Sept/Oct 2014 O&MM Fabricator by National Ornamental & Miscellaneous Metals Assn.

Ornamental and Miscellaneous Metal

Fabricator ÂŽ

The official publication of the National Ornamental & Miscellaneous Metals Association

September / October 2014 $6.00 US

2014 Top Job Gold Award Category: Structures

Inspiring World Trade Center beacon Coveted beaconhousing project reflects growth of Kammetal in remarkable way page52

Shop Talk Welding hot-dip galvanized, page 14

Shop Talk Oxy-fuel tips, page 28

Biz Talk What a fabricator is doing with $250,000, page 66

Member Talk Philippe Fiersâ&#x20AC;&#x2122; guild success, page 42

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Forging Your Future | Networking Membership in the National Ornamental & Miscellaneous Metals Association (NOMMA) offers a unique opportunity to meet and interact with the best and brightest in the ornamental and miscellaneous metalworking industry. The connections you make here will serve you in the future when questions arise, youâ&#x20AC;&#x2122;ll know what colleagues to call. NOMMA interactions lead to profitable collaborations, new jobs, and lifelong friendships. NOMMA serves its members and advances the industry through education and the promotion of a positive business environment. By becoming involved in NOMMA, you have a chance to add your voice to the conversations that shape and grow the industry. There is no better way to ensure your businessâ&#x20AC;&#x2122;s needs are part of the discussion than by being at the table with the leaders and technical minds that are shaping the future.

NOMMA events are the real power in our unique culture of sharing. Each offers an excellent opportunity to learn, network and share tips and techniques. METALfab Convention is the ultimate place to network and view the latest techniques and products. Our members also have the opportunity to meet and connect with colleagues to share ideas, challenges and succuess stories in Chapter Meetings, NOMMA ListServ (email discussion list) and Roundtable Conference Calls. Visit www.nomma.org today to discover many more compelling reasons to become part of NOMMA family.

Forging Innovation . Shaping Business . Delivering Profits

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Inside

September / October 2014 Vol. 55, No. 5

NOMMA Network

Member Talk

Northeast Chapter views gate operators demo................... 10

Also: NOMMA loses a passionate member, Setrak O. Agonian............. 11 Shop Talk Whether to weld before or after hot-dip galvanization........................ 14

The implications are different when welding steel before or after the hot-dip coating is applied. Understanding ASTM guidelines helps. This article examines the pros/cons of each process. By Dan Barlow

Filippe Fiers’ guild training helps guide his success................... 42

Philippe Fiers brings the classical fabrication skills of Les Compagnons Du Devoir to Armadillo Metalworks, and the company enjoys ‘gilded’ for tune in New York City’s high-end residential market. Top Job Profile One World Trade Center beacon housing inspires................. 52

Beating a dozen or more firms, Kam metal marks its growth as a most capable job shop by winning a highly coveted assignment: a beacon housing made of ¼-inch, 316L stainless steel for the new One World Trade Center. By Molly Badgett Welding slag

Shop Talk Primer on oxy-fuel.............................. 28

All cutting tools can have a place in your shop, if they match up with your work. This article examines oxy-fuel technology and a number of tips, too. Also: 8 tips to get the most out of your torch................................. 32 Also: 10 basic ornamental techniques........................................... 41 President’s Letter........... 7

NEF works for you.

A versatile combination oxy-fuel torch, above left, can do it all, especially the pinpoint heating required for ornamental drawing, scrolls and twists. Story, page 28.

Living Design Studios wins small business grant from Mission Main Street because of its solid business plan, community impact, and strong team. By Linda Erbele Also: How to get a Mission Main Street grant.............. 68 Ready to work at Living Design Studios.

What’s Hot! Architectural Billings Index signals improving conditions. n Feeney opens East Coast distribution facility. n

Competitiveness vs. profitability............................................... 62

What is the difference between being competitive and being profitable? Author and contractor consultant Michael Stone examines the concepts and offers essential how-to tips to keep you focused properly. By Michael Stone Also: 4 ways to handle “change work orders.”........................64

Ways to take your business pulse.

What a Fabricator is doing with a $250,000 grant....................... 66

News....................................................... 75

Biz Talk

Exec. Director’s Letter.... 8

Biz Talk

Media..................................................... 77 Products............................................... 79 NOMMA Supplier Members........ 73 New NOMMA Members................. 74 Ad Index................................................ 81

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

Finishing SS pipe rail video posted for members.

Metal Moment............... 82

Student cutting-welding contest deadline is Oct. 31.

About the cover The beacon with its housing made of ¼-inch, 316L stainless steel is raised atop One World Trade Center in New York City. Kammetal, Brooklyn, NY, won the 2014 NOMMA Top Job gold award in the Structures category for this job. See story, page 52 . September / October 2014 n O&MM Fabricator

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President’s Letter

NEF works for you This year, we added an option to which was launched in March include a financial donation to 2006. This program provided the NOMMA Education Founthe funds needed for NOMMA dation (NEF) with your memto conduct its “climbability” bership renewal. I’m thrilled at research project from 2006– the donations we’ve received 2008. The funds were used through this program, and I to create a 176-page, peerwant to thank every member reviewed study which provided Mark Koenke, who has given. evidence that existing rail codes Germantown I recently had the honor of were meeting public safety Iron & Steel serving as a NEF trustee, and I Corp, is needs. am in awe of our foundation’s Following the release of the president of NOMMA. great work. study, the International Code If you are wondering what Council’s Code Technology NEF does, the answer is simple — Committee voted to take “no further NEF provides the education for action” on the issue. NOMMA and the industry. NEF’s most visible work is during Numerous ways to donate METALfab, where the foundation proIn addition to sending a donation vides the entire education program. in with your membership renewal, you Just providing the convention educacan also donate funds via our website. tion is a major task, but NEF does so I also encourage you to participate much more. in our annual auction, either by donating an item or by bidding at the event. NEF works for the industry The auction is NEF’s primary fundTypically, 2–3 times a year NEF raising effort, and your support of this provides hands-on continuing eduprogram is important. cation programs around the country, NEF is a 501(c)(3) charitable as well as pre-convention workshops organization, and donations are tax during METALfab week. deductible. Webinars. The foundation also We also encourage members to give hosts webinars and provides grants through bequests and by making confor chapters to bring in speakers. Past tributions in honor of deceased loved topics have covered everything from ones. building codes to manufacturing prinIn summary, I wish to thank the ciples. board of trustees and NEF executive Grants. Most recently, working director Martha Pennington for all the in tandem with the Upper Midwest hard work they do. Chapter, NEF rolled out its newThe trustees have turned NEF into a professionally run organization that est program — the Todd Kinnikin prudently re-invests all proceeds back Memorial METALfab Scholarship, to the industry, and stretches every which provides selected members with dollar. financial assistance for attending the I am grateful for their work. convention. Video tutorials. Another major outreach of NEF is video education, and our foundation provides video tutorials, taping of conference sessions, and full production education videos. A last but most important part of NEF is the Lawler Research Program, September / October 2014 n O&MM Fabricator

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

President Mark Koenke, Germantown Iron & Steel Corp. Jackson, WI President-Elect Allyn Moseley, Heirloom Stair & Iron, Campobello, SC Vice President/Treasurer Keith Majka, Majka Railing Co. Inc., Paterson, NJ Immediate Past President J.R. Molina, Big D Metalworks, Dallas, TX

F ABRICATOR D I RECTORS

Greg Bailey, Bailey Metal Fabricators, Mitchell, SD Max Hains, Mofab Inc., Anderson, IN Maciej Jankowski, Artistic Iron Works, Norwalk, CT Tina Tennikait, Superior Fence & Orn. Iron, Cottage Hills, IL Cathy Vequist, Pinpoint Solutions, Jupiter, FL Henry Wheeler, Wheeler Ornamental Metals, Dothan, AL

S U PPLI ER D I RECTORS

Bill Schenke, Ameristar, Tulsa, OK Mark Sisson, Mac Metals Inc., Kearny, NJ Dave White Jr., Locinox USA, Countryside, IL

NOMMA E DUCATION F OU N DATION O FFICERS

Co-Chairs Roger Carlsen, Ephraim Forge Inc., Frankfort, IL Lynn Parquette, Mueller Ornamental Iron Works Inc., Elite Architectural Metal Supply LLC, Elk Grove Village, IL Treasurer Mike Boyler, Boyler’s Ornamental Iron Inc., Bettendorf, IA

NEF T RUSTEES

Heidi Bischmann, Hartland, WI Carl Grainger, Grainger Metal Works, Nichols, SC Mark Koenke, Germantown Iron & Steel Corp., Jackson, WI Christopher Maitner, Christopher Metal Fabricating, Grand Rapids, MI Rob Rolves, Foreman Fabricators, St. Louis, MO Greg Terrill, Division 5 Metalworks, Kalamazoo, MI

NOMMA C HAPTERS

Chesapeake Bay Patty Koppers, President, Koppers Fabricators Inc. Forestville, MD 301-420-6080 Florida Marco Vasquez, President, Vasquez Custom Metals Inc., Tampa, FL, 813-248-3348 Gulf Coast Randy LeBlanc, President, Metal Head Inc., Lafayette, LA, 337-232-38383 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 Harris Sales Director, Sherry Theien Editor, O&MM Fabricator, Robin Sherman

F ABRICATOR E DITORIAL A DVISORY B OARD

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

Ornamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA). O&MM Fabricator / NOMMA 805 South Glynn St., Ste. 127, #311 Fayetteville, GA 30214 Editorial We love articles! Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph/Fax: 888-516-8585. E-mail: fabricator@nomma.org. Advertise Reach 8,000 fabricators For information, call Sherry Theien, Ph: 815-282-6000. Email stheien@att. net. Ads are due on the first Friday of the month preceding the cover date. Send ads to: Fabricator at address above. Email ads to: fabricator@nomma.org (max. 5 megs by e-mail). Or upload ads to our website where a downloadable media kit is available: www.nomma.org. Membership Join NOMMA! Beyond the magazine, enjoy more benefits as a NOMMA member. To join, call 888-5168585, ext. 101. For a list of benefits, see membership ad in this issue. Exhibit in METALfab Exhibit at METALfab, NOMMA’s annual convention and trade show. For more information, contact Martha Pennington at 888-516-8585, ext. 104, or martha@nomma.org. Subscriptions Subscription questions? Call 888-516-8585. Send subscription address changes to: Fabricator Subscriptions, 805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214. Fax: 888516-8585, or fabricator@nomma.org. 1-year: U.S., Canada, Mexico — $30 2-year: U.S., Canada, Mexico — $50 1-year: all other countries — $44 2-year: all other countries — $78 Payment in U.S. dollars by check drawn on U.S. bank or money order. For NOMMA members, a year’s subscription is a part of membership dues. NOMMA Buyer’s Guide Published each December as a separate issue. Deadline for all advertising materials is October 31. Contact Sherry Theien at 815-282-6000 or stheien@att.net. Opinions expressed in Fabricator are not necessarily those of the editors or NOMMA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA.

How to reach us

Executive Director’s Letter

Ways to take your business pulse I am not an expert, but I get liabilities. If your quick ratio asked questions about financomes to at least 1.1, you can cial performance so often that I take a sigh of relief. I won’t torthought I’d share some tips. ture you with all the accounting You can check your comjargon, but I do encourage you pany’s vital signs in numerous to educate yourself by visiting ways. One of the basic questions various financial websites. is, “Hey, did I make a profit last Todd Daniel For a “plain English” discusis executive year?” sion on ratios, visit: www. To determine this, first make director of firepolemarketing.com/ NOMMA. sure you and the other princikey-financial-ratio. I’d also pals are drawing a reasonable salary, advise you to take a class at your local and then calculate your after-tax net college on reading financial statements. profit margin. If you are not making at least 6% Cashﬂow profit after principal salaries, you may I also talk with members who are need to examine your company’s health. struggling with cashflow, which is a One website that gives you an idea major killer. If you are facing this probof average performance is bizstats. lem, you can try a few strategies: com. I encourage you to play around n Instead of buying capital equipwith the site to see how you compare to ment that you’ll rarely use, outsource industry averages. work. If you do purchase equipment, consider a lease if you need to conserve Industry reports cash. You can obtain good comparison n On the flip side, it’s always good data by ordering a report from the Risk to pay down debt, but if you do it to Management Association (www.rmahq. quickly, you’ll feel the squeeze. Conorg) in Philadelphia. sider restructuring your debt. The report provides industry avern If your receivables continue to ages, and even though it will reduce grow, that means trouble. Consider your profits by $145, it’s still worthwhile reviewing your credit policies. to purchase it every few years. When ordering, you’ll be asked for our indus- Summary try’s NAICS code, which is 332323. At my first job at a fast-food joint my boss said, “Todd works and works Financial ratios and never gets anything done.” It’s good to regularly check your If you are having that same feeling company’s health by viewing three key you may want to give your company ratios: a medical checkup by following the 1 Liquidity ratio. tips above. 2 Activity ratio. 3 Profitability ratio. Among the most important liquidity ratios is your quick ratio, which is assets less inventory, divided by current F I LE S, U R JO B P RO CA LL FO R YO

TI PS

Are you a NOMMA Top Job winner? Do you have how-to, step-by-step tips to share? Have you solved an interesting fabrication problem? Write for Fabricator. Contact Editor Robin Sherman at nomma.editor@att.net.

O&MM Fabricator n September / October 2014

KNOWLEDGE to enlighten the industry.

METALfab 2015

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Forging Innovation . Shaping Business . Delivering Profits National Ornamental & Miscellaneous Metals Association t: 888.516.8585 f: 888.279.7994 www.nomma.org

The NOMMA Network Northeast Chapter enjoys gate operators demo At their July meeting, Northeast Chapter members were treated to a demo on gate operators, which was presented by Paul Cardillo of Power Door Products, Brewster, NY. The presentation covered swing, slide, barrier, and vertical pivot gates, as well as access controls and safety standards. The 25 attendees also toured Architectural Iron Designs and Papp Iron Works, both of Plainfield, NJ, which served as hosts for the day. For a special treat, Allan Papp gave a presentation on his collection of Samuel Yellin pieces. The chapter meeting also featured a meet-and-greet social time, business meeting, and lunch. Thanks to the team at Architectural Iron and Papp Iron Works for serving as outstanding hosts for the day.

Top, Allan Papp, at right, leads a plant tour of Papp Iron Works for members of the NOMMA Northeast Chapter. Above, chapter members take a moment to relax. Shown are Bob Balchunas, Advanced Cutting Services; Paul Montelbano, Duke of Iron; Keith Majka, Majka Railing Co.; Joey Romeo, Industrial Coverage; and Maciej Jankowski, Artistic Iron Works LLC. Left, chapter members also toured Architectural Iron and Papp Iron Works to learn and network.

NOMMA volunteers needed for booth staffing at upcoming shows FABTECH, which takes place November 11–13 at the Georgia World Congress Center in Atlanta, GA. n FENCETECH, which will be held February 4–6 at the Orange County Convention Center in Orlando, FL. n

Volunteers will be asked to work a half-day shift. During your shift you’ll pass out literature and educate attendees on NOMMA’s programs and services, as well as membership benefits. To help, contact Todd Daniel at the NOMMA office (todd@nomma.org, 888-516-8585, ext. 102). 10

O&MM Fabricator n September / October 2014

NOMMA loses a passionate member

ratively through an association to advance their businesses. In addition to metalwork, Setrak’s other love was amateur wrestling, and he was involved in the sport for most Setrak O. Agonian, 74, died on August 5. He was of his career. In 2003 he was named “USA Wresthe founder of International Creative Metal Inc. of tling Man of the Year.” His contributions to wresWoodside, NY, a NOMMA member since 1988. tling, boxing, and other amateur sports are vast and Setrak was passionate about NOMMA and a included many international events. regular participant in METALfab and the Top Job He was a long-time member of his local Kiwanis contest. He was active in the old New York ChapClub and was named “Member of the Year” in 1988. ter and occasionally hosted meetings. He was an Setrak was proud of his Armenian heritage, as well O. expert in bronze fabrication and his high-end proj- Setrak as his American citizenship. He held on to the tradiAgonian ects can be found throughout New York City and tional values and the belief that with hard work anyone around the world. in this country can still achieve the American dream. He was a strong supporter of NOMMA and continually He is survived by his wife Didi Agonian, who is also promoted the association to local architects and fabricators. involved in the business. Setrak saw the great value of metalworkers working collaboServices were held August 11 in New York City.

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NOMMA Northeast Chapter members also viewed product samples that adorned the walls at Architectural Iron Designs.

September / October 2014 n O&MM Fabricator

NOMMA Education Foundation

In partnership with the National Ornamental & Miscellaneous Metals Association

Finishing SS pipe rail video posted for members Curved stair continuing education class set for September 27 The NOMMA Education Foundation recently released a new video on “Finishing Stainless Steel Pipe Rail.” This demonstration was given at the May 2014 Upper Midwest Chapter Meeting hosted by The Wagner Companies, Milwaukee. The video is available for NOMMA members in the member’s only section of the NOMMA website, www.nomma.org.

NEF Continuing Education Class — September 27, 2014 Field measuring for a curved stair and the latest measuring technology

NEF co-chairs: Lynn Parquette, left, owner, Mueller Ornamental Iron Works Inc. & Elite Architectural Metal Supply LLC and Roger Carlsen, owner, Ephraim Forge Inc.

About the video Video Title. Finishing Stainless Steel Pipe Rail Presenter. Kane Behling, manufacturing operations man-

ager for Wagner.

Content of video. Demonstrates proper welding, refinishing, and pre-finishing stainless steel materials to make a two line railing section. Special emphasis is placed on preparation, using of proper safety equipment, and working in a clean environment. NEF thanks Wagner and its employees for hosting the meeting and Upper Midwest Chapter members for inviting NEF to record the presentation.

Kane Behling, left, pipe rail session instructor.

Don’t miss this learning experience — a one-day continuing education program hosted at Germantown Iron & Steel Corp, Jackson, WI.

Presenters. Mark Koenke, Germantown Iron & Steel Corp., and Mark O’Malley, O’Malley Welding & Fabricating Inc.,Yorkville, IL. Mark Mark Outline of class content Koenke O’Malley n How to take the field measurements and create a CAD shop drawing. n Stair layout in the shop of flat plate stringer. n Process for rolling curved plate stringer and sending proper information to supplier. n Assembly of plate stringers and stair pans.

Registration $250 NOMMA Members/$350 non-members. Fee includes class materials, supplies, lunch. Register on-line at www.nomma.org or email martha@nomma.org for a registration form. Register early — class is limited to 15 participants. This is an excellent opportunity to network with a small group of fabricators while expanding your skills. You will receive a confirmation with hotel information and the address of Germantown Iron & Steel Corp.

Left, Upper Midwest Chapter members watching finishing stainless demo during filming. DO N AT E!

For more information on donating to the NOMMA Education Foundation Contact NEF Executive Director Martha Pennington, 888-516-8585 x104, martha@nomma.org. 12

O&MM Fabricator n September / October 2014

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Whether to weld before/after hot-dip galvanization n

The implications are different when welding steel before or after the hot-dip protective coating is applied. Understanding ASTM guidelines helps. This overiew examines the pros and cons of each fabrication process.

Bulges. High silicon content in the weld material creates a bulging appearance.

By Dan Barlow Hot-dip galvanized steel has been a mainstay of North American industry for more than 150 years because of its longterm corrosion protection. As new technologies and creative chemistries continue to evolve, the specification of hot-dip galvanized steel has extended into many markets. Today, hot-dip galvanizing is specified not only for its corrosion protection, but also for its durability, maintenance-free longevity, and sustainability, as well as the aesthetically pleasing appearance of the zinc coatingâ&#x20AC;&#x2122;s natural, matte gray finish. The sustainability of hot-dip galvanized steel is made evident by itâ&#x20AC;&#x2122;s Life-Cycle Assessment found on the website of the American Galvanizers Association (AGA), Centennial, CO (www.galvanizeit.org). As the specification of hot-dip galvanized steel increases, as shown in the AGAâ&#x20AC;&#x2122;s annual market performance reports, fabricators are looking for more information on best practices when fabricating materials to be hot-dip galvanized. 14

Welding is one area where questions arise. Hot-dip galvanizing can be used successfully with welded fabrications both before and after the protective coating is applied. Welding before galvanizing and welding after galvanizing are two different processes, and as such, each one should be understood individually. In this article, we will look at the nature of the two processes, the design considerations associated with each, and the pros and cons of choosing one method over the other. Welding before galvanizing

Welding steel assemblies together before they are hot-dip galvanized ensures the fabricator will have the best chance to create a beautiful and continuous coating. Unpleasant experiences with unsightly splatter marks or a bulging appearance around a weld area, may have turned some fabricators away from welding before galvanizing. O&MM Fabricator n September / October 2014

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® 15

A full seal weld prevents cleaning chemicals from entering overlapping areas.

Using caution, a hot-dip galvanized coating may successfully be ground down to uniformity.

Welding rods tested by the AGA that produce coatings comparable to low-silicon steel Welding Welding rod Silicon process material content SMAW

Welding slag that remains after cleaning may leave uncoated areas around theAd weld. Proof - NOMMA

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Fleetwood 35 LS

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Leetwood 7

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However, these appearance issues all have simple ways in which they can be resolved. Following proper design procedures eliminates the need for extensive repair of the galvanized coating before it is put into service. Here are a few considerations when welding before galvanizing. Weld metal chemistry

When welding before galvanizing, the selection of the weld rod chemistry is important for the final appearance of the weld. The hot-dip galvanizing process coats almost any type of steel or iron, and the steel’s silicon content is the primary factor determining how thick the coating will be. Some welding rods contain silicon contents as high as 1%, causing a rapid growth of the galvanized coating when the steel or iron article is immersed in the bath of molten zinc. This coating thickness growth will generally be much greater than a steel that has silicon content of 0.2%. Because the steel and the weld will experience the same immersion time in the galvanizing kettle, the difference in growth rates creates a bulging or swollen appearance from a thicker coating on the weld material. This may happen even if the weld was ground flat before the article or fabrication was hot-dip galvanized. Choosing a welding rod material with a silicon content near the percentage found in the steel, or a material previously shown by the AGA to produce a thinner coating (see table below), achieves the goal of a high-quality, uniform, and visually appealing coating. However, if the piece has already been fabricated and galvanized, the coating in the area of the weld may be ground down to match the thickness of the coating on other areas of the fabrication. Grinding should be done cautiously to not damage the remaining coating or to not leave a bare area. Once finished the coating should still meet the minimum average thickness requirements of ASTM A123, Standard Specification for Zinc (HotDip Galvanized) Coatings on Iron and Steel Products. O&MM Fabricator n September / October 2014

CELEBRATING

YEARS! Est. 1939

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Weld cleanliness

Excessively cold

Another item that can working a fabrication significantly impact hot-dip galvanizing’s coating appear- — reshaping the steel ance around the weld is its at low temperatures cleanliness. Galvanizers use — introduces enough a series of chemical cleaninternal stress to raise a ing baths, including caustic cleaning and acid pickling concern of distortion. baths, to prepare the steel surface for the zinc coating. Zinc reacts with steel immersed in the galvanizing kettle only when the surface of the steel is completely clean. The cleaning solutions used in the hot-dip galvanizing process cannot remove welding slag or welding flux from steel. This results in small uncoated spots around the weld; therefore, slag and flux must be removed from the steel surface before galvanizing by wire brushing, flame-cleaning, chipping with a pick, grinding, or abrasive blast cleaning. Design considerations

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Hot-dip galvanizing entails fully immersing steel fabrications in a bath of molten zinc, and allowing the zinc to run throughout the piece. When you heat steel to galvanizing temperatures (830° F/443° C), it becomes flexible, which can cause or relieve stresses in the material, especially in joined areas. Keep the process temperature and necessity for zinc to flow freely to coat all surfaces in mind when welding before galvanizing. Molten zinc’s viscosity prevents it from entering any space between overlapping materials smaller than ⁄ inch (2.5 mm), leaving these tight spaces ungalvanized after immersion in the kettle. The small space becomes the residency of salt crystals as the liquid cleaning solutions evaporate in the galvanizing bath. The salt crystals can absorb water when exposed to the atmosphere and interact with the uncoated steel to form rust. A full seal-weld on all edges of overlapping areas with less than ⁄ inch prevents the cleaning solutions from penetrating into the overlapping areas and thus causes this unsightly and corrosive issue. The size of the enclosed area is important as detailed in ASTM A385 Standard Practice for Providing High-Quality Zinc Coatings (Hot-Dip). Another design concern when immersing welded fabrications is stress relief at elevated temperatures, which may cause strains in the material. These strains can distort the shape of the fabrication, potentially detracting from the usefulness of the product. However, similar to the issues with weld rod chemistry, following a few simple design guidelines minimizes the risk of distortion as described in ASTM A384 Standard Practice for Safeguarding Against Warpage and Distortion During Hot-Dip Galvanizing of Steel Assemblies. Using symmetrically rolled sections, and designing fabrications with a symmetric design, minimizes the chance for distortion. Unbalanced welding procedures can also cause uneven thermal stresses within the structure. O&MM Fabricator n September / October 2014

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Fabrications using continuously welding. Clamps, holding the material welded joints and even thicknesses to be welded, should only hold matepossess a much smaller chance rial in place without forcing it into the of being distorted during the gal correct position. Parts used in fabricavanizing process. tion should be accurately pre-formed. Excessively cold working a fabrication — reshaping the steel at low Pros and cons temperatures — introduces enough Welding before galvanizing prointernal stress to raise a concern duces a beautiful, continuous zinc of distortion. coating that provides corrosion proTherefore, all fabrications should tection performance. Having the Ad_2011:Layout 10:09 AM entire Page fabrication 1 avoid cold-working1and2/7/11 refrain from galvanized at one forcing the material in place before time eliminates the need for extensive

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repair after welding. If the material were to be galvanized separately and the pieces welded together afterwards, large areas of repair would be necessary along the entire welding seem. Usually, the use of zinc-rich paint, according to ASTM A780 Standard Practice for Repair of Damaged and Uncoated Areas of Hot-Dip Galvanized Coatings, repairs these areas. The appearance of the paint may differ from the rest of the coating and may not weather in the same manner. The benefits of properly welding before galvanizing outweigh the drawbacks of doing so. Some aspects of welding before galvanizing can be considered disadvantages: 1) An extended specifying process that includes finding a weld rod material suitable to be hot-dip galvanized. As discussed earlier, not all welding rods react the same with molten zinc. The varying reactions may produce excessively thick coatings on the welds causing an uneven appearance. 2) The need to follow specific design practices to ensure a high quality galvanized coating. The specifier must consider distortion, seal welding, and weld cleanliness — all detailed in ASTM A384 and A385. Although welding before galvanizing may take a little more time and effort in the planning stage, the quality of the finished product will be worthwhile. The corrosion protection and overall appearance of the coating will have a higher quality if your fabrication is welded before galvanizing. The uniform appearance and protection is especially desirable for those in the ornamental metals industry.

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At times, design, schedule, or other factors force a fabricator to weld material together after it has been galvanized. Using this method may compromise the uniformity of the galvanized coating, but methods exist to repair the coating to restore the corrosion protection lost in the area of the weld. While welding after galvanizing avoids some steps during the design O&MM Fabricator n September / October 2014

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stage, it adds some steps after the pieces have been welded together to ensure corrosion protection. Remove coating

Areas requiring repair will vary in appearance from the rest of the coating. Welding steel assemblies together before they are hot-dip galvanized ensures the fabricator will have the best chance to create a beautiful and continuous coating.

The American Welding Societyâ&#x20AC;&#x2122;s AWS D19.0, Welding Zinc-Coated Steel, contains instructions for welding steel that has previously been hot-dip galvanized without removing any of the coating in the weld area. The specification covers the specific methods needed for welding galvanized steel with processes such as gas metal-arc welding, shielded metal-arc welding, submerged arc welding, and more. However, following these procedures proves to be difficult in some instances because of a risk of zinc entering the weld and compromising the weldâ&#x20AC;&#x2122;s integrity. Therefore, the best practice is to remove the zinc coating on both surfaces to be welded or mask these areas before galvanizing, and proceed with a normal welding process on the bare steel. On steel of any thickness, a hand grinder, or perhaps sandblasting, sufficiently removes the zinc from the area of the weld exposing bare steel ready to be welded. The thickness of the steel to be welded dictates how much coating should be removed. For thicker pieces, where a larger area of the steel will be heated, removing the zinc coating up to 4 inches from the intended weld zone on both sides of the steel and on the edges will be necessary. On the other hand, thin pieces of steel only require the zinc be removed about 1 inch from the intended weld zone. Removing the zinc coating from galvanized steel, in proximity to the intended weld area before it is welded, ensures the weldâ&#x20AC;&#x2122;s properties will not be affected by zinc penetration and normal welding practices may follow. Weld metal chemistry

Steel pieces may be successfully welded after galvanizing. Using this method may compromise the uniformity of the galvanized coating, but methods exist to repair the coating to restore the corrosion protection lost in the area of the weld. 22

Unlike welding before galvanizing, the welding material chosen matters little when welding takes place after galvanizing. The coating repair material bonds with the weld material mechanically, not metallurgically. Therefore, no reaction will take place causing the bulging appearance O&MM Fabricator n September / October 2014

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Hot-dip galvanized steel may be welded after galvanizing if proper procedures are followed.

Zinc-rich paints can repair hot-dip galvanized coatings.

Zinc metallizing â&#x20AC;&#x201D; spraying the surface to be repaired with droplets of molten zinc â&#x20AC;&#x201D; also repairs hot-dip galvanized coatings, according to ASTM A780.

detailed earlier in welding before galvanizing. Standard welding procedures may be followed once the zinc coating has been properly removed from the proximity of the intended weld area. Repair

Removing the zinc from the area of the weld compromises the corrosion protection of the coating at the weld. While the remaining zinc will provide some cathodic protection in that 24

O&MM Fabricator n September / October 2014

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area, best practice dictates repairing the coating in the bare areas, according to ASTM A780. ASTM A780 lists three acceptable methods that can be used to repair a hot-dip galvanized coating: n Zinc-based alloy solders — melting a zinc alloy in rod or powder form unto the damaged area. n Zinc-rich paint — applying a paint with zinc dust concentrations 22144 NOMMA Sep Oct 2014.ai from 65%–69% or above 92% in the 1 dried film to the damaged area.

n Zinc metallizing — spraying the surface to be repaired with droplets of molten zinc. Much can be discussed about each one of these repair methods and each one is acceptable, according to the specification. Zinc-rich paints, which are not 100% pure zinc like most alloy solders and metalizing material, will have a different appearance than an unrepaired 8/12/14 1:51 PM hot-dip galvanized coating and may also weather in a different manner.

Pros and cons

Welding after galvanizing requires less planning during the design and fabrication process, which may make it appear easier than welding before galvanizing. However, more work may actually be needed when you consider the amount of time it takes to remove the zinc coating from the weld area and then perform the necessary repairs. Welding after galvanizing can also negatively affect the corrosion protection performance and the natural, modern appearance of an otherwise continuous hot-dip galvanized coating. The inside of a pipe or tube, for example will be inaccessible for repairs and remain uncoated if welded after galvanizing. Regardless of these concerns, the corrosion protection of a hot-dip galvanized coating is unmatched, and a fabrication welded after galvanizing still provides an opportunity to create a beautiful, corrosion-free structure lasting for decades. Conclusion

Hot-dip galvanizing offers a durable, rust-free corrosion protection system for steel fabrications that transcends time. The ability to protect welded structures adds a level of versatility that makes this coating unique and desirable. When the simple design practices outlined in ASTM A384 and A385 are followed, a high quality coating, protecting your steel structure for decades, becomes more than just a possibility. Communication and education on this subject among all parties involved in your project allow this to happen.

For your information

About the author Dan Barlow is a corrosion engineer at the American Galvanizers Association, Centennial, CO. He recently graduated from the University of Colorado with a major in engineering physics. 26

O&MM Fabricator n September / October 2014

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Shop Talk

Primer on

Oxy-fuel n

All cutting tools are useful and can have a place in your shop, if they match up with your work. This article examines oxy-fuel technology and provides a number of tips, too.

Editor’s note: This article, provided by Victor Technologies, St. Louis, is a primer on oxy-fuel cutting technologies. The features and specifications, as well as the useful tips, discussed in the article are believed to apply to oxy-fuel cutters available across the industry. For an overview of plasma cutting, refer to the SeptemberOctober 2013 O&MM Fabricator. An oxy-fuel combination torch is just as essential to a metalworker

as is a hammer, anvil, tong, vise, and a forge. A combination torch features a torch handle and attachments for cutting, heating, welding, and brazing metal. For an investment of a few hundred dollars, few tools offer such process versatility (photo 1).

What is oxy-fuel technology?

Oxy-fuel processes use a gas as fuel — most commonly acetylene, but alternately propane, natural gas, or propylene — in combination with pure oxygen to heat, cut, and weld steel. Note that if you plan to weld, you must use acetylene. Oxy-acetylene combustion produces CO2 that shields the molten weld pool from contamination. Further, a neutral acetylene flame won’t introduce oxygen or carbon contaminants. To control the oxygen and fuel gas, a combination torch (photo 1) handle has two valves: 1 A barrel (handle body) through which the separated gases flow. 2 A threaded head for connecting attachments. A welding attachment mixes the gases and directs the homogenized flow through a single orifice that enables the user to gas weld. A welding tip also enables pinpoint heating, as well as Photo 1, above. A versatile combination torch can do it all, especially the pinpoint heating required for ornamental drawing, scrolls and twists. Photo 2, right. Cutting outfit. While some cutting attachments appear to have only two tubes, they actually feature a tube-in-tube design for the pre-heat oxygen and fuel gas, which adds strength and rigidity. 28

O&MM Fabricator n September / October 2014

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brazing. A multi-flame heating attachment has several orifices to support a higher volume of gas flow to heat a larger mass more quickly. A cutting attachment has three tubes, one each for: 1 the fuel gas, 2 pre-heat oxygen (the flow of which is controlled by the valve on the torch handle) and 3 cutting oxygen, which is controlled by the valve and lever on the attachment (photo 2). In oxy-fuel cutting, the cutting attachment mixes the pre-heat oxygen and fuel gas. Once ignited, the pre-heat flames bring the steel to its kindling temperature, or to the point where the steel becomes cherry red and will readily react with oxygen. At this point, the operator depresses the cutting oxygen lever to deliver a stream of pure oxygen through the cutting tip’s large central orifice. The resulting exothermic reaction (heat release) is largely self-sustaining, and cutting proceeds quickly (photo 3). Oxy-fuel vs plasma cutting

Table 1 compares the two processes. To clarify, oxy-fuel “cutting” of steel is actually high-efficiency, high-precision oxidation, or rusting. The cutting oxygen does the real work. The process works because iron oxide melts at a lower temperature than iron. Oxides of other metals — notably aluminum — melt at a much higher temperature than base metal, which is why they are not candidates for oxy-fuel cutting. However, the plasma cutting process cuts all electrically conductive metals. Novice operators learn to cut more precisely with plasma, and the process can be precise when paired with an automated cutting table. Plasma also cuts thinner materials quickly (photo 4). For thicker material (say above 11/2 inches for hand-held applications), oxy-fuel cuts faster than plasma and can cut material that is 6 inches thick. As noted, an oxy-fuel combination torch

Table 1. Comparing oxy-fuel to air plasma cutting Cutting ferrous metal Cutting non-ferrous metal

Oxy-fuel

Air plasma

Yes

Cut thickness possible* to 6 inches Thin gauge to 11/2 inches 1/8

Precision cuts Yes, but requires more skill

Yes, and easier to learn

Dross and clean-up

More slag to clean. Slag can be harder to knock off

Less dross to clean. Dross is usually easy to knock off

Heat affected zone

Larger

Smaller

Heating Welding steel

Yes No

Yes — with acetylene

Brazing/soldering Yes Portability Productivity Purchase price Consumables costs Safety issues

Easier, anywhere the operator can move tanks

More considerations required for electricity and compressed air

Slower — not a primary issue in blacksmithing

Faster — a primary issue for higher volume fab shops

Lower

Higher

Generally higher for gas and cylinder rental, lower for tips (tips tend to last, if cared for)

Lower costs for electricity, shop air; higher tip and electrode consumption

Flammable gases, flames, sparks, some UV rays. Safety gear required

Electricity, cutting arc, sparks, UV rays/arc flash. Safety gear required.

Key take away Essential for heating, in ornamental work. Offers process versatility

Essential for higher productivity, cutting thin gauge metal, precision cuts

* For the medium- to heavy-duty torches appropriate for ornamental work and hand-held air plasma cutting systems.

Photo 3. Cutting oxygen, near right. This photo clearly shows the cutting oxygen stream in the center of the flame. Photo 4. Plasma process excels at cutting shapes, especially on thinner material, far right. 30

O&MM Fabricator n September / October 2014

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8 tips to get the most out of your torch 1 Carefully follow the safety and operating instructions included with your oxy-fuel system. See if a supplier offers free videos and support material on its website, such as Victor Technologies at training.victortechnologies.com. 2 Set gas flow rates according to the tip chart or owner’s manual included with the torch (or on the manufacturer’s website). Pressures of 3–5 psi are common for welding tips and cutting tips size 0 and smaller. 3 When using a cutting attachment, open the pre-heat oxygen valve on the handle all the way, so that the flow of the cutting oxygen won’t be restricted. Adjust the oxygen-tofuel ratio using the valve on the cutting handle.

well defined, bright blue inner cone. An “acetylene feather” protruding beyond the inner cone indicates a carburizing flame (too much acetylene); a light yellow flame does as well. An oxidizing flame (too much oxygen) shrinks the size of the inner cone and turns it white, burns with a loud hissing sound, and throws excessive sparks while welding. 6 Change tip sizes to increase or decrease heating or cutting capacity. Always keep gas pressures within recommended limits.

Tip 2. Set gas flow rates per tip chart or owner’s manual.

7 Alternate fuels are much heavier or lighter than air, so they tend to “float” when lit. Thus, learn different lighting techniques. Turn the fuel valve 1/4 to 1/2 turn and light. Place the tip on the workpiece at about a 45° angle, open the oxygen preheat valve 1/4 to 1/2 turn until the flame “snaps” into place, then walk up the flame as normal. Use this technique on a windy day, if the shop fan is blowing on the work area or if the flame goes out when using technique 1.

4 To light the torch, open the acetylene valve 1/8 turn and ignite the gas with a spark lighter. The resulting flame gives off smoke and soot. Slowly open the acetylene valve until the smoke disappears. Now slowly open the oxygen valve until you establish a bright neutral flame and the “acetylene 8 To extinguish the flame, feather” extending beyond the shut down the oxygen pre-heat inner cone disappears. If using Tip 7. Alternate fuels can “float” when lit. valve first, fuel last. If, after you a cutting attachment, depress have shut off both valves and the cutting oxygen lever; you may need to rebalance gas a small flame remains, it can indicate a leaking fuel valve. flow afterward. If you hear a popping sound, one of two things happened. You either reversed the shut off order, or you have a leaking 5 Learn to recognize a neutral flame or one with the oxygen control valve. If you suspect a leak, have your equipproper oxygen-to-fuel ratio. With acetylene, look for a ment inspected and repaired by a qualified technician.

also provides the ability to heat and weld. Because serious metal workers prefer to use the tool best suited for a given task, they usually complement their torch with a plasma cutter when funds allow. What to look for when buying

For those making a first purchase, consider an oxy-fuel system that contains all of the essential items (except gloves and leathers). A typical oxy-fuel “outfit” comes with the following: n Oxygen and fuel gas regulators. Note: Acetylene and alternate fuels 32

require different regulators. Purchase an outfit with the regulator that matches your fuel gas choice. n Hoses. n Torch handle. n Attachments for cutting, heating and welding. n Cutting tip. Note: All cutting tips are gas specific. n Spark lighter. n Tinted safety goggles or glasses. n Gas flow rate “tip” charts for easy set-up. n Operator’s manual. Some torch systems are fuel-specific;

others feature a “universal” design, or one whose gas mixer works equally well with acetylene and alternate fuels. With a universal gas mixer, you’ll never worry about not having the right attachment if your preferred fuel gas isn’t available. Torch handles also vary widely in their design. For example, newer torch handles feature improved ergonomics and have color-coded and labeled valves for greater clarity. Premium handles feature built-in check valves and/or flashback arrestors, which, respectively, help prevent reverse O&MM Fabricator n September / October 2014

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gas flow and extinguish a flashback before it can reach the gas cylinders (photo 5). Regulators also have a variety of designs and duty levels. Some are color-coded to indicate gas type (e.g., green for oxygen, red for acetylene, and orange for alternate fuels) and even feature “crumple zones” that can keep the regulator intact if the cylinder tips over. The points for a beginner are: n Select a regulator from a reputable manufacturer. n Select one that matches your fuel gas. n Be sure the threads match the gas cylinders you plan to use. On all of the above items, consulting with a knowledgeable welding supplier during the purchase process can save you from many headaches. What system ‘size’ do you need?

When considering a torch system you will typically see “light,” “medium” or “heavy-duty” (photo 6) systems offered. “Duty” does not refer to durability. These manufacturers engineer and build all their torches to take decades of hard

Control valves with stainless steel ball Stems have Teflon packing for smooth gas tight operation Brass head For strength and durability

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use. Instead, it refers to physical size and — most critically — the ability to support the gas flow rates associated with a particular attachment or tip size. With plasma cutting, you increase current to cut thicker metal. With oxyfuel, you increase gas flow and select a tip or attachment specifically engineered to support that flow.

A “tip chart” inside the outfit or in the owners’ manual provides the needed guidance, but either a medium or heavy-duty system would be appropriate for ornamental work (See “10 basic ornamental techniques,” page 41). Light-duty torches work well for artistic welding and brazing, but you might not get the cutting and heating

O&MM Fabricator n September / October 2014

Table 2. A comparison of fuel gases. Acetylene

Propane

Propylene

1.2:1

4.3:1

3.7:1

1/7th of cylinder contents per hour

N/A

Neutral flame temp in °F

5,720

4,600

5,240

Burning velocity in oxygen, ft/sec

22.7

15.2

15.0

Primary flame in BTU/ft3

507

403

Secondary flame in BTU/ft3

963

955

1,969

Total heat in BTU/ft3

1,470

1,050

2,372

Suitable for welding

Yes

Suitable for cutting, heating

Yes

Oxygen to fuel gas ratio Withdraw limits

Photo 6. A heavy duty system. “Duty” refers to physical size and — most critically — the ability to support the gas flow rates associated with a particular attachment or tip size.

capacity desired for thicker metal. If the system you select doesn’t have the correct tip or attachment size, don’t worry. You can usually find the right size at your local welding supply store. Fuel choices, cylinder size, and safety

If you plan to weld, choose acetylene. Most experts prefer this fuel because it also cuts, pierces, and heats effectively, and that includes consuming the lowest amount of oxygen (see Table 2). However, an acetylene cylinder must stay upright. For those who need to move cylinders and/or need to store a cylinder on its side, consider an alternate fuel. Can you afford to run out of gas in the middle of a project? Can you quickly and conveniently obtain new cylinders, or does the welding supply route truck only stop in your area every other week? Do you need to move the cylinders? And lastly, with acetylene, can the cylinder size supSeptember / October 2014 n O&MM Fabricator

Photo 7. Acetylene cutaway. An acetylene cylinder contains a porous mass saturated with liquid acetone.

port your withdraw rate requirements? If you’re worried about running out of gas, consider buying or renting the next largest size cylinder rather than risk unplanned downtime because you ran out of fuel. The structure of an acetylene cylinder is different from other cylinders, which are only shells. An acetylene cylinder contains a porous mass saturated with liquid acetone (photo 7). The acetylene gas is then pumped

into the cylinder and absorbed into the acetone. As you use the gas, it is released from the acetone. Because of its nature, three important safety considerations are specific to acetylene. 1 Always use and store the acetylene cylinder in an upright position. If you must put a cylinder on its side, restore it to an upright position as soon as possible. Without going in to regulatory requirements, simply play it safe Continued on page 38

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Oxy-acetylene is in Neil Mansfield’s DNA Carrying this realization forward, students at Assabet learn gas to attract students to his school’s welding before arc welding. four-year metalworking program. Mansfield took up blacksmithAs the lead blacksmithing ing 14 years ago. Today he creinstructor at Assabet Valley ates and sells ornamental work Regional Technical High School, — gates, railings, fences, and decoMarlboro, MA, Mansfield says rative home items. students’ expressing themselves “Bar stock as it comes from with hot metal appeals to their the steel mill has no life in it. The creativity and is a foundation for hammer, anvil, and torch’s heat other cutting and welding probring life to a dead piece of metal,” cesses used in a skilled trade career. Neil Mansfield, a third generation ironworker, he says. “We bring life by twisting, “The oxy-acetylene torch is in owes much of what he knows about puddle scrolling, and making it decorative. the DNA of a welder. It’s seeped manipulation from his skill as a gas welder. You need a railing for safety, but into our bone marrow,” says Mansa railing is kind of like a Christmas tree — you make it field, a third generation ironworker. decorative to add eye appeal.” When the Navy sent him to welding school, he saw Mansfield believes that blacksmiths feel a connection rows of oxy-acetylene welding torches and questioned between their eyes and the hammer, the metal, and their why they were teaching an archaic process. brain. They use the connection to add “radius lines” “Then I realized that the oxy-acetylene weld puddle to the metal, keeping the lines smooth and undulating — slows everything down,” he says. “It gave me a chance to and never flat. To add lines to metal, blacksmiths learn how to manipulate the weld puddle. All concepts of use three fundamental techniques: drawing, scrolling, puddle manipulation, whether from gas or an arc welder, and twisting. stem from the skills I learned while gas welding.”

Neil Mansfield uses blacksmithing

up to a 125-cubic-foot “WS” acetylene cylinder (17.9 ft/hour maximum withdraw rate), or use an alternate fuel that has no withdraw limitations. You may be tempted to save a buck and purchase a lightduty “tote” system. They’re popular with maintenance and HVAC professionals because of their portability. However, the small “MC” acetylene tank size cannot support the flow required for heating, so they are not suitable for ornamental work (See “10 basic ornamental techniques,” page 41; “MC” stands for Motor Car; early cars used this size acetylene cylinder for the gas flame-illuminated headlights). If you’re unsure about the correct cylinder size, rent one first. Some distributors will count your rental fee toward the purchase price.

Continued on page 35 and let the upright cylinder sit for 24 hours before using it. 2 Never use acetylene above 15 pounds pressure. Acetylene has a tendency to disassociate above 15 psi, and it can cause a chemical reaction. 3 You can only withdraw ⁄ of the cylinder volume per hour; more and you risk withdrawing liquid acetone. Take, for example, a 75-cubic-foot acetylene cylinder, often called “WQ.” Dividing 75 by 7 equals 10.7 usable cubic feet per hour of gas. By cross referencing a chart for multiflame attachments (MFA), you can see that a 6 MFA has a minimum gas flow rate of 14 ft/hour — which means you absolutely cannot use this size tip with this size cylinder. Either step down to a 4 MFA (6 ft/hour minimum), step

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September / October 2014 n O&MM Fabricator

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10 basic ornamental techniques Neil Mansfield, lead instructor at Assabet Valley Regional

Technical High School, Marlboro, MA, and post-graduate students, Cameron Hulme and K.C. Waldbillig, kindly demonstrated these tips. Related stories pages 32 and 38. 1 Clean and organize your work area. Place tools within easy reach, as you’ll only have about 30 seconds to work the metal before it cools. Clamp the barrel of the torch handle in a vice to free your hands. 2 With a torch or forge, heat the steel to what Mansfield, left, calls “forging yellow,” a temperature of about 2,000– 2,500°F.

3 Work on the edge of the anvil, not the center, so the metal has a place to go. When the hammer blow compresses the metal, it squeezes forward. Drawing out is the tech nical term for this process.

4 Make hammer blows at 90° to each other to start, and develop a consistent rhythm. Hammer 1-2-3-4, turn the metal 90° and hammer 1-2-3-4, and turn back to your starting point and repeat. Once the metal gets drawn to a spear point, hit the corners to turn a square into an octagon; hit the corners of the octagon to create 16 sides, working until you have a round point that flows back into the square bar stock. 5 Using the torch to direct heat to specific areas of metal “protects” the unheated area of the metal from being worked. A larger welding tip such as this can also heat a large area if needed.

September / October 2014 n O&MM Fabricator

6 Use a multi-flame attachment to heat a part more quickly or to heat a larger work area. Waldbillig, left, does the job.

7 To turn a point into scroll, heat the point and hammer it over the edge of the anvil. Then, turn the point upright, and working from the far side, hammer it toward you. 8 After starting the scroll, use scrolling tongs to bend the metal. Move the tongs about ¼ inch at a time to prevent flat spots. Isolate the bends by directing pinpoint heat with a torch and holding the bar stock with Wolf jaw pliers, which have indentations to firmly grip square stock on the diamond, not the flat. 9 Decorative twists are another essential element, and you’ll need stock with square edges to get the desired eye appeal. To provide even twisting power and get better leverage, Mansfield cut out a “twisting wrench” on an automatic plasma cutting machine. The wrench slots match common bar stock sizes. 10 Straighten out imper fections with a vice. Sometimes blacksmiths straighten stock with a rawhide mallet to avoid damaging the twist edges.

You’ll make a lot of mistakes while learning, but don’t worry. Just straighten out an ugly scroll, or put on the cutting attachment, remove the offending piece, and start over.

Member Talk

GUILD traınıng success

n Philippe Fiers brings the classical

fabrication skills of Les Compagnons Du Devoir to Armadillo Metalworks, and the company enjoys ‘gilded’ fortune in New York City’s high-end residential market.

Editor’s note: The attention to detail is what I first noticed about Philippe Fiers, vice president at Armadillo Metalwork in Passaic, NJ. Fiers was the insructor at a NOMMA Education Foundation workshop last year at the College of Building Arts in Charleston, SC. Among other things, he showed attendees how to pay close attention when joining handrail cap ends. His patient approach made us all feel welcome. O&MM Fabricator welcomes you to learn more about Fiers and his company in this interview. For additional information, go to: armadillometal.com. Restoration of an entrance door in a residential building. The doors were badly corroded and many decorative items were missing. The entire entrance was taken down (doors, transom, jambs, and header) and temporary sheet metal and glass doors installed. The doors were fully dismantled and patched. Some items were replaced new. The hardware and glass panels were replaced and stainless steel weatherstrips were added. The bare steel was brushed and clear-coated. The job took eight weeks to complete. 42

O&MM Fabricator How did

you get your start in metal fabrication? Philippe Fiers Pure coincidence. I studied construction estimating at the age of 15 in a technical high school in France, training that took three years. In the 1970s, you could be out of school with a fair amount of basic training in your field of study and be ready to enter the workforce by the age of 17 or 18. There were also opportunities to continue your education further, but I really wanted to earn a salary and be independent. I also had enough of the school. After graduating, I took my backpack and went to a different region in the beautiful southwest but could not find a job in estimating. A large structural steel company had an opening for an apprentice erector, so I applied and was hired. It was a difficult adaptation because I had to learn to deal with height (I fell from a height of 30 feet in my first week of employment), cold winters, and hot summers. But for three years, I enjoyed the team spirit and being able to see the fruit of your labor

O&MM Fabricator n September / October 2014

at the end of the day, to have created something tangible. Not to mention the breathtaking views from the top of the structures and the feeling of being above everything and everyone, to be unique and special. Fabricator And what about your ini-

That is a long-term vision that maintains a good pool of talented craftsmen and women in the workÂforce without depending on state-run institutions that have to deal with budget shortages, are disconnected from the real world, and have to train young people who have been put in their classes because of a lack of academic achievement. I trained and taught in the guild for seven years, and I am grateful to have done so. This painstaking education was a passport to my already quite consumed professional journey. It was also because I trained there that I was selected to be part of the team that built the new torch for the Statue of Liberty in New York harbor in 1984. That project is among

the best professional achievements of my career. Fabricator What tools and skills did

tial metal fabrication education? Fiers After three years working for this structural steel company, I realized the opportunities to grow within were limited. This would not be the kind of work I wanted to do for my entire professional life; it was physically demanding, and fraught with everyday dangers. I was not quite sure if I wanted to pursue a career in framing (wood or metal) or metal fabrication. I decided on metal fabrication, Philippe Fiers shares an office with two applied for and joined the renowned engineer/detailers. He can see most of guild of Les Compagnons Du Devoir, the shop from his desk and determine if he needs to help a crew. an institution that dates back to the middle ages and that trains some of the elite in the construction and other trades. While enrolled, you spend a year (or six months for some trades) in a city, work a full day in a company, have classes at night in French, math, technology, CAD, you name it, and full-day classes on Saturdays, mainly in drafting and workshop. Besides the training, you also discover the I trained and taught in the guild region, its people, and the way its for seven years, and I am grateful companies operate and the kind of work that is available. to have done so. This painstaking You, therefore, choose the city education was a passport to my already you will go based on the work you quite consumed professional journey. want to do and the techniques you want to learn. I was able to train in It was also because I trained there most of what the metalwork world offered, from large-scale sheet that I was selected to be part of the metal shops, mom and pop small team that built the new torch for the town forge shops to high-end ornaStatue of Liberty in New York harbor mental metal shops. In the guild, once you acquire in 1984. That project is among the best a good deal of knowledge, you are professional achievements of my career. asked to start teaching the younger trainees. This way the knowledge Philippe Fiers is transmitted from generation to Vice President Armadillo Metalworks generation.

September / October 2014 n O&MM Fabricator

you learn? Do you have a personal area of expertise? What do you especially like to do? Fiers I have been trained on all the basic equipment used within the trade, as well as the early versions of the CNC shears and press brakes. I have, however, trained in shops that did not have up-to-date equipment, which pushes you to be creative. I donâ&#x20AC;&#x2122;t really have a personal area of expertise, and I cannot qualify myself as a blacksmith even though I had the basic training for it. It is somehow a field that I was not much involved in, except during the restoration on the Neptune grilles of the Stanislas Plaza in Nancy, France (mid-1,700 grilles by the blacksmith of the king, Jean Lamour; the Plaza is a UNESCO World Heritage site). I like to do most anything, as long as it is challenging and I can make a living out of it. Once I get bored, it shows me it is time to move on. Fabricator How did you

start your work life as a business person? What is the short history of your current company? Fiers I have never seen myself as a businessman. That is not what I am good at. I like the technical side of a project, the solving of shop and site issues. However, I give 100% of my abilities to any company I work for. Because of that, I was repeatedly told that I should open my own business since I always worked like my employerâ&#x20AC;&#x2122;s shop was mine. Despite my gut instinct, I created my own company in 2002. After three years running it, with the help of poor business decisions, a poor global economy, and an unpaid project, I folded before the company took me deeper financially. Within a few days of that deci43

Satin stainless steel staircase and glass railing on three levels for a residence, Armadillo did the engineering, fabrication, and installation.

to give me the answer I was looking for or at least provide me with a valuable lead. Of course, fabricator colleagues often are a great source of advice. On projects we do in the New York metro area, it is not uncommon to have the metalwork split between two companies. This has been the case on our last three main projects. Instead of treating each other as a competitor, we feed each other advice and tricks. We collaborate and that creates a solid and fair relationship for our mutual benefit. That might also lead to a better collaboration when it comes to bidding on the same potential project later. Some projects offer true challenges and push you to be inventive, to better yourself. And, of course, be curious, don’t be satisfied with what you have done or know already. Fabricator What about mentors? Fiers I had plenty of mentors, from the companies that I

worked for, my circle of friends, my family, and my old man. You, as a human being, are a compilation of these experiences and advice you gather along your existence, from childhood until your last day. A poster above my desk reads: “The only person I am better than is the person I was yesterday.” That says it all.

sion, a general contractor with whom I did a fair amount of work told me he thought of opening his own metal fabrication shop because he had a hard time getting quality metalwork for his projects. We talked about the project and Armadillo Metalworks Inc was born. We settled in an 11,100-square-feet shop in an old factory complex in Passaic, NJ, in December 2005. Fabricator And now, how have you furthered your metal

fabrication education and training? Fiers We are living in a fast-paced world that requires constant update, so I try to keep informed of new technologies and software and adapt or upgrade as much as I financially can. There are plenty of publications out there with great information, and O&MM Fabricator is one of the leading ones. Plenty of night classes are offered by community colleges and NOMMA has its ListServ. The Internet is a fantastic tool; I don’t think it failed once

Fabricator So tell me, what is typical day like? And what

about your oﬃce personnel? Fiers I am the vice president of the company and direct the day to day operations, including sales, estimating, purchasing, engineering, fabrication, and installation, in collaboration with the shop foreman and my two colleagues in the office. I do the scheduling, site meetings, and most surveys. We have 13 employees and I have to admit that I don’t physically work in the shop any more unless the team is struggling or I need to demonstrate a particular technique, a more logical or a better way to handle a task. My day starts at 7:00 a.m. and generally doesn’t end (does it ever?) before 7:00 p.m. Sometimes I work on weekends because I can do in one weekend day what I have a hard time doing in two weekdays. I have two people in the office who help with the engineering because our work generates a lot of drawings. Both work on AutoCAD and SolidWorks software. We just hired an office person to handle the bookkeeping, payables and receivables, and tracking of hours and expenses.

O&MM Fabricator n September / October 2014

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We are currently developing new products within the high-end residential field that will eventually give us a steady flow of work for specifically trained personnel. Unfortunately, it is still being developed and I canâ&#x20AC;&#x2122;t describe what that is. Fabricator What business or market

trends do you see? Any new markets out there? What kind of market diversity should fabricators be looking at? Fiers There is a good demand for quality metalwork in the tri-state area (New York, New Jersey, Connecticut), and for us, the demand is focused on contemporary metalwork. Architects and designers put a lot of complicated metalwork in their constructions. We see a surge in metal trims, for wall bases, ceiling crowns (miles of it), as well as bronze doors and fine furniture. This demands precise coordination among the various trades involved and that time has to be accounted for when you estimate the project. As far as market diversity, well, take as much as you can and figure out how to do it, be curious, be known, and be involved as early as possible in the design process.

Set of custom bronze and glass doors separating the dining room from the kitchen in a private residence. When privacy from the kitchen is desired, you flip a switch and the resulting voltage applied to the laminated privacy glass makes them milky opaque.

Fabricator I understand that the

majority of your work is with highend residential clients. How did you decide on this market? Do you work in other markets? Are you planning to broaden the markets you work in? Fiers Our niche is high-end residential projects It took time for us to become known to architects, general contractors, and construction managers working in this field in the New

York area. Now, we are regularly consulted and asked to bid and potentially work on projects. We are set for this kind of work and we are good at it. The commercial metalwork field is completely different, especially in this area. It requires a different approach â&#x20AC;&#x201D; sometimes a lower quality of craftsmanship. Also, commercial work can be problematic because we donâ&#x20AC;&#x2122;t have a unionized work force.

Fabricator How have your markets

been for you the past couple years, last year? Fiers I will lie by saying the recession did not hit us because we were careful at pricing projects to beat a hungry competition. However, I have never run out of work. I always had a study flow of projects for the shop.

Fabricator What types of applica-

tions do you do most? Fiers When we have to explain the kind of work we do, I always says that we manufacture items, such as a piece of unique hardware that fits in your hand or the multi-ton staircase, and anything in between as long as it is challenging. However, we are primarily known to do hardware, furniture, some out of the ordinary staircases, railings, and doors.

Hou-714-nomma.indd 1

O&MM Fabricator n September / October 2014

7/23/13 10:35:51 AM

Fabricator What are your company

core strengths? Fiers We pay attention to details. We are precise. We never let something leave the shop until we are 100% satisfied. We work closely with designers and spend a good amount of time detailing and coordinating with other trades. We develop solutions when problems occur. We work with others to get the work done and the projects moving. We are proactive.

Fabricator Do you turn down certain

jobs? If so, what kinds and why? Fiers Whenever I feel the budget isn’t there. There is no sense to spend time estimating something you know in advance you have no chance to get. I am not an estimating company. A lot of general contractors only look at price. Same applies for jobs I cannot fit in our schedule, jobs that are run by flaky general contractors. And whenever I am told we were found in the Yellow Pages, I politely turn the job down under the pretext of an already booked trimester. I’ll try to steer the caller toward a fabricator in the area, preferably a NOMMA member.

heavy duty table saw. The main tools are the hands and brains of the guys on the shop floor, although a good ¼-inch x 10-foot shear would be nice to have. As for software, we use AutoCAD, Solidworks, Rhino, and Microsoft Project, all up to date. We also have a time-tracking system for the shop, field, and some of the office employees (mainly the engineering department). We are a mix of old and new school, using our core knowledge, gathered

along many years, combined with an open mind and ear to whatever is new and can benefit the company. However, because everything we do is unique and not meant to be produced in quantities (not yet), we are not looking at any automation at this point. Fabricator What type of metals do

you like to work with? Fiers We work with whatever is required on the project: carbon steel,

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Fabricator Do you do everything in

house or do you outsource? Fiers I try to do as much in-house as possible to keep control of the schedule and quality. We do outsource anything that has to do with laser or waterjet cutting, bending (brake), powder coating, polishing, and plating processes. We do our own engineering, detailing, field measurements, most fabrication, finishing, and all of our installation.

Fabricator Describe your shop. What

type of equipment you use? Fiers Our 11,000-square-foot shop is a narrow and long made of concrete and brick in the early 1900s. Besides our two CNC machining centers, most of the equipment in the shop is basic: MIGs, TIGS, spot welder, 150t press, vertical roller, cold saw and horizontal band saw, 10-foot finger brake, two Bridgeports, 1 lathe, a 13-foot spray booth, a sandblasting room, a 10-foot stroke sander, and a

September / October 2014 n O&MM Fabricator

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stainless steel, brass, bronze, copper, titanium, nickel silver, and aluminum. It varies from year to year, and yearly trends seem to apply. The material I like the least? Stainless steel. It sometimes behaves in unexpected ways, and for me, it looks cold, lifeless. Although we use 80% of bronze and brass for our projects, the material that gives me thrills is carbon steel. That material has such an unforeseen beauty. From its colors, tinted or not, its natural texture as it comes out of the mill (you have to know how to reveal it), the way it just works with you, goes to wherever you want it to go and go back to wherever you want it to go back. It is strong, although resilient and malleable. You feel it as it follows your push after being heated to that orange color and follows the jig you have made for it to follow. It just obeys your hammer blow after being pulled out of the forge, white and slightly sparkling, and laid out on the anvil. It will twist and

stay that way as youâ&#x20AC;&#x2122;re forming that complex railing. It is my favorite material, and I hope it will be applied more often in interior metalwork projects. Fabricator What technological

A temperature controlled wine display with custom bronze and glass doors for a private residence.

trends do you see coming in the next year or two? Fiers 3D printing is already making a huge difference, and we are using it more and more to create prototypes at a relatively low cost. We have also used CNC milling of hard foam to mock up complex shapes, such as custom cap rails in a tight turn of a railing. In both cases, Solidworks ensures an easy transition between the drawing and the production. We are also seeing an increase in the use of 3D surveys on sites and BIM software (building information modeling) that creates drawings or models with all the trades integrated in one file. Watch for that, it is coming strongly and is already extensively used in lots of projects we are involved with.

Fabricator How many people work in

your shop? Fiers Nine shop employees, fulltime. That is one foreman, one CNC operator/programmer, one finisher/ fabricator, three good mechanics, one TIG welder/fabricator, and two helper/ drivers.

Fabricator Do you use outside

detailers? Fiers No we donâ&#x20AC;&#x2122;t. Everything we do is engineered in house, as I like to keep control of all processes as much as possible.

Fabricator What issues do you face

when hiring new employees? Fiers Because of the bad economy of these past years, we have access to a great pool of candidates, but the selection is difficult. If you place an ad with a precise description of what you are looking for (e.g. precision, drawing, reading, English a must. . . .), you might scare everyone. If you are not precise, you might end up with 100 applications in a matter of hours. I have our office manager screen the

O&MM Fabricator n September / October 2014

résumés and phone calls, and I try to meet with two applicants a day. Once we have selected one or two candidates, based on their experience and foreseeable potential, we set a day of testing at the end of which, if successful, the candidate is hired. A day isn’t much, but it tells you a lot about a person if you give the right work to perform. I don’t systematically look at what the person has done in that day but more how the person handled the tasks. I want to know if there is potential to invest in. :tri-state-quarter page.qxd 12/19/07 9:44 AM We hired a gentleman, Lukasz, five years ago who did not know much about metalwork, but we sensed a tremendous potential in the person. At some point, he became the foreman of our shop and keeps amazing me by his abilities, day after day. We train employees to use the machines safely, and we train on anything that is needed for our projects — more like one to one, rather than in a group, although we have done some group sessions. We do not have formal AD in-house training.

Custom window limiters, left, for a residence. Armadillo wants to expand into the custom hardware market more. Custom stainless steel cup holder, below left, designed and fabricated by Armadillo Metalworks.

Fabricator Do you find employees

from trade schools? Fiers I have to admit that I have been disappointed by our local trade schools. It seems that the offered training is not always beneficial to students, despite high tuition costs. That is at least what it is in our area.

Page 1

What about hiring military veterans? Fiers We have placed ads on veteran job-seeking sites but never received a résumé from anyone. Fabricator What does the fabricator

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VOC rules, but until the water-based paints come with a better warranty and durability, we will still use paints that require solvents that are not too friendly to the environment (although legal in our state).

Armadillo’s most recent 5-axis CNC machining center, right, which boosted the company’s ability to precisely make metal components at a rapid pace.

Fabricator Who is your typical client

Fabrication in progress of two bronze doors for elevator entry in a residence, below. Infill panels are decorative resin panels made in England based on Armadillo’s specs.

Fiers Look at the problem with long-term solutions, be involved with the technical education (e.g. NEF, local colleges), make beautiful work that attracts youth, be smart and inventive, love what you do, and pay your employees decently. Spread the word that college education is not the sole solution (far from it) and that a smart and dedicated

craftsman can make as much if not more than a college educated person. Fabricator Are you into sustainabil-

ity, using green ecological principles? Fiers To some extent. We use as much as possible products and fluids that are biodegradable. We recycle some of our waste, including shavings from the machines. We follow the

and how do you find them? Fiers We work for the 1% of the 1%, meaning the community of financially “at ease.” We work on projects and houses that sometimes exceed $50 million. Getting to this point does not happen in a day. You start by working on smaller and less prestigious projects, and work your way up. Little by little, your company name starts to be familiar to general contractors, architects, and designers, and you are asked to bid on bigger “riskier” projects. You are asked help an architect in the design/budgeting phase of a project, and one day you see your company name specified for a project as “by Armadillo Metalworks Inc.” This is without saying that you spend a great deal of time (and money) to get to this point, and unfortunately, it will not take long to alter your reputation if you don’t keep up with the quality of craftsmanship your clients have been accustomed to. This community of wealthy clients is a close community and news spreads fast. We don’t advertise or use social media. Our website is in its infancy and has been “in construction” for a (ridiculously) while. This is to say that I don’t really look for work. So far I have been fortunate that the work comes to me. However, I keep close contact with whomever we’ve worked. I keep the link alive by offering my help whenever it might be needed at any stage of a project. We also are thinking of creating a periodic newsletter to keep that relation in good standing and to remind people (clients, designers, friends, suppliers, sub-contractors) that we are here.

Fabricator Do you work outside your

local geographic market? Fiers Most of our work is located in New York and Connecticut. We have quoted one or two projects in our own

O&MM Fabricator n September / October 2014

state of New Jersey, but they have not materialized. We have made custom hardware for overseas projects. We did a large project on a remote island off Barbados, are involved in the preliminary stage of a beautiful project in England, and are working quite often with European designers on projects located in the metropolitan area. The owner of Armadillo Metalworks Inc., Jesse Krzywon, also owns a construction company, and through his company, we are involved in a small project in Lima, Peru. I have never used a NOMMA member company to partner on a project for the sole reason there was never such an opportunity. If such opportunity comes up though, I will definitely consider it. Fabricator Advice for other fabrica-

tors trying to find clients? Fiers I don’t think there is a recipe for that. Every field of the metal fabrication spectrum and every geographic area has its own. All I can say is that it requires a long process of partnership with designers, general contractors, and whomever the potential customer might be. Expect to do that without the assurance of getting any work, at least not in the immediate future. Network is the keyword. Put your name out there, be known for your professionalism and ethics, be recognized, be used as a reference. At some point, you have to be the one they call for advice. Be kind to your competitors. Don’t ever say anything unprofessionally about them to others. It will bite you in unexpected ways. A couple of years ago, I was asked to inspect a metal project done by a competitor. I knew that a positive report would condition the final release of funds to the competitor, which was badly needed. I inspected the work, noted the good and the bad sides of it, created my report in a constructive way and sent it to the general contractor. In the cover letter, I said that I analyzed the work the way I would hope any competitor would have about my work. Fabricator How do you define cusSeptember / October 2014 n O&MM Fabricator

tomer service? Fiers We work in an area where people don’t wait. They want, they pay, they get. If you create a problem, solve it quickly, and return the phone call rapidly (with all the means of communication today, no escape is possible). If it is a problem you did not create but can help with, do it and get compensated (whatever that might be). Clients appreciate problem solvers and professionals with a constructive attitude. Call back, always. Fabricator Beyond the economy, how

have you resolved business challenges you faced? Fiers Not quite sure if we resolved them, all. But one thing we regularly try to do is keep good track of expenses, what we spend and what we earn. This task requires constant monitoring. It’s now easier for me since I have someone who will do it for me in-house. Mistakes and bad decisions are to some extent inevitable. Learn from them, take responsibility for them, and

move on. Keep an ear out for good ideas from your colleagues and whoever surrounds you, in and out of your field. Fabricator What fabrication job

challenges have you faced? Fiers Each project, small or big, represents a challenge. Challenge at the early stage while you price it because if you find the most rational and efficient way to do it, chances are you will get the job. A challenge once you get the job because you still need to figure out the details. We have technology, machines, good employees, schedules, and a budget to follow. If you have a good team, you can brainstorm a project. Sit down, explain, and let the ideas flow. Listen to the ideas, as bad as they might sound sometimes. Chances are that among all that will be said during the session, something will emerge as a solution, or at least, a lead to a solution.

2014 Top Job Gold Award Category: Structures

Beating a dozen or more firms, Kammetal marks its growth as a most capable job shop by winning a highly coveted assignment: a beacon housing made of ¼-inch, 1L stainless steel for the new One World Trade Center.

The beacon staged at the “top of the house” before cranes are jumped and the beacon is hoisted and placed at the top of the spire. Photo courtesy of Port Authority of New York and New Jersey. 52

O&MM Fabricator n September / October 2014

Great English literature aside, Sam Kusack

will likely remember the year 2001 as the best of times and the worst of times. For him, the story of a bittersweet year, punctuated by the epic tragedy of 9/11, has had a happy ending. As a graduate of The Cooper Union for the Advancement of Science and Art in Manhattan, Kusack opened his own metal fabrication firm in June of 2001. With no family background in the industry, this first-generation fabricator had prepared for that milestone through years of working off-hour side jobs. He admits to being a bit of a business opportunist while at Cooper, too, crafting metal display tables and sculpture components for artists and art galleries — out of the school’s shop. That summer, with a Bachelor of Fine Arts in hand and a number of jobs lined up, Kusack was ready to hang his shingle in a Brooklyn, NY, loft workspace he shared with friends. Working through the horror of 9/11, as all New Yorkers did, little did Kusack know then that his handiwork would eventually play a high-profile (in every sense of the word) role in a symbolic event to mark the city’s comeback. Just 11 years after he witnessed the fall of World Trade Center towers, Kusack’s company, Kammetal, was selected to fabricate the housing for the top-feature beacon of the new One World Trade Center, initially and often still referred to as Freedom Tower. The project won Kammetal NOMMA’s 2014 Top Job Gold award in the Structure category. “It was interesting from the standpoint of being a business owner who started a company just months before the towers fell and, during the rebuilding of the towers, expanded from a one-man shop to a company that could take part in the rebuilding

September / October 2014 n O&MM Fabricator

Above, isometric view of the beacon housing, a 3D Solidworks model created by Kammetal and used for fabrication of all components. Left, elevation view of the beacon housing created in Solidworks software.

Job basics

By Molly Badgett

Project One World Trade Center beacon housing Clients DCM Erectors, Tishman Construction, The Port Authority of New York and New Jersey Architect Skidmore, Owings & Merrill LLP, New York City Engineer BuroHappold Engineering, New York City Completed April 2013 Scope Engineering, design development, glazing, stainless-steel fabrication, installation Kammetal’s lessons to share n While bidding on a project, “ask the right questions and address the right concerns.” n Don’t be too timid to question decisions of even world-renowned architects, particularly on their choice of metals and metal finishes for a particular job. n Strong vendor relationships can come in handy at the most inopportune times.

Left, the top view of 3D Solidworks model created by Kammetal and used for fabrication of all components. Below, level by level cross sections of beacon created with Solidworks software.

of the towers,” Kusack said, with a certain modesty about having had the capabilities as a relatively young company to perform the work. “We were truly honored to have been selected to fabricate the beacon.” Established and equipped

A city like New York has no shortage of demand for artistry in metal. In meeting that demand, Kusack’s firm had grown to a company of about 25 employees since 2001, positioning itself as a highly capable job shop that also caters to artistic projects. Art fabrication projects encompass as much as 20 percent of the company’s work, which is predominately from sheet metal. High-end furniture and other interior pieces, such as heavily stylized lighting fixtures, are just as commonplace from Kammetal’s shop as are interior staircases or other large-scale, civic architectural projects. Kusack’s shop was well-suited, then, when DCM Erectors (USA), New York, NY, asked if he and his team would be interested in a project involving the World Trade Center. A division of The Davis Group of Canada, DCM Erectors was the firm hired by The Port Authority of New York and New Jersey to construct the steel components for the building. “We said, ‘Sure! Of course,’ ” Kusack said. “They gave us a typical non-disclosure agreement to sign and sent the drawings over. When I opened them up, I was extremely excited to see it was for the beacon enclosure.” Kammetal was one of about 15 firms to bid on the job. “We had a good grasp on the work and were detailed-oriented and capable of performing all of the work in house,” he said. “From there, it was really a matter of delving into the details, through the specifications, and fully understanding the scope of the project. As an architectural and ornamental fabricator, it’s all in the details.” 54

Project design

At 50 feet in height, the ultra-modern beacon housing was designed by New York architectural firm Skidmore, Owings & Merrill (SOM) to complement the torch of the Statue of Liberty, Kusack said. The beacon, after all, is seen by many as a contemporary version of the Statue of Liberty’s symbolism, balanced in view across the Hudson River. It’s also highly functional, housing the large, rotating LED-lighting apparatus and capping off the building’s 408-foot spire (see sidebar, page 5). Changing the specified metal. From the start, Kammetal’s input was significant. The beacon enclosure was originally specified as a fully welded, finished-aluminum enclosure. Kusack didn’t see that material as a viable option. For one thing, the physical size of the parts rendered the full assembly unfeasible for coating in one piece. And, because it would have a high-altitude position above the oftenrough New York City climate, its longevity would be questionable. The building, in fact, would eventually rise to a symbolic 1,776 feet in the air to become the tallest in the Western Hemisphere. “We suggested changing the cladding specification from painted aluminum to one-quarter-inch, type 316L stainless steel with a non-directional finish,” Kusack said. He prepared a finish sample to submit for review and received approval for the change by SOM’s project architect. DCM’s structural engineers also were consulted, and they calculated that the additional weight differential for the quarter-inch stainless-steel steel cladding was not a structural concern for the overall spire assembly, which totaled nearly 758 tons, or 1.5 million pounds. Structure re-engineered. On October 1, 2012, Kammetal was awarded the job and the engineering phase began immediately. O&MM Fabricator n September / October 2014

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1 2/2/2012 7:30:54 PM works on the set up and fixturing for GTAW welding of the internal support clips. Kammetalhorizontalfullcolorad.pdf Fabricator Michael Martino, left, Kammetal Fabricator Roman Mrowka, right, works on the exterior finishing of panel components after welding.

Fabricators Dragan Keri and Bryan Ruiz bump the Âź-inch stainless steel top cone on the press brake.

Kammetal then hired BuroHappold, New York, NY, as a consulting engineer to provide advice, create structural and calculation documents, and stamp the final shop drawings. The first concern was to verify the structural integrity of the design. Kammetal ended up re-engineering the entire exterior and interior of the structure because the original SOM design called for a fully welded enclosure.

CMY

O&MM Fabricator n September / October 2014

Sandy knocks Kammetal down; Trumpf gets them back up In late October 2012, just after Kammetal started the

World Trade Center project, Hurricane Sandy struck the shop. Considered the second-costliest hurricane in U.S. history, Sandy hit hard the hip, up-and-coming industrial district in Brooklyn known as Red Hook. Some flooding from Sandy likely was predicted since the area is designated as hurricane Zone 1, an area most in danger of flooding. During Sandy, Kammetal took in about two and a half feet of water. “It was during the engineering phase; it took out a lot

After their thorough examination, BuroHappold engineers determined that the components would need to be separated into individual panels to allow for thermal expansion and contraction. Also, because cladding would be installed onto the structure horizontally, the panel-system approach would help later during installation.

of our equipment,” Kusack said. “One of our machine vendors actually made a huge effort to get us back up and running.” The vendor was German-based Trumpf Inc., which has an office in Farmington, CT. “I scheduled a meeting with them and went to Connecticut to their U.S. headquarters,” Kusack said. “I met with their management and told them about the project and the position we were in.” Kusack wasn’t in any position, however, to purchase all-new equipment. “We came up with a plan, and they offered to give us a loaner machine.” In time, Kammetal had its own Trumpf machines and others up and running, but for about six weeks, the shop was off the power grid, running solely from a generator.

“The engineers analyzed our design, and we worked together to modify the parts as necessary, either increasing material thickness or altering connection designs in order to satisfy the structural requirement, as well as to optimize the manner in which the panels could be installed onto the structural frame,” Kusack said. Throughout the design process, the

Kammetal production crew worked closely with the engineering team to verify that the complex, bent, 7-gauge stainless steel clip components, which had many acute angles, were even possible to produce. In the end, the element that made everything work was a system for piecing the triangle-shaped panels together and attaching them to the

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frame while maintaining the design elements, and doing so in a way that would withstand significant thermal and weather-related movement. “We designed a proprietary clip system,” Kusack said. The unique system allowed the company to install the panels horizontally over stainless-steel weld studs and then lock all of the 48 panels in place. The company also designed and had produced a custom silicone gasketing system that sealed the vertical space between each of the panels as well as between the stainless steel and glass windows. Aside from dealing with the epic inconvenience of Hurricane Sandy, which hit the shop in late October (see sidebar, page 57), the complexity of the specialized project pieces was the most challenging aspect of the job to address, namely the many complex, compound angles that needed thorough engineering consideration.

Kammetal President Sam Kusack, above, uses suction devices to hoist panel segments during installation. Below, Fabricators/installers Alex Gonzalez and Michael Deschamps guide the overhead crane into position to place the panels.

Measurements and fabrication

DCM Erectors provided Kammetal with a 9-ton, structural, stainless-steel frame, the core “skeleton,” for the beacon project. Because there were absolutely no right angles in the structure, Kusack hired G&P Associates of Binghamton, NY, to create a three-dimensional laser scan of it. Two objectives 1 Develop a point cloud, or set of

data points, to import into Solidworks 3D modeling software to model all cladding components for the project, and 2 Verify “as built” conditions to eliminate the chance of any physical discrepancies during installation. Starting in November 2012, staff worked at Kammetal’s Red Hook shop in New York to fabricate all of the components that would be attached to the core structure, and to install them at DCM Erector’s shop in New Jersey. The first step was to produce the 48 panel assemblies and mounting clips that comprised the exterior of the beacon. To make up time lost with Hurricane Sandy, Kammetal implemented a second work shift for laser cutting. 58

The panels were fabricated in sets for levels of the structure, based on the elevation of the piece. The team started from the top of the structure and worked their way around, level by level, and down to the bottom. This sequencing also kept the installation team in New Jersey busy; the shop produced parts and constantly fed them to the installation team.

The Kammetal team implemented GTAW welding for the connections throughout the process to AWS D1.6 specifications. The Port Authority hired a subcontractor to perform subsequent NDA weld testing. The Kammetal installation crew set up the beacon frame to rest horizontally across the shop floor. Measuring 9 feet at its widest point and 2 inches O&MM Fabricator n September / October 2014

What makes Kammetal tick Kammetal relies on — and constantly invests in — sophis-

ticated, modern machinery as much as the precise planning, engineering, and craftsmanship of its project managers, engineers, and designers. Its assets include: n TIG and MIG welding. Kammetal is GTAW-, GMAW- and AWS-certified. n Set-up and fixturing. Precision Demmler welding table stations used. n Project planning and installation. Includes rigging

Permanent spire, or antenna? Controversy has surrounded redevelopment of World Trade Center property since the first time anyone breathed a word about it. One World Trade Center first was to be developed by New York’s Silverstein Properties, which was leasing the original Twin Towers. But in April 2006, ownership transferred to the Port Authority of New York and New Jersey. The Authority is in partnership with the Durst Organization, which oversaw construction and handles the building’s leasing and management. More recently, controversy focused on the height of the building’s spire. The Tall Buildings and Urban Habitat (CTBUH) determines the “official” height based on whether or not the mast on top is a “permanent architectural feature, not a piece of functional-technical equipment.” Had the Canada-built spire on top of One World Trade Center been determined to be a broadcast antenna instead of a permanent fixture, the building would have been denied its status as the tallest in the Western Hemisphere and the third tallest building in the world. In announcing the CTBUH’s decision in November 2013, Executive Director Antony Wood was quoted: “The design of One World Trade Center,... [and] in particular, the spire... shining out at the symbolic height of 1,776 feet, is especially poignant.”

September / October 2014 n O&MM Fabricator

and fitting. Hand operations. Includes heat bending, twisting, and forging in stainless steel, steel, and copper alloys. n CNC capabilities. Kammetal’s equipment includes: n CNC laser cutter (Trumpf TruLaser 1030). n CNC turret punch (Trumpf TruPunch 1000). n CNC press brakes (Trumpf TruBend 5170S and 7036). n CNC plate roller and CNC plate controller (DAVI MCA 3020). n CNC waterjet cutter (Flow Mach 4, 4030C). n Automatic saw (Marvel 380A PC3). n

at the lightning rod on the other end, the frame was supported by a rotating welding positioner. This allowed the installation team to rotate the frame so that each panel could be installed directly from the top position, horizontally speaking.

Because the panels were flat and spaced with only a ¼-inch gap from one another, the team had no viable pick points for manipulating the panels. Using overhead cranes for placement and suction components from Anver Corporation, Hudson, MA,

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Kusack designed a pneumatic, suction-cup lift to handle and install the stainless steel and glass panels onto the structural frame from above. Finishing and installation

The 316-grade stainless steel used to clad the beacon housing was purchased in a non-directional satin finish from Dynasty Metals, Rockaway, NJ. In all, 10 tons of stainless steel were used, along with 1 ton of heat-soaked, tempered and laminated glass from Oldcastle, Atlanta, GA. Fitted with stainless-steel surrounds, the 1-inch-thick glass panels provide the New York skyline a lighthouselike effect from the FAA-approved beacon-lighting assembly inside. To lift the 16-ton, 50-foot beacon to the top of a building more than 1,700 feet into the air, DCM Erectors designed and placed the entire unit, even before it was completed, on a custom-made traveling platform fabricated by DCM.

Kammetal fabricator Roman Mrowka welds the stainless steel cladding of the upper beacon section.

Then, from the time it was 100% complete in late March of 2013 until it was hoisted atop the building that May, the beacon housing remained

on the development site away from public view. The last two weeks or so before it was installed, the beacon was staged

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For your information

Kammetal 29 Imlay Street Brooklyn, NY 11231 718-722-7400 info@kammetal.com www.kammetal.com Other notable links n http://www.som.com/projects/ one_world_trade_center n http://www.panynj.gov/wtcprogress n http://time.com/world-trade-center

Fabricator Alex Gonzalez works on the installation of the upper cone section.

on a special platform built on the roof of One World Trade Center, still more than 350 feet away from its final placement. On May 10, the entire beacon section, along with the last of the spire and a U.S. flag, was ceremoniously lifted in place; a bit of history was made. “We watched the installation from our shop,” Kusack said. He and the crew at Kammetal, which sits across the Hudson from the WTC site, had a direct view. “We took a break to check it out and then went back to work.” No celebration? No champagne? No, Kusack said. “But seeing the towers fall in 2001, having the privilege to actually build the beacon was honor enough, for sure.” The Kammetal crew, now numbering closer to 35, has done larger jobs, Kusack said, but not like this. “The beacon project was a once-ina-lifetime opportunity for us. It was full of technical challenges as well as immense pressure, but we were building it for the victims of 9/11, and we were building it for the survivors of 9/11 as a symbol of perseverance and rebirth,” he said. “The beacon is the termination point of the building, the part that reaches to the sky. It has definitely been the most emotional project for us to ever take on.” September / October 2014 n O&MM Fabricator

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

It’s Top Job Time Attention Fabricators: Enter your outstanding work in NOMMA’s annual awards contest! Contest Information Deadline: December 31, 2014 Late Deadline: January 16, 2015* Entry details: Entrants enter by submitting 1-3 photos of their work plus a 160-word description. During the annual METALfab event, all images are displayed in a gallery and each NOMMA member firm is allowed one vote. Results are announced during the METALfab banquet. * Late fee required.

Prepare Now! Complete rules are available on the NOMMA home page — click on “Top Job Awards.” Benefits: Winners receive a beautiful plaque, plus recognition during METALfab, on the NOMMA website, and in Fabricator magazine. In addition, we also send press releases to newspapers in your area. Note: You must be a NOMMA member at the time of entry. Justin L. Pigott, Top Job Chair

Biz Side

Competitiveness vs. profitability ■

By Michael Stone

You have two options when it comes to pricing your jobs: 1 You can try to win the bidding game by offering the lowest price. 2 You can sell your products and services at the price needed to pay your direct costs, overhead, and make a reasonable profit. Every business owner makes this choice. Too many believe they don’t have a choice. They believe they have to bid and win jobs by having the lowest price. There’s no nice way to say they’re wrong. The first step in being profitable is knowing what your price needs to be. You find that out by calculating your markup for your business, based on your overhead and profit needs. This step isn’t usually a problem for most fabricators. You do math all the time in your work; putting the correct numbers together for your business isn’t an issue once you know the formula. The challenge is using that markup on all parts of every job you quote. Not some jobs, but all jobs. Marking up all jobs is challenging because too many contrac-

tors believe having the lowest price is the only way to get a job. They think that’s what it means to be competitive. The only way you will win as a business owner is if your business is profitable. The only way your business will be profitable is to sell your products or services at a price that covers your direct costs — all overhead — and makes a reasonable profit. If you aren’t profitable, you’ll soon be out of business. Being competitive sounds good, but it’s a losing game. The people who are telling you that you need to be competitive are our customers and others outside our industry. They’re used to buying other products on a competitive basis, such as groceries, cars, and clothing. You can buy groceries, cars, and clothing with competitive pricing because they’re mass-produced. Hundreds, if not thousands of identical products are made at one time. These businesses can raise or lower their prices on individual items as needed to create more business and profits. Cabela’s, an outdoors outfitter, does this. Have you seen all the O&MM Fabricator n September / October 2014

Characteristics common to a profit-focused company

means fewer opportunities to sell your service.

n Each job must stand on its own. They know they can’t cut their sales price on one job and hope to make it up on future jobs. They understand that cutting the price on a job will mean giving up some, if not all, the profits on that job. If they give up all the profits, it will almost certainly include more money needed to pay some or even all of the overhead for the company.

fewer problems for the company, get the work done faster with fewer call backs and take up less time of the management because they can think for themselves.

n Profit focused companies are aware of their “competition,” but they don’t worry about them.

Why? Because they know they can’t control the other company’s quotes, or how they conduct business. Thus, why waste time worrying about the other guys?

n They correctly calculate their markup or gross margin — and never adjust either because of “competition.” If other guys give their work away, hey, that is

their problem, which they will soon have to fix.

n Profit focused companies never use the word “free” in any advertising. They know that the word

only attracts those looking for something for nothing.

n They have a strong advertising program in place, 24/7/365. When the economy tightens up, they

understand the need to advertise more to reach those who are still in the market for their services. Cutting advertising is the worst thing a company can do. When you cut your advertising, fewer people get your message and that

advertising they send out each month? They lower a popular product’s price and the resulting increase of traffic to buy the sale item also generates purchases of other products or services at full markup. The result is a higher overall profit for the company. You’ve heard of “loss leaders”? They lose money on one product so they can generate sales of other profitable products.

n They maintain the highest pay scale for all employees. The best and highest paid employees cause

n Profit focused companies will only work on a fixed fee contract. They never work using a cost-plus

contract and only use time and material agreements for jobs under $2,500 to $3,000 (We cover this topic in depth on our website at: www.markupandprofit.com. n They’ve eliminated invoicing and billing. Instead, they put their payment schedules in their contracts, make sure that the customer knows what the payment schedule is, and that the job will be shut down if the customer doesn’t follow it. They also recognize that the only receivables that a company should have are on jobs in progress. n They know when to say “no” to a potential customer. They know when to say “no” to a change that will

cost them money. They do this nicely, they don’t burn bridges, but they say “no” when they have to. This is another way of saying that the profit-focused companies have a well developed nose for money. You also can make up your own mind to be profitable and start doing it. Or, you can continue with the idea that you can be competitive and slowly watch your company sink into debt. — Michael Stone

Fabrication work is not mass-produced

It doesn’t work like that in construction. In a construction-related business, you can’t mass-produce anything. You’ll rarely even do the same job twice. You can’t sell one job at a loss and hope the same client will purchase more jobs from you that are profitable. You can’t play this pricing game and win, but many do it anyway because

they believe the lie that pricing is what drives the purchase. It doesn’t. Every job you do is one of a kind. You may make doors, handrails, gates, sconces, and chandeliers repeatedly, but they are handmade, one of a kind items. You don’t mass-produce your products. You may buy pre-made parts, but you assemble them with other materials and parts to end up with the product the customer wants.

Shop tours available at METALfab2015 See you next year at Valley Forge Casino Resort King of Prussia, PA March 11–14, 2015

Knowledge to Enlighten the Industry

September / October 2014 n O&MM Fabricator

4 steps to handle ‘change work orders’ Improper use of change work orders is one of the major reasons that contractors have financial problems. It’s also the cause of many business failures “Change work orders” (also called “additional work orders”) should be written before any work is done that changes the scope of the job. This means any changes, regardless of the size.

Consider following this process 1 They ask for a change. 2 You make any drawings or sketches neces-

Unless you signed an agreement before a job starts stating that you will make any or all changes requested by the owner (not a good idea), you aren’t under any obligation to make changes to the original contract. If your client doesn’t like the price of the change, don’t do it. If they don’t want to pay for the change, don’t do it. Never wait until the end of the job to present a change work order to your client. Write the change up front and make sure you get paid on time. In commercial work, this isn’t always easy to do because of the contract. You’re often working under a contract that was written by someone else, and that contract might have elaborate ways of delaying payments.

sary, estimate the cost, apply your markup, and quote them a price. 3 If they agree, you write a change work When to walk away order. They sign it and make a payment. The contract might also include a number of 4 Then you make the changes to the job. reasons to not pay changes on time or at all. Any change with a price below $2,500 is paid When you’re presented with a contract like up front when they sign the agreement. © nishi55 - Fotolia.com this, if you’re smart, you’ll walk away. Any conAny change with a price over $2,500 should tract that doesn’t specify exactly how and when have two payments: half on signing, the other half at the you will be paid isn’t a contract you want to sign. next progress payment due for that job. Or you can insist that language be included in your If the change comes between the last progress payment contracts that clearly outline the payment schedule that for the job and the final payment for the job, it should be you’re willing to work under. This would include a penalty paid 100% up front, regardless of the size. It’s important to if payment schedules aren’t kept. If the owner or architect keep your final payment under 2% of the sales price of the or project manager isn’t willing to include that language, job and allowing a change work order to go unpaid will again, it’s time to walk away. result in a larger final payment. If you feel you have to take a job, regardless of the Change work orders should be priced using your norlanguage in the contract because you need the job or the mal markup plus at least 10%. The smaller the change, money, you need to reconsider business decisions that are the higher the markup.Ad ForProof example, if a change is under putting you in that position. 77035-CB-4829-08 — Michael Stone $1,000, it should be priced using a 2.0 markup.

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Each project is one of a kind. When a company is focused on selling at a low price, it ignores the financial needs of both the company and the employees. The owners find it hard to draw a salary, and the employees are often working for low wages because the company can’t afford to pay them more. And the employees know they are only one bad job away from unemployment. It’s no way to live. 4 ways to focus on profitability

What can you do to focus on profitability instead of being competitive?

1 Recognize that profitability is a mindset. Other guys, who sell to

the same customers you call on, make a profit on their jobs. O&MM Fabricator n September / October 2014

4 Keep a tight clamp on your resolve to make a profit. Remember,

You can’t sell one job at a loss and hope the same client will purchase more jobs from you that are profitable. You can’t play this

you’re in business to provide a service and make a profit doing it. If you’re in business for any other reason, you probably won’t survive.

pricing game and win, but many do it anyway because they believe the lie that pricing is what drives the purchase. It doesn’t.

Can you think of a company in your area that has a reputation of being the highest priced company? Have you ever noticed that they are also busy? You’ll often hear their customers say, “They are high priced, but worth it.” The owner decided to be profitable. Surveys show that the average customer, when given a list of the things that influence their decision to purchase, rank price as 7th or 8th. They know they are purchasing for their biggest asset, their home, and other things are more important than price. It’s often the salesperson who introduces price into the conversation. When your customers start talking about getting your price down, review what you’ve said to them. There’s a good chance you introduced price into the presentation, and now they’re simply feeding it right back to you.

For your information About the author Michael Stone has helped thousands of general contractors, new homebuilders, remodelers, and specialty contractors build stronger, more profitable businesses. Stone is the author of Markup & Profit; A Contractor’s Guide Revisited and Profitable Sales, A Contractor’s Guide, and has taught business management, sales, and estimating classes in 44 states to more than 26,000 contractors. He also provides coaching and consulting services and is available for expert witness and arbitrations. Contact www.markupandprofit.com, 888-944-0044.

2 Practice your presentation to eliminate any suggestion that you’re trying to be competitive.

You eliminate the talk of lowest price, low-priced materials, being competitive, and anything else that gets the potential customer thinking or believing that you play that game. 3 Market to the right people.

On the other hand, if they start talking about price before you even get your foot in the door, maybe you’re marketing to the wrong people. You can learn to recognize the wrong customer, the one who only cares about low price, and walk away. Let your competitor lose money building their job. You need to mend your advertising so you don’t attract those looking for cheapest price. September / October 2014 n O&MM Fabricator

Biz Side

What a fabricator is doing with a $250,000 grant ■

Living Design Studios wins small business grant from Mission Main Street because of its solid business plan, community impact, and strong team.

A staff passionate about their work went a long way in helping Living Design Studios win a $250,000 grant.

By Linda M. Erbele

“It came as a total shock when we learned we were being awarded the n Hired an employee to help improve the Every fabricator knows the effort to get a money,” says Jessica Adams, founder business processes. large job. It includes time to: of the company. “It’s been months now n Bought a MIG welder. n Review plans and blueprints. and I’m still in disbelief.” n Understand the client’s desires. The Mission Main Street grants, n Bought a cold saw. n Estimate material costs and labor. backed by Chase and Google, awarded n Attended NOMMA METALfab conference. n Often create numerous samples. $3 million to 12 small businesses last n Continued to use it to smooth out some You might not see a return for January. Winners also got a Google lapof the financial worry that comes with the months or even, in some cases, years. top and a trip to the Google HQ for a bureaucracy of doing large commercial jobs. Jonathan Falk, general manager of marketing workshop. Living Design Studios in Lafayette, CO, n Created opportunities for bigger jobs “We know that small businesses are by taking away some of the worry. describes a job, as yet unawarded, that the engine of the economy,” says Mary Jane Rogers, Chase’s vice president the company has been working on for of communications. “They are also the place where a lot two years. of innovation happens. Half of the workforce in the whole “It’s a very big house with a lot of metalwork,” he says. country is employed by small businesses.” “We’re working on samples for the main stair railing now. The 2013 program that Living Design Studios applied I’ll probably spend 200 hours fabricating samples. I’ve for drew 35,000 entrants, all for-profit businesses that were already spent close to $15,000 in time and materials on samrequired to have two years under their belt and fewer than ples for the fence.” 100 employees. This risk was made more bearable last January when the Dates for applications to this year’s Mission Main Street company was awarded a $250,000 Mission Main Street grant grants had not been released at press time, but the program from Chase Bank (www.missionmainstreetgrants.com). 66

How the grant helped

O&MM Fabricator n September / October 2014

A few tips from the Google marketing seminar In addition, Chase Chairwill be back this year. For the man and CEO Jamie Dimon 2012 and 2013 grants, applin Create brand awareness online (with your website, social came to Denver shortly after cations began being taken in media, YouTube, etc.) “People who want a metal sculpture or the announcement, and Adams October and winners were a railing need to know who they can go to,” Jessica Adams says. “You need to make sure the right people know you exist.” and Falk were among the 100 announced in January. top clients invited to a dinner What’s the catch? There’s not n Take advantage of search engine optimization (SEO). in his honor. That included one. The funds are to enable Learn (or hire someone who knows) what words that people put in a search box will lead them to your website. more networking and learning the small business to execute from other businesses. its business plan, resulting in n Online applications can help you achieve personal Speaking with the woman the growth of the business. relationships. “If they don’t know you exist, there’s no chance of developing a personal relationship,” Adams says. seated next to him, Falk “They’ve invested in our learned she manages a truckfuture, but they’re not calling ing firm. That contact will be us to see how we spent it,” Falk struggles, successes, and what made helpful when Living Design Studios says. things work well. completes a job on which it is working Rogers confirms. One of the great “Google gave us insights on how to that will involve a shipment to Aspen. things about the grants — recipients are use what they do. How to make your not “held accountable.” Internet presence more accessible, how “It’s basically, ‘here’s the check, now to word it so that people looking for you Company got free marketing video go and do,’ ” she says. “We like for them can find out what you do,” he says. “I Rogers arranged for a professionally to keep us posted because we consider was blown out. I’m not a computer guy, made video about the company featurthem a part of our Chase family.” but to find that you could use words ing its employees, which is posted on The family includes the other 11 win that way and incorporate YouTube into the Mission Main Street Grants website. your marketing was great.” (See list on ners. Falk said that one of the positives (http://bit.ly/LWKJxk) this page for a few other tips.) is mingling with the other grant recipi Falk said the video even played in Falk and Adams especially enjoyed ents during the 21/2-day Google marketChase New York headquarters for a few Google’s marketing seminar, although ing seminar. Meeting at the hotel and weeks. It’s hard to say, he adds, whether they’ve only begun to implement the at dinner, he said the owners from the it has actually created any business for insights. very diverse businesses talked about them yet.

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September / October 2014 n O&MM Fabricator

The Mission Main Street Grant

What you need to know

How to qualify

The Mission Main Street Grant program will be back this fall. Go to www.missionmainstreetgrants.com for deadlines, final rules, and other information. 1 Create an account with an email and password. 2 Complete the profile, which includes

business name, address, industry, owner’s name, and contact information.

3 Answer the five essay questions:

Tell us about your business. What inspired you to start your business? How is your business successful? What makes it unique? n How is your business involved with the community you serve? n What would a $250,000 grant mean to your business and how will you use the funds to ensure longterm growth and stability? n What challenges can you identify for your business, and how do you plan to overcome them?

Describe the talent and skill of your employees, and how they contribute to a successful business.

4 Get at least 250 Facebook “likes.” Who is eligible to compete?

For-profit businesses in the U.S. that have been in business for two years. Business owner or partner must be 18-years or older and a legal resident with a valid employer ID. Business must have fewer than 100 year-round, full-time employees and not be owned by or have a partner who is an employee of Chase or its affiliates. Grant recipients agree to refrain from marketing activity with Chase competitors for a year after the grant.

“I’m sure it’s had a positive effect on the public about who we are,” he says. “People tell us it’s good.” Stories about them were in local and national papers. At least one new customer called them for a stove hood because he had seen the stories. 21 ‘amazing’ staffers after 10 years

Jessica Adams founded Living Design Studios as a sole proprietorship in 1995. “It’s what I have always done as long as I can remember,” she says, although owning and running a business wasn’t what she envisioned when she was young. “I only thought I wanted to build these amazing things out of metal and see how I could stretch my limits.” Sales and stretching limits led to a business launch. In 2000, the company became a subchapter S corporation. Falk joined in 2003 and was a partner in a couple of years. Now 21 employees work in a 12,000-square-foot building. “We have an amazingly diverse team, and by pulling from the best of everyone, we are greater than the sum of our parts,” Adams says. Falk agrees that the drive and 68

What are judges looking for

Solid business and management team/owner (20%). Well thought-out and feasible growth plan (20%). n Likelihood to succeed within two years (20%). n Positive impact on local/relevant community (e.g. job creation, meeting an unfulfilled need) and demonstrated local support (20%). n Energy, enthusiasm, creativity, and passion for your business (20%). n n

expertise of the team is largely responsible for the company’s success. “Our shop staff is amazing. They are the heart and soul of the business. They’re always working on stuff and inventing tools to help do something that are just mind-boggling to me,” he says. Recently a job called for a 300 pound piece of glass for the Denver airport. Employees brainstormed a device to carry it in, roll it through the building, and then adjust it into position. Another employee, on his own, decided the company’s website could be better. He spent his weekend redesigning it. On Monday, he showed Jessica and Jonathan the results, proposing that if they liked it, they could pay him for the time, but if not, that was fine. “We were thrilled with it,” Falk says. They create staircases, railings, fireplaces, doors, gates and fences with as much of an artistic flair as a client wants. In the last few years, they’ve expanded into commercial jobs as much, if not more than, residential. The expansion grew organically as they took on bigger and more challenging jobs, but Falk says many compo-

nents to the commercial side have nothing to do with cutting metal, welding, or finishing. Approvals can take much longer resulting in delays in payment. Plus, drug testing, background checks, and audits take time. “If you’re doing a project, you’ve got to think about how to pay your employees and pay for materials while you’re waiting what could be months to get paid for the job,” he says. “It took a willingness to commit to that bureaucracy.” They’ve worked two sizable projects at the Denver airport, including 2,100 feet of railing and stainless steel elevator jambs. They are creating store fixtures for Vince clothing stores and a railing for a Jimmy Choo store in Beverly Hills. They’ve also been awarded a large project for a staircase in Miami. On the residential side, Falk says people are attracted to what he calls “pushing the envelope.” “The more you are in people’s houses, the more they understand what is possible with metal,” he says. “We’re making bookcases for a home completely out of metal. We’ve done steel panels on walls or in an elevator where O&MM Fabricator n September / October 2014

Above, an architectural bronze and stainless steel railing spans several levels and hundreds of feet. The infill is made of rolled bronze flat bar with a clear coating and square stainless steel posts. The two pieces are riveted and plug welded at the base and grab rail. Left, Jessica Adams, founder of Living Design Studios, and general manager Jonathan Falk.

someone would have just painted it. That is the kind of thing we like to offer. Sure, you can make it out of wood, but here’s a finish on steel you could use and boy, does that look good.” How they have used the money

Falk says the company was expand ing before they got the grant; business had been steadily growing. They took out a showroom in their building and re-vamped it for more workspace. In the last few months, they’ve hired three people, one specifically tied to the grant. That employee, an architect from the University of Colorado, is working on streamlining processes. “Our response time to people’s queries has been dramatically improved,” Falk says. “He has the ability to digest what a customer is looking for quickly, so the estimate is much quicker and more thorough.” Falk says they are dedicated to improving the processes involved with customer service, change orders, and billing. “What I’ve discovered is that when you grow your business, you get to the point where you have to change from a September / October 2014 n O&MM Fabricator

personality-driven business to a process-driven business,” he adds. Taking it to the architects. Much of their business comes either by referrals from contractors they have worked with or their direct marketing with architectural firms. “We bring lunch for the office and set up a projector in the conference room,” Falks says. “People don’t know what is possible with metal.” The new employee created a book of photographs of Living Design Studios’ more spectacular pieces. They take it to home shows and to architects. Jonathan is adamant that while the grant has been helpful, Living Design Studios would have found a way to do those jobs anyway. He and Jessica and the company’s employees are passionate about the work they do. “When we see something we really want to do, we take it personally,” he says. Mission broadens. The grant has created opportunities for bigger jobs by taking away some of the worry about continuing to work while waiting to get paid. They bought a $10,000 MIG welder for aluminum and a cold saw. If they are awarded the job they’ve

been working on for two years, they will buy more equipment. “We’re not as limited in our vision about what we want to build. I’m looking at a job in Santa Fe right now. Two years ago, I would have said, ‘are you crazy — that’s out of reach,’ ” he says. “Now, we go after things seemingly out of reach. Those things are out there, and they are a goal. It’ll be a huge challenge if we get it. I’ll be nervous and scared and worried, but we’ll be able to accomplish it. It used to be ‘one day.’ Now it’s ‘yes, I’m not intimidated.’ ” He says the grant enabled them to attend NOMMA’s METALfab. “We’ve wanted to go, but hadn’t,” he says. “With the grant, it was like, no question. We’ve always been big fans of NOMMA, and now we’re huge fans.” How they won

Applying for the grant is rather simple. It requires 250 Facebook “likes” from friends and clients. And five essay questions must be answered. The company got 271 Facebook votes, which isn’t as easy as it sounds. “This required a concerted effort from our whole staff and was much harder than we expected,” Adams says. “We reached out to vendors, clients, colleagues, friends, family, and many organizations that we’re part of, both as a business and personally. It was a great reminder of how involved we are with our community. And how much they wanted to see us succeed. “Once I fully understood the intent and criteria (see sidebar, page 68) for the grant and we started working on our essays, I realized we were an exact match for the kind of businesses Chase was looking for,” Adams says. “To me, the question was how good a job we would do in demonstrating that in our submission.” The essay part of the entry is, well, not the kind of thing many fabricators feel comfortable doing. Worrying about what to say kept Adams up at nights. Falk says they talked often about it, wrote, edited, then talked more. Initially, Adams thought it was limited to 500 words, then discovered it was 500 characters. They had to be “extremely succinct.” 69

of the language of art. This was new and has remained valuable. It was also a wonderful opportunity to step back and see the big picture of why and how the company started. Where we were at the time of submittal and to dream of what and who we wanted to become.” Among the criteria considered by judges, in addition to a solid business plan, likelihood of success, and passion for the business, is a positive impact on the local community. “My favorite part about the writing was realizing how much this is true for us,” Adams says. “We are a part of an eco system of other small businesses, relying on our local community for providing the right kind of staff and staying involved with the next generation to make sure that this craft stays alive.” Falk agrees. “We always have outside work done locally. We have accounts at the local lumber yard and hardware store,” he says. “I think that was a critical part of what they were looking for; a small business, adding jobs and spending money in the local community.”

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Rogers says the selection panel found Living Design Studios to be an engaging company. “They appreciated that it was a woman-owned business,” she says. “They liked the story. They found everything about Living Design Studios to be compelling and different enough to stand out.” Adams and Falk are both grateful. “I really respect them for investing in small business,” Falk says. “Every body involved is in it because they loved being in business, and they were going to do it no matter what.” Adams agrees. “There are so many great fabricators, craftspeople, and artists out there. I believe that many of us are doing similar things,” she says. “Perhaps our greatest capability is being able to understand and communicate in a language that is different than our own. Whether that be about business, state policy, education, design, welding, installation, etc., we are able to learn the needs of our clients, our team members, and our business partners and find a way to match them with our own.”

For your information

She says they wrote about growing from nothing to success. “We showed how we pulled from excellent project management to give us a competitive edge,” she says. “We showed how we are in the right place [Colorado] to succeed. . . . There are all the high-end resorts, which lend itself to commercial work. Then there are big private residen tial neighborhoods surrounding those resorts. There is a thriving commercial industry in Denver and a huge light rail transportation project going on.” Their answers showed that the grant money would provide “10-fold” growth into the future and feed on itself. The essay questions are self-reflective. “We loved that part of it,” Falk says. “It got us thinking about where we are and where we’ve been and what we want to achieve.” Spending time answering essay questions in a contest where you are competing against 35,000 other entrants might seem like a time waste. “It did feel like an exercise,” Adams says. “A very valuable one. I learned to write in the language of business instead

Living Design Studios Jessica Adams, Founder Jonathan Falk, General Manager 1005 South 120th St., Ste. 102 Lafayette, CO. 80026 Phone: 303-442-2614 info@livingdesignstudios.com www.livingdesignstudios.com YouTube video www.youtube.com/ watch?v=vA3XcV033rI Mission Main Street Grants www.missionmainstreetgrants.com Chase Communications Mary Jane H. Rogers Maryjane.h.rogers@chase.com 303-244-3142 About the author Linda Erbele, an Atlanta-based writer 15 years of journalism experience, specializes in business and travel writing.

O&MM Fabricator n September / October 2014

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NOMMA Nationwide Supplier Members NOMMA Nationwide Supplier Members Albina Pipe Bending Co. Inc. dba Albina Co. Inc. 503 692-6010

Allen Architectural Metals Inc. 800 204-3858

Alloy Casting Co. Inc. 972 286-2368

American Punch Co. 216 731-4501

Ameristar Fence Products 918 835-0898

Architectural Iron Designs Inc. 908 757-2323

Atlas Metal Sales 800 623-0143

AZZ Galvanizing

815 618-8440

Banker Wire

800 523-6772

Big Blu Hammer Mfg. 828 437-5348

Julius Blum & Co. Inc. 800 526-6293

Bridgeton Drafting Co. LLC 856 205-1279

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

Cable Art Inc.

661 257-7522

The Cable Connection 800 851-2961

Carell Corp.

251 937-0948

Carl Stahl DecorCable Innovations 800 444-6271

Century Group Inc. 337 527-5266

Chicago Metal Rolled Products Co. 800 798-4504

CM Iron Supply LLC 480 968-5121

CML USA Inc. Ercolina 563 391-7700

Colorado Waterjet Co. 866 532-5404

Custom Orn. Iron Works Ltd. 866 464-4766

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

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

DAC Industries Inc. 616 235-0140

The Iron Shop

Powder-X Coating Systems

Kammetal Inc.

Precision Glass Bending Corp.

800 523-7427 718 722-7400

King Architectural Metals 800 542-2379

DKS, DoorKing Systems

King Architectural Metals - CA

Eagle Bending Machines Inc.

King Architectural Metals - MD

800 826-7493

251 937-0947

Eastern Metal Supply 800 343-8154

Elite Architectural Metal Supply LLC 847 636-1233

EPi

714 670-8980

410 644-5932

Krando Metal Products 610 543-4311

L.E. Sauer Machine Co. 636 225-5358

Lavi Industries

800 624-6225

262 786-9330

ETemplate Systems 919 676-2244

Lawler Foundry Corp. 800 624-9512

888 326-4840

800 543-8796

ProCounsel

214 741-3014

Q-Railing USA Co. 714 259-1372

Ransburg

419 470-2000

Regency Railings Inc. 214 742-9408

Robinson Iron Corp. 800 824-2157

Rockite, Div. of Hartline Products Co. Inc. 216 291-2303

Rogers Mfg. Inc.

940 325-7806

FabCAD Inc.

Lewis Brass & Copper Co. Inc.

Sculpt Nouveau

The Fabrication Store

Lift Master

SECO South

Farris Fab & Machine Co.

Locinox USA

Sharpe Products

Feeney Inc. (Feeney Architectural Products)

Mac Metals Inc.

South Camden Iron Works Inc.

800 255-9032 866 79-FAB-4-U 704 629-6879

800 888-2418

The G-S Co.

410 284-9549

Gates That Open LLC (GTO) 850 575-0176

Geo. Bezdan Sales Ltd. 604 299-5264

718 894-1442 630 279-3600 708 579-0286 800 631-9510

Marks U.S.A.

631 225-5400

McKey Perforating 262 786-2700

McNichols Co.

847 635-5100

Hartford Standard Co. Inc.

Mittler Bros. Machine & Tool

Hayn Enterprises LLC

Multi Sales Inc.

270 298-3227

860 257-0680

Hebo/Stratford Gate Systems Inc. 503 722-7700

Heritage Cast Iron USA 918 592-1700

Indiana Gratings Inc. 800 634-1988

Industrial Coverage Corp. 631 736-7500

Industrial Metal Center Co. WLL

965 24748903/5/7

Interstate Mfg. Associates Inc.

800 467-2464 800 421-3575

Nationwide Industries 813 988-2628

NC Tool Co.

336 674-5654

O.K. Foundry Co. Inc. 804 592-2240

Ohio Gratings Inc. 330 477-6707

Orleans Orn. Iron & Casting Dist. Inc. 504 945-4466

Pacific Stair Corp.

760 432-8242 888 535-SECO 800 879-4418

856 423-1107

Stairways Inc.

713 680-3110

Suhner Industrial Products Inc. 706 235-8046

Sumter Coatings Inc. 888 471-3400

Transpacific Industrial Supply Inc. 909 581-3058

Tri-State Shearing & Bending 718 485-2200

TS Distributors Inc. 832 467-5400

Vogel Tool & Die LLC 630 562-1400

The Wagner Companies 888 243-6914

West Tennessee Ornamental Door 901 346-0662

503 390-8305

800 667-9101

September / October 2014 n O&MM Fabricator

New NOMMA Members Meet our members

NOMMA is proud of its 550+ members. As members, fabricators and suppliers show support for both the association and entire industry. To get contact information on a member, please see our Member Locater at www.nomma.org.

Hawke Industries* Fred Bredthauer Desert Hot Springs, CA Fabricator

All Metals Welding & Fabrication Inc. John Jimenez Zellwood, FL Fabricator

Iron-Works International Inc.* Angelo Viale Atlanta, GA Fabricator

Cape Cod Fireplace* Robert P. Jones Hyannis, MA Fabricator

Jones Valley Iron Works* Ray White Birmingham, AL Fabricator

Construction Services LLC* Dean Frantz Blacksburg, VA Fabricator Decorative Metal Services Inc. Margaret Kibbee-Martin Vancouver, WA Fabricator Designer Iron-Works* John Bayer Baton Rouge, LA Fabricator Duke of Iron Inc.* Paul Montelbano Smithtown, NY Fabricator Frattle Stairs & Rails Inc.* Donald Ralph Frattle Jr. Jacksonville, FL Fabricator Gator Welding Inc.* Bob Nogal Jupiter, FL Fabricator Gehret Wire Works* Robbie Ebert Philadelphia, PA Fabricator

L & L Ornamental* Larry D. Brown Salem, OR Fabricator Medwedeff Forge & Design* John Medwedeff Murphysboro, IL Fabricator Mel Glover Ornamental Iron* Mel Glover Orlando, FL Fabricator New York Architectural Metals Corp.* Ken Maksym Bellmore, NY Fabricator Noel Welding Center Inc.* Noel Strachan Chatsworth, CA Fabricator Orleans Orn. Iron & Casting Dist. Inc.* Daniel Liebert New Orleans, LA Nationwide Supplier

NOMMA is pleased to welcome our newest Gold Members — companies who have been a member for 20 years or more. These companies show a strong loyalty to both their industry and trade association. We thank them for their support. Architectural Iron Designs Inc. Berger Iron Works Inc. n Creative Forge - Reichert Corp. n D’Agostino Iron Works Inc. n DAC Industries Inc. n Emerald Ironworks Inc. n Historical Arts & Casting Inc. n Jesco Industries Inc. — Wire & Iron Products Div. n Keystone Metals Inc. n Liberty Home Products n Louis Emmel Ornamental Iron Inc. n Mac Metals Inc. n New Hampshire Steel Fabricators Inc. n Outland Steel Inc. n Pinpoint Solutions n Van Dam Iron Works n Van Linda Iron Works Inc. n n

New members as of August 15, 2014. *Asterisk denotes returning member Advanced Cutting Services* Bob Balchunas Roselle, NJ Fabricator

NOMMA 2014 Gold Members

Railco Metalcraft* Wes Shelton Butler, NJ Fabricator Rock Farm Studio Jim Laney Lacey’s Springs, AL Fabricator RW Crittenden Iron & Steel LLC Ariel Crittenden Riceville, TN Fabricator State Street Steel Co.* Chris Wierz Chicago, IL Local Supplier Weaver Welding & Fabrication* Larry Weaver Lenox, IA Fabricator Western Architectural Iron Co.* Edward M. Rundgren Chicago, IL Fabricator Zimmermann & Hughes Landmark Designs Inc.* Chris Hughes Prompton, PA Fabricator

Plainfield, NJ Houston, TX Telford, PA Rochester, NY Grand Rapids, MI Woodbridge, VA West Jordan, UT Litchfield, MI Pittsburgh, PA Denver, CO Coraopolis, PA Kearny, NJ Goffstown, NH Caldwell, ID Jupiter, FL Grand Rapids, MI Lake Worth, FL

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

Join the Iron Club 2014–2015 Get your Chapter Involved! Chapters can award a free METALfab registration for every 4 members they recruit! We will have a NOMMA Chapter competition this year and the winning chapter will be awarded a Special Reception at METALfab2015. The competition began July 1. Individuals and chapters may sponsor a member for a $75 discount off METALfab 2015 registration. Sponsor 4 members and 1 registration is free! To sponsor a member, encourage your suppliers, partners, contractors, and nearby fabricators to join. If inviting them by email, send them this link: http://tinyurl.com/q6a62r5 Contact Liz Harris at liz@nomma.org and she will follow up with you and your new member prospects. The Iron Club began a new recruiting year in July 2014. The Iron Club membership is made up of those who have sponsored (recruited) new members to join NOMMA. You can sponsor a new member by inviting them to join NOMMA and having them send in their membership application. To ensure credit for this member, have them list your company as a sponsor on their application. Iron Club Members show special dedication and leadership through their member recruitment efforts. We honor them for their outstanding efforts. NOMMA Salutes sponsors thus far for the 2014–15 membership year n Jon McGraw, Alloy Casting Co. Inc. n Mark O’Malley, O’Malley Welding & Fabricating Inc. n Dave White Jr., Locinox USA

O&MM Fabricator n September / October 2014

Whatâ&#x20AC;&#x2122;s Hot? n

Industry News

Architecture Billings Index signals improving conditions The Architecture Billings Index (ABI) is signaling improving conditions for the overall design and construction industry. As a leading economic indicator of construction activity, the ABI reflects the approximate 9â&#x20AC;&#x201C;12month lead time between architecture billings and construction spending. The American Institute of Architects (AIA) reported the June ABI score was 53.5, up from a mark of 52.6 in May. This score reflects an increase in design activity (any score above 50 indicates an increase in billings). The new projects inquiry index was 66.4, up noticeably from the reading of 63.2 the previous month and its highest level in a calendar year. The AIA has added a new indicator measuring the trends in new design contracts at architecture

September / October 2014 n O&MM Fabricator

Billings up in all building specialties for 1st time since last summer Graph represents data from June 2013 through June 2014 across three sectors: 1) residential, 2) commercial/industrial, and 3) institutional. 50 represents the diffusion center. A score of 50 equals no change from the previous month. A score above 50 indicates an increase. Below 50 indicates a decrease. 60

Residential 57.7 Commercial/industrial 53.1 Institutional 50.2

45 Jun 2013

Oct 2013

Feb 2014

Jun 2014

What’s Hot? n firms that can provide a strong signal of the direction of future architecture billings. The score for design contracts in June was 55.7 — the highest mark since that indicator starting being measured in October 2010. Other highlights n Regional averages: Midwest (56.3), South (53.9), Northeast 51.1) , West (48.7).  n Sector index breakdown: multi-family residential (57.7), mixed practice (53.8), commercial / industrial (53.1), institutional (50.2).  n Project inquiries: 66.4.  n Design contracts: 55.7. “The recent surge in both design contracts and general inquiries for new projects by

Industry News

prospective clients is indicative of a sustainable strengthening across the construction marketplace,” says AIA Chief Economist Kermit Baker. “With the first positive reading since last summer in billings at institutional firms, it appears that design activity for all major segments of the building industry is growing. “The challenge now for architecture firms seems to be finding the right balance for staffing needs to meet increasing demand.” The diffusion indexes contained in the full report are derived from a monthly “Work-on-the-Boards” survey that is sent to a panel of AIA member-owned firms. Contact 800-AIA-3837 www.aia.org

Feeney opens east coast facility Feeney, Inc., opened on June 1 an 87,000-square-foot East Coast distribution center servicing all of the company’s authorized dealers east of the Mississippi River. With an increasing dealer and customer base, Feeney is expanding distribution to maintain its commitment to delivering high-quality products and superior service, the company says. Facilitating a quicker ordering and delivery process, and reducing shipping costs, the East Coast Distribution Center will enable dealers to receive orders three to six days earlier than if shipped from the company’s Oakland, CA, plant.

The Distribution Center has case packs in stock for all of the most popular packaged products including CableRail assemblies and accessories, Intermediate Pickets, Quick-Connect fittings and cable, and DesignRail Aluminum Rail Kits. Feeney, Oakland, CA, manufactures cable railing assemblies, aluminum railings, and architectural solutions for residential and commercial buildings. Contact 800-888-2418 www.feeneyinc.com

O&MM Fabricator n September / October 2014

What’s Hot? n

Media

3D view station Kisters The company has released the 2014.1 version of its 3DViewStation, known for its modern user-interface, high performance 3D-viewing and Digital MockUp, current and mature CAD-importers for Catia, NX, Creo, SolidWorks, JT, 3D-PDF, and STEP, plus a set of functional tools to view, analyze and communicate 3D-data, the company says. The new version ships with a fresh Office 2013 compliant user interface and provides functionality that can be leveraged by the user quite intuitively, the company says.

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What’s Hot? n Digital design and specs binder available PPG Industries The company’s coil and building products coatings group has announced that its Architectural Metal Coatings binder is now available online in a digital, downloadable format at www. ppgideascapes.com. The digital binder features fully updated catalogs, product brochures and data sheets for PPG’s entire roster of PPG liquid coil coatings, such as Duranar and Coraflon fluoropolymer and Durastar polyester coatings, and liquid and powder extrusion coatings, such as Duranar and Coraflon fluoropolymer and Envirocron polyester coatings.

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The binder also contains PPG color guides, technical documents, white papers and case studies, along with sourcing information for PPG CAP certified applica-

tion program group participants and PPG-approved extrusion applicators and coil coaters. The new digital binder

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demonstrates PPG’s commitment to “green” building and design, and it will complement PPG’s growing array of online tools, including a newly enhanced searchable project gallery, says Sharon Bird, PPG marketing communications manager, industrial coatings. “PPG is committed to sustainable business practices. This new digital binder shows that commitment while giving architects, specifiers, coaters and applicators access to the latest product information from PPG, even when they are on the go,” she said. Contact 888-PPG-IDEA www.ppgideascapes. com

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O&MM Fabricator n September / October 2014

What’s Hot? n

Products

Surface finishing tool CS Unitec CS Unitec’s Varilex WSF 1800 speed-controlled surface finishing and blending tool provides 25 percent more power and increased productivity, the company says. With a powerful 15 amp (1,710 watt) motor and infinite variable-speed control (2,000–7,600 rpm), the operator can perform a multitude of tasks from rough grinding and blending to polishing up to a mirror finish. Varilex comes standard with a 5-inch safety guard. Optional guards are available in 41/2 inch and 7 inch. Variable speed control has important benefits, according to the company. It doubles the service life of the abrasive disc, and prevents glazing of the disc and heat deformation of the work piece. It also drastically reduces the noise level. Another feature of the Varilex motor is its tachogenerator feedback technology. This keeps the power output and torque constant, while operating at any rpm. The result is a uniform finish.

control system. Created for the welder on the go, the Miniflex removes and filters welding fumes wherever welding operators go, including confined and other hard-to-reach spaces. The Miniflex is less bulky than other welding fume extractors and features standard wheels, handle, and lightweight, synthetic materials. It offers a dual-filtration system made up of a primary LongLife-H filter and a HEPA output filter. Lincoln Electric’s redesigned Miniflex also includes two new features: n Carbon brush early warning system. Alerts the user when 80 percent of the

carbon brushes have been consumed. n System airflow check. Allows users to check the extraction performance of the unit and indicates when a filter is saturated and requires replacement to maintain optimal performance. Contact 888-935-3876 www.lincolnelectric.com

Designed and developed for heavy industrial use, the Varilex Surface Finishing Tool is equipped with a patented Easy-Lock clamping nut and spindle lock button allowing the user to change discs in seconds, without tools. The spindle thread connection is a standard 5/8-inch-11 UNC. An ergonomic, vibraHand Tube Bender Rolls: tion-reducing, balanced  1Hand 1/2” Square TubeTubing Bender Rolls:$499.95 handle allows fatigue-free Hand Tube Bender Rolls: grinding and the quick-lock Hand Tube Bender Square Tubing  1 x1 11/2” 1/2” Rectangular Tubing Rolls: $499.95 style power cord allows for  11/2” Square Tubing $499.95  1 1/2” Square Tubing $499.95  1 xBar 1 1/2” Tubing Flat (1/2 Rectangular x 1 1/2” & smaller) easy tool change and a safer  1xPipe 1 1/2” Rectangular Tubing Tubing 1 x(1/2 1 1/2” Rectangular x 1 1/2” & smaller)Tubing Tube Bender Rolls: Flat&Bar workingHand environment.  Flat Bar (1/2 x 1 1/2” & smaller)  Flat Bar (1/2 x 1 1/2” & smaller) Pipe & Tubing The Varilex ideal for  1 1/2”isSquare Tubing $499.95 Magnum Hand Tube  Pipe & Tubing  Pipe & Tubing Bender Rolls: use withflap 1 x discs, 1 1/2”grinding Rectangular Tubing Magnum Hand Tube Bender Rolls: and polishing discs, as well $649.95 Square Tubing  2”Rolls:  Flat Bar (1/2 x 1 1/2” & smaller) Magnum Hand Tube Bender Magnum Hand Tube Bender Rolls: as the Fix Hook and Loop $649.95 TubingTubing 1 x2”2”Square  Pipe & Tubing Rectangular polishing system, cleaning $649.95$649.95 Tubing 2” Square Tubing  2” Square  1 xBar 2” Rectangular Tubing discs, and cutting wheels. Flat (1/2 x 2” & smaller) Magnum Hand Tube Bender Rolls: : 1 x 2” Rectangular Tubing s Safety guards from 41/2 1 x(1/2 2”xRectangular Tubing Roll Flat&Bar 2” & smaller)  Pipe Tubing inches$649.95 to 7 inches are availFlat Bar (1/2Flat x 2”Bar & smaller)  2” Square Tubing (1/2 x 2” & smaller)  Pipe & Tubing able for use with various-size  Pipe & Tubing  1 x 2” Rectangular Tubing Pipe &Available Tubing grinding, blending, and polAdditional Rollers ishing discs of 4 inches to 7 Flat Bar (1/2 x 2” & smaller) Additional Rollers Available inches in diameter. 1-800-200-4685 Additional Additional Rollers Available Rollers Available  Pipe & Tubing Contact 800-700-5919 1-800-200-4685 www.csunitec.com UNIQUE1-800-200-4685 ROLLING SYSTEM 1-800-200-4685

TUBING BENDERS TUBING BENDERS TUBING BENDERS TUBING BENDERS Magnum TUBING BENDERS Hand Tube $699.95 Bender

Works with both hand tubing benders

UNIQUE ROLLING SYSTEM Additional Rollers Available Cap Rails Redesigned weld Works with both hand tubing benders UNIQUE ROLLING SYSTEM $599.95 UNIQUE ROLLING SYSTEM Works with both hand tubing benders fume extractor Works withChannels both tubing benders Caphand Rails $599.95 Lincoln Electric Cap Rails Rails Channels $599.95  Flat Bar Cap (on edge hard way)$599.95 Lincoln ElectricUNIQUE has ROLLING SYSTEM Channels Channels  Flat Bar (on R&benders D Hydraulics, Mfg. and Machine Co.edge hard way) Works with both hand tubing enhanced its next-gener Flat Bar (on edge hard way) 1431 West 5th St. Chico, CA 95928 www.rdhs.com  Flat Bar (on edge hard way) ation Miniflex weld fume Cap Rails R&D Hydraulics, Mfg. and Machine Co. $599.95

September / October 2014 n O&MM Fabricator

1-800-200-4685

1431 5th Chico, CAMachine 95928 www.rdhs.com R&D West Hydraulics, Mfg. and Co.Machine Co. R&St. D Hydraulics, Mfg. and Channels 201307-404-A 1431 West 5th St.West Chico, 1431 5thCA St.95928 Chico,www.rdhs.com CA 95928 www.rdhs.com 79  Flat Bar (on edge hard way)

R&D Hydraulics, Mfg. and Machine Co.

What’s Hot? n

Products

3-D part manipulators TDA Buddy

TDA Buddy custom designs and manufactures industrial pneumatic manipulators that help a single worker perform precise material handling placement. The 3-D part manipulators go beyond the usual pick and place tasks, says the company. They grip parts up to 400 lbs., roll, pitch, or yaw if necessary, hold it rigid, and place it accurately for the next operation. The manipulators feature a unique neutral balance tech-

nology that allows the parts to float, making them feel weightless. TDA Buddy pneumatic manipulators are available with various types of grippers to lift almost any part configuration, including metal blanks with holes. End effectors (tooling) are offered with vacuum, mechanical, or pneumatically actuated grippers. The manipulators feature a standard 10-foot reach radius, a vertical travel of 64 inches, and rotation up to 360°. Mounting options include fixed floor, fixed overhead, overhead rail, press face mounted and a portable base plate for forklift repositioning. Contact 269-349-8105 www.tdabuddy.com Tool outfit Uniweld Uniweld’s The Wurks includes the tools necessary to work on just about any project, including automotive, general home maintenance, plumbing, and welding, says the company. The Wurks

comes in three different styles and is an easy to operate, all-purpose outfit packed in its owned rugged tool box with compartmented accessory tray. The Wurks offers cutting and welding capacities with its supplied tips that can be expanded with other tips sold separately. Included in every Wurks box are one welding handle, one cutting attachment, one cutting tip, one welding/brazing tip, one medium duty oxygen regulator, one medium duty acetylene regulator, one 121/2-foot twin hose, one pair of safety goggles with flip-up shade, one flint lighter, one tip cleaner, and one set of leather welding gloves. Contact 800-323-2111 www.uniweld.com

abana.org

Join us at one of these conference locations in our series: Washington, DC April 2-3, 2014 neW orleans, la May 7-8, 2014 Boston, Ma July 16-17, 2014 st Paul, Mn Sept 25-26, 2014

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Artist-Blacksmith’s

Association of North America, Inc. O&MM Fabricator n September / October 2014

80 1-4_tradbuilding.indd 1

2/14/14 3:56 PM

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

Website

Pg Company

Website

18 Albina Pipe Bending Co. Inc. (DBA Albina Co. Inc.)................................................www.albinaco.com

35 Krando Metal Products Inc.........................................www.krando.com

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

37 Krando Metal Products Inc.........................................www.krando.com

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

38 Krando Metal Products Inc.........................................www.krando.com

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

47 Lapeyre Stair.......................................................... www.lapeyrestair.com

78 Atlas Metal Sales..................................................... www.atlasmetal.com

17 Lawler Foundry Corp.......................................www.lawlerfoundry.com

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

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

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

36 Krando Metal Products Inc.........................................www.krando.com

34 Lockey Digital Systems Inc................................... www.lockeyusa.com 45 Mac Metals Inc....................................................... www.macmetals.com

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

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

33 The Cable Connection........................ www.thecableconnection.com

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

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

65 Pat Mooney Inc............................................www.patmooneysaws.com

39 Carell Corporation................................................... www.carellcorp.com

56 National Bronze & Metals Inc........................... www.nbmmetals.com

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

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

26 COLE-TUVE/CT Machinery.......................................www.coletuve.com

40 PLASMA CAM Inc..................................................www.plasmacam.com

70 Colorado Waterjet Co............................... www.coloradowaterjet.com

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

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

59 Regency Railings............................................ www.regencyrailings.com

6 DKS, DoorKing Systems........................................... www.doorking.com

11 Rogers Mfg. Inc................................................ www.rogers-mfg-inc.com

44 Doringer Cold Saw..................................................... www.doringer.com

57 Scotchman Industries........................................... www.scotchman.com

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

24 Sharpe Products............................................ www.sharpeproducts.com

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

21 Shop Outfitters/Lockdown Securities....... www.shopoutfitters.com

4 FabCad Inc....................................................................... www.fabcad.com

70 Simonian Bender.........................................www.simonianbender.com

16 Farris Fab & Machine Company..............................www.farrisfab.com

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

31 Feeney Inc...................................................................www.feeneyinc.com

55 Stairways Inc.........................................................www.stairwaysinc.com

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

20 Sumter Coatings Inc.....................................www.sumtercoatings.com

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

11 Tom’s Ornamental Iron Works........ www.tomsornamentaliron.com

46 Hougen Mfg. Inc.......................................................... www.hougen.com

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

13 Hypertherm Inc.....................................................www.hypertherm.com

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

50 International Gate Devices........................................www.intlgate.com

19 TS Distributors Inc............................................. www.tsdistributors.com

84 The Iron Shop.......................................................www.theironshop.com

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

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

15 The Wagner Companies........................www.wagnercompanies.com

83 King Architectural Metals.................................... www.kingmetals.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 September / October 2014 n O&MM Fabricator

Advertise in the 2015 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, 2014 Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; stheien@att.net 81

Metal Moment

Student cutting, welding contest deadline Oct. 31 Victor Technologies, St. Louis, will award more than $30,000 in

Some schools receiving donations from Victor Technologies

equipment and cash prizes as part of its 2014 “A Cut Above” student contest. The contest is open to students in cutting, welding, and related programs at high schools and colleges. This year is the fourth year of the contest. Victor has awarded more than $90,000 in cash and equipment to secondary and post-secondary schools. Three beginner students will each win $250 by submitting a 500-word essay that the judges deem to best support the contest theme. Judges also choose three advanced student winning teams with each winning team member getting $500. Advanced students submit a team metal fabrication project that incorporates an oxy-fuel, air-fuel, or plasma cutting process. Each of the schools associated with the winners at their time of entry receive the following, valued at more than $4,000: n One Victor Medalist 250Medium Duty Cutting System n One Victor Thermal Dynamics Cutmaster 42 Air Plasma Cutting Outfit n One Tweco Fabricator 211i3-in-1 Stick-MIG-TIG Welding Machine Kit n Two Tweco4-sensor auto-darkening welding helmets Entries are accepted through October 31. Rules and entry forms are available at www.victortechnologies.com/acutabove. Victor Technologies provides cutting, gas control, and specialty welding equipment. Contact 636-728-3057, www. victortechnologies.com

Previous winners. Students, left to right, Garrett Shafer, Ryland Barney, and Cody Gifford of Highland High School in Gilbert, AZ, built a life-size “Victor Man” sculpture. The team combined manual plasma and oxy-fuel torches to cut the mild steel components for the body, which were then MIG welded. To create a “Halloween worthy” skull, the students used bolts and hex nuts to create an eerie look, then augmented that look by cutting a hole in the back of the sculpture where they could insert an oxy-fuel torch to light up the skull. TA LK TO US

North Baldwin Center for Technology

Bay Minette, AL

Highland High School

Gilbert, AZ

Santa Fe College

Gainesville, FL

Traviss Career Center

Lakeland, FL

George Stone Techical Center

Pensacola, FL

Clark County Area Technology Center

Winchester, KY

Assabet Valley Regional Tech High School

Marlborough, MA

Mississippi Gulf Coast Community College

Lucedale, MS

WEMOCO Tech and Career Center

Spenceport, NY

Canton South High School ECSV Career Academy

Canton, OH

Swiss Hills Vocational School

Woodfield, OH

Tennessee Valley of Applied Technologies

Union City, TN

Alto High School

Alto, TX

Bellville High School

Bellville, TX

Sulphur Springs High School

Sulphur Springs, TX

Bellingham Technical College

Bellingham, WA

Previous winners. Students, left to right, Matthew Focht, Jack Daniel, and Brett Eschliman from Highland High School in Gilbert, AZ, recreated a Victor oxy-acetylene torch on a 6:1 scale. Fabricated from sheet steel and steel tubing, the team combined manual and automatic plasma to cut most of the metal, then MIG welded the components. To simulate a torch flame, the students ran a copper pipe and synthetic propane gas hose through the torch body and connected it to a weed burner mounted inside the torch tip. The torch shoots flames about 4 ft. long, and it has been used to roast marshmallows . . . in seconds.

Something on your mind? Got something to say? Got an idea? Got a tip? Got a gripe? Do you have a story to tell? Contact nomma.editor@att.net. 82

O&MM Fabricator n September / October 2014

If you can imagine it, you can

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September / October 2014 n O&MM Fabricator

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O&MM Fabricator n September / October 2014