartphone App - Now you can access the member’s area from your handheld device. ☛ Discounts - Reduced price for all NEF publications, videos, and events, including our annual METALfab education conference and trade show. ☛ Online Tutorials - View past NEF webinars, as well as print and video tutorials. ☛ ListServ - A great place to get your questions answered and to receive the latest news and information. ☛ Insurance Program - Obtain a free safety manual and receive bulletins on hot topics.

Membership Categories / Pricing Fabricator Member ($425) - Includes metal fabricating shops, blacksmiths, artists, or other firms and individuals in the industry whose products or services are sold directly to the consumer or the consumer’s immediate agent or contractor. Supplier Member - Firms that produce or distribute materials, machinery, and accessories for the industry or provide services that may be used by the industry. • Nationwide ($595) -Operating on a nationwide or international basis. • Regional ($465) -


☛ Affiliation - Receive a NOMMA member decal and certificate to proudly display in your front office. As a member, you show the world that you subscribe to NOMMA’s Code of Ethics. ☛ Member Locator - Make it easier for architects, designers, and consumers to find you, either by state or ZIP code. ☛ Technical Affairs - A portion of your dues supports our advocacy work with code bodies, standards organizations, and government. ☛ Mentor Program - Get connected with a seasoned craftsperson to help you develop both your professional growth and business. Additional benefits: ☛ NOMMA Education Foundation (NEF) - The foundation works to provide education and research services for the industry. NEF projects include education classes and training videos, support for chapters, research, scholarships, grants, etc... ☛ METALfab is our annual education conference and trade show. This is your opportunity to receive quality education and see the latest products and technology at our trade show.

Operating within a 500-mile radius. • Local ($375) - Operating within a 150-mile radius. Affiliate Member ($310) - Affiliate membership is limited to teachers, educational institutions, and nonprofit organizations that do not engage in the fabrication of ornamental or miscellaneous metal products, do not provide products or services to the industry, but have a special interest in the industry. American Express, VISA, MasterCard, and Discover accepted. As a NOMMA member, you agree to abide by NOMMA’s Code of Ethics.

Fabricator n May / June 2011

METALfab 2011

A Special Group of Suppliers - METALfab 2011 Sponsors The sponsors for 2011 are a very special group of suppliers. In challenging economic times they are going the extra mile to help METALfab be an outstanding event. We appreciate their support! Platinum Sponsors Industrial Coverage Corporation 62 South Ocean Avenue Patchogue, NY 11772 Tel: (631) 736-7500 Toll Free: (800) 242-9872 Website: Industrial Coverage is the NOMMA endorsed insurance administrator. The Wagner Companies P.O. Box 423 Butler, WI 53007-0423 Tel: (414) 214-0444 Toll Free: (888) 243-6914 Website: Distributor and manufacturer of metal products – including handrail fittings and systems - for architectural and industrial applications. Its diverse product lines include railing products (elbows, handrail, fittings etc.) and services related to railings, such as bending, fabrication and polishing. Gold Sponsor King Architectural Metals 9611 East RL Thornton Dallas, TX 28787 Toll Free: (800) 542-2379 Website: King Architectural metals provides numerous products and services to the ornamental metal industry such as forgings, castings, access controls, stair, railing & fence components, plasma designs, etc. Lawler Foundry Corp. P.O. Box 320069 Birmingham, AL 35232 Tel: (205) 595-0596 Toll Free: (800) 624-951 Website: Lawler Foundry serves the fabricator and forger with high quality castings and forgings at popular prices. Silver Sponsors Julius Blum & Co. Inc. P.O. Box 816 Carlstadt, NJ 07072 (800) 526-6293 • (201) 438-4600 Website: Components for architectural metalwork, which are available in aluminum, bronze, stainless steel, and nickel-silver. Products include handrails, guardrails, brackets, tubing, bars and shapes.

May / June 2011 n Fabricator

Colorado Waterjet 5186 Longs Peak Road, Unit F Berthoud, CO 80513 Tel: (970) 532-5404 Toll Free: (866) 532-5404 Website: Colorado Waterjet Company is Colorado’s oldest, largest, and most experienced job shop specializing in abrasive waterjet shape cutting. Equipment includes a Dynamic WaterJet the most advanced waterjet available. D.J.A. Imports, Ltd. 1672 East 233rd Street Bronx, NY 10466 Tel: (718) 324-6871 Toll Free: (877) 773-2352 Website: Full service distributor specializing in ferrous and nonferrous metals such as ornamental steel, aluminum, stainless steel, and brass. Furthermore, they have gate and door hardware in solid steel and stainless, gate and door handles, furniture commercial furnishings, and machinery. Innovative Hinge Products Inc. 415 Jones Road Weatherford, TX 76088 Tel: (817) 598-4848 Website: Innovative Hinge Products provides high quality, cost effective hinge solutions for almost any door or gate. Bronze Sponsor Carell Corporation P. O. Box 850 Stapleton, AL 36578 Tel: (251) 937-0948 Website: Carell Corp. was founded to fill a need for tough, dependable machines capable of working day after day with minimum down time. Carell provides a range of models, options and tooling to match almost any budget. They also have an in-house machining shop for custom tooling. O.K. Foundry Co. Inc. 1005 Commerce Rd. Richmond, VA 23224 (888) 592-2240 Website: www. okfoundrycompany. com O.K. Foundry provides production, prototype and one-ofa-kind gray and ductile iron castings for engineering and architectural applications produced in a traditional jobbing foundry. 55


Nationwide Supplier Members Accurate Manufactured Products Group Inc. (317) 472-9000

D & D Technologies (USA) Inc. (800) 716-0888

Indiana Gratings Inc. (800) 634-1988

P & J Mfg. Co. (419) 227-8742

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

Industrial Coverage Corp. (800) 242-9872

Precision Glass Bending Corp. (800) 543-8796

DAC Industries Inc. (800) 888-9768

Industrial Metal Supply Co. (800) 371-4404

ProCounsel (866) 289-7833

Decorative Iron (888) 380-9278

Innovative Hinge Products Inc. (817) 598-4846

Q-Railing USA Co. (714) 259-1372

DKS, DoorKing Systems (800) 826-7493

Interstate Mfg. Associates Inc. (800) 667-9101

Regency Railings Inc. (214) 742-9408

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

The Iron Shop (800) 523-7427

Robinson Iron Corp. (800) 824-2157

Eagle Bending Machines Inc. (251) 937-0947

Iron World Mfg. (866) 310-2747

Elite Architectural Metal Supply LLC (847) 636-1233

ITW Finishing Equipment Americas (800) 233-3366

Rockite, Div. of Hartline Products Co. Inc. (800) 841-8457

Artist Supplies & Products (800) 825-0029


King Architectural Metals (800) 542-2379

L.E. Sauer Machine Co. (800) 745-4107

Artistic Ornamental Supply (305) 836-0192

ETemplate Systems (919) 676-2244

King Architectural Metals - CA (800) 542-2379

Scotchman Industries Inc. (800) 843-8844

Atlas Metal Sales (800) 662-0143

EURO-FER SPA ( 011) 39-044-544-0033

King Architectural Metals - MD (800) 542-2379

SECO South (888) 535-SECO

Banker Wire (800) 523-6772

FabCad Inc. (866) 427-2454

C.R. Laurence Co. Inc. (800) 421-6144

Sharpe Products (800) 879-4418

Barnett Bates Corp. (800) 541-3912

Feeney Inc. (Feeney Architectural Products) (800) 888-2418

Lavi Industries (800) 624-6225

South Camden Iron Works Inc. (800) 962-1029

Lawler Foundry Corp. (800) 624-9512

Stairways Inc. (800) 231-0793

Lewis Brass & Copper Co. Inc. (800) 221-5579

Steel Masters Inc. (602) 243-5245

Locinox USA (708) 579-0286

Stephens Pipe & Steel LLC (800) 451-2612

Logical Decisions Inc. (800) 676-5537

Sumter Coatings Inc. (888) 471-3400

Mac Metals Inc. (800) 631-9510

TACO Metals (800) 653-8568

Marks U.S.A. (800) 526-0233

Transpacific Industrial Supply Inc. (909) 581-3058

Albina Pipe Bending Co. Inc. (866) 252-4628 Alku Group of Companies (800) 465-7143 Allen Architectural Metals Inc. (800) 204-3858 Alloy Casting Co. Inc. (800) 527-1318 American Punch Co. (800) 243-1492 Ameristar Fence Products (888) 333-3422 Architectural Iron Designs Inc. (800) 784-7444

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 Bridgeton Drafting Co. LLC (856) 205-1279 Byan Systems Inc. (800) 223-2926 The Cable Connection (800) 851-2961 Carell Corp. (251) 937-0948 Carl Stahl DecorCable Innovations (800) 444-6271 Century Group Inc. (800) 527-5232 Cleveland Steel Tool Co. (800) 446-4402 Colorado Waterjet Co. (866) 532-5404 CompLex Industries Inc. (901) 547-1198 Custom Mfg. & Polishing Inc. (417) 831-7900 Custom Orn. Iron Works Ltd. (866) 464-4766


(262) 786-9330

Gates That Open LLC (GTO) (800) 543-4283 Genova Imports LLC (972) 395-8199 Geo. Bezdan Sales Ltd. (800) 663-6356 Glasswerks LA Inc. (800) 350-4527 The G-S Co. (410) 284-9549 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 Heritage Cast Iron USA (918) 592-1700 House of Forgings LLC (866) 443-4848 Hypertherm Inc. (603) 643-3441 Illinois Engineered Products Inc. (312) 850-3710

McKey Perforating (800) 345-7373 Metabo Corp. (800) 638-2264 Mittler Bros. Machine & Tool (800) 467-2464 Multi Sales Inc. (800) 421-3575 NC Tool Co. (800) 446-6498 New Metals Inc. (888) 639-6382 O.K. Foundry Co. Inc. (888) 592-2240 Ohio Gratings Inc. (800) 321-9800

Rogers Mfg. Inc. (940) 325-7806

Tri-State Shearing & Bending (718) 485-2200 TS Distributors Inc. (800) 392-3655 The Wagner Companies (888) 243-6914 Wasatch Steel Inc. (888) 486-4463 West Tennessee Ornamental Door (866) 790-3667 Wiss Janney Elstner Associates Inc. (847) 272-7400

Overseas Supply Inc. (866) 985-9885

Fabricator n May / June 2011


New Members We are pleased to introduce our newest members. We encourage our new member firms to “jump in and get involved.” New NOMMA Members as of April 26, 2011. *Asterisk denotes returning member.

Kasper Fabrication & Design* Cleveland, OH Fred Kasper Fabricator Southern Fabrication LLC Houma, LA Travis Breaux Fabricator Wiss Janney Elstner Associates Inc.* Northbrook, IL Penny Sympson Nationwide Supplier


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Call the Ornamental Fabricator HOTLINE for competitive pricing on custom quotes at 800-242-9872. Or visit us at our website: option 2 May / June 2011 n Fabricator

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What’s Hot? n Events August 2–6, 2011 International Preservation Trades Workshop The 15th annual IPTW will be held in Lancaster, PA, on the campus of Thaddeus Stevens College of Technology. The workshop brings together hundreds of preservation and traditional trades crafts people, as well as preservation architects, preservation consultants, building trades contractors, and other experts. Proposals from potential demonstrators and presenters are being accepted, from those who practice a traditional or preservation trade that can be demonstrated by highlighting techniques, materials, tools, and skills related to the preservation or restoration of historic structures. More than 50 presentations and hands-on demonstrations will be available. Contact PTN, (866) 853-9335;; August 18–21, 2011 Western States Blacksmith Conference Conference includes demonstrations, workshops, seminars, slide shows, and the “Blacksmith Wars,” where teams will collaborate on competitive projects. The conference will be held at Mt. Hood, OR, hosted by the NorthWest Blacksmith Association and the Alpine Village of Government Camp. Contact Darryl Nelson, (360) 832-6280; info@westernstates2011. com;


Industry News

Court upholds ‘fall protection’ directive The U.S. Court of Appeals for the Seventh Circuit has rejected a challenge by the National Roofing Contractors Association to the Occupational Safety and Health Administration’s December 2010 directive on the use of fall protection in residential construction. The directive withdrew an earlier one that allowed certain residential construction employers to bypass some fall protection requirements. “Fall protection saves lives,” said OSHA Assistant Secretary Dr. David Michaels. “There are effective means available to protect residential construction workers from falls. We applaud the court’s decision upholding this updated, commonsense directive.” Data from the department’s Bureau of Labor Statistics estimates that an average of 40 workers are killed each year as a result of falls from residential roofs. One-third of those deaths represent Latino workers, who often lack sufficient access to safety information and protections. “Fatalities from falls are the number one cause of death in construction,” added Michaels. “These deaths are preventable, and we must prevent them.”

OSHA’s new directive, Standard 03-11-002, rescinded the Interim Fall Protection Compliance Guidelines for Residential Construction, Standard 03-00-001. Prior to the issuance of this new directive, Standard 03-00-001 allowed employers engaged in certain residential construction activities to use other methods of fall protection rather than the conventional fall protection required by the residential construction fall protection standard. With the issuance of the new directive, all residential construction employers must comply with 29 Code of Federal Regulations 1926.501(b)(13). Where residential builders can demonstrate that traditional fall protection is not feasible, 29 CFR 1926.501(b)(13) still allows for alternative means of providing protection. Construction and roofing companies have until June 16 to comply. OSHA has developed training and compliance assistance materials and will host a webinar. For more information, visit residential_fall_protection.html.

Builders support mortgage interest deduction The National Association of Home Builders (NAHB) is urging members of the U.S. House of Representatives to show their support for homeownership and the mortgage interest deduction by co-sponsoring H. Res. 25. NAHB is also asking individuals who support the resolution to contact their representatives and recommend co-sponsorship. “This resolution acknowledges the importance of homeownership to individual households, the economy and the nation,” said NAHB Chair-

man Bob Nielsen, a homebuilder from Reno, NV. The resolution also states that the mortgage interest deduction “may well be the most important component of housing-related tax policy in America today” and should not be further restricted, he said. Additional information on H. Res. 25 and how to contact members of the House of Representatives is available in the “Take Action and Stay Connected” section of NAHB’s mortgage interest deduction website, Fabricator n May / June 2011

What’s Hot? n


Craft center offers metals and smithing workshops Tennessee Tech University’s Appalachian Center for Craft is offering a variety of workshops from May through July, at its facility near Smithville, TN. College credit is available for the longer classes. May 13–15 Micro forming techniques Presents the basics of micro shell forming. 5 Book ad 2011:Layout 1


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May 27–29 Building a belt grinder Students will build a belt grinder with a 1.5- or 2-horsepower motor.

June 3–5 Texturing iron Explores methods for creating patterns on steel items, and making tools for stamping. June 12–July 1 Architectural metal works Includes applications, construction, problem solving, material capability and limitations, tooling, and design. Page 1

July 10–15 Hot steel sheetsmithing Transforming flat steel sheets into dramatic forms using hot forging,

fire welding patterns and joinery techniques. July 17–22 Intro to blacksmithing Tools and techniques of the blacksmith, using gas and coal forges. July 24–29 Ordinary Damascus Exploration of pattern welded (Damascus) steel. Contact (931) 372.3051;;

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What’s Hot? n Imported specialty books Artisan Ideas At press time, minimal copies of “Locks: A Collection of Masterpieces,” and “Doorknockers” were available from Both books are limited edition photographic surveys in English and Italian. Also available is “Secrets of the Forge: Step-by-Step in Photos,” featuring 48 projects by Italian master blacksmiths. Contact Artisan Ideas, (800) 8439567; Welding videos on YouTube Bernard Product information, demonstrations and customer testimonials are now featured on Bernard’s new YouTube channel — “The Bernard Difference.” The videos feature welders,


supervisors, and business owners from a variety of industries. Contact Bernard, (800) 946-2281; Master metalworker book Astragal Press/Finney Company The book Samuel Yellin: Metalworker by Jack Andrews has recently been rereleased. It is a photographic essay and documentation about master artist-blacksmith Samuel Yellin, representing the culmination of 19th-century wrought iron design and fabrication. From 1909 to 1940, Yellin created wrought iron work for clients throughout the U.S. The book carefully docu-

ments the scope of his work. Contact Astragal Press, (866) 5433045; Metal Fabrication eCatalog Norton Abrasives A re-designed Norton/Merit welding and metal fabrication eCatalog is available, providing quick access to product selection. Featuring a comprehensive selection of metal fabricating abrasive products from the Norton and Merit lines, the catalog is expanded by more than 50% and will get quarterly updates. The eCatalog will also include accompanying eLearning modules.



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


117 DAVID BIDDLE TRAIL, WEAVERVILLE, NC 28787 DESIGN & SALES: 800-635-2596 FAX: 828-645-2128 OFFICE: 800-541-8065 • 60

Fabricator n May / June 2011

What’s Hot? n


Magnetic drill pilots for hole enlarging Hougen Manufacturing

To enlarge existing holes more easily, Hougen Manufacturing has introduced a new Hole Enlarging Pilot System, using its 2-inch D.O.C. Rotabroach Cutters and portable magnetic

May / June 2011 n Fabricator

drills. The pilot is a two-piece assembly consisting of a threaded pilot and three different-sized screw-on nosepieces, each having flats on opposite sides for easy tightening and removal with a wrench or pliers. Using a portable magnetic drill, the cutter and pilot is inserted into an existing hole, then by re-drilling the hole its diameter is increased by 1/8 inch. For example, an 11/16-inch hole can be quickly and accurately enlarged to 13/16-inch hole. The replacement nosepieces have a tapered edge for easy insertion into existing holes and are currently available in three sizes, 11/16 inch, 13/16 inch, or 15/16 inch. One pilot works for all

three nose sizes and with Hougen’s magnetic drills. Contact Hougen Manufacturing, (810) 635-7111; New engine for welder Lincoln Electric The Outback 145 engine driven welder has been updated with a Kohler 9.5 HP Model CH395 OHC (overhead cam) gasoline engine. This welder is designed for jobsites and outdoor welding applications that require a rugged and portable machine with a reliable generator. This unit is specifically designed for contractors, maintenance crews, farmers and ranchers,


What’s Hot? n as well as for use on service trucks where portable DC stick welding and AC generator power are needed. The new Outback 145’s Kohler engine features a cast iron cylinder liner for long engine life as well as automatic shutdown for low oil level. The unit delivers 145 amps of smooth DC output welding for use with up to 1/8-inch stick electrodes on steel, stainless steel, cast iron and hardfacing projects. The Outback 145 high-capacity AC generator provides 4,750 watts peak power and 4,250 watts of continuous power for accessories such as grinders, work lights and pumps. It can also provide emergency backup power.


Contact Lincoln Electric, (216) 4818100; Locking Side-Pull D&D Technologies D&D Technologies newest product is a key-lockable version of the MagnaLatch Side-Pull. It can be used on gates, doors, cabinets and other applications where a locking latch is needed and will fit metal, wood and vinyl gates. The Lockable Side-Pull is molded of strong engineering polymers with stainless steel components, to prevent rust and stains.

The MagnaLatch lockable Side-Pull complies with pool safety regulations when installed correctly and features horizontal and vertical adjustment for easy installation and to compensate for gate movement and sagging over time. The screw holes are the same as the original MagnaLatch Side-Pull, for easy upgrades to a lockable version of the product. Contact D&D (800) 716-0888; Fiber discs Norton Abrasives Norton has introduced NorZon BlueFire F826 Fiber Discs for the metal fabricating industry, offered in the “better choice” category for stainless, super alloys, steel cast iron and high pressure applications. BlueFire features a new blend of patented zirconia

er s v E aw re cut S t s it e t m s a º F o 60 0º t

Direct Drive Saws See demo on our website ‘Better than a Cold Saw’ 800-323-7503


Fabricator n May / June 2011

What’s Hot? n


alumina and ceramic alumina abrasive, with a micro fracturing capability that allows a constant supply of new cutting edges for fast, aggressive cutting that self-sharpens with use. BlueFire F826 is also available as a Speed-Change fiber disc featuring Norton’s quick, tool-free, twist-on and off Speed-Change fasteners. Available in 5–7-inch sizes with grit ranges from 25–60, Speed-Change discs lock to standard back-up pads with a unique nut design and are easily removed for increased productivity.

The BlueFire F826 AVOS (allows view of surface) discs feature a patented see-through design that allows uninterrupted cutting, reducing heat up to 30% over standard discs. The scooped holes create air flow to pull swarf away from the grinding zone, which cools cutting and extends product life. A five-degree angle back-up pad allows greater utilization of the disc surface and prevents gouging of the workpiece. Norton Abrasives has also introduced new fiber discs at the “best” and “good” price-performance categories. Contact Norton Abrasives, (508) 795-4435; Fillet weld grinder Metabo Metabo’s model KNSE 12-150 fillet weld grinder with extended nose is designed for finishing and polish-

ing hard-to-access fillet welds typically found on handrails or inside welds on staircase stiles. Standard features include a winding protection grid, electronic speed stabilization, soft start, anti-vibration side handle, variable speed, thermal overload protection, and power interruption protection. Contact Metabo, (800) 638-2264; Angle roller Carell Corp. The new 305HV is a three roll, double initial pinch, universal bending


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

Call for Free Catalog - 800/446-6498

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

May / June 2011 n Fabricator


What’s Hot? n


machine, with independent hydraulic adjustment of both lateral bending rolls and powered rotation of all three bending rolls. These units are geared for rolling standard/special sections plus tube/pipe in mild-structural-stainless steels, aluminum, brass, copper as well as other materials. Machines are furnished with a set of standard universal rolls. The 305HV includes dual LED digital displays to monitor bending roll positions, double pinch geometry, which permits pre-bending of leading

and trailing ends of the profile without removal from the machine, telescoping modular multi-component roll set specifically designed to bend standard sections including angle leg-in/out and square rectangular tube, as well as other shapes in a variety of material types, and tri-directional lateral guides with cam rollers for correcting inherent twist when rolling angle leg-in. It operates in both horizontal and vertical positions. Contact Carell Corp., (251) 9370948; Grinding and cleaning wheels CS Unitec CS Unitec’s Eco Brazing (EB) Diamond Cluster grinding and cleaning wheels reduce sparking up to 1% of that produced by resin bonded wheels, the company reports. These discs are designed for grinding and cleaning

steel, stainless steel, aluminum, fiberglass and other materials in general industrial applications, as well as hazardous environments in oil, gas, nuclear, mining, marine and other industries. The company reports that the EB abrasive wheel lasts 100 times longer than an ordinary resin bonded wheel, therefore increasing the tool life and significantly reducing abrasive dust and material waste. The EB Cluster wheels are designed for removing paint, rust and epoxy on metal, as well as high material removal on fiberglass, composites and plastics without loading up like traditional abrasives. Contact CS Unitec Inc., (800) 7005919;

Better than therapy. With a craft to show for it at the end of the session. Restoring the Past. Building the Future.

Pounding, bending, cutting…you can really work out some frustration creating something beautiful. Engaging hands and hearts since 1925. Come enjoy making crafts and good friends on 300 natural, scenic acres in western North Carolina.



Questions? Call Peter H. Miller, President: 202.339.0744 x 104. Or email


Fabricator n May / June 2011 Fabricator RM house ad.indd 1

10/12/2010 1:14:13 PM


Advertiser’s Index A thanks to the following advertisers for their support of O&MM Fabricator magazine. Pg Company


  Pg Company


60...Alloy Casting Co. Inc...........................................

57....Industrial Coverage Corp..............

13....Alumina Railing Products

40...International Gate

7...Apollo Gate

68...The Iron

18....Architectural Iron Designs

53...Jesco Industries Inc. WIPCO div...............

41....Artisan Ideas North

67...King Architectural Metals............................

57....Artist-Blacksmith’s Assoc. of N. America

60...Laser Precision Cutting....................................

52...Atlas Metal Sales.............................................

9...Lawler Foundry

15....Big Blu Hammer Mfg. Co./

2...Lewis Brass & Copper Co. Inc.....................

Oak Hill Iron 61....Blacksmiths Depot/Kayne & Son

63...Lindblade Metal 32...Marks

Custom Hardware Inc....................

62...Pat Mooney

59...Blue Moon Press....................................

63...NC Tool Company

50...Julius Blum & Co.

28...O.K. Foundry Co. Inc.....................

34...The Cable Connection................

4...PLASMA CAM Inc..........................................

64...John C. Campbell Folk


19....Chicago Metal Rolled Products Co.....................

39...R & D Hydraulics Mfg. & Machine

41....Colorado Waterjet


44...CompLex Industries

38...Rogers Mfg. Inc........................................

30...CS Unitec Inc........................................................

33...Sharpe Products....................................

17....D & D Technologies (USA) Inc...............


3...D.J.A. Imports Ltd...........................................


47....Eberl Iron Works

20...Suhner Industrial Products Corp..............

52...Electron Beam Technologies Inc........

35...Sumter Coatings


43...TigerStop LLC......................................................

42...FabCad Inc...............................................................

64...Traditional Building.......................

23...Feeney Inc.

29...Tri-State Shearing & Bending................................... 718-485-2200

(Feeney Architectural Products).....................

62...Universal Entry Systems Inc.......................................216-631-4777

49...The G-S Co..................................................................

22...Vogel Tool & Die Corp.....................................

21...Hebo - Stratford Gate Systems

27...The Wagner

53...Hougen Mfg. Inc..................................................

Contact your O&MM Fabricator sales representative Sales Manager Jim Gorzek Direct 815.227.8269 Mobile 815.985.4089 Fax 815.484.7730 jimg@

May / June 2011 n Fabricator

AL, AR, AZ, CA, CO, ID, KS, LA, MO, MS, MT, NE, ND, NM, NV, OR, OK, SD, TN, TX, UT, WA, WY Tony Arnone Direct 815.227.8263 Toll Free 888.394.4362 Fax 815.484.7758 tony@

CT, DE, MA, MD, ME, MI, NH, NJ, NY, PA, RI, VT Sean Smith Direct 815.227.8265 Toll Free 888.394.4362 Fax 815.484.7760 seans@

FL, GA, IN, KY, NC, OH, SC, VA, WV Michael J. Lacny Direct 815.227.8264 Toll Free 888.394.4362 Fax 815.484.7749 mikel@

IA, IL, MN, WI, Canada Amy Hudson Direct 815.227.8237 Toll Free 888.394.4362 Fax 815.484.7777 amyh@



Metal Moment

How to give constructive criticism By Barton Goldsmith

uncomfortable you may not be in the best frame of mind to talk about a difficult subject. With all the criticism I have received rarely has it ever 6. Do your best to avoid hurting anyone’s feelbeen constructive. So, when someone comes up to ings. Use a softened start-up followed by a gentle me after a presentation, and says, “Would you like suggestion. For example, you could say, “I really like some constructive criticism?” I always say, “No, the way you talk to your supervisor; you would get thank you.” a better response from your team members if you The problem with most people who give critispoke to them in the same way.” Barton Goldsmith, cism is that they almost always feel they could do 7. Talk about behavior, not the person. FeedPhD, an awardit better. This brings to mind the obvious question, winning keynote back is not about insulting someone’s behavior; it’s speaker, business which is — if they do it better, why aren’t they about telling him or her how to be better. For examconsultant and doing it? ple, you would never say to a child, “You are a misinternationally As leaders, we are always targets for criticism, take.” Instead, you would say, “You made a mistake.” syndicated author. and so be it; I think it’s part of the deal. Where we 8. Try gentle humor. Light-hearted criticism will He has helped fail is that we don’t train our team members to develop leadership be received in a more positive way. Humor doesn’t in Fortune 500 deliver criticism or feedback in the best manner diminish the seriousness of the feedback you are companies, possible. giving. It actually helps the person receiving the dieducational Here are 10 tips to help you give your team mem- institutions, and rection to open up and take it in. bers the feedback they need, and want: 9. Work with your team to improve the situgovernment 1. Take an honest look at where you’re coming organizations ation. This will help them make the appropriate from. If there’s some anger or resentment towards a worldwide. www. adjustments sooner rather than later. It will also team member, you’re probably not the best person BartonGoldsmith. strengthen your bond with them. Making changes is com to offer them advice. easier if you have someone supporting you. 2. Start and end with a compliment. This will help your 10. Don’t harp. Once you have asked for what you need team members take your advice and not feel that they aren’t a from your team member, let it go. If you have to ask someone failure, or that you’re not angry. to do something four times, I can promise you that the person 3. Listen to your own voice. Your tone can communicate has heard what you have to say. If you’ve reached an agreeas much (if not more) than the words you choose. If there ment or agreed to disagree, let it go and move on. Holding a is an edge to your voice, grudge is a waste of time. it will be harder for your These are the tools that team member to take your the best of the best use to How to accept criticism request. make their teams strong. 4. Eye contact is imporMany companies have an appraisal system. If your workplace Learning how to give tant. It helps both of you doesn’t, you may want to ask for feedback; it always helps to feedback and criticism in stay focused and it commuknow how we’re doing. If you work in a busy, pressured envia way that the person you nicates sincerity. It will also ronment a reminder may be necessary. Above all: are talking to will take it help you stay on topic. If in, and learn from it, may n Try to take constructive feedback in the spirit it is you’re working on the comintended. It’s not a criticism of your personality — just some be a leader’s greatest tool puter or busy with somethoughts on how things might be better approached and a look for building an effective thing, stop what you’re at where you’ve scope for improvement. team. doing and look at the perSo, the next time you n Don’t be afraid to ask for clarification and to say if you son you’re speaking to. feel the criticism is unreasonable or unjustified. offer a team member 5. Choose the best time constructive criticism, n Don’t compare yourself and your achievements with and place. Never give critiothers as a barometer of your own self-worth. they won’t go running for cism in public; in front of cover, or say, “No, thank n If you have to give someone feedback don’t criticize another person, or when them in front of others. Balance negative points with compliyou.” Instead, they will you or your team member ments, and be clear about suggesting alternative ways of doing see it as an opportunity to may be too tired or hungry things. grow. Result: Your orgato deal with it approprinization will grow along n Don’t forget to praise yourself occasionally. ately. If you’re physically with them. 66

Fabricator n May / June 2011

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