Nov 2014 O&MM Fabricator

Ornamental and Miscellaneous Metal

Fabricator ®

The official publication of the National Ornamental & Miscellaneous Metals Association

November / December 2014 $6.00 US

See METALfab2015, March 11–14, 2015, program guide after page 36

2014 Top Job Awards

Best ın class fences, raıls page54

Shop Talk Measuring bending under load, page 14

Shop Talk Case for detailing, part 2, page 24

Member Talk Greg Bailey tests rural tastes, page 47

Biz Talk Small business health SHOP online, page 60

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Forging Your Future | Business Tools 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, you’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 business’s needs are part of the discussion than by being at the table with the leaders and technical minds that are shaping the future.

Membership in NOMMA offers you a wealth of tools for you to support and improve your business. Tools such as the NOMMA Mentor Program can aid in shop efficiency and better business practices while the NOMMA Endorsed Insurance Program offers competitive rates and extras for members, such as safety materials and training. Members also recieve publication discounts on all sales and educational materals, vendor discounts from NOMMA suppliers, access to NEF Video Library and Webinars, Fabricator Magazine and Buyers Guide, METALfab Convention discount, technical support and much more.

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

November / December 2014 Vol. 55, No. 6

Knowledge to enlighten the industry METALfab2015

NOMMA Network NOMMA announces slate for 2015–16 board of directors .........10

Also: NOMMA chapter meeting and workshop roundup. .....................10 Upper Midwest Chapter meeting attendees

Shop Talk The deflection zone: 3 ways to measure bending under load ....... 14

How do we know how far is too far for steel to be bent under load? We examine an old school method, an Internet calculator, and a KISS method.

By Jeff Fogel Shop Talk The case for detailing, part 2 ....... 24

Economic and liability issues rising over the years have changed construction documents. We examine the detailer’s role today with specs and drawings and their effect on fabricators.

Also: A construction lawyer writes about the KC Hyatt hotel tragedy and shop drawings as a legal document. .. 34 President’s Letter .......... 7

Architects, codes, members, and education.

METALfab2015 Guide The only show exclusively for ornamental & misc. metal fabricators .........after 36

NOMMA and the NOMMA Education Foundation have developed a METALfab2015 program that demonstrates the value of peer networking and continuing education: n Education program n Exhibits n Awards banquet n Shop tours n Business classes, presented

by Tyler Pare, a consultant with FMI Corporation, Raleigh, NC, will offer a substantial number of how-to tips. n Keynote speaker, Barry Willingham, is the vice president/ general manager of Ameristar Perimeter Security USA Inc.

Top Job Gallery Best in class: fences, rails .............. 54

A showcase of the winners in the 2014 Ernest Wiemann Top Job Contest.

Biz Talk Affordable Care Act’s SHOP for small business comes online ....... 60

Open enrollment for the Small Business Health Options Program under the Affordable Care Act for employers with 50 or fewer full-time workers is expected to begin November 15.

By Mark Battersby Also: What’s new and updated...........61 What’s Hot! News ........................................................ 67

Feeney, King Architectural Metals sign marketing deal. n Cole-Tuve named distributor for Apollo machines. n

Media ......................................................68

Member Talk

Products ................................................69

Bailey stretching rural tastes ...... 47

Bailey Metal’s locale shapes its business model. But the company hopes its diversification test will pay off.

By Molly Badgett

Exec. Director’s Letter ... 8

Usable information ready for you.

NOMMA Supplier Members .........65 New NOMMA Members ..................66 Ad Index................................................. 73

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

Donate items for NEF’s auction at METALfab15.

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

Templates for cutting pipe.

About the cover Rod Iron Rod Inc. won the 2014 NOMMA Top Job bronze award in the exterior railings & fences — forged for this fence, 210 feet long with two sets of entry gates. All the scroll work was hand forged. See Top Job description, page 58.

November / December 2014 n O&MM Fabricator

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President’s Letter

Architects, codes, and members In January, NOMMA will cel-

ebrate its 57th birthday. I’m excited about the new initiatives that our association is bringing into the new year.

METALfab for architects

ings this spring in Memphis, TN, and another team for the fall Public Comment Hearings in Long Beach, CA. If you’re not comfortable speaking, we could still use your help for behind-thescenes logistical support during the hearings.

A strategic goal for many Mark Koenke, Germantown years, NOMMA’s AIA marIron & Steel keting team held a successful Corp, is continuing education event More active members sought president for architects and designers Our membership remains of NOMMA. at METALfab2014, and they a critical concern. Without a are doing it again at METALvibrant and growing memberfab2015. ship base, we’re unable to support the This program helps the design two programs above, as well as our community learn about our industry’s other initiatives. products.

As a member you can help our When architects attend this 2014–15 membership drive in two continuing education program at ways: METALfab, they not only earn CEU 1 Encourage prospects to join, credits, but they also see our exhibits and when you do, be sure to tell them and Top Job gallery. to put your name on the application The education we offer provides form’s “Sponsored By” line. two advantages: 2 Send the NOMMA office leads 1 It exposes design professionals to for prospective members. new ideas and options.

A thanks goes to James Minter Jr. 2 The more versed they are with for his leading this committee, and the our products, the more likely they are two new volunteers. And we’d love you to spec them. to volunteer for this effort, too.

The end result is a greater demand for our products.

METALfab info in this issue As I write this column, METALfab Need volunteers for code work is only four months away. I encourage Since the 1980s, NOMMA has you to plan now for our biggest event earned respect for its work with stanof the year. dards development, building code If you’ve never attended a convenadvocacy, and manual creation. At our tion before, I assure you that you’ll be past two board meetings, we’ve brainin for an amazing treat. The convenstormed ways to further strengthen tion will fill you with ideas, give you this program. new business connections, and proSome of our current volunteers vide you with great education. The need a break or more volunteer supshop tours particularly are a gold mine port, and the board wants to help the because you see how other fabricators technical team get what they need. We run their operations and the equipare delighted to have three new volunment they use. teers on this team, but we can always For full METALfab details, see the use more. section after page 6.

A new ICC code cycle begins next See you there! year, and we anticipate that we’ll need a team at the Committee Action HearNovember / December 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

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Ornamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the official publication of the National Ornamental & Miscellaneous Metals Association (NOMMA).

O&MM Fabricator / NOMMA 805 South Glynn St., Ste. 127, #311 Fayetteville, GA 30214 Editorial We love articles!

Send story ideas, letters, press releases, and product news to: Fabricator at address above. Ph/Fax: 888-516-8585.

E-mail: fabricator@nomma.org.

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

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

Membership Join NOMMA! Beyond the magazine, enjoy more benefits as a NOMMA member. To join, call 888-5168585, ext. 101. For a list of benefits, see membership ad in this issue.

Exhibit in METALfab Exhibit at METALfab, NOMMA’s annual convention and trade show. For more information, contact Martha Pennington at 888-516-8585, ext. 104, or martha@nomma.org.

Subscriptions Subscription questions?

Call 888-516-8585. Send subscription address changes to: Fabricator Subscriptions, 805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214. Fax: 888516-8585, or fabricator@nomma.org.

1-year: U.S., Canada, Mexico — $30 2-year: U.S., Canada, Mexico — $50 1-year: all other countries — $44 2-year: all other countries — $78 Payment in U.S. dollars by check drawn on U.S. bank or money order. For NOMMA members, a year’s subscription is a part of membership dues.

NOMMA Buyer’s Guide Published each December as a separate issue. Deadline for all advertising materials is October 31. Contact Sherry Theien at 815-282-6000 or stheien@att.net.

Opinions expressed in Fabricator are not necessarily those of the editors or NOMMA. Articles appearing in Fabricator may not be reproduced in whole or in part without the express permission of NOMMA.

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How to reach us

Executive Director’s Letter

Usable information ready for you I am continually amazed at the quality of discussions on the NOMMA ListServ, and the question I ask myself is, “How can any fabricator afford NOT to be a NOMMA member?”

The ListServ is a 24/7 fire hose of knowledge, and just a few sips will more than repay your annual dues.

8

How to find it

Sample forms

One of the golden nuggets on the ListServ is when a member shares with their fellow members a model document that they created.

At the request of several members, I am collecting and placing these in a new area on our website. Called “Models & Samples,” it will hold estimating worksheets, sample contracts, checklists, and more. Eventually, I’d like sample warranties and internal workflow forms here, too.

The idea is to make your work easier by using someone else’s form as a starting point for your own document.

The new section is a member’s-only benefit, and contributions to this pool of information are welcomed.

I applaud Richard Twiddy of Unique Iron Design and John McLellan of McLellan Blacksmithing for providing the initial samples.

Literature Guide

Occasionally, members mention books and manuals on the ListServ; we are harvesting this information as well.

For instance, Rachel Miller at Spirit Ironworks shared a book called Forged Architectural Metalwork by Peter Parkinson. For me, it was a surprise to learn that this book has a chapter F I LE S, U R JO B P RO CA LL FO R YO

© 2014 National Ornamental & Miscellaneous Metals Association

Todd Daniel is executive director of NOMMA.

dedicated to surveying a site because that topic is regularly discussed.

We already have an online literature database that we always want to update. Let us know if you have a favorite work of literature that you find invaluable. Please share it.

Since 2004, we have dreamed of creating the ultimate “knowledgebase” for our industry. Many components of this project are already on our website.

For instance, you can go online to search the O&MM Fabricator and ListServ archives to find a massive amount of information.

To help members navigate through our various online resources, I do an online webinar on the first Wednesday of each month. On even months, I do a NOMMA 101 class that covers basic resources and reviews member benefits. On odd months, I do a Not-SoDirty-Dozen webinar about 12 online resources offered by both NOMMA and related associations.

To sign up for the next class, contact Liz Harris at liz@nomma.org or 888516-8585, ext. 101.

Summary

I am a member of the American Society of Association Executives.

Three benefits make my dues worthwhile: their magazine, discussion lists, and their sample forms collection.

My hope is that the new “Models & Samples” section of our website will grow into a vital resource for all NOMMA members.

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 November / December 2014

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The NOMMA Network

NOMMA names 2015–16 board slate The NOMMA Nominating Committee, chaired by Immediate Past President J.R. Molina, has announced its 2015 slate of officers and directors, which will be presented at the member meeting at METALfab2015 next March n President, Allyn Moseley, Heirloom Stair & Iron, Campobello, SC.* n President-Elect, Keith Majka, Majka Railing Co. Inc., Paterson, NJ. n Vice-President/Treasurer, Cathy Vequist, Pinpoint Solutions, Jupiter, FL. n Fabricator Director (1-year term), Tina Tennikait, Superior Fence & Orn. Iron, Cottage Hills, IL. n Fabricator Director (3-year term), Tony Martinez, Big D Metalworks, Dallas, TX. n Supplier Director (3-year term), Stacey Lawler Taylor, Lawler Foundry Corp., Birmingham, AL. Their term begins after the swearing in ceremony at the METALfab awards banquet on March 14, 2015.

Voting takes place during the METALfab2015 opening session, March 11, at 9:15 a.m. at the Valley Forge Casino Resort, King of Prussia, PA. All current Fabricator and Nationwide Supplier members are entitled to one vote per company on items presented to the membership. *The president-elect advances to president.

Meet the new candidates Martinez of Big D Metalworks, Foundry Corp., Dallas, TX, is a canBirmingham, AL, is didate for Fabricator a candidate for SupDirector. plier Director.

He is a past She is active presenter, both at with the Gulf Coast METALfab and at NOMMA Network NEF’s 2013 continuand served as a ing education event Stacey Lawler Taylor, left, Lawler NEF trustee from Foundry Corp., and Tony Martinez, in Dallas.

Big D Metalworks.

2007 to 2010.

His firm, which Her company joined NOMMA in joined NOMMA in 1960.

1977, has won many Top Job awards.

Stacey Lawler Taylor of Lawler

Current board members continuing for 2015–2016 n Fabricator Director, Maciej

Jankowski, Artistic Iron Works, Norwalk CT. n Fabricator Director, Henry Wheeler, Wheeler Ornamental Metals, Dothan, AL. n Fabricator Director, Max Hains, Mofab Inc., Anderson, IN. n Fabricator Director, Greg Bailey, Bailey Metal Fabricators, Mitchell, SD. n Supplier Director, Dave White Jr., Locinox USA, Countryside, IL. n Supplier Director, Bill Schenke,

The Upper Midwest Chapter held its fall meeting on Oct. 18 in Elkhart, IN. The daylong meeting, photos above, featured a tour of host shop Evans Metal Products Co. The event also featured 10

n Tony

n

Ameristar, Tulsa, OK.

n Immediate Past President, Mark Koenke, Germantown Iron & Steel Corp, Jackson, WI.

Retiring board members

A “thank you” goes to the following retiring board members for their years of outstanding service: n Mark Sisson, Mac Metals, Kearney, NJ, is rotating off the board after three years of service. n J.R. Molina, Big D Metalworks, Dallas, TX, is rotating off the board. after seven years of service.

equipment demos and a business presentation given by David Evans. There was also a presentation on e-coating and powder coating.

O&MM Fabricator n November / December 2014

NOMMA and SMA hold daylong stair workshop NOMMA and the Stairway Manufacturers’ Association (SMA) held their first combined event on October 17 in southeastern Pennsylvania. Ninety people attended the event, including 65 attendees from the SMA and 25 from NOMMA. The daylong workshop started with a breakfast and social at NOMMA member shop Crystal Metalworks of Hatfield, PA. NOMMA Executive Director Todd Daniel and Vice President Keith Majka welcomed the crowd with opening remarks.

Brian Rush, vice president and manager of Crystal’s Hatfield facility, then described his company and the types of work they do, including the New Jersey 9/11 memorial that received a 2012 NOMMA Top Job award.

Attendees broke into three groups of about 30 people each for a guided tour of the various workstations throughout the shop. The Crystal facility is more than 30,000 square feet, employs 50 people, and sits on a seven-acre site.

Of particular interest was the demonstration of an Amada Promecam press brake, which could create stair pans with a minimal number of steps.

Members were also treated to a demonstration of a Messer EdgeMax CNC high-definition plasma cutting system, which the company uses to cut custom shaped parts.

After the visit at Crystal, attendees took an eight-minute drive to Advanced Stair Systems in Harleysville, PA, which provides custom wooden stair and handrail systems for the local region.

The program at Advanced started with introductions by Dave Cooper, SMA executive director; Bill Thomas, SMA president; and shop host Steve Guenzel. Daniel gave a PowerPoint program on past Top Job entries that combined wood and metal.

For the final presentation, Martin Stockhausen of Compass Software, who was an event sponsor and exhibitor, spoke about his software product, which is used for stair and rail design, including both wood and metal.

Lunch featured traditional Philadelphia fare, including Philly cheesesteaks November / December 2014 n O&MM Fabricator

The grand finale of the day was the construction of a curved stair in 60 minutes.

Attendees enjoyed breakfast and a morning program at the shop of Crystal Metalworks.

Above left, Paul Montelbano of Duke of Iron Inc., left, and Keith Majka of Majka Railing Co. Inc., center, NOMMA’s vice president/treasurer, chat with Crystal Metalworks Vice President and Facility Manager Brian Rush, right. Above right, Dave Cooper, SMA executive director, center, answers stair code questions after his presentation.

and pretzels.

Afternoon events at Advanced included a demo of a Grizzly Straight Line Rip Saw, which is a millwork saw that is ideal for handling large work pieces. For the afternoon class, Dave Cooper updated attendees on changes to the latest ICC residential codes, as well as proposals being considered for the next code cycle.

The grand finale for the day was a live demonstration of assembling a curved stair, which was completed in an hour.

A thanks goes to Crystal Metalworks and Advanced Stair System for hosting the event. A thanks also goes to the SMA for giving every attendee a free copy of the 2009 IRC Stair Codes Visual Interpretation Guide.

11

n

NOMMA Education Foundation

In partnership with the National Ornamental & Miscellaneous Metals Association

Don’t miss METALfab2015 program in this issue Donate items for the NEF auction at METALfab Among the outstanding NOMMA members If you wish to contribute an item(s) for presenting at METALfab2015, is our special this event, please go to www.nomma.org. presenter Tyler Pare, a consultant with FMI for a donation form. Questions? Call the Corporation, which provides management NOMMA office at 888-516-8585, ext. 101, or consulting and investment banking for the contact Liz Harris at liz@nomma.org. engineering and construction industry.

Tyler’s classes will cover topics such as Todd Kinnikin Memorial NEF co-chairs: Lynn Parquette, left, METALfab Scholarship Leveraging Your Competitive Advantage, owner, Mueller Ornamental Iron Connecting Actual Job Costs Back to Estimat- Works Inc. & Elite Architectural Applications for the Todd Kinnikin ing, Key Performance Indicators that Drive Metal Supply LLC and Roger Carlsen, Memorial Scholarship are now available.

Best Practices, Driving Best Practices in Busi- owner, Ephraim Forge Inc. The scholarship is given by the NOMMA’s ness Development, and How to Avoid ConUpper Midwest Chapter to honor the memfrontation with Change Orders. ory of Todd Kinnikin of Eureka Forge, Pacific, MO. Check out the education program for METALfab2015 that This scholarship provides the recipient with a full and is included in this issue of the Ornamental & Miscellaneous spouse registration for METALfab2015. Go to www.nomma.

Metal Fabricator beginning after page 36. More details will org for a copy of the scholarship application. Application come later, so continue to check the NOMMA website. deadline is January 9, 2015.

If you would like to donate to the Todd Kinnikin MemoNEF Auction donations rial METALfab Scholarship fund or need mre information, We’re also beginning work on one of our favorite fundrais- please contact Martha Pennington, NEF Executive Direcing projects — the Silent & Live Auctions held at METALtor at martha@nomma.org or 888-516-8585 x 104, or Mark fab. Whether you donate of an item for auction or you bid on O’Malley, Scholarship Chair at omalleywelding@sbcglobal. items, both are critical to the success of this project. net or 630-553-1604.

We have had fabulous items donated through the years and depend on you to help us continue this great tradition.

NEF curved stairs continuing education class Among the items the Auction Committee asks you to donate The NOMMA Education Foundation sponsored a conas auction items may include the following: tinuing education class: Curved Stairs — How to Measure, n Metalwork, such as sculptures, garden gates, or handDetail & Fabricate. This class was held Saturday, September forged furniture.

27, at Germantown Iron & Steel Corp., Jackson, WI. n Non-metal items, such as tools, gift baskets, gift certifiThe NEF trustees are grateful for the wonderful presencates/coupons, jewelry, electronics, clothing, food/wine, pre- tations by Mark Koenke, Germantown Iron & Steel Corp. of sentation drawings, the use of a condo at the beach, airline Jackson, WI, and Mark O’Malley, O’Malley Welding & Fabritickets, books, artwork, or even antiques. cating Inc. of Yorkville, IL. n Specialized services, such as offering to create a cusA special thank you goes out to Germantown Iron & Steel tom, one-of-a-kind item for the winning bidder.

Corp. owners and employees for all their efforts to make this Or be creative — the sky’s the limit! class a success and to Chicago Metal Rolled Products, ChiEvery donated item will help the Foundation provide qual- cago, for donating time and material for the class. ity education for our industry through the following platforms: Some attendees had to brave the confusion and delays n METALfab education program, caused by the fire at the FAA facility in Aurora, IL, to get to n continuing education classes, the class, but they were rewarded for their efforts with an outn video productions, standing presentation. n educational publications, and n other special projects.

We look forward to seeing you in King of Prussia.

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 November / December 2014

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November / December 2014 n O&MM Fabricator

13

Shop Talk

n Consider this.

You’re building a railing. Who’s the customer? Doesn’t matter.

The design, the measurements, the materials, only matter. And one more thing. The customer insists the vertical posts be kept thin. So, here’s your problem. How thin can you go and still have posts capable of withstanding the attendant loads of said railing? Well, you’ve just entered the . . .

By Jeff Fogel What is deflection? Imagine a metal rod, fixed in place

at one end. If you were to push sideward on the rod, it would flex in the direction you are pushing. If you suddenly stop pushing, letting go of the rod, it will return to its original position. Roughly speaking, the amount you can bend the rod and still have it return to its upright position is called its deflection.

The NOMMA Metal Rail Manual is more concise.

It defines deflection under load this way: “After the application and release of the required test load, the anchored railing system shall return to within onehalf inch of its original position.”

Put another way, “With deflection we’re talking about maximum displacement,” explains Tony Coviello, partner with Summit Engineering, Portsmouth, NH. “All beam theory relies on the principle that

The guys at Compass Ironworks demonstrate the KISS (“keep it simple, stupid”) method for evaluating post strength for odd sizes of posts. This 1-inch solid bar deflected 3 inches under 240 pounds of force applied, but it did spring back to it’s original position. This methodology was used in an application where an antique bronze newel needed to be replicated per the architect’s specifications. The findings, which seemed low, were reported to the builder, who signed off. The newels were replicated and installed. The client, builder, and code official were all pleased with the rigidity and stability of the railing based on their shared findings.

Photo courtesy of Compass Ironworks.

14

O&MM Fabricator n November / December 2014

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members should not deflect beyond ‘yielding,’ which represents the distance a member may be moved before it will return, on its own, to its original neutral axis.”

What happens to the rail if it’s bent beyond that distance? Bad things.

“The chemical bonds between the molecules in the steel lattice are ruptured,” says Coviello, “and the steel is damaged. There may be some residual strength, but it is still compromised.”

A curve indicates the yielding portion of deflection. Coviello says: “The

trick is to stay within the curve — stay below it.” This is referred to these days as LRSD or load resistant stress design.

Three ways to measure bending under load

Which raises the question: How do we know how far is too far for the steel to be bent under load? We’ll discuss three ways.

1 Old school method

Assuming we’re dealing with square tubing, (and we are), measuring the

bend deflection mainly depends on n what your material is, n the width of the tubing, and n what the wall section thickness is.

Here’s why. Newton’s first law of physics states that for every action there is an opposite and equal reaction. Based on Newton’s reasoning, and Newton had reason to spare, any bending moment M applied to a post or rail must be equally offset by a resisting moment.

This resistance is determined by the unit stress f of the railing material, and the railing’s section modulus S. Section modulus is a fancy term for the cross-section shape of the railing — tube, rectangle, or square.

This gives us: M = f x S. Now we can get more specific with M. In practical applications, M refers to the sideward load applied to the post. Because the principle of leverage would make the load greatest at the top of the post, we designate that P; the length of that “lever” is h, the height of the post.

Now we get: M = P x h.

If M is the bending moment, the resisting moment has to equal M, and the resisting moment is comprised of the allowable stress fs, and the cross-section size S, then we can set up: P x h = fs x S. Hang in, we’re going to use this handy formula for a real-life problem involving a railing.

Say a design (or maybe the code) calls for a square tube post that is 36 inches high and must withstand a horizontal load of 100 pounds. We’ll use square tube C1020 steel as a material.

How thick does the post have to be?

We know h is 36 inches high and P is 100 pounds. We can look up fs in a table: Carbon steel C1020 is 20,000 psi. Thus: S = P x h = 100 x 36 = 0.180 in³ fs 20,000

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O&MM Fabricator n November / December 2014

November / December 2014 n O&MM Fabricator

17

A look at a table for tube section moduli, available either in the NOMMA Metal Rail Manual or from any purveyor of steel products, tells us that based on S = 0.180 inches cubed, the required square tube must be 11/4 x 11/4 inches with a wall thickness of ⅛ inch.

2 Use an Internet calculator

A new school way can skin this cat.

Use the Internet. Just go to a website 22144 NOMMA Sep NOVcalcula2014.ai 1 that does metal deflection tions. Metalgeek.org will do fine (see image on page 20).

18

Once you have your known variables (S, P, or f), you simply type them into the drop-down fields, hit “calculate,” and voilà, the post or rail thickness magically appears in the answer box.

All the metal deflection calculator websites work much the same way.

None of them involve the slightest mathematical effort on your part.

Curiously, no fabricators we spoke 10/10/14 with had12:00 usedPMany of the on-line calculators even though they were aware of them. Why would anyone use the

mathematical formula with its attendant risk of miscalculation? We asked several fabricators.

One surprising answer is that there is a third way to determine square tube deflection.

3 The simple ways

“Real life, and that means KISS (‘keep it simple, stupid’),” says Amos Glick of Compass Ironworks, Gap PA. “Code [in the geographic area where Compass is located] says every railing has to withstand a 50-pound horizontal load in either direction.

We don’t use formulas. We’ll literally hang a weight on the railing to see if it can bend and return to its original position.”

Tom Zuzik of Artistic Railings in Garfield, NJ, also advocates testing, under certain circumstances.

“It depends on whether it’s a commercial or residential job. Or how many times you’re going to duplicate the design,” says Zuzik, “but generally we use testing for a bigger, commercial job.”

Zuzik tests the designs in house, using the same technique that Glick uses. But Zuzik points out that testing a single post would be out of context.

“Posts aren’t tested by themselves,” says Zuzik. “Loads are applied to the complete guard, not its elements. You either have to build it and test it, or test a mock-up or model of it.”

Zuzik’s method is to clamp a piece that is to be tested at a fixed point.

Then he hangs a barbell weight at the opposite end. He then measures the distance the piece will move and still revert to its initial conformation.

Sometimes Zuzik uses testing equipment. This consists of load sensors and software. A basic set up, Zuzik says, would run between $250 and $500.

All designs evoke form and function. But what happens when function takes the back seat? What do you do when a customer has his heart set on a rail that is just too narrow to satisfy minimal load requirements?

A couple of things.

You can use a trick that James Rucker of York Metal Fabricators in Oklahoma City employs. Simply run a steel insert inside the square tubing.

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Online calculator for deflection of metal tubing.

Found at http://metalgeek.com/static/deflection.php, the calculator is posted by Hal Eckhart of Casa Forge, Stockholm, WI, who says it “may give you a rough idea of the deflection of metal tubing, but it’s not accurate enough to do any more than estimate it. If the deflection is large enough to permanently bend the tube, then all bets are off.”

The steel weights are tweaked for mechanical tubing, he says, and will be less accurate for structural tubing. The moduli of elasticity used are 29,700,000 psi for steel and 10,000,000 psi for aluminum.

“Use at your own risk. Or you’ll be sorry,” Eckhart says.

Formulas and data gleaned from the “Elastic Beam Deflector Caluclator” at: http://1.usa.gov/1xVAjQO

Naturally, this raises the question why not just use solid stock in the first place? Because first, square tubing is stronger than solid stock. Second, refer back to the part about design; it just looks better.

Or you can do as Amos Glick does.

Find a harder material in the same alloy family. Often this simple substitution does the trick.

“I had a customer who wanted a bronze railing with a minimal look,” recalls Glick. But the size rails that fit that minimal vision wouldn’t meet

load requirements for deflection.

“So we poked around here and poked around there, and found something else in bronze. It was similar to bronze 360, a standard bronze alloy commonly used in architectural applications, but harder. It was something you couldn’t buy right off the shelf.”

Gary Eckhardt of Berger Iron Works Inc. in Houston has another method. “We can put a camber in the rail, the reverse way. So under load it goes flat.”

Trust but verify

The modern mariner avails himself of the miraculous technology of the GPS. But the prudent mariner still backs it up with old-fashioned paper charts.

This is sound advice for the fabricator who seeks to determine deflection of square tubing.

“There’s too much liability out there, these days,” muses Eckhardt. He runs the numbers in-house, and then sends it out for an engineer’s imprimatur. Once the engineer has calc’d it out

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flatly states Tony Coviello, partner with Summit Engineering, Portsmouth, NH. ‘There’s the ideal world, and then there’s reality. Sometimes simply adhering to known constraints (i.e. code) is sufficient. It all depends on the project, the budget, etc.’ as well, he’ll run “real life” tests, a la Amos Glick’s method.

“We’ll run the calcs in-house,” explains Eckhardt. “Then we send it out to the engineer for a ‘stamp.’ He might increase the wall thickness a little, but not necessarily. Then we’ll set it up on some sawhorses and hang a weight on it.”

Eckhardt continues: “Once an engineer looked at a design and said ‘It calcs but I wouldn’t swear to it.’ So, we tested it in the shop. We loaded it up three times, then sent the test results to the engineer.”

Among the adherents to Glick’s KISS methodology are the purists.

“We don’t have an engineer on staff, and I’m not an engineer,” says Mike Stylski of Accent Ornamental Iron and Powder Coating Co. in Cambridge, MN. “So we tend to overbuild things.

The code here is very specific about loads. I believe it allows for a 1/4-inch deflection for a top railing. So, we’ll select a tube with enough wall.

“If we’re talking about a 1-inch square tube, we won’t span more than 42 inches. But we’ll go out to 4 feet with a 11/4-inch, and with a 11/2-inch square tube, we might eke out 5 feet (of span),” Stylski says.

“When you’re talking about, say, 2-inches square (tubing), which has ⅛-inch wall or thicker, you can span out to 8 feet without a problem.”

You must know your materials. Stylski works mainly with aluminum but notes that you cannot go by the same deflection properties of steel. “If there’s any doubt, go up a size. Or as the case may be, several sizes,” says Stylski.

22

Stylski recalls a recent job that used a rectangular tube of massive proportion; its cross section measured 2 by 12 inches, with an 11-gauge wall (⅛ inch), and weighed a hefty 16 pounds per foot. The rails spanned 167 inches.

“The more it weighs,” says Stylski, “the less bracing you’ll need.”

Normally, Stylski doesn’t test for deflection. But for one job, a catwalk for lighting crew in a theater, the customer brought in an independent company to test. As usual, the job was, if anything, overbuilt.

“Never under-build,” says Stylski, “it will always end up costing you more.”

Marco Vasquez of Vasquez Custom Metals Inc. in Tampa is another votary of the KISS methodology. If there’s any concern about deflection, he’ll simply use tubing with a thicker wall.

Vasquez, who fabricates railings and gates and works mainly in steel, will take into account the size of the project, and if necessary, simply increases the cross section.

“We’ll just go up 1/4 inch,” says Vasquez. “We really don’t use any particular (testing) method. I mainly work with steel, but if I’m using aluminum and I have any concern (about deflection), I’ll switch to steel.”

But what do engineers think about not using engineers? You might think they’d respond with a litany of catastrophic results: failed railings, collapsed stairs, flood, fire, and famine.

But you would be wrong. At least based on the engineer we spoke with.

“You don’t always have to test. In fact, you don’t always need an engineer,” flatly states Tony Coviello, partner with Summit Engineering, Portsmouth, NH. “There’s the ideal world, and then there’s reality. Sometimes simply adhering to known constraints (i.e. code) is sufficient. It all depends on the project, the budget, etc.”

There you have it. Allowing for deflection in square tubing is not fraught with arcane math and physics.

If you’re a bigger shop, you can simply dump it in an engineer’s lap. Or, if you’re comfortable with some simple arithmetic, you can do some DIY cypherin’. For smaller shops or those less numerically capable, there are simple testing methods, or even intuition.

For your information

n

‘You don’t always have to test. In fact, you don’t always need an engineer,’

Resources Accent Ornamental Iron & Powder Coating Cambridge, MN 763-691-8500 www.accentornamentaliron.com Artistic Railings Inc. Garfield, NJ 973-772-8540 www.artisticrail.com Berger Iron Works Inc. Houston, TX 713-869-7386 www.bergeriw.com Compass Ironworks Gap, PA 717-442-4500 www.compassironworks.com Summit Engineering Portsmouth, NH 603-319-1817 www.summitengineeringinc.com Vasquez Custom Metals Inc. Tampa, FL 813-248-3348 www.vasquezcustommetals.com York Metal Fabricators Oklahoma City, OK 800-255-4703 www.yorkmetal.com NOMMA Metal Rail Manual For NOMMA members only www.nomma.org About the author Jeff Fogel began writing as a journalist with the New York Daily News. He has been a copywriter and associate creative director for advertising agency Ogilvy & Mather.

Jeff now lives in New Hampshire where the weather’s bad, the skiing’s better, and blacksmithing’s a respectable way to keep warm.

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Shop Talk

The case for

detaılıng Part 2

■

Economic and liability issues rising over the years have changed construction documents. This article examines the detailer’s role today with these specifications and drawings and how it affects the fabricator.

Editor’s note: In the March/April 2014 issue of O&MM Fabricator, detailer David Busarello, Bridgeton Drafting Company LLC, Vineland, NJ, began a two-part article on the benefits a fabricator can receive from using the services of a miscellaneous metals detailer.

The article examined what a detailer provides, the detailing process, and briefly, some of the industry changes that occurred in the past 100 years that make the services of a detailer all the more important.

Here in part 2 of the article, Busarello discusses in more detail the specific issues of liability, engineering, alternate designs, finding help, and the future of detailing for the ornamental & miscellaneous metal fabricator.

One purpose of this article, Busa­ rello says, is to help show how “a strong working relationship between owner, architect/engineer, general contractor (GC), and fabricator is vital to a successful project for all,” but it is to also focus on the “challenges facing a fabricator today.”

By David Busarello Let’s begin with a deeper examination

of the current state of construction documents (CDs), how and why they

“These two images show the hand sketch I worked from and the installed rail.

Stoop is what Philadelphians call their small front steps.”

— David Busarello

have changed over the years, how it affects you as a fabricator, and what you can do about it.

Building plans examiner, Ronald L. Geren, principal of RLGA Techni-

cal Services, Scottsdale, AZ, says The Construction Specifications Institute (www.csinet.org/store) defines CDs as “the written and graphic documents prepared or assembled by the [architect and/or engineer] for communicating the project design for construction and administering the construction contract.”* CDs may include thousands of pages of drawings and specifications for a skyscraper, or one, letter-sized sketch with a few notations for a residential step rail. Either way, the purpose of the CDs is to convey enough information that:

*From RLGA Technical Services #25-June 2007, “The Code Corner” by Ronald L. Geren, AIA, CSI, CCCA, SCIP: http://bit.ly/1lnCKpH. Ronald L. Geren, AIA, CSI, CCS, CCCA, SCIP, is an ICC Certified Building Plans Examiner, and is the principal of RLGA Technical Services located in Scottsdale, AZ, which provides specifications and code consulting services to architects, engineers, owners, and product manufacturers. A 1984 graduate of the University of Arizona, Ron has over 23 years of experience with military, public, and private agencies.

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n the project owners can see what they are getting, n the code officials can certify that the project meets local codes, and n the contractors can bid and build the project.

One can imagine this process has been around since the pyramids. The Pharaohs certainly had someone who took their vision and put it in a format the laborers and foremen could use, men who were likely illiterate common people. The format was likely sketches and diagrams similar to what our present day architects and engineers produce. At first glance, it seems not much has changed. But, as we have been told many times, the devil is in the details.

Architects and engineers are better prepared than ever. While Pharaoh hoped his structure met his needs, today’s design professionals have handy a slew of research by universities and professional organizations like NOMMA and the International Code Council.

We know how large a stairway should be and how many are needed to get everyone out of a high-rise.

Government building code officials, with support from trade groups like NOMMA, develop codes that make buildings safer and more efficient to use.

In the last 35 years, however, I see a decrease in the amount of information on CDs, as well as an increase in the discrepancies or inaccuracies.

This is especially true for smaller projects handled by miscellaneous metal fabricators. Sometimes, CDs show stairwells too small to meet the building code and dimensions that do not add up. Sometimes, detail and design criteria are missing on the bid documents. This leads a fabricator to assume what is required.

Two causes for the change in construction document 1 Economics

We’ve all seen insurance companies pressuring doctors to reduce the time they spend with patients (Newsweek, April 16, 2012) Snickers are 11% smaller and a half-gallon of ice cream is now a 3/8th gallon (Orange County Regis26

ter, August 21, 2013). The pressure to stay competitive forces companies to decide whether to raise their price or lower their costs.

The National Institute of Steel Detailing’s (NISD) Industry Standard publication “Guidelines for a Successful Presentation of Steel Design Documents” (www.nisd.org/files/ Guidelines.pdf) notes: “In recent years economic, technical, and competitive pressures have prompted experimentation with methods of preparing and releasing design documents.”

Jeffrey M. Solondz, a self-employed architect and close friend who lived in Cherry Hill, NJ, until his death a few years ago always told me, “When I worked for architectural firms, I was always pressured to get the job done in an unreasonable time frame. Our metric was the speed we could produce, not the quality of the product.”

To lower costs, design firms have computer software often operated by employees who are proficient with the program but who do not possess the knowledge of an architect or engineer.

In his February 2006 Civil Engineering article, “Ethically Understanding the Role of Computer Software in Engineering Calculations,” (February 2006, http://bit.ly/1b8loqd) Ken Maschke noted, “While software tools are making the workplace more efficient, the potential has been created for the non-engineer to attempt the same work as a professional.”

Once the documents are prepared, the professionals often don’t do a complete review of them before they are issued for bid. Maschke addressed this in the same article.

“While inherent in the mind-set of the responsible engineer, competent engineering may be reinforced by an environment that promotes responsible use of computer software.

The opportunity to check for error is inherent in the process. Engineers should consider the loss of this review time and make special effort to build confidence in the procedures performed by the software.”

2 Liability

Protection from liability is another cause. In the book Construction Budget Management by Richard Lin-

gensjo, the author quotes Henry H. Deutch of HHD Consultants Inc., a firm based in Kissimmee, FL, that provides consultancy services, such as the evaluation of plans and specifications, to the construction industry.

Deutch, says Lingensjo, noted the main problem with present-day design professionals is “a fear of future litigation and a lack of fee to properly design a project.”

Lingensjo continues with Deutch’s premise: “Fear results in the designer leaving pertinent data off the drawings, . . . effectively delegating design to contractors. When there is a problem, the design team absolves itself of responsibility, . . . and blames the general contractor or construction manager for not building what was designed but not shown.”

In the sidebar on page 34, “An attorney’s views on Hyatt hotel tragedy and shop drawings as a legal document,” Robert Heideck, Esq., former executive partner of Pepper Hamilton LLP, Philadelphia, PA, looks at the liability that fabricators have and how a detailer can help.

Heideck says: “The recent trend has been for the design team to provide little detail in the contract drawings, which enables the supplier or fabricator to work with a virtual blank slate.”

This creates new risks and responsibilities on the fabricator.

Heideck continues: “The lack of detail often creates a ‘performance’ specification by describing the item to be supplied in extremely general terms and adding performance requirements.”

In short, the fabricator bears the risk to ensure the design and fabrication meet requirements.

During the initial stages of developing this article, the O&MM Fabricator Editorial Advisory Board addressed several concerns of fabricators regarding the quality of construction documents and the liability fabricators may assume by taking on the responsibility of supplying the details lacking in the design drawings.

Here is one such comment from the Board: “Apparently, there is a trend for architects to do nice renderings for their clients, but have little detail. They are O&MM Fabricator n November / December 2014

expecting the subcontractors to supply the details. Recently, an architect told someone: ‘Why don’t you just draw something up and we will look at it then.’ If this attitude becomes pervasive, it puts more pressure on the small fabricator.”

Since we discussed the quality of the construction documents earlier in this article, let’s talk about how the fabricator, by working with a detailer, can make this issue an advantage.

Ralph Marchione of Trylon Railings, a NOMMA member based in Lyndhurst, NJ, works on many gate and fence projects, often with little more than a verbal description from an architect or contractor. Using their years of experience working with decorative ornamental iron, Ralph and his detailer design a gate or fence using the components, materials, finishes, and features that his shop is most comfortable working with and that will stay within budget.

Marchione says “. . . being able to provide detailed drawings to the project owner, GC, and architect has been a real benefit. The guesswork is eliminated. Using [detailed drawings] as a tool for the shop during fabrication has been a win-win for me; less time explaining my stick drawings and fewer mistakes.”

sented to the architect for approval, can clearly define exactly what you are providing. You can also identify conditions you feel could impact safety, schedule, or costs, such as a stair well, that are too small to meet building codes.

Matt Danza, PE, from John Maltese Iron Works in North Brunswick, NJ, says: “When the design documents provide little information, we tell our detailer to provide our standard stair and rail system. Our detailer produces the job quickly because he’s drawn it many times. Our engineer then reviews the stair drawings for a nominal fee, ensuring we are providing a stair that is structurally sound. The drawings are then sent to the architect and are usually approved without comment as it suits the design intent.

“This provides us with a document that serves many purposes. To our client, it defines what we are providing.

To our shop, it specifies exactly what materials we need to order, and how to fabricate it. To our erectors, it provides direction on how to build it. Finally, it provides a record for future use, be it future work in the same building or defense from litigation. Our firm is more efficient fabricating and erecting it, the customer is happy, and we make a nice profit.”

Shop drawings vs. architect specs

That Maltese’s engineer verifies that a fabricator’s design will structurally work leads to another comment by the O&MM Fabricator Editorial Board: 1) “Do shop drawings always have to follow the architectural plans and specifications.”

2) “We are noticing a trend where towns and cities are requiring engineered drawings for guardrails, stairs, and even handrails and drive gates.”

Since the two are linked by the need to have a professional engineer, I will discuss them together.

Can a fabricator substitute an alternate design? A quote from the movie, “The Towering Inferno,” in which a fire starts in a high-rise office/ condo building, addresses this. At one point, the architect, played by Paul Newman, accuses the general contractor, William Holden, of installing a substandard electrical system, at which time the GC gets in his face and says: “Now listen. Any decisions that were made for the use of alternate building materials were made because I as a builder have a right to make those decisions, if I remain within the building code and (bleep-bleep), I did!”

How this issue applies to stairs and rails.

How many times have you, as a fabricator, worked on a job for which a simple one-story stair is shown on the architectural plans with no design provided? Pitfalls abound as you do not know what the architect is expecting.

A clearly written proposal is essential here, however, it is unlikely the architect or owner will ever see that.

Once you start erecting a stair that does not meet the undocumented expectations of the architect or owner, you will be told to stop, threatened to remove the stair and replace it with something different (and likely more expensive), and then assessed backcharges for delaying the job. Worst of all could be the injury done to your reputation.

Providing a set of plans and sections, prepared by a detailer and preNovember / December 2014 n O&MM Fabricator

27

We all know how that worked out. What is scary is how similar this played out seven years later with the Kansas City Hyatt tragedy (see Heideck sidebar, page 34).

We all have an ethical responsibility to build something that is structurally safe or clearly going to serve the purpose for which it was designed.

Design professionals are human and make mistakes as we all do. We serve our customers well and keep our good reputation by doing what is right.

But what about situations where your knowledge, skills, and experience can provide the project owner with comparable design solutions with additional benefits, such as lower costs or quicker delivery?

Two examples 1 Library stair and rail design

On a Washington D.C. library project I worked on for Maryland Fabricators, Millington, MD, I submitted an alternate stair and rail design for a service stair in the back of the building, to be used for employees only, not the public, therefore it’s appearance was less important.

The architect’s stair design had hollow tube stringers (HSS 12 x 2 inches) and a stainless steel handrail on a brushed aluminum, 2 x 2 inches, tube guardrail system with pickets. This mirrored the design of the public stair Maryland Fabricators was building in the lobby of the library, which was a better use for this beautiful design.

The contractor told us early the owners were looking to save money.

We provided an alternate with 12-inch junior channels (MC12x10.6), and a steel pipe handrail on a two-line, steel pipe guardrail. Our engineer also provided calculations. The project architect accepted it, and it saved the customer considerably.

2 Shrine structure The Malvern Retreat House, a 125acre complex in Malvern, PA, hosts weekend retreats for thousands of people every year. For their 100th anniversary, the Retreat House leaders wanted to replace the existing Shrine to Our Lady of Fatima that was in disrepair.

An architecture firm provided a beautiful design. Unfortunately, the 28

bid was considerably more than could be raised for the project. Volunteer labor and several material substitutions helped, but the steel costs were still too high.

Malvern leaders then asked a local fabricator, NOMMA member Walt Massinger, owner Allen’s Iron Works, Yeadon, PA, for advice. Massinger’s detailer, along with a local engineer, redesigned the structure, maintaining the architect’s vision, while saving the group more than $25,000, enough to complete the project in time for the anniversary celebration.

When contract requires the fabricator to hire an engineer

The O&MM Fabricator Editorial Advisory Board also addressed the growing need for a fabricator to hire an engineer directly for the design, and therefore for the responsibility, of the fabricator’s work. How can a detailer help? The detailer can be the “bridge” Heideck says in his sidebar (see page 36).

We all have worked on small jobs where an architect or engineer was hired by the owner to provide a quick design and nothing more. The shrine at the Malvern Retreat House is an example. In these cases, we may be on our own. This is a good reason to have a working relationship with an engineer who is familiar with miscellaneous metals.

Ed Hladczuk, EH Iron Works, Philadelphia, PA, has worked on railing jobs that were sketched on a napkin during a lunch meeting (see sketch, page 24).

“I make a quick sketch, send it to the detailer, who knows what my chicken scratch means. He draws it up, sends it to my [subcontracted] engineer for his blessing. The two work out the details and send the finished drawings to my shop. I don’t have to deal with being the middle man between them. The customer looks at the drawing to verify it’s what he wants, and we build it.”

Approvals

The editorial advisory board addressed a third topic: the approval process. In part 1 of this article in

the March/April 2014 issue of O&MM Fabricator, we explained the process.

Now, we will discuss how various end results of this process affect the fabricator.

For many miscellaneous metals fabricators, shop drawings provide a clear format to show the architect what you intend to provide, and a platform to ask questions generated due to conditions not covered in the construction documents. When the drawings are returned, here’s what you may and may not find: A stamp with language similar to the following:

“This review is only for the general conformance of the design concept and does not relieve the contractor from its responsibility to comply with the requirements of the plans.”

This generally reflects what Robert Heideck notes in his sidebar, (see page 35). The purpose of the shop drawing review is to confirm the proposed items meet the “design concept of the project. This generally means that if the overall structure as designed fails or if the work does not meet the overall design, then the architect/engineer face liability even though the drawings were prepared by others.”

Later, he continues: “There are situations in which the project engineer can assign design responsibility, . . . to a fabricator . . . who provides a metal stairway that collapses [and who] would face significant liability.”

(See AIA Document 201, § 3.12.4; http://bit.ly/1fuBNum)

Architects generally base their agreement with the owner around the American Institute of Architect document “A201-AIA General Conditions of the Contract for Construction,” 2007 ed. An excellent AIA document summary, with commentary, at http:// bit.ly/1fuBNum provides specific instructions to the design professional and the contractor for the review and approval of submittals.

Here you will learn the position the architect and owner will likely take, should you find yourself in a dispute. I encourage you to read it.

It’s part of just about every project you have.

O&MM Fabricator n November / December 2014

Answers to the questions you asked about the shop drawings

Document AIA 201, section 4.2.12 explains that the architect shall review properly prepared requests for information submitted by the contractors and prepare and distribute supplemental drawings and specifications to the contractors in response. This is part of the architect’s Contract Administration Services Agreement with the client, what the architect agrees to provide (From The Architect’s Handbook of Professional Practice, 13th edition ©2000: http://bit.ly/1nm2FTt).

The A201 commentary notes that while contractors have long been obligated to submit requests for information, architects were not obligated to answer them until the 2007 version of the AIA document was issued.

By working with a detailer to clearly define what you are providing and what information is needed, the shop drawings can provide a strong argument in your favor when used in concert with this section of AIA 201.

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AIA Document 201, section 3.2.3 address this, stating the “contractor is not required to ascertain that the contract documents are in accordance with applicable laws, statutes, ordinances, codes, rules, and regulations.”

Section 3.2.4 further states “If the contractor believes that additional cost or time is involved because of clarifications or instructions the architect issues in response to the contractor’s notices or requests for information pursuant to sections 3.2.2 or 3.2.3, the contractor shall make claims as provided in section 15 of the same document.”

It finishes by saying: “If the contractor performs those obligations, the contractor shall not be liable to the owner or the architect for damages resulting from errors, inconsistencies, or omissions in the contract documents, for differences between field measurements or conditions and the contract documents, or for nonconformities of the contract documents to applicable laws. . . .”

As noted above, shop drawings can provide fabricators with documentation that can help justify increased costs.

No comments at all by the architect, engineer, or GC.

Section 3.12.14 states review by the architect is limited to section 4.2.7 and that “submittals that are not required by the contract documents may be returned by the architect without action.”

Further, section 4.2.7 states: “The architect will review and approve, or take other appropriate action upon, the contractor’s submittals, such as shop drawings, product data and samples, but only for the limited purpose of checking for conformance with the information given and the design concept expressed in the contract documents.”

So we have circled back to Heideck’s statement at the beginning of this section of the article.

What does it mean to the fabricator? It means know your obligations on each project. My experience shows shop drawings are almost universally required on each November / December 2014 n O&MM Fabricator

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project in the U.S. Northeast where architectural drawings are provided. If shop drawings are required and you’re not providing them, you are giving up on a tool that can protect you.

How the courts have ruled on liability

Various documents researched online, such as “The Use of Shop Drawings on Construction Projects” (http://bit.ly/1ruOUNy) by Jeffrey S. Wertman, Esq., an attorney with Berger Singerman, Fort Lauderdale, FL, note that courts have generally recognized that shop drawings are a product of the contractor, and therefore, the contractor bears responsibility for their content.

Reasonable people should have no argument with this. However, when disputes arise, reasonable people are hard to find.

In the book Shared Design (Aspen Publishers 2012), Dennis J. Powers, partner, DLA Piper, Chicago, noted two cases in his chapter “Traditional Shop Drawing Liability and Liability That Arises From Shared or Delegated Design” (http://bit.ly/1mzHIj7) that show how one simple document can be used in two court cases with two different outcomes.

1 Jaeger v Hen­ning­son, Durham, and Richardson Inc.

Powers says that in Jaeger v Hen­ning­son, Durham, and Richardson Inc, the contractor used 14-gaugesteel stair pans instead of the stronger 10-gauge pans specified by the archi­ tect. Ironworkers were injured during construction when the weaker pans failed.

The Eighth Circuit Court found that the architect’s approval of the shop drawings reflecting 14-gauge pans was enough to establish the action as a standard of care for an industry professional.

2 Waggoner v. W&W Steel Co.

However, in Waggoner v. W&W Steel Co., two ironworkers were killed and another injured when a structure under construction collapsed. The claim alleged the architect was negligent for approving shop drawings that 30

How to find a qualified detailer Industry organizations

First, go to industry organizations like NOMMA and NISD. The detailers who belong to these groups are active in the industry. They care about their customers enough to invest the time and money to connect and improve their skills.

The American Institute of Steel Construction (AISC) is the governing body for steel construction in the U.S. and has a list of more than 400 detailer members. While many of these detailers may not provide miscellaneous metals detailing, they often have a relationship with a miscellaneous metals detailer that they use when necessary.

One note of caution: Be careful with overseas detailers or detailers based here but who are really a front for an overseas detailing house. I have seen it work well, and I have seen it fail. A talented firm working with powerful CAD programs can be an asset on the big structural jobs where most of the work is right out of the AISC manual. As it applies to miscellaneous and ornamental metals, there is so much that is unique to the job, the locale, and the fabricator — such as codes, finishes, and field dimensions — that a lot gets lost in translation, both literally and figuratively.

Other fabricators

A great referral can come from a fabricator with whom you have a good working relationship. Be prepared for some resistance; some fabricators might be possessive about their detailers, and they often have a close relationship.

Yahoo

An excellent Yahoo Group for miscellaneous metals detailers, called “MiscIron-Detail,” (http:// yhoo.it/1ibIEIQ) is run by Ed Borg, Precision Drafting LLC, Bergenfield, NJ. Detailers in this group are from all over the United States, Canada, and abroad.

How to pare down your list

As experienced business owners, you are familiar with the vetting process as you make decisions every day. The first thing to do is trust your own gut. Ask for references, look at samples of their work, and explain what you do, then listen as they describe their experience with your type of work.

Beyond that, here are a few things to keep in mind. For years, a trained eye could look at a hand-drawn stair plan and know immediately if the person had the skills and experience required. Today, CAD drawings mask that ability. Every drawing looks good, but make sure you look at the content.

Knowing how to use AutoCAD does not make one a detailer, just as knowing how to use Microsoft Word does not make one a writer.

NOMMA member Dave Filippi of FabCAD Inc., White Stone, VA, says that often the best CAD operators are fabricators themselves.

“Detailers use the draw command. Fabricators use the edit command because they are always working the design. Designers should have shop and field experience.

Ask them if they know what GoJo is [We’re not telling. — The Editor].

If not, they probably have no shop experience,” he says.

The NISD’s certification program (IDC) tests and certifies a detailer has the knowledge and experience to provide detailing services. They also have a quality procedures program (QPP) that certifies the entire detailing firm has the procedures in place to provide quality assurance.

Finally, if you find yourself working with the same engineers and architects, ask them, because they review detailers’ drawings nearly every day. They know the good ones.

They’re the ones who call the architect to discuss a job before beginning their detailing so the approval process is quick and efficient.

— David Busarello O&MM Fabricator n November / December 2014

did not show temporary connections.

The Oklahoma Supreme Court upheld that the contractor, not the architect, was responsible for construction means and methods.

What is a fabricator to make of this?

Shop drawings can be your friend or your albatross. It all depends on who is preparing them.

As Heideck states in his sidebar: “The use of the detailer can also avoid the costly rework and delays resulting from a failure to communicate effectively and early about the hidden gaps between the designer’s concepts and the fabricator’s standard details, which might, unfortunately, only become clear after fabrication or even erection commences.”

John Hladczuk, Craft Ornamental Metals LLC, Philadelphia, PA, has stated many times: “My detailer is like my shield. He protects me from making assumptions about the designer’s intent. He gets on the phone with the architect, irons out the issues, and documents everything

discussed so that, when questions or disputes arise, and they often do, especially with ornamental iron, I have documentation that protects my company.”

The example of how a detailer can help with construction professionals occurred in 2007 and involved Todd Daniel, NOMMA’s executive director.

I was providing stair drawings for Mastercraft Iron, Neptune, NJ. The project was a building that stores road salt, a big square building with large doors. A big pile of salt sat on the floor and front-end loaders would drive in, scoop the salt, and dump it into trucks that spread it on the road. These buildings are utilitarian.

The architect, a one-man firm in New Jersey, provided a huge set of specifications covering an assortment of items that were not in the project.

Small architectural firms commonly do this because they do not have the time to assemble a 600-page spec book for every small job. We detailed the stair as designed, and it was built and installed with no issues. The building inspector even approved it.

Then the architect failed it for not conforming to the National Associa-

tion of Architectural Metal Manufacturers (NAAMM; www.naamm.org) Finishes Manual, which was referenced in his specs along with every other building organization. He held up payment to my customer, who called me for help.

I had recently joined NOMMA, and Daniel put me in touch with one of the authors of the NAAMM Finishes Manual who wrote a letter to the Ocean County Road Department (the building owner) explaining the architect was misinformed having read the manual incorrectly.

It turned out the architect was a residential architect with no commercial experience, but he had political connections. My customer’s relationship with a detailer and NOMMA got him paid.

Detailer can help you stay technologically current

Technology has entered our industry in a big way. For those like me with nearly 40 years in the trade, I still do a double take when I see a grizzled old veteran GC sitting in his trailer, flannel shirt and jeans full of dirt, cranking out Excel spreadsheets. Technology is here to stay and the sooner we

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educate ourselves, evaluate, and implement those we like into our everyday work life, the better off we will be.

The key piece of technology for us is CAD. Be it a standalone drafting program like AutoCAD or add on software like FabCAD (http://fabcad. com) and Tekla (www.tekla.com/us), these programs transformed the life of every draftsman who picked up a pencil.

In addition to the obvious benefits of cleaner drawings and a database of commonly drawn items that save time, these programs form a partnership with their counterpart — computer-aided manufacturing (CAM).

Two forms of CAD/CAM

1 Computer numerical control (CNC). Also called multi-axis routing, CNC is an end-to-end component design system that is highly automated using CAD and computer-aided manufacturing (CAM) programs. An article in the September/October 2013, O&MM Fabricator issue of this magazine by Jeff Fogel called this process “Today’s Workhorse.”

A great quote from the article described the relationship between the CAD program that creates the design and the CAM program that takes the CAD files, interprets it, and drives the machine: “The happy result of these two software programs, harnessed in tandem, is the satisfying clicks and whirrs of the router’s servos as it guides the tooling heads along its merry way while you go have a cup of coffee.”

2 3D printing. A newer form of CAD/CAM, though not often thought of as such, is 3D printing. Once a fixture only in science fiction, 3D printing is now approaching levels of affordability for small shops.

In his article, Fogel describes 3D printing, an additive technology where material is built up to form a shape, as the opposite of multi-axis routing, a subtractive technology where you begin with material stock and carve away until you have the desired figure.

Another article is notable from the May 2013 Smithsonian magazine by Elizabeth Royte. “What Lies Ahead for 3-D Printing,” is a wonderful, valuable read. “How 3D prinitng is building a 32

new future” (http://zd.net/1slxrLj) is another worthwhile read.

FabCAD’s Dave Filippi told me how 3D devices, now available for less than $2,000, can replicate many parts used by the ornamental iron shop. If you have ever worked on repairing an 80-year-old gate in a city like Philadelphia, which I have done, you know how hard it is to find old finials and spears.

“Take a unique product like an ornate 3-inch ball cap,” Dave says. “It would cost a lot of time to research it, likely ending with the supplier long out of business and no one that makes a similar item. Having one or several forged would cost a small fortune.

“Modeling it in a 3D CAD program, making it with a 3D printer, and coating it with epoxy paint would provide you with an identical match at a much lower cost and that will last just as long as the original did,” he says Dave summed up one example like this: “Say you need three spears for a fence renovation and the foundry long out of business. Take a picture of the spear, scan it, draw over it, add depth to it, send to 3D printer, make it, coat it, color it, done.” It’s getting to be just that simple.

Building Information Modeling (BIM)

One of today’s most overused acronyms is BIM. I found dozens of definitions for this concept, seemingly misunderstood by just about everyone in the trade.

The National Building Information Model Standard Project Committee defines BIM as: “Building Information Modeling (BIM) is a digital representation of physical and functional characteristics of a facility. A BIM is a shared knowledge resource for information about a facility forming a reliable basis for decisions during its life-cycle; defined as existing from earliest conception to demolition.

“A basic premise of BIM is collaboration by different stakeholders at different phases of the life cycle of a facility to insert, extract, update or modify information in the BIM to support and reflect the roles of that stakeholder.”

(See www.nationalbimstandard.org/ faq.php#faq1)

Architects used to provide this depth of service years ago when all the details of a building were coordinated before the job was released for bid.

Most of us old-timers also remember the red line set of contract drawings in the job site trailer that all the trades marked up with any changes they made so the architect could produce a set of “as-builts.”

With less detail on the CDs and more responsibility on the backs of the contractors, BIM has become mandatory on stadiums and highrises, important on large projects like schools and low-rise buildings, and it has now found its way into smaller jobs like one I lost this year.

One of my customers, Weld-Done Welding, Deptford, NJ, asked me to bid on a Princeton University dorm project of four buildings, three stories each, with two stairs in each building — a simple concrete-filled pan stair bearing on block walls with picket rails.

However, the contract called for a 3D model with BIM capabilities. I just don’t have the capability to provide 3D modeling at this time, and I was unable to take the job. Guess what I will be doing in the next few months.

Much of the miscellaneous work we do has always been an afterthought to the architect and GC. Aren’t many of the stairs we do a rush because the steel is up, and they need egress ASAP? Once onsite, we find the stairwells are too small, and the concrete floor is already poured. The need for us to get in on the job early is now being recognized.

Don’t be surprised when the architects/GCs in your area start requesting bids on these larger and mid-sized jobs before the CDs are even done.

They want the fabricator’s early input on these miscellaneous items, and BIM is leading the way. Your detailer is the one who can help you.

Early steel detailing

Getting on the job early is addressed by a process growing slowly but surely: “early steel detailing.” This brings the fabricator and the detailer into the process during the design phase.

O&MM Fabricator n November / December 2014

Sometimes the project engineer hires the detailer directly. Detailers provide the same service they’ve always provided, but in this process, they can identify construction issues during the design phase, thus making the contract drawings more accurate, rather then after the bid is awarded when time is critical and the engineer of record has moved to the next project.

Also, the shop drawings are prepared and available during the bid phase. Once awarded, a fabricator can order steel and get rolling.

This has tremendous potential but currently has few adopters. One issue is that the shop drawings would no longer have the fabricators input.

In his paper “Procuring Steel through an Early-Release Steel Package” (http://bit.ly/1aIxFHi) Auburn University’s C. Ben Farrow, MSCE, MBA, PE, concluded that: “Procurement of steel through the use of ‘early-release’ shop drawings can provide an effective way to shorten time, save money, and reduce errors on certain construction projects.

The use of ‘early-release’ shop drawings paves the way for a paradigm shift where a single owner owns a complete database for a project.

“In this future scenario, the 3-D model will be shared by designers, detailers, builders, and facility managers through the design, construction, and service life of the building.

However, resistance to change in the way buildings are delivered exists among designers, fabricators, and facility managers. . . .”

“As a first step in the process, integrated steel design can serve as a ‘stepping off’ platform for eliminating buffers in the steel industry. As designers, contractors, and detailers work together to provide an integrated steel design project, clear elements and issues will provide sharp focus on areas where critical communication and coordination is needed. A collaborative approach will then breed new ideas to drive BIM to the forefront in this area of the construction market.”

While not affecting most of us today, the jobs you bid in 10 years may come already detailed. How you will offer alternate designs, if allowed since they will cause delay and added review costs, is yet to be determined.

In closing

My hope is that the two articles, “The case for Detailing, Part 1” and “Part 2,” provide you with useful pointers and a few smiles along the way. My motivation may seem self-serving because I am a detailer. But I believe NOMMA members truly care about their industry as a whole. There is a wonderful Hindu proverb, “help thy brother’s boat across and lo, thine own has reached the shore.”

I looked at NOMMA’s membership demographics from May 2013. The first page shows 62.8% of NOMMA members have six employees or less, 20.7% have only one or two employees.

The industry has changed. The need for a fabricator November / December 2014 n O&MM Fabricator

33

to sift through incomplete contract drawings, understand the intricacies of the building codes, and be up-todate on all the latest advances that can help your production, and in some cases will one day be required of you, is greater than ever. The need for miscellaneous detailers to stay up-to-date on these issues is imperative to their survival.

I spent 22 years working in-house for fabricators. I witnessed first hand the need for someone to bridge the gap between the designers and the contractors. Our industry is fortunate that we have an established position to handle those tasks.

My relationships with my miscellaneous metals clients are different from my structural clients. The relationship is much more personal with the miscellaneous metals fabricator because we talk almost daily when I have a project from them. During my research for this article, I’ve learned my customers feel the same way, and this humbles me greatly.

I am proud to have spent 35 years in this field, and I am grateful to have had the opportunity to help my clients reach the shore.

For your information

n

Bridgeton Drafting Company LLC 520 North. West Ave. Vineland, NJ 08360 856-205-1279 856-205-1283 fax info@bridgetondrafting.com www.bridgetondrafting.com About the author David Busarello began working in his father’s sheet metal shop as a teenager. He has been in the detailng business since 1978, first employed by a structural fabricator, then as chief draftsman of a miscellaneous metals shop.

In 2000, he purchased Bridgeton Drafting from a longtime associate. The company serves about a dozen long time customers based in the Mid-Atlantic region and produces approximately 80 projects a year.

34

Shop Talk

The case for

detaılıng Part 2

An attorney’s views on Hyatt hotel tragedy and shop drawings as a legal document Editor’s Note: This article represents the views of the author, and does not necessarily represent the views of Pepper Hamilton LLP, its clients, or NOMMA. This article is published solely for general informational and educational purposes and is not intended to advertise any services, legal or otherwise.

The article should not be considered a substitute for legal advice, and it does not establish an attorney-client relationship. For legal assistance, contact an attorney licensed to practice in your jurisdiction.

By Robert E. Heideck* Pepper Hamilton LLP For many in the construction industry, the single major event which raised the importance of shop drawing review was the collapse in 1981 of the skywalk at the Hyatt Regency Hotel in Kansas City in which 114 people were killed.1 The collapse was caused by the failure of the box beam hanger rod connections supporting the atrium walkways. The original design contemplated continuous hanger rods that would be attached to the roof, pass through the fourth floor box beams and then through the second floor box beams.3 The drawings supplied to the steel erector provided what appeared to be full details for these connections, but could be read as showing that the rods terminated below each walkway box beam.4 The shop drawings prepared by the fabricator showed a double rod configuration with one rod extended from the fourth floor to the roof and the second rod from the second to the fourth floor.5 Also, the box beams were not extruded rectangular tubes but were shown to be created by welding the toe edges of two channel sections together

along the flange lengths. No stiffeners or bearing plates were shown either on the structural drawings or on the shop drawings. A copy of the configuration is set forth above.

No loads were provided on the drawings sent to the fabricator and no calculations or other analysis were performed or provided by the fabricator. The structural engineer for the project stamped the drawings as reviewed but this was not based upon any calculations of the anticipated loads.9 The changes created a doubling of the load on the fourth floor walkway beams because those beams now also carried the entire load of the lower walkway.10 Also, the offset of the two rods created a concentrated load at the end of the box beam section of the fourth floor, which created a “structural eccentricity.”11 Under load, it appears that the more heavily loaded outer rod tore through the flanges of the box beam, causing the entire walkway to fail with the resulting deaths and injuries. A copy of a photograph of one failed section is below.13 As might be expected, a myriad of lawsuits were filed and a criminal grand jury was enpaneled. No criminal indictments were issued. The major source of the “lessons learned” is the 442-page opinion of the Missouri Board of Architects, Professional Engineers & Land Surveyors, published in 1985.1 Among many conclusions reached by the Board was that the structural engineer for the project had ultimate responsibility for reviewing all shop drawings to ensure that the structural members and connections were adequate for the loads.13 As the Judge stated: “Shop drawing review allows the engineer to provide the final, unreO&MM Fabricator n November / December 2014

5th floor steel

5th floor steel

5th floor steel

Hanger rod to support 2nd floor

5th floor steel

Hanger rod to support 4th floor

4th floor walkway tube box beam

Rod passes through box beam with no connection

Hanger rod to support 4th floor

Hanger rod to support 4th floor

4th floor walkway tube box beam

4th floor walkway box beam

8x5-inch tube box beam as designed

Hanger rod to support 2nd floor (beyond)

4th floor box beam supporting itself & 2nd floor walkway 2nd floor walkway box beam

2nd floor walkway tube box beam

Hanger rod to support 4th floor

4th floor walkway channel box beam Hanger rod to support 2nd floor (beyond)

(2) 8-inch channel box beam as constructed (note seam at top & bottom)

Hanger rod to support 2nd floor 2nd floor walkway channel box beam

2nd floor walkway tube box beam

Original design, left, and actual construction, right, of Kansas City Hyatt Regency Hotel skywalk.

viewable determination and verification of strength for the protection of the public. . . .”14 The State of Missouri revoked the licenses of the two project structural engineers. That same year, the American Society of Civil Engineers issued a policy statement:15 The engineer of record should have responsibility and authority for all aspects of the structural design and his/her contract should specify that he/she either (a) designs the connections or (b) reviews and approves all shop drawings, including connections selected and detailed by the fabricator. During construction, the engineer of record should make appropriate on-site observations.

Since the Hyatt case, the law relating to shop drawings has generally developed as follows: With respect to the contractor (and/or the erector), the major purpose of the review of the shop drawings is to confirm means and methods of construction, to ensure proper sequencing of the trades, and to ensure that the proposed activities can be accomplished in a safe and effective manner. If, for example, a worker gets injured because of insufficient attachments for temporary scaffolding, the November / December 2014 n O&MM Fabricator

Kansas City Hyatt Regency Hotel skywalk detail. Above left, the engineer of record designed the 2nd floor walkway to be supported by rods that would be connected to the 5th floor steel, pass through the 4th floor box beams without connection, and then attached to the 2nd floor box beams with nut and washer.

Drawings by David Busarello, Bridgeton Drafting Company.

The fabricator determined fabrication and erection could be simplified by attaching the 2nd floor support rods directly to the 4th floor box beams, above right. This doubled the load on the 4th floor box beams and it’s rods. The fabricator also did not use the tube steel box beams as designed, substituting two 8-inch channels with the tips of the flanges welded together.

This created a zipper-like weak spot, see photo. Vibration due to human movement, like dancing on the walkways, caused the channels to fail, the nut tearing through the seam.

Photograph by Dr. Lee Lowery, Jr., P.E., Zachry Department of Civil Engineering, Texas A&M University. More photos at: http://bit.ly/1zjKjYF.

contractor is usually held liable even if the architect or engineer approved the shop drawings showing those attachments.

As to the architect/engineer, the purpose of the review of the shop drawings is to confirm that the proposed items meet “the design concept of the Project.” This generally means that if the overall structure as designed fails or if the work does not meet the overall design, then the architect/engineer face liability even through the drawings were prepared by others.

As to the fabricator, the fact that the Board in the Skywalk matter placed ultimate responsibility on the project structural engineer, as opposed to the steel fabricator, does not mean that fabricators have no liability for “design” decisions. There are situations in which the project engineer can assign design responsibility for connections, etc., to the fabricator.

In any event, a fabricator who provides a metal stairway that collapses would face significant liability, even if the shop drawings were reviewed and approved by others.

Fortunately, the horror stories about death and injury are few. There are issues, however, that arise every day on many projects, especially in the 35

For your information

References

1 Most of the facts described here are taken from the 442-page published opinion of the Administrative Hearing Commission of the State of Missouri in “Missouri Board for Architects, et. al. v. Duncan, et. al,” published in November 1985.

Hereafter cited as “1985 Missouri Board Decision.”

2 See 1985 Missouri Board Decision at pp. 98-100.

3 See 1985 Missouri Board Decision at pp. 35-36; 54-55.

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4 See 1985 Missouri Board Decision at pp. 42-43; 55-57.

5 See 1985 Missouri Board Decision at pp. 60-62; 70-72.

6 See 1985 Missouri Board Decision at pp. 46-48.

7 See 1985 Missouri Board Decision at pp. 40-42; 44-45; 72-73.

8 See 1985 Missouri Board Decision at pp. 36-37; 42-43; 62-63.

9 See 1985 Missouri Board Decision at pp. 71-74. Even though the structural engineer’s stamp only indicated that the shop drawings were “reviewed” and the word “approved” was absent, the Board decided that the review stamp functionally indicated both review and approval (pp. 31-32).

10 See 1985 Missouri Board Decision at pp. 63; 66.

11 See 1985 Missouri Board Decision at pp. 255-257.

12 See Footnote 1.

13 See 1985 Missouri Board Decision at p. 76.

14 See 1985 Missouri Board Decision at p. 216.

15American Society of Civil Engineers Policy Statement “Authority and Responsibility for Design of Steel Structures” (as adopted on October 20, 1985).

16 See 1985 Missouri Board Decision at p. 234.

the fabricator, provided that such intent is clear. In that case, the fabricator will be responsible for the engineering and design of those connections.

In many situations, the fabricator who has a detailer either in-house or as part of its team could have an advantage. A detailer has been described as the person who provides “a ‘bridge’ between the engineer (a profession) and the fabrication and erection crew (a trade) by ‘translating’ the engineer’s design intent” onto shop 1 drawings for use in construction.

Use of an experienced detailer as the “bridge” to facilitate communication could help the shop drawing and fabrication process by bridging the gaps in many ways. For example, the detailer can help to avoid the frustrating delays caused by shop drawing “ping-pong” in which the same drawings are repeatedly stamped “revise and resubmit” but there is no effective communication to identify and solve the real problems and ultimately close the gap to approval. The use of the detailer can also avoid the costly rework and delays resulting from a failure to communicate effectively and early about the hidden gaps between the designer’s concepts and the fabricator’s standard details which might, unfortunately, only become clear after fabrication or even erection commences.

n

increasingly common situation where the drawings provide few details. The recent trend has been for the design team to provide little detail in the contract drawings, which enables the supplier or fabricator to work with a virtual blank slate. There are several reasons for this trend.

First, it minimizes the work and costs of the design team.

Second, because the design team may have knowledge that is the proverbial “mile wide but only inch deep,” it prevents the unwanted consequence of the design team providing details that make little sense.

Third, it often allows greater competition at the supplier and fabricator level because the virtual blank slate enables Fabricator A, Fabricator B and Fabricator C to compete on a relatively equal footing as opposed to having to comply with a design detail which essentially favors only Fabricator C’s “proprietary” details.

In addition to its benefits, however, the virtual blank slate also creates new risks and responsibilities. The lack of detail often creates a “performance” specification by describing the item to be supplied in extremely general terms and adding performance requirements.

Generally, if the designer provides a detailed design and the fabricator follows it to the letter, the fabricator is not responsible for the result.

If the design is a “performance” specification, for example, “design, fabricate and erect a circular metal stairway installed at point x, capable of load y and meeting all applicable codes,” the fabricator bears the risk and responsibility to ensure that its design and fabrication will meet those requirements.

Moreover, as noted, the project engineer is permitted to place design responsibility for the connections on

About the author Robert E. Heideck is a partner in the Litigation Department of Pepper Hamilton LLP, www.pepperlaw.com.

In the construction industry, he has represented owners, contractors, sureties, subcontractors, including claims arising out of the construction of major highways and other projects throughout the United States.

Top Job 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.

O&MM Fabricator n November / December 2014

METALfab2015 Knowledge to enlighten the industry Celebrating 57 years March 11–14, 2015 Valley Forge Casino Resort King of Prussia, PA Join Us for a revolutionary experience at METALfab2015!

As the president of NOMMA and the chair of METALfab 2015, please join me at the Valley Forge Casino Resort, King of Prussia, PA (a suburb of Philadelphia) for METALfab2015.

NOMMA and the NOMMA Education Foundation (NEF) together have developed a program that you will not want to miss as METALfab continues to demonstrate the value of networking with your peers from across the country and of continuing education. n The education program created by the NEF will provide an excellent opportunity for you to expand your knowledge base. n The exhibits will connect you with suppliers and allow you to learn more about their products or services directly on-site. n The Party with a Purpose and Awards Banquet give you the time to make new connections and catch up with good friends from past NOMMA events. n Shop tours bring you to Philadelphia-area companies to learn about their processes. n Business classes presented exceptionally by Tyler Pare, a consultant with FMI Corporation, Raleigh, NC, will offer a substantial number of how-to tips.

FMI provides management consulting and investment banking for the engineering and construction industry. The description of Tyler’s series of classes are on pages C–D. Tyler focuses on leveraging his construction experience, coupled with his advanced knowledge of business mechanics, to help clients mitigate risks and improve productivity. This thought-provoking speaker will present useful, must-attend sessions.

French Alliance Day. Re-enactors march through the Grand Parade area at Valley Forge National Historical Park in celebration of French Alliance Day in May. Credits: Valley Forge CVB Scott Mabry.

n Our keynote speaker, Barry Willingham, is the vice president/general manager of Ameristar Perimeter Security USA Inc. His inspirational message will kick off METALfab2015.

Many thanks to our sponsors that always ensure the success of METALfab; we cannot do this without their support. Many NOMMA members have diligently volunteered to make this a special gathering just for YOU. A special thanks to everyone that has helped make this possible.

So much available March 11–14, at METALfab2015.

Please sign up early.

See you in March.

Mark Koenke

NOMMA President 2014–2015 METALfab2015 Convention Chair

Conference highlights Program at a glance Page B

NOMMA METALfab2015 Guide

Education sessions Pages C–D

Sponsors, Hotel information Pages E–F

Registration form Pages G–H A

Knowledge to enlighten the industry METALfab2015

Program at a glance WEDNESDAY, MARCH 11, 2015

8:00 am–9:00 am First Time Attendee Orientation New attendees get overview of NOMMA and METALfab 9:15 am–11:15 am Opening Session NOMMA annual membership business meeting and keynote 11:15 am–12:30 pm Lunch on your own

Lunch Break

12:30 PM–5:30 pm NEF Education Sessions 6 sessions: 2 classrooms with 3 sessions each THURSDAY, MARCH 12, 2015

8:00 am–9:30 am NEF Education Sessions 2 sessions: 2 classrooms with 1 session each 9:30 am–2:30 pm Exhibits Open Visit with exhibitors and vote in Top Job contest 10:00 am–2:00 pm Spouse Classes 2 classes for attendees with a spouse registration 12:30 pm–1:30 pm Lunch with the Exhibitors Enjoy lunch while you visit with exhibitors 2:45 pm–6:00 pm NEF Education Sessions 4 sessions: 2 classrooms with 2 sessions each 7:00 pm–10:30 pm Party with a Purpose Network, bid at the auction, enjoy entertainment, food, drink FRIDAY, MARCH 13, 2015

8:30 am–10:00 am NEF Education Sessions 2 sessions: 2 classrooms with 1 session each 10:00 am–1:00 pm Exhibits Open Another chance to visit exhibitors and vote in Top Job contest 10:30 am–12:30 pm Spouse Class 1 class for attendees with a spouse registration 1:00 pm–4:15 pm NEF Education Sessions 4 sessions: 2 classrooms with 2 sessions each 4:30 pm–6:00 pm Top Job Jamboree Learn from the members who entered the Top Job contest 6:00 pm–7:00 pm NEF Partners in Education Reception Thank you for your continued support of NEF SATURDAY, MARCH 14, 2015

9:00 am–4:00 pm Shop Tours Visit shops in the Philadelphia area to learn about their businesses 9:00 am–4:00 pm Spouse Tour A tour and luncheon for attendees with a spouse registration or ticket to this event 7:00 pm–10:30 pm NOMMA Annual Awards Banquet Install officers, present Top Job awards, closing remarks 38 B

O&MM Fabricator / December 2014 n November NOMMA METALfab2015 Guide

Knowledge to enlighten the industry METALfab2015

Education session descriptions Business classes with R. Tyler Pare, FMI Corporation

Tyler Pare is a consultant with FMI Corporation, Raleigh.

FMI provides management consulting and investment banking for the engineering and construction industry.

Before joining FMI, Pare worked for multiple general contractors in the Southeast. He has experience in construction estimating, both in negotiated and hard-bid environments and has operations experience, serving as project manager on commercial and industrial projects.

Pare has a master’s in business administration, concentrating in finance and real estate, a master’s in management, and a bachelor’s in building construction from the University of Florida. He is a LEED accredited professional.

Leveraging your Competitive Advantage by Improving Productivity

How do you win in today’s economy?

Becoming a lower-cost producer is one strategy. Much like safety, productivity improvement starts at the top. Contrary to popular belief, productivity is not a field problem, but rather a management and leadership issue.

R. Tyler Pare In this session, you’ll learn how to Consultant improve productivity to address market FMI Corporation challenges by: n understanding how a minimal improvement in productivity will make you more competitive. n implementing FMI’s P3 model: Process, Productivity Tools, People. n determining the best practices and the new technologies that will impact the industry.

Connecting Actual Job Costs Back To Estimating

One risk to a company in a low-margin construction economy is executing a project differently than how it was estimated (and vice versa). In this session, you’ll learn how to maintain profitability by: n incorporating field input into estimates and budgets, n determining the healthy differences between an estimate and a budget, n recognizing why and how actual job costs should be tracked, and n using job-cost information to improve estimating accuracy.

November /METALfab2015 December 2014 nGuide O&MM Fabricator NOMMA

Performance Indicators that Drive Best Practices

If you are going to win at the game of contracting, you have to know the score. The score, however, is made up of more than profit. Success is determined by more than whether you made or lost money at the end of the job. n Identify Key Performance Indicators (KPIs) so that contractors can develop the components of a solid game plan for tracking performance through the life of the project. n Compile the results of the KPIs to develop your overall company performance on a timely basis so you can make corrections to keep your team on course. n Measure your business’s processes to define success factors and measure progress toward strategic goals.

Keys to Effective Management

Why is it so difficult to work and get along with certain people? The answer is simple: People have different wants and needs. Recognizing and accepting differences in yourself and others is essential when you all are working toward a common goal.

To achieve the desired project results, you have to be willing to work with all types of people. Once you become adept at anticipating individual interaction preferences, you will increase your effectiveness at managing people and your relationships. n Discover how personality characteristics affect the communication process. n Understand the four basic personality types with the DISC profile. n Explore the best approach for communicating with different personality types.

Driving Best Practices in Business Development As organizations try to make sense of the changing markets around them, many are putting new effort into their approach to business development.

After observing a significant shift in this direction, FMI conducted a survey of contractor CEOs and top executives to identify the current challenges of the business development process and the solutions that are yielding positive results.

Findings from this research lead to a greater focus on solutions based on direct experiences of contractors who are leveraging a total business development culture within their firms. In this session, you’ll learn how to: n determine why some old sales tactics do not work anymore, n implement successful new business development activities and measure the results, n instill a companywide business development culture to drive new business opportunities, and n establish creative strategies that focus all of your resources on the customer.

C

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Knowledge to enlighten the industry METALfab2015

How To Avoid Confrontation with Change Orders

Change orders are a way of life in construction and, unfortunately, so is the difficulty of explaining change in project scope and subsequent price increases to your customer.

However, you can avoid confrontation and still be paid for the additional work that you have done. n Master the art of dealing with delays, accelerations, additions, deletions and other changes. n Recognize a change and get paid for it. n Understand how to document and determine the amount of a change order and how to communicate changes and their costs to clients and personnel. n Examine change costs, contract terms and overhead and the impact they have on scheduling and retention.

Where’s The Cash?

Dave Filippi, FabCAD Inc. A practical and unconventional look into small business management with answers to the following questions: n Your income statement shows profit, but where is the cash? n Primary sources of cash. n How to find hidden sources of cash. n How to stop cash from leaking out of your checkbook. n Do you really have to spend money to make money? n Is the adage “Advertising doesn’t cost, its pays” true? n Do you really need to tie up cash in inventory? n Is the customer always right? n How to develop a business plan starting with cash-onhand goal.

Hedging Your Bets on Hiring the Right Employee

Roger Carlsen, Ephraim Forge Inc. How can you design an employee search paradigm, including, but not limited to: where to look for possible candidates, first impressions insights, designing the right written test to fit your needs, thoughts on actual handson task testing, and making the final decision.

Measuring Made Easy

Mark O’Malley, O’Malley Welding & Fabricating Inc., Terry Barrett, Pinpoint Solutions This two-part class will examine the tools, technologies, and methods for field measuring, shop drawing, and shop and field layout. You’ll hear discussion about an array of lasers, electric hand and homemade tools for measuring, CAD, smartphone apps, other layout software. The speakers will share their tried and true methods along with tips and tricks that they use.

The first part of the class will be a show-and-tell about how different tools work. The second part will include the actual use of the tools on a stair or ramp in the conference hotel. Attendees may bring specific challenges for addressing in the hands-on section.

D

History of Metalwork

Eric Cuper, Cuper Studios LLC This session will focus on metal history, with an emphasis on the history of blacksmithing/decorative work and the impact of technology and modern design.

Under 40 — Hammering Out Your Course in Metalwork

Discover how the under-40 group see their future path to success. In past years, you’ve heard from veteran fabricators about the secrets of their success. This year, you’ll learn what the under-40 group sees as they create their own course for a successful future.

Shop Tours

During in-person shop tours, attendees see how some NOMMA members manage their shop. You’ll see the shop layout and equipment and processes used for fabrication.

Video Shop Tours

With current technology, we can visit the shops through video. There are some shops that we may never have the chance to visit during convention shop tours. This gives you another way to learn even more from other fabricators.

Women in the Business

A roundtable discussion for women in the metals business.

Discuss challenges, successes, and where to go in the future. Great networking for women in the industry.

ListServ Live

Meet the people that participate in the NOMMA ListServ discussions and continue the discussions in person. Discussion will include the hot topics that are challenging members today. Your participation is bound to enrich the talk.

Other classes are in the works for METALfab2015, so be sure to check the website for more details.

NOMMA METALfab2015 Guide

Knowledge to enlighten the industry METALfab2015

Spouse Program Classes, Thursday, March 12 and Friday, March 13.

Tour, Saturday, March 14.

Previous participants in the spouse program learned to work in acrylics with renowned artist Maxine Minter. This year, you’ll tackle a new subject and enjoy expanding your talent. Two additional classes will be announced later; check www.nomma.org for updates.

Other events included in the spouse registration are: n Opening Ceremonies. n Exhibits. n Party with a Purpose (NOMMA Education Foundation Auctions). n NEF Partners in Education Reception. n Awards Banquet. n Tour and Luncheon. With the wealth of historical locations in the Valley Forge/Philadelphia area the spouse tour will be “revolutionary.” The tour will include visiting several historic spots and a enjoying a wonderful luncheon.

Conference Hotel information — Valley Forge Casino Resort 1160 First Ave., King of Prussia, PA 19406 Group Rate of $139 + will be available until Friday, February 6, 2015.

Room rate of $139 applies to single, double, triple, quad accommodations. + (plus) includes local sales and occupancy tax or any additional fees owed at the time of occupancy.

Make your hotel reservations by calling the hotel directly at 610-354-8118.

To get the group rate, ask for the METALfab Room Block and request the Radisson Tower.

All hotel reservations must be guaranteed with a major credit card or guaranteed and accompanied by a first night’s room deposit including sales and occupancy tax. n Reservation cancellations must be received 3 days before arrival to avoid the billing of the first night’s room and taxes. n Early departure fee of $75 per day for any group participant wishing to check out before their checkout date once they have checked into the hotel n Group rate will be offered two days before and 2 days after the start and end dates for the conference. n

Gambling Problem? Call 1-800-GAMBLER November /METALfab2015 December 2014 nGuide O&MM Fabricator NOMMA

Keynote Barry Willingham

Ameristar Perimeter Security USA Barry Willingham is general manager of Ameristar Perimeter Security USA, a division of ASSA ABLOY Corporation, which provides solutions in the door opening and perimeter security markets.

Willingham has served the construction industry over the last 30 years, specializing in physical perimeter security, fire protection, and construction technology. He has held positions in manufacturing and security construction installation, with additional responsibilities involving training, organizational development, leadership, and operational excellence.

Previously, he held positions at HILTI that included global responsibilities; vice president of Smith & Wesson Holding Corporation; and president of Smith & Wesson’s Perimeter Security Division.

METALfab2015 Registration instructions Two ways to register for METALfab2015.

1 Go to the NOMMA website www.nomma.org and register online using your credit card.

2 Fill out the registration form enclosed in the convention guide (page G) and submit with check or credit card.

Mailing address for registrations: NOMMA, P. O. Box 124 Delcambre, LA, 70528.

Fax number for registrations to 888-279-7994.

Online registration will end on March 4, 2015.

Register onsite at the METALfab registration desk, which will open, Wednesday, March 11, at 7:30 am at the Valley Forge Casino Resort, Grand Foyer.

Reduced Registration Fees the Earlier You Register The earlier you register the better the rate. An example of the savings on a Full Conference Package for NOMMA Members: Special Fee is $450; Deadline 2/19/2015, Regular $580; Deadline 3/4/2015.

Non-members: Save money on your registration by becoming a member. When your company joins NOMMA, all of your employees qualify for the member registration rate.

For membership information go to www.nomma.org or contact Liz Harris, Member Care & Operations Manager at 888-516-8585 x 101, liz@nomma.org.

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Knowledge to enlighten the industry METALfab2015

Sponsors as of 9/26/2014 Platinum Industrial Coverage Corp.

Silver Lawler Foundry Corp.

Exhibitors as of 9/26/2014 Alloy Casting Co. Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . www.alloynet.com Architectural Iron Designs Inc. . . . . . . . . . . . . . . . . . . . www.archirondesign.com Big Blu Hammer Mfg. Co. . . . . . . . . . . . . . . . . . . . . . . . www.bigbluhammer.com The Cable Connection . . . . . . . . . . . . . . . . . . . . . . . . . . www.thecableconnection.com Chicago Metal Rolled Products . . . . . . . . . . . . . . . . . . . www.cmrp.com Colorado Waterjet Co. . . . . . . . . . . . . . . . . . . . . . . . . . . www.coloradowaterjet.com Custom Orn. Iron Works . . . . . . . . . . . . . . . . . . . . . . . . www.customironworks.com D.J.A. Imports Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.djaimports.com Elite Architectural Metal Supply LLC . . . . . . . . . . . . . . . www.elitearchitecturalmetal.com Ercolina — CML USA Inc. . . . . . . . . . . . . . . . . . . . . . . . www.ercolina-usa.com Feeney Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.feeneyinc.com Hartford Standard Company Inc.. . . . . . . . . . . . . . . . . . www.hartfordstandard.com Industrial Coverage Corp.. . . . . . . . . . . . . . . . . . . . . . . . www.industrialcoverage.com King Architectural Metals . . . . . . . . . . . . . . . . . . . . . . . . www.kingmetals.com Lavi Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.lavi.com Lawler Foundry Corp. . . . . . . . . . . . . . . . . . . . . . . . . . . . www.lawlerfoundry.com Locinox USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.locinox.com Mittler Bros. Machine & Tool . . . . . . . . . . . . . . . . . . . . . www.mittlerbros.com NOMMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.nomma.org NOMMA Chapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.nomma.org NOMMA Education Foundation . . . . . . . . . . . . . . . . . . www.nomma.org/nef Regency Railings Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . www.regencyrailings.com Sumter Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.sumtercoatings.com The Wagner Companies . . . . . . . . . . . . . . . . . . . . . . . . . www.wagnercompanies.com ABANA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.abana.org American Fence Association. . . . . . . . . . . . . . . . . . . . . . www.americanfenceassociation.com

Exhibit Schedule Thursday, March 12.......................................................... 9:30 am–2:30 pm Friday, March 13 ............................................................... 10:00 am–1:00 pm Go to www.nomma.org for an up to date list of exhibitors and sponsors.

In the background of each page in this program guide is the opening page of a delightful letter written in May 1778 by Richard Henry Lee to his brother, Arthur, while in France. Letter includes news of the replacement of Silas Deane by John Adams as American

F

plenipotentiary to France; news regarding the British occupation remains of Philadelphia and “ours at Valley Forge about 18 miles from the City — The latter growing daily stronger in numbers and discipline.”

NOMMA METALfab2015 Guide

METALfab2015 Attendee Registration Form ✂

Valley Forge Resort & Casino, King of Prussia, PA, March 11–14, 2015 See Convention Guide or go to www.nomma.org for course and event descriptions. Note deadlines for special pricing.

METALfab2015 Registration Options

Special Fee 9/1/14–2/19/15 ❑ Full Conference — NOMMA Member $450 Education Program/Opening Session/Exhibits/Thursday Party with a Purpose & NEF Auctions/NEF Reception/Shop Tours/Awards Banquet

Regular Fee 2/20/15–3/4/15 $580

❑ Full Conference — Non-Member $650 Education Program/Opening Session/Exhibits/Thursday Party with a Purpose & NEF Auctions/NEF Reception/Shop Tours/Awards Banquet

$780

❑ One Day — NOMMA Member $350 Events scheduled for day except Spouse classes and tour (check day): ❑ Wednesday ❑ Thursday ❑ Friday

$480 ❑ Saturday

❑ One Day — Non-Member $550 Events scheduled for day except Spouse classes and tour (check day): ❑ Wednesday ❑ Thursday ❑ Friday

$680 ❑ Saturday

❑ Spouse Registration $380 Spouse Classes/Opening Session/Exhibits/Thursday Party with a Purpose & NEF Auctions/NEF Reception/Spouse Tour/Awards Banquet ❑ Exhibits Only Registration Visit the suppliers on the show floor.

$0

$480

$0

Guest Tickets: Purchase deadline is 2/26/15. Not available online. You must have registered for a full or one-day registration to be able to purchase guest tickets. These tickets are for your guest that does not have a full, one-day, or spouse registrations. ❑ Thursday Dinner Party with a Purpose & NEF Auctions, Thu. 3/12: $100 — included in spouse, full and Thursday one-day registrations. ❑ Spouse Tour, Sat. 3/14: $110 — Only included in spouse registration not included in full or one-day Saturday registration. ❑ Awards Banquet, Sat. 3/14: $90 — included in spouse, full, and Saturday one-day registrations.

Name for Badge ______________________________________________________________________________________________

Payment Method (Select the payment type you would like to use.)

Check (payable to NOMMA in U.S. dollars on U.S. bank) Check #______________________ Credit Card

❑ American Express

❑ MasterCard

❑ VISA

❑ Discover

Card #___________________________________________________________________________ Exp. Date___________________ Name on card____________________________________________________________________ Card CVV___________________ Signature____________________________________________________________________________________________________

✂

Tell Us About Yourself

Name (full or one-day registrant)__________________________________________ Please check appropriate ribbons below for inclusion in your registration packet Spouse Registrant Name__________________________________________________ ❑ New Member ❑ First Time Attendee Company _______________________________________________________________ ❑ Fabricator Member ❑ NW Supplier Member Address:_________________________________________________________________ ❑ Regional Supplier Member ❑ Local Supplier Member City: ____________________________________________________________________ ❑ Affiliate Member ❑ Committee Chair State: __________Zip:_________________Country:_____________________________ ❑ Committee Member ❑ Chapter President Email:____________________________________________________________________ ❑ Chapter Member ❑ NEF Contributor Phone:_____________________________ Fax:__________________________________ ❑ Gold Member 20+ years ❑ Past President Emergency Contact Number:_______________________________________________ ❑ BOD ❑ Officer ❑ NEF Trustee/Officer Name of Emergency Contact:_______________________________________________ ❑ Speaker/Presenter Registration form continued on page H

NOMMA METALfab2015 Guide

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METALfab2015 Attendee Registration Form Additional Full, Spouse and One Day Registrants from the same company Name__________________________________________________________________________________________________________ Type of registration: ❑ Full ❑ One-day (__Wed __Thu __Fri __Sat please check appropriate day) ❑ Spouse

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Name__________________________________________________________________________________________________________ Type of registration: ❑ Full ❑ One-day (__Wed __Thu __Fri __Sat please check appropriate day) ❑ Spouse Name__________________________________________________________________________________________________________ Type of registration: ❑ Full ❑ One-day (__Wed __Thu __Fri __Sat please check appropriate day) ❑ Spouse Name__________________________________________________________________________________________________________ Type of registration: ❑ Full ❑ One-day (__Wed __Thu __Fri __Sat please check appropriate day) ❑ Spouse

Attendee Profile Tell us about your business

This portion of the registration must be completed for processing. ❑ Check here if you are not involved in the business. If you are not involved in the business this is all of the information needed. Thank you.

List three (3) products you hope to purchase from contacts at METALfab2015: _______________________________________________________________________________________________________________ _______________________________________________________________________________________________________________ _______________________________________________________________________________________________________________ 1)Primary type of business 2) Annual gross sales ❑ Fabricator ❑ Below $1 million ❑ General Supplier ❑ $1–$2.5 million ❑ Contractor ❑ $2.5–$5 million ❑ Other_____________________ ❑ Over $5 million

3) Your role in purchasing ❑ Final Say ❑ Recommend ❑ Specify

4) Job description ❑ Owner ❑ Manager/Foreman ❑ Other_______________

Important Information

Registration Registrants can to pick up their packets at the METALfab/NOMMA registration desk in the Grand Foyer of the Valley Forge Casino Resort.

Restrictions Attendees for the exhibits must be 14 years of age or older for insurance purposes.

Cancellations If received in writing prior February 25, 2015, we will be happy to refund your registration fee less a 10% administrative fee. Understandably, fees cannot be refunded for registrations canceled after that date. Registrations are nontransferable without the written permission of NOMMA. Refunds will be processed within 30 days after the completion of the conference.

Cameras Photography and videotaping are not permitted in the exhibit area, education sessions, or Top Job Gallery.

Emergency Contact We would like to have contact name and phone number in case of an emergency. This person would be contacted only in the event that you were unable to contact them yourself.

Confirmation & Updates Your confirmation and any updates will be sent by email, so please provide your email address.

Email address Your email address will be provided to the exhibitors on their attendee list. If you do not wish to have your email address provided to the exhibitors please opt out by sending an email to liz@nomma.org with the subject line “Email Opt Out for Exhibitors’ List.” This will also opt you out for updates about METALfab.

Online registrations Online registration is available for credit card payments only.

Recorded Sessions By registering for METALfab you are authorizing the use of any photographs and/or likeness in any recorded session.

Return to:

METALfab 2015 / NOMMA P. O. Box 124 Delcambre, LA 70528 Fax: 888-279-7994 Email: liz@nomma.org

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Questions?

Call 888-516-8585 extension 101 or email liz@nomma.org.

For updated information go to www.nomma.org Online Registration is available on the NOMMA website: www.nomma.org Mail checks to the “Return to” address at left.

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

NOMMA METALfab2015 Guide

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Knowledge to enlighten the industry METALfab2015

Exploring Valley Forge and Montgomery County, PA While in King of Prussia for METALfab2015, be sure to schedule in extra time before or after the event to explore the area.

Here’s a list of things to do and see: n Valley Forge National Historical Park. This 3,500acre park is a must-see. It contains 19.5 miles of trails for hiking, running, or cycling. If you want to see all the main monuments, walk on the Joseph Plum Martin Trail, which is a 6.6 mile loop. On this walkway you’ll see the Muhlenberg Brigade, an historic camp, the National Memorial Arch, Washington Memorial Chapel, and the von Steuben Monument overlooking the Grand Parade. n King of Prussia Mall. The second biggest attraction in the area is the King of Prussia Mall. Oh, sure you may say that malls are everywhere, but this is no ordinary mall. With 400 stores and three food courts it’s one of the largest shopping centers in the U.S. The mall has more than 2.6 million square feet of retail space and welcomes 25 million visitors a year. If you want to take a break from shopping, try the IMAX theater. n Spring Mountain. If you enjoy living on the edge, check out the canopy tours at Spring Mountain Adventures. Excuse the pun, but this place is no zip in the park. You’ll actually ride on an entire course of zip lines, including one that’s 340 feet (you are requested to scream the entire time). Speeds on some of the lines can get up to 45 miles an hour, which is no big deal in a car, but a bit dicey when you’re flying over treetops. n Historic sites. There’s plenty more history in the area in addition to Valley Forge park. Recommended places to visit include the Beth Sholom Synagogue, designed by Frank Lloyd Wright, and the Bryn Athyn Historic District, which features Gothic architecture. Also, Pottsgrove Manor, a 1752 Georgian mansion, and Pennypacker Mills, which is an early-1900s country estate.

Boyertown Museum of Historic Vehicles.

November / December 2014 n O&MM Fabricator

Oh, and another site you should see is the Peter Wentz Farmstead. This restored farmhouse is where Gen. Washington planned the Battle of Germantown. It features an 18th century German kitchen garden, gift shop, and adorable farm animals. n Arts & culture. Visit the John James Audubon Center at Mill Grove to see the work of American artist John Audubon, who produced hand-colored prints of, yep, you guessed it, birds! You’ll learn about his scientific studies and bird research.

Another fascinating museum is The American Treasure Tour, which takes you through eras of U.S. pop culture, from Model Ts to Betty Boop. The museum is known for having the world’s largest collection of nickelodeons, the giant music machines of the late 1800s.

Finally, take in The Stoogeum, North America’s only museum devoted to the Three Stooges. At the facility you’ll see some 100,000 collectibles, including props, posters, magazines, toys, and personal items. n Restaurants. The Valley Forge area features a wide variety of restaurants, providing cuisines that range from hamburgers to steaks. One restaurant of interest is Savona in Gulph Mills, which features world-class cooking and the largest wine cellar in Pennsylvania, with 1,200 available selections. The restaurant building was used as a lookout post during the encampment of Valley Forge during the winter of 1777. Two microbreweries are in the area, including the Rock Bottom Restaurant & Brewery in King of Prussia. n Nightlife. Looking for some evening entertainment?

You can find it at our own host hotel, Valley Forge Casino Resort. The facility offers more than 35,000 square feet of action on its casino floor, with 600 slot machines and 50 live gaming tables. The casino has several restaurants, including Pacific Prime, Valley Tavern, Viviano, and the American Grill, which features good ol’ burgers and hotdogs.

For more information, visit the Valley Forge & Montgomery County website at www.valleyforge.org.

Chanticleer gardens, left; downtown Pottstown.

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2015

METALfab KNOWLEDGE to enlighten the industry.

MARCH 11 – 14

Valley Forge Casino Resort, King of Prussia, PA

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Member Talk

STRETCHING rural sensibilities n

Bailey Metal’s local environment shapes its business model. But additional diversification is an experiment that might pay off.

By Molly Badgett In Mitchell, SD, Greg Bailey has a cus-

tomer base that’s largely conservative when it comes to ornamental and miscellaneous metals. Few people are willing to spend a lot of money on highly decorative pieces. Most of Bailey Metal Fabricators’ customers go for the highly functional.

This market has served the company well since it became the family business in the 1960s. Now, however, Greg Bailey is looking to forge, so to speak, a new direction for the company, to see what happens if the metals took on more aesthetic appeal. It wouldn’t replace the core business.

Rather, it’ll create another basket for some eggs.

Here’s my interview with Bailey, where you’ll learn more about the company’s business.

O&MM Fabricator How is your busi-

ness divided between residential and commercial work?

Greg Bailey We do so many different things; it’s hard to break it down.

We do residential railing and stairs, and commercial railing and stairs. On the commercial side, we do all kinds of things like structural steel, railing, garbage gates, sunshades, drive gates, ladders and trench drains — pretty much anything metal (a customer) could use on a commercial site. On the residential side, we do railing, garden gates, curved stairs, spiral stairs, drive gates, sunshades, and curtain rods.

We also do a lot of industrial fabricating; we make concrete forms for box

November / December 2014 n O&MM Fabricator

A family business. Left to right, Richard, Ryan, and Greg and Heidi Bailey.

The original Bailey Welding shop. In 2004, the company changed its name to Bailey Metal Fabricators to rebrand itself more to the type of work that it liked to do and that was more diverse and lucrative.

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room to expand into other areas of fabrication that have larger profit margins.

The downside is that sometimes we are busy with lower-margin items that take up some of our shop capacity.

Efficiency has been greatly improved over the years with the addition of a HyDefinition CNC plasma table with oxyfuel torch, 300-ton hydraulic press brake with CNC back gauge, and and a 0.25” X 10’ shear with CNC back gauge. Most all areas of the 16-000 squarefoot-shop are covered with cranes.

culverts, industrial platform structures, tanks, grain hoppers for the agriculture industry, aggregate hoppers and lifting devices for the concrete industry, and we do some rebar fabrication.

We’ve got a lot of equipment. We’re the go-to guys in the area because we have good-sized equipment, such as a 300-ton press brake; shear, tubing and plate rollers; and a HyPerformance

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CNC plasma cutting table with capacity to cut 22-gauge up to 2-inch plate with plasma and up to 6-inch plate with oxyfuel.

We’re in a more rural area, so we have to be more flexible and do a little bit of everything. Sometimes that’s a good thing and sometimes that’s a bad thing. What makes it good is that we usually stay very busy and there is some

Fabricator How do you go about getting business?

Bailey With our commercial work, some of it we go out looking for it and bid it. We have a couple of contractors we do quite a bit of work for; they send work our way. We don’t always have to go look for it.

Sometimes, the better work that we would like to have, we have to go out and get it. We get work in a variety of ways; we use a builders’ exchange, architects, our Web page, Facebook.

And, we have a lot of word-of-mouth advertising. It’s stuff with a little bit more margin.

For example, we got into doing some aluminum sunshades and louvers for commercial buildings and residences; there seems to be a bit more margin in that for us than doing carbon-steel work because there seems to be less competition in non-ferrous metals.

Fabricator Tell us more about the day-to-day work at Bailey Metal.

Bailey Everything we make is custom. Most of our stuff is plain and conservative, though we do quite a bit of cable railing. We are starting to do quite a bit more stainless and aluminum railing and are starting to do some hammered stuff with some forged elements in it, but not a whole lot. It’s fairly conservative. The forged work is harder for us, at this point, to quote accurately to make a profit, and it commands a higher price that typically is more high-end.

We got a really good compliment from a customer that is building another house (we did some railing in the last house that he built); he was thrilled with his railing. He’s had the (plastic and composite) kind and, in his words, it was crap.

Our stuff is as good as the day it was installed years ago. Good and solid. There’s a bit of pride that we and our employees put into making it.

We’re pretty good at a lot of different things, and there are some things that we’re not as good at as we’d like, O&MM Fabricator n November / December 2014

Aluminum sunshade for Cambria Inn and Suites. This sunshade contained aluminum components from NOMMA supplier member C.R. Laurence Co. Inc., Los Angeles, and was supported by a steel tube structure. The sunshade has a silver powder-coated finish.

The biggest challenge for Bailey Metal Fabricators was that none of the company’s steel saws was capable of making the compound miters needed at the corners.

Bailey Metal did have a small wood table saw, however, so the miter gauge was replaced with a custom designed and fabricated jig. That held the bull-nose fascia at the correct angle to make a compound miter. The result: tight-fitting compound miters for the bolted connections.

show something in a place and it’s not there. And, things turn up that change the scope of the project. Remodels of historic buildings tend to be a bit more challenging.

The Corn Palace is only two blocks from our shop, so it’s one of those projects we really wanted. We’ve done a lot of smaller projects for them before. This is a big project. They’re doing a $7 million renovation to it.

This first phase covers the front entry way. They’re modernizing it a little bit. but we pride ourselves in doing the best job we can on everything we do. It doesn’t leave our place until I’m satisfied with the workmanship; that sometimes costs us in the end. I’m fussy that way, maybe too fussy.

That’s our reputation around here, and most people would agree we’re not the cheapest. But one thing about it, when it does leave here, (the customers) know it’s right. And, we don’t want to be the cheapest. We know if we do a good job, we’re going to have our customers come back, and they’ll tell their friends, and so on.

Sometimes we’re not even bidding against anyone (for a job). Because of our reputation, some of the contracNovember / December 2014 n O&MM Fabricator

tors bring us the work, regardless of where we’re at with the price. They know we’re going to give them a fair price and very good quality.

Fabricator Do you ever do work for the Corn Palace* there in Mitchell?

Bailey We’re actually doing the structural steel for their remodeling now. They’re replacing the domes and redoing some front-entry work they refer to as “new ear-chitecture.” We’re doing the structural steel and the new stairwell. We’re replacing all the railing from the first floor to the second floor.

We’re deeply involved in this project. It has old structure challenges, things that aren’t built quite as the buildings plans show, or the plans

Fabricator How did Bailey Metal get started, and what is it like today?

Bailey The shop was started in the 1940s; we don’t know exactly when.

My dad, when he got out of the service, worked for the son-in-law of the guy that started the business and went into a partnership with the son-in-law. * The iconic Corn Palace in Mitchell, SD, dates back to 1892 as a tribute to South Dakota’s thriving agriculture industry, and today is a site for the annual Corn Palace Festival, exhibits, and civic events.

Drawing a half-million tourists a year, the building features Moorish minarets and annually designed murals made of natural corn in multiple colors.

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My dad took it over around 1960.

Since I was a little kid, I hung around the shop and knew that’s what I wanted to do when I grew up.

I idolized my dad; he was and still is my mentor. He didn’t push me into it; I hung around and enjoyed it. I was picking up garbage and scrap steel and sweeping the floor — the same stuff that other kids that grow up in a metal shop do.

When I was about 10 years old, I learned how to weld with an oxy-acetylene torch. My dad would hold my hand to show me how it was done. I just picked it up and started doing it.

I have one brother in the business, Ryan, who runs the plasma table. He does miscellaneous work, like operating the saw or doing some welding, but the majority of what he does is run the plasma table. My wife, Heidi, is the draftsman and safety director, and my dad (Richard) still hangs around about 40 hours a week, but he has slowed down some. Still, it’s not bad for a 78-year-old who can still work harder than people half his age. Most of the

time, he is doing small repair jobs and things he likes to do.

We usually have three or four others, not including family. Typically, we have between eight and 10 on board.

We just hired another employee.

Fabricator How do you find qualified

help?

Bailey We use radio advertising as a tool to search for employees. It’s worked well for us; the last three or four hires that we’ve made have come from those ads.

Usually, it’s people not typically looking for a job. They’re working for someone else until they hear our ad.

The ads run on FM, all hours of the day and night. We have a good relationship with the station.

I probably spend more on advertising than I should. We sponsor some of their sports; that’s where most of our advertising ends up, on high school basketball and football (broadcasts).

It’s a country station. We have advertised on other stations, including one rock station. But this country

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station is popular; we feel we get good advertising that way.

We don’t spend more than $400 to $500 a month. We’re right in the prime time, when people are driving to work.

We have a Web page link to our site on the radio station Web page when they do Internet broadcasting. It helps to know people, too, who work at the station. We’ve been doing it for seven, eight, maybe nine years.

They’re 30-second spots. We let listeners know that we are a small company with competitive pay and benefits and with a good working environment, and that they won’t be stuck doing the same thing every day; the projects are always changing from day to day. No production-line jobs here!

When we do these ads, we know that they’re working because people always comment on them, even people not looking for a job. They say, “I’ve heard your ad!” That’s how we know our ad dollar is working. And when we change things up a bit, we see activity.

Typically, within a couple of days of running those ads, we have applicants.

I find that they’re better-quality applications than we had before I started doing that.

We were one of the first to do that kind of advertisement, and now I know at least three manufacturers who advertise on the radio for applicants, and one of the automotive dealerships.

Now quite a few more are doing it.

I’ve talked to others in NOMMA who think I’m crazy, but maybe their advertising is more expensive.

Fabricator What else do you advertise

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for besides new hires?

Bailey The radio advertising is not great for commercial work, but it does work for our residential business. The homeowner is the one we’re trying to draw in. The target market appears to be right in that 35-to-65 age group.

This is the market spending the money with us. For some of the things that we do, it works pretty well.

Radio is where we advertise our residential railing work. We do a lot of repair work, even though we don’t push it. We don’t push our repair work because we started as a repair shop and that is what we are known for; we want to branch out to other things.

O&MM Fabricator n November / December 2014

Our business name started as Bailey Welding and under my direction in 2004 we changed our name to Bailey Metal Fabricators as a way to brand ourselves to the type of work that is more lucrative to us and that we like to do.

Part of why we advertise is that we sell a lot of metal. A farmer might want to buy a piece of iron, but the closest, large steel company is an hour away. We stock a pretty good inventory of steel, aluminum and stainless steel, so we’ll sell it in any quantity. We’ll cut it, bend it, and shape it; we’ll do whatever they want with it.

The concrete forms and that type of work that we do is for our largest customer. It’s a no-brainer to keep doing that; it’s very good work for us.

It takes a variety of work to keep you busy year-round and make you money. It gets cold here in the winter and there isn’t much work starting in the construction industry, so we need other things to do to stay busy in winter. We do a lot of different things rather than have all our eggs in one basket.

We want to do structural steel and railing and some of the other fabrication stuff, too.

Installation was a challenge on this curved stair that went in a personal residence near Freeman, SD. Blaise Bailey and John Hagman, above left, guide the curved stair as it it’s lifted by Bailey Metal Fabricator’s Broderson mobile crane.

Correct field measuring of the curved wall, above right, was critical because the inner stair stringer was bolted to the wall.

Before installation, The company rolled the plate stringers, formed the steel treads, assembled, and painted the finish in the shop.

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Fabricator Do you sell a lot to the farmers in South

Dakota?

Bailey When we started out, my dad did farm repairs and similar stuff, with a little bit of railing, structural, and pipe welding. As time passed, farms and their equipment needs got larger. With that, the demographics for our work started to change. The farmers who got bigger hired help capable of doing most of their own repairs.

We have a couple of implement dealers that we do work for. We make parts that they can’t make or repair themselves; we do a fair amount of that. We’ve got the equipment.

We do service some of the farmers, but not nearly as many as we used to. That market has changed considerably over the years. When I started, that was 75% of what we did.

Now, it may be less than 10%.

But I like more of what we do now. I’m more of a fabricator at heart. I like to be creative.

November / December 2014 n O&MM Fabricator

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Fabricator How is business?

Bailey We had a slower year last

year. This year has really gone crazy; we’ve been really busy all year.

We never really did hit the low that most of the people on the East Coast or West Coast did. We don’t seem to get as low as they do when the economy goes down. We don’t hit the high highs or the low lows, either.

With the economic times, nowadays when things start to drop, we tend to see that trend. When I first got into this business, you didn’t see that trend a whole lot.

We didn’t see much change until about 2008 or 2009. We didn’t slow down until about the end of 2010.

When everyone else was bad, we were a year behind that.

Our housing market was still going good in 2009. On the East Coast and West Coast, homes were dropping out in 2008.

I don’t think we saw it coming; it never got that bad for us anyway.

We’re really diversified; we don’t see the market just drop out from under us.

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Fabricator Are you hoping to get

into more artistic work?

Bailey It’s more (that we) “want” to do some of that stuff. I can’t say that there’s much of a market; we just started dabbling in it. We’re trying to create a market with a few forged elements; we’ll know in a year or two if we can get something moving.

It’s a matter of creating something and seeing how it goes. We intend to add a few little forged pieces to our work and display it in a small showroom; we get a fair amount of walk-in traffic from customers buying steel and other items. Quite a few gals stop in who seem to be more interested in this. The guys know it’s expensive and don’t want to pay for it.

We’re getting into copper some.

We’re trying to add a few elements to some of our railings. Again, we’re dabbling, trying to create a market for it.

People here are pretty conservative.

The exotic metals, we don’t see nearly as much. We don’t do any bronze or brass work; we haven’t had the call for it. To me, typically the more exotic metals are non-ferrous, brass,

bronze, copper, nickel, and silver.

We don’t do much blacksmithing to speak of, either. We’re thinking we can create a market for that, too, mainly because no one around here does that type of work — the more decorative and artsy pieces. Blacksmithing tends to be more on the creative and artsy side, in my opinion. It is functional but typically more high-end.

If you look through (NOMMA’s) O&MM Fabricator magazine, you’ll see quite a bit of that stuff that’s been hand-forged; it has more character than the average piece of steel so it tends to be more expensive.

But you have to find the right client to go for it. We’ve got a few around here that would be the right client.

I watch and envy some of the other guys in NOMMA and the work they do. There’s some beautiful stuff out there.

Fabricator What else do you get out of NOMMA? Bailey A lot of things. The one thing that I’d say to most members is that unless you go to the METALfab

O&MM Fabricator n November / December 2014

Two examples of product diversification.

Bailey Metal fabricates several types of concrete forms including these jackets, above, for Cretex Concrete Products, Maple Grove, MN, which produces concrete pipe, bridges, and box culverts.

A young farm couple wanted a modern rail, right, for their home in rural Mitchell, SD. Bailey Metal is testing the conservative local market for expansion into more decorative, contemporary products.

convention and socialize with other attendees, you aren’t getting the full benefit of your membership. I can’t put a value on it.

Even the curved-stair class that I just went to, I came back with a few tricks that a couple of guys use that I don’t think I’d ever thought of.

Get on the NOMMA ListServ [discussion forum] at the very least; members will help you with the day-to-day problems you encounter. I will guarantee that membership fee will pay itself back if all you do is seek out information on the ListServ. Don’t be shy, ask

For your information

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Greg Bailey Bailey Metal Fabricators Inc. Mitchell, SD 605-996-4306 605-996-6748 fax 605-999-4306 mobile www.baileymetalfab.com gregb@baileymetalfab.com About the author Molly A. Badgett is a freelance writer based in Atlanta, GA. She often covers issues related to U.S. manufacturing.

November / December 2014 n O&MM Fabricator

the questions!

Until you actually network with those people, you don’t really know how valuable that membership is. But you can’t get the full benefit of

membership sitting at home. You can’t get it by not networking with these guys, or by not reading O&MM Fabricator magazine.

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Top Job Gallery

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Best ın Class Fences & Railings

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The Top Job Gallery features entries in our 201 Ernest Wiemann Top Job Contest. Information about the annual competition, open to all NOMMA members, is posted at the NOMMA website, www.nomma.org.

Category: Exterior railings & fences — nonforged

Falling Hammer Productions LLC — Gold Wolcott, CT Designed by the fabricator, this job is roughly 125 feet of custom railings and balconies made entirely from 304 stainless steel.

The ovals were made from 1/2-inch square material that were annealed and then bent cold in halves using custom press-plates.

The resulting half-ovals were then adjusted cold to match a master and assembled into full ovals before final

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fabrication of the railing.

Small, forged collars were hammered on cold to cover the welded joints between the ovals.

Custom stainless lag bolts were also made for mounting of the balconies.

The final finish was satin black paint.

The greatest challenge was making the cap rail, which began as 3/8 x 21/2 inch 304 flat stock that the fabricator annealed and ran cold through a custom roller to create a domed crosssection.

O&MM Fabricator n November / December 2014

Allen Iron Works & Supply Inc. — Silver Birmingham, AL The castings used in this step railing offer design and detail that would have taken extensive work and time to complete if forged by hand.

By using cast iron components, this railing was able to complement the ornate architecture of this residence, yet offer an appealing “budget.�

The top handrail is 21/4-inch molded cap over 11/2-inch channel iron. The client requested laterals for both the top and bottom ends of the railings. The cast iron balusters were cut within the pieces to achieve the correct finished height without altering the appearance.

The castings used in the border were cut apart, fitted, welded back together, and ground smoothly to form the curve of the laterals.

There was a total of 14 linear feet of the railing.

The finish is oil base enamel.

The difficulty was to keep the integrity of the design while shortening it.

Approximate labor time: 82 hours. c

November / December 2014 n O&MM Fabricator

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Top Job Gallery

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Allen Architectural Metals Inc. — Bronze Talladega, AL

This architect-designed, exterior custom rail for New York’s Park Avenue Armory created challenges due to the combination of mixed materials and finishes. The cap railing was free-formed, draped, and created from 41/2-inch OD tri-state-quarter page.qxd 12/19/07 9:44 AM Page 1 copper pipe and custom copper castings.

The rail span due to inconsistent site conditions would not allow the hours and three different color comuse of a single length of copper, thus binations to achieve the finish. requiring castings and standard The fabrication and finishing of pipe. The challenge was to create this complex railing system took seamless joints in the copper top rail about 400 hours, the end result posthat was neither visible nor detectitively accepted by the client and able to the touch. architects and now the focal point at The finishing of the copper was the entrance to this newly renovated labor intensive; the custom heat ADNew PROOF - 45-3454-ACF-121807-V2 York Landmark. applied patina required about 80

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Category: Exterior railings & fences — forged

M. Cohen & Sons Inc. — Gold Broomall, PA This job is an ornate bronze sculptural frontispiece designed by a Palm Beach-based architecture firm. The entire piece is made of bronze, which was moderately antiqued during finishing.

The fabrication techniques were forging, bolting, machining, casting and extruding.

The piece was installed using invisible fasteners into marble.

The greatest challenge on this job was coordinating all the different elements.

Approximate labor time: 800 hours.

November / December 2014 n O&MM Fabricator

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Top Job Gallery

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Iron Touch LLC — Silver Louisville, KY This hand forged railing depicts the customer’s flower garden and favorite plants.

Representations under the grip rail are hand-forged stalks, trunks, and root systems, and feature Asian Maple trees, copper Canada Lillis, “Grandma’s” Iris, and Trumpeter Vine

blooms, all with fully textured vines.

The railing is fabricated by hot texturing and shaping of both flat and round iron with forged leaves.

Project challenges included continuing customer collaboration in design and corresponding custom tooling for hot texturing and shaping the various elements.

Materials include 16-ounce copper

sheet metal; ⅝-inch round bar; 1/4 x 1-inch flat bar; 1-inch square bar; and 3/8 x 11/4-inch and 3/8 x 2-inch flat bar.

Installation required core drilling holes into Bluestone and setting with high-sheer-strength epoxy.

The railing finish is a layer of primer base coat, primary color, a burnished, secondary darker color, and a final UV resistant clear coat.

Rod Iron Rod Inc. — Bronze Odessa, TX The fabricator designed all the gates and the fence (see top photo on next page and on magazine cover) for the customer in AutoCAD. There was 210 feet of fence with this job and two sets of entry gates.

All the scroll work is hand forged.

The frame is 11/2-inch square tubing with hand forged C scrolls.

The finish is Penny Vein powder coat.

The hardest part of this job was keeping the consistency of the scroll work perfect throughout the property.

Approximate fabrication time: 680 hours.

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O&MM Fabricator n November / December 2014

Compass Ironworks Gap, PA This job called for replicating a 1927 estate fence of more than 2,200 feet made of 6- and 8-foot-high aluminum with 1-inch solid forged pickets.

While researching the original job, Compass connected with a historian to view metalworker Samuel Yellin’s hand-sketches.

On top of all the replication challenges, the “new” estate had serious elevation challenges (The yellow line in the photo above shows the grade change) — 82 feet of change with heavily landscaped gardens and huge specimen trees.

Requirements specified there be no equipment over 7 PSI of turf compaction and zero damage to trees or roots.

The property had more than 100 trees, and many holes had to be air-spaded.

The perimeter was staked at every post’s location. Each elevation and angle was determined for each panel, then numbered upon construction, tracked through blasting and coating, and then loaded in sequence.

Some embankments were too steep for a skid-auger; a light track-hoe with auger was needed. Eight-foot panels were hand-carried by four men.

Approximate labor time: 3,133 hours.

November / December 2014 n O&MM Fabricator

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59

Biz Talk

ACA blueprint for small business comes online ■

Open enrollment for the Small Business Health Options Program under the Affordable Care Act for employers with 50 or fewer full-time workers was expected to begin November 15. This article gives the plan and related items a closer look.

By Mark E. Battersby As a small business owner, you dealt

Editor’s note: The Affordable Care Act is lengthy and complicated. Our purpose in publishing this article by Mark Battersby is to help you identify upcoming deadlines and information you should discuss with your professional advisors.

As in many things, independently confirm the details and discuss your particular situation with a professional.

this year with the rules, taxes, and premiums of the Affordable Care Act (ACA). Very soon, if not already, you’ll need to decide how to handle a number of items now under way or about to be.

Small business options

One important development is the opening of the new Small Business Health Options Program (SHOP) under which employers with 50 or fewer full-time employees may be able to buy coverage.

In addition, employers with fewer than 25 full-time employees may be eligible for a Small Business Health Care Tax Credit.

Businesses with 50 or fewer employees

While many employers understand the value of providing health insurance to their employees, doing so can be challenging for small businesses that lack the purchas60

ing power of larger employers. The new SHOP Marketplace is designed to help smaller operations provide health coverage to their employees.

The SHOP Marketplace was scheduled to begin open enrollment for employers with 50 or fewer full-time-equivalent employees on Nov. 15, 2014. A “soft launch” in Delaware, Illinois, Ohio, Missouri, and New Jersey in October is expected to help work out kinks in the meantime.

Each state is expected to have a SHOP Marketplace. A business must have an office or employee work site within the SHOP’s service area to use that particular SHOP. To use SHOP, a business must offer coverage to all of its full-time employees — generally those working 30 or more hours per week on average. In many states, at least 70% of your full-time employees must enroll in your SHOP plan. (Employers who apply for SHOP coverage between November 15 and December 15 each year can enroll without meeting this requirement.

Source: https://www.healthcare.

O&MM Fabricator n November / December 2014

gov/what-is-the-shop-marketplace

Starting in 2016, all SHOPs will be open to employers with up to 100 fulltime employees. The process for enrolling in SHOP plans varies by state, but in most states, it will be handled through an insurance agent, broker, or preferred insurance company.

Source: https://www.healthcare.gov/ marketplace/shop

Tax credits for business with fewer than 25 employees

Some small businesses, notably those with fewer than 25 full-time equivalent employees, may qualify for the Small Business Health Care Tax Credit.

To qualify, the business must contribute at least 50% of the full-time employees’ premium costs toward their employees’ health insurance and purchase the insurance through SHOP. The average employee salary must be about $50,000 per year or less.

If you buy SHOP coverage and have fewer than 25 employees, you may qualify for a small business health care tax credit worth up to 50% of your premium costs.

You can still deduct from your taxes the rest of your premium costs not covered by the tax credit. This tax credit is to be available only for plans purchased through SHOP. Source: https://www.healthcare.

What’s new and updated SHOP for small businesses

After a year’s postponement, the Small Business Health Options Program (SHOP) exchanges are now open At presstime, open enrollment was scheduled to begin Nov. 15, 2014.

SHOP is for small businesses with 50 or fewer employees, even though such employers do not face any penalty for not offering health coverage.

Tax credit for very small employers

Effective now, an employer with 25 or fewer full-time employees and average compen­sation of $50,000 or less may be eligible for a 35% to 50% tax credit for premiums paid toward employee health coverage.

If you qualify for the tax credit, you must enroll in a plan through the Small Business Health Options Program (SHOP) Marketplace in your state.

The employer mandate for larger businesses

The Employer Shared Responsi­ bility Payment is a requirement under the health care law that will apply to some employers with 50 or more employees in 2015 or 2016.

Expanded W-2 reporting

The ACA requires employers to include on Form W-2 the total cost of employer-sponsored health insurance coverage.

In March 2014, the IRS issued final regulations that require such reporting by large employers starting in the 2015 calendar year.

For IRS-related ACA info http://www.irs.gov/uac/ Newsroom/Questions-andAnswers-on-Employer-SharedResponsibility-ProvisionsUnder-the-Affordable-Care-Act

gov/will-i-qualify-for-small-businesshealth-care-tax-credits

Unlike most tax credits that merely reduce the final tax bill, even a small business employer who did not owe tax during the year can carry the credit back or forward to other tax years.

Also, since the amount of the health insurance premium payments is more than the total credit, eligible businesses can claim a business expense deduction for any premiums in excess of the credit. That’s both a credit and a deduction for employee premium payments.

Source: http://www.irs.gov/uac/ Small-Business-Health-Care-TaxCredit-for-Small-Employers.

Self-employed, no employees

If you are a self-employed business owner with no employees, you cannot get coverage through the SHOP. You must instead turn to the individual market Health Insurance Marketplace November / December 2014 n O&MM Fabricator

61

at heathcare.gov to see if you qualify for a subsidy. Whether you qualify for a subsidy or not, you can still buy ACA compliant insurance through healthcare.gov or directly from insurance companies.

The large business ‘employer mandate’

The ACA requires large employers of 50 or more employees to provide health coverage or pay a penalty.

Four years later and after repeated delays, the so-called “employer mandate” has become something of an orphan.

Twice in the last two years, the administration has delayed the penalties, citing difficulties enforcing the mandate.

The employer mandate is designed to prevent businesses from dropping health benefits now that the government provides subsidies to help low- and moderate-income individuals purchase health insurance.

Large employers that do not provide insurance are eventually supposed to pay a fine — called an “employer responsibility payment” — of $2,000 per employee above the first 30 employees. The employer may be subject to larger fines if its employees cannot afford the coverage offered at work and then they qualify for government subsidies to buy coverage on their own.

Source: https://www.healthcare.gov/what-do-largebusiness-owners-need-to-know

Employer responsibility provision

The Treasury Department has issued the following statement regarding 2015: “The employer responsibility provision will generally apply to larger firms with 100 or more full-time employees starting in 2015 and employers with 50 or more full-time employees starting in 2016.”

“To avoid a payment for failing to offer health coverage, employers need to offer coverage to 70% of their full-time employees in 2015 and to 95% in 2016 and beyond, helping employers that, for example, may offer coverage to employees with 35 or more hours, but not yet to that fraction of their employees who work 30 to 34 hours.”

Source: http://www.treasury.gov/press-center/ press-releases/Documents/Fact%20Sheet%20021014.pdf and https://www.healthcare.gov/what-is-theemployer-shared-responsibility-payment

The vast majority of larger businesses already provide coverage: 99% of employers with more than 200 workers offer health benefits, an annual survey by the nonprofit Kaiser Family Foundation and the Health Research & Educational Trust indicates. Because the requirement applies only to employers with 50 or more full-time workers, it might conceivably create an incentive for employers to move some people to part-time work.

Phasing in schedule

Although there are only scattered reports of this happening so far, businesses are reviewing the option as they plan for 2015, when the mandate requirement is scheduled to be phased in — unless the administration delays them further.

Beginning in 2015, the penalties are scheduled to go into 62

O&MM Fabricator n November / December 2014

effect on employers with more than 100 workers.

Beginning in 2016, penalties on employers with more than 50 full-time workers will be imposed.

The great unknown

Potentially impacting all this is that the Affordable Care Act has faced legal challenges. In July, two federal appeals courts issued contrary opinions on whether subsidies for qualifying individuals are legal, which might throw the individual subsidy issue before the U.S. Supreme Court.

If the Supreme Court takes up the issue, other aspects of the ACA could be affected, such as the requirement for larger employers to provide healthcare coverage for their full-time employees.

Expanded W-2 reporting

In March 2014, the IRS issued final regulations to enforce the Shared Responsibility and Individual Mandate provisions, the so-called “play or pay” rules, of the ACA. While reporting will be required for coverage provided during the 2015 calendar year, only large

“The employer responsibility provision will generally apply to

larger firms with 100 or more full-time employees starting in 2015 and employers with 50 or more full-time employees starting in 2016.”

— U.S. Treasury Department Fact Sheet employers that are required to file more than 250 W-2 forms must report.

Employers providing minimum essential coverage to individual workers during the calendar year must report that health insurance coverage information to the IRS and must also provide a written statement to the covered employee or former employee.

Specifically, the ACA requires such employers to report the cost of coverage under an employer-sponsored group health plan. Reporting the cost of health

care coverage provided to a worker on Form W-2 does not mean that the coverage is taxable and the value of the employer’s excludable contribution to health coverage continues to be excludable by the employee. This reporting is for informational purposes only and will provide employees useful and comparable consumer information on the cost of their health care coverage.

Additionally, a large employer with 50 or more full-time employees or equivalents must certify that it offers its full-time employees and their dependents the opportunity to enroll in minimum essential coverage on a month-by-month basis. These large employers also must provide a “qualifying employee statement” to each fulltime employee.

Source: http://www.irs.gov/uac/ Affordable-Care-Act-Tax-Provisions-forLarge-Employers

Coming later?

The excise tax on high-end plans

Beginning in 2018, any business that rewards its owners, shareholders, or employees with health insurance cover-

The Big BLU Power Hammer continues to become the workhorse and center of activity in hundreds of shops across the United States and in many foreign countries around the world.

BIG BLU HAMMER MFG. CO. 3308 Frank Whisnant Rd., Morganton, NC 28655 PHONE: 828-437-5348 • FAX: 828-437-9217

November / December 2014 n O&MM Fabricator

63

age above a certain threshold is scheduled to face a 40% excise tax on the amount considered to be an excess benefit.

Although the IRS has yet to weigh in, the dollar limit for determining the tax thresholds presently is $10,200 (for 2018) multiplied by the health cost adjustment percentage for an employee with self-only coverage, and $27,500 (for 2018) for employees with coverage other than self-only coverage.

And don’t forget Medicare tax withholding

The Medicare part A tax is paid by both employees and employers who earn over a certain amount. The ACA hiked the payment by 0.9% (from 2.9% to 3.8%) on the current total Medicare part A tax. This tax is split between the employer and employee, which means that both will see a 0.45% increase.

Employers are responsible for withholding the tax on wages that exceed a $200,000 threshold. An individual shop owner is liable for the Additional Medicare Tax if his or her wages, compensation, or self-employment income (together with that of the spouse if filing a joint return) exceed the threshold amount for the individual’s filing status.

Small businesses making under $250,000 are exempt from the tax.

Employees, even the shop’s owner making less than $200,000 as an individual or $250,000 as a family, are also exempt.

Health Flexible Spending Arrangements (FSA)

Limits on contributions to FSAs, used by many self-employed and small business owners, are now $2,500 (pretax employee contributions) adjusted for inflation.

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what-if-i-dont-have-health-coverage

Conclusion

Small business owners with fewer than 50 employees escape many of the regulations imposed on larger employers and can take advantage of of tax breaks that may help reduce the expense of their insurance as well as for insurance provided to employees.

In addition, small businesses can now investigate the options available under the SHOP Marketplace.

To fully understand your specific situation, professional assistance is strongly recommended.

n

Anvils

Kayne and Son

The mandate requiring most individuals to either obtain qualified health care coverage or pay a fee or “penalty” went into effect Jan. 1, 2014. The penalty in 2014 is calculated one of two ways. If you or your dependents don’t have insurance that qualifies as minimum essential coverage, you’ll pay whichever of these amounts is higher: n 1% of your yearly household income. Only the amount of income above the tax-filing threshold, $10,150 for an individual, is used to calculate the penalty. The maximum penalty is the national average premium for a bronze plan. n $95 per person for the year ($47.50 per child under 18). The maximum penalty per family with this method is $285.

Open enrollment for 2015 coverage was expected to start November 15, 2014.

Source: https://www.healthcare.gov/

For your information

See our work at www.customforgedhardware.com

Spring Swages www.Blacksmithsdepot.com

The individual mandate

Tongs

100 Daniel Ridge Rd. • Candler, NC 28715 Phone: (828) 667-8868 • Fax: (828) 665-8303 International Shipping Available • Inquiries Welcome

About the Author Mark E. Battersby, for more than 25 years, has written editorial features, columns, white papers, and reports for magazines, journals, newsletters, and websites about developments in the tax and financial arenas that impact small businesses.

He can be reached at MEBatt12@ Earthlink.net.

O&MM Fabricator n November / December 2014

n

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

Allen Architectural Metals Inc.

DAC Industries Inc. (800) 888-9768

DKS, DoorKing Systems

King Architectural Metals — MD

Rockite, Div. of Hartline Products Co. Inc.

(410) 644-5932

(216) 291-2303

Krando Metal Products

Rogers Mfg. Inc.

Eagle Bending Machines Inc.

L.E. Sauer Machine Co.

Sculpt Nouveau

Eastern Metal Supply

Lavi Industries

SECO South

Elite Architectural Metal Supply LLC

Lawler Foundry Corp.

Sharpe Products

ETemplate Systems

Lewis Brass & Copper Co. Inc.

South Camden Iron Works Inc.

FabCAD Inc.

Locinox USA

Stairways Inc.

The Fabrication Store

Mac Metals Inc.

Suhner Industrial Products Inc.

Farris Fab & Machine Co.

McNichols Co.

Big Blu Hammer Mfg.

Feeney Inc. (Feeney Architectural Products)

Mittler Bros.

Machine & Tool

Julius Blum & Co. Inc.

Geo. Bezdan Sales Ltd.

Multi Sales Inc.

Bridgeton Drafting Co. LLC

The G-S Co.

Nationwide Industries

C.R. Laurence Co. Inc.

Hartford Standard Co. Inc.

NC Tool Co.

Cable Art Inc.

Hayn Enterprises LLC

O.K. Foundry Co. Inc.

(800) 204-3858

Alloy Casting Co. Inc. (972) 286-2368

American Punch Co. (216) 731-4501

Ameristar Fence Products (918) 835-0898

Architectural Iron Designs Inc.

(908) 757-2323

Atlas Metal Sales

(800) 662-0143

AZZ Galvanizing

(815) 618-8440

Banker Wire

(800) 523-6772 (828) 437-5348

(800) 526-6293 (856) 205-1279 (800) 421-6144

(877) 664-4224

The Cable Connection (800) 851-2961

Carell Corp.

(251) 937-0948

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.

(800) 826-7493

(251) 937-1947 (800) 343-8154

(847) 636-1233 (919) 676-2211

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

(800) 888-2418

(604) 299-5264 (410) 284-9549 (270) 298-3227

(800) 346-4296

Hebo/Stratford Gate Systems Inc. (503) 722-7700

(610) 543-4311

(636) 225-5358

(800) 624-6225 (800) 624-9512

(718) 894-1442 (708) 579-0286 (800) 631-9510 (847) 635-5100

(800) 467-2464 (800) 421-3575 (813) 988-2628 (336) 674-5654 (888) 592-2240

Ohio Gratings Inc. (330) 477-6707

Heritage Cast Iron USA

Orleans Orn. Iron & Casting Dist. Inc.

Indiana Gratings Inc.

Pacific Stair Corp.

Industrial Coverage Corp.

Powder-X Coating Systems

Interstate Mfg. Associates Inc.

Precision Glass Bending Corp.

The Iron Shop

ProCounsel

Kammetal Inc.

Ransburg

King Architectural Metals

Regency Railings Inc.

King Architectural Metals — CA

Robinson Iron Corp.

(918) 591-1700

(800) 634-1988 (800) 242-9872

(800) 667-9101 (800) 523-7427 (718) 722-7400 (800) 542-2379

(800) 824-3608

(940) 325-7806 (800) 728-5787 (888) 535-SECO (800) 879-4418

(856) 423-1107 (716) 680-3110

(800) 323-6886

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 (888) 326-4840

(800) 543-8796 (214) 741-3014 (419) 470-2000 (214) 742-9408 (800) 824-2157

(714) 670-8980

(718) 324-6871

November / December 2014 n O&MM Fabricator

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n

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 Locator at www.nomma.org.

New members as of October 17, 2014. *Asterisk denotes returning member.

A1 Fire Escape* Thomas Curran Quincy, MA Local Supplier Borrelli Steel Fabricators Jay Price Vineland, NJ Fabricator

Eugene L. Evans Mfg. Co. Inc. Eugene Evans Anniston, AL Fabricator

Precision Metal Fab. Inc.* Frank Theodorou Brooklyn, NY Fabricator

Evolution Ironworks* Andrew VanSchoick Albany, NY Fabricator

Railing Systems Hawaii LLC Bob Tremain Kailua Kona, HI Fabricator

Craft Ornamental Metals John Hladczuk Merion Station, PA Fabricator

Frederic Zimmer Sculptor* Frederic Zimmer Honolulu, HI Fabricator

DDM Steel Construction Rich Muckenfuss Vineland, NJ Fabricator

Glenn’s Custom Metals Inc. Glenn Raulfs Red Lee Draper, VA Fabricator

Spiral Stairs of America/Innovative Metal Craft* Jon Whaley Erie, PA Fabricator

JSR Inc. Danny Frias Schertz, TX Fabricator

T & W Fabricating Tony Mertens New Holstein, WI Fabricator

EH Iron Works Ed Hladczuk Philadelphia, PA Fabricator

Ranch Services LLC* Jeffrey D Hanneken Kamuela, HI Fabricator

We are proud of our members!

NOMMA 2014 Gold Members NOMMA is pleased to welcome our newest Gold Members — companies who have been a member for 20 years or more.

These companies show a strong loyalty to both their industry and trade association.

We thank them for their support.

Architectural Iron Designs Inc........... Plainfield, NJ Berger Iron Works Inc........................... Houston, TX n Creative Forge — Reichert Corp......... Telford, PA n D’Agostino Iron Works Inc................... Rochester, NY n DAC Industries Inc.................................. Grand Rapids, MI n Emerald Ironworks Inc.......................... Woodbridge, VA n Historical Arts & Casting Inc............... West Jordan, UT n Jesco Industries Inc. — Wire & Iron Products Div.................... Litchfield, MI n Keystone Metals Inc.............................. Pittsburgh, PA n Liberty Home Products......................... Denver, CO n Louis Emmel Ornamental Iron Inc............................. Coraopolis, PA n Mac Metals Inc......................................... Kearny, NJ n New Hampshire Steel Fabricators Inc............................. Goffstown, NH n Outland Steel Inc.................................... Caldwell, ID n Pinpoint Solutions.................................. Jupiter, FL n Van Dam Iron Works.............................. Grand Rapids, MI n Van Linda Iron Works Inc..................... Lake Worth, FL n n

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

Iron Man/Woman Club Individuals who have sponsored a member for the 2014– 15 membership year, which began July 1.

NOMMA Shop Banners Let the world know that you are a NOMMA member shop!

David Busarello, Bridgeton Drafting Co. LLC, Vineland, NJ

n

Jon McGraw, Alloy Casting Co. Inc., Mesquite, TX

n

Mark O’Malley, O’Malley Welding & Fabricating, Yorkville, IL

n

Dave White Jr., Locinox USA, Countryside, IL

The Rust-Free Club Individuals who have provided the NOMMA office with a member lead for the 2014–15 membership year, which began July 1. n

Chet Dinkins, Sumter Coatings Inc., Sumter, SC

n

Dave Filippi, FabCAD Inc., White Stone, VA

n

Chris Holt (2), Steel Welding, Freedom, PA

n

Will Keeler (3), Keeler Iron Works, Memphis, TN

n

Cost: $120 + shipping

Gary Kervin, Kervin Brothers Ornamental Iron Inc., Portland, OR

n

Payment: Checks only

Allyn Moseley, Heirloom Stair & Iron, Campobello, SC

n

Contact: Frances Kinsey (fmkinsey@bellsouth.net, 770-971-2701)

Lynn Parquette, Elite Architectural Metal Supply LLC, Elk Grove Village, IL

n

Jay Shah, Architectural Iron Designs Inc., Plainfield, NJ

n

John Steel, Steel Welding, Freedom, PA

n

Dave White Jr. (2), Locinox USA, Countryside, IL

We have an arrangement with a local vendor to provide heavy-duty interior/exterior banners at a reasonable cost.

Specs: 3’x5’, heavy duty, hemmed and grommeted. Features bright gold, purple and black ink on a white banner, single sided.

Note: We have discontinued the interior banner due to slow orders and durability concerns.

66

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O&MM Fabricator n November / December 2014

What’s Hot? n

Industry News

Feeney, King Architectural Metals sign marketing deal including both digital and direct marketing campaigns in the form of quarterly and annual product catalog and catalog update mailings; and newsletter distribution to tens of thousands.”

In return, King Metals can now offer “a high-quality, competitively priced, stylistically versatile cable railing product,” according to a news release.

Feeney’s CableRail and

DesignRail products fill an existing style, design, and price gap.

“Feeney provides a superior product,” says Larry Robertson, director of marketing and advertising for King. “King Metals has a high standard for products associated with our brand, and we see our partnership with Feeney as a good match — a marriage of two brands with long, solid reputations behind us.”

Contact www.feeneyinc.com and www.kingmetals.com

Feeney Inc., known for its CableRail stainless steel railings and DesignRail aluminum railing systems, has joined King Architectural Metals in a service and marketing agreement.

King Metals, a national ornamental and architectural metal supply house, allows Feeney to expand distribution channels and build brand awareness.

“Instead of working directly with hundreds of small businesses and contractors, we will be able to service them through the distribution base of King Metals, a company with an excellent reputation in the industry,” says Feeney’s vice

president of business development, Del Leutbecher.

“Feeney will directly benefit from the prolific marketing efforts performed year-round by King Metals,

distributor in the U.S. and Canada by Apollo s.r.l., a prominent Italian manufacturer of high-speed CNC tube and pipe punching and drilling machines.

Apollo manufacturers 22 different hydraulic punching machines. Models are available for accurately punching and drilling pipes, as well as round, square and rectangular tubes in a variety of holes and shapes.

Apollo machines offer speed and accuracy (2 holes per second; up to 300,000 holes with a single punch, and as little as 0.2 mm from

$649.95 Square Tubing  2”Rolls: in the machine Flat Barmanually (1/2 x 1 1/2” & smaller) Magnum Hand Tube Bender Magnum Hand Tube Bender Rolls: $649.95 and then processed autoTubingTubing 1 x2”2”Square  Pipe & Tubing Rectangular Tubing matically, or fed automati- $649.95 $649.95 2” Square Tubing  2” Square  1 xBar 2” Rectangular Tubing Flat (1/2 x 2” & smaller) callyMagnum from a bundled storage Hand Tube Bender Rolls: : 1 x 2” Rectangular Tubing s 1 x 2” Rectangular Tubing l Rol component and processed Flat&Bar (1/2 x 2” & smaller)  Pipe Tubing $649.95 through the machine in as Flat Bar (1/2Flat x 2”Bar & smaller)  2” Square Tubing (1/2 x 2” & smaller)  Pipe & Tubing little as one meter per sec Pipe & Tubing  1 x 2” Rectangular Tubing Pipe &Available Tubing Additional Rollers ond, says the company.

Cores are available for Flat Bar (1/2 x 2” & smaller) Additional Rollers Available Additional Additional Rollers Available inside the material, and they Rollers Available  Pipe & Tubing expand each time a hole is UNIQUE ROLLING SYSTEM punched to keep it free of Works with both hand tubing benders UNIQUE ROLLING SYSTEM Additional Rollers Available fall-off. An alpha-numeric Cap Rails Works with both hand tubing benders UNIQUE ROLLING SYSTEM $599.95 UNIQUE ROLLING SYSTEM programmer is standard Works with both handwith tubing benders Works both hand tubing benders Cap Rails Channels equipment. Computer sup$599.95 Cap Rails Rails port is available to guide Channels $599.95  Flat Bar Cap (on edge hard way)$599.95 UNIQUE ROLLING SYSTEM repair in case of breakdown.

Channels Channels  Flat Bar (on R&benders D Hydraulics, Mfg. and Machine Co.edge hard way) Works with both hand tubing Contact 877-989-0700; Bar (on edge Bar hard way) 1431 West 5th St. Chico, CAFlat 95928 www.rdhs.com  Flat (on edge hard way) Cap Rails R&D Hydraulics, Mfg. and Machine Co. www.coletuve.com $599.95

TUBING BENDERS TUBING BENDERS Hand TubeTUBING BenderBENDERS Rolls: TUBING BENDERS  1Hand 1/2” Square Tubing Tube Bender Rolls: $499.95 Magnum Hand Bender Rolls: Hand Tube Bender Square Tubing  1 x1 Tube 11/2” 1/2” Rectangular Tubing Rolls: $499.95 Cole-Tuve named new distributor TUBING  1BENDERS 1/2” Square Tubing $499.95 1/2” 1(1/2 1/2” Square Tubing $499.95  1 x 1 Rectangular Tubing Hand  Flat Bar x 1 1/2” & smaller) for Apollo machines  1xPipe 1 1/2” Rectangular Tubing  1 x 1 1/2” Rectangular Tubing  Flat&Bar (1/2 x 1 1/2” & smaller) Tubing Hand Tube Bender Rolls: Tube the first to the last hole on a Cole-Tuve Inc., of White  Flat Bar (1/2 x 1 Bar 1/2” (1/2 & smaller)  Flat x 1 1/2” & smaller) $699.95  Pipe & Tubing  1 1/2” Square Tubing $499.95 tube 3 meters long.)

Marsh, MD, has been Tube Bender Rolls: Magnum Pipe & Tubing  Hand Pipe & Tubing Bender  1 x 1can 1/2” Tubing Material beRectangular placed appointed as the exclusive Magnum Hand Tube Bender Rolls:

November / December 2014 n O&MM Fabricator

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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 67 1431 West 5th St.West Chico, 1431 5thCA St.95928 Chico,www.rdhs.com CA 95928 www.rdhs.com  Flat Bar (on edge hard way)

What’s Hot? n People Underwood named president of Tampa Steel & Supply Troy Underwood has been named the new president of Tampa Steel & Supply, a metal service center with long-standing roots in the Tampa Bay area.

The company offers and inventories a full line of prime, secondary, surplus, and ornamental metals.

Features include on-hand inventory, cut-to-size services and accessories, next-day delivery capability, and a no-minimum-purchase benefit.

Industries served include welding, construction, fabrication, ornamental, and machine shops.

Contact 877-558-1480; www.tampasteel.com

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Media

New abrasive saws, sanders, and grinders in catalog Kalamazoo Industries Kalamazoo Industries is offering a new, updated full-line catalog of its abrasive saws, sanders, grinders and other components, including new additions to its line of abrasive cutoff saws.

These saws include: n the Model K1214MS metallurgical saw, which produces mirror-surface cuts; n the Model K26E large-capacity abrasive saw designed for foundries and other metal working operations handling large work pieces; and n the Model K10SW 10-inch wet saw designed for cuts in smaller work

pieces, even when cutting high alloy steel.

Other new products include: n the Model BSG14 back stand grinder for foundries needing to rapidly remove metal; n the Model S272V multi-purpose belt grinder for grinding, shaping, contouring, or other work on small parts or short-runs; and n the Model KVF3 vibratory finisher that is less expensive than hand finishing small parts.

Contact The new Kalamazoo Industries catalog is available online at www.kalamazooindustries.com; or call 269-382-2050

O&MM Fabricator n November / December 2014

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Magnetic drill pilot light Hougen Manufacturing Hougen Manufacturing, inventor of the mag drill annular cutter and a leading manufacturer of magnetic drills, has added the first-ever pilot light to the magnet of their new drill models.

The three new models of magnetic drills — the twospeed HMD905, the heavyduty two-speed HMD917, and the two-speed power feed HMD927 plus the redesigned HMD904 — all include an LED light in the magnet.

The light shines along the bottom of the cutting teeth and over the pilot tip, which extends from the end of the cutter. Shining light in this area allows the oper-

ator to easily see the pilot point and center punch of the hole.

This increases operator productivity and hole location accuracy, says the company.

The new light improves visibility in two ways: 1 in low-light to no-light conditions it sheds light on the pilot point, and 2 in brighter conditions the LED light helps to counteract the shadows from the light.

The new light works on a simple on/off switch located

November / December 2014 n O&MM Fabricator

on the drill control panel.

The operator can turn on the LED light to line up the pilot point and then, if desired, switch off before drilling.

The high output, longlife LED light is built into the magnet and protected from possible damage of chips, coolant and debris.

Contact 810-635-7111; www.hougen.com Heavy-duty wire straightener Electron Beam Technologies Electron Beam Technologies, Inc., has announced a new, larger Straight ’N Easy Heavy-Duty Wire Straightener (Part #A-2251).

The Heavy-Duty Wire

< < < < < < < < < < < < < < < < < < < < < <

Straightener features a modular design with several mounting options — face, end, and traditional.

The unit has three adaptations, including in-line, feeder mount, and pay-off for quick connect. It will accept a variety of electrodes from 5/64-inch (2 mm) to 3/16-inch (4.8 mm).

The wire straightener is lightweight and expandable. It’s also quick to install and has a longer life than

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What’s Hot? n

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friction systems, the company says.

User cost is reduced with electrode wandering, and it provides repeatability in automated systems. The unit can recast electrode for proper energy transfer.

The wire straightener is also resettable, with built-in reference scale for ease of wire changes.

Contact 815-935-2211; www.electronbeam.com Modular cast-iron railing system Wiemann Metalcraft/ Heritage Cast Iron Through its subsidiary, Heritage Cast Iron, Wiemann Metalcraft is introducing the world’s first modular, code compliant

cast-iron railing system.

Designed and engineered to meet height, load and opening requirements defined by the ICC, for both commercial and

Tube, Pipe and Profile Bending & Metalworking Machinery BEWARE OF IMITATIONS!

QUALITY BENDS IN PIPE, TUBE, SQUARES, SOLIDS AND OTHER PROFILES

residential applications, the solid, cast gray iron stair and balcony railing systems are part of the new Walnut Grove Collection and are supplied ready to install.

Provided that the rail sections are properly secured to the masonry or steel substrate, they may be used with or without posts.

Additionally, they interlock from one panel to the next, with a traditional mortiseand-tenon detail and do not require welding for satisfactory installation, says the company.

Molded cap railing or side-mounted ADA grab rails may be added by the

fabricator/installer to suit a wide range of applications.

Contact 918-592-1700; www.wmcraft.com Internet-enabled outdoor accesscontrol system LiftMaster Access-control manufacturer LiftMaster, has introduced IPAC (Internet Protocol Access Control), the first Internet-enabled outdoor access-control system with voice-over-Internet protocol (VoIP).

Using an Internet connection, IPAC quickly transfers voice and data, eliminating long-distance fees and dependence on old analog phone lines, giving high-rise, gated community

WORLD’S FIRST MAGNETIC DRILL PILOT LIGHT

 Rotary Draw Benders (Mandrel and Non-Mandrel)

 Angle Rolls -

Section Benders

 Tube & Pipe Notchers  Swaging Machines

From low light to no light, never worry about seeing where you are drilling again.

The LED Pilot Light is a standard feature on new models of Hougen magnetic drills. Visit www.hougen.com and see first hand the three new models of magnetic drills plus the redesigned HMD904.

Pat Pending

• New Models • More Speeds • More Power • More Features NEW HMD905

Phone 563-391-7700

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CML USA, Inc. Ercolina®

ercolina-usa.com

For the latest bending technology – www.bendsoveramerica.com

800-426-7818 SERVICE • INTEGRITY • RELIABILITY HOUGEN.COM O&MM Fabricator n November / December 2014

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What’s Hot? n

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and commercial and industrial facilities more robust access control.

IPAC allows property managers to access their system’s data from any browser or device, anywhere, and at any time.

Unlike other outdoor

access -control systems, IPAC does not require a dedicated computer or installed software, allowing for management of resident information from any browser through web-based software.

IPAC also stores information for up to 50,000 residents.

IPAC also includes LiftMaster’s Security+ 2.0 patented technology, which ensures a strong and reliable signal to access property quickly and safely, says the company.

A large, color touchscreen interface provides easy and familiar navigation for customers, residents and guests, and a

full keyboard search lets guests quickly find residents without having to scroll manually. Anti-glare coating and auto dimming make it easy to read the screen in any light.

IPAC offers a contemporary design, and durable scratch and dent-resistant materials that can withstand constant use, says the company.

LiftMaster’s IPAC is also designed to deal with environmental extremes. When enclosed in a custom IP65rated weather-tight enclosure, IPAC can operate in temperatures from -20°F to +130°F — providing customers with year-round protection.

Contact 800-528-5880; www.LiftMaster.com/ IPAC Auto-darkening welding helmet Victor Technologies

The new Tweco auto-darkening welding helmet features four sensors for enhanced performance and can be used in both weld mode and grind mode. It will darken when TIG welding even at 5

25 Tons of Hydraulic Power only $3,650.00!

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110V, plug it in - no hardw iring required Sm all enough for bench-top use.

Foot sw itch for hands-free operation Accepts many types of Vogel tools

Vogel Tool & Die for over 75 years, proudly made in USA www.VogelTool.com Turntable Accepts Three Pipe Notchers w ith No Changeover!

Notch Pipe

Telephone: 800-272-8946 Fax: 630-562-1500

Notch Square Tube

Notch on an Angle

November / December 2014 n O&MM Fabricator

Remove Turntable to Install Vogel Picket Former

Form Pickets

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What’s Hot? n

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amps, says the company.

The helmet has a large viewing area of 3.86 x 1.69 inches, weighs 16 ounces, uses solar power to eliminate the need to change batteries, and comes in three styles.

When switching from light-to-dark, this helmet darkens in 33 microseconds (or ⅓ of a second).

When switching from dark-to-light, users can select from three switching speeds: short (0.25s to 0.35s), medium (0.35s to 0.50s) and long (0.50s to 0.80s).

Designed to combine safety, strength, flexibility, and comfort, the Tweco WeldSkill four-sensor helmet passes all of the 49 tests required under the ANSI Z87.1-2010 standards, the company reports. This

includes the ability to retain its auto-darkening performance even after high impact by a steel ball, the company says.

The sensitivity and delay knobs are on the outside of the helmet shell so that operators can make adjustments while welding. When setting the helmet down, a recessed lens design prevents the faceplate from touching the table, protecting it from scratches.

Contact 636-728-3000; www.victortechnologies. com

Vertical lifter Konecranes Konecranes, global manufacturer of lifting technology, offers the dynamic ATL Vertical Lifter to meet the handling requirements of a variety of industries.

With a lifting capacity of up to 1,600 kg and absorption of torque up to 4,000 Nm, the ATL Vertical Lifter offers diverse, high-quality drive concepts, says the company, along with pneumatic balance controls or electrical chain hoists.

Konecranes’ pneumatic manipulators are ceiling-based solutions made up of an XA crane system and a telescopic lifting device combined with a customized gripping unit.

The design is modular for flexibility and adapt-

ability to meet the needs of individual operations.

Unlike chain or rope hoists, the ATL Vertical Lifter can lift loads outside the center of gravity, and its balancing mode makes the handling of parts feel nearly weightless, the company says. High-quality telescope guides are designed to enable precise, sway-free lifting and vertical manipulating.

Contact 937-525-5533; www.konecranes.com

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Artist-Blacksmith’s

Produced in collaboration with

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ACTIVE INTEREST MEDIA

O&MM Fabricator n November / December 2014

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n

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

Pg Company Website 29 Albina Pipe Bending Co, Inc. (DBA Albina Co. Inc.)...................................www.albinaco.com

Pg Company Website 70 Hougen Mfg. Inc............................................. www.hougen.com 58 International Gate Devices...........................www.intlgate.com

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

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

69 Atlas Metal Sales....................................... www.atlasmetal.com

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

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

75 King Architectural Metals....................... www.kingmetals.com

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

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

62 Julius Blum & Co. Inc...............................www.juliusblum.com 4 The Cable Connection........... www.thecableconnection.com 69 John C. Campbell Folk School.................www.folkschool.org 16 Carell Corporation..................................... www.carellcorp.com 15 Chicago Metal Rolled Products Co................ www.cmrp.com 70 CML USA Inc............................................www.ercolina-usa.com 18 COLE-TUVE/CT Machinery..........................www.coletuve.com 64 Colorado Waterjet Co..................www.coloradowaterjet.com 9 D & D Technologies (USA) Inc......... www.ddtechglobal.com 6 DKS, DoorKing Systems............................. www.doorking.com 6 Eagle Bending 1 Machines Inc..................... www.eaglebendingmachines.com

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

68 Marks U.S.A...................................................www.marksusa.com 50 Mittler Bros. Machine & Tool................ www.mittlerbros.com 48 Pat Mooney Inc...............................www.patmooneysaws.com 51 NC Tool Company Inc..................................www.nctoolco.com 67 R & D Hydraulics Mfg. & Machine Co..............www.rdhs.com 55 Regency Railings...............................www.regencyrailings.com 27 Rogers Mfg. Inc.................................. www.rogers-mfg-inc.com 31 Scotchman Industries............................. www.scotchman.com 33 Sharpe Products.............................. www.sharpeproducts.com 59 Simonian Bender...........................www.simonianbender.com 25 Stairways Inc............................................www.stairwaysinc.com 52 Sumter Coatings Inc........................www.sumtercoatings.com

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

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

13 FabCAD Inc........................................................ www.fabcad.com

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

1 Haberle/ 7 Ken Bergman & Associates...................www.haberleusa.com

23 TS Distributors Inc................................ www.tsdistributors.com

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

71 Vogel Tool & Die LLC.................................. www.vogeltool.com 19 The Wagner Companies...........www.wagnercompanies.com 53 Weaver’s Iron Works................. www.weaversironworks.com

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

Sherry Theien Advertising Director 8392 Leesburg Ct. Rockford, IL 61114 815-282-6000 815-282-8002 fax stheien@att.net November / December 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 28, 2014 Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; stheien@att.net 73

n

Metal Moment

From the NOMMA ListServ

Join NOMMA to get your questions answered free.

Templates for cutting pipe NOMMA member Kurt Lents of Alamance Iron Works posted this question on the NOMMA ListServ:

Does anyone have a FabCAD template for cutting 11/4inch pipe where three pipes come together for a level, 90° corner with post? All three ends should be cut in a heart shape. Many shops just make the handrail 45° and weld a post underneath. It could be done better. I’m trying to teach new guys with a sample but can’t quite figure the cuts out.

Angela D. Hertl, Big C Steel: We’ve used a website www.harderwoods.com/pipetemplate.php (see screenshot at right) to create a template with the proper angles to join pipes. Pop in the details, and it will create the cut template for you. Might help.

Stan Harder, digitalpipefitter.com: The joint in question is two miters, one rotated 90° combined on the same template. The Digital Pipe Fitter application does the combining with a union joint. This joint can be done as shown below at http://digitalpipefitter.com.

Digital Pipe Fitter supports many simple and complex joints. Experienced fabricators can lay out the simple joints manually but many customers are pleased not to do manual layout even on the simple joints. The software saves time and is much more accurate than most manual layout techniques.

Instructions at digitalpipefitter. com: Choose the type of joint you want, enter pipe sizes and desired dimensions, print a template on your printer, wrap the template around the pipe, and cut on the line.

TA LK TO US

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.

74

O&MM Fabricator n November / December 2014

Don’t just blend in...

STAND OUT with Köenig Eisen!

Photos submitted to our Facebook page by TopHand Fence, Lawton, OK.

November / December 2014 n O&MM Fabricator

75

METAL

WOOD

VICTORIAN

Easy to assemble. 5-year warranty.

For FREE catalog, call 1-800-523-7427 ext. FAB Or visit www.TheIronShop.com/FAB 76

Proudly made in the USA since 1931 O&MM Fabricator

n November / December 2014