Nov/Dec 2013 OMM Fabricator by NOMMA

METALfab, March –, St. Louis: Complete details, page 13 Ornamental and Miscellaneous Metal

Fabricator ®

The official publication of the National Ornamental & Miscellaneous Metals Association

November / December 2013 $6.00 US

Job Profile

Mid-Cities overcomes many security fence challenges page 58 Governor’s Mansion contractors: “These folks all deserve the Medal of Honor” — John Famiglio

Shop Talk How to forge in three dimensions, page 24

Shop Talk Abrasive finishing for images on stainless steel, page 38

Member Talk A2 Fabrication got a little help from its mentors, page 43

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NOMMA Membership Application Membership Category – Check One: q Fabricator - $425 $325 (to pay in four payments, you can enroll in the Quaterly Payment Plan - please see below) Metal fabricating shops, blacksmiths, artists or other firms and individuals in the industry whose products or services are sold directly to the consumer or the consumer’s immediate agent. 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. q Nationwide - $595 (operating on a nationwide or international basis) q Regional - $465 (operating within a 500-mile radius) q Local - $375 (operating within a 150-mile radius) q Affiliate - $310.00 qTeacher q School q Non-profit organization Individuals, firms, organizations and schools that do not engage in the fabrication of ornamental or miscellaneous metal products, do not provide products or services to the industry, but have a special interest in the industry. Company:____________________________________________________________________________________ Primary Contact :______________________________________________________________________________ Address:___________________________________________________________________________________ City:_____________________________________________ State: ________ Zip: _________________________ Country: __________________________________________________________________________________ Phone:__________________________Fax:________________________ Toll Free:_______________________ E-mail: ____________________________________________ Web:_____________________________________ Company Description/ Specialty:____________________________________________________________________________________ Payment method: q Check

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2013-05-4

Inside

November / December 2013 Vol. 54, No. 6

Images on metal. Metalworker Larry Wood: “Taking a well-established decorative patination process and using it for something for which it wasn’t intended.” Story, page 38

NOMMA Network

Member Talk

METALfab2014

Two NOMMA chapters full of energy and excitement.............. 10

NOMMA names Brian Maddox new marketing manager. 11 NOMMA board continues strategic discussions. 11 Shop Talk

Opening new gateways: Learn, grow, excel.......................... 13

Complete program for the 56th Annual Convention & Exhibits at the St. Charles (St. Louis) Convention Center. Join hundreds of attendees for networking and 15 educational sessions.

How to forge in three dimensions........................... 24

A2 Fabrication succeeds with a little help from its mentors........43

With self-taught fabrication skills and business advisors, A2 Fabrication’s Gale Schmidt ramped up her business moving from wheelchair ramp manufacturing to architectural and ornamental jobs. Job Profile

This article reviews the value of the third dimension in architecture, and then shows you how to forge threedimensional decorative coils. By Robert “Uncle Bob” Walsh

Mid-Cities overcomes security challenge................................ 58

Pre-Convention program............. 14 Education sessions....................... 14 Shop Tours................................... 17 Spouse program........................... 17 Registration form.......................... 21

Completing a wrought-iron fencing job for the Texas Governor’s Mansion was no small feat for Mid-Cities Ornamental Iron Works. Despite driving distances, preservation issues, and watchdogs, John and Jacob Famiglio persevere with a lot of welding and finishing work. By Molly Badgett What’s Hot!

Shop Talk

Industry News.................................... 70

Get images on stainless steel..... 38

A step-by-step, hybrid method for producing hand-drawn imagery on metal sheets incorporating chemical actions and abrasive metal finishing. — Larry Wood President’s Letter........... 7

A gift from NOMMA.

Exec. Director’s Letter.... 8

An amazing venue for METALfab2014.

New Lien & Bond Claims edition.

Products........................................71 Suppler Members............................. 67 New Members.................................... 69 Ad Index................................................ 73

NEF................................... 12

METALfab2014 — learn, grow, excel.

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

Refinishing historic exterior metal.

About the cover The new front gate of the Texas Governor’s Mansion fabricated by Mid-Cities Ornamental Iron Works, Southlake, TX. See story on page 58. November / December 2013 n Fabricator

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President’s Letter

A gift from NOMMA The holidays are upon us, a miscellaneous and architectural time for families to share meals, metals professional. NOMMA gifts, and fellowship. Beginning is here to serve you by offering value-driven benefits, educawith the Thanksgiving dinner, tion, and a yearly conference celebrating Christmas, and then that will inspire you to keep welcoming in a new year, we all pushing forward. have the opportunity to share All are good choices and can memories and create new ones J.R. Molina, Big only be planned and executed with our families and friends. D Metalworks, by you. So plan and execute I have one special memory is president that gift and become involved! that I would like share. It’s when of NOMMA. my father and I went out one afternoon to buy my mother Help us help you more and five siblings Christmas I encourage each of you to gifts. I was only 10 years old at the get involved with NOMMA, whose time, but I never forgot the advice my benefits are plentiful. But more can be father gave me that day. To help paint made available through you, the memthe picture, my parents came from ber, with increased involvement. humble beginnings not even having a We’re a nonprofit, volunteer assohigh school diploma. ciation. All our directors and committees donate their time to improve the My dad’s lesson profession for the benefit of their felHowever, what dad lacked in educalow professionals. tion he made up in hard work, conMost of our volunteer work is fidence, and determination. He was accomplished through emails and a provider who knew the value of a telephone calls. Volunteering will give dollar. That day, my dad attempted to you exposure at the next level in your teach me the value of a dollar, and more career to improve your network, job importantly, how to save. skills, and personal development. I look forward to making new conHe told me, “JR, it’s not hard to tacts and friendships with our memmake money . . . anyone can get a job bers and sponsors. and make money, but a smart man If you would like to assist with any knows how to save his money.” The “gift” he gave me that day was program or be involved with a committee or specific area, please contact it doesn’t matter what you do for a Executive Director Todd Daniel or living or even how much money you myself. make. If you have a plan and execute I hope to see everyone at METALthe plan, you can live like no one else fab2014 in St. Charles, MO, March now, so you can live like “one else” 12–15, 2014. Program information later. This gift was not realized immebegins on page . Check the NOMMA diately, but has been cherished and executed in the years since, especially website for regular updates. since adulthood. On behalf of the NOMMA staff, Now, my gift to you who are curtrustees, and directors, I wish all of rently a NOMMA member, past you a Merry Christmas and a safe and member, or considering membership prosperous New Year! is to offer the services and benefits of NOMMA. Yes, it does cost something to join, but name any organization that does not require a membership fee. Remember, NOMMA is a nonprofit, volunteer organization for the November / December 2013 n Fabricator

Dedicated to the success of our members and industry. NOMMA O FFICERS

President J.R. Molina, Big D Metalworks, Dallas, TX President-Elect Mark Koenke, Germantown Iron & Steel Corp. Jackson, WI Vice President/Treasurer Allyn Moseley, Heirloom Stair & Iron, Campobello, SC Immediate Past President Will Keeler, Keeler Iron Works, Memphis, TN

F ABRICATOR D I RECTORS

Greg Bailey, Bailey Metal Fabricators, Mitchell, SD Keith Majka, Majka Railing Co. Inc., Paterson, NJ Tina Tennikait, Superior Fence & Orn. Iron, Cottage Hills, IL Greg Terrill, Division 5 Metalworks, Kalamazoo, MI Cathy Vequist, Pinpoint Solutions, Jupiter, FL Henry Wheeler, Wheeler Ornamental Metals, Dothan, AL

S U PPLI ER D I RECTORS

Rick Ralston, Feeney Inc., Eugene, OR Mark Sisson, Mac Metals Inc., Kearny, NJ Dave White Jr., Locinox USA, Countryside, IL

NOMMA E DUCATION F OU N DATION O FFICERS

Co-Chairs Roger Carlsen, 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 T RUSTEES

Heidi Bischmann, Milwaukee, WI Carl Grainger, Grainger Metal Works, Nichols, SC Mark Koenke, Germantown Iron & Steel Corp., Jackson, WI Christopher Maitner, Christopher Metal Fabricating, Grand Rapids, MI Rob Rolves, Foreman Fabricators, St. Louis, MO

NOMMA C HAPTERS

Chesapeake Bay Patty Koppers, President, Koppers Fabricators Inc. Forestville, MD 301-420-6080 Florida Marco Vasquez, President, Vasquez Custom Metals Inc., Tampa, FL, 813-248-3348 Gulf Coast Charles Perez, President, B & O 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, 503-771-2000 Upper Midwest Mark O’Malley, President, O’Malley Welding & Fabricating Inc., Yorkville, IL, 630-553-1604

NOMMA S TAFF

Executive Director, J. Todd Daniel, CAE Meetings & Exposition Manager; NEF Executive Director, Martha Pennington Member Care & Operations Manager, Liz Johnson Editor, Robin Sherman Sales Director, Sherry Theien Marketing Manager, Brian Maddox

F ABRICATOR E DITORIAL A DVISORY B OARD

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

Ornamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA). O&MM Fabricator / NOMMA 805 South Glynn St., Ste. 127, #311 Fayetteville, GA 30214 Editorial We love articles! Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph/Fax: 888-516-8585. E-mail: 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.

How to reach us

Executive Director’s Letter

An amazing venue for METALfab Knowing our group well, the first a great sausage platter, ribs, thing I thought when I arrived and handcrafted beers. I had at the hotel and convention the barbecued smoked chicken center in St. Charles, MO, is breast, which was delicious. I’m “WOW, this venue is a perfect told other great restaurants are fit for NOMMA!” there, including wonderful Italian and Brazilian eateries. St. Charles is the site of Beyond St. Charles is the METALfab2014, March 12–15. Todd Daniel is executive greater St. Louis area, which I recently saw our convention director of features more attractions. Visitlocation while attending the NOMMA. ing the wineries was discussed, NOMMA fall board meeting. and you can tour the Anheuser For starters, our host hotel, Busch plant. the Embassy Suites, is a wonder in Of course, you have to visit the itself. The hotel features spacious twoGateway Arch, swing by Six Flags, and room suites that feel like a small apartvisit a museum or two. The St. Louis ment. A huge, free buffet breakfast is Zoo is famous, and I remember Uniready for you every morning and a versity City from my last visit — an manager’s reception each evening. A eclectic neighborhood with sidewalk bar, coffee shop — perfectly named cafes. I encourage you to plan your “Caffeina” — and the delicious Cyprus itinerary on the Web at explorestlouis. Grille restaurant adds to the amenities. com. And if you need to get the stress out of your body, a large spa awaits.

And while you’re at it

My exploration

But the hotel and adjoining convention center (see photo on page 20) are just the tip of the iceberg. I took an evening stroll over the Interstate 70 bridge. After crossing, I saw an elegant, lengthy staircase. “What is this?” I wondered as I descended down into a large shopping and entertainment area. At the stair’s base, I found a large sports bar and across the way a giant Bass Pro Shop. In fact, it’s the Mark Twain Mall. If you keep walking about three quarters of a mile, you’ll hit the Ameristar Casino and the downtown St. Charles historic area. You can also drive; it has ample free parking. The historic area promises interesting shops and restaurants. The NOMMA board dined at the Trailhead Brewing Co., which offers F I LE S, U R JO B P RO CA LL FO R YO

Certainly, the best part of your trip will be the METALfab experience, which includes four days packed with education, exhibits, networking events, and so much more. The spouse program is loaded with fun, and includes crafts, art, and a St. Louis historical tour. e METALfab Convention Guide is in this issue beginning on page , plus you can get the latest updates and register online on our website — www.nomma.org. I look forward to seeing everyone at the convention. I assure you that you are in for an incredible week of learning, exploring, and networking. See you in St. Louis/St. Charles!

TI PS

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.

Fabricator

n November / December 2013

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The NOMMA Network

NOMMA’s chapters full of energy, excitement

The Northeast Chapter’s October meeting attracted a nice turnout.

Philippe Fiers of Armadillo Metalworks demonstrates brass finishing and joinery techniques for the Northeast Chapter.

A sample of the cutouts produced by the CNC plasma cutting machine that attendees of the Upper Midwest Chapter meetings examined.

Northeast Chapter

The Northeast Chapter enjoyed a bronze handrail demo at their October 19 meeting, which took place at Mac Metals Inc., Kearny, NJ. The demo was given by Philippe Fiers of Armadillo Metalworks Inc., who demonstrated the “French method” of joining bronze handrail. The process involves upsetting and then cold hammering the joint. Other joinery methods were discussed, too. The day of fun and learning also included lunch and a tour of Mac Metals, which is a specialty brass mill and active NOMMA member. A “thank you” goes to Mac Metals Inc. for hosting the event. 10

Shop host for the Upper Midwest Chapter meeting, Max Hains of Mofab Inc., shows a set of blueprints during the shop tour. Looking on are Bill Acra, AZZ Galvanizing, and Nick and Marie Demas, The Wagner Companies. Fabricator

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Upper Midwest Chapter

The Upper Midwest Chapter learned about CNC plasma cutting at their September 28 meeting, which took place at Mofab Inc., Anderson, IN. Attendees were also treated to a shop tour, business session, and a free lunch. In the evening the action continued with a social event at Hoosier Shop host Max Hains Park Racing demonstrates the Hossfeld and Casino. Bender during the Upper At the social, Midwest Chapter meeting. attendees enjoyed a great dinner and placed their racing bets. The chapter wants to remind all NOMMA members that if you want to attend METALfab but have financial challenges, you are encouraged to apply for the Todd Kinnikin Memorial Grant. Details are available on the NOMMA website in the “NEF” section. A special thanks goes to Mofab Inc. and the Hains family for hosting. Gulf Coast Network Group

The Gulf Coast Network meeting, originally scheduled for October 5, was cancelled due to Tropical Storm Karen. A new date has not been set.

NOMMA names Brian Maddox as new marketing manager After a thorough search, NOMMA the American Association of Physihas named Brian Maddox, Aiken, SC, cians of Indian Origin, the American its new marketing manager. Society of Tropical Medicine Brian is formerly the execuand Hygiene, Academy of Eattive director of the Association ing Disorders, and the Ameriof Subcontractors & Affiliates can Board of Independent (ASA) of Chicago. Medical Examiners. In his new role, Brian will Brian holds a BA degree in oversee all marketing functions English Literature from North of the association, including Carolina Central University communications, promotions, and a MPA degree in Public research, and the development Administration. In his personal Brian Maddox, of new member products and time he enjoys writing music, new NOMMA services. In addition, he’ll be playing his guitar, and horsemarketing involved in day-to-day memback riding. manager, will bership outreach and retention. help grow the “We are excited to have association’s Brian has extensive experiBrian on the team,” said Todd membership. ence in both sales and marketDaniel, NOMMA’s executive ing. He currently works in cordirector. “Brian has a vast expeporate sales at Aiken Technical College, rience set and has shown us that he can where he sells training programs for operate both strategically and tactibusinesses. cally. He will be able to assist the board Before that, he was with ASA Chiin executing their strategic plan while cago from 2008–2011. While there, also providing day-to-day support for he improved event attendance and our existing programs, as well as helpincreased membership retention. He ing to grow our membership.” also launched new programs, most Special thanks goes to the NOMMA notably creating a team to help woo the Search Team, which reviewed resumes, 2016 Olympics to Chicago. participated in interviews, and helped Before these posts, Brian was as with countless other tasks. a fundraiser for Aiken Preparatory Search Team members include School and the executive director of Cathy Vequist, Ben Moseley, Tony Leto, several medical associations, including Doug Bracken, and Todd Daniel.

NOMMA board meets to continue strategic discussions During the NOMMA fall board meeting, which took place in St. Charles, MO, in October, board members spent an afternoon in strategic planning. Shown left to right: supplier director Rick Ralston, Feeney Inc.; Brian Maddox, NOMMA marketing manager; fabricator director Henry Wheeler, Wheeler Ornamental Metals; president-elect Mark Koenke, Germantown Iron & Steel Corp.; and supplier director Dave White Jr., Locinox USA.

November / December 2013 n Fabricator

NOMMA Education Foundation

In partnership with the National Ornamental & Miscellaneous Metals Association

METALfab2014 — learn, grow, excel

one of its favorite fundraising projects — the Silent & Live Auctions held at METALfab. standing education program planned by the Whether you donate an item for auction or METALfab 2014 Education Chair, Lynn you bid on items, both are vital to the success Parquette. Please study the METALfab2014 of this project. We have had fabulous items program in this issue of OM&M Fabricator donated through the years and depend on and join us in St. Louis, MO. you to help us continue this great tradition. Start METALfab2014 off with a unique Lynn Parquette, left, Mueller The Auction Committee is requesting experience, a one-day continuing education Ornamental Iron Works Inc. & Elite Architectural Metal Supply LLC and donations of auction items that may include: program hosted at Eureka Forge. As many of Roger Carlsen, owner, Ephraim metal sculpture, a garden gate, hand-forged you know, Todd Kinnikin from Eureka Forge Forge Inc., are NEF co-chairs. furniture, books, artwork, or antiques; nonpassed away this year. Todd’s son, Michael, had metal items, such as tools, gift baskets, gift certificates/couworked with Todd for many years and now runs Eureka Forge. pons, jewelry, electronics, The NEF trustees, and Michael, are taking the excellent  clothing, food/wine, presentation opportunity, while we are in St. Louis, to have a continuing drawings, the use of a condo at the beach, or airline tickets; education class that will be a tribute to Todd and the outspecialized services to create a custom, one-of-a-kind item standing work of Eureka Forge. for the winning bidder; or be creative — the sky’s the limit! Todd was well known for his love of making Damascus Every donated item will help the foundation provide qualblades using using Damascus steel in his ornamental prodity education for the ornamental and miscellaneous metucts, such as leaves, vines, and balusters. Fortunately, much als industry through continuing education programs, video of his knowledge and skills was passed to Michael, who has productions, educational publications, as well as supporting graciously offered his shop and skills to host a thrilling eduspecial projects important to the industry. cation opportunity. This class will cover the creation of a If you wish to contribute an item(s) for this event, please Damascus billet and the production of an ornamental object complete the auction donation form below or go to www. using many innovative techniques and tooling. nomma.org. For questions, call the NOMMA office at 888For registration information, check out the convention 516-8585, ext. 101 or contact Liz Johnson, liz@nomma.org.   guide in this issue. Thank you in advance for your help. We look forward to Now also is the time when the foundation asks for help with seeing you in St. Louis/St. Charles. The NEF trustees are excited about the out

Auction donation form Donation from (company or individual)______________________________________________________________

Descripton of item donated________________________________________________________________________

Item donated_____________________________________________________________________________________

Declared value of item____________________________ Minimum bid accepted for item___________________ Contact_________________________________________ Email__________________________________________ I will ❏ bring item ❏ ship item to METALfab. Contact Liz Johnson, liz@nomma.org for shipping instructions. Email form to liz@nomma.org or fax to 888-279-7994. DO N AT E!

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

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National Ornamental & Miscellaneous Metals Association

METALfab Opening new gateways

Learn, grow, excel 56th Annual Convention & Exhibits

March 12–15 St. Charles Convention Center One Convention Center Plaza St. Charles, MO

METALfab Opening new gateways

Make your plans to join a dynamic group of fabricators and suppliers in St. Louis/St. Charles, MO, on March 12–15, for METALfab2014. This is the perfect opportunity for you to Learn, Grow, and Excel by exploring new ideas, learning new skills, and sharing experiences with the best in the business. Pre-convention NEF Continuing Education Class*

Sam Richter, keynote speaker, will show you how to tell your story in a way that your customers want to hear it. 14

Tuesday, March  — : a.m.–: p.m. Start METALfab2014 off with a unique experience, a one-day continuing education program hosted at nearby Eureka Forge. As many of you know, Todd Kinnikin from Eureka Forge passed away this year. Todd’s son Michael worked with Todd for many years and has taken over the running of the company. The NEF trustees, and Michael, want to take the excellent opportunity while we are in St. Louis to have a continuing education class that will be a tribute to Todd and the outstanding work of Eureka Forge. Todd was well known for his love of making Damascus blades. He also used Damascus steel in his ornamental products, such leaves, vines, and balusters. Fortunately for us, much of his knowledge and skills were passed on to Michael, who has graciously offered his shop and skills to host what will prove to be a thrilling

education opportunity. This class will cover the creation of a Damascus billet and the production of an ornamental object using many innovative techniques and tooling. Your registration includes: instruction, materials, continental breakfast, and lunch. An additional fee is required for this class. See METALfab registration form for special pricing on this class and METALfab registration. You will need to provide your own transportation to Eureka Forge.

Convention program The NOMMA Education Foundation (NEF) METALfab Education Committee lead by Lynn Parquette, Mueller Ornamental Iron/ Elite Architectural Metal Supply LLC, has an outstanding education program for you. The program offers three days of educational sessions for attendees to participate and learn from others. Check the METALfab section of the NOMMA website for updates. Keynote and class presenter Sam Richter SBR Worldwide/Know More!

Wednesday, March  Sam teaches relevance acceleration — how to tell your company’s story in a manner that your buyer cares about and wants to hear. Sam’s customized programs will shock Fabricator

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METALfab Opening new gateways you, sometimes scare you, and always provide you new and innovative ways to find prospects, connect with people, and build powerful, meaningful business relationships. Know More! Selling

Know more than you ever thought you could (or should) about your prospects, clients, and competition. Business and sales is all about personal relationships. When you know more about your prospects and clients you can better relate on a personal level, build more meaningful connections, identify triggering events, tailor offerings, and ensure relevancy. Most important, studies show that when you practice “sales intelligence,” you’ll win two times more business! In this dynamic presentation, you will discover: n Web search secrets that you never thought possible for finding qualified leads, creating lists, uncovering opportunities, and understanding decision makers. n Tips and tricks for using social networks and “hidden” websites as sales and competitive “intelligence agents.” n Learn what is important to your prospects and clients on a personal level to help you close more business more quickly. n How to use information for a big-time impression with any prospect, build deeper relationships with any client, and completely differentiate yourself from your competition. This interactive presentation has a huge “wow” factor. You will be shocked at what you don’t know (but soon will). Know More! Reputations

In today’s instant communication and social networking, it’s easy to share opinions and others can share the same about you. Unfortunately, what you and others post online, text, and even email is not limited to private networks and friend groups. Rather, there’s a good chance that what you say online and what is said about you and your company is searchable, and archived, forever! This session will examine: n What is a personal brand, how to November / December 2013 n Fabricator

Special invitations to learn, grow, and excel NOMMA and the NOMMA Education Foundation (NEF) work together to make METALfab 2014 an exciting event for you. The leaders of the foundation, Lynn Parquette and Roger Carlsen (NEF Co-Chairs), and the association, J.R. Molina (NOMMA President), want to briefly share with you why they believe that you should join us at METALfab2014. J.R. Molina, NOMMA President

As NOMMA President, my goal this year 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 members to grow their business, important for the industry to grow, and important 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. Lynn Parquette and Roger Carlsen, NEF Co-Chairs

We would like to invite you to attend METALfab2014 so that you can Learn, Grow, and Excel through networking, education sessions, shop tours, and visiting with METALfab exhibitors. This is your opportunity to learn more about your business and the businesses of other attendees and suppliers as you grow new skills that will help your business excel in the future. Be sure to attend the NEF special events: n NEF Auctions on Thursday, March 13, and n Partners in Education Reception, Friday, March 14. enhance it, and how personal brands dramatically impact your company brand and reputation. n The dangers of sharing too much information, and what can happen if you’re not careful. How to respond if you don’t like what someone shares about you or your company. n Inside secrets on how to manage your online presence and Google rankings (for nontechnical people) so when people search for information on you, you control what they find. This thought provoking and entertaining program will provide you practical ideas you can immediately implement to improve your brand and your personal and business reputation. Know More! Business Planning

Learn to effectively find information, including competitive data, for better business and strategic planning.

Cover and inside arch photo credit: Gateway Arch Experience. 15

METALfab Opening new gateways METALfab 2014 Schedule Wednesday 3/12/14 8:00 AM 8:30 AM 9:00 AM 9:30 AM 10:00 AM 10:30 AM 11:00 AM 11:30 AM 12:00 PM 12:30 PM 1:00 PM 1:30 PM 2:00 PM 2:30 PM 3:00 PM 3:30 PM 4:00 PM 4:30 PM 5:00 PM 5:30 PM 6:00 PM 6:30 PM 7:00 PM 8:00 PM 9:00 PM 10:00 PM 10:30 PM

First Time Attendee 8:00–9:00 AM Opening Session 9:15–11:15 AM

Thursday 3/13/43 Education 8:00–9:30 AM Exhibits Open 9:30 AM–3:30 PM Top Job Voting 9:30 AM–3:30 PM

Friday 3/14/14 Education 8:30–10:00 AM

Spouse Classes 10:00 AM–3:00 PM

Education 12:30–2:00 PM 2:15–3:45 PM 4:00–5:30 PM

Exhibits Open 10:00 AM–1:00 PM

Education 3:45–5:15 PM

Spouse Tour 9:00 AM–4:00 PM

Dinner & Auction 6:30–10:30 PM

Top Job Jamboree 4:30–6:00 PM

NEF Partners in Education Reception 6:00–7:00 PM

March , , 

Waterjet vs. Laser vs. Plasma

This class will answer many of the questions from the NOMMA ListsServ on the differences in the three cutting types. Join in on a discussion with three NOMMA members who specialize in each. n Carl Grainger, Grainger Metal Works n L.E. Sauer, L.E. Sauer Machine Co. n Dan Nibbelink, Colorado Waterjet Hot Dip Galvanized Steel and Fighting Corrosion

Shop Tours 9:00 AM–4:00 PM

Education 1:00–2:30 PM 2:45–4:15 PM

Education sessions

The Mitch Heitler Award.

Saturday 3/15/14

Clinton Shaw, AZZ Galvanizing, will examine hot-dip galvanized steel and how it can address the growing corrosion problem throughout North America. Upon completion of this seminar, you will be able to: n Recognize the corrosion issues confronting North America. n Describe how zinc coatings, specifically hot-dip galvanizing, can protect against steel corrosion. n Incorporate sound corrosion protection into the design of steel products, which can significantly reduce maintenance costs over the life of a project.

Awards Banquet 7:00–10:30 PM

Heitler Award Winner

The Mitch Heitler Award is given to the top gold award winner in the Ernest Wiemann Top Job Contest. Join Mike and Bruce Boyler, Boyler’s Ornamental Iron Inc., as they discuss their award-winning project. Boyler’s recreated the intricate entrancedoor gates, sidelight grilles, and window grills on the Park Inn Hotel in Mason City, IA — Frank Lloyd Wright’s only remaining hotel in the world. The challenge was to craft the pieces in a manner that were an exact match to the original work. Without a single weld, the bronze and steel elements are intricately pieced together with mortises, pins, or screws just as Wright’s craftsmen would have done in 1910. New Code Updates and Why Rails Fail

Tony Leto, The Wagner Companies, presents the latest updates from the code hearings and discuss their effects on your company. He will also discuss the facts behind recent railing failures featured in media coverage.

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METALfab Opening new gateways LED Lighting

An overview of LED illuminated handrail specification, design, and fabrication considerations. Topics covered by James Woggon, The Wagner Companies, will include lighting definitions and terminology, lighting performance metrics, how to get specified, design considerations, coordination of installation, and players in the marketplace. Best Practices for Metalworking

Tired of going into disputes with architects and inspectors over reasonable procedures? Imagine if you could show a client that you followed a best practices manual. In this session, Ed Powell, Marric LLC, and panelists will lead a discussion on industry best practices. Trade practices published by related associations and NOMMA’s draft standard practices manual, “Code of Standard Practice for the Ornamental & Miscellaneous Metals Industry,” will be reviewed. The audience will be asked to share common friction points with clients and inspectors, which we may include in our upcoming manual. Uses and Applications of Power Hammers

Anderson Phillips, Oak Hill Iron Works, will discuss power hammer uses in the custom ornamental iron field, helping to bring clarity to possible applications and overcoming the challenges this versatile tool can create. In this class, we will discuss: n The types of power hammers and the advantages of each. n The functions a hammer can fulfill and its effects on your finished work. n The most important part of the tool, the operator. n How to train staff and develop the skill needed to grow the quality of your work. n Estimating art and valuing forged work. Innovation — The Way to Wealth and Growth

Every manufacturer must either embrace innovation or accept permanent levels of

November / December 2013 n Fabricator

second- or third-tier profitability. Attendees will learn a system to accelerate the creation of meaningful ideas for more profitable products, services, and processes; effectively communicate ideas; and commercialize innovations faster and more profitably. This class will be presented by Innovation Engineering Black Belt and Missouri Enterprise Project Manager Laura Lee Rose. A study of manufacturers has shown that companies pursuing innovation as their core strategy realize 50–100% higher profit margins than those who pursue low cost, high quality, fast delivery, or voice of the customer strategies. Find Out the Secrets to Their Success

Come have a candid discussion with leaders in your industry. Find out what they know and learned over the years that could be the difference for you in having a more successful business. This class was a hit last year — you will get to meet a new group of leaders in St. Louis.

Shop tours

Saturday, March  One of the highlights of METALfab are the shop tours. Rob Rolves, shop tour chair, has planned an outstanding tour for 2014. Shops on the tour: n Mittler Bros. Machine & Tool (also providing a wonderful lunch for shop tour attendees), n L. E. Sauer Machine Company, n Classic Metal Craft, n AZZ Galvanizing, and n Missouri Ornamental Iron.

To Bond or Not to Bond. There is Absolutely No Question

If you have not established a performance bond line for your company, you are depriving yourself of profitable business opportunities. It’s not as scary a process as you may think. Attend this session presented by Joe Romeo, president, Industrial Coverage, to discover the secrets of qualifying your company for performance bonds without the stress, time, and costs you’ve been afraid of. Also find out about the other types of bonds available. Then learn how you can use your bond line to market and grow your business. A must-attend for shops that want to stand out from the rest of the pack.

Spouse program

Spouse classes, March  Spouse tour, March 

Attendees will have the terrific opportunity to learn and practice what they have learned with three wonderful classes taught by an

METALfab Opening new gateways outstanding local and national artist. This is all part of the Spouse Registration offered for METALfab2014. Classes will be taught on Thursday, March 13, and the tour will be Saturday, March 15. Other events included in the spouse registration are exhibits, Thursday Dinner & NEF Auction, NEF Partners in Education Reception, and the Awards Banquet. Missouri History Museum, St. Louis

Missouri History Experience

Take a step back to 1904 in St. Louis. A time of parasols, iced tea, and the World’s Fair. Forest Park was becoming a bustling metropolis with buildings known as “palaces” being erected daily to house the various countries and merchants for the thousands of fairgoers and their families from across the globe. Sharon Smith, historian and exhibition creator at the Missouri History Museum, will present a PowerPoint presentation showcasing the 1904 World’s Fair and what it was like to be part of one of the most electric times in St. Louis’ great history. Jewelry Creation Experience Ferris Wheel at 1904 World’s Fair in St. Louis (Image cropped and reduced 87%).

Enjoy a one-of-a-kind experience where guests are led by a local jewelry professional in the creation of a custom piece of jewelry. Each guest will receive an individual jewelry kit to assemble their custom beaded creations. Use your creative side to create a wearable piece of art that you can take home. Acrylics Adventure

For those of you who participated in the spouse program in Albuquerque, you were fortunate to have the experience of working in acrylics with renowned artist Maxine Minter. This year you will tackle a new subject and have fun tapping your hidden talents. Gateway to St. Louis Tour

Trace the history of St. Louis beginning with the city’s original settlement, Laclede’s Landing, through a nine-block historic district filled with renovated turn-of-the-century buildings housing shops, eateries, and offices. Visit the famous Gateway Arch created 18

to commerate the gateway to the west for thousands of 19th century pioneers. At the arch, take a tram ride to the top for a view of the city or watch a documentary on how this magnificent steel structure was created. Just east of the Arch, pass the excursion riverboats. Enjoy a view of the Old Cathedral, the historic Old Courthouse, the setting for cases involving slavery, the fur trade, and equal rights. Of these cases, the Dred Scott Freedom Trial is the most notable. You will pass Busch Stadium, home of the St. Louis Cardinals, and St. Louis Union Station (currently a luxury hotel), which was once the busiest rail terminal in the world. At the Cathedral Basilica of St. Louis, also known as the New Cathedral, you will see a large collections of mosaics. Then explore the historic Central West End neighborhood, the Barnes-Jewish Hospital Complex, and the mansions bordering Forest Park (site of the 1904 World’s Fair), fine examples of the “Golden Age” of St. Louis at the turn of the century. Today, the Park houses the world-famous Saint Louis Zoo, the Saint Louis Art Museum, the Missouri History Museum at the Jefferson Memorial, the Science Center and the Muny, among other attractions. A seated lunch is included at one of St. Louis’ fine restaurants.

Networking opportunities METALfab offers many ways to talk to fellow attendees in casual surroundings, but that does not mean that the learning has stopped. One conversation can lead to the solution to a challenge you face. Be sure and attend these special events to Learn, Grow, and Excel. Wednesday, March 

First Time Attendee Orientation

The best way for first-time attendees to meet the NOMMA leadership and learn more about the association, the NOMMA Education Foundation, and METALfab. Annual Membership Business Meeting & Keynote

This is the membership’s opportunity to participate in the annual membership Fabricator

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METALfab Opening new gateways business meeting where officers and directors are elected, reports are submitted, and recognitions are given. A special treat: Sam Richter, CEO, SBR Worldwide/Know More! will get the education started with his keynote address. Thursday, March 

Top Job Display & Voting

This is your chance to see the 2014 entries in the Ernest Wiemann Top Job Contest. Member companies cast their ballots on Thursday during show hours. At the Top Job Jamboree Friday afternoon, you’ll have another chance to learn more about the entries from their creators. The climax to the outstanding program is the presentation of the awards on Saturday evening. NOMMA Family Reunion

This year, we’ll celebrate these connections with a good old-fashioned “Family Reunion,” complete with good food, good fun, and time to catch up with “family” members you have not seen in a year. You’ll also bid on the wonderful live and silent auctions items that you have seen displayed in the exhibit area. To donate an item to the NEF Auctions, contact Martha Pennington (martha@ nomma.org or 888-516-858 x 104) or go to www.nomma.org for an donation form. Friday, March 

NEF Partners in Education Reception

The NOMMA Education Foundation thanks its supporters for all that they do for the foundation and its programs. Be sure and join NEF trustees on Friday night for this special reception. Saturday, March 

Awards Banquet and Officer Installation

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

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METALfab2014 sponsors

Thank you for your support of METALfab! Platinum Industrial Coverage Corp.; www.industrialcoveragecorp.com Mittler Bros. Machine & Tool www.mittlerbros.com Gold Colorado Waterjet Co.; Lawler Foundry Corp.

www.coloradowaterjet.com www.lawlerfoundry.com

Silver King Architectural Metals

www.kingmetals.com

Exhibit information

Join the exhibitors to experience their products, learn about their services and educate yourself on the possibilities for the future. We have a great group of exhibitors signed up for METALfab2014. Schedule for exhibits

n Thursday, March 13, 9:30 am–3:30 pm: Exhibits Open — Top Job Voting n Friday, March 14, 10:00 am–1:00 pm Exhibits Open

Go to www.nomma.org for an up to date list of exhibitors.

Exhibitors as of 9/20/2013

Company Name Architectural Iron Design AZZ Galvanizing Big Blu Hammer The Cable Connection CM Iron Supply LLC CML USA Inc. Ercolina Colorado Waterjet Co. Custom Ornamental Iron Works D.J.A. Imports Ltd. Eastern Metal Supply Elite Architectural Metal Supply LLC ETemplate Systems FabCAD Inc. Feeney Inc. Guardian Gate Hardware Hebo/Stratford Gate Systems Inc. Industrial Coverage Corp King Architectural Metals Lavi Industries Lawler Foundry Corp. Locinox USA Marks USA Mittler Bros. Machine & Tool NOMMA/NEF/NOMMA Chapters Ramset Automatic Gate Systems Inc. Regency Railings Inc. Sumter Coatings The Wagner Companies

Web address www.archirondesign.com www.azz.com www.bigbluhammer.com www.thecableconnection.com www.cmironsupply.com www.ercolina-usa.com www.coloradowaterjet.com www.customironworks.com www.djaimports.com www.easternmetal.com www.elitearchitecturalmetal.com www.etemplatesystem.com www.fabcad.com www.feeneyinc.com www.guardiangatehardware.com www.usahebo.com www.industrialcoverage.com www.kingmetals.com www.lavi.com www.lawlerfoundry.com www.locinox.com www.marksusa.com www.mittlerbros.com www.nomma.org www.ramsetinc.com www.regencyrailings.com www.sumtercoatings.com www.wagnercompanies.com

METALfab Opening new gateways Meeting & exhibit space

All events for METALfab2014 will be held in the St. Charles Convention Center conveniently connected to the Embassy Suites.

Registration instructions Two ways to register

The host hotel

Embassy Suites St. Louis-St. Charles/ Hotel & Spa, Two Convention Center Plaza, St. Charles, MO. Attendees can make their individual reservations by calling 1-800-EMBASSY or the hotel directly at 636-946-5544. Hotel reservations

Make Your Reservation Early! The St. Louis/St. Charles Embassy Suites hotel has reserved a block of rooms for METALfab attendees. Book early so you can easily network after hours. Attendees are always able to find great conversations going on in the lobby or bar during METALfab, a great chance to get and give advice. Reservation deadline

Friday, February , , or when the block of rooms sells out. Make reservations early. Relax in a two-room suite with separate living and sleeping areas. Amenities make you feel at home: two TVs, microwave and fridge, as well as high-speed Internet access. n Located in historic St. Charles, 20 miles from downtown St. Louis, 10 minutes from Lambert/St. Louis airport. n Connected to the St. Charles Convention Center. n Complimentary cooked-to-order breakfast, complimentary beverage & refreshments at Evening Reception. Room rates Embassy Suites St. Louis — St. Charles/Hotel & Spa hotel atrium.

Single/Double $134, Triple $144, and Quad $154 per night plus applicable taxes at the time of check out. Hotel requires credit card or cash deposit with reservation.

1) Go to the NOMMA website www. nomma.org and register online using your credit card. 2) Fill out the registration form enclosed in the convention guide and submit with check or credit card. Mailing address for registrations: NOMMA, 805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214. Fax number for registrations: 888-279-7994. Online registration ends on 3/5/2014, after that time you can register onsite at the METALfab registration desk (Registration desk will open, Wednesday, March 12, 2014 at 7:30 a.m.) in the St. Charles Convention Center. Register early for lower registration fees

e earlier you register the better the rate. An example of the savings on a Full Conference Package for NOMMA Members n Early Bird $450 (Deadline 2/13/2014). n Regular $480 (Deadline 2/27/2014). n Late $550 (After 2/27/2014). We still have the multiple attendees from the same company discount for NOMMA member companies. Non-members save money on your registration by becoming a member and saving on each registration, plus you are eligible for the multiple attendee discount. When your company joins NOMMA, all of your employees qualify for the member registration rate. For membership information go to www. nomma.org or contact Liz Johnson, Member Care & Operations Manager at 888-516-8585 x 101, liz@nomma.org.

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METALfab2014 Attendee Registration Form St. Charles Convention Center, March 12–15, 2014, St. Charles, MO See the Convention Guide or go to www.nomma.org for course and event descriptions. Note deadlines for special pricing: Early Bird rate applies through 2/13/14. Regular registration must be received by 2/28/14. Late registration Late fee applies after 2/28/2014. Registration must be received or processed online by the cut-off date to receive special rate.

Step 1a NOMMA MEMBER Registration Options Choose your registration type and enter the names for badges. ❑ Full Conference Package

Early Bird (2/13/14)

Regular (2/27/14) Late (after 2/27/14)

Opening Session (Keynote, 3/12)

1 full registration .........................$450 ..................................... $480 ...................................$580

Education Program (3/12–3/14)

2+ full same company ..............$410 ...................................... $440 ...................................$540

Exhibits (3/13 & 3/14)

5+ full same company ..............$375 ...................................... $415 ...................................$515

Dinner & Auctions (3/13)

Name_________________________________________________________________________

Awards Banquet (3/15)

Name_________________________________________________________________________

Shop Tours (3/15)

Name_________________________________________________________________________ ❑ NEF Continuing Education Program & Member Full Fabricator Package (3/11/14) Early $550 Regular $580 Late $680* Space is limited to 15 participants in the 3/11/14 program

Name_______________________________________________________

❑ NEF Continuing Education Program ONLY $250*

Name_______________________________________________________

❑ Education & Exhibits Package

❑ Spouse/Guest Package $360

$350 Early Bird (2/13/14)

Exhibits (3/13 & 3/14)

$380 Regular (2/27/14)

Dinner/Auctions (3/13)

$480 Late (after 2/27/14)

Special Classes for Spouses (3/13)

Opening Session (Keynote, 3/12)

Awards Banquet (3/15)

Shop Tours (3/15)

Spouse Tour (3/15) not included in other registration packages. This registration is not available after 3/3/14. Spouse classes are available only with this registration — not sold separately.

Education Program (3/12–3/14) Exhibits (3/13 & 3/14)

Name_____________________________________________________ Name_______________________________________________________ Name_____________________________________________________ Name_______________________________________________________

Step 1b NON-MEMBER Registration Reduced pricing for multiple attendees is not available with non-member registration. ❑ $425 Make our company a NOMMA member so that we can take advantage of the great member pricing above.

Early Bird, 2/13/14

Regular, 2/27/14

Late, after 2/27/14

Full Package ..............$620 ...........................$650 .......................... $750 Name_______________________________________________________ Educ. & Exhibits ........ $520 ...........................$550 .......................... $650 Name_______________________________________________________ Spouse Package ....... $525 ...........................$555 ............................ NA Name_______________________________________________________ NEF Continuing Educaton Program Only $450

Name_______________________________________________________

Individual Tickets Tickets will not be available on site or online. ❑ Dinner & Auctions (3/14/14) $90

Name_______________________________________________________

❑ Spouse Tour (3/15/14) $100*

Name_______________________________________________________

* Limited number of tickets available. Will not be available onsite. This event is ONLY included in the Spouse Registration, not Full Registration

❑ Awards Banquet (3/15/14) $60

Name_______________________________________________________

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

❑ MasterCard

❑ VISA

❑ Discover

✂

Card #__________________________________________________________________ Exp. Date_________________________________________ Name on Card____________________________________________________________ Card CVV_________________________________________ Signature_________________________________________________________________ Continued on page 22 November / December 2013 n Fabricator

METALfab2014 Attendee Registration Form ✂

Continued from page 21

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

Please check the appropriate ribbons below for inclusion in your registration packet: ❑ New Member

❑ Committee Member

❑ First-Time Attendee

❑ Chapter President

❑ Fabricator Member

❑ Chapter Member

City_____________________________________________________________________________ ❑ NW Supplier Member

❑ NEF Contributor

State ___________ Zip_____________________ Country_________________________________ ❑ Regional Supplier

❑ Gold Member —

Email___________________________________________________________________________ Phone___________________________________ Fax____________________________________ On-site Emergency Contact Number_________________________________________________

Member ❑ Local Supplier Member ❑ Affiliate Member

Person to contact in case of emergency______________________________________________ ❑ Committee Chair

20+ Years ❑ Past President ❑ BOD

❑ Officer

❑ NEF Trustee ❑ Officer ❑ Speaker/Presenter

Step 4 Attendee Profile Tell us about your business. This portion of the registration must be completed for processing. ❑ Check here if you are not involved in the business. If you are not involved in the business, this is all of the information needed. Thank you. List three (3) products you hope to purchase from contacts at METALfab2014: _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ _____________________________________________________________________________________________________________________________ 1) Primary type of business ❑ Fabricator ❑ General Supplier ❑ Contractor ❑ Other____________________

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

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

Important Information Registration Registrants can pick up their packets at the METALfab/NOMMA registration desk in the St. Charles Convention Center. Restrictions Attendees for the exhibits must be 14 years of age or older for insurance purposes. Cancellations If received in writing prior to March 5, 2014, we will be happy to refund your registration fee, less a 10% administrative fee. Understandably fees cannot be refunded for registrations cancelled after that date. Registrations are nontransferable without the written permission of NOMMA. Refunds will be processed within 30 days after the completion of the conference. Cameras Photography and videotaping are not permitted in the exhibit area, education sessions, or Top Job Gallery. Emergency Contact We would like to have a contact name and phone number in case of an emergency. This person would be contacted only in the event that you were unable to contact them yourself. Confirmation & Updates Your confirmation and any updates will be sent by email, so please provide your email address. Email Address Your email address will be provided to the exhibitors on their attendee list. If you do not wish to have your email address provided to the exhibitors, please opt out by sending an email to liz@nomma.org with the subject line “Email Opt Out for Exhibitors.” This will also opt you out for updates about METALfab. Online Registrations Online registration is available for credit card payments only. Recorded Sessions By registering for METALfab you are authorizing the use of any photographs and/or likeness in any recorded session. *NEF Continuing Education Program Tuesday, March 11, 2014, at Eureka Forge, Pacific, MO. You must provide your own transportation to this event. See convention guide or www.nomma.org for class description.

Return to

Questions? Call 888-516-8585, extension 101, or email liz@nomma.org. For updated information go to www.nomma.org.

Fayetteville, GA 30214

Online Registration is available on the NOMMA website www.nomma.org.

Fax: 888-279-7994 22

Email: liz@nomma.org

Be sure to include your registration form when mailing or faxing your payment. Fabricator

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METALfab2014 / NOMMA 805 South Glynn St., Ste. 127, # 311

SLIP-FIT

No Weld Hand Rail System

• Mechanical System • No welding required • Steel, Stainless, and Aluminum • Significantly cuts install time

10600 W BROWN DEER RD MILWAUKEE, WI 53224 (888) 243-6914 INFO@MAILWAGNER.COM WAGNERCOMPANIES.COM

Photo 1: A three-dimensional project presented to a fabricator might come in the form of a set of curved stairs. Photo: Courtesy Architectural Impressions, Chicago IL. Forge work, Keith Johnson, Bemidji, MN.

In this article, we will review the value of the third dimension in architecture, and then show you how to forge three-dimensional decorative coils.

By â&#x20AC;&#x153;Uncle Bobâ&#x20AC;? Walsh Typically, the built environment

Shop Talk

Forging in 3 dimensions

(architecture) starts with drawings. These drawings are called plan and elevation drawings. A plan-view drawing addresses horizontal considerations and an elevation-view drawing addresses vertical considerations. These drawings are usually rooted in two-dimensional logic.

Plan view

When designing a structure from scratch, the first application of twodimensional reasoning is the plan view, often called the footprint, birds-eye view or perimeter. Property lines, street access, sun exposure, views, and trees are among the elements one considers when positioning a structure on a site. Establishing the footprint is two dimensional, width and length, with a few projections and recesses here and there. Elevation views

Elevation views include the front, sides, and rear. For example, will the structure be a two-story home or a 24

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Photo 2: High relief (more depth) is no longer a bas-relief. It is simply a mid-relief or a high-relief.

arts. For the sake of this article, we will consider a drawing as being a singledimension entity.

angle in-feeding or engineering a an oversized radius, diameter, so if the twist is applied after rolling, the amount of overall diameter reduction of the finished helix will be correct. Typically, a three-dimensional project presented to a fabricator might come in the form of a set of curved stairs (photo 1). Other applications

Two-dimensional objects

Photo 3: This sculpture, below, is located in the Hyatt Regency Hotel, San Francisco, CA. Photo: Courtesy Hyatt Regency San Francisco.

skyscraper? By combining the twodimensional logic used when laying out the plan view with the two-dimensional logic used to create the elevation views, one ends up with a threedimensional structure, a volumetric form. Thus, a three-dimensional structure is built on two-dimensional reasoning. This volumetric form is typically constructed with right angles. The third dimension

If the design process is taken further, a three-dimensional element is added into the mix. Three-dimensional elements have width, height, and depth dimensions, but are constructed with compound curves, which require an additional set of skills added to that of right-angle construction. These additional skills may include (machine) November / December 2013 n Fabricator

of the third dimension in residential architecture, although not common, might be a wavy roof simulating a thatched roof or an interesting fountain or sculpture in front of the home. Terminology

Let’s think about dimensions and terminology. In the sciences, a drawing is two-dimensional. This is because a drawing is an illustration with lines that go both side-to-side, plus up and down. Width and height are two separate dimensions. Conversely, in the arts, drawings on paper are often referenced as being a single dimension. This reference is based on drawings being made on a single “plane” These definitions are arguable depending on whether you are coming from the sciences or the

A logical question at this point would be, if a drawing is a single dimension, and a sculpture is threedimensional because it has width, height, and depth, what would be considered two-dimensional when using artwork terminology? A two-dimensional work of art is called a bas-relief. Typically, a basrelief using metal would be close to being flat, but would be tooled so it has some imagery, numbers, or some other forms slightly raised on the flat surface of the metal. A basrelief is considered low relief, typically with a depth of a fraction of an inch to few inches. Strictly speaking, high relief (more depth) is no longer a basrelief. It is simply a mid-relief or a high-relief (photo 2). In wood or stone, the opposite may be true. The image form is often carved into the surface rather than raised from it. This technique is often called “counter-relief.” Whether low, high, or counter, reliefs have depth, but are not viewed from the back side. Because reliefs have body and are not viewed from the back side, reliefs are considered two dimensional in the art world. Three-dimensional objects

In a commercial application, a sculpture with compound curves in the center of an atrium provides a great contrast with the geometric shapes of a building (photo 3). This sculpture is located in the Hyatt Regency Hotel, San Francisco, CA. 25

Photo 6: Extreme examples of threedimensional thinking can be found in the contemporary architecture of architect Frank Gehry, such as the Walt Disney Concert Hall in Los Angeles. Photo: Courtesy Carol M. Highsmith Archive at the Library of Congress. Carol M. Highsmith Photography Inc. This work has been released into the public domain by its author, Carol M. Highsmith. 2005.

Photo 5: The setting of this stainless steel bean in Millennium Park, Chicago, is a contemporary art application. The buildings in the background are vertical, hard-edged, and geometric in shape providing contrast. ÂŠ Gary 718 Dreamstime.com

The Guinness Book of Records lists this hotel atrium as being the largest hotel atrium in the world. Look at the spiral staircase in photo 4. This was produced by Anvil Craft Corporation, Easton, PA, and featured in the January/February Photo 4: This spiral staircase was produced by Anvil Craft Corporation, Easton, PA, and featured in the January/February 2013 issue of the O&MM Fabricator. Photo: Courtesy Paul Sklodowsky, Anvil Craft Corporation. 26

2013 issue of the O&MM Fabricator. The compound curves of these stairs, combined with the geometry of the building and the foliage on the opposing wall, make this example of the built environment one of the finest and most dramatic I have ever seen. Next, look at photo 5, the stainless steel bean. This is an interesting application of contemporary art. Fabricator

n November / December 2013

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Why? Look at the buildings in the background. They are all vertical, hard-edged, and geometric in shape. How would an artist complement a vertical, hard-edged, and geometric background? With something soft-looking, horizontal, and compound in shape. The bean is exactly that, soft-looking, compound in shape, plus, it is bright and ever changing with its reflection of the sky’s changing moods. This sculpture appears to be a monument to fine craftsmanship. Extreme examples of three-dimensional thinking also can be found in the contemporary architecture of architect Frank Gehry (photo 6). This is a photo of the Walt Disney Concert Hall in Los Angeles. Extreme examples of three-dimensional thinking in historical applications can be found in the Art Nouveau period. Antonio Gaudi is often the name that comes to mind (photo 7). Small shop applications Photo 7, top: Extreme examples of three-dimensional thinking in historical applications can be found in the Art Nouveau period. Antonio Gaudi is often the name that comes to mind. Jaume Meneses from Wikipedia Commons; Creative Commons Attribution-Share Alike 2.0 Generic.

We have reviewed the value of contrast when all three dimensions are used in architecture. The third dimension generally provides the focal point and is often frosting on the architectural cake. Now, for small shop applications let’s reduce the focus of this article down, way-way-way down. Not to the point of jewelry, but by comparison to the previous examples, tiny. Let’s forge some three-dimensional elements that we can use in gate and railing work (photos 8, 9). This ironwork is

Photo 8, left above and photo 9, left: This ironwork is by Master Blacksmith Cyril Colnik (1871– 1958). Photos from the book Cyril Colnik, Man of Iron. Courtesy, Alan Strekow author. Published by Friends of Villa Terrace; 1 edition (September 4, 2011).

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After forging your rod into a helix, if it is like mine

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Drawing A.

by Master Blacksmith Cyril Colnik (1871–1958). The railing in photo 9 is far beyond the scope of your typical fence, but the swags are not. Let’s start with a length of 5/16-inch round stock about 30 inches long. We will forge a small coil that will be appropriate for the upper left bouquet in our grille drawing A. In sketch 1 on the “sketch page,” (page 35) I have added a little scroll termination on the end of the coil. Delete the scroll if it does not complement what you are doing. Next, we will feed our 5/16-inch round stock over the step in the anvil at an angle, while fullering the metal into the step with a cross-pein hammer. By feeding the metal under the

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Photo 10: Coil adjusting tool.

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hammer at an angle (over the step), a helix will be created on the out-coming end of the rod (sketches 2, 3). After forging your rod into a helix, if it is like mine usually are, it will be mis-shapened. True up the shape of your helix on the face of your anvil. When you pound down on a revolution of a coil, you will notice that it closes the gap between the revolution and the coil revolution next to it. To counter this constant closing of the gaps while you work your coil; a tool as in photo 10 will do the trick. Making coils is a back-and-forth process, going between shaping your coil and constantly opening-up the spacing between the revolutions with the “wedge” tool. The wedge is simply a soft piece of A-36 steel. When working a hot coil, there is no strain on the wedge. In place of the wedge tool, you can use a screwdriver-like tool with a large “spade” on the business end and a “T” handle on the other end. On the wedge tool, on the opposite end of the wedge, is an open rectangular frame. This frame works well for twisting a revolution if it is not parallel with the other revolutions. Simply heat the entire coil, drop the coil revolution that is not parallel into the rectangular opening, and adjust. This tool also works well for adjusting the tail of coil by holding the last revolution so you can bend the tail (hot, with a scroll tongs or fork of some sort). For larger coils (photo 11), I use ⅜-inch round stock. After heating the stock in a gas forge, wrap it around a cylinder per sketches 7–9 on the Fabricator

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Making coils is a back-

sketch page and photos 12 and 13. This will take a number of heats as you and-forth process, going will be heating a long piece (5 feet) in increments. After wrapping the round between shaping your coil stock around the pipe, the coil ends and constantly openingcan be reduced in diameter with a hammer, anvil, and wedge tool just as up the spacing between we did before in sketches 4–6. the revolutions with the On the right-hand side of our grille (Drawing A, page 30), a large coil runs ‘wedge’ tool, simply a soft up the side. Making a coil like this piece of A-36 steel. Ad_2011:Layout 1 2/7/11 10:09 AM Page 1 will take you all afternoon if you

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try to wrap it as it appears to have been done. The solution: Wrap the coil off the grille. Then with a .045 cut-off wheel in an angle grinder, slice the grill frame member under where the collar will go (above the coil). Then heat, pull the grille frame member out toward you, and slip the finished coil into place. With a torch, adjust the coil. Weld up the sliced frame and cover the weld with a collar. Bingo. Large or small coils are fun to make. Once you have made a few, you will find they take about 20 minutes each. The coil on the right side of the grille will be another story because it might have to be made in two sections and welded together, depending on the size of your grille, forge, and coil.

Fabricator

n November / December 2013

Sketches 1â&#x20AC;&#x201C;9 November / December 2013 n Fabricator

Good luck. Have fun. The joy is in the journey.

For your information

About the author Robert â&#x20AC;&#x153;Uncle Bobâ&#x20AC;? Walsh has been a fabricator/artist/blacksmith for 30 years. For 10 years, his shop was in downtown Minneapolis. After the invention of the fax machine (allowing an easy interchange of sketches), he moved to semi-rural Wisconsin where he set up a cottage industry with fellow shop owners that has been chugging along for 20 years. Their ironwork can be found throughout the upper Midwest.

Decorative coils in use.

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Images on metal Shop Talk

A hybrid method for producing imagery on metal sheets is hand drawn and uses chemical actions and abrasive metal ﬁnishing.

Larry Wood (center photo above) has spent 28 years as an

artisan doing architectural metalwork for the residential, commercial, and architectural market in New York. As owner of MetalReference, he works with metal, wood, glass, stone, finishes, and fabrics. Three years ago, he added doing artwork using metal finishes, which this article is about. Larry was an untrained college dropout who found a job at a woodshop. He soon discovered that “not only that I’m no good working for other people,” that for him there would never be a profit doing woodworking. “There is a plethora of extraordinary wood craftsmen, most of whom work for very little. The competition in that field is fierce,” he says. He shifted to metalwork, “which I found a lot harder and with less competition.” He learned metalwork by getting hired on a project he knew nothing about but figured it out as each job progressed. “Kind of brutal, that learning style, but effective,” Larry says. He moved to metalwork because he “needed money, was without a diploma, and wanted to do it by myself and for myself. There’s always work for people who are willing to do the dirty work of making things. Metalwork is a good mix of difficult, beautiful, and downright dangerous, so there are 38

fewer people doing it. Also, nearly everything that’s built has metal in it somewhere, so there will always be a need.” At 26, Larry opened a business as an artisan. “I told architects and contractors that I could build their work when I had no idea how to build their work. Got the projects from them, used the down payment to buy the machinery and materials, and learned how to do the job while I was doing it. Good training in materials, albeit a little hair raising.” And what did he learn? “I learned that going out on my own seemed to promise a flexibility with time and money that I would never get working for others. After 25 years that actually came true. It’s the first 25 years of an artisan’s business that’s always the most difficult, it seems.” About his art, Larry says: “The only real innovation here is taking a well-established decorative patination process and using it for something for which it wasn’t intended. I’d never known it to be used this way. These chemicals, abrasives, processes, and materials are as old as metals themselves. I’m simply using these materials and processes in a different way, to draw a recognizable image.” Now, let’s read Larry’s first person account of how he creates his art. Fabricator

n November / December 2013

All the images on the preceeding page

were drawn on metal sheets without the use of etching, printing, pigment, ink, pencil pen, or brush. Instead, they’ve been drawn by hand using architectural antiquing chemicals and abrasives. This peculiar melding of chemical action, traditional drawing, and abrasive metal finishing can be used on sheets of stainless steel, copper, bronze, and steel to yield striking results. Here’s how it’s done

preparation for drawing on the metal. 2 Choose your metal. I chose stainless steel and had the full-scale layout nearby. Stainless steel is a personal choice, but you could easily choose bronze, copper, or steel. Each metal has a different base color; more importantly, the chemicals that you’ll subsequently apply will react with each metal with its own set of colors and tones that are characteristic of that chemical and the chosen metal. Stainless steel will color with blacks and grays, with some very muted browns, so your finished product will resemble black and white photography. Bronze and coppers will be a rich palette of warm browns and violets along with the bronze and copper of the parent metals. Steel will start grey then color to a set of blues and yellows with a hint of red rust.

1&2

1 Gather your image material and

organize it into the composition that you’d like to create on the metal. I do mostly figure imagery, so I photograph my model close to the pose I want. A drawing or a collage will do just as well. Sometimes, I manipulate the image using Photoshop, hand sketching, and cutting and pasting until I have the image the right size, the right shape, and the correct lighting. Layout starts now and is printed out full-scale in November / December 2013 n Fabricator

that serves as the background for the piece.

4 Darken the sheet with the chemicals. I like to draw starting with a dark

“canvas” — drawing in reverse, as it were. Use nitrile or latex gloves for this. The chemicals are not strongly corrosive, but they contain chemicals that can leach into your skin and cause muscle fatigue.

3 Put on gloves and don’t touch the metal surface! Start preparing the metal surface. All the metals, except

the stainless steel, are very reactive to the oils on your skin, and will tarnish with hand and fingerprints all over your image if you touch it from now on. Scuff away the surface grit, oil, marks, and oxidation to expose the fresh metal. I use 3M Scotch-Brite medium grit, maroon non-woven abrasive pads (#7447). I stroke the metal in a long linear direction to get a good base for the application of the chemical reaction but also to differentiate from my later abrasion within the image I’ll be drawing. Experiment here. The way you move the abrasive will be evident in the finished piece. Some interesting effects can be created by abrading the surface, especially on the portion of the metal

4c The chemicals are common “blackening” or “browning,” or “bluing” chemicals available from sources such as Jax Chemicals, EPI, or Birchwood Casey. They are primarily used by metal fabricators to give an antique patina to metal products. Each metal 39

has its family of chemicals that react with each different metal to make different patina colors. Learn the different patina colors by experimenting on scraps. For this image, I want an evenly darkened background. I apply the chemicals while rubbing with pads at the same time, which darken the entire piece gradually until it reaches the desired intensity.

5 Layout the position of the image.

The blackened stainless steel sheet covered over with paper to protect from scratching, except where the image is laid out. The image is cropped with a knife along the bright edge of the portrait where the hard line of her face and shoulder show against the background. This allows masking tape to be placed along that edge so that 40

later I can scuff her face and shoulder to reveal the metal underneath without scuffing the background. I then lift the image away to expose the blackened stainless steel where I want to draw the image. Now the artistic part 6 Rub the metal. With the image

nearby, and a set of sharp objects and scuff pads for me to use as rubbing tools, I rub the metal where the highlights of the image show. This exposes the bright stainless steel below. I have taken off my gloves because stainless steel is non-reactive to the oils of my skin, but if you are working in bronze, brass, copper, or steel, you should still have gloves on, and keep them on for the duration of the drawing process.

Here you can see her image beginning to appear under the rubbing with a scuffpad. The direction and style of scuffing will make a difference in the finished image, and itâ&#x20AC;&#x2122;s worth experimenting with this until you are satisfied. Sometimes I use a small piece of pad, sometimes a sharp object to press the pad into a bright spot, or the edge of an index card to scuff over the edge to make a sharp edge on the image on the metal. Go back into the drawing to scuff as many times as you need, just as you would with a pencil drawing or any painting, until the image really begins to appear correctly. After successfully abrading the image with scuffpads, youâ&#x20AC;&#x2122;ll often need to go into the image with small Fabricator

n November / December 2013

brushes, sticks, or other tools to daub some chemical back onto areas of the work that need more darkening. In the photo 6e, I removed the protective tape along the edge of her face and shoulder, exposing the background. I kept the protective paper to prevent scuffing the rest of the sheet by mistake, and I am here working chemicals into the hair to create dark streaks. Again, this is an artistic judgment, but it often enhances the work to repeatedly apply chemicals and abrasive scuffing on the image until you are satisfied. 7 The finished piece. The stainless steel doesn’t require a lacquer finish to protect it from further corrosion in the way that bronze, copper, and steel do. I rub it with butcher’s wax to give it a final shine. When you work with copper, bronze, or brass spray the finished work with Incralac, available on the Web. It’s a clear exterior-grade coating specifically formulated for copper alloys. It works well on steel, but Valspar also makes a rust-preventative clear enamel that works on steel.

November / December 2013 n Fabricator

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With a little help from her mentors n

With self-taught fabrication skills and business advisors, A Fabrication’s Gale Schmidt ramped up her business moving from wheelchair ramp manufacturing to architectural and ornamental jobs.

Editor’s note: Getting into the metalworking business was “happenﬆance,” says Gale Schmidt, owner of Milwaukie, OR-based A2 Fabrication. She was a high-tech diﬆribution manager for Wacom Technology in Vancouver when her church asked her to volunteer to help build a wheelchair ramp. “That led me to inventing a modular wheelchair ramp in which individual components interlocked to make an inﬁnite number of ramp conﬁgurations and lengths,” she says. But when she couldn’t get the parts built for her invention, she quit her job at Wacom and took a welding class. “With 5,000 from a 01(k) plan, I bought a welder, a saw, and a grinder to build and inﬆall the ramps myself. I only had to know one process — gas metal arc welding — and I only had a small number of parts to weld. I got good at welding, and I got better at designing.” From her wheelchair ramp manufacturing company, Access Ability, Schmidt moved on to eﬆablish A2 Fabrication, specializing in decorative and functional designs for fences, railings, gates, ﬆairs, as well as architectural and ornamental projects. Here’s the reﬆ of her ﬆory, including thoughts about being a woman-owned business, fabricator training, working with subcontractors, and marketing.

Gale Schmidt, owner of A2 Fabrication, stands in front of the company’s tool cart that is made with panels that swing open for tool storage and quick, easy access. “We can pack a lot more tools into a small space, and since it is on wheels we can move it to where it is needed,” she says.

Fabricator How and where did you

get your ornamental and miscellaneous metal fabrication education and training?

November / December 2013 n Fabricator

Fabricator How did you get better at

The First Presbyterian Church in downtown Portland, OR, is listed on the National Register of Historic Places. Completed in 1890, it was renovated in 2006 when a new fenced courtyard was added. A2 Fabrication made and installed the new fence and five new gates. The posts and rails are ½ x 2½ flat bar, pickets are ½-inch-square. The crown above the upper flat bar between two posts is actually one waterjet cut pattern about 6 feet long. “The uniformity is impeccable,” says A2 Fabrication owner Gale Schmidt.

Schmidt I had no prior experience in the welding trade before I started the business 17 years ago, although, I did enjoy woodworking and had a cabinet and furniture-making business for a couple of years in the early 1980s.

I could always figure out how to put things together and when I discovered that you could fix a mistake in metal by simply welding on new material I was hooked. Just can’t do that with wood. I learned by doing.

welding and design? Schmidt Everyday, I would fabricate components for the wheelchair ramp system. I’d cut shapes and weld parts together to make the modular components of the ramp system. Every day, I’d pick up a little more insight about welding. My design skills had to improve, too. Every customer that needed a ramp had a different layout requirement. Ramps were different heights. Some had landings, and some had 90° turns or switchbacks. I needed to be able to evaluate the residence, the space available, and the codes to design the appropriate ramp system. Good thing I like geometry. Fabricator How and when did you

start as a professional fabricator and business person in this market? Schmidt My business started in 1997. Because I did wheelchair ramps exclusively, I named my business Access Ability. The market for ramps was good then because the State of Oregon assisted people with disabilities

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A2 Fabrication owner. “We built every other section in the shop The historic Vista House at Crown Point on the Columbia River and connected the sections in the field. The curve of the ramp had Gorge was renovated in 2005, and A2 Fabrication added the ramp to be exact to miss running into the steps. The decking and skirting and rail — the framework that spirals around the building — for AD PROOF - 45-3454-ACF-121807-V2 (a fiberglass composite) was added by others over our frame. ADA access. “I believe we used bent 2 x 4 tube,” says Gale Schmidt,

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Portland expanded its streetcar line in 2005. A2 Fabrication provided about ¼ mile of wire mesh fencing along the line — typical galvanized finish for city projects. “We had to plumb the legs and align the horizontals of the wire mesh so that the lines looked continuous over multiple slopes and curves,” says owner Gale Schmidt.

by providing ramps to qualified applicants. I was one of only a few providers of ramps and I stayed quite busy. Around 1999, Oregon stopped funding the ramp program and the market was gone when suddenly a contractor asked me to build cages at a computer company in Hillsboro, OR. Seemed

doable and I thought I could just transfer my welding skills and equipment into making fences. Cages, fences, it was square and seemed simple. Next, I immediately connected with the Oregon Association of Minority Entrepreneurs, which was actively seeking small, minority, and woman-

owned businesses for civic projects. Through them, I got a contract to build guardrails and handrails for the expanding Portland Light Rail transit stops. That meant I was really in business. I needed employees and business knowledge about contracts, scheduling, bonding, and financing. I was in over my head, but I fell into a mentorship program offered by the Port of Portland. The program’s mission was to help get small business owners qualified to do business with major contractors. I received three years of direct mentorship with two seasoned business owners — both were women and both were in the construction trade, albeit, not fabricators. Fabricator Who were/are your

mentors? What did you learn from your mentors? Schmidt My business mentors were Rhonda Herschell, owner of Cherokee General Corporation, and Sandy Trainor of Kodiak Pacific Construction Company. Their guidance with

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A2 Fabrication’s shop is 10,000 square feet. “We have fenced storage out back to hold our four service vehicles. We came here in 2009 after I suffered a severe allergic reaction to chemical residue in a shop we had just rented in northeast Portland. This shop is perfect,” owner Gales Schmidt says.

business processes, financials, marketing, dealing with employees, and operations was essential. So many times when I was stumped, stressed, or depressed about situations, they guided me through. This was a life-

line for my business. But I’ve always had confidence in my ability to figure things out, and I love solving problems. This industry provides ample opportunities for this. What could be better?

Fabricator What hurdles, if any, have you faced as a woman-owned business? Schmidt I certainly remember when times were much more difficult as a woman in the trade. There were the vendors who did not want to take my order, or who thought I didn’t know what I wanted. I’ve had contractors require more of my company than of other firms. My biggest, most noticeable, difference working with contractors is that my calls are not returned in a reasonable time. I can leave several messages, send emails, and get no response. But, if I have one of the guys do an inquiry, they’ll get a response in short order. It’s annoying. Fabricator What types of products

and services do you provide? Why these? Schmidt About 80% of our work is ornamental products for public works projects. We do handrails, guardrails, bollards, and fencing for Portland, TriMet, and Multnomah County.

Fabricator

n November / December 2013

We also get an occasional residential project and some light structural work. The Oregon Zoo is putting in a new Condor exhibit, and we are providing 60-foot-long columns to attach netting to contain the birds. That is big for us.

gan and reflect it in their workmanship and customer relationships. We keep our contractors happy by taking care of the bureaucratic end — all the paperwork, reports, certifications, and documentation that the government wants. Other subcontractors our size have problems with that aspect.

Fabricator What sets your company

apart from others in the fabrication industry? Schmidt Our motto tells our story: “A2…We Care, We Can, We Do!” The employees really identify with the slo-

Fabricator Can you talk about the

problems subcontractors have with the paperwork?

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Schmidt In a shop where the owner does everything, time is a scarce commodity. The majority of time is spent in bidding and production. On civic projects, every little thing needs a document. Drawings need approvals, questions are formalized, and answers are binding. Every interaction requires a document. Then you have to do prevailing wages and fringe benefits and special payroll reporting. Everything is audited. And, if you need a sub yourself, you have to manage every transaction they do. Not to mention, there is usually a requirement for workforce training where the subcontractor must retain an apprentice (who is in a bona fide apprentice program) and keep track of that work too. Seems like there is more paper than steel on some projects. It’s a lot for a small company to try to manage. Fabricator What is your company’s

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core strengths and why? Schmidt Our core strengths are ingenuity, efficiency, and helpfulness. The market is really tight, and our jobs are all low-bid projects. We have gotten creative in fabricating. This year, we started printing fullscale templates for our railings. This cuts layout time by 90%. I require the shop drawings to be fabrication detailed — not just detailer detailed. Only the pertinent dimensions are on the drawings, and they are what are needed to build to. We provide the sawyer with the precise cut list, a piece-mark identification list with exact cut sizes, and angles and prep needs (such as coping or drilling). This eliminates calculation errors on the floor and makes the part prep very quick. Fabricator What is an example or

two of a detailer specification that is not important to fabricators? Schmidt One thing we see all the time is slopes being specified in rise/ run dimensions. We prefer the slope to be in degrees to the nearest tenth. We have to convert rise/run numbers to degrees anyway to set our saws for cutting. Converting rise/run to degrees is an extra step. 51

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Portland’s Rose Garden arena features 1¼-inch pipe rails made with a flair by A2 Fabrication. Owner Gale Schmidt says: “At the time we made these we did not have a bender and put it all together with elbows. Guess we could have out-sourced the bending but didn’t think of that back then. Now we do a lot of our own bending or outsource when needed.”

Fabricator What new technologies are you looking at using, both as a fabricator and as a business person? Why? Schmidt We are exploring having more files on “the cloud.” I just bought a Microsoft Surface tablet, which I hope to use in the field when measuring jobs or coordinating with customers. The tablet will also allow us to photograph and annotate pictures of project sites and access files on the cloud from anywhere. All I have to do is figure out how to use the technology (which is another learning curve to throw in the mix).

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Fabricator Do you turn down certain jobs? What kinds

and why?

Schmidt I’ll turn down a job, if it is too much of a risk, if there are too many unknowns, or if the contractor is hard to work with. By unknowns, I’m referring to the design not being well-defined, the job site may be over-cluttered with multiple trades, or the location is dangerous. That doesn’t happen often. It is hard to turn away work. Fabricator What type of equipment do you use in your

shop?

Schmidt Our shop is a rented, 10,000-square-foot warehouse with 20-feet-high ceilings and four large overhead November / December 2013 n Fabricator

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doors (see photo, page 50). I hung my own lights. We have basic shop equipment. Vertical and horizontal band saws, cold saw, 66-ton iron worker, Scotchman abrasive pipe notcher, Almi multi-port pipe notcher, shop-made backstand sander, Supermax milling machine, Eagle CP-30 and Big Brute benders, and an assortment of welders. Our rolling stock includes a 6,000-pound forklift, F-350 service truck, F-450 service truck, F-250 pickup truck, and a LCF flatbed truck. I always try to put profits back into the company to expand our capabilities or make our work easier. That usually means I add to the shop before I pay myself, except for living expenses. Got to love this stuff. Fabricator How many people work in your shop? What do

they do? How many full-time? Part-time? Schmidt I have four fabricators, a detailer, and a parttime bookkeeper. I do just about every function imaginable in and about the shop: bidding, field measuring, detailing, designing, ordering material, creating work orders, managing projects, and sometimes cutting, welding, and finishing products. Sometimes I get to eat and sleep. Fabricator Do you have hiring and training issues? How

might these issues be resolved? Are you able to find trained people to hire? Where do you find them? Community colleges and trade schools? Schmidt It is hard to find welders who are skilled and serious about their trade. Believe it or not, we have the hardest time finding welders with clean driving records. Everyone here has to drive our vehicles. We do a lot of training here, but a small shop really needs an experienced workforce. I have hired graduates from the local community colleges several times with no success. The problem is that they come to work thinking a project is a class assignment and they have all semester to turn it in. Our customers frown on that timeline. Also, they may know how to run a weld but they lack other basic skills such as reading a tape measure or a print. It is often easier to bring in someone with no experience in welding who has construction sense and teach that person to weld. That process has worked better for us. Fabricator Do you do everything in-house or do you

outsource some steps of the fabrication and finishing process? Which ones and why? Schmidt We outsource painting, powder coating, and laser or waterjet cutting. We are best at fabricating. Fabricator You’re in both the residential and commercial

market. How have each of these markets been for you the past couple years? Has it been rough with the downturn in new residential construction or no change because you are focusing on high end? Or have you such a great marketing plan that the economy has not affected you? Schmidt I’m a bit shy and so I don’t enjoy marketing, which is the chief reason I’m doing public works projects. With the public works projects, I just need to be a com54

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n November / December 2013

petitive bidder. That’s good for my non-marketing self, but tough because there is little profit in the work. We had a tough year in 2012 because of the economy. The shop was actually empty (except for me) for two months. Since then, I’ve started to try to develop good relationships with the contractors we work with and am looking at more commercial projects, in addition to public works. Fabricator How much do you use social media, email, or

newsletter marketing? How do you use it? Have you been successful with social media marketing? Schmidt I haven’t done any marketing with technology. No social media or email marketing. I haven’t set aside time to evaluate its usefulness or start playing with it. Fabricator Have you developed any useful content as a

marketing tool to help inform or get clients, e.g. how-to articles, project gallery, video of your shop, testimonials, white papers, problem-solution case studies, a blog? Schmidt I’ve thought about all of the above but have not created time to get it done. I would love to have a blog and do educational videos on the tips and tricks we have discovered over the years. Fabricator Do you use plan rooms to find work? Which

ones do your prefer and why? Schmidt I have been using a plan room for many years. But, now contactors and organizations are going to on-line plan placement. I look forward to not having to pay for plan room membership. Fabricator Are you investigating online plan rooms now? Schmidt We belong to the Contractors Plan Center of

Oregon. It is both a physical and an online plan room. I sometimes peruse the online plan center to see what projects are out for bid. I find the center to be useful for finding work and for accessing the plans. I haven’t visited the site for a few months because we are currently too busy to seek other work at this time. I can’t believe I just said that. Fabricator So, what advice do you have for other fabrica-

tors trying to find clients? What must fabricators do? Schmidt For those wanting to get into the public works arena, the most important thing is to allot time to learn all the paperwork, reporting, and safety requirements, and be prepared to be under the looking glass. Fabricator What technological or business or market

trends do you see? Schmidt One business trend I see is that contractors are buying into pre-qualification requirements and outsourcing the pre-qualification process. They are placing an extra burden on the subcontractors in three ways: 1) The pre-qualification requirements are time consuming. 2) The cost of the prequalification is passed on to the sub-contractor. November / December 2013 n Fabricator

3) The prequalification is not universal, meaning that contractors use different agencies and other contractors are not recognizing the prequalifications of others. This might be something NOMMA could investigate. Fabricator What are the prospects

for the next year or two? Schmidt I don’t have much confidence in the economy. However, 2014 looks strong for us. We have major contracts with TriMet for expansion of the light rail system — about one year’s worth of work on

deck. I’m looking to strengthen my presence in the private sector so we’ll have other opportunities at the end of this great run. Fabricator Beyond the economy,

what business challenges have you faced? What business strategies enable you to succeed? Schmidt Besides having to learn a new trade and learning to run a business, the biggest challenge has been finding the right people. I’ve met more than my share of “fabricators” whose primary fabrica-

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tion work was only their description of their skill set. Oh, the stories I could tell. My business strategy is to look for efficiencies. Always, always, always look for a better way to get something done. Fabricator How do you define

“customer service”? Schmidt Each of the letters in our motto “CARE, CAN, DO” have a meaning. CARE = Careful, Alert, Respectful, Enthusiastic. CAN = Competent, Able, kNowledgeable. DO = Deliver on time Optimum products and services. That’s what it means to us. Fabricator What fabrication job

challenges have you faced? How have you resolved them? Schmidt Fabrication is all about challenges. How do we turn an architect’s vision into a 3D product? We are always dealing with angles, spaces, weight, codes, and connections. One project we had was to build a “bike corral” out of stainless steel pipes that were crisscrossed in multiple, precise angles and connected to an array of top pipes that were slanted on two axes (see photo, page 57). It was sort of an elongated teepee configuration. It had to be built upright since no surface was in the same plane with any other surface. We built a fixture for the positioning the bases and mounted the top on temporary legs to position it over the base fixture. Then the vertical, crisscrossing supports were placed with the use of laser beams. Very fun to figure out and get it right. Fabricator Have you ever had an

“a-ha” (a compelling discovery) business or fabrication moment? Talk about it. Schmidt Seems I wake up at least once a week with a way to do something that had me puzzled the day before. Just last week I racked my brain all day trying to figure out how to attach a handrail to a post to get the look the architect wanted. The architect was mixing steel and stainless and had a Fabricator

n November / December 2013

complicated, convoluted attachment system that was labor intensive and the connection was prone to failure — it would break with usage. Then it hit me — a post and nut configuration that eliminated the extra steps and material, looked like the architect wanted, and was 10 times stronger. We just got the approval for this. Fabricator What NOMMA resources

and/or volunteer work have benefitted you most? And how are you involved in NOMMA? Schmidt NOMMA has been invaluable to me. The ListServ is the most phenomenal tool a fabricator could have — like having a staff of experienced fabricators, engineers, code experts, and business partners all in your office. I’ve learned so much from the expertise of NOMMA. Everything from “what wire do I use for Corten” to “what do I do about employees who come late to work?” I’m currently President of the Northwest Chapter of NOMMA. I and the other board members (Greg Madden, Larry Jenks, and Brad Adsit) have organized two chapter events so far. Getting the chapter running has been a bit more challenging than anticipated. I think the NOMMA members in our area are extremely busy. But over time, we hope to show folks that there is a benefit to the time spent.

A2 Fabrication crew that built this completed stainless steel bike corral for Portland’s Bureau of Environmental Services. The stainless steel finish is bead-blasted. Several rows of half-barrels on top to grow plants will be added. The runoff from the building roof will be routed to the planters and then into a catch basin. The City may want replicas around Portland.

Fabricator Anything else you’d like

to share that you think is important or would be helpful for other NOMMA members to know? Schmidt I love this profession and one of the things I’m trying to accomplish is to elevate the image of welders. I would like to see welders recognized as professionals, not macho, crude, under educated laborers. Every day is a learning opportunity for all of us. The trade is complex and skilled welders are technicians as much as anything. Hats off to the folks who do this work.

November / December 2013 n Fabricator

By Molly Badgett

Job Profile

Mid-Cities overcomes securıty challenge n

Completing a wroughtiron fencing job for the Texas Governor’s Mansion was no small feat for Mid-Cities Ornamental Iron Works. Despite driving distances, preservation issues, and watchdogs, the Famiglios persevere with a lot of welding and ﬁnishing work.

Every now and then, a fabrication project will come along that’s so aggravating you’ll curse the day you ever agreed to take it on. That is, until enough time passes and a sense of satisfaction helps fade the frustrations. John Famiglio readily recounts the “special challenges” of the 15 months he and his staff from Mid-Cities Ornamental Iron Works, Southlake, TX, spent on the grounds of the Texas governor’s mansion in Austin. The task: Constructing 480 feet of replacement wrought-iron fencing around the historic site, along with other ornamental-iron details on the property. The latter included camera posts and beams, decorative bollards, automatic gates, interior gates, and decorative pieces for the garden area. Mid-Cities’ work was part of a $25 million project to restore the governor’s mansion and increase its security after the historic building was set ablaze by an arsonist in the summer of 2008. While Mid-Cities signed a non-disclosure agreement to prevent it from revealing too much detail about the decorative fencing, several news outlets refer to it as “reinforced perimeter walls” that, along with a new surveillance system, gates, and guardhouses, make up the enhanced security.

Getting the job

Famiglio and his team, which included his 25-year-old son Jacob, were recommended for the project based on their reputation, and were selected after completing an expectedly extensive bidding process. Jacob handled the paperwork, which included a portfolio to show all the organizations involved in the project all the work Mid-Cities had done through the years.

John Famiglio, left, and son Jacob (Jake). Fabricator

n November / December 2013

A B

Counter-clockwise, starting above A) Each transition fence section was “radius’d” one foot for the periodic change in grade. The top cap rail had to match the post for aesthetic reasons, except at profile columns. B) One of the large profile columns fitted to accommodate a security camera post. C) Camera posts and photo beam brackets on the north wall. Along with constant patrolling by Texas state troopers, the Texas Governor’s Mansion security “is second to none,” says Mid-Cities’ John Famiglio.

“We’d never had one,” Jacob says of the portfolio, which he thinks showed the preservation board that MidCities could properly represent the governor’s mansion. “That wound up being a big factor in getting the job; it included a lot of stuff.” Their portfolio included photos of work done at three television studios of the Trinity Broadcasting Network in Texas, California, and Tennessee; residential entry gates; and commercial work. Photos were submitted from 15 jobs that seemed equivalent to the size of the governor’s mansion project. November / December 2013 n Fabricator

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‘Two-and-a-half football fields of welding’ and a lot of finishing As if access to work on the governor’s

solid steel met the decorative connection steel collars and horizontal 2 x 1-inch, C-channel iron. Welding on the fence was done using gas metal arc (GMAW) with E-70S-6, .030 mild steel, John says.

property wasn’t challenging enough, the work building a perimeter fence grand enough to do a historic site justice made Mid-Cities Ornamental’s work one for the memory books. “To call it a fence is almost a disservice. It really was a very, very high degree of difficulty,” John says. “Everything was one-off, from the fence posts to the photo-beam brackets.”

Finishing was time-consuming

First sense of distinctiveness

At key locations along the fence, 10-foot fabricated columns lend the first clue that the fence is not your average decorative property border. Each column, all 12 of which feature plate steel and water-tableeffect Julius Blum extrusions for the recess panels, took 74 feet of TIG, gas-tungsten arc welding (GTAW). “That’s two-and-a-half football fields of welding,” John says. “All of it was done in the shop in Southlake, then brought in. I worked many weekends and holidays, 18-hour days to get this done. The finishing, grindingwise, would take three times as long as the mild steel take-down. The other columns and products mostly followed the same procedure as the fence finish. Painstaking, but rewarding.”

Fabricator Jose Medina welding one of 55 custom fence posts, specifically welding 1½-inch, halfround solid steel to form a decorative collar effect, along with ¾-inch solid bar.

Coating was outsourced

All metal products were outsourced for coating. The spec was sandblasted and had two coats of semi-gloss black. Between the posts and columns, the fence’s main sections were created with 9-foot, squared pickets made of three-quarter-inch solids. They were bent into a semi-circle on both ends to form repeating arches and were connected, also on both ends, with half-inchthick, notched collars.

Detailed treatment for fence posts

The fence posts, while smaller than the columns, were still given detailed treatment to adequately complement the fence panels. The square tubes graduated from 3 inches at the top to 4 inches at the base. Half-round and flat-metal borders were placed along the tubing to add design interest along the transitioning width. This, John says, was among the biggest, most time-consuming problems, and one that destroyed the initial timeline. “Because of the metallurgic composition of the molding material, I couldn’t use mild steel to weld. All of these columns were welded using GTAW and stainless-steel filler rod. Because the butt welds needed to look like one piece, another step was added: stainless steel grinding wheels.” The mansion project had many welded connection points where the ¾-inch-square

John and the crew used 4½-inch-diameter fan discs of 80, 120, and 200 grit. In most cases where access was easiest, the results were good. In hard-to-get areas, they used a Dynafile with a ¼-inch belt at 80 and 120 grit. Again, good results but extremely time-consuming, John says. “Overall, the client was very happy with the finished product.” Other products that required finish included the photo-beam brackets, 13-feettall camera posts with support arms, fenceand gate-support posts, the large steel columns, and two 8-foot decorative columns at the main entrance on Colorado Street.

Plasma torch vs water jet

All seams of the profile columns were TIG (GTAW) welded solid by using stainless steel 308L filler rod. This column was going to the grinding and sanding area.

The first 200 or so of the collars were cut using a plasma torch, but a water jet proved to be more effective because its clean cut allowed a faster and more precise fitting of the pickets into the collar recesses. The panels were positioned between a detailed channel along the bottom of the fence and a built-up piece of decorative cap at the top. Periodically along the run, 1-foot stepdowns were placed to align the fence with the grade of the property, which differed 8 feet from one end to the other, sloping toward the front and as much as 6 feet down to the sides. — Molly Badgett

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n November / December 2013

The Famiglios sent in their proposal for the job in June 2011; they signed the contract in late July and started the project in August. The project was finished in August 2012. Several challenges

“We were lucky enough to be selected; I guess it was a very satisfying job,” says John, his enthusiasm still restrained. As he explained, the job that ended only last fall is still fresh in

his mind, and the complications were not easy to forget. Driving distance. From Southlake, TX, where Mid-Cities is located, to Austin is a three-and-a-half-hour, 210mile trip. Much of the work had to be done at the 7,000-square-foot shop, so the drive to and from the mansion cut down on productive time. To illustrate, the Mid-Cities crew is known to have set 1,000 fence posts in a day. On this project, because of

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This is one of two columns that were water-jet cut designs and frame the entry gates at the Governor’s Mansion’s front steps on Colorado St. The columns are 7 inches wide and 8 ½ feet tall. November / December 2013 n Fabricator

the time spent traveling and many other obstacles, it took more than a dozen trips to set only 55 posts. Razor wire and preserving trees.

Jose Guerrero and Ricardo Garza work on bending and perfecting the ¾-inch-square solid radius pickets at the Mid-Cities shop.

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Once at the site, the crew was faced with the daunting task of working around protected, 150-year-old live oaks whose limbs dangled within only a few feet from where the new fence posts were to be positioned. Near them, a temporary screening fence complete with razor wire on top provided another obstacle for the large post panels. “You’d have to lift (panels) over the fence with razor wire without hitting a tree or knocking a leaf off, or without damaging the existing or new fence,” John recalls. “It was a very, very difficult job,” he says, adding, “It was like working on a cracker.” Jacob, however, knows that there’s another side to the story and laughs a bit at his father’s pejorative take. “He’s definitely proud of it,” says Jacob, who especially appreciates the beauty of the work. “It’s a physical product that’s going to be there for years. It’s a throwback to Old World design and style; it’s great to be able to tribute that.” To his father’s point, Jacob also acknowledges the difficulties he had in his own support role. “It wasn’t easy to get there; it was hot in Austin. There were a lot of times when it just got hard.” No free rein. As one might imagine, gaining access to the home of a state governor, Rick Perry — especially one making an animated run for U.S. president — was met with an aggressive array of security measures. Regardless of having gained prior access and any necessary work permits, anyone seeking entry to the property had to submit — every time — to an FBI background check and warrant search. (Until early March of this year, those same rules applied even to state lawmakers entering the residence. They were relaxed when some in office protested publicly.) For the half-dozen Mid-Cities employees on the site at any given time, those requirements weren’t a problem. But because the job was so massive, more workers were needed, and many simply couldn’t meet the qualifications. “Welders work hard and play hard,” John offers as an explanation. “If they Fabricator

n November / December 2013

got into a little trouble one way or another, it was, ‘Sorry, but no admittance.’ That reduced the pool of workers 100-fold and made it that much more difficult to get the job done.” In addition to those security measures for the entrance to the site, pairs or trios of Texas state troopers were out in force at any given time, watching everyone who came onto the site to do any kind of work, inside or outside of the mansion, which sits only one block south of the state capitol. Awash in watchdogs. Then there were the politics. Oversight for reconstruction of the mansion belonged to the Texas State Preservation Board, which worked closely with the Austin city officials, the state Department of Public Safety, and the Texas Historical Commission on the closely monitored, publicly sponsored endeavor. John witnessed these groups and, especially, the preservation board’s renowned project manager, Dealey Herndon, handle everything “from every crystal on the chandelier, to every room being restored to the way it was decorated in 1856.” For their part, the Famiglios worked closely with White Construction of Austin, which was named Construction Manager-at-Risk, or lead construction manager, for the project. It subcontracted for all of Mid-Cities’ work, along with landscaping, masonry, demolition, and painting services. The landscaper on the project was Trent Rush with TBG Architects of Austin, who drew all the plans for the grounds work and with whom Mid-Cities had worked before. In fact, TBG was the company who referred Mid-Cities to the governor’s mansion assignment. “These folks all deserve the Medal of Honor,” John says, giving specific praise to Duane Campbell and Jerry Ott of White Construction for coordinating more than 50 workers and for balancing the ongoing meetings. “They were on site the whole time,” John says. “They handled the dayto-day as a liaison to the Texas state troopers, the preservation board and the contractors; they had the worst of all possible worlds. “They made my life miserable and good; they were both helpful and they November / December 2013 n Fabricator

One man, one Molotov cocktail, one much larger project An hour and a half past midnight on June 8, 2008 security cameras caught a man tossing a fiery object onto the front porch of the governor’s mansion in Austin, TX. In no time, nearly 100 firefighters poured inside and around the 8-foot, chain-link fence that surrounded the mansion that night, emptying about 2 million gallons of water onto the four-alarm blaze. The timing could have been worse. Governor Rick Perry and his family had moved out of the mansion the previous fall to prepare for a $10 million renovation of the Greek Revival home built in 1856. Also, gone into storage or temporarily displayed elsewhere were irreplaceable mansion treasures, such as R.J. Onderdonk’s 1903 painting, “Fall of the Alamo,” featuring Davy Crockett, and a four-poster mahogany bed used by Sam Houston, gov-

ernor from 1859–1861. But then, if it had to happen at all, the timing of the arson could have been much better. The smaller-scale renovation would have included a fire alarm and sprinkler system. The fire severely damaged the second floor and the roof, which collapsed under the barrage of water. Eight inches of water reportedly stood on the floors of the mansion in the fire’s wake, and smoke damage was heavy throughout. Still, preservationists were able to decode enough details of the architecture to render the reconstruction a success. The $10 million renovation of the 11,000-square-foot mansion, included the addition of 1,000 square feet of livable space at a $25 million expense borne by taxpayers ($21.5 million) and private donors ($3.5 million). At presstime, the arsonist in the case has not yet been identified. The state fire marshal’s office is offering a $50,000 reward for information leading to his arrest and conviction.

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did their job,” John says. “They’re going to look back and be very proud of what they did in the years to come.” And how about John Famiglio of Mid-Cities Iron Works? Will he be proud of what his company did in Austin in the years to come? “I think so; I’m still not far enough away from it yet,” John says, slowly conceding with, “I feel very good that it was a bonded job. We haven’t had many bonded jobs.” Well, that’s a start. Anything else? “Once everything was signed and the retainer was paid, it was a great sense of relief; everybody was happy. That, at many times, seemed like an impossibility,” John says. “It’s going to be nice to know that my grandkids — and I’m counting on one of my two kids to come through on that — my grandkids can go back (to the mansion) and they can hear, ‘This is what your grandfather did.’ ”

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John Famiglio, 57, started in the ornamental metals business much like others have, picking up the skills from family members and carrying them into a career. In his case, however, he had started in New Orleans, the city that artist Harriet C. Joor in 1906 dubbed “the city of iron lace.” That’s because in New Orleans, ornamental iron is, as John puts it, Fabricator

n November / December 2013

The north perimeter wall in the early stages on Governor’s Mansion property, left, shows that although the retaining wall was uneven, the post had to be set so that the tops were level. No final adjustments were allowed; Mid-Cities had one chance to get it right. At right, the first installed panel on the south wall.

“ingrained in the culture as much as jazz music is.” “I started as a kid going to my uncle’s shop in New Orleans, working with my dad. I was 9 or 10 years old and worked on Saturdays bending scrolls,” he says. “We did New Orleans-type of ornamental iron: burglar bars, storm doors, railings; a lot of casting work.” He’s clear when it comes to the source of his skills. “My mother is an artist in her own right. My father has worked in ornamental iron and has a strong work ethic; I’m a result of the combination of the two,” he said. His grandfather is the one he credits for teaching him casting work. As he got older, John worked during the summers, then on a more full-time basis at his family’s shop. “I did it for a period of time in New Orleans and gradually found my way to Texas,” he says. The initial lure: his soon-to-bewife, Kendra, who now works for MidCities Ornamental in a limited capacity, mostly managing project photography. “I didn’t really plan to start an ornamental iron business; in fact, it was the last thing I wanted to do,” John admits. “I had been made to do it when I was younger, so I was a bit resistant.” Still, with a two-year degree in business management from North Lake College, November / December 2013 n Fabricator

Irving, TX, he found that things just happened naturally. Educator for awhile

For starters, after graduation John worked as a welding instructor for four years for the Dallas Community College District; he welded at night. He started on high-end residential stair railings and driveway gates, and business got better and better. Although he liked teaching and didn’t necessarily want to leave it,

Hou-714-nomma.indd 1

money became a motivating factor for going, again, full-time into the ornamental metal business. This time, his own. “I was making $20,000 a year as an instructor, but I could make that easily in a few months with my business. I had a family; my first child was on the way,” John says, adding that art played a part, too. “There are a lot of rewards in being a teacher and helping people. I really enjoyed it, but I had a creative outlook

7/23/13 10:35:51 AM

Installation working conditions were tight, above. The trees hung low, the temporary fence was 10 feet high, and after setting the posts the challenge was to install the fence without touching either. Special thanks to Ben Horton, who assisted with the installation. At right, powder-coated fence posts were set in the center of the brick wall. Extensive masking and protection were used during the installation process.

philosophy served us well for most of the time we’ve been in business.” Focus on quality and finish

Today, John oversees as many as half a dozen employees, including his 25-year-old son, Jake, who was similarly persuaded into the business as was his father. John also has a daughter, Kali, 27, who lives in California but who doesn’t work in the industry. John counts on his Jake quite a bit and appreciates his son’s work in the ornamental metals industry while making other life plans, such as a possible career in the film industry. “My

For your information

that I had to express.” Officially, the date was July 4, 1984. “It just so happened that was the day,” John says, referring to the holiday. “We had a break at school; that’s when I contracted a small building to use for a shop. It was big enough to put 20-foot materials in plus a welding machine, cutting machine, and a cutting table.” The building had a dirt floor and a few electrical outlets, but no running water or working toilet. Eventually, John stopped teaching and took on more work, primarily for high-end residential and high-end commercial projects. The business grew on word-of-mouth advertising. “I’m proud of that,” John says. “When you hire us, you get more than what you pay for; you get something that’s going to last longer than your grandkids’ lifetime. We don’t cut corners; we purposefully embellish. We’ll make the product better if given the permission to do so.” To him, that’s a calling card. “The same materials are available to everyone in the business,” he said. “It’s what you do with it. It’s the talent that you have behind it; it’s the work. That

About the author Molly A. Badgett is a freelance writer based in Atlanta, GA. She often covers issues related to U.S. manufacturing.

son is indispensible as far as communications and the computer; he operates our plasma. He is very multi-talented.” Together, the two Famiglios work toward maintaining a reputation for quality custom work. “When we first started working in this [geographic] area, there were not many people with the skills or ability to do it,” John says. “We were afforded the opportunity to have a lot of jobs and to master our craft. We became the “go-to” for custom interior railings.” At its peak, from the mid-1990s to about 2003, Mid-Cities Ornamental has had nearly a dozen employees. Its current ideal staff size is six or seven. “When you have highly skilled people,” John says, “you don’t really need that many. You can either do the work or you can’t.” Education, he says, is important. He attends NOMMA meetings as often as he can to stay current on trends. “I look at different tools, what the suppliers have to offer; I’m always interested in different ways to make our product better, faster, cleaner, and more cost effective,” John says. “We’re a lost art, and you’re not going to reinvent the wheel. If there’s a way to make our employees safer, our shop cleaner, and our environment safer, we want to know about it.” To keep an edge, John tries to keep up with — or ahead of — the housing market, especially the design trends. “As a business philosophy, you have to stay with the trends,” he says. “You can’t follow it; you have to set it. You can do that . . . if you know what the really good architects are doing; if you know the trends in home design. “From traditional, to French, to French eclectic, to Italian, to Old World, to Spanish, to industrial; your job is to be a chameleon and change with the times,” he explains, “If you can’t, they change without you. If you don’t recognize the changes in the market, then you won’t be in business long.” John J. Famiglio Mid-Cities Ornamental Iron Works 2365 Michael Dr. Southlake TX 76092 817-379-9379 www.jjfamiglioinc.com

Fabricator

n November / December 2013

Nationwide Supplier members Albina Pipe Bending Co. Inc.

ETemplate Systems

King Architectural Metals - CA

Allen Architectural Metals Inc.

FabCAD Inc.

King Architectural Metals - MD

Alloy Casting Co. Inc.

Feeney Inc.

Krando Metal Products

American Punch Co.

The G-S Co.

L.E. Sauer Machine Co.

Ameristar Fence Products

Gates That Open LLC (GTO)

Lavi Industries

Architectural Iron Designs Inc.

Geo. Bezdan Sales Ltd.

Lawler Foundry Corp.

Atlas Metal Sales

Guardian Gate Hardware

Lewis Brass & Copper Co. Inc.

AZZ Galvanizing

Hartford Standard Co. Inc.

Lift Master

Banker Wire

Hayn Enterprises LLC

Locinox USA

Big Blu Hammer Mfg.

Hebo/Stratford Gate Systems Inc.

Mac Metals Inc.

Bridgeton Drafting Co. LLC

Heritage Cast Iron USA

Marks U.S.A.

C.R. Laurence Co. Inc.

House of Forgings LLC

McKey Perforating

Cable Art Inc.

Illinois Engineered Products Inc.

Mittler Bros. Machine & Tool

The Cable Connection

Indiana Gratings Inc.

Multi Sales Inc.

Carell Corp.

Industrial Coverage Corp.

Nationwide Industries

Carl Stahl DecorCable Innovations

Industrial Metal Center Co. WLL

NC Tool Co.

Century Group Inc.

Interstate Mfg. Associates Inc.

O.K. Foundry Co. Inc.

CM Iron Supply LLC

Julius Blum & Co. Inc.

Ohio Gratings Inc.

CML USA Inc. Ercolina

King Architectural Metals

Pacific Stair Corp.

(503) 692-6010

(800) 204-3858 (972) 286-2368 (216) 731-4501

(918) 835-0898 (908) 757-2323

(800) 662-0143 (815) 618-8440 (800) 523-6772 (828) 437-5348 (856) 205-1279 (800) 421-6144

(877) 664-4224 (800) 851-2961

(251) 937-0948 (800) 444-6271 (337) 527-5266

(480) 968-5121 (563) 391-7700

(919) 676-2244

(800) 255-9032

(800) 888-2418 (410) 284-9549 (800) 543-4283 (604) 299-5264 (800) 213-9525 (270) 298-3227

(860) 257-0680 (503) 722-7700

(918) 592-1700x. 12 (866) 443-4848 (312) 850-3710

(800) 634-1988 (631) 736-7500

(011) 965-2-474-8903 (800) 667-9101

(800) 526-6293 (800) 542-2379

(714) 670-8980

(410) 644-5932 (610) 543-4311

(636) 225-5358

(800) 624-6225 (800) 624-9512 (718) 894-1442

(630) 279-3600 (708) 579-0286 (800) 631-9510 (631) 225-5400 (262) 786-2700

(800) 467-2464 (800) 421-3575 (813) 988-2628 (336) 674-5654

(888) 592-2240 (330) 477-6707

(503) 390-8305

Colorado Waterjet Co. (866) 532-5404

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

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

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

DAC Industries Inc. (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 (847) 636-1233

EPi

(262) 786-9330

November / December 2013 n Fabricator

Nationwide Supplier members Precision Glass Bending Corp.

(800) 543-8796

Sharpe Products

(800) 879-4418

ProCounsel

South Camden Iron Works Inc.

Q-Railing USA Co.

Stairways Inc.

RAMSET Automatic Gate Systems Inc.

Sumter Coatings Inc.

(214) 741-3014 (714) 259-1372

(800) 771-7055

Ransburg

(419) 470-2000

Regency Railings Inc. (214) 742-9408

(856) 423-1107

NOMMA Gold Members NOMMA is pleased to welcome our newest Gold 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.

(713) 680-3110 (888) 471-3400

TACO Metals

(305) 770-2373

Transpacific Industrial Supply Inc. (909) 581-3058

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

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

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

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

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

Hebo/Stratford Gate Systems Inc.........Clackamas, OR

Johnston Products of Dallas Inc............Cedar Hill, TX

Robinson Iron Corp.

Tri-State Shearing & Bending

Robinson Laser LLC

TS Distributors Inc.

Rockite, Div. of Hartline Products Co. Inc.

Vogel Tool & Die LLC

n Picasso Gate Inc........................................Cheyenne, WY

The Wagner Companies

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

(800) 824-2157

(219) 398-4600

(216) 291-2303

Rogers Mfg. Inc.

(940) 325-7806

SECO South

(888) 535-SECO

(718) 485-2200

(832) 467-5400

(630) 562-1400 (888) 243-6914

West Tennessee Ornamental Door (901) 346-0662

See Us A t Booths S FABTECH 2233 & S 2234

n King Architectural Metals.......................Dallas, TX n Mainer Iron Works Inc.............................Fort Smith, AR n Republic Fence Co. Inc............................Granada Hills, CA n Western Architectural Iron Co...............Chicago, IL

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

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n November / December 2013

House ad 13 x 28p Pg. 69

New Members Meet Our Members

NOMMA is proud of its 550+ 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.

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. n Amos Glick, Compass Ironworks, Gap, PA n Keith Majka, Majka Railing Co. Inc., Paterson, NJ n Tony Martinez, Big D Metalworks, Dallas, TX n JR Molina, Big D Metalworks, Dallas, TX n Mark O’Malley, O’Malley Welding & Fabricating Inc., Yorkville, IL

Members as of October 18, 2013 *Asterisk denotes returning members. Industrial Metal Center Co. WLL Giragos Kuyumjian Kuwait City, Al Farwaniyah Kuwait Nationwide Supplier International Forge LLC Joan Shuhnicki Haskell, NJ Fabricator Pace Metal Fab Tom Pace Pinnacle, NC Fabricator

NOMMA Membership Campaign We have kicked off the 2013–14 membership campaign. And yes, there are prizes! n Sponsor a member for a $75 discount off METALfab 2014 registration. n 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

METALfab 2014 St. Charles/St. Louis, Missouri March 12 - 15, 2014 Full Details At: www.nomma.org

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November / December 2013 n Fabricator

What’s Hot? n News Brief BenFab hires lead fabricator Michael Shedaker has joined BenFab Architectural Metalwork as Lead Fabricator for Stainless Steel Applications. He’ll lead jobs through the design, fabrication, and installation of stainless steel in the residential and commercial sectors. With 22 years’ experience in ornamental architecture, Shedaker knows TIG, MIG, and stick welding of steel, stainless steel, bronze, and aluminum and has AutoCAD skills. Shedaker will lead BenFab’s growth into the stainless steel market, the company says.

Industry News

New edition of Lien & Bond Claims in the 50 States available Construction subcontractors that regularly work in more than one state know it’s difficult to stay on top of various mechanics’ lien and payment bond filing requirements. Claims procedures and deadlines vary widely. The Foundation of the American Subcontractors Association’s (ASA) new edition of Lien & Bond Claims in the 50 States provides subcontractors with the most current information for filing claims — no matter where in the U.S. The updated 2013 edition provides subcontractors with: the latest lien claim requirements for each state; critical filing deadlines; legal requirements

for executing bond claims; and exceptions to claims procedures. This easy-to-use downloadable file divides the various lien and bond requirements for each state and the District of Columbia by private and public work, putting the essentials of lien laws and bond requirements right at the reader’s fingertips. It describes whom to notify of claims, critical deadlines, and features an appendix with legal citations. The guide is $55 for ASA members and $80 for nonmembers. To order: www.contractorsknowledgedepot.com; then click on “Browse Products.” presents

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Fabricator

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What’s Hot? n

Products

Rotary draw tube and pipe bender CML USA Inc. Ercolina’s Top Bender model TB100 is designed to produce consistent quality bends in large diameter pipe, tube, squares, rectangular, solids, and other profiles, and features the following: n Touch-screen programming with system diagnostics in multiple languages. n Quick-change tooling system.

n Digital display of bend angle. n Material springback

compensation. n Remote control of bend, return, and emergency stop functions. n Electronically monitored counterbending die vise position for accuracy and repeatability. n Heavy-duty steel gear case. Contact 563-391-7700; www.ercolina-usa.com. Stainless steel polishing and grinding Suhner Industrial Products LLC Suhner Abrasive Expert has launched the new UMC 6-R L Electric Power File/Polishing system, designed

to “revolutionize” the finishing of difficult-access polishing, graining, and brushing applications. Whether working on stainless steel or aluminum polishing and finishing, UMC 6-R offers low vibration, powerful action for close edge work.

Stainless and aluminum polishing to a “grained” finish of internal corners has always been problematic. Suhner’s tool offers a file-type action so that the brush effect can be made in the same direction right up to the weld/internal joint, the company says.

U R N EW S SE N D US YO

Let us publish your news. Company news, new products, new literature, events: face-to-face/virtual, people hires, promotions. Please send your press releases to editor@nomma.org.

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What’s Hot? n By using hook and loop attachment of abrasive pads and surface conditioning pieces, the UMC 6-R L can quickly solve any finishing application, according to the company. Suhner’s loopbacked abrasives can be rapidly applied. UMC 6-R L is a 500w, light-weight electric power file with an 8 millimeter stroke and variable rate of oscillation from 2,500 to 5,250 strokes per minute. Its compact dimensions allow for a fit into tight places. Typical applications for stainless and aluminum graining and finishing are: n Furniture internal leg joint finishing. n Scallop joint finishing on balustrades. n Fillet weld blending. n Internal section de-burring. Users can benefit from a Suhner mobile demo service directly onsite that provides free advice from experienced field workers.

Products

Contact 706-235-8046; www.suhner.com New heavy duty weld flange for mounting of structural posts The Wagner Companies The Wagner Companies has added four new heavy-duty weld flanges with canopy that meet structural load requirements for surface mounted railings. They are available for 1¼-inch or 1½-inch pipe sizes — 1.66 inch or 1.90 inch, respectively. Current model code requirements require that guards and handrail must meet either a 50-pound/foot uniform load or a 200-pound concentrated load. This has been a challenge when surface mounting a post-mounted railing system. Under load, most flanges used for a surface mount will deform, the company says. The new heavy-duty weld flange has been designed and tested to meet the

Restoring the Past. Building the Future.

www.restoremedia.com www.period-homes.com www.traditional-building.com www.traditionalbuildingshow.com www.traditionalbuildingportfolio.com www.tradwebdirectory.com www.traditionalproductgalleries.com www.buildingport.com

abana.org ABANA

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

Questions? Call Peter H. Miller, President: 202.339.0744 x 104. Or email pmiller@restoremedia.com

Artist-Blacksmith’s

Association of North America, Inc. Fabricator

72 Fabricator RM house ad.indd 1

model code load requirements when properly specified and installed. Wagner recommends welding the flange at both the top and the underside of the flange to achieve maximum strength. Contact 414-214-0444; www.wagnercompanies.com

10/14/2011 12:45:08 PM

n November / December 2013

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

Website

Pg Company

Website

53 Albina Pipe Bending Co.........www.albinapipebending.com

65 Hougen Mfg. Inc............................................ www.hougen.com

59 Allen Architectural Metals Inc.............www.allenmetals.com

67 International Gate Devices..........................www.intlgate.com

37 Apollo Gate Operators............................www.apollogate.com

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

33 Architectural Iron Designs Inc.......www.archirondesign.com

69 Kalamazoo Machine Tool............................ www.kmtsaw.com

72 Artist-Blacksmith’s Assoc. of North America Inc..........................................www.abana.org

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

70 Atlas Metal Sales....................................... www.atlasmetal.com

56 Lapeyre Stair............................................ www.lapeyrestair.com 27 Lawler Foundry Corp.........................www.lawlerfoundry.com

52 Big Blu Hammer Mfg. Co. / Oak Hill Iron Works..........................www.bigbluhammer.com

2 Lewis Brass & Copper Co. Inc............... www.lewisbrass.com

64 Blacksmiths Depot / Kayne & Son Custom Hardware Inc............... www.blacksmithsdepot.com

50 Marks U.S.A..................................................www.marksusa.com

9 Locinox USA..................................................... www.locinox.com

55 Julius Blum & Co. Inc...............................www.juliusblum.com

62 Mittler Bros. Machine & Tool................ www.mittlerbros.com

51 The Cable Connection.......... www.thecableconnection.com

63 Pat Mooney Inc..............................www.patmooneysaws.com

71 John C. Campbell Folk School.................www.folkschool.org

69 NC Tool Company Inc.................................www.nctoolco.com

31 Carell Corporation..................................... www.carellcorp.com

30 Ramset Automatic Gate Systems......... www.ramsetinc.com

29 Chicago Metal Rolled Products Co............... www.cmrp.com

71 R & D Hydraulics Mfg. & Machine Co.............www.rdhs.com

32 CM Iron Supply LLC........................... www.cmironsupply.com

36 Regency Railings...............................www.regencyrailings.com

61 Colorado Waterjet Co..................www.coloradowaterjet.com

44 Scotchman Industries............................ www.scotchman.com

45 D & D Technologies (USA) Inc......... www.ddtechglobal.com

54 Sharpe Products............................. www.sharpeproducts.com

6 D.J.A. Imports Ltd.................................... www.djaimports.com

62 Simonian Bender...........................www.simonianbender.com

70 DAC Industries Inc...............................www.dacindustries.com

42 Stairways Inc........................................................... 713-680-3110

31 Eagle Bending Machines Inc..................... www.eaglebendingmachines.com

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

61 Eberl Iron Works Inc...................................www.eberliron.com

48 TACO Metals Inc........................................ www.tacorailing.com

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

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

47 FabCAD Inc........................................................ www.fabcad.com

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

68 Haberle/ Ken Bergman & Associates...................www.haberleusa.com

68 Vogel Tool & Die LLC.................................. www.vogeltool.com

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

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

Sherry Theien Advertising Director 8392 Leesburg Ct. Rockford, IL 61114 815-282-6000 815-282-8002 fax stheien@att.net November / December 2013 n Fabricator

34 Sumter Coatings Inc.......................www.sumtercoatings.com

23 The Wagner Companies..........www.wagnercompanies.com

Advertise in the 2014 NOMMA Buyer’s Guide Your one-stop resource for shop and office personnel The Buyer’s Guide is available in 3 versions: 1) print, 2) online, and 3) database. Closing date November 30, 2013 Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; stheien@att.net 73

Metal Moment

From the NOMMA ListServ

Join NOMMA to get your questions answered free.

Refinishing historic exterior metal In the past, we have successfully refinished historic fences and

gates with the following process: n Pre-blast to remove paint/rust before making repairs. n Replace damaged elements with new fabrications. n Steel shot blast large area sections. n Brush blast/hand-sand delicate areas to not alter ornamental detail. n Iron phosphate wash and non-chrome conversion coating (designed for corrosion resistance). n Zinc primer n Final powder coat Typically, we choose powder coating over galvanizing due to possible distortion of the metal. We are currently working with a client who has galvanizing in their specs but due to the age of the gates (over 100 years), and the fact that there will be some restoration, we are looking at alternatives to galvanizing and/or powder coating. The reason is that visible seeping of existing corrosion during wash or after powder coating is probable based on the age, condition, and fabrication method of the gate. Has anyone had success with other methods or products? — Rob Gladu, Heritage Industries

n Apply an epoxy mid-coat (optional). n Apply a urethane top coat.

— Doug Bracken, Wiemann Metalcraft

Great info. We typically send out these items to professionally

blast so we don’t worry about the harsh chemicals. The metal is of sufficient size 2 x 2, 8 ga. tubing and 1 x ¼-inch scrolls. It would get brush blasted again after fabrication. I agree that galvanizing is the wrong way to go. Zinc metalizing is a good alternate, but why do you prefer liquid over powder coating? — Rob Gladu

Pre-Prime gets into cracks that powder won’t.

— Doug Cernonok, Myers & Company Architectural Metals

Could the Pre-Prime hold up to the heat if we decided to move

forward with the powder coating?

— Rob Gladu

We avoid powder except on small production parts. The Pre-Prime will not hold up to the powder oven nor will any liquid paint. I can never get a color/sheen match with paint to powder so touch-up is a headache. Even when we did get Based on the description, I wouldn’t powder coat ornate metal.  a color/sheen match, the paint oxidizes at a different rate Everything else you listed seems sound. Blast to see what than the powder; the touch-ups became visible again in less you are really working with, make necessary repairs doing than a year. your best to match existing piece. Your powder finish is as good as it is applied; check coatFor finishing, I would use a liquid epoxy primer and poly- ing thickness just like paint. I once pulled up 600 feet of solid urethane topcoat, brushing in all the tight spaces to ensure iron fence and blast and re-powder because the first coat was a good coating (maybe even dip if possible). If you want an too thin, and it started rusting within a month of install. extra layer of protection, look at zinc metallizing instead of — Doug Bracken galvanizing. This is our experience for a top quality, durable finish in our climate and coastal conditions on exterior iron. Thank you all for your input. I thought I would share our — Maciej Jankowski, Artistic Iron Works current direction. Due to the age and delicate condition of some materials and details involved in this particular project, I, too, prefer liquid paints and would also propose using we have proposed the following scope to our customer. chemical strippers on older metals so you can contain any n Commercial Blast Cleaning SSPC-SP 6/NACE No. 3 lead-based paints in trash bags and reduce the chance of n Scraper, wire brush and power wire brush destroying what is left with an aggressive blast media. n Detergent and water cleaning I discourage hot dip galvanizing for antiques. The gate n Water Rinse and dry is made of wrought iron (corrosion resistant to begin with; n Primer (1 Coat Epoxy Primer): that’s why it’s still in service after 100 years). It could be damn SSPC-PA 1 Paint application specification #1 / Sherwin aged gravely in a tank with power transmission and cell Williams B58B00600 — Macropoxy 646 Fast Cure Epoxy phone tower poles. For fine metalwork, I would: n Paint (2 Coat): Sherwin Williams B65T00204 — low VOC Corothane II Satin Polyurethane n Strip using paint strippers and, if needed, minimal blasting. Dispose of waste in the trash. No dust plume. Although we have had great success powder coating historic exterior projects in the past, and we highly recommend n Make all necessary repairs. powder coating projects containing “new” material, we feel n Address all crevices and tight joints with Pre-Prime 167 Epoxy or similar product, a super-thin paint that runs that the above approach will yield the best overall result in like water to find and seal joints that cannot be painted. preserving the historic value of this particular project. — Rob Gladu n Apply a zinc rich primer (liquid). 74

Fabricator

n November / December 2013

METAL

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from $605

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