ISFA's Countertops & Architectural Surfaces vol. 2, issue 4, 2009

VOLUME 2 • ISSUE 4 • 2009 • SINGLE ISSUE $14.95

What’s Inside: • Innovations in Solid Surface

Page 28 • From Curbing to Countertops

Page 32 • The Secret to Invisible Seams

Page 38 Plus Tips for Easy Stone Repair, and How to Deal With an OSHA Inspection!

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Table of Contents

Invisible Seams When should translucent adhesives be used?

Page 38

High End Sterling-Miller Designs takes solid surface to another level.

Page 40

GFRC An inside look at glass fiber reinforced concrete and what to look at when considering the options.

Page 46

Concrete Spraying Tips Jim Ralston shares a few tips to help avoid problems when face coat spraying concrete countertops.

Page 50

Departments

Table of Contents

Beyond rtops & Counte eld Shopping tfi ’s Wes ce London ts a solid surfa ge Partner. & f p Centre o k y Ross facelift b Page 28

file tor Pro Fabrica olutions S n ig s te De FRC. Concre ove to G es its m discuss Page 32

epair Stone R ring and Cu V U t s. a k A loo dhesive crylate A Cyanoa Page 36

06 - From The Editor 08 - President’s Letter 10 - Executive Director’s Letter 14 - Safety Corner

Supplier Profile: Park Industries A short history of North America’s largest manufacturer of stone fabrication machinery and how it got where it is today.

Page 60

15 - Calendar Of Events 16 - Industry News 20 - Education Connection 22 - Business Solutions 24 - Featured Commentary 52 - ISFA News

Product News The latest and greatest products available on the market.

Page 62

62 - Product News 66 - Classifieds 66 - Ad Index

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 3

M agazine Credits

Letters To The Editor Countertops & Architectural Surfaces welcomes Letters to the Editor. If you have questions about the magazine, or would like to make a comment, or voice an opinion about the magazine, ISFA, or the industry in general, please feel free to write to us.

Please send letters to editor@isfanow.org or to Letters, ISFA, PO Box 179, Lehi, UT 84043 or fax to (801) 3417361 attention: Editor. Include a telephone number and address (preferable email address). Letters may be edited for clarity or space. Because of the high volume of mail we receive, we cannot respond to all letters. Send queries about Countertops & Architectural Surfaces to editor@isfanow.org or mail to ISFA, PO Box 179, Lehi, UT 84043 or fax to (801) 341-7361 attention: Editor.

Contacting ISFA Phone: (801) 341-7360 Toll Free: (877) 464-7732 Fax: (801) 341-7361 About This Magazine Countertops & Architectural Surfaces is published quarterly by the International Surface Fabricators Association (ISFA). Individual copies of Countertops & Architectural Surfaces are available at the non-member “newstand” price of $14.95. Countertops & Architectural Surfaces is also available by individual subscription at the following rates: ISFA non-members, one year (four issues) $30.00; ISFA members, one year free with every membership renewal. Special rates and charges apply for orders outside of the United States. Call for details. To subscribe, call (877) 464-7732. Printed in the United States of America. Copyright © International Surface Fabricators Association 2009. All rights reserved. No part of this publication may be reprinted or otherwise reproduced without publisher’s written permission. Countertops & Architectural Surfaces and The International Surface Fabricators Association assume no responsibility for unsolicited manuscripts or photographs. Materials will be returned only if accompanied by a stamped, self-addressed envelope.

For change of address, please include old label with new information, including both old and new zip codes.

Allow 3-6 weeks for address change to take effect.

Periodicals postage rate is paid at the Lehi, Utah, post office as well as others. Opinions expressed by writers in this magazine are not necessarily the opinions of Countertops & Architectural Surfaces or the International Surface Fabricators Association, but rather those of the individual writers.

Postmaster: Send address change to Countertops & Architectural Surfaces magazine, PO Box 179, Lehi, UT 84043.

4 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Photography: Photos in this publication may not depict proper safety procedures for creative purposes. ISFA and Countertops & Architectural Surfaces support the use of proper safety procedures in all cases and urge readers to take steps to institute such procedures.

Photography Provided By: Joel Miller, Rosskopf & Partner, CDS, Tom Fischer, Jim Ralston, ITW Plexus, Integra Adhesives, Park Industries, Domain Industries, and Mory Ludwick.

Magazine Credits Publisher & Editor Kevin Cole Creative Director Joseph Winters Contributing Editors Russ Lee ISFA Officers Of The Board Sid MacKay, President Evan Kruger, Vice President Hunter Adams, Secretary Ted Sherritt, Treasurer Joe Hoffman, Assistant Treasurer Michael Job, Director-At-Large Kurt Bonk, I.T. Officer Todd Werstler, Past President Russ Lee, Executive Director of ISFA ISFA Directors Mike Nolan, Director Mike Langenderfer, Director Martin Funck, Director Dave Paxton, Director Mike Cook, Director Harry Hollander, Associate Member Rep. Bryan Stannard, Associate Member Rep. ISFA Staff Russ Lee, Executive Director Jeff Pease, Art Director & Web Services Kevin Cole, Communications Director Sandy Milroy, Membership & Event Director Margaret Pettingill, Administrative Assistant Cover Photo: Fabricator Joel Miller, of Sterling-Miller in Brockton, Mass., demonstrates a variety of uses for solid surface, including this modular bookshelf in the New Museum of Contemporary Art in New York City.

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FromThe Editor From the desk of Kevin Cole, Editor & Publisher, and ISFA Communications Director

Investing In Innovations In putting together this issue of Countertops & Architectural Surfaces, we made it our mission to focus on innovation. It really is what drives this industry.

New advancements and new techniques can set you apart from your peers and get you into doors that may have otherwise been closed.

Consumers don’t want ‘just a countertop,’ because if that was the case, anyone could slap a piece of plywood on a cabinet and everyone would be happy. Your customers, and potential customers, want appeal. They want something that reaches them on any number of levels and makes them feel good about what they have invested in. Whether it’s the physical properties or aesthetic appeal of the material used, the craftsmanship that went into it, the application itself or any combination of these things, innovation can be the key to success.

Don’t get me wrong, I know the roots of any successful business are the basics: a sound business model; good strategic planning; reliability; great customer service; solid workmanship; etc. The importance of just getting the work done properly and on-time cannot be overlooked, but once those basics are mastered, the possibilities only broaden.

Many of the most successful companies are known for their ability to look beyond the status quo, whether that is developing new applications for the products they work with, coming up with new, more efficient techniques or even creating whole new products. And once these innovative new methodologies or products are available, successful companies will evaluate them and, if they find potential, take advantage of the opportunities for new business or new productivity they afford.

as hard just to maintain the ground we have already gained. And this can put time at a premium, but it is these times in particular that we need to be even more diligent in exploring every avenue to make a sale and squeeze out every efficiency we can. And if you can put out a better seam or nicer polish, or offer more value, then you stand a better chance of pleasing your customers and doing more business.

So, I urge you to look beyond your, perhaps aching, bottom line and see what others are doing. What new technologies will save you time and money or give you more capabilities?

What new applications could you be delving into to keep up sales volume? What new idea can you explore to better serve your customers and keep them coming back?

When I think of “innovation” I tend to think of big, all-encompassing changes, and you might also. It can sound a bit frightening in that context, although maybe you are ready for some big overhaul of your operations. But when I think about it, it’s not always the case that innovation equals a giant pain in the butt. Sometimes small changes can have big rewards, and a series of small changes might make a huge difference, so don’t overlook the little things.

So whether you are investing in some major new piece of equipment or revamping your whole facility, are taking on some project that is just a little outside your comfort zone or are just tweaking the way you do something, be creative and give it the thought it deserves. Because these things – the innovations – are what set apart a good company from a great one.

As always, I look forward to your feedback.

Sincerely,

Kevin Cole Editor & Publisher kevin@isfanow.org

Sometimes, particularly during rough economic periods, we are forced, it seems, to work twice 6 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

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FromThe President From the desk of Sid MacKay, ISFA 2009-2010 President and proud ISFA member since April 15, 1997.

Live and Learn Many years ago I had an experience that taught me a principle that is probably the basis for most of the success that I have had in my business. It took place in 1982, and at that time I had a small custom cabinet company with only two employees. While these employees had worked for me for more than a year, it was difficult for me to just turn them loose on a project. I was in the shop each day telling them exactly what to do, how to do it and in what order to do it in.

I can still remember telling them almost weekly to make sure that any nails were placed in the grain of the wood so as not to be as visible.

Watching over them so closely made it difficult for me to get anything accomplished during the day, and so I spent many nights estimating jobs, writing proposals and doing layouts for the next day’s production. As much as I tried, it was just too hard for me to let them work with out hovering over them to make sure they were doing everything right.

Then something wonderful happened, even though it didn’t seem so wonderful at the time.

While playing softball, I slid into third base and ended up with a broken leg. By the time they were ready to put a cast on my leg, it had swollen so badly that they decided to just put a splint on it until the swelling went down. They told me to just stay off it, keep it elevated and to come back in 10 days.

Those 10 days just confirmed what I already knew. Without me there to oversee what my employees we doing they took twice as long to accomplish everything and made a lot of mistakes. We lost a lot of money on one particular job, and I was still pretty incapacitated during the next job. However, I started to notice that they were not making as many mistakes. We almost broke even on that job, and with each job that followed things got better. Before long we were making money again.

From this experience I learned that if you are hovering over your employees and constantly telling them what to do, they have no reason to think and learn on their own. But if you let them think things out and make a few mistakes, they will learn from them and not repeat them. The

more responsibility and freedom I gave them, the more they were able to accomplish. One of the greatest benefits to me was all the time I could now spend on running and growing the business. My quality of life also improved because I didn’t have to spend all the late hours doing paper work.

While I would never want to repeat that experience, I am very grateful for having had it. As I look back on the times when things were tough in business, I can see that each time I was able to learn principles that have made my business better and stronger.

And these last two years have been no different.

Sometimes I feel like I am working on my Masters Degree from the University of Hard Knocks, but the things we have learned and implemented have us ready to take advantage of our market and grow when the economy turns.

I recently heard a man tell about his life as an East German refugee after WWII. He talked about the struggles he and his family experienced as they found themselves facing new challenges in unfamiliar territory. He told of the poverty he and his family dealt with as they tried to survive, and how hopeless things looked. He also went on to explain how they were slowly able to work out of their poverty as they worked together as a family. Even as a nine year old, he had to work after school making deliveries on an old bike.

Today he can see how his character was built during those hard years, and how the principles of hard word and patience have helped him his entire life. He, too, has no desire to repeat his experience as a refugee, but is very grateful for the things he learned during that hardship.

While I hope we never have to go through this experience with the economy again, we are trying to stay positive. We are trying to enjoy the blessing of this experience NOW, without waiting a lifetime to recognize it. Just as we know that spring will follow winter, we also know that a recovery will eventually follow our present sluggish economy.

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

Sincerely,

Sid MacKay ISFA President sid@creativesurface.com

8 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

No reveals! No overhangs! Just seamless integration!

With Lansen’s ground-breaking patented technology you can now offer your customers nothing but the edge! The new EDGE stainless steel sinks

by Lansen are the world’s first seamlessly integrated stainless steel sinks for solid surface and stone countertops.

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FromThe Executive Director From the desk of Russ Lee, Executive Director of ISFA, Charter Fabricator Member (1997) and Industry Partner (2007).

Beyond Countertops

countertops.

Thirty years ago when I set up shop as a solid surface fabricator, countertops ruled the day. That was because countertops were just about the only market for solid surface at the time, and because none of us really had a clue of the potential for the material beyond

Today, technology has changed much of that landscape. We can make practically anything a person can envision from virtually any material and, often, at a very favorable price point. It’s about imagination, functionality and expanding the market potential.

It is that combination of constantly emerging technology and the fabricator’s burgeoning sense of awareness regarding the possibilities at his/her fingertips that make an annual design contest such an interesting spectacle.

While it is true most of the entries in the contest feature some kind of countertop installation, the expertise, creativity and craftsmanship involved leads one to conclude that we, as an industry, have moved beyond just countertops. We now produce works of art in a production format.

This year’s competition, aptly named the Innovations in Design Competition, which is jointly sponsored by ISFA and Surface Fabrication magazine, offers a little wrinkle from design contests of years gone by. A new category has been added called, “On Site Vanity Fabrication.”

Now fabricators can strut their fabrication stuff in full view of their peers at ICE, the industry trade show and conference, to be held at Mandalay Bay February 7-10, 2010. The rules are pretty straightforward: use your creativity and expertise to fabricate a vanity top using any combination of materials during regular exhibit hours.

The only requirement is that the tops conform to certain dimensions, so that the vanities may be donated to charity at the end of the competition.

Of course, we will continue to recognize and honor fabricators who excel in the traditional design contest categories, such as residential kitchen/bath, commercial, institutional, freestyle and other areas. To learn more about the

competition and/or to download an entry form, go to www.countertopexpo.org or call us at the ISFA office at 877.464.7732.

Speaking of ICE, all the elements of a spectacular Expo are coming together. Starting with the Big Game Football Party at Hard Rock Hotel and Casino on February 7th (did you know the Super Bowl was that weekend?), we are making it easy for folks to get together and socialize in a really fun atmosphere.

The next day – ICE begins on Monday this year – we start right off with relevant and essential educational conferences and then interrupt them at mid-day for another party! The Networking Luncheon features a light lunch with your friends and colleagues immediately before the opening of the exhibits. At 1pm we all leave the luncheon and head to the exhibit hall together, located convenient to the dining area.

In order to make your Expo experience even more worthwhile, we are encouraging exhibitors to stage demonstrations of their products and services in their booths all three days of the show. At regular intervals the location of a new demonstration will be announced.

There’s another reason you will want to come early and stay late for ICE. On the afternoon of Wednesday, the 10th, we announce the winners of the Innovations in Design Competition and immediately follow it up with the Dream Sweeps Giveaway drawing. Industry vendors have generously donated a virtual cornucopia of valuable prizes, including trips, tools, materials, gift certificates and more. What’s cool about this drawing is the more you visit the exhibits during the three days of the show, the better your chances are of winning.

February is approaching rapidly. I would encourage you to make your reservations soon to capitalize on our guaranteed room rate and the current environment of favorable airline pricing. I can’t wait to see you there.

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

Sincerely, Russ Lee Executive Director, ISFA russ@isfanow.org

10 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

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LettersToTheEditor Regarding “Turning Scraps Into Cash...”

Dear Editor: I read your article in Countertops & Architectural Surfaces regarding ways to use scrap [“Turning Scrap into Cash”; Vol. 2, Issue 3] and I wanted to tell you about a local fabrication shop that has found a couple of pretty cool ways to turn its scrap into cash.

I’ve been the manager for the Hamilton Parker Co. for 15 years, and we distribute ceramic tile through most of the state of Ohio for commercial and residential projects. Jim Lind, of Lind Stone Works in Columbus, used to be a tile installer but he opened up a stone fabrication shop about eight years ago, and he has some great ideas on what to do with his scrap.

One thing he does is to make memorial stones for pets out of it, which I thought was a very clever idea. Another thing I see Jim doing with his cut-outs from the sinks is to waterjet the state of Ohio out of them and sell them to taxidermists to mount animal heads on.

Another idea I had given to him was to check with local aquarium shops; they all sell small pieces of natural stone for aquariums.

Thanks, David Sammons dsammons@hamiltonparker.com Dear David: Thanks for sharing this information. Some of the best ideas come from looking at what others in the industry are doing.

Sincerely,

Kevin Cole Editor & Publisher kevin@isfanow.org

12 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

The Official Show of the International Surface Fabricators Association

There’s Nothing COLD About The Industry’s HOTTEST Event.

February 7-10, 2010, Mandalay Bay Resort & Casino Las Vegas, NV ISFA will be hosting a new industry trade show called ICE (The International Countertop Expo) in 2010. ICE showcases the latest products, newest innovations and most up-to-date training for the countertop industry.

Call for more info: (702) 240-1660 Email for more info: expo@isfanow.org

INTERN ATION AL SURFACE FABRIC AT ORS ASSOCIATION

In Conjunction With

SafetyCorner From the desk of David Mack, Senior Account Executive of Schechner Lifson Corporation. www.schechnerlifson.com

Are You Ready For an OSHA Inspection?

The Inspection Even though OHSA inspectors show up unannounced, employers have the right to request an inspection warrant before walkthrough.

This can be a pretty stressful scenario, given that citations carry penalties ranging from $7,000 to $70,000 for each violation.

Imminent danger type situations receive top priority. Fatalities must be reported to OSHA within eight hours. Employees may request anonymity when filing complaints. Onsite inspection begins with a review of injury records and required official OSHA postings. A thorough visual inspection is conducted during the jobsite walkthrough.

After the walkthrough a closing conference is held to discuss the findings and possible courses of action required of the employer as well as employee rights. OSHA citations and penalties are issued within six months.

OSHA Consultation Alternately, OSHA offers a free consultation service that can provide employers help discovering potential hazards at worksites and improve occupational safety and health management.

This consultation program is completely separate from the inspection process. Findings are kept strictly confidential and are reported only if the employer fails to correct imminent danger. The consultation is voluntary and at the employer’s request.

Although OSHA encourages a complete inspection, the employer may limit the review to specific areas. OSHA will provide assistance with the development of an effective safety and health program, and provide training and education for the employer. There will be no penalties for violations of OSHA standards and a detailed report of findings will be sent to the employer.

The employer receives the benefit of knowledge of workplace hazards, and ways to mitigate or even eliminate accidents before they happen.

This service will improve the business’ operation and help strengthen the existing employee health and safety programs.

Safety Practices and Avoiding Citation The 10 Most cited OSHA standards for “Cut Stone and Stone Products” are as follows: 1. Hazard Communication 2. Respiratory Protection

3. Powered Industrial Trucks 4. Electrical Generation 5. Air Contaminants 6. Noise Exposure 7. Electrical 8. Lockout/Tagout 9. Machine Guarding 10. Personal Protective Equipment

(NIOSH) 100 fatalities and 20,000 injuries are related to forklift incidents every year.

On all grades the load is to be tilted back, raised only high enough to clear the roadway and the forks are not to be moved while in motion. Wear seatbelts and head protection, and perform maintenance service checks at least once per day.

Personal protective equipment (PPE) is a good place to start. PPE protects employees from injuries and illnesses in the workplace. Face shields, safety glasses, hard hats, safety shoes, coveralls, gloves, vests, earplugs and respirators will help prevent serious injuries to employees. OSHA mandates that employers provide workers with appropriate PPE, proper use instruction training and regular maintenance.

Lastly, nothing can replace a well-planned and written formal loss control and safety program. Fortunately there is a risk transfer, loss control and safety program available to all members of ISFA that is specific to your industry.

One major danger for those working with natural and/or engineered stone is silicosis. Silicosis is a serious debilitating condition for which there is no cure. The most common cases occur after 15 to 20 years of moderate to low exposure to silica dust and symptoms may not be obvious. Progression leads to shortness of breath, fatigue, chest pain or respiratory failure. Monitor your exposure limits or OSHA will do it for you!

Noise is another area that should be examined.

Monitor noise levels for hearing conservation.

When you arrive at work in the morning, turn your radio down until you can barely hear it and turn off your car. When you turn your car back on after leaving work, see if you can still hear the radio. Hearing loss occurs slowly over time and when it’s gone you can never get it back!

OSHA’s standard for the control of hazardous energy, or “lockout/tagout”, outlines the procedures required to protect employees servicing or maintaining electrical equipment. Make sure you are familiar with it. This protocol prevents an estimated 120 deaths and 50,000 injuries each year according to OSHA. Slab handling is another area to watch out for. Make sure to use the appropriate lifting equipment! Too many fatalities are caused by misusing or repairing and/or modifying old, broken equipment. Broken equipment needs to be destroyed and discarded properly. You should also know your load limits! Avoid pinch points, keep equipment lanes clear, obey warning signals, walk to the side when tending loads and do not walk under a suspended load!

Closed top containers are the most frequently used and are the most dangerous. Establish a well-documented standard operating procedure for handling, moving, transporting, loading and unloading slabs. Inspect and repair or replace storage racks, A-frames and pole frames.

Forklift safety is also paramount to avoiding problems. According to the National Institute for Occupational Safety and Health

14 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

David Mack joined Schechner Lifson in 2006, before which he managed a small insurance agency in Plainfield, N.J. He has a BA in education from Kean University and is a New Jersey certified Teacher of the Handicapped. He worked as a volunteer for Youth at Risk as a team Leader in charge of training and fundraising. He can be reached at 908-598-7875 or davidm@slcinsure.com

Calendar of Events Buddy Rhodes Comprehensive Concrete Training Oct. 9-10 San Francisco, Calif.

415-431-8070 CCI: Intensive Precast Countertops 101 Oct. 12-14 Raleigh, N.C. 888-386-7711 CCI: GFRC for Concrete Countertops 201 Oct. 15-16 Raleigh, N.C. 888-386-7711 CHENG GFRC Training Oct. 19-20 Berkeley, Calif.

510-849-3272 ext. 217 StonExpo/Marmomacc Americas 2009 Oct. 21-24 Las Vegas, Nev. 866-550-6808 ZOW Italy Oct. 21-24 Verona, Italy +49-521-964-3370 The Pinske Edge Fabrication Seminar Oct. 28-30 Plato, Minn.

800-847-6753 AZ School of Rock Basic Fabrication Course Nov. 2-5 Gilbert, Ariz.

480-309-9422 Mid-Atlantic Buildings & Facilities Management Show Nov. 4-5 Somerset, N.J. 732-764-0777

Buddy Rhodes Comprehensive Concrete Training Dec. 4-5 San Francisco, Calif.

415-431-8070 CCI: Intensive Precast Countertops 101 Dec. 7-9 Raleigh, N.C. 888-386-7711 AZ School of Rock Basic Fabrication Course Dec. 7-10 Gilbert, Ariz.

480-309-9422 The Pinske Edge Fabrication Seminar Dec. 9-11 Plato, Minn.

800-847-6753 CCI: GFRC for Concrete Countertops 201 Dec. 10-11 Raleigh, N.C. 888-386-7711

Calendar of Events

AZ School of Rock Basic Fabrication Course Oct. 5-8 Gilbert, Ariz.

480-309-9422

The Pinske Edge Fabrication Seminar Jan. 13-15 Plato, Minn.

800-847-67531 World of Concrete Feb. 1-5 Las Vegas, Nev. 972-536-6446 International Countertop Expo Feb. 8-10 Las Vegas, Nev. 877-464-7732 The Pinske Edge Fabrication Seminar Feb. 24-26 Plato, Minn.

800-847-6753

Buddy Rhodes Comprehensive Concrete Training Nov. 6-7 San Francisco, Calif.

415-431-8070 Buddy Rhodes Advanced Concrete Training Nov. 9-10 San Francisco, Calif.

415-431-8070 CCI: Intensive Precast Countertops 101 Nov. 9-11 Raleigh, N.C. 888-386-7711

NA IN T E R

T IO N A

L S U R

FA

R IC A C E F A B

T O R S A

S S O C IA

T IO N

USGBC Greenbuild 2009 Nov. 11-13 Phoenix, Ariz.

202-742-3818 CCI: GFRC for Concrete Countertops 201 Nov. 12-13 Raleigh, N.C. 888-386-7711 ISFA Total Fabricator Training Nov. 16-19 Orem, Utah 877-464-7732

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 15

InTheIndustry In The Industry has the latest news and events for the decorative surfacing industry.

Sterling Surface Hosts NEAWI Shop Tour

Vetrazzo Partners with SmartStone for Distribution

Sterling Surfaces, a fabricator based in Leominster, Mass., hosted the New England Board of Directors and chapter of the AWI for a tour of its fabrication facility in September.

The purpose was to connect with AWI millwork shops in the New England area and highlight the many opportunities there are to work with solid surface. More than 60 attendees representing many millwork shops were at the event, including students from the New England Architectural Woodworking School.

Vetrazzo LLC, makers of recycled glass surfaces, has partnered with SmartStone of Denver, Colo., a division of Green Mountain Soapstone, as a distribution outlet for distribution for Colorado, Wyoming and New Mexico. Effective immediately, SmartStone will provide full distribution services in the Rockies from their warehouse in Denver.

Live demonstrations on the use of advanced CNC programming technology, CNC routers and 3-D thermoforming particularly focused attention on applications that move solid surface past just a flat surface and into an almost infinite shaping medium. An architectural-based seminar titled “Cutting Edge Solid Surface Millwork; How Outsource Fabricators support the Architectural Millworker” was given by Grant Garcia of Sterling Surfaces, as well as presentations by Atlantic Plywood, SL Laser and E-Template Systems. Sponsoring the event were Atlantic Plywood and LG Surfaces. Shop tour pictures are available for viewing on the Sterling Surfaces Facebook fan page.

Structural Stone and AC Stone Graned DBE, WBE Certification Structural Stone LLC and AC Stone LLC have both been granted Women Business Enterprise and Disadvantaged Business Enterprise Certifications in the state of Rhode Island.

16 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Samsung Staron Earns SCS Certification for Recycled Content

Staron Surfaces was recently awarded SCS Material Content Certification for seven of its surfacing products. The certification, issued

by Scientific Certification Systems, recognizes Staron for the use of recycled material in several of its acrylic surfacing options. The certification was awarded to the following Staron solid surface products: Pebble Seastar - minimum of 5 percent pre-consumer recycled resin and chip content; Aspen Mine - minimum of 10 percent pre-consumer recycled resin and chip content; Aspen Snow - minimum of 10 percent pre-consumer recycled resin and chip content; Pebble Basalt - minimum of 25 percent pre-consumer recycled resin and chip content; Sanded Wheat - minimum of 25 percent pre-consumer recycled resin and chip content; Pebble Fennel - minimum 30 percent pre-consumer recycled resin and chip content; and Sanded Noir – minimum of 30 percent preconsumer recycled resin and chip content.

EOS Hires Midwest Sales Manager Gordon Shell has returned to EOS Surfaces as the Midwest sales manager, covering, Ohio, Mich., Ind., Ky., Ill., Wis., Minn., Iowa, Mo., Ark., Texas, Okla., Kan., Neb., S.D., N.D. and Manitoba, Canada. His background includes being a DuPont Certified instructor in both Corian and Zodiaq, on-going training and instruction on lean manufacturing, industrialized manufacturing and through-put management, digital templating and digital implementation in stone, millwork and solid surface, and as an owner/operator of a commercial and residential

building company.

Water Treatment Technologies Returns to Direct Ordering Water Treatment Technologies has announced that the company’s products will no longer be exclusively disturbed by any company.

“We need to be connected first hand to new prospects for our systems and remain directly connected to our customers; to hear their comments, concerns and service issues first hand,” said National Sales Manager John Fallon.

Innovative Stone Rededicates Freedom Stone

On Sept. 11, 2009, the 8th anniversary of the attacks on the World Trade Center, Innovative Stone rededicated the Freedom Stone for public

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“The fact that three of our existing products, plus four new products, contain recycled content is one of many benefits commercial and residential users will experience with Staron,” said Dale Mandell, Staron’s North America Sales Director. “Staron solid surfaces have already earned two GREENGUARD certifications as low-emitting interior building products, which further demonstrate Samsung’s focus on improving the well-being of our environment.” Products certified by SCS as containing recycled materials can help meet the criteria for LEED MR 4.1 and/or MR 4.2 as specified by the U.S. Green Building Council.

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International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 17

viewing in a new memorial garden at its Long Island headquarters. The company proudly donated the Freedom Stone to serve as a 9/11 memorial and cornerstone of the Freedom Tower at the site of the World Trade Center.

This 20-ton solid granite monument was mined from the Adirondack Mountains and is flecked throughout with magnificent crystals of garnet, the official gemstone of New York.

Industry News

The Freedom Stone was unveiled by Governor Pataki and Mayor Bloomberg during the ground breaking ceremony on July 4, 2004. As plans continually changed at the World Trade Center, the Freedom Stone was returned to Innovative Stone’s care in 2006. The rededication ceremony keynote speakers included John Feal, President & Founder of the FealGood Foundation, an organization which represents 9/11 first responders, and Sara Wingerath, MPA, Director of Mentoring for Tuesday’s Children. The ceremony included special performances by the Long Island Symphony Choral Association, Michelle Herman - Soloist, bag pipers, a blessing of the Freedom Stone and the release of monarch butterflies to remember the souls that were lost and a white dove to signify peace.

“There has been an overwhelming reverence and respect at our company for the Freedom Stone, from the moment it was carved to its placement at Ground Zero and still today”, says Karen Pearse, CEO and Founder of Innovative Stone. “Despite construction delays, this symbolic memorial stands beautiful, proud and resolute. It remains a symbol of hope, peace and rebuilding, while honoring those who were lost that tragic day.”

Eastern Surfaces Participates in Construction of Bethel Woods Center for the Arts Eastern Surfaces, with two locations in Pennsylvania, recognized the 40th Anniversary of Woodstock and took part in the construction of Bethel Woods Center for the Arts, by creating countertops for the center in Bethel, N.Y. Eastern Surfaces installed countertops in the museum, concert venue, arts pavilion and Visitor’s Center. “We were very excited to be part of bringing the Bethel Woods Center for the Arts to life,” said Chuck Martin, co-owner of Eastern Surfaces. “We are delighted to be part of enhancing the Woodstock cultural celebration.” Bethel Woods Center for the Arts recaptures the magic of Woodstock by providing 18 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

artists with the opportunity to perform on its multiple stages and guests the occasion to enjoy concerts in an historic and extraordinarily beautiful setting.

North Star and Vetrazzo Offer AIA Approved CEU

North Star Surfaces and Vetrazzo offered the “Recycled Glass Surfaces Raising the Bar for True Sustainability” program in September at Timothy J Kitchen & Bath in Milwaukee, Wis. The program was AIA approved for Continuing Education credit.

Lincoln Laminating Receives BBB Integrity Award Lincoln Laminating, a fabricator and installer of solid surface, quartz, granite and recycled products for residential and commercial projects, received the Better Business Bureau (BBB) Integrity Award in September. These awards focus on demonstrated ethical business practices with key stakeholders including customers, employees and community at large, rather than a company’s growth, profitability or popularity. The Integrity Award winners were chosen by an independent panel of business leaders and members of the academic community.

New Freedonia Countertops Study Available

The Freedonia Group, a research company, published a new industry study in September. that were published in September, titled “Countertops.” The new study covers expected growth in the countertop industry through 2013 and includes break-outs by material type. A link to the study is available on the ISFA Web site at www.isfanow.org.

Surfacing Solutions Celebrates 10th Anniversary Surfacing Solutions Inc., of Temecula, Calif., is celebrating its 10-year anniversary throughout 2009. What started out 10 years ago as a company specializing in epoxy garage finishes and decorative driveways has steadily grown into a business that is successful in all aspects of decorative concrete applications and restorations. The company has received several awards and honors throughout the years and recently completed a project on the new Simpsons Ride at Universal Studios.

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The Official Show of the International Surface Fabricators Association

Education Connection

TheConferencesatthe International CountertopExpo (ICE) ICE offers a conference program chock-full of information on marketing, best business practices, solid surface, laminate, stone, concrete, emerging surfaces and much more. For more information on ICE or the conference program go to countertopexpo.org Monday, February 8, 2010 8:30 - 9:15 am Advanced Selling Skills This conference covers the mechanics of selling, from obtaining leads, to needs-based selling, to closing techniques that help you increase profitability.

Bonding Dissimilar Surfaces Solid surface to glass, granite to wood, laminate to stone? Today’s consumers want to personalize their tops by combining dissimilar surfaces in every conceivable way. We show you how.

Paper Based Products Although they fabricate “similar” to solid surface, there is much about paper-based decorative surfacing products to set them apart as their own fabrication animal. If you are contemplating tapping into the Green movement with one of these eco-friendly products, you will want to attend this session for some important tips and tricks to fabrication.

Shop Layout/Installation Trucks This is a two-part session. Part I focuses on the philosophy behind efficient shop layout, regardless of the size of the space. Part II is all about

20 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

installation trucks – the different types in use by fabricators today and how to outfit them. This session will be illustrated with real life photos and video clips.

9:30 – 10:15 am What Do You Mean by Green?

This is a presentation designed to engage the participants through data and questions. “What Do You Mean by Green?” encourages the individual audience member to take conscious thought regarding their potential impact upon the total ecosystem. This is not a radical, tree-hugging presentation, rather it is a rational presentation that is closer to a rational thoughtprovoking conversation intended to inspire greater awareness and a sense of balance in our world.

Turning Scrap into Dollars Converting your “bone yard” into cold, hard cash may be easier than you think. These fabricators have done it and they’ll show you how you can too. Warning: Attending this class may increase your bottom line.

Setting up a Concrete Shop What does it take to make concrete countertops? Well, that depends. We’ll walk you through the specifics of what you need to get started and where you can find it.

Another Look at Laminates: The Journey from Everyman to Gotta Have And you thought laminates were dead? Check out the latest innovations in high pressure laminates that reinforce its position as the #1 seller in decorative surfacing.

Pricing Strategies You know you should get paid well for what you do. But how do you set up a pricing structure that returns a profit, yet still is competitive? We’ll show you how.

Advanced Solid Surface Fabrication There are those who say every solid surface countertop should be made with a coved backsplash. But how can you do it and still stay competitive? Discover the secrets to building affordable integral splashes, as well as thermoforming, fabricating shower pans and repairs that will take your solid surface operation to new levels of competence and profitability.

Advanced Quartz Fabrication Learn the secrets of a no-hassle, practically invisible scratch repair. See how the experts execute super-tight, highly polished seams.

Discover methods for creating specialty edges that sell for a premium, but are easy to do.

Tuesday, February 9, 2010 8:30 – 9:30 am Emerging Products – Session 1 Whether you plan to diversify or not, you need to be current on what’s new in the field of decorative surfacing. Hear it straight from the horse’s mouth as we investigate what just might be the next new thing(s).

Installation Techniques – Avoiding the Pitfalls A successful installation can add profit to the bottom line, whereas an installation gone bad keeps rearing its ugly head while draining your cash and resources. If you’ve been thinking of installation as a necessary evil, it’s time to take another look.

How to Run a Countertop Shop A craftsman can build a gorgeous countertop, but PULLLEEEZ, don’t ask him to manage the operation. Creating Standard Operating Procedures, employee management, labor saving forms, project management and other crucial skills are discussed in this all-important session.

Setting up a Successful Stone Shop - Hope is not a Business Plan ™ Find out what you need to know to enter the stone business. This session includes a case study on a stone shop that started 11 months ago and has grown 10 percent per month.

9:45 -10:45 am Emerging Products – Session 2 Part II of our expose of what’s new in decorative surfacing.

Making Money as a Green Fabricator The learning curve is steep, but worth the effort. After pointing his shop toward sustainable materials and practices, this Florida fabricator has more high-margin work than he can handle – and the future is looking brighter every day.

Whether you are serious about getting into Green or just curious about the phenomenon, you will leave this session totally jazzed.

Industry Panel Discussion What are the burning issues in our industry today? A panel of industry leaders offers their perspective on the direction of the decorative surfacing industry.

Using the Internet as a Marketing Tool The Web is everywhere, your smart phone is getting smarter every day – and don’t even talk about Social Networking! With so much out there, where (and how) do you begin? Come find out.

Wednesday, February 10, 2010 8:30 – 9:30 am Beyond Countertops – Don’t Leave Money on the Table Although your bread and butter might be countertops, the desert is often in the extras. You’ll be amazed at the potential profits when you stop looking at upgrades, backsplashes, sinks, accessories and other “creative” applications as distractions and turn them into low overhead gold mines.

Glass Countertops, Backsplashes & Accessories Find out how to order, install and fabricate glass countertops as well as options for templating & installing while having someone else to do the fabricating. Includes a brief analysis of cost vs. benefits.

Marketing on a Budget While marketing your business may not be free, there are ways to make your cash stretch further. Explore the techniques and benefits of guerilla marketing, social networking and good old fashioned branding for fun and profit.

European Design: The WOW Factor 3-D thermo-forming, structural design, exterior applications, pop-art: Europe often leads the world when it comes to great design. Some of Europe’s most innovative fabricators show off their creativity and craftsmanship in this pictorial review of decorative surfacing across the Big Pond. If you watch closely you may even pick up a few fabrication secrets.

Education Connection

10:30 – 11:30 am Marketing to Architects & Designers If you’re serious about commercial work you need to be a part of the A & D community. No one works with architects and designers better than Sterling Surfaces. Grant Garcia shares some down-to-earth methods for cultivating those all-important relationships.

9:45 – 10:45 am How To Reach Specifiers – An Architect Tells All When it comes to dealing with the A & D community, what you don’t know can definitely hurt you. This is a rare opportunity to view the architect/fabricator relationship from the other side of the table and pick up a few pointers that just might save your bacon.

Concrete Sealers No matter what your level of artisanship, if the sealer fails, so do you. In this session, we take a hard look at the various sealers on the market today and how to use them.

Laminate Fabrication High-pressure laminate is enjoying a resurgence in popularity due, in part, to new aesthetics and technologies. Learn the secrets of turning out the kind of craftsmanship and quality that is propelling laminate countertops into the custom home market once again.

Solid Surface: A Designers Dream Discover the uniquely wonderful properties that make solid surface a true designers dream, from countertop options to vertical applications, you will be amazed at the possibilities.

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 21

g n i w o l S n i s t i f o r P r e t s a F omies n o c E ByDonSchmincke

You cut, slashed and hammered costs till your knuckles bled. Now what?

Is there another, perhaps faster, way to grow profits?

Research of successful companies find profits grow faster in challenging times with approaches contrarian to typical slash and burn methods. Some of these approaches have ancient roots. It’s not the first time organizations have encountered threats to their survival. And it won’t be the last. But managing through this current episode may require to you to reconsider the typical approaches we so often use.

Analyzing 5,000 years of management history reveals a few insights that prove valuable in helping us thrive. These contrarian methods prove profitable by companies using them even today. Adding them to your arsenal may be the best decision you make. What can you do to learn from these leaders?

Stop Retrenching; Strike Instead Historically, economic downturns show winners don’t retrench out of fear, but strike early. They accelerate their business by taking advantage of the fact that now their competition weaker than ever. But striking takes two things: strategy and passion. Do you have a strategy? Are you sure? Studies find that most strategic plans end up being mere tactics. Avoid this mistake by: 1) Calling a meeting with your staff.

2) Laying out your strategic plan.

3) Probing and challenging the assumptions.

Does the plan show how you shall outmaneuver the competition? Does it show what position you seek in the competitive landscape? Or how you will exploit competitor weaknesses?

Getting strategy is only half the battle. What about passion? Our brains light up when we see something inspiring. Touchy-feeling mission statements are out. Sagas that inspire perseverance, unselfishness and sacrifice for the strategic win are in. It’s not a new idea. It’s been used for centuries. But we don’t teach the crafting of stories anymore.

1) Have you captured your strategy into a

compelling saga?

2) If not, condense your winning strategy into language that inspires passion for the strategic result.

3) Then edit and re-edit. Remember, it’s about crafting not analysis.

Hire the Brave, Not the Desperate Cowardice stops leaders from challenging the status quo, holding others accountable and exposing weaknesses. Cowardice hinders decisive action by stopping the essential act necessary to accelerate profits and survive a recession – tell the truth.

Cowardice Eats Truth; Lack of Truth Eats Profits Telling the truth can upset people, and desperate people don’t dare risk it. But organizational cultures that promote bravery, and the speed of execution that comes from it, love it. It drives accountability to new levels. The alternative of keeping the truth at unspeakable levels only produces collateral damage like: • Accumulating dead-weight of marginally performing employees • Avoiding the real issues thwarting meaningful change and profitability • Sticking with doomed projects far too long Strengthen your organization and enhance competitive advantage by enrolling and inspiring bravery.

Group Think is Good We’ve been trained to feel that if everyone thought like us it would be a bad thing. In some cases that’s true. But fast companies train their employees to think alike; they train them to think like a CEO. Do your employees know how every decision affects the balance sheet? Field experience finds that employees placed in simulations where they have to run a company achieve new levels of understanding. With a balance sheet and a P&L statement in front of them, employees realize how every decision requires

22 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

movements of cash. New perspectives forge as they have to decide how to go to market. What price? How much volume? Where do we advertise? Choices for growth and expansion become visceral AND real.

Not surprisingly, these employees go back to their jobs with fresh insights on how their actions affect cash flow. They find money. They detect waste and inefficiencies. Opportunities for improvement surface, which help companies needing to accelerate profitability.

Say “No” to Customers Battles are often won by knowing where to strike, and where not to. There was an interesting story about Southwest Airlines. Co-founder of Southwest Airlines, Herb Kelleher received a scathing letter from a passenger criticizing how they made jokes during the safety instructions required by the FAA. Fun is a key value at Southwest, and humor helps us pay attention versus falling asleep during these standard reviews. This particular passenger was not amused. Kelleher wrote back a one-sentence letter: “We’re going to miss you.”

How many times do you try to do too much for too many? Such mistakes stretch resources, distract strategic focus and decimate morale.

Instead: 1) Assess what the Return-on-Energy (ROE) is for your customer segments (how much profit customers bring for the total cost of selling and servicing them).

2) Identify those clients whose ROE is minimum or, gasp, negative.

3) Start writing “We’re going to miss you” letters.

Eventually, and hopefully soon, we’ll all emerge from the recession. Until then, don’t hesitate to act now to accelerate your business. Remem-

ber, retrenching and waiting for it all to pass only gives your competition an opportunity to outrun you. Take the lead. Just because times are slow, doesn’t mean you have to be.

A dynamic speaker and author, Don Schmincke began his career as a scientist and engineer. After graduating from MIT and Johns Hopkins University, he spent decades researching and applying anthropology and evolutionary genetics to management theories. He authored the bestseller The Code Of The Executive and High Altitude Leadership with co-author Chris Warner.

Visit www.HighAltitudeLeadership.com for a free team assessment exercise

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 23

TURNING SCRAPS INTO CASH.

By Kevin Cole

ImprovingEmployee JobPerformancein5EasySteps.

ByBobCicerone About The Author: Bob Cicerone is Director of Customer Loyalty Services for ETC Institute in Olathe, Kan. The firm’s market research services provide information that helps organizations to make better decisions. He can be reached at 913-829-1215 and by e-mail at rcicerone@etcinstitute.com.

24 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Contrary to conventional wisdom in the business community, the actions that managers take – or fail to take – are a primary reason that employees upset customers and fail to contribute to a company’s goals.

C

Employees who work within a dysfunctional or incomplete process for managing job performance are unlikely to perform as managers or customers expect. When this happens, managers typically complain to each other about the employees. Yet these managers have inadvertently created the very situation they complain about!

Successfully managing employee job performance, especially job performance that impacts customer satisfaction and company goals, is essential for the sustained growth of a company. However, experience in many industries shows that management processes are seldom subjected to process improvement, particularly in small to mid-size companies. Management processes established early in the life of a company often continue with little change as the company grows in size and complexity. However, it is just as important to improve the process of management as it is to improve the processes used to create products and deliver services.

The importance of effectively managing employee job performance is shown by this general principle: If a top performing person is placed into a dysfunctional or incomplete process for managing job performance, then sooner or later the management process will transform the top performer into an average or below average performer (or the employee will resign).

Imagine, then, what a dysfunctional or incomplete management process does to the job performance of a typical employee.

The discipline of Human Performance Technology provides an explanation of employee job performance that identifies 13 factors, acting together, that control employee job performance: Seven factors that act on the job performance of individual employees; three factors that act on the output of a work process; and three factors that act on a company’s entire workforce.

when their job performance meets or exceeds expectations and when it doesn’t.

Abilities: The skills and knowledge required for job performance to meet expectations.

Resources: The tools, supplies, materials, equipment, procedures and physical space required for job performance to meet expectations.

Capacity: The physical capabilities required for job performance to meet expectations.

Seven Factors That Act on Individual Employee Job Performance

Preference: Whether an employee chooses to perform as expected.

Expectations: The standards that customers expect a product or service to meet; how customers expect to be treated by employees; and what managers expect employees to contribute to company goals.

Feedback: Data that tells employees how closely their job performance meets the expectations.

Three factors That Act on the Output of a Work Process

Consequences: What happens to employees

Complexity: The number, sequence and difficulty of the steps in a work process; interference from competing assignments.

Internal Supplier/Internal Customer Relations: How well the work of internal suppliers (individu-

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 25

als and departments) meets the expectations of their internal customers (individuals and departments) who contribute to the same work process.

Process outcome specifications: How closely specifications for the output of a process match the expectations of the internal and external users of that output.

Three factors That Act on a Company’s Entire Workforce Customer Focused Mission: A mission statement that clearly dedicates a company to satisfying its customers; and then living up to the intent of the statement.

customers?

•

•

When these employees consistently annoy or upset their external or internal customers, do their managers deal effectively with this poor performance?

•

Do the current procedures for selecting people for this position show whether candidates have all the skills and knowledge needed to meet the expectations?

•

Do these employees always have the equipment, materials, supplies, work space, procedures and tools in the quantity and quality needed to consistently meet the expectations?

•

Are the work procedures used by these employees regularly reviewed to determine if their outcomes would improve by eliminating unnecessary steps, combining steps, changing the sequence of steps, simplifying the steps or eliminating boring repetition?

•

Does the performance appraisal/review process clearly and explicitly hold these

Compensation: Bonuses, salary/wage increases and promotions given to employees who regularly meet expectations.

Performance Appraisal: Every employee is held accountable in some specific way for meeting the expectations of their internal and/or external customers and contributing to company goals.

Five Steps to Determine Opportunities for Improvement Follow these five steps to proactively determine if opportunities exist to strengthen what your company does to manage employee job performance that impacts customer satisfaction and company goals.

Step 1: Select a position in your company with significant impact on customer satisfaction and/or on your company’s overall goals.

When the work of these employees consistently meets the expectations, are they regularly given appreciation, praise or thanks?

employees accountable for how well their individual job performance meets the expectations?

Step 3: Answer the questions in Step 2 as they apply to the position that manages the position selected in Step 1.

Step 4: For each ‘No’ answer in Steps 2 and 3, identify how the current situation could hurt your company’s efforts to attract first time buyers, convert first time buyers into customers, retain existing customers, increase the value of purchases by existing customers and to meet overall goals.

Step 5: If the negative consequences identified in Step 4 are unacceptable, revise as appropriate what your company does to manage the job performance of the positions selected in Steps 1 and 3.

Using these five steps to evaluate your company’s process for managing employee job performance at regular intervals (e.g., annually) will continuously improve the impact on your company’s overall goals and on customer satisfaction of the management practices used in your company to control employee job performance.

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

Been in a Countertop Shop Lately?

Chances are You’ve Seen a Striebig.

Step 2: Answer these questions as they apply to employees in the position selected in Step 1. (Note: Space limitation prevents including all the diagnostic questions for each of the 13 factors that control customer satisfaction.)

•

Do these employees know the specific features your core products and/ or services must have in order for prospects and customers to buy from you instead of from a competitor?

•

Do these employees know the standards their work unit must achieve in order to consistently meet the expectations for their work unit?

•

Do these employees know in specific detail how prospects and customers expect to be treated by these employees?

•

Do these employees have current information about how closely your core products and/or services meet customer expectations and how closely their work unit’s performance meets the expectations of its internal

26 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

East: 888-777-2729 • West: 800-252-6355 www.csaw.com • saws @ csaw.com Circle Reader Service # 6 on the Reader Service Page or go to www.isfanow.org/info

INNOVATIONS IN DESIGN COMPETITION

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Do you have what it takes to be the best in the world?

• Open to all decorative surfacing materials • Live fabrication competition Visit ISFAnow.org/designcontest for details

The International Surface Fabricators Association (877) 464-7732 • www.ISFAnow.org

Figure 1 – LCDs integrated into monolithic 3-D solid surface displays, provide a good example of what is capable with such a versatile material.

COUNTERTOPS & BEYOND A SOLID SURFACE SHOPPING CENTER 28 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Figure 2 – Two information counters, which also feature integrated LCD touch screens for locating shops and for general orientation, are conveniently located to assist visitors new to the complex

The highly visible Westfield Shopping Centre and Recreational Complex in London, England, is the largest urban indoor shopping complex in Europe. The finished project showcases the versatility of solid surface in the form of shop counters and sales areas, signage and multimedia applications.

Fabricated and installed by German fabricator, Rosskopf and Partner (R+P), the project employs creative techniques of relief milling and backlighting to add appeal and interest to this multi-dimensional use of solid surface.

The scope of the Westfield project is massive.

Situated on more than 1.5 million sq. ft. and five floors, more than 250 retailers from 15 countries offer their products at the facility.

Visitors may also take advantage of sports and spa services, and dine at 50 restaurants and fast food facilities. The complex features 4,500 parking spaces and four metro stations of its own.

Among the various architects and planners responsible for the development, design and implementation of this Westfield Group project, Pearson Lloyd in London designed the signs and displays in collaboration with CBS Outdoors Ltd. and BF Technology Ltd. Different designers created each of the individual restaurant counters, and the coordination of the work was carried out centrally by the Retail Design Westfield planning office. R+P coordinated the development of prototypes through their engineering department. Altogether, the largest volume of processed solid surface material that has ever been used in a project in the U.K. was employed for this project.

Figure 3 – The shopping complex also takes advantage of the translucent properties of solid surface in its use of backlit signs.

Signage Many different signpost applications were designed to assist customers with orientation in the modern shopping complex. Interactive ring-like electronic orientation aids with integrated LCD touch screens are some of the most impressive 3-D objects to be implemented (see Figure 1). They appear to have been molded as monolithic elements, an impression that is further reinforced by a uniform groove in the circumference of each unit.

visitors to the mall (see Figure 3). Even the restroom signage is made of solid surface.

Customized Backlit Counters For the restaurant sector, a variety of solid surface patterns were designed and milled

Two information counters, which also feature integrated LCD touch screens for locating shops and for general orientation, are conveniently located to assist visitors new to the complex (see Figure 2).

Multiple back-lit signs with printed panels provide orientation and guidance for shoppers and Circle Reader Service # 7 on the Reader Service Page or go to www.isfanow.org/info International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 29

Figure 4 – Backlighting, milled patters and storage recesses are all unique features of

the countertops&installed complex.

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in straight flat surfaces as well as complex, multi-dimensional curved sections. The final result provided clearly individual solutions, which as a whole can be still recognized as a uniform style. Recesses for removing plates and cutlery, reversible lighted display panels for the menu and glass covers for the food counters were also integrated to meet the requirements of individual customers (see Figure 4). These counters were supplemented by specially manufactured containers on rollers for various storage options.

Displays Offer Attractive Presentation Possibilities Display enclosures made of LG HI-MACS with integrated flat screen monitors are both eye-catching and durable. The internal monitors are reversible from the outside and have an interconnecting groove around the circumference. In addition, the displays are splatter-resistant to liquids and are equipped with an integrated outlet pipe, which prevents the penetration of accidentally (or deliberately) spilled drinks into the displays.

Figure 5 – A column and low anchor wall were made for each stand to display the names of the vendors in illuminated lettering. Thus, although each vendor can implement his or her own branded lettering style, the viewer also recognizes a uniform trend in the design of the stalls.

Modern Sales Areas To facilitate uniform presentation of the open sales stands, a column and low anchor wall were made for each stand to display the names of the vendors in illuminated lettering.

Thus, although each vendor can implement his or her own branded lettering style, the viewer also recognizes a uniform trend in the design of the stalls (see Figure 5).

A Project with a Special Challenge The use of solid surface was particularly applicable for this project because of its thermoformability and translucent properties.

Many individual items created for the Westfield Shopping Centre had never before been manufactured in this form anywhere in the world. It was an accomplishment made possible through the coordinated efforts of the architects involved and the R+P engineering team.

A particular challenge in this project lay in its enormous scope. In a turnaround time of just five months, challenging details had to be implemented to meet widely differing requirements for various individual clients. To complete this project, detailed development work was necessary to find innovative solutions for the various fixtures, lighting and material combinations. At times, up to 10,000 people worked on the site.

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

For more information, visit www.rosskopf-partner.com.

Circle Reader Service # 9 on the Reader Service Page or go to www.isfanow.org/info

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 31

Fabricator Profile - Concrete Design Solutions

By Kevin Cole, Editor Todd Trent of Concrete Design Solutions (CDS) in Bigfork, Mont., wanted to expand his business of concrete landscaping and curbing when he decided the company could no longer afford the lack of business during the long Montana winters. In response, he and his partner Cory Smith, decided to investigate the manufacture of concrete countertops and in 2005, after completing the CHENG Advanced Training course, converted the company’s 4,000-sq.-ft. shop to produce custom concrete countertops.

At first, the company focused on wet cast, which is a more common method of manufacturing concrete countertops, and made products to some success, but decided a concentration on producing a more personal countertop product was the route to take. To accomplish those ends, a decision was made to move into the realm of glass fiber reinforced concrete (GFRC). “Our focus has shifted from concentration of heavy aggregates, inlays and drain boards to a more refined product,” said

Trent. “Our customers want something that does not look like a concrete floor.”

we also take care of our clients before, during and after the sale.”

The Transition CDS focuses on high-end, quality work, typically handling about three jobs per month, producing and installing 150 to 200 sq. ft. of surfacing. “We are a small shop, so making sure that we can deliver a top notch product in an efficient and effective way is most important,” explained Trent. “It is crucial that

To those ends, CDS laid out the extra capital to do the job right. Trent made sure his shop could handle GFRC by adding a large air compressor and 220v, 3-phase power to allow for a big mixer. “We have probably invested a total of $70,000 in training, equipment and supplies,” he said. “It can be done for much less, but we are very serious about what we

32 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

do. This is not a side job for us.

This is how we make a living.

The equipment has already paid for itself in saved labor and quality control in the last year alone.”

Trent and his team underwent “a great deal of transition difficulties” with the full commitment coming only after nine months of training and preparation, which included not only first-rate training, but also research/testing of the various polymers, plasticizers, sands and cements. In the beginning, the GFRC process was labor intensive as Trent had no knowledge of pouring GFRC or using a pump sprayer. But CDS continued to develop a better understanding of the process and made refinements over time.

Along with making sure the shop had all of the correct equipment and supplies, such as grinders, core bits, slab dollies and vibratory equipment, Trent made it a point to connect with others in the industry through training and research.

“We mentored with two very influential GFRC experts, the Cook brothers [Mike and Tommy],” he said. “Networking with other artisans has been invaluable.”

Beyond Transition GFRC has opened new doors for the company, which now offers countertops, panels, mantels, hearths, sinks, signs and more. “With GFRC we are now able to build larger, more detailed pieces that are easier to manage,” explained Trent. “I believe that we now have more control over what we can do with the concrete as a finished product and in the mixing/ casting process. In taking on GFRC we have also learned a lot about the capabilities of concrete in general.”

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 33

“I think that the increased time of casting was an initial negative result as well as the start-up cost,” he said. “However, those are both offset by the ability to ramp up production in hours after the pour instead of days. Less wasted shop time equals higher profit margins and increased performance.”

In the years after the transition to GFRC, Trent and his team have gained more control and skill in what they can do during mixing and casting, as well as what they can turn out as a finished product. In the beginning they were worried about the quality of their work and unsure if it met standards, but through experience they learned exactly what concrete could and should do and how it handles. “We have more piece of mind with the increased strength of our products,” Trent said. The strength has been crucial not only for the customer’s sake, but for his company’s as well. The Montana environment is not always an easy one to ship through and some of their customers live in rough terrain up to 600 miles distant. “With GFRC we can embrace the movement that the product demands in every way, from curing to flipping to transporting and even at install,” he added.

Trent estimates that his return on investment for the transition completed in about 10 months. He was pegging for a quicker return, but said he has been hampered by the slow economy. Once Concrete Design Solutions overcame the difficulties in the production transition, they still had to face the transition

in sales. “Getting people to open their eyes is the first hurdle, but when they see that we can offer them a superior product at a similar price, it is hard to beat,” said Trent. One factor that helped his high-scale residential demographic is the fact that he operates a small shop and his product is completely hand-crafted.

Trent credits this hands-on, personal touch for the bulk of his success and relies heavily

34 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

on word-of-mouth and on forming personal relationships with the local builders, designers and architects. He loves to give tours of his facilities, which never fails to impress.

Looking Ahead Trent knows that he is dealing with an uncertain economy and rocky future, but has a strong faith in his product. “I believe that creativity and flexibility with clients will carry

us through these tough times,” he said. “Offering a product you can stand behind and believe in helps give consumers a picture of how passionate you really are and that is contagious.”

He also has gives a lot of credit to his partner, Cory Smith, who he said has stuck with the company through highs and lows and attributes as “the driving force in our mix design and sourcing for GFRC materials.”

Trent’s parting advice: “Don’t make promises you can’t keep.

Being forthright and honest will go a lot further than making quick sales and not delivering on what you stated. Showing that you are willing to go the extra mile and make the purchase more simplified, not just with money, but also with piece of mind makes a difference.”

For more information, contact Todd Trent at Concrete Design Solutions, P.O. Box 2602 Bigfork, MT 59911, 406-755-0616, www.cdsmontana.com.

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 35

The first step when repairing damage to granite or quartz surfacing using a UV Cure method is to apply the adhesive to the damaged area.

Next, a curing sheet is applied to the area over the adhesive.

Natural and Engineered Stone Repair:

A Comparison

of UV Curing and Cyanoacrylate Adhesives

By Pat Shannon

In this article we will be discussing two of the most cost effective and popular adhesives used for the permanent repair of natural and engineered stone: UV curing adhesives and cyanoacrylate adhesives (CAs). A look into the procedures for making repairs with these adhesives will be reviewed along with an explanation of the technological differences of the two chemistries. Finally the advantages and disadvantages of each repair will be reviewed.

Naturally, at some point in the fabrication or in the installation of natural and engineered stone, a scratch, chip or gouge can rear its ugly head. These blemishes can happen during hole cutting if the proper pattern or fixture is not used. They can happen during fabrication in the shop, during the installation process on the job site and can easily happen when a home owner inadvertently drops a pan, dish, mug or bottle onto the edge of the countertop. At times you may also find that a piece of quartz pops out of the engineered stone requiring the new void to be filled; or a crack develops in natural stone requiring a repair to keep it from propagating.

The procedures to administer a repair with both the UV Adhesive and cyanoacrylate adhesive are very similar; in both instances you are filling the repair with the adhesive and finishing. In the case of the cyanoacrylate adhesive you are spraying an accelerator onto it to drive the cure, as a CA adhesive requires the presence of moisture to initiate cure. With a UV curing adhesive you are relying upon ultraviolet rays to drive the cure. Exposing the wet adhesive to ultraviolet rays drives the cure. In either case, once the adhesive is cured within manufacturer’s specifications, the finishing method can be conducted, and in both instances the finishing procedures are just about the same.

The finishing procedures for both technologies are often recognized to be the following: Hold a straight edge razor vertically and plane or scrape the adhesive flush to the surface of 36 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

the stone. This procedure needs to be done gently and it will produce fine white shavings until the repair is flush to the surface. You will want to use fresh sharp razors for this procedure and more than one may be required. To complete the repair you may have to polish the adhesive to blend it with the stone surface.

Polishing can be conducted using commercially available polishes. Check with your adhesive supplier for polish recommendations.

Each of these technologies is conducive to making stone repairs, but there are clear and distinct differences between the adhesives.

These differences are seen in the way the adhesives are handled during the repair, how the product cures and, most importantly, how the adhesive performs in the repair and how it stands up over time. Below is an explanation of the adhesives with advantages and disadvantages for each.

UV Curing Adhesives UV curing adhesives are widely used in industrial applications ranging from headlamp bonding in the transportation industry to coating of electronic circuit boards and bonding of needles and respiratory devices in the medical industry.

These adhesives are one-component adhesives that stay wet where the adhesive remains dormant until they are exposed to ultraviolet light. Once exposed to the proper

Then a ultraviolet curing light is held close to the area being repaired. This step takes around 3 minutes to complete.

wavelength of light, they cure instantly within a wide range of cycle times. UV curing lights can range in size and intensity. Large, high-intensity light boxes can be used in a manufacturing setting to bond hundreds of automotive headlamps in a single shift. Small keychain lights can be used for consumer repair applications where a fast cycle time of the automotive application is not necessary and when cost is a factor.

Advantages of UV Curing Adhesives: • High impact resistance • Repair will not yellow • Good solvent resistance • Fast easy cure Disadvantages of UV Curing Adhesives: • A UV light is needed to cure adhesive • Ultraviolet light must be in contact with adhesive to cure • Adhesive is light sensitive, cartridges must be capped and stored properly • Not as widely accepted as competing technologies Cyanoacrylate Adhesives (CA or Superglue) Cyanoacrylate adhesives were originally developed in the late 50s and later gained popularity during the Vietnam War for emergency wound repairs. Modern day applications include the bonding of tight fitting plastic parts, metals and some types of rubber. These adhesives are very appealing because of

Once cured, the excess adhesive is removed using a razorblade. This procedure must be done gently and it will produce fine white shavings until the repair is flush to the surface.

their fast acting, extremely strong bonding characteristics.

CA adhesives cure rapidly when exposed to moisture; this moisture is required to drive the cure of the adhesive. In many instances a micro layer of moisture is present on the repair surface which drives the cure of the adhesive.

If a larger repair with a big gap is needed, the use of a spray accelerator is required to cure excessively thick sections.

A typical repair using a CA adhesive would first involve cleaning the repair with some type of an industrial solvent. You would then apply the adhesive to the damaged area and spray an accelerator onto the adhesive to drive the cure. Remember, you will have to work fast, as the more moisture in the air the faster the adhesive cures. The dryer the air, the slower the adhesive cures. In these instances or when the repair is especially deep, multiple layers of adhesive and the use of an accelerator may be required. After the adhesive has cured according the manufacturers instructions, you are now ready to finish the repair as outlined above.

Advantages of CA Adhesives: • One-part system • Fast, easy cure • Solvent-free • Acceptable method of repair

To complete the repair you may have to polish or buff the adhesive to blend it with the stone surface.

Disadvantages of CA Adhesives: • Bonds skin instantly, posing safety risks • Becomes brittle with age • Poor impact resistance • The more accelerator you use, the weaker the adhesive becomes • Poor solvent resistance • Bonds could yellow with excessive accelerator use Both technologies are widely used in many industrial markets and are proven technologies. Both offer cost-effective repair methods for natural and engineered stone repairs. The products are readily available to the stone industry and the procedures of repair are very similar to one another. There are many advantages and disadvantages of both adhesives, but the main difference in these technologies is in the dispensing of the adhesive, how they achieve cure and how they perform once in service.

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About The Author: Pat Shannon is a 19-year veteran of the adhesive industry familiar with many adhesive technologies. Primary market experience has been in the surfacing, transportation, marine, alternative energy and general industrial markets. Pat is the North American Sales & Marketing Manager for ITW Plexus and can be contacted at pshannon@ itwplexus.com .

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 37

InvisibleSeams: IsThereAMagicBullet?

ByChadThomas Inconspicuous and even invisible seams have long been one of the most impressive features of solid surface countertops. The fabrication of quartz and engineered stone started out using technology from the stone industry and early installations were not as impressive by comparison, however new methods and new adhesive systems are allowing the quartz industry to also produce a highly desirable “almost seamless” appearance.

One of the more recently promoted ideas in surfacing adhesive seaming is the use of highly translucent colors with the goal of reducing the overall number of glues a fabricator needs to keep in stock and still achieve inconspicuous seams.

The question is, does it work and what are the pros and cons?

A number of years ago Integra developed translucent adhesives to better match some of the polyester “Glass” type sheets and other colors that had depth (high translucency). This highly translucent adhesive was also found to be an acceptable second color match option for certain products provided there is a very good fit (narrow seam) and the sheet has particulate, texture and/or is fairly translucent.

Since its development other colors with varying levels of white pigment were developed and can be used on darker or lighter colors again producing acceptable results if the correct color is not available and the fit is tight.

Several manufacturers are now offering these adhesive colors that are “nearly” universal matches for many solid surface colors.

The development of these “non colors” of adhesives is obviously no accident. There is drive to reduce the number of colors of adhesives: it simplifies the supply chain and both distributors and adhesive manufacturers have the potential to be more profitable as a result. Considering adhesives usually make up roughly of 5 to 10 percent of overall material costs, there is the potential for substantial savings.

So what is the downside of these new translucent products? It all sounds too good to be true.

Testing has shown that there are actually few

sheet colors that will have an acceptable match using one of these translucent colors unless the seam is nearly perfect. The whole idea behind having colored matched adhesives to begin with is to make an inconspicuous seam when it’s not quite right and you have a small gap. This is one of the redeeming properties of solid surface and it separates it from all other surfacing materials.

How many times have you heard this?: “ I have been fabricating for X years and my seams are so good that I can use a black adhesive on a white top and no one would ever know.” While this may be almost true for some, the real situation is that there are many different skill levels in most shops today and the correct color matched adhesive gives the fabricator the ability to still produce that desired invisibility, even if he is having an off day or maybe hasn’t been around for X years.

The other major effect on the number of adhesive colors made by manufacturers is the ever expanding number of products and color variations available worldwide. Most manufacturers launch new colors each year and trends vary region to region. For example, Europe has an increasing demand for bright solid colors where a translucent adhesive would simply not work. Most of these colors require a very specific custom match to produce the desired results. Here in North America, there is still a slightly more traditional pallet in solid surfaces but an increased demand for new vibrant colors in quartz and engineered stone.

In 2003, Integra produced a total of 31 adhesive colors for solid surface and stone, with cross reference charts consisting of approximately 1,500 color matches. Today, our stock adhesive color list contains 120 entries and the custom color list tops out at 143. Our lab has performed color matching using a standardized method for well over 5,000 surfaces from all over the world.

These are daunting numbers if you are thinking of keeping a complete inventory, but it should be noted that the 80/20 rule does apply: Approximately 80 percent of what is fabricated will be matched with the top 20 percent of the colors available.

While the main workhorse adhesive colors haven’t changed all that much, there are many new sheet and slab colors that require new adhesive colors and densities. Most fabricators still use a combination of the manufacturers recommended matches and their own personal preferences taken from experience to develop an inventory of

38 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Translucent Adhesives Currently Available Chameleon – Integra Adhesives Magic – Integra Adhesives Transparent White – Integra Adhesives Translucent White – DuPont Bisque – DuPont Opal – ITW Plexus

adhesive colors that work.

While some manufacturers recommend these translucent adhesives for dozens of colors, we feel exact color matches are best for producing the most inconspicuous seams. And, when recommended color matches are not possible for whatever reason, new tools such as these translucent colors are a good second option for fabricators – provided they get a good fit and the material in play is appropriate for these “universal” colors. For some materials (heavily pigmented colors, quartz surfacing, solids) these translucents will not work well, leaving a distinct dark line at every seam. It is probably also a good idea for shops to have a few of these cartridges in house for emergencies or for when you don’t have quite enough to finish a job.

Adhesive manufacturers should develop colors with the goal of keeping the required number of matches to a minimum, while making inconspicuous (if not invisible) seams an achievable result. It costs a little more for adhesive suppliers to produce exact color matches, and it does cause some inventory challenges, but lowering the industry standard (and the customers’ opinion of the product) during a time when solid surface is competing for market share cannot be the right answer.

About The Author: Chad Thomas has been with Integra Adhesives Inc. for more than 5 years as an adhesive technician. Additional information is available via email at chad@integra-adhesives.com or phone at 888-862-6665.

As always with adhesives, this pursuit is a balancing act between performance, practicality and quality. New processes and products will continue to keep it interesting – of that I’m sure.

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 39

HighEnd. 40 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

.

It’s pretty simple, really.

told them we were able to quickly under-

Whatever the customer wants,

anything left open to interpretation. This

stand their exact design intent without

find a way to do it. And if you

was critical especially since so much time

are Joel Miller of Sterling-

tor able to complete the project.”

Miller Designs in Brockton, Mass., you find a way to

was initially lost trying to locate a fabrica-

Ten Glacier White tables slide on aluminum tracks to make a single larger table,

do it with style. “We are not

or any combination of smaller indepen-

designers and we are not

each table leg is a Teflon insert that in-

dent tables, as needed. On the foot of

engineers,” he said, “but we

dexes into an aluminum groove built into

know how to make a design

slide effortlessly. The insert is made so

become a reality.”

the floor, and which enables the tables to that it can be replaced as needed. Thus, the tables have no parts to wear out, except for the Teflon inserts, which are easily replaced.

New Museum A case in point is the New Museum of Contemporary Art in New York City.

Architect, Martin Finio of Christoff:Finio Architecture, was just about ready to scrap the idea of using modular Corian tables and bookshelves on the 5th floor of the museum because he couldn’t find a company with the expertise to build the project. Then, he learned about Sterling-

Modular Glacier White Corian bookshelves line the walls of the room, and are mounted together to look like a single, integral structure. “The Corian itself is heavy, and when you add the books, these shelves carry a lot of weight,” said Miller. “The support system had to be invisible, making the shelves look like

Miller Designs.

they are floating. In addition to the custom

“Probably one of the reasons they felt

had custom steel brackets fabricated,

aluminum tracks for the tables, we also

comfortable with our company was that we had been working with the same 3-D design software that the architect was using for this project,” Miller explained. “This

The bookshelves were built as modular units that nest together.

which were concealed in the shelving. It was an engineering accomplishment.”

Sterling Miller mounted Teflon inserts to the table legs, which glide in specially fabricated aluminum channel embedded in the floor.

42 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Although each table is independent, they slide effortlessly together to create a single larger table when needed.

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 43

As a load-bearing element, the lower deck section was built to have zero deflection.

Vila, N.M. As you might have guessed, Sterling-Miller Designs tends to specialize in the type of 3-D projects that require an intricate fit combined with elements of structural engineering. “I could count on one hand the number of conventional kitchen countertops we have done in the past year,” Miller said. “But, we don’t turn anything away, because you never know what it could turn into.”

Like the thermoformed kitchen island made of Peach Corian, designed by Amsterdam architect, Ben van Berkel of UNStudio. Designed to mimic the shape of the house, the 12-ft.-long island features dual Mixa sinks with custommade Corian covers. The countertop deck is 1-1/4-in.-thick, which required some engineering to fabricate because Peach Corian is available only in ½-in thickness. The lower section of the island was constructed as a weightbearing piece with no deflection whatsoever.

Tight fitting doors in the base of the island create an effect that is almost invisible to the casual observer.

44 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Vila,N.M. The shape of the kitchen island echoes that of the house, which was designed by Dutch architect Ben van Berkel.

Five Franklin Place As often happens on a custom project, the Vila, N.M. residential kitchen led to a high-end commercial project in Manhattan, called Five Franklin Place. SterlingMiller fabricated a Glacier White Corian reception desk and library stand for the post-modern condominium project.

As with the Vila, N.M. project, Ben van Berkel designed the building and the architectural surfaces.

“The entire project was thermoformed,” Miller explained. “All the molds were custom.”

LED lights concealed at the bottom of the structure give it a hovering appearance.

Internal bracing within the reception desk supports the solid surface to create a feeling of weightlessness in the design of the structure.

FiveFranklinPlace.

Flowing, curved lines and internal bracing inside the overhang make this reception desk an engineering marvel.

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 45

GFRC

Lighter, Faster, Stronger

By Tom Fischer Using GFRC technology, surfaces can be cast thin as 1/2 to 3/4 in. and achieve similar strengths to 2-in.-thick steel reinforced concrete. I have been a “wet caster” using steel reinforcement for quite a few years and have switched over almost completely to GFRC for countertops.

The two main differences between the make up of traditional “wet cast” concrete and GFRC are the addition of acrylic curing polymers like Polyplex & Forton and alkali resistant (AR) reinforcing fibers.

Curing Compound Acrylic curing polymer allows concrete to be de-molded and processed after just 24 hours, eliminating the need for a seven-day wet cure. This polymer forms a continuous matrix within the cement, trapping in the moisture so the cement can hydrate properly to develop strength and minimize potential curing and/ or shrinkage. The polymer has many other benefits including an increase in flexural and impact strength.

AR Glass Fibers To combat the high alkalinity in cement, the

glass fibers used in GFRC must be alkali-resistant with a high zirconia level of 16 percent or higher. It is typically dosed in a range of 3 to 5 percent of total batch weight. AR glass is available in roving, chopped strand and scrim types.

or mist coat. This ends up being the surface that is seen (the beauty layer as I call it). The surface coat is then followed by a backer coat, which contains a heavy load of AR Glass fibers that provides the structural support but isn’t desired in the surface that is seen.

The roving type comes in a continuous roll and is used primarily by larger producers with the help of a concentric spay/chopper gun.

The gun chops the fibers to desired length and sprays the cement all in one step.

Using a GFRC system one can achieve just about any look that can be made with traditional wet cast concrete surfaces, whether it’s a veined, terrazzo or a cream look.

Chopped fibers are perhaps the most popular for countertop and smaller applications.

Chopped fibers typically come in lengths ranging from 1/2 to 2 in. (3/4 in. is the most popular for countertops) and get blended with the cement before application.

Lastly, the scrim type is a net-like continuous strand of fiber that resembles a fishing net.

This type of AR is used when ultimate strength is needed.

How GFRC is Produced Generally speaking, GFRC is produced by placing or spraying in what’s called a face

46 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

I group the different techniques of GFRC into three different categories: 1.

Spray Up – This is when you use a hopper gun or spray gun to spray in a mist coat. This coat is usually only 1/16 to 1/8 in. thick and produces a very consistent and clean finished look. The mist coat is then followed by one or more high fiber backer coats. I find this method is best for contemporary styles and also for high detail work. With this process you would not need, nor want to polish the surface too much, or you may expose the fibers from the back coat.

2.

3.

Premix/Hand Place – This method differs from the spray up in that you hand place a “face coat” in followed by the high fiber backer coat(s). The face coat differs from a mist coat in that it is usually thicker and should include PVA type (or equivalent) fibers to minimize shrinkage cracking because of its thickness.

Using the face coat method you can achieve a terrazzo finish by including decorative aggregate in the face coat and then polishing down. Using your imagination you can also achieve variegated and other looks with a face coat.

Premix/Self Consolidating (SCC) –You can also skip a separate face/ mist coat and just pour a self-consolidating batch that has the AR glass fibers throughout. In order to keep the premix GFRC flowing, you will usually want to lower your fiber loading down to between 2 and 4 percent.

With this application no polishing can

occur or the fibers will begin to show.

However, I have found that exposing the fibers adds a unique look and dimension to the piece in many cases, which you may find you like.

Advantages of GFRC There are quite a few advantages to utilizing a GFRC system. Some of these are based on the fact that steel rebar is not used, such as not having to worry about corrosion and ease of drilling, particularly on site.

Additionally, GFRC allows the pick up of high detail in 3-D shapes and also allows for the creation of longer spans without seams.

Another one of the many benefits of GFRC is weight reduction. It’s not that the concrete itself is any lighter with GFRC, but rather it’s that you are able to create a surface much thinner while increasing the surface’s strength.

Take for example a 4- by 8-ft. counter 2 in. thick. In wet cast it would weigh approximately 775 lbs., but by casting it in GFRC 3/4-in. thick with a 2-in. apron front the weight would be approximately 350 lbs. That’s more than a 50 percent reduction in weight.

Start Up Costs If you already have experience and the tooling to make wet cast concrete surfaces, adding the additional tools and materials needed for GFRC may not be as costly as you may think.

Whether you are looking to just try out GFRC surfaces or to go in full tilt, you will want to find a reputable/knowledgeable concrete countertop supply company that can work with you to acquire the proper materials and equipment.

The equipment you will want to consider varies on how much you will be using it.

For light use (once a week or less), the cost to get the necessary equipment will be in the range of $1,000 to $3,500. The bare minimums to switch to or add GFRC to your operations are as follows:

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 47

1. Tooling • An air compressor – I recommend a minimum of a 5 HP compressor with a 20 gal. tank (typically $200 to $800) • A spray hopper gun – depending on the features can cost up to $500 • Compaction rollers ($30 to $150) • A hand-held cement mixer with a 1.5 cu. ft. capacity (generally between $400 and $800) 2. Materials • Portland cement (locally sourced) • Sand (#30 sieve preferred) • AR chopped glass fiber (around $130 for a 44 lb. bag) • Film forming acrylic polymer (around $130 for a 5 gal. bucket) • AR glass scrim (reinforcement netting; around 40 cents per sq. ft.)

3. Admixtures (basically the same as for wet cast) • Premium superplasticizer • Pozzolan, such as Metakaolin or VCAS • Viscosity modifying admixture (VMA) • Defoamer • Accelorator/Retarder (optional, but good to have on hand) For medium or heavy use, such as the serious daily manufacturer of GFRC surfaces or for very large panels, the cost of the necessary equipment will be in the $20,000+ range. Generally speaking, the medium to large use start up costs are the same for materials and admixtures as with lighter operations (obviously in much larger quantities), but the cost of tooling can be significantly higher. Commercialsized premix mixers can cost $15,000 or more, and you will most likely be looking for a spray-up type pump/sprayer with concentric chopper gun, which also start in similar price ranges.

Of course, there is more than one way to produce GFRC surfaces and methods may differ from business to business. And along those same lines, just about any look you can produce with wet cast can be done with GFRC. The key is to let your creativity be your guide and to experiment with your methodology until you achieve the desired results.

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

Tom Fischer is owner of Fishstone Studio, a concrete countertop manufacturing company, and Concrete Countertop Supply by Fishstone. More information is available at www. concretecountertopsupply.com or by contacting him at info@concretecountertopsupply.com or 847-515-2232.

48 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

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ISFA Membership: $400 - Any Specialty Surfaces company that has been in business at least two years and carries appropriate liability insurance.

Sponsor Company:

Subscriber Membership: $400 - Applicant companies which meet all other qualifications, but have been in business for less than two years shall be eligible for Subscriber Membership in the Association

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Branch Membership: $200 - Branch Membership is available to companies having more than one location. Each location must fill out seperate membership applications. Branch Membership annual dues are one-half that of the headquarters location. Each location wll be treated as a seperate member in all respects except only headquarter locations may vote in General Elections.

regarding an ISFA member or company willing to sponsor you in. If you do not know what to put in this section, just leave it blank. We will help you with this.

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Each member of the International Surface Fabricators Association agrees to observe high standards of honesty, integrity, and responsibility in the conduct of their business. By adhering strictly to the highest quality standards of fabrication, manufacturing and installation. By promoting only those products and services that are proven quality and value. By writing contracts and warranties that are clear, honest, and fair to all parties involved. By honoring all contractual obligations in a reasonably prompt manner. By quickly acting on and attempting to resolve all customer complaints, and in situations where complaints appear unreasonable and persistent, by encouraging the customer to initiate and approach third party dispute settlement mechanisms. By being fiscally responsible and honoring all legitimate financial obligations; By maintaining all required licenses and insurances; I,_______________________________, do hereby certify that the foregoing is true and correct to the best of my knowledge, and do agree to abide by the Code of Ethics of the International Surface Fabricators Association for as long as I hold an active membership therein.

Face Coat Spraying Concrete Countertops

Tips to help avoid problems

By Jim Ralston When it comes to tools and equipment, I always say you should buy the best you can afford. And this rings true when it comes to your spraying equipment for face coats.

For example, I suggest the Kraft EZY Deck Pro Hopper that is designed for texturing floors. It has the handle and hopper slanted at about a 30 degree angle, so that when it is pointed toward the floor, the material doesn’t spill out. This is in contrast to the hoppers that can be bought at the big box stores, which are designed for texturing walls and ceilings.

Those types of hoppers are much larger and the handle needs to be reversed in order to work properly for concrete countertops. They do work and they are less expensive, but they are harder to use.

A specialty hopper gun I recommend is Power

Tex, manufactured by Power Spray. It has an oscillating head, and in my opinion is much more robust. At a cost of $400 to $500, it is more expensive than most other brands, but in certain applications, such as fireplace surrounds, planters and bench molds, etc., where there are tight spaces and high detail, it is worth its weight in gold.

might, when you spray over that cold joint it will show in the final product. There is nothing remedial that can be done afterwards.

I also suggest having a backup hopper that is ready to go in case something happens to the one you are using in your regular operations.

While in the process of spraying a face coat it is very frustrating when your hopper stops functioning properly. It always seems to happen when you are half way through a piece.

By the time you spend the 15-20 minutes it normally takes to fix the hopper, the face coat you were spraying has dried enough to create a “cold joint” along its leading edge. Try as you

About the Author: Jim Ralston, president of Urban Concrete, in Phoenix, Ariz., has spent his life in the concrete industry. His father owned a ready mix company and at the age of 19 Jim began work as a master mold maker and caster. Seventeen years later he started his own precast/countertop company.

An expert in GFRC manufacturing, he is also a wellknown trainer in concrete countertop manufacturing.

More information is available at www.urbanconcretedesign.com or via e-mail at concretejim2@yahoo.com.

50 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

In all of these cases, investment up-front is going to save a lot of time and headaches (and potential disaster) when all is said and done.

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FREE Product Information Form (or visit www.ISFANow.org/info to fill out our online form) I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

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26

Here.

Now. News.

52 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Holiday at ICE Halloween, Thanksgiving, Christmas, New Years, ICE . . . well maybe ICE isn’t a holiday, but it is just as fun and, at four days in length, it lasts a lot longer. Like any holiday, ICE is coming just as quickly and will be here before you know it.

Which means now is the time to prepare for the most fabricator-friendly trade show and conference in the universe.

Speaking of holidays, February 7th is Super Bowl Sunday, which happens to be the day we kick off ICE with the Big Game Football Party at Hard Rock Hotel & Casino by special arrangement. Come party with 400 of your closest industry friends and colleagues with burgers and brews until the final whistle. For more information or to register, go to the ICE Web site at www. countertopexpo.org, or call the ISFA office at 877.464.7732.

Advisory: Super Bowl Weekend is huge in Las Vegas and rooms are often hard to find. If you take advantage of the ISFA room block at Mandalay Bay and make your reservations now, you are guaranteed a luxurious room at our special pricing. For more information go to the ICE Web site at www.countertopexpo.org/travel.

The Official S

But ICE is not all fun and games. It’s also solid information, geared to help you become more profitable in your business. Check out the ICE Pre-Show Planner inserted in this issue of the magazine to see the full lineup of killer conferences ISFA has planned.

Considering the wealth of information on display at ICE, it might be a good idea to think about how many people you want to bring from your shop. Everywhere at ICE the “Buy Two, Get the Third Free” is in effect. In other words, buy two exhibit hall passes and get the third for free.

Buy Two three-day conference passes, and get the Third for Free. Even better, anyone who purchases a Three-Day Conference Pass gets admission to the Big Game Football Party and Networking Luncheon for free. That’s a combined savings of $50, right off the top!

The best part of ICE is the sense of community you feel everywhere. Some people call it the Spirit of ISFA. Whatever you call it, it’s the feeling you get from being a part of a community of like minded people. And from those people, you will receive valuable nuggets of knowledge.

One fabricator put it best when he said, “I’m not going to ICE to find answers to my questions. I can do that on the Internet. I am going to ICE to find answers to questions I never even thought to ask.”

Did we mention ICE will be a lot of fun? Sure, there will be onsite countertop fabrication as part of the Innovations in Design Competition, and yes, there will be lots of demonstrations on the show floor, but . . . what about the fun? How about the raucous raffle we have dubbed the Dream Sweeps Giveaway Drawing to be held on the final day of the show in the Exhibit Hall?

What could be more fun than capping four days of networking, learning, seeing and doing than winning valuable prizes generously provided by our industry partners? You could win exotic vacations, tools and equipment, fabrication supplies, gift certificates and more, simply by being there for the drawing. Even better, your chances of winning go way up when you take the time to visit all of the vendors who have booths in the show. It’s a classic, win, Win, WIN! Oh, and did we mention, YOU CAN’T DO ANY OF THIS ON THE INTERNET!

Certification A stark reality of today’s economic environment is there are fewer customers out there ready and willing to buy, which means fabricators must work harder every day to earn their business.

What you need is a marketing tool that helps your business stand out from the competition – especially one that engenders instant credibility with potential clients.

Have you considered doing what it takes to become an ISFA Certified Professional? This is ethics-based ISFA certification that is being marketed to the end-user as the ultimate assurance of a job well done.

ISFA Certified Professionals must obtain all applicable state and local licenses, carry proper business insurance, use standardized contracts and have in place a resolution policy for customer complaints. They must also sign and notarize their compliance to the ISFA Code of Ethics and submit to a yearly Certification Documents audit.

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 53

The message to consumers is that ISFA Certified Professionals will do whatever it takes to make the countertop purchasing experience enjoyable.

ISFA Certification is a marketing tool to help get your company noticed and to help sway the end-user in your direction. When you become an ISFA Certified Professional you receive valuable marketing tools, including: • Two professionally written press releases for distribution to your local media outlets highlighting your company as an ISFA Certified Professional.

• A trifold point-of-purchase brochure you may use in your showroom or distribute to your dealers that proclaims the benefits of using an ISFA Certified Professional.

• Posters for display in your showroom.

• A CD containing a full assortment of files for promotional flyers, featuring every kind of countertop material.

• A certificate suitable for framing.

• Electronic versions of the ISFA and ISFA Certified Professional logos, along with instructions on how to use them in branding YOUR business.

• Assorted door clings and vehicle decals.

ISFA Certification is the single most popular reason new members cite for investigating the benefits of joining ISFA. They recognize the value industry certification brings to their fabrication business.

So don’t delay reaping the benefits. You can learn more at www.ISFAnow.org/certified, or call the ISFA office for more details.

ISFA Web Site In June, the Find A Countertop Professional feature was launched on the ISFA Web site. All ISFA members in good standing are listed in the directory, which is zip code based. If you are an ISFA member, you should have been receiving regular reports on the number of times your information has been accessed by potential customers.

ISFAnow.org, unlike other trade association Web sites, is geared to providing solid information to consumers and specification professionals first, thereby driving traffic – and potential sales – to our valued members. Of course, there is a section dedicated to fabricators, which brings the visitor up to date on the latest information and events in the decorative surfacing industry. But, the focus is on the end-user.

New Design Contest ISFA is proud to announce that it has teamed up with Cygnus Business Media, publisher of Surface Fabrication magazine, to host the inaugural Innovations In Design competition, which showcases fabricator projects in a wide variety of decorative surfacing materials in multiple application environments. Winners of the competition will be announced at the International Countertop Expo (ICE) to be held at Mandalay Bay in Las Vegas, Feb. 8-10.

An exciting feature of this year’s competition will be live fabrication of vanity countertops on the trade show floor. The only parameters will be the dimensions of the vanities – everything else about the design is up to the skill and creativity of the fabricator. At the end of the competition all vanity tops will be donated to charity.

The Innovations In Design competition is open to all decorative surfacing fabricators and may include any decorative surfacing material – or combination of materials – in the final entry. Categories include, Residential Kitchen, Residential Bath, Commercial/Institutional, Freestyle/Art, Artisan and Green.

Best of Show will be selected from among the winners in each category.

“The Innovations In Design competition is an excellent way to showcase the extensive talents and craftsmanship that characterize members of the decorative surfacing industry,” said Tim Campbell, Group Publisher for Cygnus. “It’s a way for fabricators to push the application and design envelope for these extremely versatile materials and to be recognized by their peers for their expertise.”

To register for the Innovations In Design competition, fabricators may visit the ISFA Web site at www.ISFAnow.org/design or call the ISFA office at 877.464.7732 to obtain a registration packet. The deadline for entries is Dec. 22, 2009. Only those projects completed during the 2009 calendar year are eligible for the competition. Entries will be on display at ICE during normal show hours.

It is appropriate that the industry’s first design competition that includes all types of countertop materials will premiere at ICE, which is the only trade show for the entire decorative surfacing industry.

For more information call the ISFA office at 877.464.7732 or visit ISFA online at www. isfanow.org/design

So check out ISFAnow.org today. And if you see something we need to add, please drop us a line.

54 • Vol. 4, Issue 3, 2009 • International Surface Fabricators Association

20 Shop Tours in a Day Everyone loves a shop tour. This year at ICE, the most fabricator-friendly Expo on the planet, you can gorge to your heart’s content on virtual tours of large and small shops from across the globe.

Visit us at the ISFA booth where we will be screening virtual glimpses of every kind of countertop operation nonstop as long as the exhibit hall is open. This is your chance to pick up those little golden nuggets of information that just might make your shop a little more efficient and more profitable.

The 20 Shop Tours in a Day project is a collaborative effort, which means we are soliciting videos and photos from anyone who is a decorative surfacing professional. You can help ISFA build its virtual library by dusting off the video camera and recording your staff and shop for posterity today. Don’t worry if you think your shop layout needs work – you are in good company. One of the most interesting aspects of the project is seeing what fabricators have done to take a less than perfect situation and turn it into a cash-generating, dust-churning, dream-fulfilling enterprise.

Don’t have a video camera? No worries, send us your still pictures and we’ll turn them into a streaming movie suitable for use in your showroom.

So, don’t delay. Put on your director’s hat today and get filming. We’ll take any kind of video – from analog to digital. You can send the final cut by snail mail to Jeff Pease at ISFA, 910 W. State St., PO Box 179, Lehi, UT 84043. For those of you with Internet savvy, send your finished file to Jeff@ISFAnow.org.

After the close of ICE, all video shop tours may be found at the industry Web site, www.ISFAnow.org.

The Spirit of ISFA is all about learning and sharing with like-minded industry professionals. We invite you to be part of that community.

Happy filming.

International Surface Fabricators Association • Vol. 4, Issue 3, 2009 • 55

ISFA Board of Directors & Staff Sid MacKay President Creative Surface Solutions 2855 Coleman Street • Las Vegas, NV 89032 Phone: 702-365-6444 • Fax: 702-365-6798 Email: sid@creativesurface.com www.creativesurfaces.com Evan Kruger Vice President Solid Tops, LLC 505 South Street • Easton, MD 21601 Phone: 410-819-0770 • Fax: 410-819-0783 Email: evank@solidtops.com www.solidtops.com Hunter Adams Secretary TRINDCO 1004 Obici Industrial Blvd. • Suffolk, VA 23434 Phone: 757-539-0262 • Fax: 757-539-8921 Email: hunteradams@trindco.com www.trindco.com Ted Sherritt Treasurer FloForm Countertops 125 Hamelin Street • Winnipeg, Manitoba R3T3Z1 Phone: 204-474-2334 • Fax: 204-475-9295 Email: tsherritt@floform.com www.floform.com Joe Hoffman Assistant Treasurer Hoffman Fixtures Company 9421 E 54th St • Tulsa, OK 74145 Phone: 918-627-3055 • Fax: 918-627-3560 Email: joehoffman@hfccountertops.com www.hfccountertops.com Michael Job Director Quality Surfaces, Inc. 2087 Franklin Road • Spencer, IN 47460 Phone: 812-876-5838 • Fax: 812-876-5842 Email: mikej@qualitysurfaces.com www.qualitysurfaces.com

Kurt Bonk I.T. Officer Cabinets2Countertops 7142 Frank Avenue NW • N. Canton, OH 44720 Phone: 330-244-0221 • Fax: 330-266-7635 Email: CCBONKCO@aol.com Todd Werstler Immediate Past President Tower Industries P.O. Box 647 • Massillon, OH 44648 Phone: 330-837-2216 • Fax: 330-837-2642 Email: twerstler@towersurfaces.com www.towersurfaces.com Russ Lee Executive Director of ISFA 910 West State Street Unit 1 • Lehi, UT 84043 Phone: 702-567-8150 • Fax: 702-567-8145 Email: russ@issfa.org www.issfa.org Mike Nolan Director Windbound Co. 113 Craftsman Drive • Morganton, NC 28655 Phone: 828-438-0892 • Fax: 828-438-0893 Email: windboundco@bellsouth.net www.windboundhomes.com Mike Langenderfer Director The Countertop Shop Ltd 10406 Geiser Road • Holland, OH 43528 Phone: 419-868-9101 • Fax: 419-868-9104 Email: mike@countertopshop.net www.countertopshop.net Martin Funck Director Rosskopf & Partner AG Bahnhofstrabe 16 • D 09573 Augustusburg Hennersdorf Germany Phone: 493-729-12524 • Email: martin.funck @rosskopf-partner.com www.rosskopf-partner.com

56 • Vol. 4, Issue 3, 2009 • International Surface Fabricators Association

Dave Paxton Director Paxton Countertops P. O. Box 174 • Grand Ledge, MI 48837 Phone: 517-719-0146 Email: paxtoncountertops @yahoo.com

ISFA Staff

Mike Cook Director Concrete Approaches 2246 Vantage St. • Dallas, TX 75207 Phone: 406-544-5150 • Fax: 214-637-1529 Email: mcook@concreteapproaches.com www.concreteapproaches.com

Jeff Pease Creative Director & Web Services Email: Jeff@isfanow.org Office: (877) 464-7732 ext. 11 Direct: (702) 468-2639

Harry Hollander Associate Member Representative Moraware 3020 Zeus Way • Reno, NV 89512 Phone: 650-242-4272 • Fax: 309-414-1013 Email: harry@moraware.com www.moraware.com Bryan Stannard Associate Member Representative ITW Plexus 30 Endicott Street • Danvers, MA 01923 Phone: 210-389-2917 • Fax: 978-774-0516 Email: bstannard@itwplexus.com www.itwplexus.com ISFA Legal Counsel William Barton, Esq. ISSFA Legal Counsel Barton, Baker, McMahon & Tolle, LLP 1320 Old Chain Bride Road, #440 • McLean, VA 22101 Phone: 703-448-1810 • Fax: 703-448-3336 Email: wbbarton@aol.com

Russ Lee Executive Director Email: russ@isfanow.org Office: (877) 464-7732 ext. 12 Direct: (801) 735-7606

Kevin Cole Communications Director Email: kevin@isfanow.org Office: (877) 464-7732 ext. 13 Direct: (815) 721-1507 Sandy Milroy Meeting & Membership Director Email: sandy@isfanow.org Office: (877) 464-7732 Direct: (702) 240-1660 Margaret Pettingill Administrative Assistant & Registrar Email: meg@isfanow.org Office: (877) 464-7732 Ext. 10 Main Office Toll Free: (877) 464-7732 Direct: (801) 341-7360 Fax: (801) 341-7361 Email: info@isfanow.org Web: www.ISFANow.org

ThankYou.

To more than 60 companies that are new members or have recently renewed their membership with ISFA.

A. I. A. Countertops LLC Alaskan Counter Fitters Berea Top Shop, Inc. Betterley Industries, Inc. Carolina Custom Surfaces Carroll’s Contemporary Designs, Inc. Caulk-EZ, LLC CFM Stone & Solid Surface Classic Carpet of Lawton, Inc. Colonial Saw Company Concrete Countertop Supply by Fishstone Concrete Design Solutions Consolidated Supply Company Counter Fitters Counterscapes, Inc. Countertop Pros Countertop Shoppe division of Fishor’s Fixtures Inc. CreativeCrete Custom Marble Inc. Domain Industries Eagle Fabrication, Inc. Emerson-Swan

Energy, Management and Engineering European Artstone Inc Fabricator’s Choice FloForm Countertops Heritage Woods Inc Hoffman Fixtures Company InConcrete Custom Countertops and Design Elements IT Directions and Strategies, LLC Jaco Builders, Inc JC Tops, Inc Klingspor Abrasives Laser Products Industries, Inc. Lifetime Surfaces Martin Fabricating Mother Hubbard’s Kitchens North Star Surfaces, LLC Northwood Machine Manufacturing Co. Oldcastle Surfaces, Inc. Oldcastle Surfaces, Inc. Oldroyd Custom Woodworking Parman Brothers Ltd. Pauma Valley Custom Woodworking

Penn Fabricators, Inc. Performance Abrasives, Inc. Precision Works Products Rogue Valley Countertops Shelby Millwork, Inc Solid Fabrications, Inc. Solid Surfaces Plus Spaulding Fabricators, Inc. Spectrum Surfaces, Inc. Stone Merchant StoneCrafters, LLC Superior Property Transformations Surecrete Design Products Surface Designs, Inc. Surface One Systechs Top South Transolid, Inc. Unico Special Products, Inc. W R WATSON INC Windbound Co.

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 57

mail it in and that’s it! Your subscription automatically starts the next time an issue is mailed out. What’s even better is that if you subscribe,

you save half off the cover price!

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Certified.

Yep. We’re ISFA

ISFA Certified Why Look for The k?

Professional Mar Peace of mind. is your ed Professional ing the Using an ISFA Certifi job well done. Follow Ethics, assurance of a of d in the ISFA Code principles outline contractor ensures that your rtop ISFA Certification counte install your new will fabricate and ry standards. More sional to the highest indust ISFA Certified Profes lly importantly, every ss ethica conduct busine e. has promised to e of customer servic with a high degre t sionals must submi ss ISFA Certified Profes tion of their busine inspec us rigoro to a of insurance, ing verification practices, includ reasonable es, use of fair and for applicable licens system ished establ contracts and an . An ISFA er service issues handling custom the value sional understands and Certified Profes ss in a reasonable of conducting busine proud to stand behind and is ethical manner, his work.

Get Certified. Get Ahead.

sionals take Certified Profes cts, That means ISFA clearly written contra and pride in providing service t and courteous providing promp sale. service after the ed of the ISFA Certifi Look for the mark ance of a your only assur Professional. It’s job well done.

In times like these it makes sense to separate your company from the competition any way you can.

ISFA Certification communicates peace of mind to end-users with the message that using an ISFA Certified Professional is the ultimate assurance of a job well done.

n about ISFA Certified Get more informatio Now.org visiting www.ISFA Professionals by

ISFA Certification provides valuable marketing tools to help you stand out. When you become certified you get: • Two professionally written press releases featuring your company for distribution to local media outlets.

• Copies of a Point of Purchase brochure proclaiming the benefits of using an ISFA Certified Professional.

• Signage for your showroom.

• Branding materials for use in your literature and showroom.

• A CD containing electronic copies of the ISFA Certified Professional logo, the ISFA logo, press releases, brochures, fliers and posters.

• A marketing guideline for proper branding procedures in your business.

Why Loo k for The ISFA Ce rtified Professio nal Mark?

Using an ISFA Certifie assurance d Profess the princip of a job well done. ional is your les outline Following of Ethics, d in the ISFA ISFA Code your contrac Certification tor will fabrica ensures that your new te and countertop standards. to the highesinstall t industr Certified More importantly, y Professional every conduct has promis ISFA business ed to ethically degree of with a high customer service.

ISFA Certifie d Profess submit to ionals a must their busine rigorous inspect ion verification ss practices, includinof licenses, of insurance, applica g use of fair ble contracts and and an establisreasonable for handlin hed g issues. An customer service system ProfessionalISFA Certified understands the value of conduc business ting in and ethical a reasonable manner, is proud and to his work. stand behind What that means is ISFA Certifie Professionals d take pride in providi clearly written ng contracts, providing prompt and courteo service and service us the sale. after Look for the mark Certifie d Profes of the ISFA sional. your only It’s well done. assurance of a job

Your Assuranc e of a Job Well Done.

Becoming an ISFA Certified Professional may be much easier than you think. To get more details visit the ISFA Web site at www.ISFAnow.org/certified or give us a call at 877.464.7732.

ISFA Certification Means Business

Supplier Profile: Park Industries From its humble beginnings in 1952 when it was founded as Gran-A-Stone by Leon Schlough, Park Industries in St. Cloud, Minn., has grown to become North America’s largest manufacturer of stone fabrication machinery.

But in the beginning, it wasn’t all about stone equipment, but rather a stone-like concrete veneer product. The next year, when Schlough’s customers needed a better way to split the material, Park Tool, a division of GranA-Stone, was born. In its 56 years, the company has installed more than 7,000 stone working machines in 20 countries, but hasn’t left behind its focus on quality, people and customer service.

In 1972 Park Tool Company split from GranA-Stone and became an incorporated entity of its own, and four years later Tom and Joyce Schlough bought it from Leon, Tom’s father, and still run it today.

“Dad understood that customers drive the business,” said Tom. “When his customers needed a better tool to split the stone, he designed one.” And that same philosophy of helping the customer still pervades at the company.

Tom Schlough, owner of Park Industries

Tom shares a story from his past that illustrates just why the company focuses its energies where it does. Many years ago, Tom saw how not to treat a customer and it has become his example. The story goes that the

60 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

crankshaft broke on his neighbor’s car and the local dealership where the friend bought the car offered to fix it—but at full rate, because the warranty was expired. Tom’s friend pointed out that crankshaft breaks were very rare and this was clearly a manufacturing defect. But the dealership wouldn’t listen.

Needing his car and having no other choice, Tom’s friend angrily agreed to the repair.

Then he vowed never to buy from that dealer or that car manufacturer again. And Tom took that to heart. To remind everyone at Park that customer service is everyone’s responsibility, Tom put miniature crankshafts on employee desks as a symbol of the right way to do business.

Prior to Tom’s purchase of the business, it

focused almost exclusively on equipment to split hard materials, such as the company’s Gran-A-Stone product and natural stone, but in the 70s the company began to expand more into other aspects of the stone industry, including equipment to produce monuments and the company’s first diamond-tipped saw blade.

The 80s saw the company delving deeper into wider areas of stone fabrication, and in 1983 released its first slab polishing system. Two years later, in 1985, the company changed it’s name to Park Industries and moved to a new 30,000-square-foot facility to respond to its customers’ growing needs.

And in 1988, the company debuted its first CNC router for the dimensional shaping and cutting of marble and granite for primarily countertops and vanities. And understanding the value that the company’s employees brought to the table, in 1989 adopted the Park Quality System, which invites all of its employees to suggest ways to reduce cost and improve performance.

The 90s saw the introduction of some of the company’s most popular shaping and polishing machinery while the technology behind all of the equipment continued to advance. A variety of new machines were launched and the company continued to grow.

has been at the heart and soul of our business for over 50 years, and will continue.”

As such, Park contributes time, manpower, in-kind services and money to literally dozens of worthy causes ranging from the local and national charities to youth activities to local and national institutions of learning and more.

“Learning moves us all forward,” added Gary Stroeing, vice president of sales with Park Industries. “Mutual benefit is the desired outcome of our efforts. We also know that our employees are essential to our customers’ success and our own, so we employ a staff of skilled people—experts who truly understand customer service as well as they understand stoneworking. We respect their capabilities and entrust them with the company’s reputation.”

Maybe all of that is why some of the company’s first machines are still on the job.

I N T E R N AT I O N A L S U R FAC E FA B R I C AT O R S A S S O C I AT I O N

For more information, contact Park Industries at 6301 Saukview Dr., St. Cloud, MN 56303, (800) 3282309, park@parkindustries.com, www.parkindustries.com.

In the year 2000, with the popularity of quartz surfacing and engineered stone growing by leaps and bounds and the division between solid surface fabricator and hard surface fabricator blurred, Park Industries joined ISFA and set out to help the association’s members to better understand the stone side of the countertop industry.

Park was productive in the years that followed, refining and launching equipment as well as getting involved in the manufacture of equipment for thin stone veneers. And while Park Industries has took its lumps over the tough economy of the last year or two, it is still going strong, offering equipment for sawing, splitting, shaping and polishing stone for interior or architectural applications.

But, Park doesn’t only help its customers take advantage of the technologies available, it also gives back to the community.

“As responsible corporate citizens, we are committed to making a positive and meaningful impact on the communities where our employees live and work,” said Schlough.

“We believe that by sharing our resources with these communities, we invest in the wellbeing and success of future generations. Our philosophy of giving back to our communities International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 61

ProductNews Groves Supplies New SixWheel Installation Carts

Groves Inc. now offers six-wheel installation carts with raised material supports for ease of loading, which will keep finished material high off the ground. The carts hold up to 4,000 lbs. and can be moved by forklift, to help with loading and unloading of delivery equipment and moving raw material to the fabrication area.

The carts have four heavy-duty swivel casters with brakes on the ends of the base for stability.

Two wheels located in the center of the base provide easy mobility and a zero turning radius, reports the manufacturer. Heavy duty rubber is mounted on the base and the uprights to help prevent slipping and damage to the material and ratchet straps are provided to secure material to the cart. Two models are available to move anything from full slabs to finished countertops. Circle Reader Service # 12

for doors, large signs and other sizeable displays. Three-axis travel on both models lets users make straight or curved cuts at various depths. To design projects and control the router, the Shark includes version 5.0 of the VCarve Pro software, which has a flexible and accessible interface that includes the unique ability to import outside graphics and automatically convert them to line art for routing. The Shark is also compatible with a wide range of other software. For maximum stability, the machine’s gantry moves while the workpiece stays clamped in place. This setup prevents accidental slippage and routing errors that can occur with stationary-router/moving-workpiece systems. The machine also has a unique cutting mechanism. Instead of using an expensive built-in router, the machine works with an offthe-shelf Bosch Colt palm router. This independent design not only reduces cost, it lets users work with a wide variety of standard bits and also minimizes replacement costs if the router should fail. Additional features include steel and polyethelene construction, plunge cut capability, direct drive from the motors to the lead screws, an open design for easy access and cleanup, table slots for attaching hold-down clamps and precision machined parts.Circle Reader Service # 13 on the Reader Service Page (pg. 51) or go to www.ISFAnow.org/info

Dynabrade Introduces New Random Orbital Sanders

on the Reader Service Page (pg. 51) or go to www.

ISFAnow.org/info

Rockler Provides New Introductory CNC Routers Rockler Woodworking and Hardware has introduced the new CNC Shark and CNC Shark Pro, two smaller, yet full-featured CNC routing systems. The smaller CNC Shark has a 15-3/4 by 31-1/2 in. table and will handle a variety of signs, carvings and other small projects. For bigger jobs, the Shark Pro nearly doubles the X-axis travel (from 13 to 24 in.), equipping it 62 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

The new Dynorbital Silver Supreme Random Orbital Sander from Dynabrade is an American made air-powered sander suitable for high production areas. The tool is suitable for flat and horizontal sanding, and for use on wood, metal, composites, solid surface, plastic and fiberglass. The 12,000-RPM sander is available in 3, 3-1/2, 5 and 6 in. diameter models. Each tool includes a low profile,

8-in. casters allow resting on stair treads.

Pneumatic casters dampen vibrations and enable travel across rough terrain such as gravel or lawns. The wheelbase makes the cart very stable, even with large tops, and the cart’s high ground-clearance allows “popping of wheelies” over larger curbs, reports the manufacturer. In many cases, one person can push and maneuver the cart. Tops are secured by clamps located on each side of the cutout to reduce breakage in the middle. The optional upgrade kit enables the cart to be folded for easy storage (reduces cart width to 9 in.) All of the company’s products are engineered, manufactured and assembled in the United States and are covered by a one-year manufacturer’s limited warranty.

Reader Service # 15 on the Reader Service Page (pg.

51) or go to www.ISFAnow.org/info

Domain Industres New 2010 Affinity Solid Surface Line

on the Reader Service Page (pg. 51) or go to www.

ISFAnow.org/info

Omni Cubed Offers All-Terrain Installation Cart

Solid Surface Redefined.

Domain Industries, Inc., a nationwide supplier of kitchen & bath products, has announced the introduction of its new 2010 color line for it’s Affinity brand solid surface, featuring 52 reformulated and redefined colors that reflect current and future consumer life trends.

Product News

premium urethane weight-mated sanding pad.

The tool also features various ergonomic features including a comfort platform, which provides additional wrist support, and a rubber overmold, which eliminates cold air transmission to the operator’s hands. Other features include a throttle lever that is recessed into the housing (eliminating pinch points) and a stay tight muffler system. Three different sanding orbit diameters are offered; 3/8-in. diameter orbit for aggressive material removal, 3/16-in. diameter orbit for general sanding and a 3/32-in. diameter orbit for ultra fine sanding. It is available as a non-vacuum sander, a self-generated vacuum sander and a central vacuum sander. The steel cylinder and end plates inside the tool stay perfectly aligned. The unique design of the end plates keeps more air in the cylinder, increasing motor efficiency, according to the manufacturer.

Various accessories are also available, which include dust collection systems, portable vacuum systems, downdraft tables, replacement sanding pads and abrasives. Reader Service # 14

The colors are divided into two collections, Essentials and Surreal, which feature enhanced tones, and the use of translucent particulates.

Both color lines grasp onto elements found in modern day life and redefine the boundaries of traditional solid surface.

The Pro-Cart AT1 from Omni Cubed is designed as an alternative to large and cumbersome countertop installation carts. The cart is constructed from aluminum tubing, and weighs only 46 lbs. For climbing stairs, the cart stays attached to the countertop when lifted and the

“The Essentials Collection features 15 colors that reportedly cover 80 percent of the market demand for standard solid surface patterns.

The Surreal Collection is a dramatic new approach to solid surface and boasts a uniquely personified collection that has the ability to mimic natural looking stone and quartz products, while still keeping the freedom and ease of fabrication International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 63

of solid surface material.

Domain will showcase the colors from their new Affinity collection at The International Countertop Expo, scheduled for February of 2010 in Las Vegas, NV. Circle Reader Service # 16 on the Reader

popping off when their backs are turned. J Hooks are also included. Electric Install Portable 4-Pod Clamps and Standard 4-Pod Clamps for solid surface materials are also available. Circle Reader Service # 18 on the Reader Service Page (pg. 51) or go to www.ISFAnow.org/info

Service Page (pg. 51) or go to www.ISFAnow.org/info

ITW Plexus Adds UV Stone Repair Kit to Line Up

Product News

ITW Plexus has added a UV Stone Repair adhesive to its lineup of products. The adhesive is used when a fast permanent repair is needed to fix scratches, chips, gouges, cracks and nicks on natural and engineered stone, reports the company. This adhesive incorporates a proprietary “Curing Sheet” that ensures a tack free permanent repair. The adhesive is a single component acrylic that requires no mixing and is cured with a low dose of UV (Ultraviolet) light (385nm). The adhesive is non-yellowing, UV stable and will not scratch or mar, according to the company. Circle Reader Service # 17 on the Reader Service Page (pg. 51) or go to www.ISFAnow. org/info

Select Machinery Offers Monument Toolworks Portable Gorilla Grip Clamp

New Faucets From Artisan

`

Artisan Manufacturing now offers nine faucets suitable for kitchens, bathrooms and bar sinks.

The faucets have a satin nickel finish and some models are also available in chrome. With solid brass construction, a durable ceramic disc cartridge and high quality triple satin nickel plating, these faucets are engineered for long-service and come with a limited lifetime warranty, reports the company. Circle Reader Service # 19 on the Reader Service Page (pg. 51) or go to www.ISFAnow.org/info

The Monument Toolworks Portable Gorilla Grip Clamp for Stone is available from Select Machinery and features a powerful and precise clamping mechanism that pulls together and perfectly aligns the heaviest of stone tops with a minimum of effort, reports the company. An electric vacuum pump is used to insure reliable, consistent and powerful clamping of the pods to the deck. According to the company, fabricators will no longer have the problem of suction cups 64 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Houzer Inc. introduced a new series in its line of stainless steel sinks – The Nouvelle Series. The sink places an increased emphasis on presentation and offers a fusion of symmetrical minimalism and modern design. The unique 25mm radius gives it a large capacity with its deep well and straight walls. The sinks fit in elegant as well as modest applications and are available in three of the most popular designs: standard-sized single-bowl, large-sized single-bowl and 50/50 double-bowl. Grade T-304 stainless steel is used throughout this 18 gauge sink series. Innovative SpecPlus edges offer strength while MegaShield insulation for sound absorption with StoneGuard undercoat, makes it quiet, reports the company. A complimentary strainer and bottom grid are included along with a lifetime warranty. Circle Reader Service # 20 on the Reader Service Page (pg. 51) or go to www.ISFAnow. org/info

Align Rite Supplies Inlay Products Align Rite offers a variety of products for solid surface inlays, including two sizes of solid color inlay kits, particulate kits and the Air-X-Tractor to remove unwanted air from inlay mixes. The solid color inlay kits come in 30 gram and 60 gram sizes, each containing six bottles. The particulate kits and 30 gram solid color kits each inlay 150 in., 1/4-in.-wide by 1/8-in.-deep. The 60 gram solid color kit inlays 300 in. 1/4-in.-wide by 1/8-in.-deep. The company stocks particulate, solid colors and custom color match to the Pantone color chart and just updated its list to show the Pantone equivalent number to its stock color number to make color ordering easier. The Air-XTractor works in conjunction with a compressed air line and requires approximately 80 PSI to operate. This vacuum mixing system is used to remove unwanted air from inlay mixes to create bubble-free inlays, reports the company. Circle Reader Service # 21 on the Reader Service Page (pg.

51) or go to www.ISFAnow.org/info

J. Aaron to Provide Fabricated Tops J. Aaron LLC is an Atlanta-based manufacturer of wood and concrete countertops that can be offered through fabricators.

Fabricators wanting to offer the tops take the orders and perform all the field measurements, then provide the company with the cut files or templates. The company then manufactures the product to spec, and the finished tops are shipped out for the fabricators to install. Concrete tops and sinks are available in seven colors. Several wood choices are available for wooden tops, and two finishes are offered. Circle Reader Service # 22 on the Reader Service Page (pg. 51) or go to www.ISFAnow.org/info

Deerwood Offers Updated Countertop Fasteners Deerwood Fasteners International now offers Zipbolt connectors to replace the “old style” draw bolts commonly used in laminate countertop installation. The Zipbolt has an integrated gearing system (UT – Universal Technology), that allows the user to tighten the part with a 4mm hex drive bit in a drill, hand driver or Allen key.

This promotes easier, faster and safer tightening of the part, according to the company. When using a driver bit in a drill, the part reportedly can be tightened in seconds. The product comes in 360 pieces (6 mini boxes of 60, each with a 4mm hex drive bit). Circle Reader Service # 23 on the Reader Service Page (pg. 51) or go to www.ISFAnow.org/info

Product News

Houzer Offers New Series of Stainless Steel Sinks

BLANCO Introduces New Sink to Fit 36-in.

Cabinets BLANCO has added two new 1-3/4 PERFORMA undermount sinks to fit 36-in. cabinets.

The new models complete this collection of 37 stainless steel and SILGRANIT sinks for both standard and custom cabinetry.

PERFORMA’s design is styled to timelessly blend with any décor, and it is engineered to maximize counter space, reports the manufacturer. The sinks have a satin polished finish and sound dampening insulation. Other features include: 18 gauge stainless; rear drain placement to allow more usable sink space; 10-in. deep bowls on large and 9-in. deep on small; 15-in. width by 20-in. length for the large bowl and 15-in. width by 15-1/2-in. length for small bowl, which minimizes the cutout while maximizing usable working space. Specially designed accessories are available, such as stainless steel grids, integrated walnut cutting boards and mesh colanders. Circle Reader Service # 24 on the Reader Service Page (pg. 51) or go to www.ISFAnow.org/info

International Surface Fabricators Association • Vol. 2, Issue 4, 2009 • 65

A d Index & Classifieds

Classifieds For Sale

2003 floor model Polytherm 3000 Solid Surface Thermoforming Technology Size: 4x6 feet Two Units: Heat Press, Vacuum Table New $26,000, Asking $18,000 (negotiable) See Video: www.norford.com.au Contact: ckaetzster@gmail.com or (570) 517-1387

Position Available Large fabricator in Georgia has position available for Solid Surface Division Manager.

Position responsibilities include, supervision of all aspects of solid surface fabrication and installation. Candidate must have documented managerial success in the solid surface business.

Fax resume and salary history to 770-422-4045 or email to jroelle1972@yahoo.com.

In Search Of Opportunity

Experienced distributor and fabricator commercial sales professional seeks challenging and rewarding sales position involving market development and expanding new business, negotiating, closing, customer service, problem solving, presentations, and relationship building/strengthening. Active in construction industry including membership in CSI and USGBC, pursuing LEED certification and OSHA “30-Hour” credentials. Developed and delivered presentations at surfacing expos, wrote magazine articles, created sales materials and aids. Prefer southeast U.S. location but will consider other areas. Call 919-801-8021 for more information.

66 • Vol. 2, Issue 4, 2009 • International Surface Fabricators Association

Ad Index Referral Number

Page Number

07

31 - Apollo Sinks

05

26 - Colonial Saw

01

02 - Domain Industries

06

29 - Federal Saw & Tool

08

67 - Integra Adhesives

04

09 - ITW Plexus

03

07 - Karran/Lansen Sinks

09

68 - Kohler

02

05 - Moraware

Attention Fabricators ISFA Fabricators, do you have used equipment taking up space in your shop that you would like to sell? Are you looking to fill a key position in your operations? We have 10,000 readers that might be interested. Why not submit a FREE classified ad? That’s right, classifieds in this publication are free to ISFA fabricators! Just send us the text you’d like us to run, and we will do the rest. Email us today at editor@isfanow.org. To place your ad or for non-member classified rates, email us at editor@isfanow.org or call 887.464.7732.

INTEGRA Surface Bonder XI

Adhesive with Epoxy High Strength Fast Cure Superior color matching Solid Surface Quartz Natural Stone

3G

THIRD GENERATION ADHESIVES

Cartridge System

Molded in North America Hi-Impact Nylon 6™ reduces breakage Pre-blending with Coaxial activator injector Seal and O-ring extends shelf life

Mixing Tip

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To learn about our range of products: Call toll free (North America) 888.862.6665 Phone (1)-604.850.1321 Fax (1)-604.850.1354 info@integra-adhesives.com Circle Reader Service #10 on the Reader Service Page or go to www.isfanow.org/info

See what’s new at

KOHLER® Cast Iron Kitchen Sinks.

Over 20 gorgeous colors to coordinate with today’s most popular kitchen cabinets and countertops and an enameled surface guaranteed not to chip, crack or burn.

Circle Reader Service # 11 on the Reader Service Page or go to www.isfanow.org/info

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