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Ornamental and Miscellaneous Metal


The official publication of the National Ornamental & Miscellaneous Metals Association

November / December 2012 $6.00 US

Focus on success

55th Annual Convention & Exhibits

page 14

March 20–23, Albuquerque page 47

Fencing Top Job Gallery page 37

Shop Talk Decorative options for acanthus, page 14

Shop Talk ExOne’s 3D printing for fabricators, page 28

Biz Side Succession plan ideas, page 57

Biz Side 9 Business principles not to ignore, page 60

69-60 79th St., P.O. Box 67, Middle Village, NY 11379

Become A NOMMA Member Members Receive Awesome Benefits

“The best thing I did for my business was to join NOMMA. I didn’t work in a railing shop before, so a lot of what I’m doing is new; I’ve learned a lot from my fellow members. NOMMA shops provide their support readily and generously.”

— Scott Hess Hess Orn. Iron LLC, Felton, PA

Membership Benefits Online Video Library Scott Hess

Let NOMMA’s Resources Drive You To Success Tap into a rich pool of knowledge specifically designed for your shop. • ListServ - Member email discussion list • Annual Convention Education Sessions • Continuing Education • Webinars • Telephone Roundtables • Online Resource Areas • Streaming Video Library • Buyer’s Guide • Chapter Meetings • Online Knowledgebase

Member Resource Kit Subscriptions

(O&MM Fabricator & NOMMA Newswire)

Webinars Vendor Discounts Awards Contest Discounts on all Media & Events ListServ (member-to-member list) Insurance Program (free safety manual) Mentor Program & Buddy System Member Locator (let new clients find you) Technical Support (on codes & standards) Chapters*

(automatic membership in your local chapter)

Free Downloads (tech data & more) Knowledgebase Online Tutorials

Past education topics have covered: Measuring, Bronze Finishing, Shop Organization, Cash Flow & Markup, Sales & Contracts, Family Business Issues, Installation Methods, Finishing, Anchoring & Fasteners.

Roundtable Conference Calls

Fabricator dues are $425/yr. Installment plan available: Four payments of $112.50. More info on reverse.

NOMMA Buyer’s Guide

Join Online: 888-516-8585, ext. 101

Affiliations (NOMMA decal & certificate) NAAMM-NOMMA Finishes Manual Recognition in O&MM Fabricator & NOMMA Buyer’s Guide † Exhibitor Discount Mail List Access



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*In areas with a chapter. † Only Nationwide Suppliers are listed in Fabricator. Membership application on reverse.

FAX TO: 888-279-7994

Join Online: • By Phone: 888-516-8585, ext. 101

NOMMA Membership Application Membership Category – Check One: q Fabricator - $425 (to pay in four payments, you can enroll in the Quaterly Payment Plan - please see below)

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.


Supplier members are those members that produce or distribute materials, machinery, and accessories for the industry or provide services that may be used by the industry.

q Nationwide - $595 (operating on a nationwide or international basis) q Regional - $465 (operating within a 500-mile radius) q Local - $375 (operating within a 150-mile radius)

q Affiliate - $310.00


q School

q Non-profit organization

Individuals, firms, organizations and schools 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.

Company:____________________________________________________________________________________ Primary Contact :______________________________________________________________________________ Address:___________________________________________________________________________________ City:_____________________________________________ State: ________ Zip: _________________________ Country: __________________________________________________________________________________ Phone:__________________________Fax:________________________ Toll Free:_______________________ E-mail: ____________________________________________ Web:_____________________________________ Company Description/Specialty:_________________________________________________________________ Sponsoring Member: _________________________________________________________________________ Payment method: q Check

(Payable to NOMMA, in US dollars, drawn on US bank)

q AMEX q Discover q MasterCard q VISA Card # _________________________________________________ Exp.:________________ CVV: ___________ Print name on card: ___________________________________________________________________________ Signature_____________________________________________________________________________________ JOIN BY DECEMBER 31, 2012 AND RECEIVE 2 MONTHS FREE MEMBERSHIP Return to: NOMMA, 805 South Glynn St., Ste. 127 # 311, Fayetteville, GA 30214 • Ph: 888-516-8585 Fax: 888-279-7994 • •

Quarterly Payment Plan (there is a $6.25 processing fee for each transaction) q Please enroll me in the Quarterly Payment Plan.

As a member you agree to follow NOMMA’s Code of Ethics (viewable at

Payment method: q Please auto charge my credit card. q Please bill me each quarter. Questions? Contact: Liz Johnson, Member Care & Operations Manager: (888) 516-8585, ext. 101, 201111-fab



November / December 2012 Vol. 53, No. 6

Albuquerque International Balloon Fiesta each year offers a variety of balloons, page 54. Maybe you’ll see a few at METALfab2013. Photo credit: Raymond Watt

Biz Side

NOMMA Network Gulf Coast Chapter meeting attendees see Robinson Iron presentations.......................................... 10

If your health insurance is up for renewal, consider NOMMA’s new member benefit, page 11. Shop Talk Decorative options for acanthus leaves............................. 14

Adding artful, ornamental flourishes to acanthus leaves might help you win a commission and get you appropriately compensated for your skills. By “Uncle Bob” Walsh

METALfab2013 sessions and registration information........... 47

Nine sessions, tours, exhibitors, Spouse Program, and special events set for METALfab2o13, Albuquerque, NM, March 20–23. Your chance to Focus on Success by: n Discussing how to manage your business better. n Learning new skills. n Sharing experiences with the best in the business. Join us for a dynamic experience!

When considering a solid succession plan, you’ll want to know, in detail, the who, what, when, and why, and how you’ll execute ownership and management changes. Here are some options. By Mark E. Battersby Biz Side 9 Business management principles.................................................... 60

We often need a refresher in sound business practices. Don’t ignore these common sense ideas. By William J. Lynott

Shop Talk ExOne’s 3D printing technology for fabricators............ 28

3D printing technology has evolved past printing patterns in plastic or wax. Digital materialization can print a mold or the final object in metal. By Jeff Fogel

Succession planning: Keeping your company steady after you’re gone.................................. 57

What’s Hot!

Job Profiles Top Job Gallery: Fencing................... 37

Nine fabricators have their Top Job contest entries shown in our Gallery this issue, along with the entrants’ descriptions of their work.

Industry News.................................... 65 People.................................................... 67 Media..................................................... 68 New Products..................................... 69 Nationwide Suppliers.................... 63 New Members.................................... 64

President’s Letter........... 6

Exec. Director’s Letter.... 8

NEF Chair Letter............ 12

Metal Moment............... 74

Find happiness in your work.

Why members join.

Time to think about your charitable donations to NEF.

Dominating the service truck wrap, Jack.

About the cover Hot air balloons are a common sight in Albuquerque. Plan now for METALfab2013, March 20–23, 2013 (see page 47). Shrock Fabrication, Bird-in-Hand, PA, made the six-foot-tall, high-end fence out of solid aluminum. See full description of the fence on page 44. November / December 2012 n Fabricator


NOMMA O FFICERS President Will Keeler Keeler Iron Works Memphis, TN

President-Elect J.R. Molina Big D Metalworks Dallas, TX

Vice President/ Treasurer Mark Koenke Germantown Iron & Steel Corp. Jackson, WI

Immediate Past President James Minter, Jr. Imagine Ironworks Brookhaven, MS

F ABRICATOR D I RECTORS Todd Kinnikin Eureka Forge Pacific, MO

Ray Michael R & F Metals Inc. Clinton, MD

Tina Tennikait Superior Fence & Orn. Iron Cottage Hills, IL

Keith Majka Majka Railing Co. Inc. Paterson, NJ

Allyn Moseley Heirloom Stair & Iron Campobello, SC

Greg Terrill Division 5 Metalworks Kalamazoo, MI

S U PPLI ER D I RECTORS Gina Pietrocola Rick Ralston D.J.A. Feeney Inc. Imports Ltd. Eugene, OR Bronx, NY

Mark Sisson Mac Metals Inc. Kearny, NJ

NOMMA E DUCATION F OU N DATION O FFICERS Chair Roger Carlsen Ephraim Forge Inc. Frankfort, IL

Vice Chair Christopher Maitner Christopher Metal Fabricating Grand Rapids, MI

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

NEF T RUSTEES Heidi Bischmann Milwaukee, WI Carl Grainger Grainger Metal Works Nichols, SC

J.R. Molina Big D Metalworks Dallas, TX Lynn Parquette Mueller Ornamental Iron Works Inc. Elk Grove Village, IL

NOMMA C HAPTERS Chesapeake Bay Patty Koppers, President Koppers Fabricators Inc. Forestville, MD 301-420-6080

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

Florida Cathy Vequist, President Pinpoint Solutions Jupiter, FL 561-801-7549

Pacific Northwest Gale Schmidt, President A2 Fabrication Inc. Milwaukie, OR 503-771-2000

Gulf Coast Charles Perez, President B & O Machine Welding Brookhaven, MS 985-630-6943

Upper Midwest Mark O’Malley, President O’Malley Welding & Fabricating Service Inc. Yorkville, IL 630-553-1604

NOMMA S TAFF Executive Director, Editor J. Todd Daniel, CAE Managing Editor Robin Sherman Sales Director Sherry Theien


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


Dedicated to the success of our members and industry.

President’s Letter

Find happiness in your work Are we having fun yet? How participation on a project. Since many times has someone said we have multiple projects going that during a time when no one on simultaneously, there is a is having any fun whatsoever? steady supply of worry without Most of us are in the meta break. Even with office work, alworking profession because if I spend hours preparing a we chose to. However, it is not quote for a large project, there always easy to actually do the is no feeling of relief after subWill Keeler, things we enjoy the most. I mitting the proposal because I Keeler Iron suppose this is true for many start thinking about what hapWorks, is people, but it is particularly so president pens if we actually sell the job. in small businesses. The question is, how do we of NOMMA. create more of the activities we Sheryl Crow sings in one of enjoy back into our work life? her songs “If it makes you happy, How do we do what makes us happy? it can’t be that bad.” I don’t believe she For starters, it helps to take on projwas referring to work, but I think her statement is relevant to my point. ects that we actually look forward to doing. There is always the risk of falling in love with a job and not making Preference for the ‘real’ work a realistic proposal because we want I would prefer to spend my time on the project too much. But when I come the following: Working on a method across a job that will be challenging, that will give us a competitive advandynamic, or bring some good PR to the tage on a quote, closing a sale, openfirm, I get a little more aggressive on ing checks (one of my father’s favorite bid day. tasks), solving design problems, managing the workflow in the shop, and researching and learning about new NOMMA can help with your mundane work equipment/software to make us leaner and smarter. Or, having a good day of NOMMA is here to help its memactually getting dirty in the shop. bers with many of the functions that Much of my time, however, is are not fun so we can focus on the focused on some mind numbing tasks: things that are. Reading contracts, staring at confusing Did your insurance provider ask architectural plans, calling customers about your safety program? Why spend on past due accounts, studying some hours creating a safety manual from new environmental regulations and fig- scratch when NOMMA has one for you. uring out how it will impact our busiThe ListServe is there to call on help ness, dealing with contractors that treat when we need it. us as an adversary rather than a partWhat is more fun than winning a ner, wondering about sales tax audits. Top Job award? I could go on and on. Have you been to METALfab? Not At a recent METALfab convention, only can we learn all matter of things to I remember Douglas Bracken of Wiehelp us work smarter and not harder, it mann Metalcraft stating that he spent is a hell of a good time. 50% of his time doing business chores I hope with an improving economy, and 50% on things he enjoyed. I wish we all can turn a profit. Because for me, I only had to spend 50% of my time on that is a lot of fun. daily business tasks. Something that I find lacking in my daily work life is the sense of accomplishment that comes from hands-on Fabricator n November / December 2012

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November / December 2012 n Fabricator


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 Sherry Theien, Ph: 815-282-6000. 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. Contact Sherry Theien at 815-282-6000 or 2012 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. © 2012 National Ornamental & Miscellaneous Metals Association 8


How to reach us

Executive Director’s Letter

Why members join One of the tasks I enjoy at

members. These videos cover everything from finishes to stair fabrication. One thing we are finding is that our online resources are not as organized and accessible as they should be, and streamlining our digital resources is a project I’ll be Todd Daniel is executive A member asked them working on over the next few to join. Usually, it is a supplier director of months. NOMMA. inviting a member or a member For an overview of what we encouraging a supplier to join. offer online, click the “Member Resources” button on the The fabricator joined to access NOMMA home page. our education resources — our NEF videos, downloadable publications, Awesome chapter and webinars. In other news, I’d like to give a To improve on the first point, we “shout out” to the members of the must continue building a strong culture Gulf Coast NOMMA Network. On of membership in our organization. October 13, I had the honor of visiting Our board is setting a their fall meeting, great example in this which was held at regard. Four board Robinson Iron Corp., members have sponAlexander City, AL. sored a member in The Gulf Coast group the last six months. In is warm and enthuaddition, board memsiastic, and I left bers have been active the meeting feeling in our member-tototally charged. member campaign, NOMMA now and one even schedhas six chapters and uled member visits if you are in an area during his vacation. serviced by a chapter, I often think I strongly encourabout the story of the age you to attend late Ernest Wiemann, Todd Daniel is shown at the recent Gulf regularly. one of NOMMA’s The connections Coast NOMMA Network Meeting, held greatest legends, who October 13 in Alexander City, AL. you make will last built our membera lifetime, and will ship in the 1970s by traveling around likely lead to more work referrals and the western U.S. visiting shops. It partnering opportunities. Plus, you will gain knowledge from is this kind of personal contact and both the education programs and by relationship building that will make networking with your peers. I like to NOMMA grow and remain strong. Regarding the second point, both think of chapter meetings as “mini NOMMA and the NOMMA Educaconventions.” Sincerely, tion Foundation (NEF) have created great educational resources, and many of these are available online. Last year, NEF allowed its entire video library to be placed online as a free benefit for NOMMA is making welcome calls to our new members. When chatting with them I always ask WHY they joined. The answers typically fall into two categories:

1 2

Fabricator n November / December 2012

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Gulf Coast meeting attendees see 3D scanner demo and restoration presentation at Robinson Iron Corp. Robinson Iron Corp., Alexander City, AL, specializes in historic preservation and restoration. Throughout its facility, the company incorporates the latest technologies, including water jet cutting and AutoCAD. Thus, a great place for a NOMMA Gulf Coast chapter meeting. After coffee and donuts, the day started with a tour of the large Robinson campus. Robinson team member Blake Owen, a CAD operator and pattern maker, gave a fascinating demo on a 3D Scotty Howell, Robinson Iron, left, gives attendees a tour of his company’s facility. The laser scanner. The scanned information is company does high-end conservation, preservation, and restoration work. Also pictured, fed into the company’s 3D router to make left to right: Scott Colson, Iron Innovations; Lamar Smith, Allen Iron Works; Carol Perez, B&O Machinery; and James Minter Jr., Imagine Ironworks. detailed replica parts. refurbished the 56-foot statue. After the tour, Scotty Howell, vice president and genAfterwards, everyone enjoyed a delicious barbecue lunch eral manager, presented a slide show on the restoration of and awaited their name to be called in the buck-in-a-bucket Vulcan, a giant, cast iron statue that serves as a landmark door prize drawings. and icon for the City of Birmingham. Originally cast in the The afternoon sessions consisted of two more PowerPoint early 1900s, Scotty told how the Robinson team restored and


Fabricator n November / December 2012

Chapter vice president Randy LeBlanc, standing, makes business announcements during the meeting. Also shown are James Minter Jr. and Sue Minter of Imagine Ironworks, and Scott Colson of Iron Innovations Inc.

Blake Owen demonstrates a 3D laser scanner. Once the data is fed into the computer it can be used for creating exact replicas of a part or pattern.

shows given by Scotty. The first session covered Robinson’s main specialty — restoring cast iron foundations around the country. The meeting then ended with a second program on cast iron. After the meeting, attendees visited the Russell Retail Store where they were given a generous discount on apparel. A thanks goes to the staff at Robinson Iron for being fantastic hosts! The meeting was well attended, and it was a great day of learning and networking.

Is your health insurance renewing soon? The NOMMA Board of Directors has approved a new partnership with Mass Marketing Insurance Consultants Inc. (MMIC) to help members lower their health insurance costs. MMIC specializes in individual and group health insurance to association members. If your health insurance is up for renewal, they will evaluate and negotiate with two companies in your area for a plan that is a “best fit” for your needs. Best of all, they will provide the free, noobligation quotes within 48 hours. The program allows you to obtain a free discount pharmacy card that can provide you with a savings of 10–60%. Contact NOMMA,, 800-349-1039. To get your discount card, go to the their website and click on “Free Prescription Discount Card.” November / December 2012 n Fabricator



NOMMA Education Foundation

In partnership with the National Ornamental & Miscellaneous Metals Association

Time to think about charitable donations NEF has numerous programs that need your continuing help It is that time of year . . .

I want to thank you for your support of the NOMMA Education Foundation (NEF) in 2012. Since the year is quickly coming to a close, I would like to offer you the opportunity to make an end of year donation to the NOMMA Education Foundation. Because of the income tax charitable deduction, individuals who make their gifts by December 31, 2012 and itemize can reduce their income taxes. You can make a donation to NEF and help support the operation and programs of the foundation.

METALfab 2013 needs your items for the auction

Also, at this time of year we ask everyone to help with one of our favorite fund raising projects — the Silent and Live Auctions held at METALfab2013. Whether you donate an item for auction or you bid on items, both are very important to the success of this project. We have had fabulous items donated through the years and depend on you to help us conUpdate from tinue the great tradition. NEF Chair The auction committee requests donations of Roger Carlsen, items that may include: Ephraim n Metal items. Metal sculpture, garden gate, hand Forge Inc. NEF provides more than a few programs forged items, books, artwork, antiques. Your donations are what make it possible for the n Non-Metal items. Tools, gift baskets, pottery, foundation to provide: jewelry, certificates/coupons, jewelry, electronics, clothing, food/wine, presentation drawings, use of n Continuing education programs, vacation properties. n Educational videos, n NEF publications, n Specialized service to create a custom one-of-a kind item. n METALfab education program, n NEFERP, n Or be creative. The sky is the limit! With your help, we will have another successful auction! n Zi8 video program, Every donated item will help the foundation provide quality n NEF webinars, education for the architectural, ornamental, and miscellan New chapter support, neous metals community. n NEF Lawler Research Program, and much more. Please help us continue and expand our If you wish to contribute an item(s) for this event, please exciting programs in 2013. complete the auction donation form available at www. How you can help For questions contact Martha Pennington, NEF Executive Ways that you can help NEF continue to provide its outDirector, or 888-516-8585 x 104. standing programs: Thank you in advance for your support. We look forward to seeing you at METALfab2013! n Cash donation (tax deductible for individuals), n Donate or bid on an item at the NEF auction, Roger Carlsen n Volunteer to help with NEF programs, or NEF Chair n Make a honorarium or memorial donation to recognize a special person in the industry. Forms for donations can be found at under the Foundation tab or contact Martha Pennington, NEF Executive Director, at or 888516-8585 x104, who will be glad to help you process your donation.


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

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Shop Talk

Decorative options for acanthus leaves n

Adding artful, ornamental flourishes to acanthus leaves might help you win a commission and get you appropriately compensated for your skills.

Editor’s note: This article is the sixth in a series of articles about using acanthus leaves in your work. In the first article, “Drawing large acanthus leaves” (Fabricator, November/December 2011), you saw how to draw a simple, single-sided, front view acanthus leaf in 11 steps by alternating “C” curves with “S” curves. The second article, “Drawing acanthus side views” (Fabricator, March/April 2012), introduced the grille and an explanation of the four types of acanthus leaves. The sequential steps used to draw a side view of a leaf was presented. The third article, “Building acanthus patterns” (Fabricator, May/June 2012), walked the reader through making a full-scale, “stretch out” pattern for a wrap-around leaf. The fourth article, “Cold forming acanthus leaves” (Fabricator, July/August 2012) examined how a wrap-around acanthus leaf was produced with top and bottom tools made of wood to avoid hammer marks. The fifth article, “Bob’s Tijou tour of acanthus, interactively,” (Fabricator, September/October 2012), took us on a Wikipedia and YouTube tour of the work by Jean Tijou and Jean Lamour. 14

Photo 1. Notice raised veins in the leaves.

Photo 2. left. Two different leaf styles. Photo 3. above. Leaves on a recent project. The leaves are bronze waiting to be pickled and patinated. We will use steel for the leaves described in sidebar, page 18.

By “Uncle Bob” Walsh This sixth acanthus leaf installment addresses ornamental options when you

make your leaves. Veining options and rolling the end of your leaf over backwards are examined. Forging acanthus leaves is easy. What I hope you have learned from this series of five articles published thus far in Fabricator is how to design leaves in any shape or size for your projects. If you are following these acanthus leaf articles, I hope you enjoyed the video discussed in last issue’s article (Fabricator, September-October 2012, page 14). Even though some may feel the video was long at 14 minutes, the ending was well worth watching. The leaf in the video went into quite the project!

Decorative options

n Raising a central vein. A raised vein stands above the main body of your leaf. Notice the leaf on the left in photo 2, above left, and the leaves in the background of photo 1, top. Raised veins can also be added to petals. n Sinking. Recessing a given area. Notice the example in photo 1, just above the hammer head, the leaf petals in photo 3 and the leaf on the right in photo 2. n Ornamental leaf tips (terminations). See sketches A through H, page 16. Lay down your spine line and compose from there. It is the quality of the design that gives metalwork its value. I hope by adding a few artful leaves to a project, you will not only win that commission, but also be appropriately compensated.

Production sequence of a typical face leaf (one-sided leaf)

1. Artwork. Designing your leaf, generally on paper. 2. Incising. Chiseling the design of your leaf into the metal sheet while it is Fabricator n November / December 2012

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still flat. This is often done by spray gluing your paper pattern directly onto your metal and chiseling right through it. When finished, the paper can be easily burned off the metal. 3. Repoussé. Turning your leaf over and pounding the leaf face down into a cavity, negative space, or soft substrate to make the face side convex. 4. Chasing. Flipping the leaf right-side-up and usually with the same chisel used for incising, pushing the incised lines back down. Often these lines are pushed down farther than the original baseline to create deep valleys. . Raising & sinking. Raising, sinking and leaf tips are addressed in this article. . Ornamental Leaf Terminations. The leaf tip.

Raising & sinking

Arch Metal 2011-11 Proof 7396-2768=1400 Figures A and B, top. Sketches A through H., 2nd-3rd row.

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Sometimes you may not want all your line work to be recessed lines. Raising thin metal is physically easy. Directing the hammer blows from your hand is the skill to acquire. Adding raised main and petal veins brings another form of ornamentation into your leaf. Raising tools. When forming 16–18 gauge (1008– 1010 is an easy-to-find soft steel) consider purchasing three hammers. The first is a 300-gram (11 ounce) hammer with ball ends. The second has two large cross pein ends and weigh 300 grams. A third 300-gram hammer has small radiused ends. All three hammers are made in Germany or France (Peddinghaus), and can be purchased from the Pieh Tool Company, Camp Verde, AZ. The part number for the hammer with the ball

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Fabricator n November / December 2012

July / August 2012 n Fabricator


hammer will be overkill. Draw a leaf pattern Bottom tools. (See photo 1, page 14 & photo 4, left). The tall tool in photo 1 is a good quality axe I found in a flea market. The blade width has been narrowed down (torch cut) and the cutting edge is not sharp, but slightly radiused. This tool should have been narrowed even more, which would then work Photo 4. This tool works well inside better when raising in tight curves. confined spaces. The shorter tool in photo 4 is the “business end” of an old air hamends is # 52020000. The part numFirst, layout the spine lines of your leaves in a mer bit, reground to again, have a ber for the hammer with the large configuration that complements your project. slightly radiused top edge. This tool cross pein ends is #53020300, and Next, add the central petal lines to the works well inside confined spaces, the part number for the hammer spine lines. Then add the alternating “C” and like under a rolled over leaf tip. with the tightly radiused ends is “S” curves per acanthus leaf article, FabricaI have hammered on these tools #0057020300. tor, November/December 2011. If you’re working with 20-gauge a lot and don’t believe the top edges Notice the double lines going around the have ever been redressed. Rememmetals, these hammers may be a perimeter. The inside line is the size of the finber, you’re not pounding on the top little heavy. If you’re working with ished leaf, the outside line is about ⁄ outside 16–18-gauge steel, bronze, or brass, I edge of the tool, but coming at the the finished-size line to allow for shrink when see no room for improvement in the tool with diagonal blows on the side corrugating the leaf. weight of these hammers. A lighter of the edge. Neither of these tools Add more or less shrink allowance where hammer won’t move the metal over were hardened and tempered after needed. they alteredProof in my4332-4599=2890-4 shop. your stake as desired and a heavier EPiwere 2011-11

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Fabricator n November / December 2012

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May / June 2012 n Fabricator


Let’s raise some metal

The process. First, mark your metal with a magic marker or silver pencil where you want it to be raised or where you want to create the edge of a dished area. Next, hold the metal over your stake and strike it with hammer blows that come down just on your side of the bottom tool, rather than directly on the stake (figure A, page 16). You can work by the sound of the blows. You want to hear the hammer make a solid sound as it forms a little and hits the side of the bottom tool. If you are too far away from the blade, instead of hearing a solid strike, you will hear a dead thud. Feel the process, evaluate, and modify what you are doing as you go. For a dished area (examples in photo 1, above the hammer, the petals in photo 3, and the leaf on the right in photo 2, page 14), only work your metal on one side of the bottom tool. For a raised spine or petal vein, simply work both sides. Lock your body with one foot in front of you and the other behind you. Sometimes I find it helpful to press my

elbow against my hip for better hammer control. You want your body to be as stable and controllable as a machine. If you feel like you are doing all the right things and getting nowhere, you are probably correct. Work hardening is an issue to watch for. Stop, heat your metal up to just past the magnetic range, and let it air cool to relieve (normalize) the stress. I normalize often, probably more than I need to. Once the metal is soft again, you will be back in the running. Like most metalworking hand skills, after about an hour of frustration, you will start to get a feel for the process. How do you design a leaf tip?

Of course, this question has many answers. From my perspective, I suggest you start by designing your leaf tips either with one large “C” curve, two “S” curves, or exactly as we have designed our leaves, by alternating a “C” curve with an “S” curve. We’re back to Charlie and Samantha (Fabricator, November-December 2011, page 25), which is classic and works well.

When designing your overall leaf, add small facets (figure B, page 16) above and below your main petals. Now use the same approach, only in the case of the tip, the small facets are now applied on both sides of the tip (sequential sketch step “G”). Remember, make your tip oversized because when it is dished, the width will be reduced. Designing the leaf tip is easy. What becomes tricky (at least for me) is laying out the pattern of the leaf when the tip will be flipped over and coming back at you. Simply coming straight back at you is not a problem. When you start twisting and turning it, I often feel I should just pick up a Rubik’s Cube and finish off my pending insanity. To solve the problem, when you think you have the pattern worked out, make a quick sample and roll it back towards you so you can evaluate how it looks. Good luck. The joy is in the journey. P.S. Oh, and about the Rubik’s Cube dilemma. I have found that a Louisville Slugger (baseball bat) works wonders!

Typical steps in sequence used to form a face leaf

Photos 6–8, left, top to bottom; Photo 9, above. When making your tip, do not put any line work in it before forming your concave shape. The line work will either crack or fold in on itself. Either way, it will be ruined. Once the top has been dished, next comes the line work. Photo 5. Because the patterns can be misleading when rolling the tip backwards, I like to make a quick test piece.


Photo 10. With the tip formed into a half sphere, I thought I would try out the tooling for incising the lines. The lines are laid out with the marker.

I started out with wood, but the cavity was too large. A smaller cavity was in order. I did not have a smaller cavity in wood, so I used steel. In this application, steel worked great. Note, when dishing a tip, always start from the end of the tip and work inward. Sinking a tip into a cavity requires about one-tenth the labor that forming it over a ball stake would take.

Photo 11. This tool flexes, but gets the job done. Fabricator n November / December 2012

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Photo 13. Now, comfortable that the pattern and tooling will work well, let’s make two leaves. One leaf will have a recessed central vein and dished veins on the petals, and the other leaf will have a raised central vein and recessed petal veins.

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Photo 14. To give these leaves some texture, the metal was textured. This is not the ideal power hammer die for the job, but with random rotating, 15 minutes later the stock was textured. Regarding texturing, the more severely you form your leaves, the more texture you will lose as the metal stretches. To combat the loss, error up when initially texturing your metal.


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Photo 15. The textured leaf blanks. Fabricator n November / December 2012

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Photo 16, far left. The line work is incised with a walking chisel (radiused in both directions) over a rubber pad. You can incise over steel and then chase the line work down into a valley shaped bottom tool (described in a previous acanthus leaf article in Fabricator, July/August 2012). I am new to using rubber, but so far, think this is the way to go. The difference between photos 16 and 17, near left, is in the lines being incised. The patterns for the two leaf styles remains the same, but in photo 16 the petals are incised and the central vein is not. The leaf in photo 17 wil be just the opposite.

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Photo 18. The leaf banks being heated to stress relieve them and they are easily flattened while hot.

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Photo 19. Repoussé time. Here the areas between the incised lines have been pushed out with the wooden tools into the carpet. It worked well, but the metal was not formed as deeply when compared to using wood. Possibly, if layers of carpet were built up, the result might be the same. Fabricator n November / December 2012

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Photo 20. Wood tools used on a treadle hammer.

Photo 23. Silver pencil reference lines for dishing (left leaf) and raising (right leaf).

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Photo 21. The metal coupon on the lower left is a forming sample that was quick to make. The steel was first incised with the hinged tool. Next, it was flipped over and in a treadle hammer, pushed out using a wooden top tool into one of the bottom tools shown. Finally, it was flipped right side up, and the incised lines were chased back down over the rubber pad. This piece could be three times the size and not require much more labor (which was very minimal). Photo 24. Raising. Work by the sound that the hammer makes when striking the metal.

About the author Robert “Uncle Bob� Walsh has been a fabricator/artist/ blacksmith for 30 years. For 10 years, his shop was in downtown Minneapolis. After the invention of the fax machine (allowing an easy interchange of sketches), he moved to semirural Wisconsin where he set up a cottage industry with fellow shop owners that has been chugging along for 20 years. Their ironwork can be found throughout the upper Midwest. CO NTAC T

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Photo 22. Leaf petals formed in a cavity. 26

Photo 25. Incising and dishing the tip. Here the tip is being dished over the small stake in photo 4 after the incising has been done.

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A pair of metal bowls is an example of ornamental fabrication using the new ExOne technology. The design was sent as a computer file and “printed” at ExOne as a one-off. Design by Carl Bass

Shop Talk

Cutting-edge technology for real world fabrication

Digital materıalızatıon By Jeff Fogel

n 3D printing technology

has evolved past its original ability to simply print a pattern in plastic or wax. Digital materialization can actually print a mold or even the final object in metal.

Computers have collided with casting. The result is additive technology, or 3D printing and scanning. Some love it. Some don’t. But two things are undeniable. It’s here to stay. And it is constantly evolving.

Even in its basic form, additive technology is impressive. Here’s how it works:


A specialized inkjet squirts a wafer-thin layer of liquefied plastic onto the surface of a liquid medium. This layer is one cross section of the object to be printed.

2 This layer of liquid plastic sinks just below the liquid medium’s surface. 3 The jets make another pass, creating another cross section.

Ultimately, you have a three-dimensional object submerged in the build box’s medium. This finished object is your pattern. Of course, you still have to make 28

Fabricator n November / December 2012

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a mold from it, if you actually want to pour something. Enter the latest additive technology

Digital materialization retains the basic concept of 3D — printing multiple layers to reproduce the physical contours of a threedimensional object. But with a new twist. Rather than use plastic as a medium for the jets, the medium is The actual hardware, digital materialization in action. contained in the build formed. Without a pattern. Well, withbox. The jets squirt directed layers of out a physical pattern. The pattern is binder into the medium, which in this taken directly from cyberspace. instance is sand. The medium is conAlthough not quite as applicable tained in a deep tray that serves as the work surface. This deep work surface is to the average ornamental or architectural shop, here’s yet another twist. called the “build box.” The build box medium may even be a The binder reacts in a precise laypowdered metal, in which case the ering pattern with the sand, forming jets shoot binder into the medium in internal as well as external contours. Ultimately, a highly accurate mold is a directed flow.

The result, in this case, is not a mold but an actual finished part. Apparently, comedian Jay Leno is a fan. It seems he needed a part for a rare antique car. Sources for “out of production” parts are typically companies that have purchased the original inventories and stored them. These inventories are known as “old new stock.” Rather than scouting the terrain for old new stock, he turned to additive technology for the replacement part.1 Why the holdouts?

Of course, there are many holdouts. A stubborn canard remains by which many simply don’t see the advantage of cozying up to a computer, then bundling the design off to a newfangled gizmo that produces the very same object that a guy wielding a mallet


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and chisel can whittle in a wood shop. Then there are those who still feel 3D printing produces, at best, a scabrous pattern that requires further finessing, thus eliminating any time or money savings from the technology. But Nicole McEwen, marketing director at ExOne, Irwin, PA, says all this needn’t be a concern these days. The patterns and molds of this generation of 3D are, if anything, more capable of intricate nuance. Better technology, experience

Part of the reason is the experience gained as the technology has advanced. The people doing the patterns and molds, at this stage in the game, know how to anticipate geometrical considerations, such as draft and parting lines. They are, in effect, virtual pattern makers. “The objective,” says McEwen, “is to have first pour work.” That is, to eliminate the trial-and-error problems of

Let me count the ways. Seven.


This sand mold shows that the molds can be fairly intricate and sturdy enough to be shipped.

the past, which resulted in the need for additional casting pours. Besides, why worry about a pattern’s sophistication when there needn’t be a physical pattern in the first place? ExOne has a process by which a binder is jetted into a build box containing sand. The jets make the same passes as a printer, building the mold layer by layer. The result is a sand mold, sans pattern, which can be sent right to the foundry. How it might help your shop

Wild stuff. But how exactly does it help the small or medium size ornamental or architectural shop?

No pattern, no problem. Let’s say a customer comes to you for a new casting. Let’s say it’s an antique lantern. Further, let’s assume said lantern is valuable and irreplaceable. Perhaps it’s one of a kind. Your customer might, understandably, have a few butterflies in his belly about using the original as a pattern. After all, it’s going to be sent off to who knows where and packed in sand. With the new additive technology, his heart need not be troubled. A quick 3D scan of the piece yields an insanely accurate virtual rendering of the original. This virtual rendering is then sent via a CAD file to ExOne to fashion a sand mold. The valuable original piece remains safely clutched to the bosom of the customer. As a fabricator, you have just adhered to a cardinal rule in customer relations: Instill confidence. It’s an undeniable competitive edge when unlike your tradition-bound competitors, your customers aren’t nervous.



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The theory of relativity. This theory of the time-space continuum holds that time actually slows when you’re waiting for a sub-contractor. And that makes you nervous because you have to reassure a customer who’s wondering when he’s going to get his casting. Nick Studley, ExOne’s industrial sales manager, says two to three days are a typical turnaround time for a pourable mold. A traditional pattern maker can take up to five weeks.

3 Parts on an “as needed” basis. For

cheap. Apart from mold printing, digital materialization can print parts. If an functional metal part can be made without pouring so much as a drop of metal, that changes the entire customer relations paradigm. For example, you needn’t clog your inventory on the off chance you have a customer who needs a single part. Why? Because you can have it made, quickly, and inexpensively. This applies to molds, as well. And in this economy, that’s no small consideration.



The technology is getting cheaper. Just like computers, 3D hardware is moving toward the small shop and even the home. You can buy a 3D printer, capable of making patterns for less than $3,000. Compare that to the hourly rate of a master pattern maker. As more fabricators buy into 3D, the demand will ineluctably bring down the price. If older generation 3D hardware is getting cheaper, you can bet that digital materialization generation hardware will as well. It’s only a matter of time, supply, and demand. The market already has cheaper versions of the printers, such as Makerbot, Brooklyn, NY. While it lacks the sophistication of ExOne, the price is definitely right, and it’s as good a way as any for the small fabricator to get his feet wet in 3D technology. Then there is the software. You can purchase software for scanning or printing. It’s available online, it’s cheap, and getting cheaper. There’s Rhino3D (Rhinoceros, Seattle, WA), for instance. It’s even compatible with ExOne.


Cyber patterns can do what wood cannot. Some of the objections to earlier generations of 3D technology involved a notion that the 3D patterns and molds lacked sophistication and finesse. That they would require several iterations of trial and error, or at the very least, a good bit of sanding to make them mold ready. In fact, the opposite is true. Studley says he runs into pattern makers at trade shows who marvel at some of the molds he has on display. They tell him that they are unable to make a pattern for such a mold out of traditional material. While many of these complex molds are “one-offs,” if a pattern is needed for large-scale production, the pattern can be reverse engineered, so to speak, from the mold.


Cheaper prototypes can more easily be made. As Miyamoto Musashi aptly pointed out in e Book of Five Rings, a Samuri’s book of martial strategy, “the strategy used against one man is exactly the same as the strategy used against ten thousand men.” He could have been

Fabricator n November / December 2012

just as easily talking about casting runs using digital materialization. Let’s say a customer knows much of what he wants, but not exactly. Let’s say the customer can make a better decision if he sees the finished product. That puts you in the unenviable position of either telling the customer he needs to come back with a wheelbarrow full of money or telling him he’s just going to have to imagine it. As Studley says, digital materialization can yield several one-offs for a customer to view. Now the customer doesn’t have to imagine the prototype. Nor does he have to spend a lot of money. Once the customer decides on the prototype, the mold can be reversed engineered and made into a pattern. The pattern can then be used to produce large casting runs with economies of scale. Or not. Maybe all the customer needs is one casting, but can’t make up his mind. Same process. Same time and cost savings. Same happy customer.

7Think big. In its newest incarnation,

additive technology creates no limits on

November / December 2012 n Fabricator

project size. Twenty tons was the figure that Studley used as an example of a large casting. The mold is created in parts that are bolted together. The only limitation is based on the casting size and how large a piece may be actually poured. This is good news for architectural and ornamental shops that are doing large outdoor statuary.

isn’t intricate enough. n It’s expensive. n We’ve been doing it with wood patterns for years, and we’re doing just fine, thank you. The first two concerns are easily assuaged. The latter argument is more difficult. Despite reluctance in the industry, ever since the last time we wrote about 3D (Fabricator, Sept.-Oct. 2012, page 27), some shops have looked into it. Trade shows are good venues to view this eminently practical technology. Meanwhile, many websites offer a good glimpse into the hows and whys. While one can’t quite say that ExOne is not your father’s 3D, you can certainly describe this innovation as “not your older brother’s 3D.” Why not give it a whirl on a project. You might conclude it makes good business sense.

Then what’s the problem?


Two objections to earlier 3D technology: n 3D patterns, molds lacked

sophistication and finesse. n Required several trial and error iterations, or . . . a good bit of sanding to make them mold ready. In fact, the opposite is true.

Why isn’t everyone using this new technology? Some have valid concerns: n The pattern and mold geometry

1. Popular Mechanics, June 8, 2009, ‘Jay Leno’s printer replaces rusty old parts’.


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About the author Jeff Fogel began writing as a journalist with the New York Daily News. He has been a copywriter and associate creative director for advertising agency Ogilvy & Mather. Jeff lives in New Hampshire where the weather’s bad, the skiing’s better, and blacksmithing’s a respectable way to keep warm.

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Top Job Gallery



This issue we are continuing our popular “Top Job Gallery” section. We hope you enjoy looking at these jobs entered in our Ernest Wiemann Top Job contest. Category: Fencing

DeAngelis Iron Work Inc. — Bronze South Easton, MA This Project involved the fabrication, finishing, and installation of about 450 linear feet of custom iron fencing. Fence posts, picket finials, quatrefoils, and flowers were all custom cast using new pattern work created for this project. Two separate patterns were required for casting two types of quatrefoils: 1) one flat quatrefoil and 2) one slightly pitched quatrefoil. Flower ornaments (at center of quatrefoil) were cast separately and applied to both sides of the quatrefoil

New Top Job Award Design for 2013

during fabrication. Castings were poured with ductile iron so that they could be welded to pickets. Cast iron posts were secured to granite curb via a stainless steel threaded rod running up the center of the (hollow) posts. Post finials (2 types) were drilled and tapped to receive rod. The entire fence (and a few gates) received a 3-coat paint system consisting of a zinc-rich primer, epoxy bridge coat, and an aliphatic urethane top coat. Approx. labor time: (fabrication and installation): 1,242 hrs.

Winners for the 2013 Top Job Contest will receive a plaque newly designed to feature the event and city where the award was presented, plus the NOMMA logo. All members in good standing are eligible for the contest. Entry deadline is December 31 (late deadline is January 7). For full details, see the front page of the NOMMA website.

November / December n Fabricator





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The 7200ETL-IL Slide Gate Operator & The 7300ETL-IL Slide Gate Operator - New internal limits to reduce breakage and operator error - Meets UL325 standards - 12V DC single and dual residential slide gate operator - Installed Radio Receiver - Operate slide gates up to 25 ft., 800 lbs. - Weather resistant - Timer option - 7200 is post mounted - 7300 is pad mounted - Two-year warranty

Ask your Distributor about the new lower prices on these products and our new 24V commercial operators. July / August 2012 n Fabricator


Top Job Gallery


Artistic Railings Inc. Garfield, NJ This project was fabricated for a private residence. All the railings are fabricated from C38500 alloy bronze. All material is solid and has a brown black patina. The entire project was mechanically assembled by machining dovetails for all the connections and then hidden screws, set screws and pins. The only welding done on the entire project was for (9) volutes. Materials: posts 11/4 inch square; bottom bar, ⅜ x 11/4 inches; balusters, ⅝ inch square; Y’s, 1/4 x 1 inch; scrolls, ⅜ x ¾ inch; the under bar (1/2 x 11/2 inches) was machined in to a “T” to mate the 11/4inch posts with the 21/4inch bronze top molding. An estimated 460 feet of railing was fabricated, five walkway gates and approximately 20 feet of fence. Approx. labor time: 1,75 (plus 320 hrs. installation).


Fabricator n November / December 2012

Top Job Gallery


Bettinger Welding Inc. Tallahassee, FL This fence was for a high-end contractor’s prime residence. The fabricator worked closely with the contractor to brainstorm the fence design. FabCAD was used to draw the fence, and it was sent to the customer for approval. The fence was fabricated in the company’s shop, and it was all hand forged, then sandblasted, and powder-coated black. The customer was pleased. Approx. labor time: 120 hrs.

November / December 2012 n Fabricator


Top Job Gallery


Cape Cod Fabrications East Falmouth, MA This 250-foot mesh fence enclosure and gate system for a pool was designed by the landscape architect. Cape Cod fabricated all components using #316 grade stainless steel with a glass-bead blast and wax finish on all framing components and hardware. The woven mesh was imported from Germany and stretched in a custom jig to eliminate any oil canning. The total job time was approximately 400 hours with about 80 hours for erection and installation. 42

Fabricator n November / December 2012

Top Job Gallery


Swinger 300� Darling’s Blacksmithing Tollhouse, CA The knot pattern in this courtyard fence archway follows through as a theme for the entire home. The material is mild steel and forged wrapped collars continuous from end to end. Uprights are 11/2 inches tapered from bottom to top. Designed by the fabricator, the fence is based on a bottom bar, with feet bolted down (done in 6 sections). The fitted bottom bar was taken to the shop where the vertical scroll work was forged and welded in place. The courtyard archway required a forklift to install. The section was bowed slightly and then released when it was in position, where it springs into perfect alignment with the archway. A challenge of this job was maintaining place on the bottom bar of the fence sections while welding the vertical scrollwork in place and afterward in the final application. Approx. labor time: 960 hrs.

November / December 2012 n Fabricator

* * * * * Adjustable Bottom Hinge Included� *

48” Gate - 300 lbs Max.� 2” x 4” x 12” 16 ga. Gal. Steel Cover.� Non-Handed.� Opens to Full 105 Degrees.� 2 Separate Closing & Latching Valves.� Factory Tested 1,000,000 Cycles.�



Top Job Gallery


Custom Iron by Josh Westlake, LA This fence is about 100 feet with a walk gate and drive entry system. The fabricator designed the fence with tips from the owner and decorator. Stock components were used to make a unique design for a one-off fence. The stock com-

ponents are made on a Hebo machine in-house. All scrolls are made from ¾-inch solid square bar. Runners are 11/2 x 11/2-inch square tubing and the posts are 3 inches. You may notice the hammered 11/2inch tubing down the center of the panel. This goes well with the textured spear.

Shrock Fabrication Bird-in-Hand, PA In the company’s showroom, a customer saw a large picture of a high-end driveway gate. The customer said, “I want my fence to look like that.” The end result is a majestic 6-foottall fence made of solid aluminum. The entire fence about 200 feet long. Much of it is curved to fit the pool patio. Pictures don’t do justice to the majestic beauty of this design. The holes through the horizontals were drilled and broached. Product was blasted then powder coated matte black (satin black). All the hammering, texturing, and scrolling was done in-house. The customer was ecstatic. 44

Fabricator n November / December 2012

Top Job Gallery


Ad_2011:Layout 1


10:09 AM

Page 1

Metal Master Terry Spatz Coleman National Sales Rep (800) 589-5545 Steel Welding Freedom , PA A Japanese Garden is a focal point of this historically significant home built in 1902. The owners wanted to combine the garden with the unusual architecture of the home so that a fence would balance with the oversized details of the home. The fence design was inspired and modified by the fabricator using the reference book Metal Design International. The chevron pattern throughout the 35-foot fence includes two 3-foot gates that carry a rhythmic design. The chevrons appear to be riveted, however, expert welding imitated an endless amount of rivets visible from both sides. Each ⅝-inch round picket was forged to wrap around the ¾-inch top bar. Two alternating designs for the ball finial terminations add a variety to the fence when closely examined. The fence height is 56 inches tall and 22 inches tall on the stone wall. “Chevron” handles were designed for the gates. Approximate labor time: 200 hrs. November / December 2012 n Fabricator

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Top Job Gallery


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Virginia Architectural Metals Fredericksburg, VA The covered canopy, fence, and gate system was the concept of local architects for a new winery facility. The fabricator designed this grape vine effect with operative gate and copper covered structural steel canopy frame. Telescoping 8- and 6-inch pipe columns were braced with 2 x 4 steel tubes to form the covered canopy frame structure. Grape vines were forged from 11/2 inch solid bar tapered for the main trunks with weld texture forming the “grain.� Smaller bars were tapered for the limbs. Grape clusters were fabricated using a variety of steel balls painted multiple colors to attain a realistic look. Purchased grape leaves were welded and hand painted. Each grape cluster weighed about 25 pounds and a total vine section about 750 pounds. The dimensions of each section were 91/2 x 8 feet. The entry gate (about 6 x 7 feet) resembles the other vine sections, but has forged textured bark handles. The canopy is about 47 x 12 feet. Approx. labor time: 900 hrs. Fabricator n November / December 2012

Register now for

METALfab2013 Focus on Success

National Ornamental & Miscellaneous Metals Association

55th Annual Convention & Exhibits March 20–23, Albuquerque, NM Hyatt Regency Albuquerque

METALfab2013 Focus on Success! Make your plans to join a dynamic group of fabricators and suppliers in Albuquerque, New Mexico, March 20–23, for METALfab2013. This is the perfect opportunity for you to Focus on Success by exploring new ideas, learning new skills and sharing experiences with the best in the business.

Education Program @ METALfab2013

The NOMMA Education Foundation (NEF) METALfab Education Committee lead by Lynn Parquette, Mueller Ornamental Iron Works Inc./Elite Architectural Metal Supply LLC, has created an outstanding education program for you. Here are some of the planned sessions. Remember to check the website ( for updates on the education program. Find out the secrets to their success!

Come sit and have a candid discussion with leaders in our industry: Roger Carlsen, Ephraim Forge; Joe Turner, Turner Manufacturing; Ed Mack, Fine Architectural Metalsmiths; Dave Filippi, FabCAD Inc. just to name a few. Finding out what they know could be the difference for you in having a more successful business. Sales Ben Mosely, Heirloom Stair & Iron

As we climb out of this downturn, it is time to return to profitability again and stop running your business with the goal of survival. It all starts with sales. In this session, Ben will define the difference between a sale and a quality sale. Also covered in this session: n How to maximize the sale. n How to get residual benefits from the sale. n What tools to bring into the sales meeting. n How to avoid unproductive meetings. n How to avoid costly and unnecessary travel time by bringing the customer engagement to your own turf. n Most important you will learn how to overcome price objections and close the deal! Pattern making 3-D Scott Howell, Robinson Iron Corp.

Take a look at how digital pattern making has moved the time-honored craft of pattern making into the future. Architectural design Robert Baird, Historical Arts & Casting Inc.

Join Robert for a discussion on architectural design.


Robert spent several years in Washington working with the National Trust for Historic Preservation before returning to the private sector. He will share his wealth of experience on architectural design. Properties, performance and preservations Robert Baird, Historical Arts & Casting Inc.

This course explores the properties of architectural cast metals including: cast iron, bronze, and aluminum. Their benefits and advantages will be examined. Other topics discussed will be manufacturing, the sources of deterioration, and maintenance. Conservation and restoration methods will be covered referencing completed projects and practical applications. As an added treat, the documentary “ZCMI a Legacy Cast in Iron” will be screened. Combining technology & practice to merge field measuring to shop drawings, layout and field installation Mark O’Malley, O’Malley Welding & Fabricating Inc. Terry Barrett, Pinpoint Solutions

This class will show the tools, technology, and methodology used by these miscellaneous and ornamental businesses for merging the operations of field measuring, shop drawings, and shop and field layout. Discussion topics will include an array of lasers (electric, hand and homemade) for measuring; CAD; smart phone apps; other layout software. The presenters will share tried-and-true methods along Fabricator n November / December 2012

METALfab2013 METALfab 2013schedule Schedule Wednesday 3/20/13

Thursday 3/21/13

Friday 3/22/13

Saturday 3/23/13

8:00 AM 8:30 AM 9:00 AM 9:30 AM

First Time Attendee 9:00 AM - 10:00 AM

10:00 AM 10:30 AM

Opening Session

11:00 AM

10:15 AM - 11:30 AM

11:30 AM

Lunch Break

12:00 PM

11:30 AM - 1:00 PM

Education 8:00 AM - 9:30 AM


9:45 AM - 11:15 AM

9:00 AM - 12:00 PM 9:00 AM - 4:00 PM

Optional Spouse Tour

Exhibits Spouse Classes

12:30 PM

11:45 AM - 12:45 PM

1:00 PM

1:00 PM - 2:00 PM

Off Site

10:00 AM - 4:00 PM

Lunch Break

9:00 AM - 4:00 PM

12:00 PM - 1:30 PM

1:30 PM


2:00 PM

1:00 PM - 2:30 PM


2:30 PM

2:45 PM - 4:15 PM

1:30 PM - 3:00 PM

2:15 PM - 3:15 PM

3:00 PM 3:30 PM 4:00 PM 4:30 PM 5:00 PM 5:30 PM 6:00 PM 6:30 PM 7:00 PM 8:00 PM 9:00 PM 10:00 PM 10:30 PM

Shop Tours

3:15 PM - 4:45 PM Education 3:45 PM - 5:15 PM

5:00 PM - 6:30 PM Top Job Jamboree

Theme Dinner 6:30 PM - 10:30 PM NEF Auctions

NEF Partners in Education Reception 6:45 PM - 7:45 PM

Exhibits & Reception 4:15 PM - 7:30 PM

with tips and tricks that they use. This class will be in two parts. The first part is a showand-tell of the different tools and their processes. The second part of the class will include the actual use of these tools and techniques on a stair or ramp in the hotel. Skills to becoming a better salesperson Joe Turner, Turner Mfg. Co.

Joe will share his years of experience as a master salesperson to show you how to sell your jobs and how to work with the client on the best material and style needed to fit in the surroundings.

LEED made easy Tom Zuzik, Artistic Railings Inc.

LEED can be complicated, but Tom walks you through the process with ease. Learn about information that is specific to the ornamental and architectural metals. Trends in glass railing design Valerie Block, DuPont Glass Laminating Solutions

Glass railing systems are being designed with less metal — putting more of an emphasis on the structural and safety performance of the glass. In many cases, laminated glass is being used over monolithic tempered glass to provide the added structural and safety properties necessary. ASTM E 2353 and E 2358 address the testing and specification of glass in glass railing systems, guards, and balustrades. The Canadian Standards Association is currently November / December 2012 n Fabricator

Awards Banquet 7:00 PM - 10:30 PM

working on the development of a standard, following incidences of falling glass in Toronto. The International Building Code in the United States, as well as the Florida Building Code, requires laminated glass in exterior glass railings for protection against wind-borne debris. Typically fabricated with heat-strengthened or tempered glass, laminated glass will retain glass fragments in the event of breakage. By doing so, the glass balcony will continue to serve as a barrier until replacement can be made. In addition, the risk of falling glass is averted, creating a safer environment for people walking on the street below. This presentation will address trends in glass railing design and the growing use of laminated glass in these systems. Oustanding shop tours planned for METALfab2013

Shop Tours are back for 2013. So far, three shops are confirmed for the tours and a few more in the works. James Minter (2013 Shop Tour Chair) has the following facilities scheduled: n Kenneth Ray, Raysteel Inc., Albuquerque. n Robb Gunter, Architectural Metals, Tigeras, NM. n Pete Shufelt, Backerworks Skilled Welding, Albuquerque. Backerworks is a fabricating facility that does a lot of work for the Sandia National Laboratories and Los Alamos. They also do some warhead manufacture in Amarillo, TX. This is a great line up, but be sure and check back (www. for additional shops as they are confirmed. 49

METALfab2013 Focus on Success! Spouse Program @ METALfab2013

Sue Minter, spouse program chair, has planned an exciting program for METALfab2013. Attendees will have the opportunity to learn and practice what they have learned with three wonderful classes taught by outstanding local and national artists. This is all part of the Spouse Registration offered for METALfab2013. Classes will be taught on Thursday, March 21, and the tour will be Saturday, March 23. Other events included in the spouse registration are: n Exhibits, n Theme Dinner & n NEF Auction, n NEF Partners in Education reception, and the n Awards Banquet.

Spanish Colonial Tinwork. Jason is a juried member of the Spanish Colonial Arts Society and teaches for Albuquerque’s Senior Arts program. All necessary tools, materials and instruction will be provided and all experience levels are welcome. You’ll enjoy a presentation on the history of tin and Spanish Colonial Art in New Mexico, a review of safety procedures and basic skills, and demonstrations with instruction on how to create your own art. You will create your own handcrafted keepsake to take home. Spouse tour, Saturday, March 23

You will travel north to historic and picturesque Santa Fe. Founded in 1610, Santa Fe was the last stop on the Camino Real, the fabled Royal Road that stretched from Mexico City to the northernmost reaches of the Spanish Empire. Today, it is the heart and soul of Spouse classes the Southwest, and “Santa Fe Style” For those who participated in is synonymous with the best in the the spouse program in Orlando, region. Its historic Plaza, winding you were fortunate to have the streets, covered arcades, hidden experience of working in acrylics gardens, and Pueblo-style architecwith renowned artist Maxine ture reflect the blending of Indian, Minter. Hispanic, and Anglo cultures. This year you will tackle a new Guided walking tour. Upon arrival you will take a guided subject and have fun tapping your walking tour, visiting the historic hidden talents. We had some great Plaza, St. Francis Cathedral, the auction items from this class. Loretto Chapel (see photo), with its Joe Dan Lowry is an internationally known expert on New “miraculous” staircase, and the San Miguel Mission. Mexico’s state gemstone and the Lunch. Enjoy lunch at La Casa popular mineral most often Sena, the historic house built by associated with the Southwest and Major Jose Sena in the 1860s. Native American jewelry — turLoretto Chapel Miraculous Staircase. La Casa Sena features an quoise. A phosphate of aluminum Photo Credit: Daniel Nadelbach. internationally acclaimed menu that contains small quantities of drawn from the best in Santa Fe and copper and iron, turquoise has been prized throughout the centuries as a medical wonder, southwestern cuisine, and is a recipient of Wine Spectator’s ornament, and religious symbol. “Best Award of Excellence.” Joe Dan is the author of Turquoise Unearthed: An An incomparable collection of museum-quality paintings Illustrated Guide and Turquoise: the World Story of a adds to the ambiance. Fascinating Gemstone. On your own. You may continue to explore on your own This is an entertaining and informative lecture and or indulge in a southwestern shopping spree at the many presentation. Joe Dan will also have some of his pieces unique specialty stores and galleries around the Plaza. available for purchase. Nearly all the city’s main cultural attractions are also Jason Younis y Delgado is a fifth-generation tinsmith, within walking distance of the Plaza, including the Georgia and the owner of the TINtero gallery in Albuquerque’s Old O’Keeffe Museum and the Palace of the Governors. Town. He will conduct an open workshop in traditional 50

Fabricator n November / December 2012

Exhibitors @ METALfab2013 Join the exhibitors to experience their products, learn about their services, and educate yourself on the possibilities for the future. We have a great group of exhibitors signed up for METALfab2013 at the Hyatt Regency. Exhibitor demo classes are scheduled for Thursday. You can learn more about their products and services. Schedule for exhibits n Wednesday, March 20, 4:15 pm–7:30 pm:

Exhibits and Reception.

n Thursday, March 21, 10:00 am–4:00 pm:

Exhibits and Demo Classes.

n Friday, March 22, 9:00 am–12:00 pm:

Exhibits and Breakfast.

Sponsors @ METALfab2013 as of 9/17/2012


as of 9/17/2012 Company Name.................. Web address The Cable Connection.......... Carell Corp............................ CML USA Inc. Ercolina....... Colorado Waterjet Co.......... www. Custom Orn. Iron Works..... D.J.A. Imports Ltd................. DeVilbiss, Ransburg, BGK, Binks......................... Doringer Cold Saws.............. Eagle Bending Machines Inc....................... Elite Architectural Metal Supply LLC............... ETemplate Systems............... FabCAD Inc........................... Feeney Inc.............................. Hebo/Stratford Gate Systems Inc................ Industrial Coverage Corp.................... King Architectural Metals.......... Lavi Industries....................... Lawler Foundry Corp........... Marks USA............................ Metabo Corp......................... Mittler Bros. Machine & Tool.................. NOMMA/NEF/ NOMMA Chapters............ Regency Railings Inc............ Sumter Coatings....................

Platinum Industrial Coverage Gold Colorado Silver King Architectural

Thank you to these outstanding companies for the support of METALfab2013!

The Wagner

November / December 2012 n Fabricator


METALfab2013 Focus on Success! Hotel Reservations @ METALfab2013

Registration @ METALfab2013

Make your reservation early!

Two ways to register:

METALfab2013 events will be held at the host hotel, Hyatt Regency Albuquerque. The hotel has reserved a special block of rooms for METALfab attendees. Book your room early to be part of the networking after hours. Attendees always find great conversations in the lobby or bar during METALfab. This can be one of the most important moments when someone shares an idea that can make a big difference to your future. Hyatt Regency Albuquerque 330 Tijeras NW Albuquerque, NM Room rates per night for METALfab2013 Single/Double $129 Triple $154 Quadruple $179 Suites $350 Room rates are quoted exclusive of applicable state and local taxes or applicable service or hotel specific fees in effect at the hotel at meeting time. Different room types, such as panoramic views, are available for additional charges. After 2/24/2013 or when the block sells out, this rate will not be available. Check the NOMMA website ( for the link to make your reservation online. If you wish, make your reservation by calling 888-421-1442 (toll free) or 402-5926464 (non-toll free). Be sure and mention that you are with METALfab/NOMMA.

Convention Guide Cover Photo Credit: Anvil Craft Corp., Easton, PA.


1 Go to the NOMMA website and register online using your credit card OR 2 Fill out the registration form enclosed in the convention guide and submit with check or credit card. Mailing address for registrations NOMMA 805 S. Glynn, Ste. 127, #311 Fayetteville, GA 30214 Fax number for registrations to 888-279-7994. Online registration will be turned off on 3/14/2013. Afterward, you can register onsite at the METALfab registration desk in the Hyatt Regency Albuquerque. Reduced registration fees the earlier you register

This year the earlier you register the better the rate. An example of the savings on a Full Conference Package for NOMMA Members: n Early Bird $420 (Deadline 2/14/2013). n Regular $450 (Deadline 3/8/2013). n Late $550 (After 3/8/2013). We still have the multiple attendees from the same company discount for NOMMA member companies. Non-members save money on registration by becoming a member, which saves you about $200 on each registration. Plus, you’re eligible for the multiple attendee discount. When your com­ pany joins NOMMA, all of your employees qualify for the member registration rate. For membership information go to or contact Liz Johnson, Member Care & Operations Manager at 888-516-8585 x 101,

Host hotel: Hyatt Regency Albuquerque. Photo credit: Hyatt Hotels.

Fabricator n November / December 2012

Special Invitation to Focus on Success @ METALfab2013 NOMMA and the NOMMA Education Foundation work together to make METALfab2013 an exciting event for you. Leaders of the Foundation, Roger Carlsen (NEF Chair) and Will Keeler (NOMMA President), briefly describe below what METALfab has meant to them and why they believe that you should join us @METALfab2013 to Focus on Success. Will Keeler, President of NOMMA

It is my pleasure to invite you to attend METALfab2013. During these difficult economic times, NOMMA recognizes the imperative that you get a return on your investment for attending the conference. Well, I believe the hard working convention committee has done a fantastic job lining up an education program and interesting shop tours that will do just that. I have attended nearly 20 METALfab conventions, and I always leave with knowledge of new products, technologies, fabrication methods, better business practices, and a renewed excitement for doing my job. Please join me at METALfab2013 in Albuquerque, March 20–23, to recharge your batteries and Focus on Success.

Roger Carlsen, Chair of the NOMMA Education Foundation

Anyone who has used the NOMMA ListServ realizes how valuable this forum is. Even though we know this benefit is worth the cost of our annual membership, we have thought “wouldn’t it be even better if we could actually talk to the person who responded to our post? Many times I have thought “I would just like to be able to put a face with the names of the people that seem so intriguing on the NOMMA ListServ.” All of this and more can happen at METALfab2013 in Albuquerque, NM, March 20–23. METALfab is like “reality ListServ” on steroids. Not only will you meet, greet, and talk with people you have seen post on the ListServ, but there is so much more. Each year that I attend METALfab, I come away with a wealth of information and a greater wealth of friends. I encourage everyone to see this as an investment in you and your business! Register today and be sure and stay at the Hyatt Regency Albuquerque so that you can enjoy the after hour conversations.

Special Events @ METALfab2013 Opportunities abound at METALfab to spend time with fellow attendees in a casual surrounding but that does not mean that the learning has stopped. One conversation can lead to the solution to a challenge you’re facing. Be sure and attend these special events (see schedule on page 49) to continue your Focus on Success. .

The Top Job Jamboree on Friday afternoon gives you the opportunity to learn more about the entries from their creators. The climax to the outstanding program is the presentation of the awards on Saturday evening at the Awards Banquet.

First-time attendee orientation

Here’s where METALfab attendees come together for a night of fun, food and exciting auctions. This year southwestern attire is the style. This is your opportunity to bid on the wonderful items in the live and silent auctions that you have seen displayed in the exhibit area. To donate an item for the auction, contact Martha Pennington (martha@ or 888-516-858 x 104) or go to for an auction donation form.

First-time attendees meet the NOMMA leadership and learn more about NOMMA, the NOMMA Education Foundation, and METALfab. Opening session: Annual Membership Business Meeting

This provides great speakers, important information, and time to handle the business of the association. Top Job display & voting

This is your chance to view the entries in the 2013 Ernest Wiemann Top Job Contest. Member companies will cast their ballots on Wednesday and Thursday during show hours. November / December 2012 n Fabricator

Thursday night celebration and NEF Auctions

NEF Partners in Education Reception

The NOMMA Education Foundation will thank its supporters for all

NEF Auction table. Donate an item!

that they do for the foundation and its programs. Join NEF on Friday night for this special reception. Awards Banquet and officer installation

A wonderful event to close an exciting week of activity. Saturday night’s banquet is a special event where we recognize members for their service, present Top Job Awards, and install the newly elected officers and directors.


METALfab2013 Focus on Success!

Extend your stay; Albuquerque is worth it Albuquerque, NM is a wonderful place to visit. The true southwest awaits you. Immerse yourself in the rich culture and heritage rooted in centuries of history. Soak in the blue skies and sun that shines about 310 days a year, perfect for outdoor activities, such as ballooning, biking, hiking, golfing, and touring. Whether you want to visit native American pueblos, try hot air ballooning, or enjoy outstanding local cuisine, Albuquerque is ranked among the top 10 U.S. Value Destination by Go to for more information on Albuquerque.

Albuquerque International Balloon Fiesta. Each year the Balloon Fiesta offers a great variety of balloons, you won’t find two alike.

Five reasons to visit Albuquerque

Photo credit: Raymond Watt.


Arts. Ranked as one of the top arts destinations in the country, Albuquerque offers abundance and variety to anyone seeking traditional or contemporary arts and culture.


Ballooning. Home to the International Balloon Festival — the clear skies, clam winds, and mild temperatures are the norm in Albuquerque encouraging hot air ballooning year round. With more than 300 resident balloonists this could be your opportunity to take a ride.


Culture and Heritage. Albuquerque is a culturally diverse city. This rich heritage is reflected in the architecture, artwork, cultural centers, and cuisine.


History. Many forces have developed the character of Albuquerque, from the native American population to the Spanish explorers and the residents of today. There are Cuisine. Meals in many connections to the past Albuquerque allow you to from ancient rock carvings at Gathering of Nations Pow Wow. World’s largest pow wow with more Pietroglyph National Monuexperience the exotic, than 500 tribes held annually in Albuquerque in the Spring. addictive flavors of ment, the historic Old Town Credit: Gathering of Nations, Derek Mathews. America’s most unique Plaza, and the trail of vintage and historic regional neon signs along Route 66. Take cuisine. some time and explore Albuquerque. Experience the blend of native American food, such as METALfab2013 promises to be a wonderful experience so blue corn and squash with chile peppers, wheat flour, pork be sure and mark your calendar for March 20–23. Check the from the Spanish settlers, which created a distinctly New NOMMA website for additional information as well as Mexican Cuisine. You will soon learn to answer your servers following #METALfab2013 on Twitter. questions — “red or green?” with authority or say “Christmas” and get both red and green chile. See You in Albuquerque!



Fabricator n November / December 2012

METALfab2013 Attendee Registration Form Hyatt Regency, 330 Tijeras NW, Albuquerque, New Mexico, March 20–23, 2013 See the Convention Guide or go to for course and event descriptions. Note deadlines for special pricing: Early Bird rate applies through 2/14/13, Regular registration must be received by 3/8/13. Late registration Late fee applies after 3/8/2013. Registration must be received or processed online by the cut-off date to receive special rate.

Step 1: NOMMA Member Registration Options Choose your registration type and enter the names for badges.

❑ Full Conference Package

Early Bird (2/14/13)

Regular (3/8/13)

Late (after 3/8/13)

Opening Session (Keynote)

1 full registration .........................$420 ..................................... $450 ...................................$550

Education Program

2 full same company .................$380 ..................................... $410 ...................................$510


3 full same company .................$345 ..................................... $375 ...................................$475

4+ full same company ..............$315 ...................................... $345 ...................................$445

NEF Auction


Theme Dinner

Awards Banquet


Shop Tours



❑ Spouse/Guest Package $325

❑ Education and Exhibits Package $320 Early Bird (2/14/13)

Exhibits & Opening Reception (Wed., 3/20/13)

$350 Regular (3/8/13)

Theme Dinner/NEF Auction (Thu., 3/21/12)

$450 Late (after 3/8/13)

Special Classes for Spouses (Thu., 3/21/12)

Opening Session (Keynote)

Awards Banquet (Sat., 3/23/12) Spouse Tour — Santa Fe Tour (Sat., 3/23/12)

Shop Tours Education Program

This registration is not available after 3/14/13. Spouse classes

NEF Auction

are available only with this registration — not sold separately.

Name_____________________________________________________ Name_____________________________________________________ Name_____________________________________________________ Name_____________________________________________________

Non-Member Registration Reduced pricing for multiple attendees is not available with non-member registration. ❑ $425 Make our company a NOMMA member so that we can take advantage of the great member pricing above.

Early Bird, 2/14/13

Regular, 3/8/13

Late, after 3/8/13

Full Package ..............$620 ...........................$650 .......................... $750 Name______________________________________________________ Educ. & Exhibits ........ $520 ...........................$550 .......................... $650 Name______________________________________________________ Spouse Package ....... $525 ...........................$555 .......................... $655 Name______________________________________________________ Individual Tickets Tickets will not be available on site. ❑ Theme Dinner (Thurs. 3/21/13) $99


❑ Spouse Tour — Sanata Fe (Sat. 3/23/13) $110*


* Limited number of tickets available. Will not be available onsite.

❑ Awards Banquet (Sat. 3/23/13) $70


Step 2: Payment Method Select payment type Check (payable to NOMMA in U.S. dollars on U.S. bank) Check #_____________ ❑ American Express

❑ MasterCard


❑ Discover

Card #__________________________________________________________________ Exp. Date_________________________________________ Name on card____________________________________________________________ Card CVV_________________________________________ Signature___________________________________________________________________________________________________________________ Continued on page 56 November / December 2012 n Fabricator


METALfab2013 Attendee Registration Form ✂

Continued from page 55

Step 3: Tell Us About Yourself Be sure and enter name(s) beside appropriate registrations that you selected on other side of this form. Company _______________________________________________________________________ Address_________________________________________________________________________

Please check the appropriate ribbon below for inclusion in your registration packet. ❑ New Member

❑ Committee Member

❑ First-Time Attendee

❑ Chapter President

❑ Fabricator Member

❑ Chapter Member

City_____________________________________________________________________________ ❑ NW Supplier Member

❑ NEF Contributor

State ___________ Zip_____________________ Country_________________________________ ❑ Regional Supplier

❑ Gold Member —

Email___________________________________________________________________________ Phone___________________________________ Fax____________________________________ On-site Emergency Contact Number_________________________________________________

Member ❑ Local Supplier Member ❑ Affiliate Member

Person to contact in case of emergency______________________________________________ ❑ Committee Chair

20+ Years ❑ Past President ❑ BOD

❑ Officer

❑ NEF Trustee ❑ Officer ❑ Speaker/Presenter

Step 4: Attendee Profile Tell us about your business. This portion of the registration must be completed for processing. ❑ Check here if you are not involved in the business. If you are not involved in the business, this is all of the information needed. Thank you. List three (3) products you hope to purchase from contacts at METALfab 2013: _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ 1) Primary type of business ❑ Fabricator ❑ General Supplier ❑ Contractor ❑ Other____________________

2) Annual gross sales 3) Your role in purchasing ❑ Below $1 million ❑ Final Say ❑ $1–$2.5 million ❑ Recommend ❑ $2.5–$5 million ❑ Specify ❑ Over $5 million

4) Job description ❑ Owner ❑ Manager/Foreman ❑ Other____________ ___________________

Important Information Registration Registrants can pick up their packets at the METALfab/NOMMA registration desk in the Pavillion Landing of the Hyatt Hotel. Restrictions Attendees for the exhibits must be 14 years of age or older for insurance purposes. Cancellations If received in writing prior to March 14, we will be happy to refund your registration fee, less a 10% administrative fee. Understandably fees cannot be refunded for registrations cancelled after that date. Registrations are nontransferable without the written permission of NOMMA. Refunds will be processed within 30 days after the completion of the conference. Cameras Photography and videotaping are not permitted in the exhibit area, education sessions, or Top Job Gallery. Emergency Contact We would like to have a contact name and phone number in case of an emergency. This person would be contacted only in the event that you were unable to contact them yourself. Confirmation & Updates Your confirmation and any updates will be sent by email, so please provide your email address. Email Address Your email address will be provided to the exhibitors on their attendee list. If you do not wish to have your email address provided to the exhibitors, please opt out by sending an email to with the subject line “Email Opt Out for Exhibitors.” This will also opt you out for updates about METALfab. Online Registrations Online registration is available for credit card payment. Recorded Sessions By registering for METALfab you are authorizing the use of any photographs, name, and/or likeliness in any recorded session. Questions?

METALfab 2013 / NOMMA

Call 888-516-8585, extension 101, or email

805 South Glynn St., Ste. 127, # 311

For updated information go to

Fayetteville, GA 30214

Online Registration is available on the NOMMA website

Fax: 888-279-7994 56


Fabricator n November / December 2012

Return to

Biz Side

Succession planning

How to keep your company steady after you’re gone

© almagami -


One day you’ll no longer run the company, keeping it on a strong foundation. When considering a solid succession plan, you’ll want to know, in detail, the who, what, when, and why, and how you’ll execute ownership and management changes. Here are some options.

By Mark E. Battersby Eventually, everyone thinks about

retirement. For those who own a closely held or family ornamental and miscellaneous metalworking business, retirement is more than deciding not to go to work anymore. In addition to ensuring you’ll have enough money for retirement, fabricators, shop owners, shareholders, and partners must decide what will happen to the business when they are no longer in control. An effectively developed succession plan may involve selling the business to provide a retirement nest egg, or continuation of the metalworking business, with gradual changes in management and/or control, to ensure a source of retirement income or any combination thereof.

Planning basics

At its most basic, a succession plan is a documented road map in the November / December n Fabricator

event of an owner, partner, or shareholder’s death, disability, or retirement. Succession plans can include a program for: n distributing the stock of the metalworking operation or other assets, n retiring the operation’s debt, n obtaining life insurance policies, buy-sell agreements between partners and heirs, n dividing responsibilities among successors, and n any other elements that affect the business or its assets. Although tax planning should never control any business decisions, estate taxes play a big role. Tax law changes in 2001 contained a one-year elimination of the so-called “death tax.” The estate tax rose from the grave at the end of 2010, with a Bush-era top rate of 35% and an applicable exclusion amount of $5 million ($5.12 million in 2012). In 2013, the death tax will revert to its antiquated, pre-2001 form. The

applicable exclusion amount will plummet to $1 million, and the top marginal rate will leap twenty points to 55%. A 5% surtax will also return, to be levied on estates between $10–$17 million. This raises the top effective rate of the death tax to 60%. Giving it away

Because a key way to reduce estate taxes is to lower the value of assets that are in the estate, “gifting” strategies can legitimately lower any owner, partner, or shareholder’s tax liability. Fortunately, gifts can be made outright in several ways and all serve to reduce the amount of the overall estate: n Annual gift tax exclusions. Currently, property valued at up to $13,000 per year per donee (i.e. person gifted) may be gifted without any gift tax consequence. n Other gift tax exclusions. Gifts for the purposes of the donee’s health or education are excluded from gift tax calculations (this is why parents could 57

seemingly pay unlimited amounts for their children’s doctor appointments and, for some lucky ones, schooling expenses). n Lifetime gift tax exemptions. In 2011 and 2012, giving lifetime gifts of up to $5 million before any estate, gift, or generation-skipping taxes are imposed are possible. Unfortunately, none of these gifting strategies directly benefit the ornamental and miscellaneous metals business. Other strategies for transferring the shop or business do exist, however; strategies that frequently allow the owner to retain control. Flipping for FLPS

To be complete and effective, a succession plan

must be continually revisited, reviewed, and updated to reflect changes in your circumstances. Buy/sell agreements

A buy-sell agreement, often called a “business prenup,” is a legal contract that prearranges the sale of a business between a seller and a willing buyer. The agreement allows sellers to keep control of their interest until an event specified in the agreement occurs, such as the seller’s retirement, disability, or death. Other events, such as divorce, can also be included as triggering events under a buy-sell agreement. When the triggering event occurs, the buyer is obligated to buy the interest from the seller, or the seller’s estate, at its fair market value (FMV). The buyer can be a person, a group (such as co-owners), or the business itself. Price and sale terms are prearranged, which eliminates the need for a fire sale if the owner, partner, or major shareholder becomes ill or dies.

By controlling the metalworking business through a “family limited partnership” (“FLP”), or a “family limited liability company” (“FLLC”), everyone can get the added benefit of gifting shares at considerable discounts. A FLP OR FLLC can also assist in transferring a business interest to family members. First, a partnership with both general and limited partnership interests is created. Then, the business is transferred to this partnership. A general partnership interest is retained for the owner, allowing a continuation of control over the day-to-day operation AdtheProof of the business. Over time, limited77035-CB-4829-08 Selling it to the employees partnership interest is gifted to family An Employee Stock Ownership members. Plan (ESOP), allows the owner of an

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incorporated ornamental and miscellaneous metalworking business to sell his or her stock to the ESOP, and defer the capital gains tax. Ownership can be transferred to the metalworking operation’s employees over time, and the business can obtain income tax deductions for contributions to the plan. An ESOP provides a market for the shares of owners who leave the business, a strategy for rewarding and motivating employees, as well as benefitting from available borrowing incentives, and acquiring new assets using pretax dollars. An outright sale

To keep the income rolling in without having to show up for work every day, succession planning might look at selling an owner, shareholder, or partner’s interest in the shop or business outright. When the business interest is sold, the seller receives cash (or assets that can be converted to cash) that can be used to maintain the seller’s lifestyle, or pay his or her estate taxes. The time to sell is optional — now, at retirement, at death, or anytime in between. As long as the sale is for the full fair market value (FMV) of the business, it is not subject to gift tax or estate tax. Of course, a sale that occurs before the seller’s death may be subject to capital gains tax. Liquidity strategies = Cash

So-called “Liquidity” strategies permit a metalworking business owner to take cash out of the business in exchange for the transfer of assets to another individual. While liquidity options are most common with sales of the business are to a third-party, they can also be used when the assets are being transferred to family members or business insiders (such as partners). A private annuity involves the sale of property in exchange for a promise to make payments for the rest of the seller’s life. Business ownership is transferred to family members or another party (the buyer). The buyer, in turn, makes an unsecured promise to make periodic payments for the rest of the seller’s life (a single life annuity), or for the seller’s life and the life of a second person (a joint and survivor annuity). Fabricator n November / December 2012

A joint and survivor annuity provides payments until the death of the last survivor; that is, payments continue as long as either the husband or wife is still alive. Again, because a private annuity is a sale and not a gift, assets can be removed from an estate without incurring gift tax or estate tax. A self-canceling installment note (SCIN) permits the transfer of the business to a buyer in exchange for a promissory note. The buyer must make a series of payments to the seller under that note. A provision in the note states that upon the owner’s death, the remaining payments will be canceled. SCINs provide for a lifetime income stream and avoidance of gift tax, and estate tax in a manner similar to private annuities. Unlike private annuities, however, SCINs give a security interest in the transferred business. Successfully planning succession

Developing a succession plan is a multi-phase process outlining in detail the, who, what, when, why, and how changes in ownership and management of a business are to be executed. At a minimum, a good plan should help accomplish the following: n Transfer control according to the wishes of the operation’s owner, shareholder or partner; n Carry out the succession of the business in an orderly fashion; n Minimize the tax liability of all involved; n Provide economic well-being after the owner, partner or shareholder steps aside. Obviously, business owners seeking a smooth and equitable transition of their interests should seek competent, experienced advisors to assist them in this matter. No matter how talented and earnest those professional advisors are, their limited specialties should never dictate the choices for the business or the owner, shareholder, or partner’s family. A tax lawyer can make compelling arguments for strategies that can minimize estate and gift taxes. A CPA can be very convincing when suggesting strategies for controlling income taxes. And it is a similar story with financial planning and insurance professionals. In fact, tax planning should never control any business decisions. Finally, succession planning can’t be done once and forgotten. To be complete and effective, a plan must be continually revisited, reviewed, and updated to reflect changes in About the Author For more than 25 the value of your years, Mark E. Battersoperation, market by has written editoconditions, and the rial features, columns, owner, shareholder or white papers, and partner’s health, as reports for magazines, well as the abilities and journals, newsletpassion of the people ters, and websites about news and developments in the tax and financial to whom the operation arenas that impact small businesses. will be passed.

For your information


He can be reached at MEBatt12@

November / December 2012 n Fabricator


Biz Side

9 Business management principles Employees

Cash flow









We often need a refresher in sound business practices. Don’t ignore these common sense ideas.

By William J. Lynott The more things change, the more they stay the same. So goes that old saying that illustrates an important business truth. While old and proven principles of sound business management are often wrapped in new clothes and offered as fresh discoveries, careful examination usually reveals the reality: The most important doctrines of successful business management have been around for a long time. Here are nine of those reliable management principles that are essential to business success but too often ignored these days:

1Get to know your customer

“In order to provide the correct type of service in the correct manner, you absolutely have to know with whom you are dealing,” says Pete Staagard, president of Mastercraft Iron, Neptune, NJ. “If you’re working with the type of individual who is going to make the bulk of his decisions based on price 60

alone, that needs to be your top priority when proposing your services. Past performance and reputation will swing the job in your favor only if the price is competitive. “Other customers are more concerned with quality; that’s when you can let your skills and capabilities lead your discussions. Either way, knowing with whom you’re dealing and what their needs are will result in happy customers and increased business. “In our line of work, we’re constantly working with contractors who are waiting to collect money from their clients so their suppliers can get paid. We keep that in mind to create the most comfortable relationship possible so we as the fabricator can work together smoothly with the general contractor.”

“Pay your best employees good salaries and treat them well,” says Sally Mounts, Ph.D., president Auctus Consulting Group, Washington, Pa. “Successful owners know that their most valuable resource is the people they employ. They reward them liberally and encourage their growth. They look for ways to affirm their value to the company through personal attention and acknowledgement. The result is employees who stay with the company for years, saving hundreds of thousands of dollars the owner would otherwise be spending in training a succession of new hires.” Billie Blair, Ph.D., president, Change Strategists Inc., Los Angeles, adds this advice: “Ensure that employees are fully aware of the nature, intent, and direction of your business through their involvement in its strategy development and generation of new ideas and new ways of operating.”

2 Guard your most precious asset 3 Understand cash flow vs. profit “Take care of your people,” says Wally Adamchik, president, FireStarter Speaking and Consulting. “Leadership is about people. Fundamental to this concept is that leaders take care of their people.”

Many fabricators keep records on the accrual basis, which typically means that revenue is recognized as soon as the customer is invoiced. Expenses are typically recognized when something is “used up” Fabricator n November / December 2012

© fotomatrix -


within a given period of time (such as a month) to get the revenue recognized during that time. “None of this has anything to do with when cash flows in or out of the business,” says Jerry F. White, director of Caruth Institute for Entrepreneurship, SMU Cox School of Business, Dallas. “Irrespective of ‘profit,’ if enough cash does not flow into the business in a given time period to cover mandatory payments, such as payroll and debt service, the business will fail.” How can cash flow be improved? “By collecting accounts receivable quicker, delaying payables as long as practical, increasing the time period for debt repayment, and figuring out how to operate with a lower level of inventory,” says White. “Profit is important to the longer term health and prosperity of a business, but cash flow is critical to short term survival. The tendency is to think that if there is a strong profit the cash flow will also be strong. It is common, however, in a growing business, to have solid ‘profits’ and a negative cash flow. Businesses that survive and prosper over time never forget that profit is not cash flow.”

approach to the details. Business owners need to remember that people follow up on what the boss deems important. To be sure that your ideas are being thoroughly and correctly carried out, you must continue to pay attention to the small, daily activities that are essential to your operation.”

6 Set the example

In a small business, the owner’s behavior, actions, and attitudes establish the guidelines for employees. “Many so-called leaders in the small business world believe that they can operate with impunity because of their position as owners or managers,” says Mounts. “Do as I say, not as I do is their mantra. They do such things as criticize employees openly in front of their peers, leave early on Friday afternoon for a round of golf, or treat vendors discourteously. “If a leader wants to build a healthy company culture, he or she needs to discuss problems with employees in a private setting. If she wants people to work hard on Fridays to get ready for the coming week, she needs to stay late herself. If she wants courteous

employees, she must offer courtesy to others. In short, the person leading the company must display the behavior he or she wants others to emulate.”

7Embrace change; it’s inevitable

You like doing things the way you’ve always done them. You may not like the idea of change, but change is both inevitable and healthy. “At the end of the day all we can count on is change, and a business owner’s ability to adapt to change is a major factor in determining the success of the company,” says Justin Green, business coach, The Impel Group, Chicago, Il. “A business owner must remain steadfast to core values while constantly evaluating how the company can best adapt to changes in the market place. If your business doesn’t fill that need someone else will. The best way to identify these changes is to be inquisitive, talk with suppliers, customers and employees to understand what is changing and how you can adapt.” Carl Doerksen, director of corporate development, Generational

4 Keep a tight lid on overhead

“Some businesses suffer from ‘creeping overhead’ caused by unnecessary spending on things that are not essential and which the business really can’t afford,” says White. “High overhead limits a business’s flexibility to maneuver. It drains the company of resources needed to grow and improve. It also elevates the risk that the business will not survive an unexpected financial downturn. Long-term, successful business owners understand the need to focus on essential expenditures and work continually to keep overhead low.”

5 The devil is in the details

Successful business owners often establish their success in part by knowing every facet of their business. Some then want to hand over the reins to someone else so that they can just ‘be the boss’,” says Dr. Mounts. “They forget that what got them success in the first place was their hands-on November / December 2012 n Fabricator

Call for Nearest Dealer


Equity, Dallas, TX, agrees. “In today’s business world the new norm is constant change,” he says. “If you and your company are not responding to this reality and constantly looking for new ways to better service your customers, you will eventually lose out to your competition. One of the easiest ways to find out what your customers need from you is to simply ask them; they can be your best source of new ideas for products and services.”

8 Never break a promise

If there is one certain way to alienate a customer, it’s by breaking a promise. Surveys show that broken promises are always among the most prominent reasons why customers abandon a busi-

ness. You probably know from your own experience just how frustrating it can be when a business breaks a promise to you. Should you find yourself in a position of having to break a promise, any promise — no matter how seemingly harmless — always contact the customer as soon as you learn about the problem. An early explanation and a sincere apology will go a long way toward easing the customer’s frustration. And it works the same way with employees. “The workplace is full of unwritten psychological contracts,” says Dr. Mounts. “One is that bosses must act with integrity, keep their word, and fol-

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low through on things they’ve promised. A boss who breaks this vital precept will never be viewed in the same way; the damage to the work relationship is virtually irreversible. Don’t fall into that trap. Keep your word — literally, figuratively, and psychologically. It will pay huge dividends in employee loyalty.”

9 Don’t be a finger pointer

When former President Harry S. Truman coined the phrase, “The buck stops here,” he acknowledged his willingness to shoulder the blame when things go wrong. He put his subordinates and constituents on notice that he wasn’t a finger pointer. If those around you feel that you’re never willing to shoulder even part of the blame for business miscues, they’ll withdraw from the kinds of decisionmaking and innovative thinking that could make your life easier and your business more successful. When things go wrong, consider that your instructions weren’t clear or that the involved employee made what reasonably appeared to be a good decision at the time. Once in awhile, accept the blame even when you know you weren’t at fault. That’s a sure way to ban the destructive finger pointer from your business culture.

For your information


About the author Bill Lynott is a longtime business writer for Fabricator. Since 1957, he has written nearly 1,000 essays and columns and is the author of three books: 1 Professional Service Management (McGraw-Hill); 2 Power Letters for Service Executives, (Lynco Publications); and 3 Money: How to Make the Most of What You’ve Got (Author’s Choice Press). Bill also has an extensive background in management, consulting, and marketing. CO NTAC T



Fabricator n November / December 2012


Nationwide Supplier Members Albina Pipe Bending Co. Inc. (503) 692-6010

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

Alku Group of Companies (905) 265-1093

DAC Industries Inc. (800) 888-9768

Allen Architectural Metals Inc. (800) 204-3858

Decorative Iron (888) 380-9278

Alloy Casting Co. Inc. (972) 286-2368 American Punch Co. (216) 731-4501

Eagle Bending Machines Inc. (251) 937-0947 EPi

Architectural Iron Designs Inc. (908) 757-2323

ETemplate Systems (919) 676-2244

Atlas Metal Sales (800) 662-0143

The Fabrication Store (866) 79-FAB4U

Big Blu Hammer Mfg. (828) 437-5348

Gates That Open LLC (GTO) (800) 543-4283

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

Geo. Bezdan Sales Ltd. (604) 299-5264

The Cable Connection (800) 851-2961

Glasswerks LA Inc. (323) 789-7800

Carell Corp. (251) 937-0948

The G-S Co. (410) 284-9549

Carl Stahl DecorCable Innovations (800) 444-6271

Hartford Standard Co. Inc. (270) 298-3227

Lavi Industries (800) 624-6225 Lawler Foundry Corp. (800) 624-9512 Lewis Brass & Copper Co. Inc. (718) 894-1442

Hayn Enterprises LLC (860) 257-0680

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

Heritage Cast Iron USA (918) 592-1700

Colorado Waterjet Co. (866) 532-5404

Illinois Engineered Products Inc. (312) 850-3710

Ransburg (419) 470-2000 Regency Railings Inc. (214) 742-9408 Robinson Iron Corp. (800) 824-2157 Rockite, Div. of Hartline Products Co. Inc. (216) 291-2303 Rogers Mfg. Inc. (940) 325-7806 L.E. Sauer Machine Co. (636) 225-5358 SECO South (888) 535-SECO Sharpe Products (800) 879-4418

Lift Master (630) 279-3600

South Camden Iron Works Inc. (856) 423-1107

Locinox USA (708) 579-0286

Stairways Inc. (713) 680-3110

Mac Metals Inc. (800) 631-9510

Hebo/Stratford Gate Systems Inc. (503) 722-7700

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

King Architectural Metals - CA (714) 670-8980

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

(262) 786-9330

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

Custom Orn. Iron Works Ltd. (866) 464-4766

King Architectural Metals (800) 542-2379

Krando Metal Products (610) 543-4311

Banker Wire (800) 523-6772

Century Group Inc. (337) 527-5266

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

The Iron Shop (800) 523-7427

DKS, DoorKing Systems (800) 826-7493

Ameristar Fence Products (918) 835-0898

ProCounsel (214) 741-3014

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

Marks U.S.A. (631) 225-5400

Suhner Industrial Products Inc. (800) 323-6886

McKey Perforating (262) 786-2700

Sumter Coatings Inc. (888) 471-3400

Metabo Corp. (800) 638-2264

Transpacific Industrial Supply Inc. (909) 581-3058

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

Tri-State Shearing & Bending (718) 485-2200

Multi Sales Inc. (800) 421-3575

TS Distributors Inc. (832) 467-5400

NC Tool Co. (336) 674-5654

The Wagner Companies (888) 243-6914

Indiana Gratings Inc. (800) 634-1988

Ohio Gratings Inc. (330) 477-6707

Industrial Coverage Corp. (631) 736-7500

Precision Glass Bending Corp. (800) 543-8796

Wasatch Steel Inc. (888) 486-4463

Super Thanks!!! A thanks to our members who have sponsored a new firm for our 2012–13 membership drive. We encourage everyone to sponsor a member and/or send the NOMMA office your leads. If needed, we will be glad to send you a supply of membership brochures. n n n

Julius Blum & Co. Inc. Keeler Iron Works National Ornamental Metal Museum

November / December 2012 n Fabricator

n n n

Cuper Studios LLC Lawler Foundry Corp. R & F Metals Inc.

n n

D.J.A. Imports Ltd. Majka Railing Co. Inc.



New Members

Help Take NOMMA To The Top

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 October 31, 2012. *Asterisk denotes returning members Artistic Anvil Metalcraft LLC Palm Harbor, FL Mark Dierking Fabricator

CML USA Inc. Ercolina* Davenport, IA Kim Stevens Nationwide Supplier

Atelier Custom Design LLC Kennewick, WA Joe Molvik Fabricator

Mid South Soda Blasting Germantown, TN Cory McCabe Local Supplier

Bedford Iron Works* Bedford Hills, NY Phil Thomas Fabricator

Miscellaneous Metals Inc. Frederick, MD Kenneth G. McCombs Fabricator

Brighton Fabrication Inc. Orange, CA Daniel Cooper Fabricator

RISA Management Corp. Westbury, NY Shridatt Prashad Fabricator

Take part in our membership contest. Photo credit: Big D Metalworks, Dallas, TX,  Top Job Entry.

Attention NOMMA Members - Help us to rebuild our membership while earning discounts for METALfab 2013. For every member you sponsor, you’ll receive $75 off your Albuquerque convention registration. Sponsor 4 members and your registration is free! Eligibility: Any NOMMA member who sponsors a member between April 15, 2013 and February 28 2013.

Restoring the Past. Building the Future.


259 Muddy Fork Road Jonesborough, TN 37659 423/913-1022


Association of North America, Inc. Questions? Call Peter H. Miller, President: 202.339.0744 x 104. Or email


Fabricator n November / December 2012 Fabricator RM house ad.indd 1

10/14/2011 12:45:08 PM

What’s Hot? n Industry Briefs New website provides auction sales information for industrial equipment End-use buyers can now take advantage of a new data searchengine platform developed by Auction Price Results, Akron, OH, to help them define specific, actual prices on sought-after equipment, and where to find them. is classified as a “freemium” website. Much of the information provided to users, such as where to find equipment at auction and how many of the items have sold and where, is free. Auction companies can also upload their upcoming auctions for free. Users of the website may then purchase other information, such as the actual price paid at auction when the gavel dropped. Cost is determined by the number of results chosen and the price bracket of each item. Results often cost as little as $1 for items valued at between $1,000–$5,000. “It’s a great tool for everyone involved in the acquisition and disposition of used industrial equipment,” says Rich Bishop, team member at AuctionPriceResults. com. “Our data has helped purchasing managers at large corporations and universities, all the way down to small mom-and-pop operations with limited resources of time and money, to find the equipment they need to grow their business.” offers data on these categories, among others: industrial machinery, agriculture/construction, HD truck/trailer. Contact 330-592-0164

November / December 2012 n Fabricator

Industry News

FabCAD adds to its design library

FabCAD Inc., White Stone, VA, a leader in ornamental CAD software products and services, has expanded its design library from 13,000 to more than 15,000 parts with additions to the King Architectural Metals and Lawler Foundry collections. FabCAD’s library also has designs from eight other industry leaders. Free upgrades are available to all FabCAD 2010+ users and can be purchased by other FabCAD users for $95. The library is available to other

CAD users, as well. The FabCAD Design Library is an extensive library of castings and forgings from the leading manufacturers of ornamental components. It gives access to industry designs for customer and shop drawings, saving the time of drawing these by hand and ensuring that all components are to exact scale and compatible with most CAD systems, says the company. Contact 800-255-9032

American Punch gets ISO recertification American Punch Company, Cleveland, has announced their recertification in accordance with the ISO 9001:2008 credentials. ISO 9001:2008 is the international standard for achieving quality in manufacturing processes. The recertification allows American Punch Company to show its highest level of commitment to quality in manufacturing and customer service. A copy of American Punch Company’s Certificate of Registration is at The ISO 9000 family addresses various aspects of quality management and provides guidance and tools

for companies and organizations that want to ensure that their products and services consistently meet customer’s requirements, and that quality is consistently improved. American Punch is a leading manufacturer of punches, dies, and shear blades used in the structural steel and metal fabricating industries. The company also supplies precision die components to the stamping, roll forming, and metal-forming industries. The company can ship stock round and oblong punches and dies, and flat bar and angle blades, same day ordered. Contact 800-243-1492 65

What’s Hot? n

Industy News

Mid South Soda Blasting offers mobile service for paint, contaminant removal Using its new self-sustained mobile equipment, MidSouth Soda Blasting (MSSB), Memphis, TN, can now bring surface restoration services directly to industrial clients, allowing for convenient, “at-your-door” service. The company removes paint and contaminants from a variety of surfaces for commercial and residential customers. With the mobile unit, MSSB can often complete off-site jobs in the same day Traditional power, electrical, or water hookups are not necessary. “Because the mobile unit is self-contained, it allows us to start jobs faster and complete them faster,” says Mid-

News brief Website to connect artists for commisioned projects A website designed to connect architects, designers, and art consultants with artists worldwide for commission projects is launching. The beta version of the website is expected in November 2012. The site will provide free listings and photos featuring a variety of work in architectural glass, architectural metal, sculpture, atrium sculpture, work for the wall, and other categories. Design trade professionals will be able to search a database of images, and register for additional services to create online design boards, post requests for proposals, and email artists directly. Contact

South Soda Blasting co-owner D.J. McCabe. MidSouth Soda Blasting was formed in 2011 and services homeowners, businesses, insurance companies, and property management firms. The Memphis-based company guarantees experienced workers, environmentally friendly methods and, now, mobility. It provides a spectrum of services geared toward the industrial sector, including steel cleaning and maintenance, metal cleaning work, and surface prep and coating. Contact 901-324-3900

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People Brief Kuddes named sales technician at Security Brands Denver-based Security Brands Inc. has hired sales technician Colton J. Kuddes. He has a background in sales and the customer service industry. Kuddes is supporting sales throughout the U.S., Canada, and Mexico, and will use his knowledge of circuit board manufacturing to grow the territory. He holds associate degrees in marketing management and audio music production. Security Brands Inc. has three divisions that relate to the perimeter access control industry: American Access Systems, Summit Access Control, and Kodiak Black.

Lincoln Electric promotes Chantry to director of marketing, North America The Lincoln Electric Company, Cleveland, has promoted Bruce Chantry to director of marketing, North America. Chantry will oversee all core functions for Lincoln Electric’s North American marketing efforts, including industry segment management, product management, advertising, web development, creative services, events, trade shows, and celebrity endorsements. Chantry has been with Lincoln Electric for 17 years. Before assuming his new role, Chantry spent four years as a portfolio manager for Welding Equipment, overseeing the equipment product management team, strategic

planning for the entire welding equipment portfolio, new product development, market analysis, product positioning, and product promotion. Chantry previously served as a product manager for advanced welding equipment and as a regional manager for the company’s sub-Saharan Africa region. He also spent time in Lincoln Electric’s Moline, IL, and Grand Rapids, MI, sales offices. Chantry holds a bachelor’s degree in electrical engineering from the Colorado School of Mines and graduated from the Thunderbird School of Global Management’s International Consortia Program. He is a member of the American Welding Society (AWS). presents






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New edition: Lien and Bond Claims

Foundation of the American Subcontractors Association Lien and Bond Claims in the 50 States, published by the Foundation of the American Subcontractors Association (FASA) and written by construction attorneys, contains an entry for each state and the District of Columbia. It divides the various lien and bond requirements by private and public work. The publication provides subcontractors with: the latest lien claim requirements for each state; who to notify; critical filing deadlines; legal requirements for executing bond claims; and exceptions to claims procedures. An appendix has legal citations. “Being attentive to the changing notice requirements and claims procedures is paramount for subcontractors who want the maximum protection of lien and bond rights afforded by law,”

says FASA Vice President of Education David Mendes. Lien and Bond Claims in the 50 States (Item #5006) is provided as a downloadable and searchable PDF file. Cost is $55 for members of the American Subcontractors Association and $80 for nonmembers. Contact 888-374-3133 www.contractorsknowledgedepot. com Instructional product application videos Rex-Cut Abrasives Two instructional product application videos describing stainless steel finishing kits for satin finish or highly polished finish have been introduced. Videos for finishing stainless steel rails and tubing demonstrate two new kits containing everything required for achieving a satin or highly polished

finish. Featuring a three-step process for each kit, these instructional videos demonstrate corner blending from a weld to a final finish in about 1 hour and 45 minutes each. Showing a list of materials and how to finish stainless steel rails using each of them, the videos for finishing stainless steel include a satin finish instructional video that can be viewed at www., and a polish finish demonstration at www.youtu. be/3SKuXuxaShg. Contact 800-225-8182

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New flap disc Klingspor

The new SMT850 Plus combines non-woven and coated abrasives in one flap disc. With this combination, the SMT850 Plus offers a high rate of stock removal with a high-quality surface finish, says the company. This leads to fewer processing steps and reduction of machining times, therefore lowering overall finishing costs. The discs are available in 41/2 inches, with three different finishing grades — coarse, medium, and very fine. Contact 828-322-3030

November / December 2012 n Fabricator

Liquid paint marking solution LA-CO Industries Inc./Markal Markal’s Pro-Line XT features a highly visible paint formula that allows for continuous marking, even on rough, rusty, and dirty surfaces. The enamel-based paint binds quickly to the surface for wear, weather, UV,

and chemical resistance, improving part traceability and eliminating lost parts and reworks, says the company. Available in 14 colors, it is designed for trade professionals in steel warehouses, metal production factories, welding, and machining shops. The

formula is free of xylene and other harmful chemicals and has a marking temperature range of -50°F to 150°F (-46°C to 66°C). The marker also has 12 color options that are low in chlorides, halogens, and sulfur for use on stainless steel or with any low-corrosion marking applications. Contact 800-621-4025 or Multi-process welder Lincoln Electric The new Power Wave S500 is designed for welding on thicker materials. With more than 65 standard welding waveforms designed to optimize arc performance for specific applications, this compact, multi-process power source is suited for a variety of industries, including construction, fabrication, and general production


What’s Hot? n applications, says the company. The Power Wave S500 can power Stick, DC TIG, pulsed DC TIG, MIG, pulsed MIG, and flux-cored processes. Advance Waveform Control Technology processes include pulse-on-pulse, Power Mode, RapidArc and new Rapid X. The machine is rated 450 amps, 36.5 volts at 100% duty cycle, and a maximum 550 amps, 41.5 volts at 40% duty cycle, with an output range of 5–550 amps. This model is IP23 rated, for durability in harsh environments. The Power Wave S500 features Lincoln Electric’s latest hardware and software enhancements: Contact 888-355-3213


Floor stand disc sander Kalamazoo Industries Model DS20 Disc Sander is a floor stand unit designed for non-production applications that require a rugged, dependable machine at an economical price. The sander features cast iron and steel construction, a 20-inch steel disc, a tilt table with mitre gauge, and a reversing drum switch. The unit is available with either a 1,740 rpm, 2 hp, 3-phase motor (220/440V), or 11/2 hp single-phase motor (110/220V). It weighs more than 1/4 ton. Contact 269-382-2050

Precision gear drive saws Pat Mooney Inc.–The Saw Company The FMB Saturn Precision Gear Drive Saws are designed for a large capacity in a range of iron and steel applications. FMB Mitre Bandsaws combine the advantages of a circular cold saw with the speed of an abrasive saw and the capacity of a traditional bandsaw, says the company. Equipped with a swivel saw head with a precision protractor, the FMB Saturn mitre cuts 0–45° left and 0°–60° right. The vise slides on linear guide rails for easy setup of mitre cuts. The Saturn has carbide blade guides with roller guides and a saw drive via gear reductor with case-hardened and ground helical gears supported by a heavy-duty machine base. Other features include a quickacting clamp and mechanical blade tension with a built-in indicator.


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length stop is 23 inches. Variable blade speeds range from 52–396 FPM. The infinite variable speed motor is controlled via Omron Inverter. The saw motor and coolant motor perform at 2 HP and ⅛ HP, respectively. The Saturn occupies 38 x 63 inches of floor space and weighs 1,700 lbs. Contact 800-323-7503 The FMB Saturn+G+V Model features hydraulic cutting control. The “G” allows the use of either pull down and enables fast sawing and operation on light jobs, with the added convenience of hydraulic downfeed for heavy tubes, profiles, and solids, the company says. The “G” lets the operator “walk away” while the machine completes the cut and shuts off. The Saturn’s blade size is 11 feet, 3 inches x 1 inch x .035 inch and the

Oval punch and flares Mittler Bros. Machine & Tool The Jamey Jordan Signature Series Oval Punch & Flares, model 1320, are used in press to punch smooth, flared oval holes in sheet metal panels. The “True Ovals” improve the strength and appearance of panels, says the company. They are machined

from high-grade tool steel and heat treated to a Rockwell Hardness of 58. They are available in sets or as individual sizes. One Press Block will work for all three Oval Punches. Drill template is included. Material thickness capacities are: aluminum .060 inches; mild steel .060 inches; and stainless steel .040 inches. A universal press block is sold separately. Contact 800-467-2464

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


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Learn new strategies to grow your business – and stay ahead of the competition. Join your colleagues and meet potential partners at AFA’s 2013 FENCETECH. Check out the latest advances in fences, decks and railing, security, gate operations, access control -- and more. EXHIBIT FLOOR HOURS Wednesday (2/27) ........12:00 - 6:00PM Thursday (2/28) .............12:00 - 6:00PM Friday (3/1) ............. 9:00AM - 12:00PM

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Fabricator n November / December 2012 9/25/12 9:57 AM


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


Pg Company


72 American Fence Association Inc. .................

68 John C. Campbell Folk School

38 Apollo Gate

71 Kalamazoo Machine Tool .................................

39 Apollo Gate Operators II 21 Architectural Iron Designs Inc.

59 Julius Blum & Co. Inc. 67 Kalamazoo Metal Muncher...................

16 Architectural Metal Works

69 Ken Bergman & Assoc. LLC

64 Artist-Blacksmith’s Assoc. of North America

15 Krando Metal Products

70 Atlas Metal Sales ............................................ 30 Big Blu Hammer Mfg. Co. / Oak Hill Iron Works 58 Blacksmiths Depot / Kayne & Son Custom Hardware Inc. .................................... 35 Carell Corporation .......................................... 25 Chicago Metal Rolled Products Co. .................... 62 Colorado Waterjet Co. 10 Custom Ornamental Iron Works Ltd. 17 D & D Technologies (USA) Inc. ..........................

75 King Architectural Metal .............................. 13 Lawler Foundry 2

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

68 Lindblade Metal 34 Marks U.S.A. 27 Metabo Corp. 42 Mittler Bros. Machine & Tool ..................... 70 NC Tool Company Inc. 61 Pat Mooney Inc. 9

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

71 R & D Hydraulics Mfg. & Machine Co. 40 Regency Railings 62 Rogers Mfg. Inc. ......................................

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

32 Scotchman Industries ..................................

67 DAC Industries Inc.

22 Sharpe Products ...................................

66 Doringer Cold Saw ............................................

19 Shop Outfitters/ Lockdown Securities ..............................


35 Eagle Bending Machines Inc. .........................

33 Stairways Inc................................................................. 800-231-0793

44 Eberl Iron Works Inc.

11 Suhner Industrial Products Corp. ..............

46 Encon Electronics

45 Sumter Coatings Inc.

18 EPi .....................................................................................

24 The Cable Connection ................

23 FabCAD Inc. ............................................................

76 The Iron

29 Hebo - Stratford Gate Systems Inc.

31 The Wagner Companies

41 Hougen Mfg. Inc. .................................................

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

43 International Gate Devices

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

43 Jansen Ornamental Supply Co. ............

69 Universal Entry Systems Inc. ....................................800-837-4283

66 Jesco Industries Inc. WIPCO Div. .............

36 Vogel Tool & Die LLC .......................................

Your advertising contact for O&MM Fabricator NOMMA Buyer’s Guide NOMMA website CO NTAC T

Sherry Theien Advertising Director 8392 Leesburg Ct. Rockford, IL 61114 815-282-6000 815-282-8002 fax November / December 2012 n Fabricator

Advertise in the 2013 NOMMA Buyer’s Guide Your one-stop resource for shop and office personnel The Buyer’s Guide is available in 3 versions: 1) print, 2) online, and 3) database. Closing date November 30, 2012 Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; 73


Metal Moment

Dominating the wrap, Roland Turn your service truck into a rolling billboard sign Editor’s note: We recently caught up with long-time member Roland Anderson of Metal Market Inc., Fort Payne, AL. Metal Market is a full-service ornamental metal shop that produces gates, fences, handrails, and miscellaneous items. Roland has turned his service truck into a moving marketing tool by covering his vehicle with a colorful wrap, which was provided by a local sign shop. We asked Roland a few question about this creative and eye-catching advertising medium. Fabricator: Where did you get the idea for the wrap? Anderson: After noticing several trucks in other professions with wraps, I wanted to do something that explained what exactly Metal Market creates. Sometimes the name Metal Market can be confusing for customers as to what we make. This is my second truck that I have had wrapped. Fabricator: Why did you choose this marketing method? Anderson: I tried newspapers and radio ads, but I was not happy with either of these marketing methods as I did not seem to get my money back from them. Using the wrap, my truck is similar to a rolling billboard, and compared to the cost of a billboard, it is a bargain. Fabricator: What is a wrap and how does it work? How long does it last? Anderson: The wrap is a 3M vinyl film that is covered by a layer of laminate film. It covers the entire truck on all sides. The installer recommends it being replaced after three years, which

Its a wrap. The first wrap, top, was applied to a Metal Market truck in 2009. For the new truck below it, the fabricator wanted a new design distinctly different from the prior truck.

works great for me because after two years my truck has a lot of miles on it. Fabricator: Explain the design process for the wrap. Anderson: A local sign shop, Accel Graphics, designed and installed the wrap. They pulled pictures from the Metal Market website and came up with a few designs to choose from and emailed me. We emailed until I found a design that I was pleased with. I wanted the truck to be different from the previous truck so that people would notice a different Metal Market truck.

Fabricator: What kind of responses have you gotten from the public? Anderson: The responses have been great. People notice the truck wherever I go. I give out a lot of business cards from people coming up noticing the truck and saying they had been wanting someone to build a spiral staircase or handrail. I have had phone calls from people saying they saw my truck passing through and were needing some work done. This wrap also makes it important to have good driving skills or people can call about your driving habits.


Something on your mind? Got something to say? Got an idea? Got a tip? Got a gripe? Do you have a story to tell? Fabricator magazine would like to interview you for a Metal Moment story. Please contact editor Todd Daniel at 74

Fabricator n November / December 2012

November / December 2012 n Fabricator





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2012 11 fab  
2012 11 fab