Sep/Oct 2013 OMM Fabricator

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

Shop Talk Plasma cutting has several benefits, 14

Shop Talk Multi-axis routing is today's workhorse, 22

Member Talk Blankenship has winning touch, 12

September I October 20 IJ $6.00

us

Biz Talk 6 Steps for starting content marketing, 57

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INTRODUCING

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We pride ourselves on our high quality and our customized service. Our complete cutting and polishing facilities will meet your every need.

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*In areas with a chapter. t Only Nationwide Suppliers are listed in Fabricator.

2013-09-fab

FAX TO: 888-279-7994

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

NOMMA Membership Application Membership Category - Check One:

0 Fabricator· $.42'5 $325 (to pay in four payments, you can enroll in the Quaterty 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.

Suppliers 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.

0 Nationwide· $595 (operating on a nationwide or international basis) 0 Regional· $465 (operating within a 500-mile radius) 0 Local· $375 (operating within a 150-mile radius)

0 Affiliate - $310.00

OTeacher 0 School 0 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: _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ __

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Questions? Contact: Liz Johnson, Member Care & Operations Manager: (888) 516-8585, ext. 101 , liz@nomma.org • This Introductory Rate is only availabl e to first-ti me members.

2013-054

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Videos on YouTube September I October 201J

Vol. 54, No. 5

Email newsletter Website articles

Linkedln, Facebook company pages

Content marketing: How to put the puzzle together. Story, page 57.

NOMMA Network

Member Talk

Shop tours announced for METALfab2014, March 12-15 ...... JO METALfab keynoter to talk about "relevance acceleration:' JO Top Job submission deadline with no late fee is December 31. JO Pacific NW Chapter enjoys social media class, pulsed MIG demo. 11

Biz Talk

Blankenship's touch wins .......... 32 The hard work, vision, perseverance of Sherman Blankenship, and an inspiring mentor, helped Louisville metal shop Iron Touch thrive.

Not all healthcare act provisions under way yet.............. 53 Some provisions of the health care act have already kicked in. Others will in 2014 and 2015. Still more in 2018.

Here's what is means for you now.

'By :Mark E. 'Battersby

'By 'Peter J{ildebrandt Biz Talk

Top Job Profile

6 Steps to content marketing .... 57 Shop Talk

Riveting know-how...........-.........40

The benefits of plasma cutting···············-··············· J4 The advantages of plasma cutting over mechanical equipment are numerous.

Steel Weldings Top Job of a fireplace door is an example of understanding history and bringing back old skills, incljuding riveting.

There's more to content marketing PR and advertising. This article shows you what it is, and 6 steps to get your message out effectively.

'By Chrfa'line "Dunn

'By Chris J{olt

What's Hot! Shop Talk

Industry News................................... 66 Wagner takes numerous steps toward sustainability and saves money.

Multi-axis routing is today's workhorse........-...............22

Products ....................................... 68

While new 3D printing technologies are getting the notice now, multi-axis routing is still pervasive partly due to its versatility, material variety, precision, ease of use, and efficiency.

Suppler Members ............................ 64 New Members ................................... 65 Ad lndex............................................... 73

'By Jeff 'Fogel

President's Letter .......... 7 Exec. Director's Letter ... 8 NEF.................................. J2 Metal Moment .............. 74 The ROI ofNOMMA networking.

The steps for a successful strategy.

Help support your foundation.

Ways to clean pickets and posts before fabrication.

About the cover The fireplace door, fabricated by Steel Welding, Freedom, PA, was designed to resemble a Pittsburgh blast furnace. It won a 2013 Top Job Gold Award in the Furniture & Accessory Fabrication - Nonforged category. See story on page 40.

September I October 2013 •

Fabricator

5

1 closer to fit all gates Industrial quality for gates up to 330 lbs.

Simple installation with QUICK-FIX fasteners (0 5/8" holes) Hydraulic, temperature independent dosing performance Smooth opening operation (bearing based) Smooth dosing or "snap" shut for positive latching Vertically & Horizontally adjustable %" ADA Compliant

No need to drill large holes No need to paint or powdercoat brackets yourself No endless hinge & closer combinations No (separately sold) mounting brackets needed

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Dedicated to the success ofour members and industry.

President's Letter

The ROI of NOMMA networking

J.R. Molina, Big D Metalworks, Dallas, TX

'By J. 'R. Jl{olina

Mark Koenke, Germantown Iron & Steel Corp.

Jackson, WI

NOMMA OFFICERS President President-Elect

"Where did your company learn

around people that are better at it than you are: "That's when we found NOMMA. Now ornamental iron is 60% of our business. We attribute this directly to our embracing the relationships that NOMMA offers. The willingness of the membership to share their knowledge has been vital and inspiring for our business:'

to produce such incredible stairs and rails?" is a question I am often asked by Big D customers.

My response: "Our expertise was not acquired overnight It took many years and a lot of lost time J.R. Molina, Big D Metalworks, and money to gain the experiis president ence and reputation we have:' of NOMMA. About 20 years ago, Big Greg Bailey D was a pool fence and gate company. We grew into the Bailey Metal Fabricators Inc. "I have multiple cases where a company we are today by building our knowledge base at NOMMA conNOMMA member has helped me or I have helped them. In November 2012, we ventions and participating in various classes. The education and support we had a request from a contractor out of Indianapolis working in Sioux Falls, SD. gain through our NOMMA membership helped Big D gain confidence to A NOMMA member I met in Orlando sell stair and rail projects. at METALfab recommended us.

"This project came when business We began fabricating high-end was slow. It actually made our yearresidential gates and interior stair railend very good. Had it not been for ings, and with the education and proNOMMA, I would have never made fessional connections we acquired at METALfab, we aspired to greater levels. contact with this contractor.

Since we've been in NOMMA, Big D "In early 2012, we fabricated a small has built relationships with other great project for Keeler Ironworks that was companies in the industry. We have delivered 30 miles from our location. partnered with Keeler Iron, Alamnance Again, NOMMA made it possible.

Iron, Boyler Iron, and others to learn ''.A few years ago, we needed pickets where a Y:z-inch rod is tied in a knot. I and share knowledge. These relationships, and the access to professional posted on the NOMMA ListServ what I education, are paramount to the value needed, and Carl Grainger responded.

His work turned out exactly like we of Big D and drive our desire to conwanted and on time. I feel these projtinue being involved with NOMMA. Knowing that other NOMMA mem- ects have more than paid my dues for many years to come:' bers have experienced similar gains on their membership investment, two As shown in these testimonials, Board members agreed to share some NOMMA is a valuable resource. I of their experiences: can say with confidence: "If you need something, just ask:' Allyn Moseley Heirloom Stair & Iron NOMMA'.s Board and members are here to support, listen, and assist you in "Before 2003, Heirloom was a wood fabrication shop, with no metal capagaining knowledge and value so your bilities. All of our metal balustrades business can thrive in your community. were outsourced and profits were outsourced with it. We then moved it all in-house with the motto: 'If you want to get really good at something, hang

q .

September I Odober 2013 • Fabricator

Vice President/Treasurer

Allyn Moseley, Heirloom Stair & Iron, Campobello, SC Immediate Past President

Will Keeler, Keeler Iron Works, Memphis, TN FABRICATOR DIRECTORS

Greg Balley, Bailey Metal Fabricators, Mitchell, SD Keith Majka, Majka Railing Co. Inc., Paterson, NJ Tina Tennlkalt. Superior Fence & Orn. Iron, Cottage Hills, IL Greg Terrill, Division 5 Metalworks, Kalamazoo, Ml Cathy Vequlst. Pinpoint Solutions, Jupiter, Fl Henry Wheeler, Wheeler Ornamental Metals, Dothan, Al SUPPLIER DIRECTORS

Rick Ralston, Feeney Inc., Eugene, OR Mark Sisson, Mac Metals Inc., Kearny, NJ Dave White Jr•• locinox USA. Countryside, IL NOMMA EDUCATION FOUNDATION OFFICERS Co-Chairs

Roger cartsen, Ephraim Forge Inc., Frankfort. IL Lynn Parquette, Mueller Ornamental Iron Works Inc., Elite Architectural Metal Supply LLC, Elk Grove Village, IL Treasurer

Mike Boyler, Boyler's Ornamental Iron Inc., Bettendorf, IA NEF TRUSTEES

Heidi Blschmann, Milwaukee, WI cart Grainger, Grainger Metal Works, Nichols, SC Mark Koenke.• Germantown Iron & Steel Corp., Jackson, WI Christopher Mahner, Christopher Metal Fabricating.

Grand Rapids, Ml Rob Rolves, Foreman Fabricators, St. Louis, MO NOMMA CHAPTERS Chesapeake Boy Patty Koppers, President. Koppers Fabricators Inc.

Forestville, MD 813 -248-3348 Florido

Marco Vasquez. President. Vasquez Custom Metals Inc., Tampa, Fl, 813-248-3348 Guff Coast

Charles Perez. President. B & 0 Machine Welding.

Brookhaven, MS, 985-630-6943 Northeast

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

Gale Schmidt, President, A2 Fabrication Inc. Milwaukie, OR, 503-nl -2000 Upper Midwest

Mark O'Malley, President, O'Malley Welding & Fabricating Inc., Yorkville, IL, 630-553-1604 NOMMA STAFF Executive Director, J. Todd Daniel, CAE Meetings & Exposition Manager; NEF Executive Director, Martha Pennington Member Core & Operations Manager, Liz Johnson Editor, Robin Sherman Soles Director, Sherry lhelen

FABRICATOR EDITORIAL ADVISORY BOARD

Terry Barrett, Pinpoint Solutions, Jupiter, Fl Doug Bracken, Wiemann Metalcraft, Tulsa, OK Biii Coleman, Arc Angels, Dunedin, Fl Nancy Hayden, Tesko Enterprises, Norridge, IL Chris Holt. Steel Welding. Freedom, PA Rob Rolves, Foreman Fabricators, St. Louis, MO 7

How to reach us Ornamental & Miscellaneous Metal Fabri cator (ISSN 0191 -5940), is the

official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA).

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Executive Director's Letter

The steps for a successful strategy

O&MM Fabricator I 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: fabricator@nomma.org.

Advertise Reach 8,000 fabricators For information, call Sherry Theien, Ph: 815-282-6000. Email stheien@att. net. Ads are due on the first Friday of the month preceding the cover date. Send ads to : Fabricator at address above.

Email ads to: fabricator@nomma.org (max. 5 megs by e-mail). Or upload ads to our website where a downloadable media kit is available: www.nomma.org.

Membership Join NOMMA ! Beyond the magazine, enjoy more benefits as a NOMMA member. To join, call 888-5168585, 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 martha@nomma.org.

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: 888516-8585, or fabricator@nomma.org.

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 stheien@att.net.

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.

'By Todd 'Daniel

• Create an "operational strategy" where you provide the money, staff, and volunteer resources to make it happen.

• Always make adjustments.

The process reminds me of old war movies, where the soldiers take one hill, regroup, and take the next one.

Recently, president-elect Mark Koenke and I attended a CEO strategic planning presentation that gives me more clarity on how a nimble and successful Todd Daniel association should perform. is executive We got a "big picture" view director of on how NOMMA can better NOMMA. meet our industry's needs. The NOMMA's big goal While NOMMA has had principles apply to any business, a purpose and mission statement for and I encourage every member to create years, only recently has the Board set a a strategic plan, or at least, a basic businew "big goal": "To deliver outstanding ness plan for your shop. programs and services to our members, NOMMA has engaged in strategic planning since the 1980s, but, until resulting in competitive advantages and recently, we didn't have continuity or industry excellence within the ornafollow-through. In 2010, we adopted the mental, architectural, and miscellaneous "Tecker Model" developed by a longmetalworking industry:' Our goal will be reached by focusing time association consultant and considon a few objectives each year, which will ered a "best practice" by the American Society of Association Executives. be backed up by strategies. From there, The NOMMA board is getting better an action plan is formed and the needed at "visioneering" where it wants to go, funds and labor are appropriated. fleshing out ideas, providing resources Forward thinking for implementation, and building a One of the greatest transitions in stronger organization to achieve our goal: solving problems for members and NOMMA'.s history was in 2010 when helping them to be more successful. its Board switched from operational to strategic. The idea: The Board charts The strategic roadmap direction, set policies, and serves as overseer.It's the committees, task forces, • Determine your purpose, values. and staff that do the "heavy lifting" and • Decide where you would like to go and set your "big goal:' execute the strategic plan of the Board.

This is how a healthy association • Look for challenges, opportunities. works, and I'm delighted to see NOM• Create a smaller set of goals, objectives, and strategies.

MA'.s board getting better at this. Without this process, we would be a ship • Pick 1-3 objectives per year. The without a rudder, and I'm thrilled that Board and association should rally we are now sailing "full speed ahead:' behind them.

• Review goals annually to ensure they are on track and fit with your purpose. Set new priorities as needed.

..-Ill• "·•1n:r@i'"f'\...,...•••-

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© 2013 National Ornamental & Miscellaneous

Are you a NOMMA Top Job winner? Do you have how-to, step-by-step tips to share? Have you solved an interesting fabrication problem?

Write for Fabricator. Contact Editor Robin Sherman at nomma.editor@att.net.

Metals Association 8

Fabricator • September I Odober 201 l

Established in 1987, Krando Metal Products, Inc. has effectively developed a reputation by continuously providing high quality components in a timely manner. This reputation has helped Krando Metal differentiate ourselves from other companies in the industry.

Krando Metal Products Inc. , is constantly updating its facility with state-of-the-art machinery, so that we may remain more diversified and versatile in the products we manufacture and the services we offer.

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These modern technological capabilities provide Krando Metal with a competitive advantage.

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The NOMMA Network

Shop tours announced for METALfab2014, March 12-15 To help you plan for NOMMA'.s 56th annual convention and exhibition, March 12-15, in St Louis (St. Charles), MO, the METALfab2014 Convention Committee has named the shop tour stops for the convention: • Missouri Ornamental Iron , St. Louis: Family-owned fabricator specializing in railings, gates, and fencing.

• Mittler Brothers Machine & Tool,

Foristell: A nationwide supplier offering a line of metal fabrication tools, including notchers and benders.

• LE. Sauer Machine Company, St Louis: A nationwide supplier providing laser cutting, machining, and heat treating.

• Classic Metal Craft, St. Louis: Family-owned fabricator focusing on fencing, handrails, and other customdesigned ironwork.

• AZZ Galvanizing, St Louis: Nationwide supplier member offering full galvanizing services for a variety of industries.

of SBR Worldwide/ Know More! He is considered one of the world's foremost sales intelligence thought leaders, and he will share a secret that most of us already know - knowledge is power!

While every sales program and book teaches the value of knowing what's important to the other person and connecting on a personal level, Sam will show you how to do it!

Sam was recently named one of the "Top 25 Most Influential People In Sales" by InsideView, a marketing intelligence company.

He has won numerous awards and has been featured in various magazines, including the 'Business Journal, which included him in their "Forty Under 40" list.

Top Job submission deadline December 31

'This list is tentative and subject to change. ~ thanks to 'Rob 'Rolves oj'foreman 'Fabricators 1nc., who is serving as 2014 Shop 'Tour Coordinator.

METALfab2014 keynote speaker to talk about relevance acceleration' 1

Sam Richter, our keynote speaker, will teach you how to "tell your company's story in a manner that your buyer cares about and wants to hear:' His presentation will provide attendees with new and innovative ways to find new prospects, connect with people, and build powerful and meaningful business relationships.

An internationally recognized expert on sales, marketing, and leadership, Sam is a well-known speaker, author, and founder and CEO 10

Start thinking about the 2014 Ernest Wiemann Top Job Contest The deadline is December 31, with a late deadline ofJanuary 13 (late fee

required).

The contest is open to all NOMMA members, including nationwide suppliers. Full information is available from the NOMMA website (www. nommaorg).

Judging will be done by members during METALfab2014, and the awards will be presented at the Awards Banquet Saturday, March 15, 2014, in St. Louis, MO. For the 2014 contest the Top Job

An invitation from JR Molina, Big D Metal-

works, NOMMA President & Convention Committee Chair, 2013-2014

I would like to extend an invitation to every NOMMA member and nonmembers alike to attend METALfab 2014 in St. Charles, MO, March 12-15.

Each year before the convention, attending members from my company meet to plan our METALfab strategy. In other words, we develop a list of goals we want to accomplish, what we want to obtain or learn from our attendance. This may include information on a particular tool the shop needs, on collaboration software, or how other companies do their drawings.

Whatever the needs are, we always have an agenda before we leave. We always see a return on our investment from attending METALfab in the form of gaining knowledge relevant to our current needs.

METALfab objedive My goal for METALfab 2014 is to offer attendees the best education programs possible and to provide new and exciting products for attendees to learn about Attending METALfab every year is important for several reasons: • For members to grow their business.

• For the industry to grow.

• For NOMMA to stay relevant in the metal community.

Therefore, I challenge everyone to attend METALfab and let's give back to an association that has given so much to so many.

I look forward to seeing everyone at METALfab2014 in St. Louis/ St Charles, MO.

-JR !Molina

Fabricator • Septem ber I Odober 2013

Pacific NW Chapter enjoys social media class, pulsed MIG demo The Pacific Northwest Chapter enjoyed a social media presentation at their June meeting in Portland, OR The session showed members how to use various online tools and the pros and cons of each. Attendees also discussed the time investment required for social media.

Attendees saw a pulsed MIG demonstration, and host Greg Madden, Madden Fabrication, led a shop tour.

Other highlights included a great lunch, raffle drawing, mini-vendor display, and business session, at which Greg discussed the benefits ofNOMMA membership and introduced the vendors, who then gave a short presentation.

A thanks goes to Madden Fabrication for hosting the meeting and to Colleen Wright, Response Interactive, for leading the social media presentation.

Committee is announcing a new addition - award certificates! All winners can now purchase certificate plaques to present to other individuals involved in the project, including clients, subcontractors, and employees.

A sample award certificate will appear at the Top Job Gallery voting booth during METALfab, and the estimated cost will be between $60-$70 per plaque.

There are no rule changes for the contest, but the committee has issued a couple of clarifications: • Definition of a Door: "A door divides an exterior and interior space and/or is designed for temperature control:' Comm entary: This definition helps to clarify doors/ gates that open into courtyards or wine cellar gate/ doors.

• Anonymity Rule: Jobs previously appearing in print or online in a NOMMA publication or website are ineligible for the competition.

Commentary: For the past decade there has been confusion about rule # 13, which requires anonymity. The rule was originally intended to prevent entrants from discussing their work in the gallery area, but questions have repeatedly come up about the scope of this rule. The statement above provides clarity.

Contact Top Job Chair Justin Pigott, Emerald Ironworks, 703- 690-2477 ext 3, or send an email to: topjob@ nomma.org.

September

I Odober 2013 • Fabricator

Fabrication team member, right. demonstrates pulsed MIG welding technique w ith chapter attendees

Call for Speakers METALfab2014 If you have a t opic that you wo uld like to share with METALfab2014 atte ndees at the conventio n, March 12-15, in St. Lo uis/

St. Charle s, MO, please contact: Lynn Parquette NEF METALfab education chair lynn@ornamentallron.net

11

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NOMMA Education Foundation 'In partnership with the 'National Ornamental & ::Miscellaneous ::Metals .Jlssociation

Help support your foundation The NOMMA Education Foundation (NEF)

a memorial gift (passing of someone in the industry) or honorarium (letting an induswas established in 2001 to provide educatry member know that you honor them and tional opportunities to the ornamental & miscellaneous metals industry. their contribution while they are still part of To this end, NEF has: the industry, at retirement, or other special occasions in their business life).

• provided education at the annual conference (METALfab), When you make a memorial gift or honLynn Parquette, left, Mueller • created video education, orarium a special letter is sent to the family Ornamental Iron Works Inc. & Elite Architectural Metal Supply LLC and • supported new and existing chapters or individual acknowledging the honor Roger Carlsen, owner, Ephraim with education programs, that has been bestowed on them or their Forge Inc., are NEF co-chairs. loved one.

• hosted educational webinars, Through these donations, the foundation can continue • provided continuing education classes, and • funded research projects beneficial to the industry. and expand its work to provide educational opportunities, Each year we ask for your support through financial plus you let someone special know that they are important to donations, for example: you and the industry.

• providing items for the NEF Auctions held during NEF is your foundation. It depends on your support.

METALfab, Please consider a donation, honorarium, or memorial gift today. You can fill out the form below and send to NEF, • bidding on items at the auctions, and • participating in other fund raising activities.

805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214 or Please also remember the foundation at special times with fax to (888) 279-7994.

Yes! I want to help support NEF operation and programs with a donation.

City_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _State._ _~Zip_ _ _ _ __

x 1

Is the donation D Personal or D Company Type of Donation D Cash donation Donation Amount D $20

x

D Honorarium D Memorial Gift

I

D $50 D $100 D $500 D $1,000 D Other$_ _ _ _ _ _ _ _ __

Payment Method D Check Credit Card: D AMX D MC D Visa

D Discover

Credit card number_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ Expiration _ _ _ _ _CCV_ _ _ __ Name on card_______________Signature_________________

Your suppott of the foundation and its programs is greatly appreciated!

tMfr"1 For more information on donating to the NOMMA Education Foundation Contact NEF Executive Director Martha Pennington, 888-516-8585 x 104, martha@nomma.org.

12

Fabricator • September I Odober 201 l

~··

2014 Contest For details, visit: www.nomma.org ·All NOMMA members are eligible.

A Member?

1 oo discount Ask about our $ mbershiP offer. introductory me

Not

Contest Information Deadline: December 31, 2013 Late Deadline: January 13, 2014*

·Win a beautiful plaque for your winning Top Job entry.

Details: Categories, rules, and entry form are contained in the Contest Brochure, which can be downloaded from the NOMMA website. Or, call the NOMMA office and we can fax or mail you a copy (888-515-8585, ext.

101).

• Press releases are sent out for winners.

Rule Cha nges: Prints are now required for each entry, but we encourage you to include digital copies as well on a CD (or via email).

·Voting is done by NOMMA members during the METALfab convention.

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September

I Odober 2013 • Fabricator

13

Take care to use proper protection when plasma cutting. including closed shoes, glove s, long-sleeved jacket and correctly shaded eye protection in the form of a welding he lmet, goggles, or safety glasses.

Editor's note: This article provided by Lincoln Electric Co., Cleveland, OH, is a primer about plasma cutting technologies. The features and specifications, as well as the useful tips, discussed in the article are believed to apply to plasma cutters available across the indu~ry.

Do yo u need a cutting tool for occasional repair and maintenance work?

Have you embarked on a project that requires higher cutting volumes? Or, are you looking for an alternative to your current mechanical saw?

Each of these scenarios are reasons to investigate plasma cutting or oxyfuel, the two primary alternatives to mechanical cutting.

Plasma, however, might be the method to use now because the costs of the machines are declining; smallersized, portable machines are flooding the market; and the technology offers more benefits, including ease of use, higher quality cuts, and faster travel speeds.

14

What is plasma cutting technology?

In simplest terms, plasma cutting is a process that uses a high velocity jet of ionized gas that is delivered from a constricting orifice. The high velocity ionized gas, that is, the plasma, conducts electricity from the torch of the plasma cutter to the work piece. The plasma heats the work piece and melts the material. The high velocity stream of ionized gas mechanically blows the molten metal away, severing the material.

Plasma cutting can be performed on any type of conductive metal - mild steel, aluminum and stainless are some examples. With mild steel, operators will experience faster, thicker cuts than with alloys.

How does plasma cutting compare to oxyfuel cutting?

Oxyfuel cutting, however, using a flame containing oxygen and a fuel, cuts ferrous material by burning, or oxidizing the metal it is severing.

Where plasma cuts using heat, oxidizing involves a chemical reaction that can only be obtained when the process is applied to ferrous materials, hence a limitation of oxyfuel cutting. Metals such as aluminum and stainless steel form an oxide that inhibits further oxidization, making conventional oxyfuel cutting impossible.

Plasma cutting does not rely on oxidation to work, and thus it can cut aluminum, stainless, and any other conductive material. Plasma cutting only relies on compressed air and electricity.

Essentially, electricity brings high heat to the compressed air to create plasma, which is concentrated through a nozzle.

The plasma cuts while the force provided by the compressed air blows away the slag to provide a clean cut While different gasses can be used for plasma cutting, compressed air is typically used for the plasma gas because it is usually already in most shops for other applications.

Another reason other gases aren't used is due to their higher costs and the Fabricator â&#x20AC;˘ Septem ber I Odober 2013

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need for separate distribution systems.

However, sometimes in the field, where compressed shop air is not available, a nitrogen gas cylinder will be used air cylinders may be more expensive.

Plasma cutting is typically easier for the novice to master, and on thinner materials, plasma cutting is much faster than oxyfuel cutting. However, for heavy sections of steel (1 inch and greater), oxyfuel is still preferred because it is typically faster, and for heavier plate applications, very high capacity power supplies are required for plasma cutting applications.

What can I use a plasma cutter for?

Plasma cutting is ideal for cutting steel, and non-ferrous material less than 1 inch thick.

Oxyfuel cutting requires that the operator carefully control the cutting speed to maintain the oxidizing process. Plasma is more forgiving in this regard.

Plasma cutting really shines in some niche applications, such as cutting expanded metal, something that is nearly impossible with oxyfuel. Compared to mechanical cutting, plasma

cutting is typically much faster and can easily make non-linear cuts.

What are the limitations to plasma cutting?

Where is oxyfuel preferred?

The plasma cutting machines are typically more expensive than oxyacetylene, and oxyacetylene does not require access to electrical power or compressed air, which may make it a more convenient method for some. Oxyfuel can cut thicker sections (>1 inch) of steel more quickly than plasma.

What to look for when purchasing a plasma cutting machine

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Once you have determined plasma cutting is the right process for you, look at the following factors when making a buying decision.

1 Determine the thickness of the metal that you will most frequently cut One of the first factors to determine is the thickness of metal most frequently cut. Most plasma cutting power sources are rated on their cutting ability and amperage. If you most often cut IA -inch-thick material, consider a lower amperage plasma cutter.

If you most frequently cut metal that is 1h inch in thickness look for a higher amperage machine.

Even though a smaller machine may be able to cut through a given thickness of metal, it might not produce a quality cut Instead, you might get a sever cut that barely makes it through the plate and leaves behind dross.

Dross is a byproduct of metal impurities created as the base material melts during cutting. Dross must be removed to the greatest extent possible so it won't negatively impact weld quality.

Every unit has an optimal range of thickness. Make sure it matches what you need. Generally, a IA-inch machine has about 25 amps of output, a 1h-inch machine has a 50-60 amp output while a% inch-1 inch machine has 80 amps output 2 Select your optimal cutting speed Do you perform most of your cutting in a production environment or in Fabricator • Septem ber I Odober 2013

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an atmosphere where cutting speed pie, a less than 90°-angle cut on a isn't as critical? part that requires a perpendicular When buying a plasma cutter, cut (90°) would be out-of-spec. the manufacturer should provide Look for a plasma cutter that offers a tight, focused arc that concutting speeds for all thickness of metal measured in IPM (inches per centrates more cutting power on the work piece. minute). If the metal you cut most frequently is >A-inch, a machine Another test is to lift up the that offers higher amperages can plasma torch from the plate while cutting. See how far you can move cut through the metal much faster than one rated at a lower amperage, the torch away from the work piece although both will do the job. and still maintain an arc. A longer For production cutting, a arc means more volts and the ability good rule of thumb is to choose to cut through thicker plate. a machine that can handle about 6 Pilot-to-cut and twice your normal cutting thickness. For example, to perform long, cut-to-pilot trans fers fast, quality production cuts on The transfer from pilot arc to >A-inch steel, choose a Y:z-inch-class cutting arc occurs when the pilot (60 amp) machine. arc is brought close to the work Lead instructor Neil Mansfield assists student Mikayla piece.

A voltage potential from If you are performing long, time- Bradford, showing her how to hold the correct torchnozzle to work piece is the means consuming cuts or are cutting in to-work distance with the oxyacetylene cutting process. Bot h are from Assabet Valley Regional for this transfer. Traditionally, a an automated set-up, check into Technica l High School, Marlborough, MA. the machine's duty cycle, the time large resistor in the pilot arc current path created this voltage potential. you can continuously cut before the machine or torch will overheat and is caused by the electric potential from This voltage potential directly affects nozzle to work. the height at which the arc can transfer. require cooling.

Duty cycle is rated as a percentage After the pilot arc transfers to the work piece, a switch (relay or transistor) is of a 10-minute period. For example, a 4 Compare consumable cost versus consumable life 60% duty cycle at 50 amps means you used to open the current path.

Plasma cutting torches have a varican cut with 50 amps output power Look for a machine that provides a quick, positive transfer from pilot to ety of wear items or consumables that continuously for six minutes out of a 10-minute period. The higher the duty require replacement Consumables for cutting at a large transfer height. Your cycle, the longer you can cut without plasma cutting include compressed gas equipment manufacturer or distribusuch as air or nitrogen, the cutting elec- tor should be able to provide informataking a break. trodes, and the welding tips. tion regarding transfer. These machines J Can the machine offer alternative will be more forgiving to the operator Look for a manufacturer that offers to high frequency starting? a machine with the fewest number of and will better support gouging, the consumables. Also, see how long a con- removal of imperfections in the mateMost plasma cutters have a pilot arc rial, or even old welds. In gouging, the sumable will last. Be sure when comthat uses high frequency to conduct electricity through the air. However, paring one machine against another cut does not pass all the way through high frequency can interfere with comthat you are comparing the same data. think of digging with a shovel.

Some manufacturers will rate consumputers or office equipment that may be A good way to test transfer characables by number of cuts while others in use in the area. Thus, methods that teristics is by cutting expanded metal will use the number of starts. or gratings. In these instances, the eliminate the potential problems assomachine will be required to quickly ciated with high frequency starting circuits may be advantageous. transfer from pilot to cut and back to 5 Test the machine and The lift arc method features a DC+ examine cut quality pilot very quickly. nozzle with a DC-electrode inside.

To get around this, a manufacturer Make test cuts on a number of Initially, the nozzle and the electrode machines, traveling at the same rate of might recommend you cut expanded physically touch. When the trigger is speed on the same thickness of material metal using only the pilot current. pulled, current flows between the electo see which machine offers the best Given the many openings in trode and the nozzle. quality. As you compare cuts, examine expanded metal or gratings, the Next, the electrode pulls away from absence of the metal switches the curthe bottom of the plate for dross.

Also, see if the kerf (the gap left rent to pilot mode. When the metal is the nozzle and a pilot arc is established. encountered again, the current switches The transfer from pilot to cutting arc by cut) angle is 90° or less. The angle occurs when the pilot arc is brought can affect assembly operations or may again for cuttings. This means that the close to the work piece. This transfer result in out-of-spec parts. For examplasma cutter must switch rapidly back 18

Fabricator • Septem ber I Odober 2013

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Ways to make the most of a plasma cutting tool After you have selected the plasma protect your eyes from the cutting arc.

5 Beginners should use a drag

11

cutting machine that is right for you, here are some tricks-of-the-trade that will help beginners make the best possible cut.

l

Set-up procedures

Before you start, check for the fol lowing items: • A clean compressed air supply, without water or oil. Consumables that wear quickly, or black burn marks on the plate, may indicate that the air is contaminated.

• Correct air pressure that can be checked by looking at the gauges on the unit • A nozzle and electrode that are correctly in place.

• A good connection of the work lead to a clean portion of the work.

2 Safety gear Some basic safety practices should be observed.

• Read your instruction manual thoroughly to understand the machine.

• Wear long sleeves and gloves while cutting since molten metal is generated during the cutting process.

• Eye protection such as dark goggles or a welding shield is required to

and forth between pilot and cutting current. If that does not occur, it is best to keep the current set for pilot

7 Check the machine's working visibility As you work on an application, you want to see what you are cutting, especially when tracing a pattern. Visibility is facilitated by the geometry of the torch - a smaller, less bulky torch will enable you to better see where you are cutting, as will an extended nozzle.

8 Look for the portability factor Many fabricators use their plasma cutter for a variety of cutting applications and need to move the machine around a plant, job site, or even from site to site. Having a lightweight, 20

Typically, a darkness shade of #7 to #9 is acceptable.

• Follow all safety tips and guidelines that are detailed in your instruction manual.

3 Piercing the work Many inexperienced users try to pierce the metal by coming straight down, perpendicular (90°) to the work. This results in molten metal being blown back into the torch. A better method is to approach the metal at an angle (60° from horizontal, 30° from vertical) and then rotate the torch to the vertical position. This way, the molten metal is blown away from the torch.

4 Don't touch the nozzle to the work piece Do not touch the nozzle to the work when using current levels of 45 amps or more. Doing so will drastically reduce the nozzle life because the cutting will double arc through the nozzle. Double arcing can also occur if the torch is guided by dragging it against a metal template. The result is the same as dragging the nozzle on the work - prematurely worn nozzles.

portable unit and a means of transportation for that unit - such as a valetstyle undercarriage or shoulder strap - make all the difference. Additionally, if floor space in a work area is limited, a machine with a small footprint is valuable.

Also, you may want a machine that offers storage for the work cable, torch, and consumables. Built-in storage improves portability since these items will not drag on the ground or get lost during machine transport.

9 Determine the ruggedness of the machine For today's hard job site environments, look for a machine that offers durability and has protected controls.

For example, fittings and torch connec-

cup to facilitate the cut Many systems offer an insulated drag cup, which snaps over the nozzle.

This allows the torch to rest on the work piece and be dragged along to facilitate a consistent cut

6 Travel at the right speed When moving at the right cutting speed, the molten metal spray will blow out the bottom of the plate at a i5°-20° angle.

If you move too slowly, you will create slow speed dross, which is an accumulation of molten metal on the bottom edge of the cut When moving too fast, high-speed dross on the top surface is created since you are not allowing time for the arc to completely go through the metal. Traveling too fast or too slow will create a low-quality cut Typically, low speed dross can be distinguished from high-speed dross by ease of removal. For example, low speed dross can be removed by hand whereas high-speed dross typically requires grinding.

7 Set the current to maximum as you begin When setting the current, put it on the maximum output of the machine,

tions that are protected will wear better than those that aren't.

Some machines offer a protective cage around the air filter and other integral parts of the machine. These filters are an important feature since they ensure oil is removed from the compressed air. Oil can cause arcing and reducing cutting performance.

Protection of these filters is important because they ensure oil and water, which reduces cutting performance, is removed from the compressed air.

10 Is the machine easy to operate, is it comfortable?

Look for a plasma cutter that has a big, easy-to-read control panel that is user-friendly. Such a panel allows someone who does not normally use Fabricator •

September I October 2013

then turn it down as needed. More power is usually better, except when doing precision cutting or when you need to keep a small kerf.

8 Minimize pilot arc time Because of the wear it creates on the consumables, minimize the time spent in pilot arc mode. To do this, position the plasma torch by the edge of the work before starting the arc so you can get right to cutting.

9 Maintain a constant work distance Optimally, you should maintain a Y.6-inch to \IS-inch distance from the nozzle to the work. Moving the torch in an up and down fashion will only hinder your efforts.

J0 Travel in the diredion that will give you the best finished work If you are making a circular cut and plan to keep the round piece as your finished work, move in a clockwise direction. If you plan to keep the piece from which the circle was cut, move in a counterclockwise direction.

As you push the torch away from you, the better cut will appear on the metal that is on the right-hand side, since it will tend to have a better, squarer edge.

JJ End with a push angle on thick material One trick to use on thicker material is to rotate the torch slightly, increasing the torch orientation to a push, rather than a drag angle as you cut through the last section of material. This increase in the push angle at the finish will cut through the bottom first and get rid of the bottom corner that is usually left at the end of thick plate.

Never finish a cut by using the torch to hammer away the last corner of the work.

a plasma cutter to use it more easily. A machine with procedural information clearly printed on the unit helps with set-up and troubleshooting.

How does the torch feel in your hand? You want something that has good ergonomics and feels comfortable.

11 Look for safety features

Look for a machine that offers a true nozzle-in-place safety sensor. With such a feature, the plasma cutter will not start an arc unless the nozzle is in place.

Some safety systems can be fooled into thinking the nozzle is in place even when it is not If the output is turned on without correct installation and placement of the nozzle, the operator will be exposed to 300 volts DC, a very unsafe condition.

Look for a machine that provides a pre-flow sequence.

This feature provides a warning before the arc initiates. In addition, look for a machine that provides a three-second, pre-flow safety that gives users a warning to make sure all body parts are clear of the nozzle before the arc initiates. fl@ September I October 2013 â&#x20AC;˘

Fabricator

21

Robinson Iron's 3-axis HAAS router was used to mill the

pattern in house.

Shop Talk

tin r

11

IS

â&#x20AC;˘ While new 3D printing technologies are getting the notice now, multi-axis routing is Sl:ill pervasive partly due to its versatility, material variety, precision, ease of use, and efficiency.

'13y Jejj''Fogel Multi-axis routing has been around for decades.

Never ballyhooed six ways to Sunday like 3D printing, it has nonetheless been doing all the work while its flashy new cousin is out partying with the media.

Today, pattern makers, foundries, and even fabricators use multi-axis milling.

Dave Nugent, Nugent Patterns, Laconia, NH, has been using multi-axis routing since around 2003. Before that, he was shaping his patterns on a used Deckel milling machine.

22

"That's pretty much the way everyone was doing it before the computer:' says Dave, "the models were made by hand in clay, wood, or foam, and then you'd trace it (for a template) for the Deckel machine:' Conceptually, multi-axis routing is the opposite of 3D printing. While 3D printing is referred to as "additive" technology, that is, material is built up to form a shape, multi-axis routing is "subtractive" technology; you begin with material stock, and carve away until you get a desired figure.

The two technologies are similar in their shared dependence on computers. Both are digital.

Fabricator â&#x20AC;˘ September I Odober 2013

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Fabricator

Proud Member

23

The router is guided by Mastercam code to caive the urn pattern based on the client's CAD file design.

The multiaxis router saves weeks of work and is done right in house for better quality control.

But first. a definition of terms.

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A multi-axis router is simply a machine for carving, cutting, or otherwise shaping material. The difference is that the tool paths are not manual; a computer using several types of software in tandem directs them.

Like virtually all fabrication projects, multi-axis routing begins with a design; a three-dimensional design, manifested in a CAD program (Computer Assisted Design) and saved as a sendable file.

But the CAD program is incomprehensible to the routing machine, however, and requires a program that can translate the CAD into instructions written - or coded - in a language that the machine can understand.

These instructions are called "g-codes" and are provided by the CAM (Computer Assisted Manufacture) software.

The happy result of these two software programs, harnessed in tandem, is the satisfying clicks and whirrs of the router's servos as it guides the tooling head along its merry way while you go have a cup of coffee. This may be one of the nicest things about the whole system; it doesn't require your presence.

Fabricator â&#x20AC;˘ September I October 2013

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Fabricator

25

The staircase that graces the Anthropologie store in London, England is a good example of what multi-axis routing can yield. The patte rns for t he cast iron staircase were designed using MasterCam, a nd tooled with a three-axis router.

Other tangible benefits.

don't need to have a two-piece pat-

Versatility. The advantages of multiaxis routing are manifold. For pattern makers, like Allen Morris, Mesquite, TX, there's versatility.

"With my five-axis router:' says Morris, "undercuts are possible. You

tern:' That translates into an advantage for the guy doing the pouring - it simplifies life for him. variety of materials. Not to mention the smorgasbord of both tooling and pattern materials. Bill Davis, co-

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owner of West Patterns, Cranbury, NJ, uses his three-axis router for everything from metal patterns for high production, to urethane, and wood.

Davis uses SolidWorks for design and SurfCam for the tooling language.

Effidency. Tom Zuzik, CEO of Artistic Railings, Garfield, NJ, explains anecdotally. 'Tm doing a 280-foot fence for a client; a solid % x i 1h inch flat (stock) but the pickets are square (stock). To punch and straighten (draw out) them by hand could take a week and a half. So I send it out to a shop with a multi-axis water jet machine:' For Zuzik, the decision is not whether or not to use multi-axis routing but rather whether or not to do it in-house or sub it out.

"It's a fine line:' explains Zuzik, "while it's often cheaper to farm it out, there's not as much control on how soon it can be done:' On the other hand, using the inhouse multi-axis machine ties up time and personnel when they might be working on getting other clients' projects out the door.

For Zuzik, what it boils down to is time. When time is of the essence for a job, then in-house multi-axis machining makes sense. Otherwise, farming it out is more cost efficient.

Even companies heavily invested in the more exotic 3D printing technologies are still relying on multi-axis routing.

Additive Workshop, Wilsonville, OR, which appeared in an earlier article in this magazine (March-April 2013, page 20) on 3D printing, is one such company, although their multiaxis systems are strictly in the rarified air of the upper end of the technology spectrum.

Their set-up is a six-axis robotic arm that articulates a 20-hp tooling head. The system actually has a seventh axis in the form of a rotisserie work table. Made by Robotic Solutions, Milwaukee, WI, it comes with its own proprietary software called Code Breakers to drive the tooling.

Nugent's shop also has 3D printing capability, which he uses mainly for creating prototypes to show clients.

But multi-axis routing is the mainstay of his shop.

Fabricator • Septem ber I Odober 2013

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Fabricator

27

Drives most tooling types

One of five sections (quadrants and base) of the pattern for an urn that will grace the United States Botanic Garden in Washington, DC. Note the pattern's detail, photo on page 2 9, for the inset that will house an LED strip on the finished urn.

Multi-axis routing's pervasiveness is most likely due to its protean ability to take so many forms. The basic software can drive most types of tooling from wood or urethane routers to steel and alloy milling machines.

An example of wood routing for patterns is Robinson Iron's latest project. The Alexander City, AL, shop is creating a 14-foot-diameter urn that will grace the U.S. Botanic Garden in Washington, DC. The um, cast from aluminum, originated as a large pattern carved from laminated poplar. Robinson Iron received a CAD file from its client. They then used the Creaform program to make a few modifications in the design.

MasterCam was then used to translate the CAD file and drive the tooling, a HAAS three-axis milling machine.

Starting with rough bits for fast initial material removal, the tooling uses increasingly finer bits and is accurate enough that little finessing is needed for the pattern to be ready for pouring.

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Fabricator • September I Odober 201l

paint to fill in any microscopic surface imperfections, and the pattern will yield a clean break from the sand.

Of course, not all patterns are sculpted from wood. As Bill Davis of West Patterns points out, wood has a life span and tends to "move" as it ages, making it less accurate. This requires that metal or urethane patterns be shaped for molds requiring more precision and tighter tolerances. Multi-axis routing lends itself extremely well to this type of application.

The software for multi-axis routing has been around for decades. "I was in on it from the beginning:' says Dave Nugent, "I guess I evolved with it But for people starting to get into it now, it might be a little harder:' The complexity of CAD/CAM also expands or contracts to meet the needs of the user. Let's say you're using it mainly for prototyping. "When you're just making one, you don't need all the fine tuning for the tool path:' explains Nugent, "so that keeps it simpler:' But if you're doing a job that entails repetitive fabrication, such as a railing,

â&#x20AC;˘ September

info@artacora iling.com I Odober 2013 â&#x20AC;˘ Fabricator

800.7 43.3803 29

too much for a lot of people. So you should do some research. Do you really need all the features? Pattern and mold making is much more complex than the needs of most machine shops or fabricators."

Nugent also suggests visiting Internet forums for new software users.

Many software companies host these forums and offer a wealth of information for the neophyte.

5 ways to improvement

The cast aluminum urn, above, will be poured in quadrants, then MIG-welded toget her with t he heavier seam on t he inside to reduce finish work.

well, CAD/CAM was born for this. A major advantage is its nearly limitless capacity for fine-tuning the tooling with little effort beyond a few keystrokes. A tweak here, a tweak there, and you can finesse a project to meet the standards of even the most compulsive fabricator or his customer.

Speaking of customers, multi-axis routing driven by good software can keep you from losing money - and your sanity - on a project that a customer would otherwise turn into a nightmare with incessant changes. Just let your fingers do the walking.

Jim Collins of Talladega Foundry, Talladega, AL, uses multi-axis routing for not only patterns but for fabrication as well.

The staircase that graces the Anthropologie store in London (see photo, page 26), is a good example of what multi-axis routing can yield.

The patterns for the cast iron staircase were designed using MasterCam, and tooled with a three-axis router. Collins notes that the three-axis router is quite handy when they need to fabricate parts for the shop that would otherwise be hard to find or expensive.

So what about the software?

These days, the software for multiaxis routing is varied enough to meet most needs but not so varied as to be confusing. The same names keep popping up.

For design, there is MasterCam or SurfCam. Tom Zuzik of Artistic Railings has been using SolidWorks for his design. While Dave Nugent mainly relies on Rino 3D and Rinocam.

Like most software and computer peripherals, the cost for CAD/ CAM programs has been steadily deflated, and most users feel it justifies the cost.

"It was kind of expensive back in 2003, recalls Nugent, "but it paid for itself pretty quickly, within a year or less."

SolidWorks, which is manufactured in Waltham, MA, will set you back around $5,000 for a basic CAD package. It's compatible with BobCad, MasterCAM, and DelCam to translate the g-codes for the tooling.

But as Nugent points out, it pays to shop around.

"Some of the programs can go for around ten grand:' he says, "and that's

Be you foundry or fabricator, multi-axis routing is the quiet workhorse that can improve your bottom line, quality control, and customer relations, five ways.

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J More consistent. It's just the ticket for quality control.

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5 Easy to use. And thanks to the Internet and good customer service from the software manufacturers, it's getting easier all the time. â&#x20AC;˘

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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 di rector for advertising agency Ogilvy & Mather. Jeff now 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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Fabricator â&#x20AC;˘ September I Odober 2013

Iron Touch designed and fabricated this 4 1h -feet-tall fence railing. The design featured hand-forged, ¥s-inch textured scrollwork and :I/a-inch textured vine with veined leaves, hand woven throughout the length through the brick wall and up the side of the house. The materials used were 2-inch O.D. schedule 40 pipe for the framing. %-inch and ¥9-inch round bar, and I I-gauge sheet metal.

Approx. labor time: 360 hours.

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Member Talk

I nkensh1

w1nn1ng to

• Hard work, vision, perseverance, and an inspiring mentor helped Louisville metal shop Iron Touch thrive.

'1Jy Peter 9-{ildebrandt Sometimes a true mentor can make all the difference in the world.

George Bandarra's amazing work combines iron with exotic metals, such as stainless steel, copper, brass, bronze, and aluminum to create seemingly "handforged" metal art, merging both enduring traditions echoing his Portuguese roots as well the avant-garde.

Bandarra has also changed the life of Sherman Blankenship through his skilled mentoring and inspiration - as important in its own way as the many awards he's received and the three sculptures he has registered with the Smithsonian lnstitute's National Museum of American Art and Cultural Property.

Bandarra was teaching at Murray State College 32

What you'll learn • How to start up a metalworking business and be successful in spite of the economy.

• How one NOMMA member made his business in crafting with metal work, through an excellent mentor already in NOMMA. • How going with your own vision, talent, and gut instincts can help you survive in the end.

• How to meet the exact needs and specifications of all your customers without a lot of high-tech equipment.

• Demonstrate how your work is done by inviting clients to watch you work.

• How to advance from "just paying the bills: to higher end work and more enjoyment in your work.

• How a small metal workshop used simple - "not rocket science"- techniques to find work.

a.1m• Sherman Blankenship Iron Touch LLC 3934 Bardstown Road Building B Louisville, KY 40218 www.irontouch.com 502-491 -0084

About the author Peter Hildebrandt is a long-time senior writer for Fabricator. He specializes in writing company profiles.

Fabricator • September I Odober 2013

when Sherman Blankenship ized that's what I wanted to be:' attended to become an artistic Blankenship says.

"George taught me everyphotographer in the mould of thing I know aside from how Ansel Adams. But Blankenship became disenchanted with the to run a business:' explains program because he couldn't Blankenship. "That's been a little bit of trial and error. photograph nature as he'd hoped (though he now can Being a niche industry like this means there's not a whole lot add realistic natural touches to his metalwork). Blankenof people who want to do this - and there is not a whole lot ship met Bandarra at the colof people who want it or who lege after he realized Bandarra have the budget for it; the final would happily help him. product is expensive, this is if During a visit to Bandarra's shop, someone was unable to you want fine, quality, handThe beginning of the fence railing was the greatest challenge pour metal. Sherman was asked with complex roll forming and vine weaving. The ra iling was set forged work:' in post holes with concrete and finished with a three-step primer if he'd pour it instead. He did Bandarra's shop was virtuand was hooked. He wanted to base coat. black topcoat, and a green coating on t he vine work. ally identical to the Quonset hut shop that Blankenbe around hot metal the rest of ship now uses, minus the insulation. his life.

"When I saw this building I thought Blankenship finished his degree it was funny; I trained in one of these in metal sculpture and along with it a structures, and now I'm going to start background in metallurgy that turned into doing ornamental iron. "I had an leasing one:' says Blankenship. "I like it here, my neighbors are great" incredible time studying with George Louisville's Iron Touch LLC, is in and learning over in Europe. He gave me the opportunity to work for him. good company. Nestled among a numWhen I came down to the shop, I realber of other construction-related busi-

September

I Odober 2013 â&#x20AC;˘ Fabricator

33

nesses, the Quonset-style building is not going anywhere anytime soon. Owner Blankenship has been in the structure from the start, finding the location through a friend of his father some 10 years ago.

The structure makes an excellent shop with plenty of floor space and headroom.

years. Four years into the business he received his first NOMMA award 2005 Ernest Wiemann Top Job Award Gold exterior forged railings - for his botanically correct grapevine fence. He also won a bronze Top Job award in 2007 for exterior railings and fences. ''.Any acknowlStaying simple edgement through such awards makes leads to distinctive work me happy; when my colleagues say 'you're Blankenship got a huge, wheeled, doing great work' that's enough for me.

A-frame lift from his From what rm told, uncle. The lift can be moved to the worktarm the youngest busible, which it is able to ness owner affiliated with NOMMA to have straddle. If the object received two awards. is too large for the This 5.5 x 6-foot forged gate with two doors opens to a newly renovated courtyard worktable, sawhorses entrance. The two doors are flat, braided iron, textured scrolls, textured vines, and "My business has handle the rest of the veined leaves. The lock box is forged and hammered compatible to the textured reached the point work. Blankenship has scrolling. The challenge was to blend function and design to suit the aesthetic taste where most of my jobs of the owner, the given topogra phy, and landscaping plan. now are really interbeen doing this work by himself for a long esting and a lot of fun. time now.

I'm not doing the simple stuff, such as straight rails any more, He recently completed a gate for a local Catholic girls work to simply pay the bills. school's athletic field. "Here on Now I have jobs where people are looking for something my table it's gigantic:' explains Blankenship. "But when I that's theirs exclusivelY:' Blankenship's business now got it into the setting it was designed for, this 1300-pound comes mostly from the Intergate fits perfectly and wasn't net or from word of mouth. large at all.

Internet users searching under "ironwork in Louisville, KenThe gate was built in three tucky" see Iron Touch on the pieces with an arch and two big gates on it. Each of the gates first search page of Google.

A number of wealthy famiweighs about 400 pounds.

With a little assistance from Materials consist of 1 x I/a-inch flat bar, ¥11 x 1 'h-inch flat bar, S/a and lies in the city patronize local some people from Wayne's ¥&-inch round bar, 11-gauge sheet metal, and 3-inch-square tubing. artisans and businesses, but Lawn Service next door, Blan- Posts were set in concrete tubes to below the frost line. Custom they generally stay with the techniques included bark-patterned dyes for vine and scroll artisan they are familiar with. kenship could flip the gate to texturing as a natural compliment to further planned structures. work on the other side.

"One of my colleagues here Finish consists of primer base coat, black topcoat, and green in town has been working with Blankenship is filming the painting on vine work and leaves. Labor time: 200 hrs. fabrication process of his curthe same family for some 30 rent project, the one on the feet Since Blankenship's worktable years. Their friends are patrontable before us as he speaks, for a gate is only 5 x 12 feet, sawhorses come in izing me, and rm getting some really cool work; the quality of the work is handy. It will be a challenge to get the for Sacred Heart All Girls Catholic much more detailed now:' School. The gate is 11 feet tall and piece out of his shop.

16 feet wide at its widest point The He considers himself fortunate to On his huge worktable is a gate he's just set that will match a railing in individual sides of the gate are 5 x 7 have kept his company alive the past 34

11

Fabricator •

September I October 2013

Old Louisville that is already in place in Belgravia Court, one of the prominent residential areas in Louisville.

"You have to jump through all sorts of hoops to get your work approved by the local associations and landmarks in the area:' says Blankenship.

He has no problem helping people out, doing what it takes to get him a job; he is patient about it. Most customers know what they want when they get designs from him, and he listens to what they say.

"If they say go with it as is, that's great. If they need changes, I work with them to get those. The fact of the matter is, it's cool to have work in places like that, where your work looks like it should be there:' For example, the original design of the work on the table before us is one-half of this design cut To match the first half of the design, Blankenship moved all the metalwork involved around and then straightened that out The other rail simply went down beside some steps. He tweaked all the aspects of additional metalwork so that the same design would now fit perfectly in a rectangular area. By flipping the entire piece, Blankenship was able to make this design work, including the center part, which will contain a latticework pattern.

In the nearby St. James Court district, the art fair each year is one of the largest in the U.S. Some 750 booths from artists all around the country set up.

Blankenship's railing is right on the court He got it installed just before the art fair started. He takes on new work projects wherever they might arise, mostly in Louisville, but he does send work to other areas of the country.

One project he's been contracted to do will be shipped for the exterior work on a house in the Bahamas.

However, most of his metal work does not end up gracing homes and businesses in such distant locations.

"Designs don't get replicated out here in my shop:' explains Blankenship. "Even when people like a particular design, they do whatever they can to tweak it some so they can make it theirs, their personal design."

September I October 2013 â&#x20AC;˘

Fabricator

The background of a mentor: George Bandarra

and unique fabrications.

He has thirty years of experience in forging iron and has commissioned work at Murray State Unir-- - - - - - - ..-.c versity, Kentucky State Editor's note: The Parks System, and the following is adapted Cairo, Illinois Historic from a statement on website of Mentor Library.

House Gallery: www.

He also has three mentorhousegallery. sculptures registered with the Smithsoncom/pages/ pageo2bandarra. html ian Institute's National Museum of American Art and Cultural The artwork of George Bandarra, Sherman BlanProperty. kenship's mentor, comHe is a member of bines iron with exotic the National Ornamental & Miscellaneous metals such as stainMetals Association. He less steel, copper, brass, has received four awards bronze, and aluminum for his iron works and to create "hand forged" sculptures and decorative sculptures. ornamental metal works.

Bandarra currently Bandarra, of Porturesides in Murray, KY, guese descent, skillfully George Bandarra where he operates his business, The Iron Hamforges enduring traditions of old with art to produce new mer (geoju@wk.net).

Being a one-man operation lends itself to individual care and bringing the customer in so they can be part of the process and see how work is proceeding while in progress - and ultimately appreciate the skill, work, training, and vision involved with finished metalwork project

money. I typically fill my propane tanks about every two weeks after days of daily use.

"It's actually fairly efficient for my small forge. I'm not exactly sure that will be the case when I get the bigger forge I'm planning on setting up in my building.

It will have a much bigger space to heat:' Staying afloat Blankenship buys grinddespite economy ing disks as he needs them A small forge looks like for his jobs. That also helps a primitive microwave oven him control the cost of jobs. He can show what is minus the door. Fueled by This iron sculpture was needed for each job, which propane, this equipment has inspired by natural floral helps him know how to bid worked fine for Blankenship designs found in the on a job. over the years.

Midwest. It is forged completely with a "George Bandarra used propane when I trained with polished finish and clea r No material inventory; coating. It stands 5 feet, buys for the job him. It fires hot and it's not 2 inches tall and 2 feet "That whole process hooked up to your local wide at the widest girth. works out just fine for me. power company, so you As far as starting a business it's always don't have to pay exorbitant amounts been that way; I never buy in bulk. I for this source of energy. As a small business I do whatever I can to save buy my metal for each job as the job 35

goes through without keeping a stock of metal. The stock I do have is material I didn't need from jobs I've done, and I don't have to track the prices of metal and materials either:' Metal prices go up and down on a daily basis, Blankenship says. The metal store that he uses honors the price on his bids for a couple of months. If too much time passes, vendors often will re-run the price. If metal prices have dropped, he gets a better deal.

"I have rapport with them. I don't shop around for things as far as where I get my paints, where I go to get grinding, or where I go to get my metal. I stay with the same people, and that way when I need a deal, it's not a competition between everybody.

"Most places have a minimum order of $200, but I don't need $200 worth of metal; I may need $58 worth of metal.

Most of my suppliers of materials are here locally in Louisville. When I first started in my business, I told them that I won't shop my prices:' he says.

He asked them to help him out with prices from time to time, know-

I guess I - like [George] Bandarra - go more with my gut instincts when it comes

to the materials needed for a project.

Sherman Blankenship

ing it's not going to be something that happens every time and that he's not going to have to chase that money.

This allows Blankenship more time to work. He knows that ifhe needs something he can go get it and not have to worry so much. He also buys materials per job. He gets quotes for materials emailed to him and then builds that right into the cost he charges for a project or bid.

"When I trained with George Bandarra, with every job, we'd go down with the trailer and pick up all the metal that was necessary for the job.

That's how I was trained; that's what I'm used to. Larger companies have someone tracking the price of metal

per pound, and they have a much more precise idea of what it's going to take to do a job. I guess I - like Bandarra - go more with my gut instincts when it comes to the materials needed for a project:' Blankenship says.

The challenge now is managing the volume of work "I've made it through some pretty hard times:' he continues. "I've been fortunate enough to do that. But things are turning around with the economy, cash is loosening up, and my jobs are getting bigger and more involved. My biggest challenge right now is the volume of work I have. Staying booked is a challenge for a young business like mine. I'll be real busy for nine months, do just a few things for a month or so and then be busy again. It's up and down and all around:' When he started, Blankenship would be busy for a month and then there would be nothing. He reached a point where he'd get two big projects that would pay for his year. Now he's getting four to five big projects

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annually. "It's growing and it's getting better, and the more people that are satisfied with me the better off I am. I have an A-plus rating with the Better Business Bureau:' Blankenship's customers don't complain because he is personable and he tells the truth.

"If I can't meet a deadline, I let them know immediately. You have to be honest in how you treat the customers, and I have excellent rapport with them. When other customers

ask for references, I say 'call any of my former customers'. You're not going to please everybody; but I've done real well at pleasing most everybody.

They know they're going to be getting something that's going to be awesome:' he says.

Blankenship gets customers involved in the process "When I leave them, what I hear out of their mouth is 'it's perfect: 'I love it: I get that ego boost. That's why

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I stay in it:' he adds.

"A lot of people can't see in their minds what they want. I scale things out on quarter-inch graph paper so I can draw it out and transfer it right to my table. It works better in my head that way. I trace it onto white paper and that's how I do it No one else can replicate it My bark texturing is a secret No one has any idea how I do this:' People have difficulty imagining how everything comes together; measuring is done with a tape measure directly on his drawings.

Getting a project to meet a customer's budget can be difficult Generally, Blankenship meets their demands to stay within budget He guides them on how much certain types of work costs per foot He leaves them with samples of the work, the metal, and when he shows up with the finished product they tend to be astounded.

"They feel like they are part of the design process:' he says. "They have something tangible while I'm working on the project, and they are welcome to watch me while I'm working.

"People need to see why things are costing as much as they are; this helps them to do that. When they see what goes into it, a light bulb goes off in their heads.

'Tve had some customers who had trouble visualizing at first - wondering if I'd ever be able to pull it off but then when they saw the finished product they were thrilled.

"I was trained the right way.

George Bandarra did a phenomenal job. I thoroughly love doing this. I owe everything to him.

"He knows so much about this industry, knows metals inside and out, is a wealth of knowledge on those, and can tell you what metals do what and why.

"This made me come around to this way of thinking. It was like taking an extra course:' ~

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201J Top Job Award: Furniture & Accessory Fabrication - Nonforged

• Steel Welding's Top Job of a fireplace door is an example of understanding history and bringing back old skills.

'By Chris :Holt

Pittsburgh has long been a hub of metal activity, thus it is no surprise that Steel Welding, Freedom, PA, located north of Pittsburgh and primarily a company that does residential work, explored the chance to fabricate a distinctive outdoor fireplace door that would depict styles used by old steel mills and reflect the city's past Pittsburgh, with its close location to railroads and river transportation and the local availability of coal for making coke, limestone, and iron ore, made this city perfect for manufacturing steel - a smoky city whose banks of the Monongahela, Allegheny, and Ohio rivers were lined with mills and factories.

The fireplace door (closed above; open at left) was designed to resemble a Pittsburgh blast furnace. Eatn' Park Hospitality Group's new restaurant, "The Porch" recognized the city's past with a unique design.

%r your information ~ What you'll learn • Study a job's associated history to inform your work. Fully understand the job's background. An example was the research Steel Welding did for the skip hoist on a blast furnace that included "authentic looking" details.

• Take a risk. learn a new technique or revisit a skill to use in a new way, such as the way riveting was in this job. This step develops a broader base of fabricating experience and abilities for future work.

• Give client reasons to like you by instilling confidence in their decision. Keep in touch with your client, send photos via email of progress, provide samples for approval.

• Stay on schedule and work with other contractors without a fuss. Be the easiest contractor to work with on the job.

• Offer new clients a special gift. Steel Welding made steel cookies based on one of its client's products.

40

Steel Welding John Steel, owner 2063 Lovi Rd., Freedom, PA 15042 www.steelwelding.net; steeljw@comcast.net; 724-774-6757 About the author Chris Hoh won the 2012 ABANA Joe Humble Award for the Pittsburgh Area Artist Blacksmiths Association newsletter and has written articles for Anvil's Ring, Hammer's Blow. The Ironworker, Schoo/Arts Magazine, and O&MM Fabricator. She is also designer and blacksmith for Steel Welding.

Holt is a Master Gardener with Phipps Conservatory and Botanical Gardens and has a Florist Arranging certificate, which is beneficial in her company's ironwork designs.

Fabricator • September I Odober 2013

The decorative food service door for walk up customers that carried through with the design of the furnace door. The location of the restaurant is near the hub of the University of Pittsburgh.

September I Odober 2013 â&#x20AC;˘

Fabricator

"Miss Sunbeam," the wood furnace probably built in the 1930s inspired the riveting design. The client was attracted also to the burnt patina and functional look.

41

The architect wanted the fireplace to imitate the look of a skip hoist on a blast furnace. They wanted it to look like it was actually removed from a steel mill and "up cycled" - made from recycled materials but with a

much higher quality than the original product or material - into the use of a fireplace door.

By i911, half of the nation's steel was produced here.

The making of steel was the making of the city. Thus, Steel Welding was excited when a new restaurant that reflected the city's history of steel making was set to open in the winter of 2011.

The client, Eat'n Park Hospitality Group, Homestead, PA, was opening an upscale bistro near the University of Pittsburgh. This premier location would be visited by a diverse population.

In business for 60 years, Eat'n Park Restaurants are located in Pennsylvania, Ohio, and West Virginia. It has more than 75 restaurants and 8,ooo employees.

The name is familiar to all residents in the area and its

Steel Welding's John Steel and Chris Holt working on detail element in shop.

When working at the forge, John Steel and Chris Holt rotate jobs. When one is using the hammer, the other is tending the coal fire. One of Steel Welding's power hammers is a Kreiger Berger self-contained, 88kg air hammer. It has a quick stroke and is very controllable, Holt says.

42

Fabricator â&#x20AC;˘

September I October 2013

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A rivet gun, top, is estimated to be from the 1940s. The snap, wired on for safety, is the recessed end that forms the head of the rivet.

A close up view of the rivets on the furnace, left, was the inspiration for the fireplace design.

44

Fabricator â&#x20AC;˘

September I October 2013

service to the community helping children, serving food grown by local farms, and being environmentally conscience before it was fashionable.

Right, is a close-up

view of the jaws on throwing tongs, and close-up of pick-up tongs.

These were used when rivets were the means of connecting structural steel.

The opening dance At our fabrication shop, Eat'n Park's in-house architect Andy Dunmire, as well as one of the company's owners, Mark Broadhurst, explained their concept to us: an outdoor fireplace with a guillotine-style door, and its requirements.

The architect wanted the fireplace to imitate the look of a skip hoist on a blast furnace.

They also wanted it to look like it was actually removed from a steel mill and "upcycled" - made from recycled materials but with a much higher quality than the original product or material - into the use of a fireplace door. We were familiar with blast furnaces .

We examined the design of a guillotine and a sluice gate used for irrigation, although neither was dependent on counterweights.

Below, the reins of

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gate used in irrigation and with these two concepts the design of the fireplace door came together.

In this case, "form really did follow function:' The door needed to open easily for the restaurant staff and to have safety elements around the moving parts. We needed rivets to satisfy the "look" the clients wanted.

During our planning meetings, we brought samples of rivets, patinas, and material. This was helpful for us as well as the client so that we could gauge the direction the client wanted us to follow.

During fabrication, we also emailed photos to show our progress and design.

other parts of job were riveting Above, this fireplace door photo was emailed to the client for review. Steel Welding finds it helpful to keep clients informed of progress and prefer them to visit the shop, even though scheduling is not always rea listic.

At right, the door is tested to ensure it works properly.

They toured our office and shop and pointed out the "look" they wanted was similar to the coal/wood furnace we have in our shop, a Sunbeam coal furnace probably built in the 1930s.

What attracted the client were the rivets, burnt patina, and functional look.

We found it interesting that an everyday, uncelebrated item like this old coal furnace was now a "celebrity example" in the shop. Who would think that "Miss Sunbeam" would soon be the center of attention and guide us toward winning NOMMA'.s Top Job Gold award in our division? We were given complete artistic license to design the 46

project with these parameters.

Their vision and our background made this project a good match. The industrial look was a perfect connection for John Steel, Steel Welding's owner. His background as an ironworker, Local #3, and my experience watching my dad work at American Bridge Company as a machinist, allowed us to perfectly identify with the history of hard working steel workers and fabricate this project accordingly with the traits or characteristics representative of a time long ago.

We studied the photo of the guillotine. John related a design of a sluice

The fireplace door was just one of the projects we made for the bistro. We also made a service door for walk-up customers similar to the fireplace door (see photo on left, page 41), bike racks with a rivet design (see photo at top, page 50), a small stairway railing that also included a rivet feature (see photo, page 51), and a downspout with a custom finish.

One of the rivet guns we have in the shop was from American Bridge Co. John estimates its age around 70 years old (see top photo, page 44). He had purchased it from American Bridge Co. when the company's fabricating plant was closing and had a plant auction.

In days when riveting was the connection of choice, five iron workers in a riveting gang on structural steel work were required, plus a punk (apprentice).

The gang consisted of the pusher (foreman) who directed the crew and a heater who made sure that a rivet of proper length was heated to the proper temperature.

The heater also threw the heated rivet to a catcher who would insert the rivet in the proper hole. The heater needed to be very accurate in his throw. His throwing tongs had Fabricator â&#x20AC;˘ September I Odober 201l

Top, counterweight with wheels. Well wheels are used on a construction site for hoisting material by hand with a rope.

Above, close-up of wheel with safety guards.

September I Odober 2013 â&#x20AC;˘

Fabricator

47

The distinctive outdoor fireplace door, located in the outdoor seating area seen from walkway, that depicts styles used by old steel mills and reflect the city of Pittsburgh's past.

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Fabricator •

September I October 2013

one straight jaw on the bottom and a hooked jaw on the top with long reins.

The catcher would use short pick-up tongs to retrieve the rivet from the funnel shaped catch can and put in place (see photos, page 45).

Before each rivet was installed, every hole had to have a barrel pin driven through the hole to make it dear for the rivet so it would not hang up in the opening.

The bucker-up would buck up (back up) on the rivet head so it would not back out of the hole when it was riveted by the riveter (also known as a driver). Historically, the heater heated rivets throughout the job while the other members of the gang rotated throughout the day performing as a bucker-up, catcher, and driver.

The strength of a rivet is dependent upon completely upsetting - compressing the metal to be larger than its original size - inside the hole to make it solid iron. There could be no play or space between the structural steel.

The shrinking of the length of the rivet would compress the iron.

A good riveting crew working on a large connection could complete an area from start to finish installing about 50 rivets in one hour.

But our staff was not standing delicately on a float on a river building a bridge; we hand-carried the rivet to the project Steel Welding took all the safety precautions, staying out of the weather on our shop floor with no fear of falling from extended heights, unlike workers on more demanding high-rise structural jobs.

This being an "open shop" contractor job, we were hired directly by the owner for the custom artwork. We worked with the general contractor in an amiable manner. The site-specific items - fireplace screen, walk-up service door, bike racks, small railing, and downspout - that we created could not be easily fabricated without an artistic handle on the concept the architect envisioned.

both sides and have no sharp edges.

They are still made today for making buggy wheels used by the Amish, for example.

The frame gave the door the impression of being a boiler plate. This project had to be designed with a two-step installation because the concealed anchoring system had to be installed on the block chimney before the decorative stone fascia could be completed.

First, we had to create a back-up plate anchored into the cement block chimney. This plate also had axles

attached to receive the pulley wheels for the counter weight chains.

The door weighed 80 pounds and measured 4-feet, i-inch x 34-inches. It was lifted by two, 40-pound skip hoist rail counter weights. Steel Welding actually had on hand authentic skip hoist rail in its inventory.

The second step was installing the door after the masonry was complete.

It included safety guards to prevent hand entrapment when raising and closing the door, to keep hands a safe distance from the pulleys.

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September I October 2013 â&#x20AC;˘

Fabricator

49

The bike racks at the restaurant. above, are a simple design with rivet accents as all the projects of this job had. Below, is a close-up view of rivet on handrail.

50

Fabricator â&#x20AC;˘

September I October 2013

A safety lock and pin was also installed to keep the door in an upright or down position. The door can be easily opened and shut with one hand.

Finishing up The requested finish, applied before installation, was to resemble a blast furnace with a burnt appearance. We used high-temperature paint for the interior of the door.

The outside of the door had a variety of oil-based paint colors. John left the shop when I started spraying loud fluorescent orange, red, and yellow on the beautifully fabricated door.

The technique I used was to layer the colors to create the patina. My first attempt was visually disturbing, but as the colors built, the burnt furnace "look" appeared as planned.

We first applied Sumter Coatings oil-based primer, then started with the loudest, most riotous, fluorescent colors I could get my hands on. All colors were considered. Then a toning-down layering process ensued to develop a burnt, aged patina.

Blacksmith Chris Winterstein once said at a conference we attended, "You gotta work through the ugly parts!"

This door is located on an outside fireplace in an elevated eating area with a sidewalk nearby. We stayed on schedule, in fact we were commended for our reliability and clairvoyance of our installation times!

We were very pleased to be a part of this new bistro type restaurant. The owner and management were clear in their vision and direction they wished this 86-hour project to reflect By the way, to show our interest in fireplace project at our first meeting, we made the restaurant's signature cookie, called the "Smiley Cookie:' out of steel circle punchouts with weld icing. We presented them on a tray.

Needless to say, we did get the job, and I must say between "Miss Sunbeam:' the old coal furnace, and our baking skills in the welding shop, it was a recipe for a golden success story. fl@

Handrail with rivet detail. In addition to designing the fireplace door and service food door, a small railing was requested. The rivets at the base tied in with the overall design.

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WHAT'S HAPPENING IN VEGAS! Fence Industry Week: March 4 - 8, 2014

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Health care ad prescription not all under way yet â&#x20AC;˘ Some provisions of the health care ad have already kicked in. Others will in 2014 and 2015. Still more in 2018.

Here's what is mean s for you now.

Editor~ note: The Affordable Care Aa is more than 2,000 pages long.

Subsequently, this law generated 46,000 pages ofregulations by executive branch agencies. 111e purpose of this article is to alert readers to some of the complexities related to the aa and to offer a few suggestions. The reader should consult with their legal, tax, and financial advisors about tlreir specific situation.

'By !Mark E. 'Battersby Lawmakers are attempting to repeal it businesses are suing to prevent its implementation, and local governments and unions continue their efforts to be exempted from the massive, and controversial, "Patient Protection and Affordable Care Act" (ACA), the health care "reforms" enacted in 2010.

Only now, as those new "reform" laws begin to fully come into play, are many owners and managers in the metalworking industry learning about its potentially expensive complexities even in light of the recently postponed penalties for employers that don't provide insurance (or provide insurance deemed inadequate or unaffordable).

Some employers may see their pocketbooks lightened as the law's provisions kick-in, but few appear to be taking advantage of tax credits and other sweeteners for employers created as part of the ACA and already in effect.

The small business health tax credit The Internal Revenue Service is encouraging small businesses to explore and, if qualified, claim a unique health insurance coverage tax credit. The credit was created for eligible small businesses* that *The definiti on of a small business under the Affordable Care Act is complex because it is defin ed not only by number of employees, but also by dollar volume and other factors, all of which varies among different agencies and among provisions of this law. Best to see your financial advisor to examine your specific situation.

September/ Odober 201 l â&#x20AC;˘ Fabricator

53

either maintain their current health insurance coverage or begin offering health insurance coverage to their employees.

Small employers (no more than 25 employees and average wages below $50,ooo annually) are eligible for this federal tax credit, a direct reduction of the your operation's tax bill, for up to 35 percent of the amount spent on health insurance for their employees.

However, the full amount of the credit is available only to an employer with 10 or fewer full -time equivalent employees (FTEs) and whose employees have average annual full-time equivalent wages from the employer ofless than $25,000. These wage limits will be indexed to the Consumer Price Index for years beginning in 2014.

Self-employed fabricators, including partners and sole proprietors, 2% shareholders in S corporations, and 5% owners are not treated as employees for purposes of the Small Employer Health Insurance Credit In fact, a special rule prevents sole proprietors - and their family members - from receiving the credit

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Certain employers subject to the Fair Labor Standards Act (FLSA)

must provide a written notice to employees beginning in October on health insurance coverage options.

The notice Beginning on January 1, 2014, individuals and employees of small businesses can access new competitive private health insurance markets called the "Health Insurance Marketplace:' Initially, states were required to create "exchanges" where state citizens could shop and purchase health insurance. When many states failed to set them up, the federal government

created "marketplaces" that would be only for those states that turned down having a state-run exchange.

The Marketplace will offer "onestop shopping" to find and compare private health insurance options. Open enrollment for health insurance coverage through the Marketplace begins on October 1 as does enrollment for state exchanges.

Certain employers subject to the Fair Labor Standards Act (FLSA) must provide a written notice to employees beginning in October on health insurance coverage options. That means employers with one or more employees who are engaged in, or produce goods for, interstate commerce. For many, a test of not less than $500,ooo in annual dollar volume of business will also apply.

The notice must be provided to each employee, regardless of plan enrollment status, or of part-time or full time status. What's more, the notice must be provided in writing in a manner calculated to be understood by the average employee.

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Before the passage of the ACA, no federal rule or law required that employers offer health insurance coverage to employees or to their families.

Today, new "Pay or Play" provisions in the ACA require employers with 50 or more full-time equivalent employees to offer qualified medical benefit plans to employees who work an average of 30 hours per week. But those rules will not be enforced until 2015.

The Federal government estimates that it will pick up $130 billion in Obamacare penalties over the next decade from businesses that either don't provide employees health insurance or what the government considers to be "inadequate" health insurance.

Fortunately, with the postponed "Employer Mandate:' you will have more time to plan. That planning should consider these four strategies to reduce this upcoming burden: 1 the mandate does not apply to

operations with fewer than 50 workers, 2 the mandate doesn't apply to Fabricator • September I Odober 201l

employees who work fewer than 30 hours, l the employer doesn't have to offer or subsidize family coverage; and 4 rather than provide health insurance, an employer can pay a $2,ooo per (full-time) worker fine.

However, be cautious when deciding whether a worker is full-time or part-time on January 1, 2015 when the provision kicks in; the government will look at the average weekly hours worked in the previous year.

Plus, the IRS has already signaled that, in addition to full-time employees, it will count "full-time equivalents:' when calculating the number of workers. This is determined by dividing the total number of hours worked by employees who are not full-time for the month used for the computation by uo (30-hour-minimum work week times four weeks in each month, on average).

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When access to the marketplaces begins January 1, 2014, tax credits will start flowing to millions of people, helping them pay the premiums.

start flowing to millions of people, helping them pay the premiums.

Under the original ACA, businesses in those non-participating states should have been free of the employer mandate. However, last spring, without authorization from Congress, the IRS expanded those subsidies to cover states that refused to set up exchanges.

Not too surprisingly, lawsuits are pending that argue that the IRS has no legal authority to rewrite an "essential part of the law:'

'Free choice' vouchers and accessible for small businesses and the self-employed, is supposed to be operative by then.

While 33 states have opted out of creating "Health Insurance Marketplaces:' open enrollment for health insurance coverage through existing exchanges begins October 1, 2013 for individuals and employees of small businesses.

When access to the marketplaces begins January 1, 2014, tax credits will

After 2013, employers offering minimum essential coverage through an eligible employer-sponsored plan and paying a portion of that coverage will have to provide qualified employees that choose not to participate with a voucher that can be applied to the purchase of a health plan through an Insurance Exchange.

The value of the voucher would be equal to the dollar value of the employer contribution to the employer

Skinny insurance coverage A number of employers are avoiding the ACA by offering so-called "skinny" insurance plans that provide employees with minimum coverage.

Minimum coverage, such as preventive care but little else, qualifies as acceptable under the new law thus making an easy sell for insurance brokers.

Employers can avoid a $2,ooo-perworker penalty by providing such policies, even though the plans often don't cover basics, such as surgery, x-rays, or prenatal care, let along hospitalization.

For some businesses, low-benefit plans (e.g. "mini-meds:' among a lot of other plans.) costing as little as $40 to $100 per employee per month are an attractive alternative even though they could still face penalties, albeit less than the $2,ooo per worker for opting out of Obamacare.

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I Odober 2013 â&#x20AC;˘ Fabricator

Metal Fabrication Services A Divi.,ion of fberl Iron Work'!., Inc.

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includes interest, dividends, royalties, rents, gross income from a trade or business involving passive activities, and net gain from disposition of property (other than property held in a trade or business).

Income "actively" earned by anyone running a small, closely-held business is exempt from the unearned income surtax. Be aware that income from the reserve accounts of pass-through business entities, such as S corporations, is considered "investment" income.

) ~_/ !J.J./

j~~~J / Income â&#x20AC;˘actively' earned by anyone running a small, closely-held business is

exempt from the unearned income surtax.

offered health plan.

Those who continue to go without coverage will have to pay a penalty to the IRS, except in cases of financial hardship. Fines will vary by income and family size. For example, a single person making $45,000 would pay an extra $1,125 in taxes when the penalty is fully phased in, in 2016.

Additional tax on high-wage earners To help pay for making health insurance affordable for small businesses and the middle class, the law included an increase in taxes for high earners.

Specifically, the hospital insurance or "HI" tax rate has been increased by 0.9% on individuals earning more than $200,000 ($250,000 for married couples filing jointly).

The unearned income surtax Beginning in 2013, a 3.8% surtax called an "Unearned Income Medicare Contribution" was placed on the net investment income of anyone earning more than $200,000 ($250,000 for a joint return). Net investment income

Summary Whether because of politics or economic realities, the Obama Administration has postponed the date it will begin enforcing the requirement that employers of more than 50 workers provide health insurance from 2014 until 2015. An earlier announcement revealed that small businesses will not be able to access the health insurance "Marketplaces" until 2015, thus limiting the affordable options available.

The so-called "Individual Mandate:' requiring all individuals to have health insurance remains.

The implementation of many of the provisions of the Affordable Care Act the requirement for employee notices be sent in October 2013, the tax credits available to small employers for healthcare related expenses that started in 2010, along with the increase in Medicare payroll taxes that began in 2013 are already a reality.

The tax on high-cost "Cadillac" policies favored by the unions and many corporate executives will not, however, go into effect until 2018. Are you ready? â&#x20AC;˘

<For your information ~

About the Author

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For more than 25 years, Mark E. Battersby has written editorial features, columns, white papers, and reports for magazines, journals, newsletters, and websites about news and developments in the tax and financial arenas that impact small businesses. He can be reached at MEBatt12@ Earth link.net.

Fabricator â&#x20AC;˘

September I October 2013

Videos on YouTube

Blog

Photos on Pinterest

Website articles

Linkedln, Facebook company pages

Biz Talk

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Content marketing abuzz â&#x20AC;˘ You've heard it mentioned a lot, right? Well, it's more than PR and advertising. This article shows you what it is, and 6 steps to get your message to your consumer and business clients effedively.

Editor~ note: This is the ftr3'l in a series of articles about content marketing 3'frategies, e.)]Jecially on digital platforms.

"By Christine 1>unn Content marketing. Social media. Digital media Inbound vs.

outbound. Message vs. story. Push vs. pull.

What does it all mean?

Marketing used to feel relatively straightforward when it was print and broadcast only. In the toolbox were a few options: Ads in a newspaper, or if you felt like splurging, maybe on the radio or TV. Public relations might have been a possibility, if you felt a local newspaper or a national business-to-business (B2B) trade magazine could reach a key audience. And perhaps you sent a postcard in the mail September I October 2013 â&#x20AC;˘

Fabricator

if you obtained a good list of potential customers.

These days the buzz words, and techniques, are changing at a pace that is trying to keep up with the rapid advancements in technology. Moreover, the advent of mobile from smartphones to tablets - makes demand for the latest types of marketing grow stronger.

It's easy to feel overwhelmed, and might seem hard to set priorities. So let's break this down into bite-size chunks (a good way to present your information to your customers, by the way) to make structuring an online strategic marketing program for your business a little bit easier.

Content marketing is today's online toolbox In the same way that newspaper ads, press releases, and direct mail are tools of a traditional print marketing plan, 57

social media, blogs, e-newsletters, videos, and podcasts are tools for your digital content marketing strategy online.

Like any project in your own metal shop, you need to choose the tools that best fit your needs.

The following step-by-step process will help you organize the information you have available now (and what you might want to develop) to create a cohesive strategy that integrates your different types of content with the numerous digital platforms.

1 Find out oil about your clients Begin by asking yourself questions: • Who are you trying to reach?

(Who are your business clients and who are your consumer customers?)

• What do you want each of them to know about you? (What's your story?

How can you be useful to your clients?)

• Where do they reside online?

(What are their favorite online applications? What blogs do they read? What Linkedin discussion groups do they participate in?)

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• What do they read/watch? (What websites, blogs, group discussions do contractors, architects, homeowners read? Where are they on Linkedin, Facebook, Instagram, or Pinterest?)

• What triggers a response? (Do they like pictures? Do they comment on print, digital magazine, or newspaper stories?)

• What useful information do they both need to know and want to know?

• Can you show your clients a return on their investment? How? • How can you provide your own return on investment?

These questions will help you identify the variety of applications at your disposal, many without cost to you, and the types of content you'll need.

Caution: Don't try all of the tools at once. A mistake by new content marketers is using many programs at once.

Choose one or two to start, test them, and master them. If you're spread too thin, it's hard to sustain a program, especially while you are still learning.

The first attribute in a successful content marketing program, then, is learning the art of patience.

The second is remembering that it's not about creating a lot of volume. It's about being consistent, credible, and open, transparent, and honest

2 Build o relationship When people talk about content marketing, much discussion centers on the term, "consumer engagement:' whether in business-to-business or business-to-consumer markets.

In successful content marketing, the current wisdom says, companies or "brands" are pulling clients in with the information they provide and communicating with them about it in real-time (or close to it) instead of pushing out a series of"messages:' like an ad tagline or pure promotional offer. This is the difference between so-called inbound marketing and outbound marketing, and what makes online interactions unique in today's mobile world.

Inbound marketing is advertising a company through marketing tools such as blogs, podcasts, video, eBooks, e-newsletters, whitepapers and social media. It is marketing that aims to earn the attention of customers, make the Fabricator •

September I October 2013

company easy to be found on the Web, and draws customers to your website by producing useful, actionable content Outbound marketing pushes out a message to consumers through such programs as sales flyers, direct mail, radio/print/TV advertisements, and other traditional advertising programs.

It's easy to get hung up on the technical terms, so let's put aside the jargon and instead start with one simple goal: Focus on building relationships.

Businesses are built on relationships.

If you're kicking off a traditional one with a prospect or new customer, most likely you have a series of steps that you take to get to know them, understand them a little deeper, share information about yourself, and earn their trust Tip: Think about what you ask your customer For example, when a new customer comes through your doors, what's the first thing you do? Probably ask them some questions about: • How they heard about you.

• What they're interested in.

• Do they have a specific project in mind?

• What their tastes are.

• Do they have a budget?

Tip: Consider what customers ask you.

Consider the following: • Information about the variety of products and styles you offer?

• What types of materials are used?

• What process is used to create your products?

• How do you differentiate offerings from the competition?

• Where do you make your products?

• How much of your products are hand-made?

• What is the process for identifying a concept or design?

• How long will it take to complete?

• What will it cost?

Now think about how you share your answers: A portfolio of photographs might help illustrate your work, or perhaps you have samples that allow you to point out different characteristics of your craftsmanship.

Similarly, your content marketing strategy should work toward the same September I October 2013 •

Fabricator

steps. The questions, and the way in which you answer them, provide building blocks to start building relationships with your customers online.

• • • •

J What types of information do you already hove ovoiloble and what do you need to create?

• Company mission.

• Way your company likes to work.

• Company ethics.

• Company history.

• Product and service list and explanations divided up into logical categories for easy, quick searches.

• Frequently asked questions.

• • • • • • • •

-

KEL -

• •

Short updates and announcements.

White papers.

Problem-solution case studies.

Instructional, how-to, step-by-step articles showing your expertise.

Client list and testimonials.

Photo gallery of finished work.

Photos of work in process.

Bios of major staffers.

Awards.

News published about you.

What certifications you have.

What conferences you have spoken at, exhibited at.

Links to useful articles.

Link to NOMMA.

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4 Create on editorial calendar

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Now you can start developing a content marketing plan.

On a sheet of paper, create three columns. In the first column, outline the frequently asked questions that you pose to your clients, and that they pose to you.

In the second, write possible answers to these questions.

In the last column, show the supporting information you'll use to illustrate responses: photos, sample products, or useful reference materials from publications such as 'Fabricator.

The information in these columns are the basis for an editorial calendar, a scheduling tool. The beauty of this exercise is that you are starting with information that you know, and know well, and with evidence and materials to support it Remember, one of the founding principles of a good content marketing program is to be credible. This means offering useful information that your client values. Always answer the question: What's in it for your client? Supporting your content with facts and examples helps you earn your client's trust.

When you're starting out, keep it simple: Use a calendar or a spreadsheet to block out the topic, supporting material, and date on which you plan to publish (see sidebar, page 62).

Create a schedule that you can sustain. Starting slow with a once-a-week commitment with quality content is better than trying to be too ambitious, too quickly. This will help you accomplish one of the other founding principles of good content marketing: consistency.

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5 Examine the different digital marketing channels:

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• Social media.

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• 257 .

• 250 .

• 249 .

• 251

456 457 455 449

• 355 . 356 • 357

. 349

Hole

Width

318' 1/2' 518'

1 1/4' 1 1/4' 1 318' 518' 1 318' 314' 2 112' 1' 2 112' 11/4' 2112"

1 518'

'Malleable ltoo

ANGLED ROUND HOLE BASE I Satin Finish Hole a b Width . 461 Nickle-Silver 518' 23/16' 1 118' 1 3/8' . 359 Mal. Iron 318' 1 7/8' 1' 11/4' . 360 Mal. Iron 112· 1 7/8' 1' 11/4' . 361 Mal. Iron 518' 2 3/16' 1 118' 13/8' 112· 17/8' 1' 11/4' • 260 Bronze 518' 2 3/16' 1 1/8' 13/8' • 261 Bronze

Julius Blum&Co.lnc.

Stock Components For Architectural Metal Work

For a complete product listing and tedmical specifications, request a FREE catalog. Simply call of visit our website:

60

Fabricator • September I October 2013

Organizational goals for 828 content marketing

...s_ra_n _d_A _w _a_r_ en_e_ss_____

1~

ro

Percentage of B2B marketers who use various social media sites to distribute content

Customer A~uisition Lead Generation

% lo

Lead Mana~ment/Nurturing

%

Sales Total marketing budget spent on 828 content marketing

Micro (Fewer Than 10 Employees)

,_ _ _ _ _ _ _ _ _ 34%

42%

Small (10-99 Employees) Midsize (100-999 Emp oyees) 22%

·- ------- 23% • 2012 • 2011

Overall

• 2012 • 2011

The data above and on page 60 are from "B2B Content Marketing: 2013 Benchmarks, Budgets, and Trends-North America" produced by the Content Marketing Institute and MarketingProfs and sponsored by Brightcove. The survey was mailed electronically to a sample of business-to-business marketers from among members and subscribers of MarketingProfs and Content Marketing Institute. 1,416 responded from companies in August 2012, representing a full range of industries, functional areas, and company sizes. For more information: http://www.marketingprofs.com/charts/2012/9184/2013-b2b-content-marketing-benchmarks-budgets-and-trends

their products and services through photo albums and status updates, and connect with people on their personal pages. This is good for the general consumer, a homeowner, for example.

• 'Linked'ln: Designed mainly for professional networking, companies can create a page that offers a description and a few visuals of their business.

Fabricators can also join numerous discussion groups that directly relate to your clients, e.g. contractor and architect groups.

• 'lnstagram: A program that allows you to take a picture and share it easily through different social media applications • Pinterest: A scrapbook/pinboard online that can build up your brand, especially with photos/portfolios. Becoming more business oriented.

• '){ouzz: A website and online community about architecture, interior September I October 2013 •

Fabricator

design, landscaping, and decorating • e-Newsletters. Usually sent to an email list, can be created via a service, such as Constant Contact or Mail Chimp for a small fee.

• Podcasts. Audio recordings that can be posted online.

• Biogs. Short articles or posts that demonstrate thought leadership.

• Webinars. Online seminars.

• Problem -solution case studies.

These can be stand-alone or integrated in a blog.

• How-to, step-by-step articles.

These can be stand-alone, or integrated in a blog.

• Videos. You Tube, for example.

Build your own channel.)

6 Start with o tool you know Now that you have the editorial calendar in place, it's time to determine which tool in the toolbox to employ.

Whatever tool you choose, the goal is to play to your strengths.

To decide, look again at your editorial calendar and examine the types of content you have available: • Is it mainly visual or written?

• Do you enjoy snapping pictures with your camera?

• Do you spend more of your time pulling out articles you've written in magazines?

• Do you comment on the biogs or discussions of architects or contractors?

Add a column to your editorial calendar and assign a digital outlet to each type of content Which channel comes up the most often? Facebook?

The website?

Focus on the one that comes up most. Begin by creating a schedule for your regular updates of new information on that channel.

61

Month

anuary

Title/Description Status How to pick a fence

How to pick a fabricator

Swimming pool access

Date

Date

In Wed, Wed, Progress Dec 19 Jan 2

Assigned

On Hold

Wed, Wed, Dec 26 Jan 9

Content Designer

Editor

Audience

Blog Post Bob S.

Jenny L.

Considering Bio customers g

Channels

Blog Post Stephen P. Jenny L. Contractors Website

Mon, Mon, Video Dec3 Jan 14

Mike D.

Watson Customers You Tube T. with kids channel

Promotion Tags

Metrics

Social media

TBD

links; Social Sharing

Social media

Keywords: architect contractor homeowner links; Social Sharing Description : How to pick a fabricator

Paid ad TBD promotion

Notes

Video production Channel on hold Subscriptions until revised graphics are

approved Staircase types

Pending

Wed, Jan 2

Wed, Blog Post TBD Jan 16

Jenny L. Architects

Editorial calendar template With your goals and timely considerations laid out in a spreadsheet, you can plan the production of content.

By identifying all the moving parts in production, publication, and measurement, your content marketing will be easier.

Here are the terms used in the template and their meaning: • Title/ Description. The handle for the content piece, like a blog post title or video concept description.

• Status. Where the content project stands - e.g. in production, on hold, published.

• Due Date. When the project is due from the producer/ designer.

• Publish Date. When the content piece goes live.

• Type of Content. The format for the content - e.g.

Social E V b . ma1 we site media

TBD

links; Social Sharing

onsite article, blog post, infographic, whitepaper.

• Producer/ Designer. Who will be producing/designing this piece of content.

• Editor. Who will be editing/formatting this content.

• Target Audience. The audience, industry or other segment you are looking to reach.

• Distribution Channels. Where this content will be published - e.g. blog, resource articles, otfsite.

• Promotion. The promotion and/ or social media channels that will be leveraged for this specific content.

• Metadata Tags. The meta title, description, and/or keywords for this piece of content.

• Metrics. The specific metrics - e.g. links, traffic, conversions - the client will try to target and track with the content piece.

- 'Vertical !il{easures, LLC. :JI.II 'Rights 'Reserved. © 2013 Choose a timeline that is manageable within your schedule. While frequency helps, consistency matters more. It's better to update twice a month, and provide solid content, than to try to update every week and have quality

In today's competitive world, Hougen gives you an edge with holemaking tools that will be ready when you are. From mag drills & annular cutters to outstanding service and support, you can trust Haugen's over years experience to get you the products & solutions you need. Hougen has the power, performance and reliability that you demand from your tools backed by the company that built them.

62

suffer. ~

<For your information ~ About the Author

Christine Dunn is president of Savoir Media, an awardwinning communications firm in Boston. Previously, she served as Boston Bureau Chief for Bloomberg Nevvs. She has written for Compliance Week, ComputerWorld, and Chief Content Officer magazine. Compliance Week, ComputerWorld, and Chief Content Officer.

Fabricator •

September I October 2013

A 360° VIEW OF THE MOST INNOVATIVE TECHNOLOGY AND PROCESSES. FABTECH 2013.

METAL FORMING

I FABRICATING I WELDING I FINISHING

FABTECH represents every step of the metal manufacturing process from start to finish. It's where new ideas, products and technology are highlighted through interactive exhibits, education and networking.

Compare solutions from 1,500+ exhibitors, find machine tools to improve quality and productivity, and learn ways to increase profit.

REGISTER NOW for the show with a degree of difference.

November 18-21, 2013

I Chicago, IL I fabtechexpo.com

,FAB--ECH ,.•.. .".. ....[ ,, •.·"·'·'"J North America's Largest Metal Forming, Fabricating, Welding and Finishing Event

Cosponsors:

•

-

Sme~

PMA •

Scan code to watch video.

• [!)

· .

"'"'"'' t: rum

~

Nationwide Supplier members Albina Pipe Bending Co. Inc. (503) 692-6010 Alku Group of Companies (905) 265-1093 Allen Architectural Metals Inc. (800) 204-3858 Alloy Casting Co. Inc. (972) 286-2368 American Punch Co. (216) 731-4501 Ameristar Fence Products (918) 835-0898 Architectural Iron Designs Inc. (908) 757-2323 Atlas Metal Sales (800) 662-0143 All Galvanizing (815) 618-8440 Banker Wire (800) 523-6772 Big Blu Hammer Mfg. (828) 437-5348 Julius Blum & Co. Inc. (800) 526-6293 Bridgeton Drafting Co. LLC (856) 205-1279 C.R. Laurence Co. Inc. (800) 421-6144 Cable Art Inc. (877) 664-4224 The cable Connection (800) 851-2961

Carell Corp.

(251) 937-0948 Carl Stahl DecorCable Innovations (800) 444-6271 Century Group Inc. (337) 527-5266

Elemplate Systems (919) 676-2244

Industrial Coverage Corp.

(631) 736-7500

FabCAD Inc. (800) 255-9032

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

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

CM Iron Supply LLC (480) 968-5121

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

CML USA Inc. Ercolina (563) 391-7700

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

Colorado Waterjet Co. (866) 532-5404 Custom Orn. Iron Works Ltd. (866) 464-4766 D&D Technologies (USA) Inc. (714) 677-1300

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

D.JA. Imports Ltd. (718) 324-6871 DAC Industries Inc. (800) 888-9768 DKS, DoorKing Systems (800) 826-7493 Eagle Bending Machines Inc. (251) 937-0947 Eastern Metal Supply (800) 343-8154 Elite Architectural Metal Supply LLC (84 7) 636-1233 EPi

Guardian Gate Hardware (800) 213-9525 Hartford Standard Co. Inc. (270) 298-3227 Hayn Enterprises LLC (860) 257-0680 Hebo/ Stratford Gate Systems Inc. (503) 722-7700 Heritage cast Iron USA (918) 592-1700 House of Forgings LLC (866) 443-4848 Illinois Engineered Products Inc. (312) 850-3710 Indiana Gratings Inc. (800) 634-1988

(262) 786-9330

The Iron Shop (800) 523-7427 King Architectural Metals (800) 542-2379 King Architectural Metals - CA (714) 670-8980 King Architectural Metals -MD (410) 644-5932 Krando Metal Products (610) 543-4311 L.E. Sauer Machine Co. (636) 225-5358 Lavi Industries (800) 624-6225 Lawler Foundry Corp.

(800) 624-9512 Lewis Brass & Copper Co. Inc. (718) 894-1442 Lift Master (630) 279-3600 Locinox USA (708) 579-0286 Mac Metals Inc. (800) 631-9510 Marks LI.SA. (631) 225-5400 McKey Perforating (262) 786-2700 Mittler Bros.

Machine & Tool (800) 467-2464

Multi Sales Inc. (800) 421-3575 Nationwide Industries (813) 988-2628

Sharpe Products (800) 879-4418 South Camden Iron Works Inc. (856) 423-1107

NC Tool Co. (336) 674-5654

Stairways Inc. (713) 680-3110

O.K. Foundry Co. Inc. (888) 592-2240

Suhner Industrial Products Inc. (800) 323-6886

Ohio Gratings Inc. (330) 477-6707

Sumter Coatings Inc. (888) 471-3400

Pacific Stair Corp.

(503) 390-8305 Precision Glass Bending Corp.

(800) 543-8796 ProCounsel (214) 741-3014 Q-Railing USA Co. (714) 259-1372 RAMSET Automatic Gate Systems Inc. (800) 771-7055 Ransburg (419) 470-2000 Regency Railings Inc. (214) 742-9408 Robinson Iron Corp.

(800) 824-2157 Robinson Laser LLC (219) 398-4600 Rockite, Div. of Hartline Products Co. Inc. (216) 291-2303

TACO Metals (305) 770-2373 Transpacific Industrial Supply Inc. (909) 581-3058 Tri-State Shearing & Bending (718) 485-2200

TS Distributors Inc. (832) 467-5400 Vogel Tool & Die LLC (630) 562-1400 The Wagner Companies (888) 243-6914 West Tennessee Ornamental Door (901) 346-0662

Rogers Mfg. Inc. (940) 325-7806 SECO South (888) 535-SECO

NOMMA Gold Members NOMMA is pleased to welcome our newest Cold Members - companies who have been a member for 20 years or more.

These companies show a strong loyalty to both their industry and trade association. We thank them for their support.

• Bracci Iron Works ..................................... Brooklyn, NY

• Mainer Iron Works Inc............................. Fort Smith, AR

• Armin Iron Works Inc............................... Pittsburgh, PA

• Picasso Gate Inc........................................ Cheyenne, WY

• Boes Iron Works Inc................................. New Orleans, LA

• Republic Fence Co. Inc............................ Granada Hills, CA

• Broome Welding & Machine Co. Inc. ... Galveston, TX

• Superior Fence & Orn. Iron ..................... Cottage Hills, IL

• DoorKing of Texas Ltd............................. Dallas, TX

• Western Architectural Iron Co............... Chicago, IL

• Hebo/Stratford Gate Systems Inc. ........ Clackamas, OR • Johnston Products of Dallas Inc........... Cedar Hill, TX

We greatly thank these companies for their two decades of loyalty and support.

• King Architectural Metals ....................... Dallas, TX 64

Fabricator • September I Odober 201 l

~

New Members Meet Our Members NOMMA is proud of its 500+ members. As members, fabricators and suppliers show support for both the association and entire industry. To get contact information on a member, see our Member Locator at www.nomma.org.

New/ returning members as of August ll, lOll:

*Asterisk denotes returning members.

Fox Valley Sandblasting & Powder Coating

Mr. Jim Schwebke Yorkville, IL local Supplier Iron Touch LLC*

Mr. Sherman Blankenship Louisville, KY Fabricator Piedmont Metalworks

Mr. Ron Hamilton Durham, NC Fabricator

Iron Club Thank you to the following individuals who have sponsored members for the new membership year. They are now an official member of the NOMMA Iron Club.

• Amos Glick, Compass Ironworks, Gap, PA • Tony Martinez, Big D Metalworks, Dallas, TX • JR Molina, Big D Metalworks, Dallas, TX • Mark O'Malley, O'Malley Welding & Fabricating Inc., Yorkville, IL

Come join us for NOMMA's annual convention & expo St. Louis, MO• Mar. 12-15, 2014 Opening New Gateways Learn, Grow, Excel

Packed with education & fun: ./ Education Sessions will cover both shop and business issues. ./ Vendor Ex hibits are free and will be open Thursday and Friday. ./ Spouse Program - Bring your spouse ... bring the whole family! ./ Shop Tours - Five shops scheduled. It will be a ft.*1 Saturday! ./ MORE - Top Job awards contest, Thursday the auctions, Saturday banquet, first-time attendee

But wait, there's more: St. Louis is an incredible venue that offers TONY of ./ Cruises

./ Tours

./ Museums

./ Galleries

./ Sports events ./ Music

./ Nightlife

NOMMA Membership Campaign We have kicked off the 201l-14 membership campaign. And yes, there are prizes!

• Sponsor a member for a $75 discount off METALfab 2014 registration.

• Sponsor 4 members and your registration is free!

To sponsor a member, simply encourage your suppliers, partners, contractors, and nearby fabricators to join.

If inviting them by email, you can send them this link: http://tinyurl. com/ ca769do

Call far Speakers METALfabl014 If you'd like to speak at METALfab 2014, March 12-15, in St. Louis/St. Charles, MO, please contad Lynn Parquette, NEF METALfab education chair: lynn@ornamentaliron.net.

September

I Odober 2013 • Fabricator

./ Golf

A t hanks to our SP, PLATINUM - Ind

s todo:

l ./ Outdoor hKf'88 ./ Winerie\

./ CasiPos ./ Dh•lng

V

S opping

Keynote Speaker: Sam Richter, best selling author and expert on " sales ln~ligence."

65

AJ!hafs Jl{)t?

1ndustry 'News

~

News Brief

Victor contest for users of oxyfuel and plasma cutters Victor Technologies, St Louis, has launched two contests as part of its 10oth anniversary celebration of its Victor brand of cutting and gas control equipment.

The ''.A Cut Above" contest is open to students in cutting, welding, and related programs at secondary and post-secondary schools and will award more than $30,ooo in equipment and cash prizes.

Beginner students will write a 500word essay supporting the contest theme, while advanced students will submit a team metal fabrication project that incorporates an oxyfuel, air-fuel, or plasma cutting process.

The "Show Us Your Innovations" 2014 contest will award 12 Victor Medalist 250 Cutting Outfits, and a Victor Thermal Dynamics Cutmaster 42 plasma cutter as the Grand Prize for the best photos and associated captions of the entrant using any Victor or Victor Thermal Dynamics cutting equipment.

"Winners will demonstrate innovation, craftsmanship and an appreciation for quality tools that enable them to shape their world;' says Martin Quinn, CEO, Victor Technologies.

Both contests run through September. Winners will be named at the Victor Technologies booth at FABTECH 2013 Expo in Chicago.

Contact 636-728-3000 www.victortechnologies.com

Wagner takes several steps to improve efficiency with sustainability program The sustainability buzzword is the Wisconsin Economic Developheard everywhere, but what does being ment Corporation and funded through a federal grant to the State Energy a sustainable company actually entail?

For The Wagner Companies, MilOffice from the Department of Energy waukee, a manufacturer and supplier through the American Recovery and of railing systems and components, Reinvestment Act This program also uses a three-step sustainability has meant more profit approach to help small and midsize Wagner initiated sustainability in 2004 through energy reduction. The company contacted Focus on Energy, a Wisconsin energy efficiency and renewable resource program, to determine potential projects, incentives, and cost reductions. As a result, three projects were developed: 1 Ughting upgrade. The first project was changing from metal halide lamps to TS fluo rescents, which resulted in an energy reduction of 15 to 20%. Jeff Wissbroecker with Wagner's new fiber optic 2 Variable speed drive air laser system. compressor installation. The second project was moving to a varimanufacturers bring the greatest ROI able speed drive air compressor, which and a positive environmental impact.

1 An audit. A consulting firm comled to a 30% energy savings.

J New boiler installation. The boiler pleted a sustainability audit. now compiles data on various tem2 Logistics partner. Wagner partnered with a third party logistics firm perature levels that is used to adjust the firing rate - achieving a high effifor outbound less-than-truck-load (LTL) shipments, which resulted in an ciency of 92%.

All three projects were simple and immediate cost savings of 30% on all were completed in 2006. Wagner outbound LTL freight. recovered its costs in two years.

Wagner also reduced paperwork, The next sustainability step was in and staff used LTL loads more efficiently because they could quote vari2010 when Wagner applied to participate in the Profitable Sustainability ous carriers and bundle shipments.

J Energy dashboard. The consulting Initiative (PSI) program, a Wisconfirm also created an "energy dashboard" sin state initiative begun in 2009 by

SEND US YOUR NEWS

Let us publish your news. Company news. new prooducts, new literature, events: face-to-face/virtual. people hires. promotions.

Please send you r press releases to editor@nomma.org.

66

Fabricator â&#x20AC;˘

September I October 2013

<Wbqt's

'Industry 'News

Jtot? '"

News Brief

Bendinelli wins tuition for Goldman Sachs program

The sustainable lighting installation in the Wagner plant, below. Above, before installation.

for Wagner that served as a springboard for all of their future energy reduction projects. The dashboard gives access to the data that helps Wagner justify new projects and tracks results of implemented projects.

Wagner's initiatives continued in 2012 with the introduction of the Me2 and Me3 programs, which also help manufacturers cut costs and help to minimize negative environmental impacts.

1 The installation of a building automation system, which brought about a 6% reduction in overall utility costs. Additional savings came from streamlining maintenance activities, such as monitoring for proper function and extending the life cycle ofHVAC equipment September I October 2013 •

Fabricator

2 Searching for an alternative to the water jet cutting system - a large consumer of electricity and water.

Wagner replaced the water jet with a fiber optic, flat laser.

Benefits included: • 15% improvement in material use, • productivity increase of 400%, • elimination of 66 tons/ year of garnet waste disposed at the landfill, • energy savings of 114,000 kilowatt hours a year, and • the elimination of the second shift, which resulted in an additional energy savings of 156,000 kilowatt hours a year.

Contact 414-214-8395 www.wagnercompanies.com - '13en Perreault, Sustainability 'Intern University of 'Wisconsin, Oshkosh

Bill Bendinelli, owner/president ofBenFab Architectural Metalwork, Lansdowne, PA, is a student in Goldman Sachs 10,000 Small Businesses Initiative. He was one of 25 business owners selected last May. "I knew that my business had significant growth potential but I was aware that I was lacking the necessary business skills to bring it to the next level:' Bendinelli says.

Goldman Sachs partnered with Community College of Philadelphia and Babson Col/ lege to develop the business curriculum.

The curriculum includes accounting, negotiations, sales and marketing, and HR management Bill Entrepreneurs Bendinelli participate in workshops led by industry leaders, inclassroom discussions, one-on-one counseling, and networking opportunities. They also will have access to business support services and learn how to position their business to access financing and capital.

Upon completion of the 11-session program, entrepreneurs will have developed an integrated, customized business growth plan.

Selectees get a scholarship for all tuition and program materials.

Applicants must meet the fol lowing criteria: • Be a business owner/co-owner.

• Have a business in operation for at least two years.

• Business must have revenues between $150,000 and $4 million in the most recent fiscal year.

• Business must have a minimum of four employees.

Contact 610-626-9100 www.benfabrailings.com

67

JYlzats JLOf?

Products

''t#

Cotton fiber quick-change discs Rex-Cut Abrasives

Rex-Cut Abrasives is offering a full line of cotton fiber quick-change discs designed for removing small welds and machine tool marks, as well as edge breaking and related finishing tasks.

The discs are rigid enough to reach into small corners, yet flexible enough

for use on flat and contoured surfaces to remove small welds and break edges, according to the company.

Revealing fresh abrasives as they work, the discs are made from multiple layers of reinforced non-woven cotton that are impregnated with abrasive grains, then pressed and bonded together, and fitted with Type-R and Type-S style fasteners.

Capable of grinding and finishing in one step, the discs are designed to provide smooth, controlled grinding action with no smearing on titanium and stainless steel, and are non-loading on aluminum, Kevlar, and other composites, says the company. They are for right-angle grinders in 2-inch and 3-inch sizes with aluminum oxide and silicon carbide abrasives, in seven different grain sizes and three different bonds.

Contact 800-638-8501 www.rexcut.com

• Sta ndard Welding C able exceeds NEMA Class K rating.

• Made of stranded, annealed copper wires.

• Long life, cross-linked rubber insulating jacket.

• Direct-to-You Pricing, No Minimum.

Angle and shape bending rolls Cole-Tuve Inc.

New 4-roll angle and shape bending rolls with capacities up to and including 4 x 4 x Yi inches have been added to the lines of angle rolls, plate rolls, and other metal fabricating machines supplied by Sahinler Metal Makina.

These new rolls address fabricators' needs for more controlled and accurate bending capabilities. Because of the geometry of the rolls' positions and according to the work at hand, each

Why limit yourself? ALLOY CASTING offers new, decorative castings in a variety of metals and finishes to help you achieve dramatic and creative results on your next project. Custom or catalog designs in:

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68

ltfA!ioyCasting I

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American Made - American Quality • American Deliveries

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Bronze and Stainless Steel samples available in #8102 shown above

www.alloynet.com

Fabricator •

September I October 2013

<Wbqt's

Pro duds

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machine can be used as a pyramid roll, 3-roll initial-pinch or double-pinch roll, or 4-roll double-pinch roll, and even as a press, the company says.

The mountable outboard supports for the shafts keep deflection to a minimum when under heavy load or when extreme accuracy of bend is required.

Using the lower roll as a support roll allows light and thinner shapes to be bent without distortion or being crushed. Substituting special rolls for the lower rolls, for example for bending structurals the hard way, adds to the advantages of this type of machine.

The machines are especially suited for the addition of NC or CNC. Contact 877-989-0700 www.coletuve.com

Fully automatic handsaw Kalamazoo Machine Tool The Kalamazoo Machine Tool Model H360A fully automatic bandsaw

is designed for demanding production sawing applications. The saw is engineered as a one-piece unified construction so that the machine maintains alignment and accuracies throughout its life, ensuring a+/- 0.008-inch feed accuracy, says the company.

The saw is fully hydraulic, with shuttle barfeed and heavy-duty carbide guides. It features mitering capability up to 60 degrees right in automatic and up to 45 degrees left in semi-automatic, and variable blade speeds from 55-330 fpm.

The operator's control system allows access to important sawing data and is designed to make setup quick and easy.

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Fabricator

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Optimum cutting rates are attainable with controls over the saw pressure and sawing speed. Infinitely variable vise-clamping pressure is standard equipment, as is a top clamp to facilitate holding and cutting multiple pieces. A CNC controlled version the H 360A NC - is also available.

Contact 269-321-8860 www.kmtsaw.com

Double-fluted step drills Hougen Manufacturing Inc. Hougen Manufacturing has new step drills made from premium cobalt M42 high-speed steel with a TiN coating to improve tool life.

The drills also feature an angled double flute which increases penetration rates and reduces the force needed when drilling.

Starting the hole is made easy with the Hougen split point, says the company.

C.D.A. Alloy 655 • SHEET & PLATE • ROUND ROD • SQUARE ROD • ROUND TUBING •WELDING ROD •FLAT BAR • CASTING ALLOYS: • SQUARE TUBING 95-4-1 & 92-4-4, 1/2" cubes to 20 lb. ingots Fabrication Properties Rating Corrosion Resistance Excellent Capacity for being cold worked Excellent Capacity for being hot formed Excellent Suitabil ity for being joined by: Brazing Excellent Oxyacetylene welding Good Gas shielded arc welding Excellent Resistance welding Excellent Hot forgeability rating 40

ATLAS METAL SALES

1900 W. 12th Ave. • Denver, CO 80204 800-662-0143 • 303-623-0143 liiifiiiiiil Fax: 1-303-623-3034 lllliiiillm E-Mail: jsimms@atlasmetal.com

-

69

JYlzats JLOf?

Products

''t#

large heavy-duty, production-style magnetic drills.

Contact 810-635-7m www.hougen.com

mary materials, says the company.

The new tool features 2.3 horsepower, and weighs 12 pounds.

Contact 810-632-5400 www.heckind.net

Hand-operated weld shaver Magnetic latching system

Heck Industries

D&D Technologies

The new step drills are available in three sizes: Part No. 35200 for sizes Ys inch to Yi inch for Ys-inch materials; Part No. 35201 for sizes 3/ 16 inch to Yi inch for %-inch materials; and Part No. 35202 for sizes 3/ 16 inch to % inch for Ys-inch materials.

Hougen Manufacturing also provides machine shops, fabricators, erection and installation crews, and maintenance personnel with a wide range of hole making equipment, from lightweight ultra-low profile drills to

Heck Industries has a new hand-operated fillet weld shaver that uses indexable carbide inserts in a milling cutter to remove weld beads from both flat "butt" welds and inside 90-degree "fillet" welds.

The new Model WS90 features both adjustable depth of cut and an adjustable fence, making it easy to remove only a weld bead and not the surrounding pri-

FIRE YOUR FORGE TODAY! Proven design Efficient-Reaches 2350 Degrees Versatile Portable Many Models Available

D&D Technologies' LokkLatch Magnetic is a magnetic latching system that fits any metal, wood, and vinyl square post It offers coordinating trim covers, that match gate hinges, lighting and yard accessories.

The product is engineered with durable materials and finishes to withstand the harsh effects of time and weather, says the company.

Features include D&D patented magnetic latching, intuitive push/ pull action, and dual 6-pin, re-keyable locks, as well as vertical and horizontal adjustment and no visible fasteners.

BUilT FOR A LIFETIME OF COLD SAWING 2 Heavy Duty Cold Saws from opposite sides of the world

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Haberle H90 MADE JN GERMANY

Includes Double Grip Vice 8t Trigger Switch

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WWW .BroboUSA.com

Haberl e HR302 Tube

• Burr Free 8t Milled Finish Deburring Machine • Cuts Steel, Stainless, Aluminum 8t Other Non- Ferrou s Metal s • Miters 45°-0°-45° • Built For Full-Time Use • Machine Models from 9" - 18" SawBlade: max • Sawblades in Stock (6.3 .. Tube) • Sharpening Service Exclusive Representative & Service In the US: BROBO and HABERLE

Ken Bergman & Associates LLC CALL 1-800-956-1313

s ince 1976

Located just outside Chicago, Illinois USA

70

Fabricator •

September I October 2013

<Wbqt's

Pro duds

Jtot? '"

power down feed, a massive 25 horsepower, threephase 220/ 440 V motor with magnetic starter, and a 1'!4inch arbor with sealed ball bearings.

~~

There are optional decorative trim covers and strong engineering polymers and stainless steel components. The product fits any square post gate of 11h inches to 6 inches.

Contact 800-716-0888 www.ddtechglobal.com Abrasive saw Kalamazoo Industries Inc. Kalamazoo Industries has introduced the model K3oPH 30-inch abrasive saw that features air/ oil

WWW.

kalamazooindustries.com

The saw measures 36 inches long x 24 inches wide x 84 inches high and has a capacity of up to 5-inch solids and 8-inch shapes.

C360SA SemiAutomatic Cold Saw Vertical column construction for vibration-free sawing Simple controls for high volume production work Two-speed spindle (18 & 36 rpm) Heavy-duty precision-ground saw bed Heavy-duty drive ~ 4 hp TEFC motor Totally enclosed transmission

KALAMAZOO

September I October 2013 •

Options include a totally enclosed hydraulic down feed, stock conveyor, air vise and oscillation: gear/motor or hydraulic, coolant, 30, 40, 50 horsepower.

Contact269 -382-2050

Fabricator

6700 Qualitv wav Portage, Ml 49002 269-321-8860 Fax: 269-321-8890 www.kmtsaw.com

Press brake Cincinnati Inc. The company's new Baseform press brake is a bending and forming solution for shops looking to quickly expand metal fabrication services or bring outsourced metal forming operations in house at an affordable price.

The Baseform includes a PC-based control and is available in 90- and 175-ton capacity models. It includes a micro-crowned bed and

±0.0004-inch (±0.01 mm) repeatability. Optional offline programming increases throughput and decreases scrap, says the company.

The Baseform comes standard with a backgage designed to reduce setup and handling time. Operators can program backgage positions necessary to form multiple flanges in one handling. Gage allowance, clamp position, retract distance, and gage pause are also programmable, and a closedloop servo drive provides fast, precise gage positions.

A full-length bar, two adjust-

able gage holders with two sets of fingers and a positioning tool are standard.

Baseform's PC-based control combines 3D graphics interface with touchscreen operation. New part programs can be generated through manual data entry or by drawing the part in cross-section or flat pattern, and then selecting tooling and bend sequence.

Contact 513-367-7100 www.e-ci.com Portable floor scale Alliance Scale Inc. The company has a new portable floor scale with a folding ramp and batteryoperated weight indicator that is available with stainless steel construction to resist chemical attack.

The DeckHand Portable Floor Scale is suited for drum weighing applications where the risk of chemical spills is present or frequent wash-downs are required.

The digital weight indicator is a 5-digit, 1-inch LCD display with a RS-232 communications port It is powered by six "C" cell alkaline batteries and includes a no VAC adapter.

The scale has a column

71

JYhats JLOf? c

i#

with two hand grips and a 31x41x4.5inch non-skid platform and ramp. It is available in 500-, 1,000-, and 2,000pound capacity models.

Contact 800-343-6802 www.alliancescale.com Flush-head studs PennEngineering

PEM type FHP self-clinching flushhead studs are designed to install permanently into thin stainless steel sheets, providing solutions for attachment applications that require superior corrosion resistance. They install more

72

Produets

easily at lower cost than weld studs, says the company, and can contribute to thinner and lighter designs for component assemblies.

These studs mount flush and permanently in stainless steel sheets as thin as .040 inch (and greater) and become integral to an assembly with only a mating nut required for final attachment The A186 stainless steel is designed to impart high hardness and the studs can be specified reliably for use in stainless sheets with hardness of 92 or less on the Rockwell "B" scale.

PEM type FHP flush-head clinch studs are supplied in thread sizes #4-40 through #10-32 and M3 through Ms, and in a range of 10 standard lengths.

Contact 800-237-4736 www. pemnetcom Protective barrier hand lotion CAIG Laboratories Inc. Hand-E-Glove protective bar-

rier hand lotion, originally developed for use in the electronics industry, is now available for consumers and those working in various industries.

It is applied like ordinary hand lotion, before starting cleaning tasks, and allows the user to easily wash away glue, ink, plumber's putty, and other products using plain soap and water.

Hand-E-Glove can also be used under winter gloves to prevent skin from drying and cracking, and has a skin-softening and anti-static formulation.

Contact 858-486-8388 www.caig.com

Fabricator â&#x20AC;˘ September I Odober 201l

~

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

Pg Company Website 21 Albina Pipe Bending Co............... www.albinapipebending.com

Pg Company Website 51 International Gate Devices ................................ www.intlgate.com

11 Allen Architectural Metals lnc................... www.allenmetals.com

76 The Iron Shop............................................... www.theironshop.com

68 Alloy Casting Co. Inc.......................................... www.alloynet.com

48 Jesco Industries Inc. WIPCO div............... www.jescoonline.com

52 American Fence

71 Kalamazoo Machine Tool ................................. www.kmtsaw.com

Association Inc. ................. www.americanfenceassociation.com 72 Artist-Blacksmith's Assoc.

of North America lnc................................................www.abana.org 69 Atlas Metal Sales ............................................ www.atlasmetal.com 70 Ken Bergman & Assoc., LLC ....................... www.haberleusa.com

44 Big Blu Hammer Mfg. Co. /

Oak Hill Iron Works ............................... www.bigbluhammer.com 51 Blacksmiths Depot/ Kayne & Son

Custom Hardware Inc..................... www.blacksmithsdepot.com 60 Julius Blum & Co. lnc.................................... www.juliusblum.com 38 The Cable Connection ................ www.thecableconnection.com

69 John C. Campbell Folk School ......................www.folkschool.org 37 Carell Corporation .......................................... www.carellcorp.com 43 Chicago Metal Rolled Products Co..................... www.cmrp.com

56 Colorado Waterjet Co.......................www.coloradowaterjet.com

33 Custom Ornamental

Iron Works Ltd .................................... www.customironworks.com 19 D & D Technologies (USA) Inc.............. www.ddtechglobal.com 30 Doringer Cold Saw ............................................ www.doringer.com

75 King Architectural Metal.............................. www.kingmetals.com

9 Krando Metal Products Inc................................ www.Krando.com 16 Lapeyre Stair .................................................. www.lapeyrestair.com

24 Larsen Innovations LLC ............................. larseninnovations.com 28 Laser Precision Cutting .................................... www.lpcutting.com 15 Lawler Foundry Corp...............................www.lawlerfoundry.com

2 Lewis Brass & Copper Co. Inc.................... www.lewisbrass.com 6 Locinox USA........................................................... www.locinox.com 23 Mac Metals Inc............................................... www.macmetals.com

36 Marks U.SA........................................................ www.marksusa.com 26 Mittler Bros. Machine & Tool ..................... www.mittlerbros.com 54 Pat Mooney lnc. ...................................www.patmooneysaws.com 28 National Bronze & Metal............................ www.nbmmetals.com 70 NC Tool Company lnc. ......................................www.nctoolco.com 50 Regency Railings ....................................www.regencyrailings.com 41 Scotchman Industries .................................. www.scotchman.com 47 Sharpe Products ................................... www.sharpeproducts.com

63 Society of Manufacturing Engineers....................... www.sme.org

37 Eagle Bending

Machines Inc. ......................... www.eaglebendingmachines.com

39 Stairways lnc................................................................. 800-231-0793

55 Eberl Iron Works lnc......................................... www.eberliron.com

49 Suhner Industrial Products Corp............... www.suhnerusa.com

68 Electron Beam Technologies Inc. ....... www.electronbeam.com

58 Sumter Coatings lnc.............................www.sumtercoatings.com

25 FabCad Inc.............................................................. www.fabcad.com

29 TACO Metals Inc.............................................. www.tacorailing.com

17 Feeney Inc..........................................................www.feeneyinc.com

72 Traditional Building....................... www.traditional-building.com

27 Hebo - Stratford Gate Systems Inc.... www.drivewaygates.com

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

62 Hougen Mfg. Inc. ................................................. www.hougen.com

59 Vogel Tool & Die LLC ....................................... www.vogeltool.com 31 The Wagner Companies ................ www.wagnercompanies.com

Your advertising contact for O&MM Fabricator NOMMA Buyer's Guide NOMMA website

a.mun

Your one-stop resource for shop and office personnel The Buyer's Guide is available in 3 versions:

Sherry Theien

Advertising Director 8392 Leesburg Ct. Rockford, IL 6 1114 8 15-282-6000 8 15-282-8002 fax stheien@att.net September I Odober 2013 â&#x20AC;˘

Advertise in the

2014 NOMMA Buyer's Guide

1) print, 2) online, and 3) database.

Closing date November 30, 2013 Contact Sherry Theien, 8 15-282-6000; 8 15-282-8002 fax; stheien@att.net

Fabricator

73

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Metal Moment

~rom

the NOMMA 2iftServ

How to clean pickets, posts before fabrication Greg Bailey, Bailey Metal Fabricators Inc., Mitchell, SD, www.baileymetalfab.com, posted a question on the NOMMA ListServ.

I want to clean pickets and posts before fabrication.

W hat do you use to clean and degrease your railings? I planned to use a dip tan k. Some say that the mineral spirits dries their hands out.

Several NOMMA members respond It's som etimes possible to open a bundle, spread them out a bit, and pressure wash with a biodegradable solution.

'Doug Cernonok :Myers & Co . .Jlrchitetlural :Metals

the gloves, which stand up to Xylene and MEK - solvents we use in painting. So having one product works well. :Maciej Jankowski .Jlrtiftic 'Iron rworks LLC

A chemist friend told me that anything that removes grease or oil will necessarily remove body oils from unprotected skin, which is why one gets chapped hands, and which is why protection is required no matter how earth-friendly the cleaner is.

We use a locally produced product similar to Simple Green using waterproof gloves and eye protection.

'Bruce 'Berg Outland Steel

Look into using a barrier cream. Any heavy degreasers are going to dry out hands.

'Robert Sarpy 'Rusty 'Ripple 'Ironworks

We use mineral sprits, and we provide large heavy duty rubber gloves. We have done this for years.

'Tony :Martinez 'Big 'D :Metalwork's

We like Simple Green. Spread out materials on stands. Soak with a pump up sprayer, then follow with a rag and 5-gal. bucket of diluted solution.

Jeffery Presbaugh .Jlberdeen Custom <jate & 'Iron

We use Formula 51 by Zep. We wear rubber gloves when cleaning metal so our hands don't dry out 'Downtown Ornamental 'Iron 'Inc.

We have been using an ind ustrial degreaser/parts cleaner made by TSP. Heavily concentrated, so you dilute as needed.

Disposable nitrile gloves (industrial grade) work well. We get the gloves through Amazon (very inexpensive, and they also hold up to all of our solvents in the paint department.

As others have mentioned - layout on "saw horses" wash with degreaser (plastic bristle brush), rinse with water, and set in sun to dry or towel down depending on weather.

Gets to be a bit more tricky in the winter.

Works well. We have not had issues with hands and

Go to Smart & Final and get their "Cleaner-Degreaser" that is for cleaning commercial kitchens. Works great It's only $25 for a 5-gal. bucket. With a discount if you get two or more.

We use a long-handled scrub brush, and rinse it off with a hose. No protection needed. If it's a stubborn grease, we'll use a Scotch-Brite pad and the cleaner. Then it's good to use gloves.

John :Mc'Lellan :Mc'Lellan 'Blacksmithing

Response from Bailey Metal Fabricators Our ListServe post provided several ideas. We fabricated a dip tank with an expanded tray to hold the parts off the bottom and in a clean solution. We require using rubber gloves and a face shield. We use mineral spirits for our cleaner. On bigger parts, we use a steam pressure washer with a degreaser.

Just one more example of how supportive NOMMA members are and how vital the ListServe is to our success!

Join HOMMA ... to get your questions answered on the Listserv The NOMMA Listserv is an ongoing email discussion list where NOMMA members get quick, free answers to their important questions. A valuable benefit for members.

If you are a NOMMA member and not subscribed, contact support@nomma.org.

If you are not a NOMMA member, we encourage you to join your industry's trade association.

i'''"¡'IEI

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 your story for a Metal Moment. Please contact Editor Robin Sherman at nomma.editor@att.net.

74

Fabricator â&#x20AC;˘ September I Odober 201l

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