Ornamental and Miscellaneous Metal
Fabricator 速
The official publication of the National Ornamental & Miscellaneous Metals Association
March / April 2013 $6.00 US
Member Talk
Getting the keys to Germantown page 38
Shop Talk 3D printing for casting, page 16
Shop Talk How to hot-form thick acanthus leaves, page 24
METALfab2013 Exhibitor showcase report, page 46
Biz Side Fiscal solution helps small business, page 57
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Testimonial: Mark O’Malley When I left for my first NOMMA convention I thought I knew my business, but when I returned I realized how little I knew. Attending the METALfab convention has allowed me to gain friendships and knowledge. There is nothing like meeting a colleague who is going through the same problems and growing pains as yourself. Meeting with fellow fabricators provides a different perspective on an idea, and you can talk freely with someone who is 1,000 miles away, as opposed to another business owner down the street. Through the relationships I have forged through NOMMA I can say that both me and my business have become more technical, creative, business savvy, and more professional. My NOMMA membership and attending METALfab are essential to my business and part of my operating budget. — Mark O’Malley O’Malley Welding & Fabricating Inc. Yorkville, IL
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Inside
March / April 2013 Vol. 54, No. 2
A model strikes a pose as it is 3D scanned. Story, page 16.
Member Talk
NOMMA Network Chapter members attend demos and classses............................ 10
At the Metal Museum’s Repair Days, the public brings metal items for repair; Volunteers attend programs 12
Shop Talk 3D printing for casting..................... 16
Five 3D printing vendors tell their stories about the advances of this technology. At least one says the list of fabricators using it for mold making and prototyping is growing. By Jeff Fogel
Biz Side
The 3 Keys to Germantown.............. 38
Germantown Iron & Steel’s success is based on 1) diversification, 2) good relationships with contractors, and 3) investing in the business. By Bobby Hickman
METALfab2013
Exhibitor Showcase page 46
Shop Talk How to hot-form thick acanthus leaves....................... 24
In this article, you’ll learn how to hot-form a 1/8-inch-thick acanthus leaf that won’t require an afternoon making a stretch-out pattern. With the exception of some obvious extra metal allowance needed, by drawing the leaf on your layout drawing and then tracing it, you’ll almost have a workable pattern By “Uncle Bob” Walsh
Learn about some of the most useful products from 22 exhibitors at this year’s METALfab2013.
Fiscal puzzle solution helps small business......................... 57
The fiscal cliff agreement renewed several expiring tax breaks for small business, many retroactively creating or saving $76 billion in tax breaks.. By Mark E. Battersby Biz Side 10 Banking mistakes to avoid.... 61
Banks are in business to make money just as you are, and they are looking to take a bite out of your bottom line. Here’s how to keep them from chipping away at your net income. By William J. Lynott What’s Hot!
Top Job Gallery ....................................... 50
Industry News.................................... 66 Events.................................................... 68 Literature............................................. 68 People.................................................... 69 Products............................................... 70
In this seven-page section, we continue last issue’s roundup of railings from our Ernest Wiemann Top Job contests. Category: Non-forged interior railings.
Nationwide Suppliers.................... 64 New Members.................................... 65
Job Profiles
President’s Letter........... 7
Exec. Director’s Letter.... 8
NEF .................................. 15
What is excellence?
What NOMMA is all about.
New officers, trustees named. Handling existing ironwork — part 2.
Metal Moment............... 74
About the cover This view of the Hostetler house, also called the pinwheel house, shows the finished exterior with two levels of decks and the exterior railings, which were fabricated by Germantown Iron & Steel, Jackson, WI. See story on page 38. March / April 2013 n Fabricator
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www.lawlerfoundry.com
19 A
hinges p. 3-5
latches p. 6
locks & lock boxes p. 7-9
closers & springs p. 10-11
drop bolts p. 12
gate wheels p. 13
HARDWARE SUPPLEMENT - effective JANUARY 1, 2013
19 A
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Fabricator n January / February 2013
misc p. 14
paint p. 15
castings & forgings - still in Catalog 19-A
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President’s Letter
What is excellence? or the weld joints are cleaned meeting in Atlanta in October, appropriately. It also means honwe had an interesting strategic est and fair treatment of our cusplanning session. Near the end, tomers. It means meeting schedwe focused on developing our ules, good communication, paying taxes, providing a safe “Big Hairy Audacious Goal” for environment for our employNOMMA. The BHAG, as it is ees, following building codes, also known, focuses on a single, Will Keeler, structural integrity, and ethical audacious, long-term goal. The Keeler Iron integrity. purpose of the goal is to align Works, is Excellence means striving to volunteer leaders and staff to president do business just a little better work together for a great cause. of NOMMA. than your competition. It means There was much discussion being outstanding, not only with about NOMMA being a vital the products we produce, but in the component for our member’s “sucmanner in which we produce them. cess.” During our brainstorming, Allyn Moseley raised an interesting question, “What exactly does being sucNOMMA promotes excellence cessful mean?” For our industry, does How does that relate to NOMMA? it just mean making a profit? Well, all I believe NOMMA represents these of us know of companies that turn out characteristics and works hard to help substandard products, or are dishonest members achieve excellence. Just readwith their customers. I would venture ing an average day’s email traffic on the to say that for many NOMMA memListServ, it is plainly clear that particibers, our organization represents much pants are interested in bettering their more than just making a profit. skills, products, and businesses. They are striving to achieve excellence. Excellence in everything I’ve enjoyed visiting NOMMA shops Our discussion then focused on during METALfab or at chapter meetthe word “excellence.” Mainly, that ings. Last May, I attended the Gulf Coast we think NOMMA and its members NOMMA meeting in Denham Springs, should represent characteristics that LA, hosted by A-1 Southern Iron Works. demonstrate industry “excellence.” I was impressed with their dedication to Webster’s dictionary defines excellence provide quality, and long lasting paint as, oh, who cares! I am sure you are finishes on the gates and fences they not interested in that. But what exactly made. In south Louisiana, steel tends to does “excellence” mean for our indusrust fast; I mean a rust-while-you-watch try? Does excellence mean producing kind of fast if the metal is not properly highly polished, shiny decorative stain- protected. They had tanks for degreasing the materials and dip tanks for less steel panels or elaborate handpainting to get every nook and cranny. forged steel rails that have been connected with mortise and tenon joinery? A1 was providing an “excellent” finish that was also affordable. Sure, but not exclusively. As for myself, I don’t believe I have We are accustomed to seeing excelachieved excellence on anything, except lent work in the Ernest Wiemann Top maybe taking a nap. However, I’d like Job Contest. It also means producing a 2-line steel pipe guard rail. How is that to think that I am always striving. possible? There are many elements that go into the goal of excellence. A simple rail can be considered excellent if it fits perfectly At our last NOMMA Board
March / April 2013 n Fabricator
Dedicated to the success of our members and industry. NOMMA O FFICERS
President Will Keeler, Keeler Iron Works, Memphis, TN Vice President/Treasurer Mark Koenke, Germantown Iron & Steel Corp. Jackson, WI President-Elect J.R. Molina, Big D Metalworks, Dallas, TX Immediate Past President James Minter, Jr., Imagine Ironworks, Brookhaven, MS
F ABRICATOR D I RECTORS
Todd Kinnikin, Eureka Forge, Pacific, MO Keith Majka, Majka Railing Co. Inc., Paterson, NJ Ray Michael, R & F Metals Inc., Clinton, MD Allyn Moseley, Heirloom Stair & Iron, Campobello, SC Tina Tennikait, Superior Fence & Orn. Iron, Cottage Hills, IL Greg Terrill, Division 5 Metalworks, Kalamazoo, MI
S U PPLI ER D I RECTORS
Gina Pietrocola, D.J.A. Imports Ltd., Bronx, NY Rick Ralston, Feeney Inc., Eugene, OR Mark Sisson, Mac Metals Inc., Kearny, NJ
NOMMA E DUCATION F OU N DATION O FFICERS
Co-Chairs Roger Carlsen, Ephraim Forge Inc., Frankfort, IL Lynn Parquette, Mueller Ornamental Iron Works Inc., Elite Architectural Metal Supply LLC, Elk Grove Village, IL Treasurer Mike Boyler, Boyler’s Ornamental Iron Inc., Bettendorf, IA
NEF T RUSTEES
Heidi Bischmann, Milwaukee, WI Carl Grainger, Grainger Metal Works, Nichols, SC Mark Koenke, Germantown Iron & Steel Corp., Jackson, WI Christopher Maitner, Christopher Metal Fabricating Grand Rapids, MI
NOMMA C HAPTERS
Chesapeake Bay Patty Koppers, President, Koppers Fabricators Inc., Forestville, MD, 301-420-6080 Florida Cathy Vequist, President, Pinpoint Solutions, Jupiter, FL, 561-801-7549 Gulf Coast Charles Perez, President, B & O Machine Welding, Brookhaven, MS, 985-630-6943 Northeast Keith Majka, President, Majka Railing Co. Inc., Paterson, NJ, 973-247-7603 Pacific Northwest Gale Schmidt, President, A2 Fabrication Inc., Milwaukie, OR, 503-771-2000 Upper Midwest Mark O’Malley, President, O’Malley Welding & Fabricating Inc., Yorkville, IL, 630-553-1604
NOMMA S TAFF
Executive Director, J. Todd Daniel, CAE Meetings & Exposition Manager; NEF Executive Director, Martha Pennington Member Care & Operations Manager, Liz Johnson Editor, Robin Sherman Sales Director, Sherry Theien
F ABRICATOR E DITORIAL A DVISORY B OARD
Terry Barrett, Pinpoint Solutions, Jupiter, FL Doug Bracken, Wiemann Metalcraft, Tulsa, OK Bill Coleman, Arc Angels, Dunedin, FL Nancy Hayden, Tesko Enterprises, Norridge, IL Chris Holt, Steel Welding, Freedom, PA Rob Rolves, Foreman Fabricators, St. Louis, MO
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Ornamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA). O&MM Fabricator / NOMMA 805 South Glynn St., Ste. 127, #311 Fayetteville, GA 30214 Editorial We love articles! Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph/Fax: 888-516-8585. E-mail: fabricator@nomma.org. Advertise Reach 8,000 fabricators For information, call Sherry Theien, Ph: 815-282-6000. Email stheien@att. net. Ads are due on the first Friday of the month preceding the cover date. Send ads to: Fabricator at address above. Email ads to: fabricator@nomma.org (max. 5 megs by e-mail). Or upload ads to our website where a downloadable media kit is available: www.nomma.org. Membership Join NOMMA! Beyond the magazine, enjoy more benefits as a NOMMA member. To join, call 888-5168585, ext. 101. For a list of benefits, see membership ad in this issue. Exhibit in METALfab Exhibit at METALfab, NOMMA’s annual convention and trade show. For more information, contact Martha Pennington at 888-516-8585, ext. 104, or martha@nomma.org. Subscriptions Subscription questions? Call 888-516-8585. Send subscription address changes to: Fabricator Subscriptions, 805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214. Fax: 888516-8585, or fabricator@nomma.org. 1-year: U.S., Canada, Mexico — $30 2-year: U.S., Canada, Mexico — $50 1-year: all other countries — $44 2-year: all other countries — $78 Payment in U.S. dollars by check drawn on U.S. bank or money order. For NOMMA members, a year’s subscription is a part of membership dues. NOMMA Buyer’s Guide Published each December as a separate issue. Deadline for all advertising materials is October 31. Contact Sherry Theien at 815-282-6000 or stheien@att.net. Opinions expressed in Fabricator are not necessarily those of the editors or NOMMA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA.
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How to reach us
Executive Director’s Letter
What NOMMA is all about The NOMMA Board of Directors nings, something equally wonis undergoing a review and derful occurs: NOMMA memupdate of its strategic plan. At bers networking in the bar and the beginning of our strategic lobby late into the night. Again, fabricators are fulfilling NOMplan is our most important MA’s purpose, or as they say in statement: our “Purpose” and Star Trek, the Prime Directive. reason for being. Our purpose is: “To promote the common Todd Daniel is executive business interests of those We work on your behalf engaged in the ornamental and director of Think of NOMMA as a conNOMMA. miscellaneous metals industry.” duit that provides vendors and During my recent visit to fabricators with creative ways New Jersey to attend a Northeast Chap- to jointly advance everyone’s business ter meeting, this “Purpose” came to life interests. This advancement is done not for me. I was sitting in the audience only through education and networkand the members were talking about ing, but also through our advocacy purchasing a booth at a local AIA show work with architects and code bodies, to promote our industry. “That’s it,” I through our awards contest, member thought to myself. “This is the essence benefits, education foundation, and of what NOMMA is all about.” Here I countless other ways. Whether you are was, witnessing a group of ornamenmaking a donation to the NOMMA tal and miscellaneous metal fabricators Education Foundation or attending a working collectively to promote their chapter meeting, your actions support common business interests. NOMMA NOMMA’s purpose. cannot be defined any better than that. A year after NOMMA’s birth in 1959, the association purchased a magazine. In the mid-1960s, the association hired Get practical solutions its first employee. The magazine, along More recently, a new member with NOMMA staff, convention, and joined from Texas and the fabricator foundation are the tools that join fabrisaid, “I have my first spiral stair job cators together and help them accomand was wondering if anyone could plish their work more effectively. help me.” When a call for help went As a child, my father owned an aviaout on NOMMA’s email discussion list, tion business and his membership in a.k.a. The ListServ, an amazing seven various associations played an integral people offered to help. Again, this is role in his life. I can’t imagine what it what NOMMA is all about — members would be like to be a “lone wolf ” in helping members to promote our common business interests. our current unpredictable economy. One of the more selfless acts of Nonmembers may reap the benefits of sharing takes place each year at our NOMMA’s work, but members gain so national convention, METALfab. Most much more. I encourage you to join. of our speakers are veteran fabricators who freely share their expertise. Between classes and late in the eveB R IC AT O CA LL FO R FA
R IT E RS W H O W
Fabricator needs you. Have you solved an interesting fabrication problem? © 2013 National Ornamental & Miscellaneous Metals Association 8
Do you have useful how-to, step-by-step tips to share? We’d love to hear from you. Contact Editor Robin Sherman at nomma.editor@att.net.
Fabricator n March / April 2013
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The NOMMA Network
Upper Midwest Chapter enjoys bender demo Attendees at the Upper Midwest Chapter meeting were treated to a double-header of a Hebo machine demo and a class on sandblasting and prepping work for powder coating. The January meeting, attended by about 30 people, also featured a hands-on session to create items for the annual NEF auction at METALfab. Following tradition, a shirt design was presented for the METALfab theme dinner and orders were taken. At the business session, chapter leaders discussed upcoming events at METALfab, the new health insurance plan, and plans for the spring meeting, which will be at AZZ Galvanizing, Dixon, IL. The meeting’s education component was a tour of nearby Fox Val-
ley Sandblasting, where attendees saw the firm’s sandblasting operation and newly expanded powder-coating facility. A thanks goes to O’Malley Welding & Fabrication, Yorkville, IL, and nearby Fox Valley Sandblasting for cohosting the event. In September, the group met at Lincoln Electric in Bollingbrook, IL. After a business session, members and guest toured the facility and received a class on advanced welding technology. Afterward, the group lunched at Dell Rhea’s Chicken Basket. Northeast Group receives powder-coating prep class
The Northeast Chapter’s January meeting focused on metalizing and
preparing both steel and aluminum for powder coating. About 25 members and guests attended the meeting, hosted by Peerless Coatings LLC, Hawthorne, NJ. The business meeting saw a lively discussion about the chapter’s plans for exhibiting at an upcoming AIA show. Todd Daniel, NOMMA’s visiting executive director, updated the audience on METALfab and the association’s latest benefits and projects. Joe Romeo also took the stage to discuss the special features and benefits of NOMMA’s new commercial and general liability insurance program that provides features custom tailored for our industry. A thanks to the Peerless Coating staff, as well as the staff at Majka Railing Co. Inc., who all worked hard behind the scenes to make the meeting a success.
Above, Upper Midwest chapter attendees gather around for the Hebo bending demo. Closeup view, top left, of hot bending techniques on the Hebo. top right Some interesting insects were spotted during the NEF auction item workshop. At the Northeast chapter meeting, right, Joe Hyer, Peerless Coatings LLC, gives a talk on powder-coating preparation.
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Industry News
Metal Museum ‘Repair Days’ Public brings metal items for repair; Volunteers attend program By Chris Holt Steel Welding Sometimes you just have to follow the voices. The Metal Museum, Memphis, TN, has an annual event called “Repair Days,” the major fund raising event for the Museum and a calling to all artisans who have metal skills. This event is something I have always wanted to attend and owner John Steel, Steel Welding, Freedom, PA, also was interested. The voices we heard leading us to this event, well let’s just say the Garmin (GPS) was a helpful traveling companion. The Metal Museum is located next to the Mississippi and has a picturesque view of the river. The National Ornamental Metal Museum, according to its website, “is the only institution in the United States devoted exclusively to the preservation and promotion of fine metalwork.” Unlike ordinary museums, it isn’t just a place where art is displayed; it’s a place where art is made. The campus is composed of a variety of buildings, including the grand Julius Seen at Repair Days. Top, the Blum Library, Lawler Foundry, grand Julius Blum Library. Above, Schering-Plough Smithy, River volunteer repairing item with onlookers learning technique. Bluff Pavilion, galleries, and Right, an Emmy for repair. beautiful grounds. Access to the library collection online is available through the generosity of thing made of metal that needs fixing. Robert and Barbara Keeler. The library I do mean anything, and that is where has about 6,000 books, 10,000 images, the fun really kicks in. The Incomand extensive material on metal work. ing items are reviewed, the customer First time attendees are introduced agrees on a fee, and those funds are to the repair work facilities. There is the donated to the Museum. smithy for blacksmiths, areas for repairThe volunteering artisans repair ing gold, silver, and pewter. Tents are set priceless items, nostalgia items, and up for welding repairs, blade sharpenitems that are questionable but are cering, tinning, and a special triage area for tainly broken. Everybody is encourestimating repairs as they arrive. aged to observe, exchange ideas, and The public is invited to bring anylearn from one another. 12
I walked into the more precious metals repair area, and at a distance, I spied a recognizable object. Could it be? Yes, it was indeed an Emmy in need of repair. It was the closest I believe I will ever come to seeing an Emmy up close. And yes, I held it in reverence. I returned to my station where we were repairing expanded metal lawn furniture. Damaged webbed lawn furniture seemed to be a popular repair this year. We repaired about 14 pieces as well as an antique sewing machine base, a horse with a broken leg, (I thought they shot them), and an outdoor candle holder. The weekend is full of activities. “Three squares” are provided to all the volunteers in a conveniently located large party-sized tent. Throughout the weekend, volunteers heard lectures and gallery talks and attended other activities. Volunteering at a significant site, such as the Metal Museum, helps build camaraderie. Even though businesses have long workweeks and deadlines to make, value comes in building a “team” in your work force. At Steel Welding, we volunteer to repair one significant metal item in our community each year. In the past, we donated a set of cemetery gates and a public garden bench, repaired an ornamental plant holder damaged by salt, and fixed metal chairs in a historical home open to the public. Whether your business is a small shop or a larger company, you might like to encourage giving back to your community or to an organization that can benefit from your skills. Taking part in Repair Days just might be the number you are looking for. Fabricator n March / April 2013
The NEF invites you to join them to learn, network, and improve your business
at METALfab 2014 in St. Louis / St. Charles, MO, March 12–15, 2014 at the Embassy Suites St. Charles and St. Charles Convention Center.
NOMMA Education Foundation announces new officers and trustees The NOMMA Education Foundation is pleased to
introduce its 2013 officers and trustees.
Co-chairs Lynn Parquette, Mueller Ornamental Iron Works Inc. Elite Architectural Metal Supply LLC Roger Carlsen, Ephraim Forge Inc.
Lynn Parquette, far left. Roger Carlsen, near left.
Treasurer Mike Boyler, Boyler’s Ornamental Iron Inc. Trustees Heidi Bischmann Carl Grainger, Grainger Metal Works Chris Maitner, Christopher Metal Fabricating Inc. Mark Koenke, Germantown Iron & Steel Corp. Get involved
The NEF officers named above are volunteers who are always looking for donations and other volunteers, which are the life blood of NEF. The Foundation has numerous ways to be involved from volunteering during METALfab to planning an auction workshop. If you would like to help with NEF programs, fund-raising projects, or even become a Trustee, simply click on the “donation” or “volunteer opportunities” link on the NEF page at www. nomma.org. The NEF mission
The NOMMA Education Foundation (NEF), founded in 2001, advances the educational mission of the National Ornamental & Miscellaneous Metals Association (NOMMA). Among the NEF’s most visible programs is developing the educational sessions for all of NOMMA’s METALfab conventions. The NEF also provides numerous other educational services including instructional videos, continuing educaMarch / April 2013 n Fabricator
tion programs, educational publications, NEFERP grants, webinars, and education support for NOMMA chapters. The NEF’s core values include: n Commitment n Open communication n Desire to learn n Exchange of ideas n Integrity n Ethical behavior n Good stewardship Now, the NEF extends a invitation for you to join them to learn,
Middle row, left to right, Mike Boyler, Heidi Bischmann, and Carl Grainger. Bottom row, left to right, Chris Maitner and Mark Koenke
network, and improve your business at METALfab 2014 in St.Louis/ St. Charles, MO, March 12–15, 2014 at the Embassy Suites St. Charles and St. Charles Convention Center. Donations to the Foundation are welcomed. Funds help support the current programs and create new ones. For more information, go to www. nomma.org and either click on or mouse over the word “Foundation” at the top of the horizontal navigation bar on the home page. 15
Shop Talk
3D printing for casting By Je Fogel
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Five D printing vendors tell their stories about the advances of this technology. At least one says the list of fabricators using it for mold making and prototyping is growing.
If you happened to catch the movie Skyfall, the most recent incarnation of Ian Flemming’s durable MI6 spook, you were witnessing something far more impressive than the pyrotechnics, SFX, or Bond girl pulchritude. The emblematic Aston Martin DB5 used in the riskier stunts was printed. That alone should tell you the state of the art of 3D printing technology. And while the technology has found a home in the every day operations of the fabricating world, it is no child of a lesser god. The very same cutting edge technology that can print out A live model, top, strikes a pose as it is 3D scanned. A computer calibrates the scaling of the 3D file and shrinks it to the desired size, perfectly maintaining proportions. The downsized image is then printed. The white figurine, right, is the result. Photos courtesy Additive Workshop Fabricator n March / April 2013
Glossary of 3D terms Technology is what drives industry. It also drives people crazy if they aren’t versed in the thicket of terminology most technology employs. 3D printing is no exception. It’s chockablock with an alphabet soup of initials and abbreviations. Herein is a lexicon of terms. Additive technology A term which describes the essense of the 3D printing process, whereby you start with raw materials and add them, layer by layer, to form a finished object. Binder A substance which, when injected into the build material, fuses the particles together in a prescribed pattern to form a layer of hardened material. The layers will ultimately form the three dimensional object. Build box That portion of the 3D printer which holds the object being a rare vintage car for a multimilliondollar movie is also used to make prototypes in ordinary casting operations. Before we examine who’s doing what, a brief overview of the process might be helpful. What 3D means
When we say 3D, we’re not referring to the process of digitally scanning a three-dimensional object. While this process does play a role in the greater scheme of 3D printing technology (which we’ll get to later) for the purposes of this article, 3D refers, strictly speaking, to the actual printing process. “Printing what?” you might ask. It depends on your needs. You might simply need a pattern with which to make a mold. Or maybe you want the mold itself. Or you just want to skip the casting process altogether and print your final object. Any of the above is now possible. How it works
Design. As with any fabrication, 3D printing begins with a design. It may be an existing design, or a brand new design. Either way, it is drawn in three dimensions on a computer, using comMarch / April 2013 n Fabricator
printed. It is analogous to a welder’s table. It differs, however, from a welder’s table in one respect. While the welder’s table provides a flat surface to hold the work piece, the build box consists of four walls to form a container the hold the piece being printed. DMLS Direct Metal Laser Sintering. Essentially the same as SLS but referring specifically to printing a metal finished object. Digital parts materialization
A proprietary process of ExOne Corp. It is a method of 3D printing that allows for complex internal and external geometries which permits accurate forming of angled passages, undercuts, and multi-piece assemblies. Draft An allowance for shrinkage which occurs during casting, facilitating separation from the mold. Parting line A line, typically latiputer assisted design (CAD) or some similar software. Printing. The completed design is placed in a file and sent to the printer. The printer operator has a choice of several materials: polymer or metal, for instance. The choice depends on the fabricator’s needs. If a simple pattern will do the trick, then a polymer may suffice. If the fabricator wants a finished object, the printer’s material selector must be set on metal. But what about a mold, say one made of sand? The process is still the same. But instead of polymer or metal, a special binding agent will be used. So what is the actual process? The printer itself consists of two parts: 1) The injectors that work much the same as a desktop printer, in principle anyway, by squirting the material onto a surface. 2) The surface. It’s also called the build box and is essentially a large tank that holds a material in which the object will be suspended. The material may be liquid, sand, or metal filings. Surface in this context refers not to the build box but to the surface of the liq-
tudinal, along which a mold is separated (or parted) into two halves in order to release the casting. Sintering Fusing particles of material, metal for example, usually by means of a laser. SLS Selective Laser Sintering. A build box is filled with metal powder or filings. A laser moves across the surface of the powder, fusing selected particles in order to form a shape. SLA Stereolithography. Basic 3D printing. A rose by another name with an equally lovely result. Subtractive technology A term which describes traditional pattern making which is, in essence, subtracting material as it is carved from a solid mass of material. 3D scanning Using a laser to capture the three dimensional contours of an object. The image is stored digitally, and used as a template.
uid (or powder) within it. In the case of a simple plastic object, the injectors will squirt a polymer onto the liquid surface to create a thin layer that will sink just below the liquid’s surface and then another layer will be laid down. And so on, until you have a complete three-dimensional object submerged in the liquid medium. Printing metal or sand is simply a variation on this theme. For a mold, the build box is filled with sand instead of liquid medium. And a binder is injected onto the sand’s surface to create the layers. With final objects, metal flakes or filings fill the build box. And a binder is injected, working much the same as building a sand mold. The OK Foundry story
By now, you can see that this process permits one-offs or limited runs. This is precisely how OK Foundry, Richmond, VA., is using it. OK Foundry, an early adopter of the technology, has of late, been creating sand molds to cast prototype parts for one of its major clients (1). “The (sand) molds are being used to make prototypes involving eight or nine castings,” explains James O’Neil, 17
president of OK Foundry. The client needed two of each, and the most cost effective and accurate way of making them was to print them.” OK Foundry also recently printed some cores for another client. “This could have been done by ‘blowing out’ some ceramic molds,” says O’Neil, “but that’s quite expensive. Blowing out a core entails using minute blasts of air pressure to fill the nooks, crannies and fissures that comprise the fine surface of a casting’s mold’s interior. While O’Neil has found 3D printing to be a highly efficient way to produce one-offs or prototypes, he much prefers using the technology for molds than patterns or finished objects. The reason for his preference is in the details. 3D printed patterns often require finessing to address the minutia of design criteria, such as parting lines and draft, O’Neil says. There are two reasons for this: 1) The expertise of the technology has not benefited from the years of experience that pattern makers have
accumulated. Even the best printers have their trial and error moments. 2) Sand printed molds are not as finicky about draft and parting line placement, O’Neil says. The ExOne story
Yet, not all regard pattern printing as a hit or miss proposition. ExOne, North Huntington, PA, a 3D printing company included in the previous article in this saga (Nov./Dec. 2012, Fabricator, page 28) prides itself in what it refers to as a “first pour” goal in their patterns. Evidently, they meet this goal with regularity says Marketing Director Nicole Mcewen. One way they meet this objective is by running a simulation. This determines draft, parting lines, and even gate placement with extreme accuracy. It eliminates trial and error, producing a good casting on the first pour. Hence, the slogan. But whether you are using sand molds or patterns, the fact remains that 3D is a handy way of creating prototypes of short runs, something
you simply couldn’t make money with heretofore. The RapidMade story
Of course, prototypes aren’t the only way to make a short-run buck in the casting business. RapidMade, Portland, OR, has been printing all manner of final working parts, including antique and car restoration parts. And that includes ornamental and architectural jobs, such as an historic Art Deco light fixture reproduction from the roaring ’20s. The 3D mold was printed using a Z Corp machine (2). The antique replicas typically involve reverse engineering from an original, says Erin Stone, RapidMade’s president and business development director. This is done by digitally scanning the original to create a CAD (refer to paragraph two of this article) that is then delivered to a printer to make the final part. RapidMade uses Direct Metal Laser Sintering (DMLS) for the printing. Although more expensive than ExOne, says Stone, it possesses the
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advantage of printing pure metals rather than alloys. Even with a damaged or corroded part, the computer can virtually fill in the missing sections, Stone says. This is a big advantage in printing car restoration parts or architectural elements. Emerging as a nascent trend in our last visit to 3D technology in the fabricator’s world was the hybridization of 3D with older subtractive technology. “It’s not an either-or proposition,” notes Stone. For some it’s a way of transitioning from one technology to another. But for others it’s simply the most efficient way of getting a job done. RapidMade often gives clients several bids that may include CNC milling in addition to 3D printing. This gives customers flexibility. And flexibility gives them competitiveness. “This (allows 3D) to compliment subtractive technology,” explains Stone, “with an intermediate step, dealing with small batch (production) in a cost effective way.”
The American Precision Prototyping story
Chaera Stone (no relation to Erin Stone) of American Precision Prototyping, Tulsa, OK, concurs. APP has been doing a lot of work recently with ornamental and architectural shops that need prototypes to show their clients. As Chaera Stone explains, this gives them the opportunity to let the clients poke, prod, and otherwise examine a corporeal sample of the piece to be cast. It’s a lot easier to see what tweaking or finessing is needed on the prototype. “It’s better to find out what needs to be changed now rather than find problems with it thousands of dollars later,” says Chaera Stone. For 3D printing, APP has a few ways to go. They can use standard method of SLA (stereolithography), or the newer SLS (selective laser sintering). Either one can produce a pattern, mold, or finished object. Chaera notes that there’s been an increase in architectural clients because of an interesting trickle down effect of the technology.
It seems that architects and designers were early adopters of 3D printing, using it to create scale models of their projects. It was a lot easier than using Legos, sugar cubes, or cardboard. And more accurate. It was only a matter of time before it dawned on them that they could produce details of the models in full size. From there, it was obvious that the process could, in fact, produce the objects the models represented. As for ornamental clients, Chaera Stone says the list is steadily growing, with mold making and prototyping being the most common application. The Additive Workshop story
Additive Workshop, Wilsonville, OR, is another shop that sees an expanded ornamental and architectural market for its 3D services. “We actually began mainly with artists,” says Christine Alex, Additive Workshop’s manager of operations. Now Alex envisions ornamental and architectural fabricators as a natural extension of that customer base.
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A build box, top left, is filled with powdered medium. Submerged beneath the surface is a fully printed object. The printed object, top right, is removed from build box, still partly covered with unsintered medium.
Excess powder, above right, is vacuumed away, revealing printed piece. VoilĂ . A finished printed object, right, which may be used as a pattern with which to fashion a mold. Or it may be simply used as a prototype. All photos this page courtesy of RapidMade.
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References
1 Early Adopter: A marketing segment that embraces innovations and new products. From VALS (Values and Lifestyles), Stanford Research Group, 1978, Menlo Park, CA. 2 Z Corp: A manufacturer of 3D printers. Now known as 3D Systems, Rock Hill, SC.
Fabricator n March / April 2013
Conclusion conundrum
The refinements and advances in 3D technology are growing apace. There is even laser 3D printing (see sidebar, page 17). And those who have taken the plunge report glowingly of its effect on their operational efficiency. All of which makes 3D technology’s leaden incursion into the world of ornamental and architectural fabricating inexplicable. While the question of why fabricators are not jumping on this technology is open to conjecture, some signs show that they don’t understand the technology well citing cost, time, and geometrical considerations (see Sept./Oct. 2012 Fabricator, page 27). This may be one reason fabricators are embracing multi-axis routing, which is perceived as a halfway point to moving entirely to 3D printing. Fabricator expects to address this more in a future article.
For your information
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Moreover, their compliment of multi-axis routing, along with 3D scanning and printing, presents the hybrid approach that has become de rigueur in the world of fabrication.
Additive Workshop 27929 Southwest 95th Ave. Ste. 601 Wilsonville, OR 97070 503-582-9898 www.additiveworkshop. com American Precision Prototyping 19503 East 6th St. Tulsa, OK 74108 918-266-1004 www.approto.com
ExOne Digital Part Materialization 127 Industry Blvd. North Huntington, PA 15642 877-773-9663
Wiemann Metalcraft 639 West 41st St. Tulsa, OK 74107 918-592-1700 www.wmcraft.com
OK Foundry Company Inc. 1005 Commerce Rd. Richmond, VA 23224 804-233-9674 www.okfoundrycompany.com
Z Corporation (Now known as 3DSystems) 333 Three D Systems Cir. Rock Hill, SC 29780 803-326-3900 www.zcorp.com
RapidMade 2828 Southwest Corbett Ave. Ste. 121 Portland, OR 97201 503-943-2781 www.rapidmade.com
About the author Jeff Fogel began writing as a journalist with the New York Daily News. He has been a copywriter and associate creative director for advertising agency Ogilvy & Mather. Jeff now lives in New Hampshire where the weather’s bad, the skiing’s better, and blacksmithing’s a respectable way to keep warm.
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Shop Talk
How to hot-form thick acanthus leaves n
In this article, you’ll learn how to hot-form a ⅛-inch-thick acanthus leaf that won’t require an afternoon making a stretch-out pattern. With the exception of some obvious extra metal allowance needed, by drawing the leaf on your layout drawing and then tracing it, you’ll almost have a workable pattern.
Editor’s note: This article is the seventh in a series of articles about using acanthus leaves in your work. In the first article, “Drawing large acanthus leaves” (Fabricator, Nov./ Dec. ), you saw how to draw a simple, single-sided, front view acanthus leaf in steps by alternating “C” curves with “S” curves. The second article, “Drawing acanthus side views” (Fabricator, March/April ), introduced the grille and an explanation of the four types of acanthus leaves. The sequential steps used to draw a side view of a leaf was presented. The third article, “Building acanthus patterns” (Fabricator, May/June ), walked the reader through making a full-scale, “stretch out” pattern for a wrap-around leaf. The fourth article, “Cold forming acanthus leaves” (Fabricator, July/ Aug. ) examined how a wraparound acanthus leaf was produced with top and bottom tools made of wood to avoid hammer marks. The fifth article, “Bob’s Tijou tour of acanthus, interactively,” (Fabricator, Sept./Oct. ), took us on a Wikipedia and YouTube tour of the work by Jean Tijou and Jean Lamour. The sixth article, “Decorative options for acanthus leaves,” (Fabricator, Nov./Dec. ) addressed the ornamental options when you make your leaves. Veining options and rolling the end of your leaf over backwards were examined. 24
Photo 1. Cold-formed face leaves with 18 gauge.
By “Uncle Bob” Walsh In “Decorative options for acanthus leaves” (Nov./Dec. 2012 Fabricator) we cold-
formed face leaves with 18 gauge (photo 1). Face leaves are leaves viewed from one side only. To contrast working with thin metal, let’s now hot-form some leaves with 11 gauge A-36. Eleven gauge is less than six thousandths short of being 1/8 inch thick. If you are going to make only one leaf, the most time consuming leaf style is a wrap-around leaf (photo 2) similar to the one we made in “Building acanthus patterns” (May/June 2012 Fabricator). The reason has to do with making the pattern. A wrap-around (stretch-out) pattern is not difficult but will consume an afternoon of your time: Add the time laying out the pattern to the leaf-forming time, and if this work is your profession, you now have an expensive leaf. Face leaves of the kind we made in “Decorative options for acanthus leaves” (photo 3), and which now will be made with 11 gauge, do not require an afternoon making a stretch-out pattern. With the exception of some obvious extra metal allowance needed (drawing 1), by simply drawing the leaf on your layout drawing and then tracing it, you almost have a workable pattern. Cool! After you have traced the leaf over your layout drawing, add some extra material for width, your leaf tip if you plan to flip it, and the stem if you plan to wrap it around your scrollwork. Voilà, a workable pattern. Face leaves are the most commonly used type of leaves (it seems to me) because face-leaf patterns are easy and fast to make and face leaves are much faster and easier to make than wrap-around leaves. Fabricator n March / April 2013
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Photo 2. The most time consuming leaf style is a wrap-around leaf.
Drawing 2. The original grille drawing. Drawing 3. Grille drawing with the upgrade, layered acanthus leaves.
Photo 3. Face leaves of the kind made in photo 3 in “Decorative options for acanthus leaves” (Fabricator, Nov./Dec. 2012) and which now will be made with 11 gauge, do not require an afternoon making a stretch-out pattern. Drawing 1, right. With the exception of some obvious extra metal allowance needed, by simply drawing the leaf on your layout drawing and then tracing it, you almost have a workable pattern.
Upgrade
I would like to offer an upgrade option for our grille project. In place of making the main acanthus leaf as illustrated in the original grille drawing (drawing 2), consider layering another leaf over the first leaf to give the grille more depth (drawing 3). This brings me to an “Uncle Bob” story. About a zillion years ago, I took a class in the Minneapolis College of Art and Design. I had forged a small grille that I was quite proud of. With grille in hand, I asked the sculpture instructor for a critique. The instructor examined the grille qui26
etly and kindly said, “This grille is nice, but you have only taken advantage of two of the three dimensions available to you. Iron is a three dimensional medium, and you have only used two of the three dimensions.” That was not what I wanted to hear, but he was right. If you found a mailbox slot wide enough, you could have slipped the grille through it. I know most people reading this are not making sculpture (including myself) but instead, applied art (art applied to function). While keeping function in the forefront, it seems safe to say that working Fabricator n March / April 2013
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the third dimension into your ironwork (spatial drawing) only makes a project look better. Could this be why twisted baskets (figure A, in sidebar, page 17) are so popular with the public? Back to our grille, I hope three things work in its favor: 1 Flow of the design within the elements. 2 The variety of elements used. 3 Use of the third dimension.
acanthus leaf in drawing 3 (page 15). In another project, try making this rod with bronze and then either paint/patina the overall leaf to coordinate it with the bronze, or make the overall leaf (and rod) with bronze and then play with patinas and highlighting. I think there are some great possibilities here.
Use of the third dimension
I can hear many fabricators thinking right now, great, but when using all three dimensions, how do you get paint behind the overlapping elements so you don’t have rust problems? There is no magic solution. The only way I know of getting complete coverage on exterior projects with non-accessible overlaps is by submerging your metalwork into paint or zinc, or by constructing the work with non-ferrous materials. In some situations, a little creativity with caulk will get the job done.
Photo 4. A jeweler tapered a length of round material and soldered it on top of the leaf to create a raised vein.
Pattern development of a leaf tip
Leaf styles
Let’s make two leaves. Instead of making the leaf illustrated in the original grille drawing, let’s raise the bar and make two leaves in different styles. These two leaves will cover all the steps required to make the original leaf illustrated in drawing 2 (page 15), plus more. Leaf 1 (photo 4) Have you noticed on some silver jewelry (typically in the Southwest style) that instead of having an incised or raised central vein, the jeweler tapered a length of round material and then soldered it on top of the leaf to create a raised vein? Let’s try this jewelry technique on the large 28
Leaf 2 (drawing 3, page 15) The overlaying leaf will be ornate in a different way. Think about the words “form” and “ornament.” In this case, the overall shape and contours of the leaf provide the “form.” The incised lines on the face of this leaf provide the “ornament” or ornamentation for the form. Let’s ramp up the amount of ornamentation on this form by adding more lines on the face and tip.
Photo 5. Bend a soft wire (3/32-inch-aluminum welding rod) in the shape you want the spine of your leaf to be.
Photo 6. 20-gauge test pieces. The leaf on the left had too much material in the pattern, so the pattern line was brought in about .25 inch. The leaf on the right lost its glued pattern because it was annealed while forming.
I have trouble drawing the pattern of a flipped over leaf tip when drawing from intuition. My solution is: n Bend a soft wire (3/32-inch-aluminum welding rod) in the shape you want the spine of your leaf to be (photo #5). n Lay the bent wire on your drawing. n Apply perpendicular strips of masking tape across your wire. n Cut the excess tape off so the tip looks like the tip you want your finished leaf to have. n Roll the wire mock-up straight forward. n With a pencil, mark on your paper pattern, the width of your leaf and where the spine line goes. A little freehand finishing and bingo! Fabricator n March / April 2013
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Reviewing the leaf-making process Design steps (drawing 4, B through D)
1 Lay out the spine line of your leaf in any shape that complements your work (figure B). 2 Add an ornamental tip if desired (figure C). 3 Add petal lines approximating the centers of your petals (figure D). 4 Add “C” and “S” curves to start the shape of your petals. 5 Add a facet on the top and bottom of your petals as space will allow. 6 Refine your sketch. 7 Trace your sketch or go over it with ink and erase the pencil construction lines. The drawings you are looking at were traced over sketches on a cheap (free) homemade light table. 8 Be proud. The above sequence is slightly altered from the sequence in previous articles. The increments are the same, but you may find the above easier.
ing.” Heat the steel up to the point of being non-magnetic and then let it air cool. True “annealing” requires a much slower heating and cooling process. 6 Repoussé Turn your leaf over and with the face-side down over a cavity,
and with the same walking chisel used before, chase your incised lines back down. Chase these lines down farther than your original base line if it complements the look of your leaf. I generally use concave wood bottom tools for this, but well-rounded steel tools work just as well. Acanthus leaves are
Process steps
After the design comes the process of making the leaf. The steps for making a leaf with cold metal typically are those below. If you’re making a leaf hot, steps 5 and 7 (annealing) are eliminated. Whether making a hot or cold leaf, the steps below are just an outline. Assess the progress of your leaf and proceed accordingly. Note If you are making a flippedover leaf tip, make a quick 20 or so gauge sample of just the tip to test your pattern. This half-hour step is worth it. Tip patterns can be deceiving when the tip rolls into a helix shape (drawing 5). 1 Artwork I prefer to do this on paper and then spray-glue the pattern onto the metal. 2 Incise Chisel through the paper pattern with a walking chisel, a conventional chisel that has been radiused in all directions (photo 11) with no sharp corners or edges. Incise over a rubber pad (when using thin metal). 3 Burn off your pattern. 4 Deepen your incised lines. 5 Anneal Actually the correct term for what we are doing is “normaliz-
30
meant to be ornamental; work the metal and make them so! 9 Raise & sink (generally with 16 gauge or thinner). With a silver pencil or felt tipped pen, layout any lines you want to raise or you would like to sink over a stake. When raising or sinking, be conservative. Visually, a little goes a long way, and it is easy to get carried away once this process into wood, or a soft back-up material, starts. Especially watch the “fading drive from the back side (with wood out” of the lines on the petals, so they driving tools for cold metalwork) the gradually blend into the mother form. Also, watch for work hardening; norareas in-between the incised lines so the pushed out areas are convex on the malize as necessary. 10 Leaf Tip (termination). Ornaface side of the leaf. Wood driving tools are softer than steel and are not as likely ment as will appropriately detail your to put dents in thin metal as steel tools. composition. Ornamental tips put life 7 Anneal (normalize). and character into your leaves (along 8 Chase With the leaf face-side up, with the third dimension).
Drawing 4, above. Drawing 5. On classical acanthus leaves, if the leaf tip is flipped over, it generally curls straight back 90° from the main body. This is not what we are doing here. The leaf tips on these leaves (more-so) on the leaf on the lower right (photo 19) curl back at an angle. This means that after the leaf tip cross section has been formed into a half oval in the wood, which also makes the tip curl back coming at you, it is then twisted into a helix.
Fabricator n March / April 2013
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Photo 7, left. This is a cast steel knife makers attachment for use in a vise. After welding the angle iron on the back to keep the tool stable in the vice, removing the little bumps on the jaw in the center so that the vice pinches the leaf in two locations (on the sides), it now works reasonably well.
Photo 8, left. Filing. With this tool, you can comfortably file the concave areas of your leaf.
Photo 9, right. The leaves with the edges cleaned up after being cut with a bandsaw. The convex curves were cleaned up with a belt sander and the concave curves were filed. The leaves are now ready for incising the linework on the face.
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Photo 10, above. The incising process. Once you get the hang of rotating a walking chisel to turn corners, incising is easy in a treadle hammer. Adjust the springs on your hammer so they just barely lift the head. Sit on a stool for comfort and stability. Light your work well. Put a stopper-block under your treadle for safety. Turn on the radio and enjoy the process.
Fabricator n March / April 2013
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March / April 2013 n Fabricator
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Photo 11, below. The incised leaves. Notice the walking chisel (large chisel) radiused in all directions. Look at the central lines that converge on the leaf on the left. Where the lines meet, a graceful transition from two lines into one is hard to make.
Photo 13, right. This staged photograph shows the incised leaf being formed. When working hot, thick metal over wood, there is an impressive amount of smoke and flames — a great demonstration if you want to wow an audience.
Photo 12, above. Whenever possible, instead of converging lines as in the previous photo, notice how the lines on the sides of this central vein just fade out. Not only are lines like this easier to make, they are visually more effective. This leaf is a good example of alternating “C” and “S” curves to create petals. After the basic petal has been laid out, facets above and below each petal are added as space allows. Acanthus leaves like this are visually effective and at the same time, quite mechanical in design.
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Photo 14. The remnants of two of the three white oak blocks used to make the two acanthus leaves. The third block was not burned as deeply because it was used for the large radiuses under the petals. Here’s how this works: With typical metalworking processes where there might be a concave metal bottom tool used, the metal (in this case, the leaf) is driven down and takes on the form of the steel bottom tool (assuming you bottom out a similar top tool). When using wood, the wood is sacrificial and the leaf takes on the shape of the top tool in your hand. The wood offers resistance, but just keeps melting away below your work. Do you carve the concave shapes in the wood blocks before using them? No. The blocks you are looking at were flat when I started. The metal burns away where the most pressure is, which is under your top tool as you go.
Fabricator n March / April 2013
Photo 15, far left. Tools to make the leaves. If you’re cutting up wood blocks, cut plenty of extra blocks because they are consumables when you use this process. Photo 16, left. The three steps: 1) Pattern 2) 20-gauge test leaves 3) 11 gauge
Photo 17, above; photo 18, above right. To make the leaf tip transition from the curledback half-circle into a helix, the 20-gauge test pattern was held at an angle on the pipe tool. Then the raised area was pounded down with a wooden mallet (on the left). The overall half-circle shape then turned into a helix, screwing off to the right. The thicker (.125-inch leaf) was heated to an even heat and then the tip was twisted by holding the body of the leaf with tongs and with another set of tongs, twisting the tip.
Photo 19, left. The forged leaves. Each leaf took about 15 heats in a gas forge to form. Maybe two heats to dish the petals, maybe four heats to sink the tail, and maybe four more to form the tip. Add a heat to twist in the helix and another heat to adjust everything. The heats go fast in a gas forge. After forging, the leaves were sanded to clean them up for the photo. The top lobes on the petals were then placed face down over a sharp edge on a white oak block and from the back side, pounded slightly to tip the lobe forward.
Note. The pipes on my tools extend 3 inches past the vice jaws. Make yours 4 inches and they will work better.
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Fabricator n March / April 2013
For your information
Photo 20. The layered leaves on the grille. The leaves, starting to look good, now need to be re-heated and the stem widths reduced to snugly wrap around the scrollwork. Following this, with a ball top tool and a little more pounding into wood, the leaf tops will receive a little more dome/crown. Assemble these leaves with a layered ornamental collar (as in drawing 3, page 15) and this (or your) grille will start to become quite rich in all three dimensions.
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About the author Robert “Uncle Bob” Walsh has been a fabricator/artist/ blacksmith for 30 years. After the invention of the fax machine (allowing an easy interchange of sketches), he moved to semi-rural Wisconsin where he set up a cottage industry with fellow shop owners that has been chugging along for 20 years. Look for their ironwork throughout the upper Midwest. CO NTAC T
R. Walsh Gate & Railing 306 Lake St. Pepin, WI 54759 715-442-3102 robertwalsh@robertwalsh.com www.robertwalsh.com
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Member Talk
3 keys to Germantown n
Germantown Iron & Steel grows from a family basement into a 45-year-old custom build/design structural steel and ornamental fabricator through 1) diversification, 2) good relationships with contractors, and ) investing in the business. By Bobby Hickman Early in his fabrication career, Boyd
Germantown Iron & Steel owners Dave Gutbrod, left, with Ken Gutbrod. Founder Boyd Gutbrod, right.
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Gutbrod was frustrated. His employer was entirely focused on structural steel, and when customers asked for simple miscellaneous work, “the boss said no — they would have to get that from someone else,” recalls his son, David. “My dad wanted to sell the whole job.” When one client wanted a basic retaining wall railing, Boyd finally asked the boss if he could do that work on his own time. “He worked in my grandfather’s basement where there was a welding machine and other equipment,” David says. That was the beginning of the Triple A Railing Company in 1968. Over time, the miscellaneous fabrication company outgrew that basement and became German-
The “pinwheel house” private residence, top and page 40–41, on Pine Lake in southeastern Wisconsin. It was featured on HGtv’s Extreme Homes. The company received two awards — Gold for structures and Silver for Stairs, Complete Residential — in the NOMMA Top Job contest.
Fabricator n March / April 2013
town Iron & Steel, Jackson, WI. David, now president, and his brother Ken, who now provides most of the estimating and oversees the accounting department, helped in the shop while they were in elementary school and grew up in the business. Now they are co-owners of Germantown, which they bought from their father in 1995. David, who oversees the general management and the design and fabrication departments, says the company has diversified far beyond its roots. Germantown has three divisions 1 heavy structural, 2 light structural, and 3 stairs and rails.
Heavy structural is the largest part of the business by dollar volume, but stairs and rails has more employees, as that work is more labor-intensive, David says. The company has 46 employees and a 54,000-square-foot facility. Gutbrod attributes much of the company’s success to its diversification. “A lot of companies just do structural steel,” Gutbrod says. “We do ornamental, stairs and rails, commercial, residential, stainless steel, aluminum, non-ferrous steel.” Employees specialize in certain areas but are also crosstrained to help in other departments. Quality is also a high priority. Mark Koenke, manufacturing manager for the Stairs and Rails Division, spends much of his time taking measurements in the field. “We’re different from some fabricators,” he notes. “We field measure everything from ladders to pipe railings to gates. We don’t rely on contractors for dimensions.” Also, Germantown employees install everything. “We want to be sure we aren’t causing problems for ourselves,” he adds.
Spiral, Circular and Helical Metal Bending -Stringers, Staircases & Handrails Pipe, Tube and Structural Bending - Decorative Gates, Fences & Signage
Focusing on core partners
Germantown works with a core group of general contractors who “pay their bills well” and are easy to resolve conflicts with, David Gutbrod says. However, when the market slowdown began in 2008, many core customers scaled back and the company sought new sources of work. “One thing that hurt us during the recession was having to go outside that comfort zone” and find new customers. Some of those companies did not share Germantown’s business integrity. David adds, “There were some things we stubbed our toe on, such as bidding jobs at a whisker and losing, particularly out of state.” While much of their work is commercial/industrial, a home project garnered Germantown its latest NOMMA Top Jobs honors. “Most of the residential work we’ve done is for general contractors themselves,” Koenke notes, or for former core partners who have moved into homebuilding. One such project was the “pinwheel house” — a “giant home” in Chenequa, WI, that took three years to build. The house was featured on the “Extreme Homes” TV show and won Germantown two Top Jobs awards in 2012: a gold for structures and a silver for stairs complete — residential.
March / April 2013 n Fabricator
12080 SW Myslony St. Tualatin, OR 97062 Toll-Free: (866) 252-4628 Direct: (503) 692-6010 info@albinapipebending.com
www.albinapipebending.com 39
A view of the structural steel about 75% installed. The round concrete elevator shaft is on the left.
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Fabricator n March / April 2013
A view of the inside stairs, left, and a closeup of the stair detail, above. A plate stringer was anchored to the round poured concrete elevator shaft. The treads were fabricated from tube steel into pie shapes that were field-welded to the plate stringer. The tube structure was then encased in wood and the concrete and stringer covered by the stone work. The result: the finished appearance of floating wood treads projecting from the stone. The horizontal rails pieces were rolled in the shop and went through pre-drilled angled holes in the posts to allow the rods to be uninterrupted and make a smooth transition through the posts rather than welded at each post. March / April 2013 n Fabricator
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Mark Koenke moving up in NOMMA Association members go out of their way to help you
Mark Koenke, manufacturing manager at Germantown Iron & Steel, Jackson, WI, has worked with NOMMA since the earliest days of his career. Now he is poised to become president of the national association in 2014. Koenke worked as a drafter in high school and studied architecture at the tri-state-quarter page.qxd 12/19/07 9:44 AM University of Wisconsin-Milwaukee, while working part-time as a drafter at Germantown. By graduation, he decided, “architecture wasn’t for me. I enjoyed working in the steel industry and working for the two brothers who own the company.” He has been at Germantown for 23 years. Koenke was in his 20s when he attended the first Upper Midwest chapter meeting many years ago. “I’ve felt pretty welcome in NOMMA ever since.”
He volunteered for a board position at the first meeting, worked his way up to chapter president, and now is presidentelect of the national organization. Family mentors
Koenke’s primary mentors have been the Gutbrod family who own and run Germantown. “The only other way I’ve learned things has been through NOMMA,” he adds. Fellow members have shared their knowledge and “confirmed the way we’re doing things is the Page 1 right way to go about doing it.” For example, Germantown attended a NOMMA convention in Savannah, GA, “not knowing how we were going to do a stainless steel project.” One evening they met representatives of Sharpe Products, a supplier in the Milwaukee area working with stainless steel. “They invited us over to their shop. Then they showed us how to use the tools, and what tools and materials we needed.” Koenke says Germantown “used to
Mark R. Koenke, Germantown manufacturing manager, touts NOMMA shop tours: “You’ll get a lot of great ideas just by walking through other people’s shops (at chapter meetings), seeing how they operate, . . .”
be leery of stainless. Now we know how to bid them. We’re not afraid to take on stainless projects we might have stayed away from in the past.” Another benefit: when Germantown’s general contractors work out of state. “We’ll follow them as long as they pay us to ship the material there,” Koenke says. On several occasions, Germantown contacted NOMMA members in other states to fabricate items locally, avoiding
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shipping costs. “They are able to do the job in a way to make everybody profitable,” he says, and contractors “get something at a moment’s notice without having to wait for us.” Best help is face-to-face
Germantown uses email and the NOMMA ListServ to get advice from the NOMMA community. But Koenke says personal interaction remains important at conventions and during chapter sessions. “You’ll get a lot of great ideas just by walking through other people’s shops (at chapter meetings), seeing how they operate, what new technology they use, or what market niches might be available in your area. If don’t attend those meetings, you’re really missing out on a lot NOMMA has to offer. “With NOMMA, the more you help out, the more you contribute to the group, the more you get out of it.”
March / April 2013 n Fabricator
Diverse products, partnerships drive growth
The market in the Milwaukee area has been difficult over the past three years, with at least eight fabricators going out of business — including Boyd Gutbrod’s former employer, which had continued to focus exclusively on structural steel.” Germantown officials attribute their survival to diversification, solid relationships with good general contractors, and investing in growing the business. David noted the “economy is slowly coming back” in southern Wisconsin and Germantown is “bidding a lot more jobs.” The core group of sound customers “are coming around again and we’re bidding a lot of that work again. From our general contractors’ standpoint, things are getting better.” Koenke says the company is “doing more work for the industrial market and for other material handling companies.” While Germantown is not necessarily a job shop, “we’re willing to look
CAD technology has
“really allowed us to go off in more complicated and diverse areas of the business,”
Dave Gutbrod President Germantown Iron & Steel
at any fabricated steel that might be customized, or at some larger projects that a smaller shop might not be able to handle.” Most work is done in-house. Investing in infrastructure
Continuing investment in facilities, equipment, and technology has also been a vital component in Germantown’s success. After moving from the basement into rented space, Germantown built its first facility in 1972. At that building, David says, “We had to provide a higher degree sales pitch to people that we were really
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capable of doing the job.” When they constructed a new 43,000-square-foot building in 1997, “We did not have to make that big a pitch. Our credibility grew just by having a new building,” he says. Germantown moved to its current headquarters in 2008. The company also upgraded its professional presence by buying new trucks and having employees wear uniforms. “We started out buying second-hand trucks from utilities,” David says. They later decided that clean, well-maintained trucks were “better for our image — plus they were not breaking down as often.” In addition to boosting creditability and employee pride, those trucks are widely admired and imitated, Koenke adds. “We custom-fitted the cabinets and racks so they could carry all the tools and equipment the installers needed. They even have microwaves for cooking lunch on the job site. We get quite a few compliments from other installers.” Similarly, Koenke says that when he started at Germantown, “we were still drafting on the board.” But the company soon embraced computer-aided design. “Welding has pretty much stayed the same over the last 50 years,” he says, “and the technology to build stairs and railings has not changed much. But the owners saw that computers and CAD drafting would be a way to get an edge on the competition.” Gutbrod says Germantown was one of the first in the industry to “bite the bullet with computers” and invest in AutoCAD. “They have made things so much easier. For instance, if we are working on a curved stair, we have the ability to solve all the mathematical problems with the Fabricator n March / April 2013
For your information
n
About the author Bobby L. Hickman, a freelance business journalist in Atlanta, covers economic development, international trade, the travel industry, insurance, and similar topics. CO NTAC T
Field truck, above, with cabinet doors open in garage, one of three identical trucks. Opposite page, top, Stairs and Rails fabrication bay. Opposite page, bottom, Daren Lehto, shop foreman for Stairs and Rails, is polishing and finishing a stainless steel handrail.
March / April 2013 n Fabricator
computer, instead of using the old pad and calculator and reams of written calculations to find the properties of a circle.” CAD technology has “really allowed us to go off in more complicated and diverse areas of the business,” such as large shop assembled structures and creative stairs and railings, David adds. “It also helps your image to understand the technology when you are working with general contractors and engineers who are in tune with all of that.”
Germantown Iron & Steel Corp. N174 W21370 Alcan Dr. Jackson, WI 53037 262-677-2530 www.gogis.com David Gutbrod, president daveg@gogis.com Mark Koenke, manufacturing manager markk@gogis.com
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METALfab2013
Exhibitor Showcase n
If you were not able to attend METALfab201, the only trade show for the ornamental and miscellaneous metals industry, in Albuquereque, here’s a product sampling and a few words from attending exhibitors.
The Cable Connection Due to fabricator demand, The Cable Connection has introduced a 2-inch version of its swageless Ultra-tec Pull-Lock and Push-Lock fittings, to match its 2-inch Receiver tensioning device. Both the Receiver and Push-/Pull-Lock fittings hide completely inside the end posts, as they fit flush through 2-inchsquare tube, according to the company. This allows you to drill through both end posts at the same dimension, greatly simplifying the drilling process, and speeding up installation. Contact 800-851-2961, www.ultra-tec.com Carell Corp. The T150A represents the latest generation of high-tech ironworkers. You can work iron bar cold, saving valuable time, space, and money. It allows ornamental fabricators to easily create scrolls, hooks, bar twisting, rings, links, and flat bars. The T150A is easy to use and is fully programmable, says Carell. The T150A comes with a digital and programmable control center making mass production of custom pieces easy and accurate every time. The machine can memorize eight different twistings and has a piece counter for additional convenience. It comes with a complete set of versatile tooling. Contact 251-937-0948, www.carellcorp.com CM Iron Supply CM Iron Supply says it prides itself on their U.S.-made, US bar and tube ornamental iron products. The company offers a variety of forged steel and aluminum items, ranging 46
from scrolls and hammered tube to textured square and flat bars. As a U.S.-based company with local suppliers and manufacturing facility, it is never short or back-ordered. Along with standard inventory products, custom orders can also be filled using the company’s materials and your specifications. Contact 480-968-5121, www.cmironsupply.com CML USA Inc. Ercolina’s 050KD is ideal for bending pipe, tube, squares, rectangles, solids, and other profiles. It bends ferrous and non-ferrous materials ¼ to 2½ inches and accepts Ercolina’s two-axis A40/P positioning table for multiple and sequential bends, according to the company. A heavy-duty gear case accommodates radii up to 11⅞ inches centerline radius. Standard tooling is available in multiple radii from stock with CLR as small as two times diameter. Operator friendly control programs bend angles to 180° with individual spring back setting. Contact 563-391-7700, www.ercolina-usa.com Colorado WaterJet Co. Colorado WaterJet Co. can create custom railing infill panels like the panel cut from 1 inch aluminum, right. Any design, any material can be cut. You can deliver to your customer a unique design at a reasonable price. Let your imagination run wild. Fabricator n March / April 2013
METALfab2013
Exhibitor Showcase Cold-cutting process avoids warping, hardening, and slag, and it eliminates welded joints. The comapny says it is dedicated to detail and committed to quality. It has served NOMMA members since 1998. Contact 970-532- 5404, www. coloradowaterjet.com Custom Ornamental Iron Works Ltd. Offering many products, scrolls are perhaps the company’s most versatile ones, says the company. Like its balusters, the company’s scrolls are made with round, square (smooth or hammered edges) material. In addition to round and square material, scrolls are also made with flat bar. Although the company stocks standard sizes and popular styles of scrolls, they can be made to your specifications. Scrolls can add detail and flare to any gate or fence. Contact 866-464-4766, www.customironworks.com D.J.A. Imports Ltd. D.J.A. says it “is not your typical distributor.” It has “an eclectic catalog of products.” As a nationwide distributor, it “supports high quality products.” D.J.A. continues to diversify its inventory with a large selection of Cantilever Gate Systems for sliding gates, adjustable hinges, heavy duty overhead tracks, ornamental steel components, hard-to-find bar stock, and “golf ” components. As an architectural steel and gate hardware distributor, and by bringing together artisans and ideas from across the world for your projects, D.J.A. provides industrial, commercial, and residential solution. Its newest component is the “Aluminum Split Shoe.” An installation demo may be viewed at DJAImports.com. Contact 718-324-6871 djaimports.com Doringer Cold Saws Cold sawing is the fastest growing method of steel cutting in the ornamental iron industry. There is no faster, safer, or more economical way to cut steel, stainless steel, or aluminum than with a Doringer cold saw, the company says. And every cut comes out square, with a smooth finish, and burr-free. March / April 2013 n Fabricator
Imagine going directly from sawing to welding or assembling. No secondary deburring operation. Doringer — American made and serving NOMMA for over 20 years. Contact 800-962-6800, www.doringer.com ETemplate Systems ELaser is the newest addition to ETemplate’s line of award winning 3D measuring technologies. It dynamically generates a 2D/3D CAD drawing as measurements are taken with the 3D laser head. Points can also be integrated with the EPhoto data. ELaser represents the latest laser technology, including live video through the laser head. These include photographs for job site documentation and a zoom lens with crosshair for precise targeted measurements. The laser operates with a wifi connection. Contact 866-877-6933, www.etemplatesystem.com Elite Architectural Metal Supply LLC Elite Architectural Metal offers hand-forged and cut lambs, tongues, and scrolls in bronze, aluminum, and steel all made in the U.S. These rail ends are made from Wagner handrail but can be made from other handrail molding. The company says it also has a custom line of one-piece cast aluminum and iron newel posts and caps, along with many custom patterns available for casting. Elite says it has recently added 316 alloy Stainless Steel Railing Systems by Lavi Railing to its product line, which already includes hammered and textured bars, Grande Forge and Lawler steel forgings, Regency railing panels, and Heritage cast iron gates and fences. Contact 847-636-1233, www.elitearchitecturalmetal.com FabCAD Inc. In addition to its state of the art CAD systems, the company has available on the App Store its “gamechanging” selling tool that allows you to show the customer exactly how the finished prod47
METALfab2013
Exhibitor Showcase uct will look on your iPad, iPad Mini, or iPhone. You can use photos of the job site or select gates from the company’s design library. You can also use your own and sell the job on the spot. No drawing required. Contact 800-255-9032, www.fabcad.com Feeney Inc. For more than 65 years, Feeney Inc. has pioneered industry-leading cable rail systems and other architectural and rigging products. The company says it is known for its “very high quality,” and constantly strives to simplify the way its customers work with the company and its products. Feeney believes you will find its CableRail, DesignRail, and QuickConnect products easy to use, with features and benefits that are innovative and compelling. Contact 800-888-2418, www.feeneyinc.com Hebo
Hebo (German blacksmiths) invented the modern wrought iron machine for the ornamental iron and fencing industry over 40 years ago. The multi-functional Hebo system can twist, endforge, scroll, texture, hammer tube, make baskets, press belly pickets, and drill and polish stainless steel. Save time and money and start making your own parts. Check out the viral video on YouTube: “The Money Machine 2.” Packages available for any budget. Contact 503-722-7700 for a free DVD, www.usahebo.com King Architectural Metals The beauty of King’s stainless steel railing systems is matched only by the effortlessness of its installation, the company says. You’ll appreciate the attention to detail that makes every part fit together perfectly. Prefabricated posts allow for quick and easy installation saving you time and money, and the modular design offers you options usually associ48
ated with custom-made systems. See the entire line of stainless steel assemblies at kingmetals.com in the Stainless Steel button! Contact 800-542-2379, www.kingmetalscatalog.com Lavi Industries Prefabricated cable railing posts simplify installation and eliminate welding. They offer an attractive, affordable, low maintenance and easy-toinstall railing option for residential or commercial applications, according to the company. Extremely durable and virtually invisible, they allow for beautiful, unimpaired views. They are available with many options, such as floor or facia mount, 36 inches or 42 inches post height, 1/8-inch or 3/16-inch cable, and numerous handrail options. Contact 800-888-2418, www.railings.lavi.com Lawler Foundry Corp. Lawler’s natural finish, high quality iron castings and steel forgings are sold to fabricators and forgers to design, fabricate, finish, and install residential and commercial ornamental metalwork. Lawler introduced its economical “QC Forgings” line in 2007, and is now introducing its extended line of “Gold Medal” Hardware and Accessories. These additions allow the fabricators and forgers to offer high quality at reasonable prices. According to the company, it remains the preferred supplier to more than 1500 full-time fabricators and forgers of ornamental metal products in the U.S. Contact 800-624-9512, www.lawlerfoundry.com Marks USA Ornamental Iron Locksets are available in US 26D, US 3, US 15, and US 10B finishes. These locksets feature a 9 Series mortise lock body, thru-bolted solid brass trim assemblies, and spring loaded captivated spindles. Marks USA locksets are backed by a lifetime mechanical and electronic warranty. Contact 631-225-5400, www.marksusa.com Fabricator n March / April 2013
METALfab2013
Exhibitor Showcase Metabo Corp. This tool is designed for burnishing, finishing, and recondition stainless steel, steel, non-ferrous metals, plastic, and wood, the company says. With a 270° wrap angle, this machine is particularly agile and powerful, ideally suited for finishing or repairing pipes and tubes. Special VTC electronics ensures you always get a smooth and consistent result, and the robust Long Life Motor with double gear reduction delivers the power to finish faster. Contact 610-436-5900, www.metabousa.com Mittler Bros. Machine & Tool Among Mittler Bros. many offerings is a single-speed Ultimate Tube Notcher used in many NOMMA member shops for stairs, gates, and furniture work, according to the company. Among the features are: special end mills for 1.25, 1.5, and 2-inch pipe, which are designed for fast metal removal; vise capacity that can be upgraded from .75 inch to 2.375 inches, swivel vise with 1° increments; a V-block design for quick setup; maximum diameter 2 inches OD standard vise, 2.375 inches OD upgraded vise. Contact 800-467-2464, www.mittlerbros.com
both primer and topcoat built into one paint. The first coat acts as a primer, and second coat yields a beautiful satin finish. Contact 888-471-3400, www.sumtercoatings.com The Wagner Companies LEDpod illuminates in an asymmetric distribution without the need to tilt the handrail, thus eliminating unwanted and disturbing glare. With an individual driver for each LED, failure is limited to a single LED in each instance. LEDpod is suitable for curved handrail (subject to radius). It has an optically designed glass lens and a large heat sink with excellent mass and surface areas for efficient heat dissipation, according to the company. Contact 888-243-6914, www.wagnercompanies.com
Regency Railings Inc. Regency Railings offers components for any staircase regardless of radius and slope, and any level railing regardless of radius with the following limitations. Regency’s says its components are designed for use on any incline radius greater than 30 inches and inclines of 52° or less. The level railing components were designed for a radius greater than 28 inches. Use on a tighter radius or greater degree of incline might require significant modification to allow installation and to pass codes. Contact 214-742-9408, www.regencyrailings.com Sumter Coatings The Metal Master brand is composed of primers and topcoats that are specifically formulated for use on ornamental and miscellaneous metals, says the company. The company’s most popular product is the “Satin Shield,” which is a fast drying, direct-to-metal paint. This product is March / April 2013 n Fabricator
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Top Job Gallery
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The Top Job Gallery features entries in our Ernest Wiemann Top Job Contest. Information about the annual competition, open to all NOMMA members, is posted at the NOMMA website, www.nomma.org. Category: Non-forged interior railings
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Eureka Forge — Silver Pacific, MO This three-level balustrade was designed and created by the fabricator for clients seeking a departure from traditional scrollwork. The armature (or frame) was created in the field with a portable pyramid roll and fitted to steel embeds set in the rough framed curb. The intersecting ovals were first cold formed and bent to match the curb radius. The intersections were marked and mortised on a vertical mill so that the ovals would set in a single plane. The vertical edges of the ovals were then cut, fit, and welded to form a continuous focal element. “Echoes” were handformed to finish each panel. The finish was accomplished by sandblasting (tool marks were not removed per client request), priming, base and stipple coating, and finishing with metallic silver overspray and clear coat. Approx. labor time: 301 hrs. Gulf Coast Metal Works Inc. — Bronze Cape Coral, FL This project was originally designed using custom handrolled scroll work. The client had to be convinced to pay for the extensive labor hours. A design was created using forged steel components and the cost was brought down, but still give the client the look she wanted. Knowing ahead of time that to get the rail height needed using the pieces shown, the home builder agreed to provide a 7-inchheight curb wall and stringer that added to the overall look of the job and allowed us to meet the rail height required by code. Materials: steel with hammered forged components; powder-coated, oil rubbed bronze; approximately 36 L.F. of decorative rail and 12 feet of wall mounted handrail. Approx. labor time: 62 hrs. (includes installation). 50
Fabricator n March / April 2013
AMERICAN-MADE STOCK HANDRAIL FITTINGS • Full line of stock architectural handrail fittings including, elbows, wall brackets, flanges, caps, and more at our low price guarantee. • Stock fittings are available in aluminum, steel, and stainless steel. Alameda Ornamental Iron Inc. Denver, CO The client was looking for a unique and artistic style of railing. She found the picture of a similar railing that the company previously built in its idea book. The company’s fabricator modified the design to be uniform including the compound curved areas. Alameda used ½-inch-square solid material with a 2¼ inch molded cap. Fabrication began with a skeleton for the compound curved areas, onsite. The fabricator then laid out the design in the shop. All the rings were rolled, laid out, and cut to fit the curved areas, welding each piece. The greatest challenge of the job was to fabricate all the components on the same plane, and keeping the uniformity of the design throughout the entire railing. The entire job was fitted onsite, powder-coated black, and installed. Approx. labor time: 240 hrs for the fabrication and grinding of the welds.
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March / April 2013 n Fabricator
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Artistic Railings Inc. Garfield, NJ This project was fabricated for a four-story mausoleum. All the railings are fabricated from mild steel and all material is solid. The railing was fabricated with an arched pattern that was rolled and or pressed pending size. Of particular difficulty was the constant changes in mounting heights and clearances from walls to allow for casket head stone removal. Materials: posts 1¼-inchsquare, balusters ⅝-inch-square, and 1¼-inch bottom bar. The finish on the railings is a powder coating. An estimated 680 feet of railing was fabricated which include the threestory open stairs and the four-story rear stair flight all done in the same pattern. Approx. labor time: 56 hours of design & drafting, 870 hours fabrication, and 160 hours installation. The photos were taken approximately six weeks after installation.
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Avery Railing & Metal Arts Studio Dubuque, IA This job was done to replace a wood baluster type railing that the owner wanted to replace with ornate metal. The interior railing with overlapping, framed-scroll design panels were made from hot rolled steel that was almost all cold formed. Scrolls were made from mostly ½-inch-square bar with some small ones from 3/8-square bar. Mounting was done by a screwed down flange that had a solid bar that slid into the post and tightened down with set screws. A cast shoe was slid onto the post before it was slid over the mounting flange bracket. After the set screws were tightened, it was epoxied in place. The top plate was drilled and countersunk for standard, off-the-shelf wood cap railing components to be installed by others. Finish was a powder coat done by others. The top straight section was made in one 14-foot length, which made it difficult to handle and maneuver into place. The owner had a small picture that inspired the design concept. Approx. labor time: 150 hrs. Christopher Metal Fabricating Inc. Grand Rapids, MI Timeframe and location were the two major issues Christopher Metal faced on this project, which had rails designed by the architect. The project was 200+ miles from our shop and the stair fabricator was 95 miles away. The two had to work closely together. The stair fabricator did a small sample section of the stringer to get the helix and curve. The rail had to be there within a week after the stair being installed to meet the job progress. The final transition point at the top had to wait for the finished stair before Christopher Metal could complete their part. When the sloped rail was completed, the homeowner visited the shop and said she wanted the pickets to lean rather than be vertical. All the pickets had to be broken loose, lean them about 10 degrees, and reassemble.
The bottom rail is solid ⅝ x 1 bar. Pickets are ⅝-square bar. The cap rail is 3/8-thick flat bar with a Dixie cap rail. The rail was blasted, darkened, and clear coated. A gold gilding paint was used on top rail and covered with a clear coat. Approx. labor time: 494 hrs. Fabricator n March / April 2013
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Croissant Custom Fabrications Denver, CO This job consisted of approximately 40 linear feet of interior stair railing in a new custom home. The design was sketched by the customer, however, it was done to our design suggestion. The material used was hot-rolled steel. The frames were site-fitted, then shop fabricated, installed, and had a powder coat finish. However, our greatest challenge was getting and letting the customer get involved with the design. It started off as a simple horizontal style rail, but when we saw that the style of their home was artistic, we suggested another style. The customer was extremely pleased. Approx. labor time: 60 hrs.
March / April 2013 n Fabricator
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horizontalfullcolorad.pdf 1 2/2/2012 7:30:54 PM
Flaherty Iron Works Inc. Alexandria, VA This railing was installed at top of second floor stairs in a town home. A 3/16 x 1-inch flat bar was used. It was cold formed, using bending and welding joints at corners to make the shapes. This rail was designed by the owner and the fabricator chose the material. It is primed and painted black, and it has a wood top. Approx. labor time: 200 hrs.
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Downtown Ornamental Iron Inc. foot of the stairs changed dramatically, Bend, OR twice. After extensive measuring and This helix and radius railing was pre-rolling of material, two employees made with 1¼-inch-standard pipe top spent 20 hours onsite roughing in the rail and ½-inch-round rod pickets. helix guard rail and handrail. Then it Problems: The helix was not a true helix; returned to the shop for finishing. The it changed angles in two diff spots77035-CB-4829-08 upper radius was done completely inAderent Proof thus hard to meet code and ensure good house. This helix was designed by the flow. Also, the newel post angle at at the owner/fabricator with the homeowner. Finelli Architectural Ironwork Solon, OH The stair railing design was presented to us by the interior designer who provided a color photo from a magazine shot. The design originally was traditional with brass centers and leaves. Finelli modified the railing to give it a more transitional look since the home was more contemporary. This was a double staircase with second floor and balcony rail to match. The hard part on the helix was that the oval shapes that had to be individually fit in to match the skeleton of the railing. The material used for the shaped piece was ¼ x ½-inch bar, 11/8-inch-solid steel bars and 1¼ x ¼ inch-diameter disks. The ball and center disk attachments were all concealed with no welds exposed. The top rail was constructed with maple. All material was sandblasted, and the finish was applied using a pewter base with a black glazing rag technique. Approx. labor time: 671 hrs. (includes wood cap rail fabrication and installation).
March / April 2013 n Fabricator
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Vasquez Custom Metals Inc. Tampa, FL Each bar on this handrail was machined from ž-inch-round bar to ½ inch on a 4-inch section. The rings were then laser cut to fit over the bar to separate the two different size sections, and were TIG welded and ground smooth so that no welds were visible. The Dixie cap profile needed to be thick so two square bars were welded to the bottom so it looked bold. There are no visible welds on the handrail. The top and bottom rails were drilled and each picket was TIG welded in place. The entire length of the Dixie cap was TIG welded and ground smooth. The whole rail was polished with a rotary brush and clear-coated. Finally, the handrail cap was faux finished to a bronze tone and each of the rings were hand painted to a rustic gold finish. Approx. labor time: 200 hrs.
Fabricator n March / April 2013
Biz Side
Fiscal puzzle solution helps small business © 3Dmask - Fotolia.com
By Mark E. Battersby
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The fiscal cliff agreement renewed several expiring tax breaks for small business, many of them retroactively creating or saving $76 billion in tax breaks.
March / April 2013 n Fabricator
The so-called “Fiscal Cliff” tax package recently signed into law renewed more than 50 temporary tax breaks through 2013, saving individuals and businesses about $76 billion. However, employees are already finding less in their paychecks because the American Taxpayer Relief Act did not extend the payroll tax holiday that had reduced Social Security payroll deductions from 6.2% to 4.2% on earned income up to the Social Security wage base ($113,700 for 2013). It is a similar story for the self-employed. For the owners and operators of small- and medium-sized businesses in the ornamental and metalworking industry there is good news and bad news contained in the fiscal cliff tax laws. Some good news is greater certainty in taxes. The owners and operators of many ornamental and miscellaneous metals fabricating businesses have grown used to many longstanding tax breaks, but they also have had to get used to the uncertainty of whether they will be renewed each year. While many tax breaks were allowed to expire at the end of 2011, the new tax law renews them retroactively allowing metals fabricators to claim them on both their 2012 and 2013 tax returns.
Equipment write-offs for profitable operations
The American Taxpayer relief Act extended through 2013 the Tax Code’s Section 179, first-year expensing write-off. Now, the higher expensing limits in effect in 2011 have been reinstated for 2012 and extended for expenditures made before December 31, 2013. Thus, a metalworking business can expense and immediately deduct up to $500,000 of expenditures in 2012 and 2013, subject to a phase-out if total capital expenditures exceed $2 million. The maximum amount that can be expensed in years beginning after 2013 will, unless the rules are changed, drop to $25,000 with a $200,000 investment limit. 57
The election to expense the off-the-shelf computer software used by some shops under Section 179 is also extended and applies to expenditures made before December 31, 2013. The tax break that allows profitable fabricators to write-off large capital expenditures immediately — rather than over time — has long been used as an economic stimulus. One hundred percent “bonus” depreciation expired at the end of 2011. Today, the new law allows 50% bonus depreciation for property placed in service through 2013. Some transportation and longerlived property are even eligible for bonus depreciation through 2014. To be eligible for bonus depreciation, property must be depreciable
especially for small businesses. Property qualifying for the Section 179 write-off may be either used or new in contrast to the bonus depreciation requirement that the taxpayer be the “first to use.” Research credit extended
© 3Dmask - Fotolia.com
under the standard MACRS system, and have a recovery period of less than 20 years. Code Section 179 first-year expensing remains a viable alternative
The new law extended the often overlooked, neglected, and difficult-to-understand research credit, which expired at the end of 2011 through December 31, 2013. The research credit or research and development credit as it is often labeled, may be claimed for increases in businessrelated research expenditures. While only for research in the clinical sense, many of the small businesses have in the past shied away from the complex rules. Perhaps the potential of reaping a share of the $14.3 billion in tax savings may entice more fabricators to investigate the research tax credit. Credit for hiring from special groups
Another tax credit reducing the operation’s tax bill, rather than a tax deduction that merely reduces the amount on which the tax is computed, is the Work Opportunity Tax Credit (WOTC). The WOTC, a tax credit that rewards employers that hire individuals from targeted groups has been extended to December 31, 2013 and applies to individuals who begin work for the employer after December 31, 2011. Under the revised WOTC fabricators hiring an individual from within a targeted group are eligible for a credit generally equal to 40% of first-year wages up to $6,000. Target groups are generally hardto-employ workers. At one point, this had been limited to veterans, but when final rules come out it will no doubt revert to many of the old categories, such as welfare recipients, ex-cons, and the long-term unemployed. More education assistance
The new tax law also permanently extends the exclusion from income and employment taxes of employer58
Fabricator n March / April 2013
provided education assistance up to $5,250. Businesses may also deduct up to $5,250 annually for qualified education assistance paid on behalf of an employee. Excludable education payments may not cover tools or supplies that the employee retains after completion of a course, or the cost of meals, lodging, or transportation. Although the courses covered by the plan need not be job related, an exception applies to courses involving sports, games, or hobbies. These courses may only be covered if they involve the employer’s business or are required as part of a degree program. Extends exclusion on certain ‘small business stock’ gains
The new law extends the temporary exclusion of 100% of gain on certain small business stock used by so many businesses to attract investors. In general, an investor can exclude from his or her income 100% of any gain realized on the sale or exchange of so-called “small business stock” acquired prior to January 1, 2014 and held for more than five years. The amount of gain that can be ignored is limited to the lower of $10 million or 10 times the basis or book value of the small business stock disposed of during the tax year. To be eligible, small business stock must have been issued after August 10, 1993, and acquired by the investor at its original issue. The small business stock must also have been issued by a regular domestic, incorporated metals fabrication business, with gross assets of less than $50 million. Although an S corporation is a pass-through entity and not usually subject to income taxes, it is liable for the tax imposed on built-in gains or capital gains. The tax on built-in gains is a corporate level tax on S corporations that dispose of assets that appreciated in value during the years when the operation was a regular “C” corporation. The new law provides for a five-year holding period for the sale of property with built-in gain for taxable years beginning in 2012 or 2013. March / April 2013 n Fabricator
© 3Dmask - Fotolia.com
Taxing it alone
Thanks to the Health Care and Education Reconciliation Act of 2010, beginning in 2013, many individuals discovered they are subject to a 3.8% Net Investment Income (NII) tax and a 0.9% Additional Medicare tax. The new taxes apply to single tax-
payers with a modified adjusted gross income (MAGI) in excess of $200,000 and married taxpayers with a MAGI in excess of $250,000 if filing a joint return, or $125,000 if filing a separate return. More recently, single individuals with incomes above the $400,000 level and married couples with income higher than $450,000 will pay more in taxes in 2013 because of a higher 39.6% income tax rate and a 20% maximum capital gains tax. For others, the alternative minimum tax has finally been indexed for inflation. Ironically, the AMT was created to ensure that wealthy individuals would pay some income tax, not middle-income households. The new law increases the 2012 exemption amounts to $50,600 for unmarried individuals and $78,750 for jointly-filing couples. For 2013, the AMT exemption amounts are predicted to be $80,750 for married couples filing jointly and $51,900 for single individuals.
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Some changes to estate taxes
Always of significant interest to family-owned businesses, the estate tax has long been a bit of a mixed bag. The $5 million per person exemption was kept in place (and indexed for inflation). The top rate was, however, increased to 40% — effective date January 1, 2013. This change to 40% is expected to increase government revenues from 2012 levels by $19 billion. Ad_2011:Layout 1 2/7/11 10:09 AM Other good news for estate plan-
ning — portability is kept in place and estate and gift taxes remain unified, i.e., the $5 million stays in place for gift tax purposes as well as estates. And it is all permanent. Planning opportunities abound with dozens of tax credits
The majority of fabricating businesses operate as pass-through entities, such as partnerships and S corporations. are passed through to PageProfits 1 their individual owners and therefore
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are taxed at individual income tax rates. A regular “C” corporation, with its current tax rate of 35%, may become more attractive with rates rising to 39.6% for some individuals. The increase in the top tax rates, the AMT relief provided for 2012 tax year, and the hidden taxes all combine to make it possible that many small and medium businesses that weren’t eligible for business credits thanks to AMT limitations in 2011 will now potentially be able to take advantage of these dozens of credits — in essence a backdoor opportunity for small businesses — similar to when Congress expanded eligibility for credits for 2010. Although many popular but temporary tax extenders relating to businesses were included in the American Taxpayer Relief Act, it is not the grand bargain as envisioned by lawmakers. Despite the Code Section 179 small business expensing, bonus depreciation, and the Work Opportunity Tax Credit, the new law is effectively a stop-gap measure designed expressly to prevent the onus of the expiration of the Bush-era tax cuts from falling on middle-income taxpayers. Congress must still address spending cuts and may even tackle tax “reform.” The time is now — hopefully before filing your operation’s 2012 tax returns — for every business owner, operator, and manager to consult with their accountants or tax professionals to focus on the potential savings offered by these newly revised, extended, and expanded business credits, deductions, and tax write-offs.
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About the Author For more than 25 years, Mark E. Battersby has written editorial features, columns, white papers, and reports for magazines, journals, newsletters, and websites about news and developments in the tax and financial arenas that impact small businesses. He can be reached at MEBatt12@Earthlink.net.
Fabricator n March / April 2013
Biz Side
Checklist of 10 banking mistakes to avoid By William J. Lynott
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As a bank business customer, stay upto-date on the most current banking practices. These suggestions will give you a head start on maximizing your financial potential.
March / April 2013 n Fabricator
Your bank may not be the scoundrel
that some would have you believe, but don’t mistake it for your kindly old uncle either. Banks are in business to make money just as you are, and today they are looking to take a bigger bite out of your bottom line. Here’s how to keep them from chipping away at your net income:
1 Failing to steer clear
of those new and increasingly oppressive bank charges
One of the techniques most banks use to beef up their bottom lines are increased service charges. The average ATM service charge — the fee charged by the machine’s owner to a non-customer — has risen to record highs for the seventh consecutive year. Overdraft fees brought in nearly $30 billion in 2011, according to a report from Pew Charitable Trusts. That’s up from
© sgursozlu — Fotolia.com
$10.3 billion in 2004. If you allow yourself to get careless and bounce a check, you’ll likely get hit with one of those oppressive overdraft fees, one of their most profitable ploys. Most banks now automatically enroll their checking account customers in an overdraft program that allows them to hit you with an overdraft charge of as much as $35 each time you write a check for more than your account balance. Sixteen of America’s largest banks charge tiered overdraft fees that go higher after the first one, according to a study by the Consumer Federation of America. Some banks set no limit on the number of overdraft charges in a single day, so a little carelessness on your part could cost you a bundle. How can you minimize getting caught with these charges? Most important: Watch that checking account balance with an eagle eye. Under public pressure, Congress is considering legislation designed to 61
rein in the raft of some of these new and increased bank fees. Meanwhile, protect yourself by staying aware of your bank’s policies.
survey by the American Bankers Association.The preference for online banking was followed by visiting branches (21%), and using ATMs (17%). While experts agree that online banking is as safe, perhaps even safer, than conventional banking, don’t be complacent about your online password. Resist using something as simple as your birth date. Use a combination of letters and numbers chosen at random, and never do your online banking from a public computer. Do remember that bad guys out there, such as identity thieves, are an even bigger threat than banks to your financial well being.
2 Failing to monitor your
bank statement closely
Those monthly bank statements may not make for exciting reading, but they could make for profitable reading. Banks can and do make mistakes, so you or your accountant need to make sure that you’re not being hit with incorrect charges, especially in this age of new and unfamiliar charges. It will only take a few minutes to examine each entry on your monthly statement.
3 Leaving an inviting paper trail
Identity thieves and scam artists are lurking everywhere these days, and businesses that are careless with banking documents are one of their favorite targets. Leaving old bank statements, voided checks, or other banking documents where others may find them makes your business an easy target for the bad guys. Every one of your old or discarded bank documents should be torn into small pieces or, preferably, shredded. Office shredders are now inexpensive
© sgursozlu — Fotolia.com
enough to make them a wise investment for every NOMMA member.
4 Using a weak online password
Online banking is so convenient and easy these days that an increasing number of businesses and consumers (25%) prefer the speed and convenience of conducting their banking transactions on the Internet rather than visiting their local branch, according to a
5
Making deposits directly into your checking account
While the interest rate on virtually all banking accounts is sickly these days, it’s virtually non-existent on business checking accounts. That’s why you should never make your deposits into your checking account. Instead, open up a money market account at your bank and ask to have it linked to your checking account. Then make all of your deposits into the money market account where your money will draw a better interest rate (rates will likely be going up soon, making this step even more worthwhile). Then, transfer money from your money market account to your checking account online or by phone as needed to cover checks written.
6 Overlooking
the dangers of ATMs
Crimes involving users of ATMs are growing nationwide. When you use your ATM, take precautions to protect yourself and your money. Keep yourself aware of persons around you and make sure that you shield your PIN number when you’re typing it in. Once you’ve made a withdrawal, put your money safely away before you walk to your car and make sure you have your card with you. The chances 62
Fabricator n March / April 2013
of being robbed at an ATM may seem slight, but it can and does happen.
7 Failing to check with other banks for the best interest rate if you need a loan
When you need a business loan, it’s only natural to look first to the bank where you do your regular banking, but you shouldn’t stop there. The banking industry has become competitive in these difficult times. The result is a wide variance in such things as interest rates on loans. Always shop around for the best interest rate. Other than banks, consider credit unions and online banks such as Ally Bank (www. ally.com)or Ing Bank (https://home. ingdirect.com). Caveat emptor.
8 Opting out of paper statements You’ve probably noticed those inviting suggestions from your bank that you opt-out of receiving paper statements each month. It’s a good idea for the bank because it saves them time and money, but it may not be a good
For your information
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Pew Charitable trusts study http://bit.ly/VG6BPl Consumer Federation The specific study is an older one and apparently has been removed from their website, however, their latest comments are at: www.consumerfed.org/news/604 American Bankers Association report http://bit.ly/Vb28Ty About the author Bill Lynott is a longtime business writer for Fabricator. Since 1957, he has written nearly 1,000 essays and columns and is the author of three books: Professional Service Management (McGraw-Hill); Power Letters for Service Executives, (Lynco Publications); and Money: How to Make the Most of What You’ve Got (Author’s Choice Press). Bill also has an extensive background in management, consulting, and marketing. 215-886-3646 Lynott@verizon.net March / April 2013 n Fabricator
idea for you and your business. It’s much easier to spot irregularities when you examine your paper statement each month than it would be on a Web page. Even if your bank charges you a few cents for paper statements, it might be best not to opt out. Failing to carefully examine paper statements each month is one of the most common and potentially costly banking mistakes.
9 Failing to recognize ‘phishing’ e-mails
Every day, scammers send millions of authentic-looking e-mails asking the recipients to provide sensitive business or personal information. On the pretext of being from a legitimate company or bank, the message will often instruct the recipients to click on a link that sends them to a fake website. These fraudulent sites will ask for information such as name, address, phone number, date of birth, Social Security number, and bank or credit card account numbers. Never, never provide such personal information in response to an e-mail, no matter how authentic it may appear. Legitimate companies and banks will never ask you to provide that kind of critically important information in response to an e-mail.
10 Failing to develop a personal relationship with your branch manager
If you want to be sure that you’re getting the most favorable treatment from your bank, establish a personal relationship. Ask for a meeting with your local branch manager to introduce yourself
and your business. When it comes to fixing a problem or asking for a loan or other help, there’s no substitute for being personally acquainted with the powers that be. Banking is a tricky and complex business these days. As a business customer, you need to keep yourself up-to-date on the most current banking practices. Following these suggestions will give you a head start on maximizing your financial potential.
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CML USA Inc. Ercolina
Heritage Cast Iron USA
Colorado Waterjet Co.
House of Forgings LLC
Custom Orn. Iron Works Ltd.
Indiana Gratings Inc.
D & D Technologies (USA) Inc.
Industrial Coverage Corp.
(908) 757-2323
Atlas Metal Sales
(800) 662-0143
AZZ Galvanizing
(815) 618-8440
Banker Wire
(800) 523-6772 (828) 437-5348
(800) 526-6293 (856) 205-1279
(877) 664-4224 (800) 851-2961
(251) 937-0948
Carl Stahl DecorCable Innovations (800) 444-6271
Century Group Inc. (337) 527-5266
(800) 446-4402 (563) 391-7700
(866) 532-5404 (866) 464-4766
(714) 677-1300
(919) 676-2244
(800) 255-9032 (866) 79-FAB-4-U
(800) 888-2418
(800) 543-4283 (604) 299-5264 (323) 789-7800 (410) 284-9549 (800) 213-9525 (270) 298-3227
(860) 257-0680
(503) 722-7700 (918) 592-1700
(866) 443-4848 (800) 634-1988
(800) 421-6144
(800) 624-6225
(800) 824-2157
(216) 291-2303
(800) 624-9512
(940) 325-7806 (636) 225-5358
(718) 894-1442
SECO South
(888) 535-SECO
(630) 279-3600
Sharpe Products
(800) 879-4418
(708) 579-0286 (800) 631-9510
(856) 423-1107
(631) 225-5400
(713) 680-3110
(262) 786-2700
(225) 387-1838
(800) 638-2264 (800) 467-2464
(800) 323-6886
Sumter Coatings Inc. (888) 471-3400
NC Tool Co.
Transpacific Industrial Supply Inc.
O.K. Foundry Co. Inc.
Tri-State Shearing & Bending
Ohio Gratings Inc.
TS Distributors Inc.
Pacific Stair Corp.
The Wagner Companies
(800) 421-3575
(909) 581-3058
(336) 674-5654 (888) 592-2240 (330) 477-6707
(503) 390-8305
(631) 736-7500
(718) 485-2200
(832) 467-5400 (888) 243-6914
Wasatch Steel Inc. (888) 486-4463
Super Thanks!!! A thanks to our members who have sponsored a new firm for our 2012–13 membership drive. We encourage everyone to sponsor a member and/or send the NOMMA office your leads. If needed, we will be glad to send you a supply of membership brochures. n n n n 64
Julius Blum & Co. Inc. Industrial Coverage Corp. Majka Railing Co. Inc. R & F Metals Inc.
n n n n
Cuper Studios LLC Keeler Iron Works National Ornamental Metal Museum Steel Welding
n D.J.A. Imports Ltd. n Lawler Foundry Corp. n O’Malley Welding & Fabricating Inc.
Fabricator n March / April 2013
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New Members We are pleased to introduce our newest members. We encourage our new member firms to “jump in and get involved.” New NOMMA Members as of February 22, 2013. *Asterisk denotes returning members Delta Welding and Fabrication Goleta, CA Andrew Vonnegut Local Supplier
Kelley’s Custom Weld* Lake Charles, LA Trevor Lee Kelley Fabricator
O.K. Foundry Co. Inc.* Richmond, VA James O’Neil Nationwide Supplier
Barnett Aldon Ironworks* Albuquerque, NM Don Best Fabricator
E.H. Schwab Co. Turtle Creek, PA Neal Harrison Fabricator
Legacy Ironworks Inc. Hanover, VA Heather Long Fabricator
Bighorn Forge Inc.* Kewaskum, WI Dan Nauman Fabricator
Guardian Gate Hardware* Tuscon, AZ Jesse Lopez Nationwide Supplier
RAMSET Automatic Gate Systems Inc.* Sun Valley, CA Ken Lehmann Nationwide Supplier
AZZ Galvanizing Dixon, IL Clinton Shaw Nationwide Supplier
C.A.N. Art Handworks* Detroit, MI Carl A. Nielbock Fabricator Coast Iron Works* Wilmington, CA James Peterson Fabricator
House of Forgings LLC* Houston, TX Manuel Vela Nationwide Supplier
The Metal Works Inc.* Lexington, SC Troy Dixon Fabricator Mid-Cities Iron* Southlake, TX John J. Famiglio Fabricator
Rock Wood Iron Works Lubbock, TX Kenn Ruckey Fabricator Steel Geisha Designs Inc. Sonoma, CA Steven Chiurco Fabricator
NOMMA Gold Members NOMMA is pleased to welcome our newest Gold Members — companies who have been a member for 20 years or more. These companies show a strong loyalty to both their industry and their trade association. We thank them for their many years of support. n n n n n n n n n n n n n
Bracci Iron Works .......................................................... Brooklyn , NY Armin Iron Works Inc. .................................................. Pittsburgh, PA Boes Iron Works Inc. .................................................... New Orleans, LA Broome Welding & Machine Co. Inc. ........................ Galveston, TX DoorKing of Texas Ltd. ................................................. Dallas, TX Hebo/Stratford Gate Systems Inc. ............................ Clackamas, OR Johnston Products of Dallas Inc. ............................... Cedar Hill, TX King Architectural Metals ........................................... Dallas, TX Mainer Iron Works Inc. ................................................ Fort Smith, AR Picasso Gate Inc. ........................................................... Cheyenne, WY Republic Fence Co. Inc. ................................................ Granada Hills, CA Superior Fence & Orn. Iron ......................................... Cottage Hills, IL Western Architectural Iron Co.................................... Chicago, IL
METALfab 2013 A thanks to our METALfab2013 sponsors The sponsors for 2013 are a very special group of suppliers. In challenging economic times they are going the extra mile to contribute to the success of METALfab 2013. Their support is greatly appreciated.
Platinum Sponsors Industrial Coverage Corporation 62 South Ocean Avenue, Patchogue, NY 11772 Tel: (631) 736-7500 • Toll Free: (800) 242-9872 Website: www.industrialcoverage. com The Wagner Companies P.O. Box 423, Butler, WI 53007-0423 Tel: (414) 214-0444 • Toll Free: (888) 243-6914 Website: www.wagnercompanies. com
Gold Sponsors Colorado Waterjet 5186 Longs Peak Road, Unit F, Berthoud, CO 80513 Tel: (970) 532-5404 • Toll Free: (866) 532-5404 Website: www.coloradowaterjet.com Lawler Foundry Corp. P.O. Box 320069, Birmingham, AL 35232 Tel: (205) 595-0596 • Toll Free: 800624-951 Website: www.lawlerfoundry.com
Silver Sponsor King Architectural Metals 9611 East RL Thorton Fwy., Dallas, TX 75228 Tel: (800) 542-2379 Website: www.kingmetals.com
We greatly thank these companies for their two decades of loyalty and support. March / April 2013 n Fabricator
65
What’s Hot? n Industry Briefs Cable Connection expands cable railing kit offerings The Cable Connection re-launched its Ultra-tec cable railing kits last year, with two new Push-Lock models. The kits, originally available in lengths from 5 feet to 25 feet, incorporated one tensioning device (preswaged at the factory) and a swageless fitting on each cable, so the cable can be trimmed to exact length on-site. Now longer kits over 25 feet are available at 30-, 40-, and 50-foot lengths. “Longer cables often mean turning corners, and in order to maintain the proper tension, our long cable kits supply a minimum amount of take-up,” says CEO Lou Marino. “There is a big difference in what you need, however, if you’re going around two corners instead of just one. Ultra-tec offers cable railing kits that successfully tension around two corners, up to 180°.” Ultra-tec has also created kits for wood posts with composite sleeves that have extended length lags. The lags go through the sleeve and deep enough into the wood post to ensure a secure hold. Kits for wood posts with composite sleeves also come in lengths up to 50 feet. Contact 800-851-2961, http:// thecableconnection.com/pdfu/ application-guide10-22-12.pdf
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Industry News
Custom Metals floor integrates Prairie-style stainless/stone design Custom Metals Inc.’s award-winning offices in an historic Madison, WI, milkhouse, now have a custom-designed floor by Wausau, WI-based craftsman Alex Taylor, founder of Innovative Creations. The floor is a Prairie-style stone and stainless steel creation designed to meet corporate sustainability goals and as an extension of the office’s unique literal and figurative Prairie style. Taylor helped Custom Metals refine the design of the stainless steel inlaid into the floor, then completed the custom stonework using environmentally friendly Nature Stone. Custom Metals is housed in a century-old milkhouse on privately owned lands that are part of a prairie restoration project, which is regularly featured in a southern Wisconsin Prairies on Parade event. The company is known for metal restoration in Wisconsin’s state capitol building, at the University of Wisconsin, and in Ganz Hall at Chicago’s Roosevelt University. They are also the recipient of the Mitch Heitler Award for Excellence and three Ernest Wiemann Top Job awards from NOMMA. Tony Cole, owner of Custom Metals, said of Taylor’s work in the showroom: “Visitors love the change. The stainless steel and stone complement each other. And the design is true to Frank Lloyd Wright’s precepts — integrating design and nature as one. We admire that approach and worked out a design for the floor that would complement our surroundings as well as our ideals.” “By collaborating, we met every one of their goals,” says Taylor. “It makes a
The floor is a Prairie-style stone and stainless steel creation designed to meet corporate sustainability goals.
great first impression on the architects and designers who visit the showroom, it showcases their metalworking talents, it’s eco-friendly and it can withstand the flooding, mud, and wearand-tear of a showroom housed in the midst of the prairies,” he adds. Custom Metals specializes in steel, stainless steel, brass, bronze, copper, pewter, aluminum and zinc custom metal craftsmanship. Innovative Creations designs and custom crafts floors, cabinets, and concrete countertops. Contact www.custommetals.com; www.innovativewisconsin.com Fabricator n March / April 2013
Industy News
What’s Hot? n
Banker Wire mesh used in Hong Kong restaurant Award-winning steakhouse Carnevino, a popular restaurant in Las Vegas, was looking to make an immediate impression for diners at its newest location in Hong Kong. The goal was to create a high-end luxury steakhouse accented with details inspired from vintage racing motifs. To turn this vision into reality, Carnevino’s designers utilized wire mesh from Banker Wire, giving the décor key metal finishes that fit with the race-inspired machine aesthetic. Banker Wire’s DS-1, SZ-4 and IPZ-25 mesh styles were chosen and used throughout the restaurant as a background accent material for stone, metal and leather paneling. The use of wire mesh helped bring depth and texture to Carnevino’s walls, providing a visual experience that conveys luxury and richness. “Creating a warm, inviting ambience is a top priority for Carnevino and plays a huge part in providing its guests with the ultimate dining experience,” says Cliff Lin, senior designer at New York-based architectural firm, AvroKO, which oversaw the project. “We chose Banker Wire mesh due to its quality and reputation as a leading manufacturer of unique wire materials. The wire mesh we used helped breathe life into the décor and brought the overall palette together in a truly rich manner.” “The versatility of wire mesh makes it a perfect accent material for premiere dining establishments like Carnevino,” says Harrison Horan, vice president of Banker Wire. “By utilizing three different wire meshes at its new Hong Kong location, diners will enjoy a unique visual experience that will set Carnevino apart from other restaurants in the area.” Contact 800-523-6772 www.bankerwire.com
March / April 2013 n Fabricator
Banker Wire’s DS-1, SZ-4 and IPZ-25 mesh styles were used throughout the Carnevino restaurant in Las Vegas as a background accent material for stone, metal, and leather paneling. Photo credit: Dining Concepts.
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What’s Hot? n Literature Expanded welding gear catalog
Lincoln Electric Lincoln Electric’s 2013 Welding Gear Catalog offers new apparel and tool products designed to be functional, stylish, and safe.
n Jessi Combs women’s welding gear. Tailored for female fab-
ricators, includes the Viking 1840 Series Amp Angel Auto-Darkening Welding Helmet, Women’s Shadow Welding Jacket, and several glove options sized for female hands. n Facial protection. More face protection equipment, including clear, padded safety glasses; face shields; and Shade 3 and 5 cutting and grinding goggles. Also new are welding curtains, brushes, blankets, and helmets. Contact 888-355-3213 www.lincolnelectric.com
Events / Literature
March – June , ‘Weather Moves Metal’ exhibit The Metal Museum, Memphis, TN, has announced an exhibit called “When Weather Moves Metal: Whirligigs and Weathervanes.” With work from the Metal Museum’s permanent collection, local collectors, and nationally recognized whirligig makers, this exhibition of kinetic, weather-driven machines will feature both highly trained and vernacular artists. General admission applies. Members are free. Contact 901-774-6380 www.metalmuseum.org
Call for Nearest Dealer
April –, Blacksmithing conference The Metal Museum’s annual “Forging on the River” blacksmithing conference takes place on the Metal Museum grounds in Memphis, TN. This year’s conference features internationally recognized demonstrator and tool maker, Brent Bailey, who will lead a session on power hammer and flypress tooling. Workshops, presentations, and demonstrations will bring smiths together from all over the country. A silent and live auction will include a range of forged, cast, and fine metals. All proceeds benefit the Metal Museum. Contact 901-774-6380 www.metalmuseum.org/fotr April–Oct., Blacksmithing and specialty classes The John C. Campbell Folk School in Brasstown, NC, is offering the following classes, among others: April -12: Blacksmithing Techniques, with a Twist April 12–14: Finishes on Metal April 21–2: Build a Table — Intermediate to Advanced April 2–May 3: Critters May 3–5: Beginning Blacksmithing — Fun with Fire May 5–11: Basic to Intermediate Blacksmithing May 12–1: 18th-century Tobacco and Smoking Implements May 1–25: Flowers in Metal May 2–31: Cock-a-doodle-doo May 31–June 2: Blacksmithing — Starting with Fire June 2–: Beginning Blacksmithing Techniques Aug. 4–10: Steel Repoussé — Chasing and Wonderful Colors Aug. 11–1: Copper Critters Sept. 2–Oct. 4: Mixed Metal Mania Contact 828-837-2775 (ext. 127) www.folkschool.org
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Fabricator n March / April 2013
What’s Hot? n
People
NOMMA board member Gina Pietrocola honored by National Association of Professional Women Gina Pietrocola, a long-time member of NOMMA and president of D.J.A. Imports Ltd., ornamental steel and gate hardware supplier, has been named “Woman of the Year 2012-13” by the National Association of Professional Women. Pietrocola is known for her longterm commitment as a volunteer in the Mahopac (New York) Central School District. A former special education teacher, Pietrocola has been a member of Mahopac Central School District SiteBased Teams for 17 years. Site-based teams are composed of five teachers, five parents, an administrator and a community member. They make recommendations about
Gina Pietrocola is the “quintessential school volunteer,” says Mahopac District Superintendent Thomas J. Manko.
curriculum and programs in specific schools, with a goal of improving the school experience for students, teachers and staff. Mahopac District Superintendent Thomas J. Manko called her “the quintessential school volunteer.” Pietrocola started her work at Lakeview Elementary School when her sons, David, Joseph and Alexander, were students.
“I wanted to be engaged,” she said. Later, she joined the middle school and high school Site-Based Teams and now serves those teams as a community member and chairperson. Pietrocola is completing her sec‑ ond term as a supplier member on NOMMA’s Board. She is also active in her local chapter (Northeast), is on the Nominating Committee, and served on several task forces during her six-year term on the Board. In regards to her volunteer work, she says, “I’ll keep doing it as long as I feel I am bringing something to the table.” In addition to NOMMA, Pietrocola is a member of other industry-related organizations.
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March / April 2013 n Fabricator
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What’s Hot? n Brush-on blackener Birchwood Technologies Presto Black BST4 brushon liquid from Birchwood Technologies is an instantacting cold blackener for all iron and non-stainless steels. When applied to a clean ferrous metal surface, the BST4 solution blackens within 30 seconds and forms a durable black finish that can be top coated to form an attractive, protective black oxide finish, says the company. In the machine shop, Presto Black BST4 liquid serves as a fast-acting blackener of re-machined areas or reworked metal parts. It’s useful as a quick repair for scratches or damaged areas
Products
on parts that were previously black oxide finished. For these applications, users degrease the surface using either a cold solvent wipe (alcohol, acetone or lacquer thinner) or a detergent wash, and then apply the BST4 liquid with sponge or swab. When the surface has turned sufficiently black, the liquid is rinsed off with
cold water and a water-displacing rust-preventive oil is applied for maximum corrosion protection. The resulting finish has a black color that blends well with existing black oxide finishes and will withstand the same degree of salt spray exposure as the original black oxide, says the company. Contact 952-937-7931 www. birchwoodtechnologies. com Fifty-ton ironworker Scotchman Industries Scotchman Industries has introduced the new 50514CM, five-station, 50-ton ironworker. There are five
stations on the 50514-CM, including: 1) A 50-ton punch station with 6-inch throat depth, which can punch 13/16-inch holes in ¾-inch material 2) A 4 x 4 x 3/8-inch angle shear 3) 14-inch flat bar shear capable of shearing ¾ inch x 4 inches, ½ inch x 8 inches, 3/8-inch x 10 inches and ¼ inch x 14 inches 4) The rectangle notcher, a new built-in feature, capable of notching 21/2 x 3 x 5/16-inches and/or 21/2 x 23/4 x 3/8 inches 5) The fifth station, located on the tool table workstation next to the angle shear, which allows an optional pipe notcher to be
Better than therapy. With a craft to show for it at the end of the session.
Pounding, bending, cutting…you can really work out some frustration creating something beautiful. Engaging hands and hearts since 1925. Come enjoy making crafts and good friends on 300 natural, scenic acres in western North Carolina.
JOHN C. CAMPBELL FOLK SCHOOL folkschool.org BRASSTOWN
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1-800-FOLK-SCH NORTH CAROLINA
Fabricator n March / April 2013
What’s Hot? n
Products
mounted without removing the angle shear. The 50514-CM has many standard features, including: adjustable stoke control, a keyed punch ram for safe and positive punch alignment, an electric box supplied with emergency palm button, lock-out tag-out accommodations, and all guards necessary to comply with ANSI B 11-5 standards. Contact 800-843-8844 www.scotchman.com
Explosion-proof LED light fixture Larson Electronics Larson Electronics has announced the release of an explosion-proof LED light fixture with higher-output second-generation LED lamps. The HAL-48-2L-LED-G2 Hazardous Location LED Light provides weatherproof construction, Class 1 Division 2 approval, and improved performance through the addition of second-generation LED lamps which boost output to 5,000 lumens, says the company. Designed for use in demanding environments, these lights feature copperfree aluminum housings,
TUBING BENDERS
aluminum reflectors with highgloss finish, shatter- and heat- resistant clear acrylic lens, and two second-generation LED tube lamps. The second generation LED lamps produce more than 2,700 lumens each, more than the previous LEDs and resulting in a total of over 5,000 lumens from 56 watts of power consumption. These LED tubes produce 98 lumens per watt, have a 5,600K color temperature, and carry a standard 50,000hour operational life rating, nearly twice that of standard
T8 fluorescent lamps. The housings on these explosion-proof fixtures resist corrosion and dampness and feature UL 595 Outdoor Marine Type and UL 1598A Marine approval. Power options include the standard 120-277 volt capability, and 12-24 volt DC configurations for use with low voltages. The HAL48-2L-LED-G2 is U.S.- and Canada UL-approved Class 1 Division 2 Groups A, B, C, and D, and carries a T4A temperature rating as well as approval for use in marine environments. These LED lights are designed for operators in hazardous locations who wish to upgrade to LEDs yet must also meet stringent requirements for resistance
Hand Tube Bender Rolls: 1 1/2” Square Tubing 1 x 1 1/2” Rectangular Tubing Flat Bar (1/2 x 1 1/2” & smaller) Pipe & Tubing
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$599.95
Channels
Flat Bar (on edge hard way) R&D Hydraulics, Mfg. and Machine Co. 1431 West 5th St. Chico, CA 95928 www.rdhs.com
March / April 2013 n Fabricator
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What’s Hot? n to corrosion and wetness, and provide improved performance over fluorescent lamps and older LED designs. Contact 800-369-6671 http://larsonelectronics. com Laser cutting system Mazak Optonics Corp. Mazak Optonics now offers the Super Turbo-X Champion with an available 2.5 kW resonator. Along with the new Type 10 resonator, the STX Champion can deliver a combination of economy, rugged construction and performance not found in lighter weight designs, says the company. Built on Mazak’s hybrid platform, which is known for rigidity, accuracy and durability, the STX Champion
Products
includes a 1,786-pound workpiece capacity for sheets up to 0.87 inches thick, high positioning accuracy, improved machine travel support, and easy loading access. Equipped with Mazatrol Preview function control, the STX Champion achieves improved efficiency and ease of use. Preview automatically determines the cutting speed and acceleration from each cutting point to the next and uses integrated technology tables for a wide range of materials and thicknesses. The product contains features to increase throughput and ROI. These standard features include: Mazak’s cutting-edge Type 10 resona-
abana.org ABANA
Association of North America, Inc.
Electronic pipe and tube belt sander Metabo Corp. Metabo Corporation is offering an electronic pipe and tube belt sander for burnishing, finishing and reconditioning steel, stainless steel, and non-ferrous pipe and tube. The RBE12-180 Pipe and Tube Belt Sander adapts to every contour and is easy to handle, says the com-
pany. The tool is designed to render weld seams invisible and to give stainless steel a mirror finish. The RBE12-180 features Metabo’s Marathon motor with 1,200 W and 10 A of power, double gear reduction for a high rate of material removal, an exact sanding belt guidance feature for even grinding results and a 270° maximum wrap angle that allows the tool operator to work more efficiently. The new pipe and tube finisher includes Metabo’s Vario Tacho Constamatic electronic speed stabilization for increased productivity. Contact 800-638-2264 www.metabousa.com
Restoring the Past. Building the Future.
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Artist-Blacksmith’s
tor with Eco mode, a power conveyor to reduce required floor space and three pneumatic workpiece clamps to help position and secure full sheets and remnants during cutting. Contact 847-252-4500 www.mazakoptonics.com
www.restoremedia.com www.period-homes.com www.traditional-building.com www.traditionalbuildingshow.com www.traditionalbuildingportfolio.com www.tradwebdirectory.com www.traditionalproductgalleries.com www.buildingport.com Questions? Call Peter H. Miller, President: 202.339.0744 x 104. Or email pmiller@restoremedia.com
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Fabricator n March / April 2013 Fabricator RM house ad.indd 1
10/14/2011 12:45:08 PM
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Advertiser’s Index A thanks to the following advertisers for their support of O&MM Fabricator magazine. Pg Company
Website
Pg Company
Website
39 Albina Pipe Bending Co................www.albinapipebending.com
62 Hougen Mfg. Inc................................................... www.hougen.com
21 Architectural Iron Designs Inc.............www.archirondesign.com
56 International Gate Devices.................................www.intlgate.com
11 Architectural Metal Works.........................www.architectural-metal-works.com
76 The Iron Shop...............................................www.theironshop.com
72 Artist-Blacksmith’s Assoc. of North America Inc.................................................www.abana.org 71 Atlas Metal Sales............................................. www.atlasmetal.com 49 Ken Bergman & Assoc., LLC........................www.haberleusa.com 18 Big Blu Hammer Mfg. Co. / Oak Hill Iron Works................................www.bigbluhammer.com 55 Blacksmiths Depot / Kayne & Son Custom Hardware Inc...................... www.blacksmithsdepot.com 41 Julius Blum & Co. Inc.....................................www.juliusblum.com 29 The Cable Connection................. www.thecableconnection.com 70 John C. Campbell Folk School.......................www.folkschool.org 43 Carell Corporation........................................... www.carellcorp.com 33 Chicago Metal Rolled Products Co...................... www.cmrp.com 56 Colorado Waterjet Co........................www.coloradowaterjet.com 45 Custom Ornamental Iron Works Ltd.....................................www.customironworks.com 13 D & D Technologies (USA) Inc............... www.ddtechglobal.com 9 D.J.A. Imports Ltd........................................... www.djaimports.com 69 Doringer Cold Saw............................................. www.doringer.com
20 Jesco Industries Inc. WIPCO div................ www.jescoonline.com 75 King Architectural Metal............................... www.kingmetals.com 4 Krando Metal Products Inc................................ www.Krando.com 6 Lawler Foundry Corp................................www.lawlerfoundry.com 2 Lewis Brass & Copper Co. Inc..................... www.lewisbrass.com 70 Lindblade Metal Works...............www.lindblademetalworks.net 40 Marks U.S.A.........................................................www.marksusa.com 67 Mittler Bros. Machine & Tool...................... www.mittlerbros.com 68 Pat Mooney Inc.....................................www.patmooneysaws.com 54 National Bronze & Metal............................. www.nbmmetals.com 44 National Custom Craft Inc..........www.nationalcustomcraft.com 69 NC Tool Company Inc........................................www.nctoolco.com 71 R & D Hydraulics Mfg. & Machine Co....................www.rdhs.com 58 Regency Railings.....................................www.regencyrailings.com 55 Rogers Mfg. Inc........................................ www.rogers-mfg-inc.com 37 Scotchman Industries................................... www.scotchman.com 51 Sharpe Products.................................... www.sharpeproducts.com 63 Simonian Bender.................................www.simonianbender.com 35 Stairways Inc.................................................................. 800-231-0793
43 Eagle Bending Machines Inc........................... www.eaglebendingmachines.com
53 Suhner Industrial Products Corp................ www.suhnerusa.com
59 Eberl Iron Works Inc..........................................www.eberliron.com
60 Sumter Coatings Inc..............................www.sumtercoatings.com
23 Electron Beam Technologies Inc......... www.electronbeam.com
72 Traditional Building....................... www.traditional-building.com
27 FabCAD Inc.............................................................. www.fabcad.com
42 Tri-State Shearing & Bending.................................... 718-485-2200
19 Feeney Inc...........................................................www.feeneyinc.com
23 Vogel Tool & Die LLC........................................ www.vogeltool.com
63 Goddard Manufacturing Co...............www.spiral-staircases.com
31 The Wagner Companies.................www.wagnercompanies.com
25 Hebo - Stratford Gate Systems Inc.....www.drivewaygates.com
Your advertising contact for O&MM Fabricator NOMMA Buyer’s Guide NOMMA website CO NTAC T
Sherry Theien Advertising Director 8392 Leesburg Ct. Rockford, IL 61114 815-282-6000 815-282-8002 fax stheien@att.net March / April 2013 n Fabricator
Advertise in the 2014 NOMMA Buyer’s Guide Your one-stop resource for shop and office personnel The Buyer’s Guide is available in 3 versions: 1) print, 2) online, and 3) database. Closing date November 30, 2013 Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; stheien@att.net 73
n
Metal Moment
Handling existing ironwork — part 2 Editor’s note: NOMMA often gets calls on the restoration, maintenance, and repair of ironwork. The following is adapted from a popular article in our online archives, and serves as an unofficial “best practices.” Part appeared in the Jan.-Feb. Fabricator. This article first appeared in the Jan.-Feb. Fabricator and is reprinted with permission from The Golden Age of Ironwork by Henry Jonas Magaziner. Working on a cast iron restoration project? Get this full “best practices” article at the NOMMA website. Members should click on “Fabricator,” then “Best of Fabricator Series” and then download “Good Ironwork Practice.” Repair and maintenance of iron n Once an iron casting is clean, various imperfections may appear. Some may even go back to the original manufacture of the casting. Discoveries may include cracks, air holes, cinders, or cold shuts — the latter caused by interrupted pouring or “freezing” of the surface during casting. Occasionally, old castings are excessively brittle. Sometimes they have impact damage, structural failure, broken joints, damaged connections, missing elements, or loss of anchorage in masonry. Non-structural small cracks and holes may be filled with epoxy steel.
above. Replacement castings can be aluminum, which was not available during the cast iron period. It will not rust. To prevent electrolytic action, insulate the aluminum from the iron. Spar varnish is good for that. Use only stainless steel pins or fasteners to reassemble old units or to add new ones. Painting existing exterior ironwork n Once all repairs have been made and any necessary replacements added, paint all exterior ironwork immedi-
ately. Otherwise, it will rust. Regardless of which paint system is used, the surfaces must be properly prepared. Clean the ironwork, free of rust, scale, grease, or oil. Poorly prepared surfaces will not retain even the best paint. n Never paint on a wet or damp surface; during a fog, mist, or rain, or when the relative humidity is above 80 percent; if the temperature is expected to fall below 50° F within 24 hours. Preferably, do not paint ironwork in direct sunlight. The paint dries too quickly. n Cover the metal with quality rust-inhibitive metal primer. is badly corroded and many of
The cemetery fence, left, the elements will likely need replacing. The mausoleum door, right, has many layers of paint that should be carefully removed.
n Red lead was once the traditional primer. It is tough,
elastic, and impervious to water. However, it contains heavy metal compounds and is toxic, as is zinc chromate, another good n Although cast iron is difficult to weld, it can be welded if the welding rod is pure nickel. Sometimes internal stresses primer, so now both of them are prohibited in most areas. build up at the interface with the nickel and may cause (Some areas do allow their use for industrial purposes.) under-bed cracking or breaking of the cast iron. To relieve n Alkyd or acrylic primers have replaced them. While such stresses, peen all nickel welds with a chipping hammer. these dry faster, their effective life is shorter. Alkyd rustinhibitive primers contain pigments such as iron oxide, zinc n Important. Never weld cast iron structural members. Defective structural members must be replaced; do it with oxide, and zinc phosphate. Such primers are suitable for steel. Replace any cast iron structural members found to be less replacement parts and for cleaned, previously painted surthan 3/8-inch thick. Replace them with steel if parts of a castfaces. One coat, or better yet two, should be used. ing are needed. Prepare a pattern. It should be exactly like the n After priming, finish coats of alkyd enamel or, for betdesired casting but slightly larger since iron shrinks 1/8 inch per ter color and gloss retention, silicone alkyd. Ensure the finfoot as it cools, changing from molten metal to a solid casting. ish paint contains rust inhibitors, fungicides, and ultraviolet Place the pattern, very firmly, into a bed of clay-stabilized sand. blockers. For longer protection, zinc-rich primers with zinc Remove it. Then pour molten iron into the void. dust can be used. However, only use such primers on new sand blasted pieces, shop cleaned to a “bare white” condition. n To save time and expense, use an existing similar casting as a pattern. The resulting new casting will be slightly n Never use water-based latex house paints as primers on smaller than the original due to the shrinkage mentioned bare iron. They will cause immediate rust. TA LK TO US
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Fabricator n March / April 2013