Jan/Feb 2015 O&MM Fabricator

Ornamental and Miscellaneous Metal

Fabricator ®

The official publication of the National Ornamental & Miscellaneous Metals Association

January / February 2015 $6.00 US

See METALfab2015, March 11–14, 2015, program guide after page 34

2014 Top Job Gold Award: Non-forged, exterior railing and fence

Making stainless look forged Modifying tools crıtıcal to completing Falling Hammer Productions’ job page 45

Shop Talk What fabricators say about 13 estimating apps, page 14

Shop Talk 13 bending tips, page 30

Biz Talk The face of tech school apprenticeship, page 51

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Forging Your Future | Recognition 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.

The NOMMA annual Ernest Wiemann Top Job Awards program recognizes excellence in metalwork craftmanship regardless of size or scope. The Mitch Heitler Award for Excellence, which is the highest honor given by NOMMA, is chosen from among the gold winners of the Ernest Wiemann Top Job Awards by a panel of judges. The program has helped innovate and advance the industry by showcasing ideas that push the envelope, overcome challenges, and improve upon existing concepts. All winning projects are showcased in the Fabricator magazine and featured on the website. Press releases are mailed to newspapers in the winning shop’s community. The contest is a great marketing tool to showcase your business!

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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Join NOMMA Today and Save $100 Visit us online at www.nomma.org and enter promo code: DM2-2014

National Ornamental & Miscellaneous Metals Association t: 888.516.8585 f: 888.279.7994 www.nomma.org

First time members, offer expires March 31, 2015

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FAX TO: 888-279-7994

Join Online: www.nomma.org • By Phone: 888-516-8585, ext. 101

NOMMA Membership Application - Join Us! Membership Category – Check One: Fabricator Member Metal fabricating shops, blacksmiths, artists or other firms and individuals in the industry whose products or services are sold directly to the consumer or the consumer’s immediate agent. q Micro Shop - $350 (annual gross revenues under $250,000) q Medium Shop - $425 (annual gross revenues $251,000–$2,499,999) q Large Shop - $500 (annual gross revenues $2.5 million and higher) Supplier Member Supplier members are those members that produce or distribute materials, machinery, and accessories for the industry or provide services that may be used by the industry. q Nationwide - $595 (operating on a nationwide or international basis) q Regional - $465 (operating within a 500-mile radius) q Local - $375 (operating within a 150-mile radius) q Affiliate - $310.00 q Teacher q School q Non-profit organization Individuals, firms, organizations and schools that do not engage in the fabrication of ornamental or miscellaneous metal products, do not provide products or services to the industry, but have a special interest in the industry.

Company:____________________________________________________________________________________ Primary Contact :______________________________________________________________________________ Address:___________________________________________________________________________________ City:_____________________________________________ State: ________ Zip: _________________________ Country: __________________________________________________________________________________ Phone:__________________________Fax:________________________ Toll Free:_______________________ E-mail: ____________________________________________ Web:_____________________________________ Company Description/ Specialty:____________________________________________________________________________________ Payment method: q Check

(Payable to NOMMA, in US dollars, drawn on US bank)

q AMEX q Discover q MasterCard q VISA Card # _________________________________________________ Exp.:________________ CVV: ___________ Print name on card: ___________________________________________________________________________ Signature_____________________________________________________________________________________ Return to: NOMMA, 805 South Glynn St., Ste. 127 # 311, Fayetteville, GA 30214 • Ph: 888-516-8585 • Fax: 888-279-7994 • nommainfo@nomma.org • www.nomma.org

Quarterly Payment Plan q Please enroll me in the Quarterly Payment Plan.

As a member you agree to follow NOMMA’s Code of Ethics (viewable on the NOMMA website).

Payment method: q Please auto charge my credit card. q Please bill me each quarter.

Questions? Contact: Liz Johnson, Member Care & Operations Manager: (888) 516-8585, ext. 101, liz@nomma.org FAB 201501

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Inside

January / February 2015 Vol. 56, No. 1

Knowledge to enlighten the industry METALfab2015

NOMMA Network Gulf Coast members show favorite measuring devices........... 10 NOMMA loses Sam Paresi and Bob Ponsler Jr...................................... 11 Letter to the Editor............................. 11

Strength of square tubing vs. square solid.

Shop Talk

What fabricators say about 13 estimating software programs... 14

Whatever tool you use for estimating the costs from job to job, make sure your method is consistent. Software helps you achieve this.

While sometimes tedious to learn, software can also save you time and cut down on mistakes.

Which program works is for you?

By Linda Erbele

Bent offerings...................................... 30

You can find bending tips in a variety of places, including the NOMMA ListServ. But when O&MM Fabricator magazine wanted to find a few, we spoke directly to the fabricator. Here’s a baker’s dozen worth of ideas.

By Jeff Fogel METALfab2015: You’re invited!

The only show exclusively for ornamental & misc. metal fabricators........... after 34

The METALfab2015 program demonstrates the value of peer networking and continuing education: n Education sessions n Exhibits n Awards banquet n Shop tours Heitler Award n Business classes, presented

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

Biz Talk The current face of technical school apprenticeship............................. 51

Trade schools depend on advice from local companies to help build their programs. Here’s what Savannah Technical College, Savannah, GA, has learned.

By Steve Hartley and William Burns Also: 5 ways you can help students get the training they need for you........... 55 What’s Hot! News......................................................... 59

Demand softens, but outlook of the Architecture Billings Index remains positive. n Construction employment increases in 37 states and District of Columbia. n

Events......................................................60

Plan now for blacksmithing classes through September.

Media....................................................... 61

Shop Talk

President’s Letter.............. 7

METALfab2015 Guide

Top Job Winner Profile Making stainless look forged........ 45

Stainless steel is harder to bend and more finicky to weld. Find out how Falling Hammer Productions took extra care during design and fabrication of this Top Job gold-winning railing.

By Peter T. Swarz-Burt

Exec. Director’s Letter..... 8

Trello helps you organize workflow.

Review of Ironwork Today 4: Inside and Out.

Products.................................................62 NOMMA Supplier Members.......... 57 New NOMMA Members................... 58 Ad Index..................................................65

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

Foundation names new leadership team.

Metal Moment.................. 66

Dragon Forge has the passion to do it for television.

About the cover Falling Hammer Productions LLC, Wolcott, CT, won the 2014 NOMMA Top Job gold award in the nonforged, exterior railings & fences category for this 125-foot, 304 stainless steel railing for a large residence. See story, page 45.

January / February 2015 n O&MM Fabricator

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President’s Letter

METALfab2015: You’re invited! some actual shop visits. The video and actual shop tours always provide a wealth of ideas by seeing how other fabricators organize their shops and the equipment they use.

The arrival of a new year means new year resolutions, a fresh start, and most importantly, the time to sign up for METALfab.

This year’s annual conference takes place March 11–14 at the Valley Forge Casino Resort, just outside of Philadelphia.

Tools that improve ROI As NOMMA’s president and Mark Koenke, The exhibits open Thursday Germantown convention chair, I’d like to morning; you’ll see your favorIron & Steel extend an official invitation for Corp., is ite vendors from around the you to join us. Our Convention president world. The METALfab show Committee and NOMMA Edu- of NOMMA. provides a great opportunity to cation Foundation have spent see the latest industry prodmonths planning an outstanding proucts and obtain ideas for future jobs. gram that features excellent education, Chances are you’ll see a tool that will shop tours, exhibits, and social events. save you money.

Look for opportunities

Starting Wednesday morning, our keynote speaker, Barry Willingham, will discuss how to find opportunities during times of adversity and challenge. Considering the recent recession and the many changes occurring in our industry, I think this presentation will hit home for many members.

Barry, who is vice president and general manager of Ameristar Perimeter Security USA Inc., is one of our own members and a seasoned speaker.

Ways to manage business better

In the area of education, I’m particularly excited about our business class series, which will be led by Tyler Pare of FMI Corp.

His classes will cover improving productivity, connecting actual job costs back to estimating, developing business, managing effectively, handling change orders, and learning how to measure business performance.

The knowledge you gain from these classes will more than pay for your METALfab costs.

Other education sessions will cover cash flow, hiring employees, and measuring.

I’m delighted to report that the popular video shop tours are back, plus we’ll board buses on Saturday for January / February 2015 n O&MM Fabricator

How the top fabricators did it

As the former Top Job Awards Contest chair, one of our most useful resources is the Top Job Jamboree, which takes place Friday afternoon.

During the Jamboree, the entries from the awards contest are flashed on a screen and the entrants come forward to talk about their work. Often, an interesting conversation ensues with members of the audience. The Jamboree is a true goldmine of information.

Benefits of engaging interaction

While you’ll gain an incredible amount of knowledge from our stellar education line-up, another great source for learning comes from conversations during class breaks, at social events, and on the bus during shop tours.

We call this interaction the “NOMMA Network,” and it will provide you with tons of benefits.

Finally, we will have an exciting spouse program. I encourage you to bring your better half, and bring your employees as well. Also, be sure to plan time before and after the event for sightseeing.

I look forward to seeing each of you at METALfab2015.

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 ndation O fficers

Chair Lynn Parquette, Mueller Ornamental Iron Works Inc., Elite Architectural Metal Supply LLC, Elk Grove Village, IL Vice Chair Rob Rolves, Foreman Fabricators Inc., St. Louis, MO 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 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

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How to reach us

Executive Director’s Letter

Trello helps you organize workflow I always look out for organizacan attach a file, create a checktional software that will increase list, assign it to a coworker, and my efficiency at work. Recently, color code it. You can write I stumbled on a useful tool for notes on it, too.

NOMMA member shops — a Trello has many competiweb-based project management tors, but I chose it after testing program called Trello. several systems. My runner-ups Trello, now with reportinclude Basecamp, 5pm, and Todd Daniel is executive edly 5 million members, runs Zoho Projects. from your Internet browser and director of Trello is my favorite because NOMMA. uses the idea of a whiteboard of its simplicity, and it’s not with sticky notes. Mainly used to track packed with confusing bells and whisworkflow, it has other uses as well. tles that I’ll never use. However, Trello One use is that rather than seedoes have some hidden advanced feaing one project board in a conference tures you can use as needed, e.g. a calroom, all members of your team can endar, card aging, and voting. view the board from their computer or The basic Trello is free. You can get mobile device at all times. more features by purchasing Trello Trello’s workflow system can be Gold or Trello Business Class, which traced to the famous kanban schedulboth cost $45 per year per user. The ing system that was made famous by paid versions allow you to upload huge Toyota in the 1980s. As your jobs move attachments, which may be handy through the shop, you simply advance when sharing design drawings. The the cards from one stage to the next. free version limits you to attachments You can also list months to make it no larger than 10 MB. a calendar or design it as your personal I’ll conduct a webinar on this soft“to do” task manager. ware later. And soon I’ll share another The real power of Trello is what you ing online tool called Priority Matrix. can do on the back of a card. If it were Best of luck with a real yellow sticky, you’d run out of your organizing! room quickly. By using the back, you

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. F I LE S, U R JO B P RO W E W AN T YO

© 2015 National Ornamental & Miscellaneous 8

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 O&MM Fabricator. Contact Editor Robin Sherman at nomma.editor@att.net.

O&MM Fabricator n January / February 2015

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The NOMMA Network

Gulf Coast members show favorite measuring devices The Gulf Coast NOMMA Network held their fall meeting in Clinton, MS, on November 15, with Iron Innovations Inc. serving as host shop.

The main program for the day was “Show-n-Tell,” where members demonstrated their favorite tools, in this case, a variety of laser measuring devices.

Scott Meckes of Doorking also demonstrated a radio transmitter that tested signal strength. The device ensures that gate operator electronics will have a sufficient signal during the design stage.

For the business session, NOMMA Executive Director Todd Daniel gave a slide show called the “Not So Dirty Dozen.”

He showed 12 online information sources that you can access from either the NOMMA website or from related associations.

Scott Colson, who served as host for the day, showed a television commercial he recently produced and gave a short talk on advertising.

There were the usual favorite events, including a shop tour, the famous buck-in-a-bucket raffle, and a delicious barbecue lunch.

During the tour, attendees, saw Iron Innovations’ torch cutting system and several jobs in process. Attendees were particularly interested in the company’s parts organization rack, which used 5-gallon buckets.

The next meeting is tentatively planned for Fort Payne, AL, and time and date will be announced.

The Gulf Coast NOMMA Network enjoyed a nice turnout at their November meeting, with attendees coming from Alabama, Louisiana, and Mississippi.

James Minter Jr., left, shows his favorite laser measuring device to a captivated audience.

During the tour of the Iron Innovations shop, the parts organization rack, featuring 5-gallon buckets, was a hit with attendees.

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O&MM Fabricator n January / February 2015

In Memoriam

NOMMA loses 41-year member Bob Ponsler Jr.,

NOMMA loses Sam Paresi, past volunteer

Bob Ponsler Jr., 66, of Wonderland Products Inc., Jacksonville, FL, died suddenly on December 14, 2014.

Bob was a 41-year NOMMA member and served as Florida Chapter president in 2003 and also as chapter representative to the NOMMA board.

In 2006, he served on the NOMMA Technical Committee and attended the ICC spring code hearings that year. He also attended many METALfab conventions.

His father, Bob Ponsler Sr., was a past NOMMA president and NOMMA legend.

He served in the Florida Army National Guard for many years and retired as a major.

Wonderland Products started out by building playground equipment in the 1950s. From there, the company moved into light industrial blacksmithing and later became known worldwide for its high-end ornamental work.

The company has won numerous awards in the Top Job contest.

One of the things the company is known for is its expertise in working with Monel metal.

Bob is survived by his wife Daysi Melo Ponsler, mother Thelma Ponsler, sister Jeanie Allen, brother David Ponsler and three sons Robert Ponsler III (Rachael), Joseph Ponsler (Sarah) and James Ponsler (Tayna) and eight grandchildren. Two of his sons — Joe and Jimmy — continue to run the business.

Sam Paresi, 88, a long-time NOMMA volunteer, passed away on December 27, 2014. He was employed with Julius Blum & Co. Inc. for 66 years before his retirement in 2011.

Sam was a regular participant at METALfab conferences and a founder of the National Ornamental Metal Museum in Memphis, TN. He served on the NOMMA Standards Committee for many years and helped develop standards that are still used to day.

He also helped to create the Metal Rail Manual and NAAMMNOMMA Finishes Manual.

In 1992 Sam received the Julius Blum Award for outstanding service to the industry. In 2010, the NOMMA board voted him as an honorary lifetime member, and he was recognized at a special ceremony during a Northeast Chapter meeting in January 2011.

Sam began his career at Julius Blum in 1944, at age 18, as an errand boy, and then moved up to inside sales, warehouse foreman, and then outside sales. The only time he left Blum was to serve his country in the Korean War. Sam will always be remembered for being kind, friendly to all, and for being passionate about the industry. At NOMMA conferences, he always made a point to say hello to everyone and he had a true concern for the well being of others.

Services were held December 30 in Massapequa Park, NY. Donations in his memory should go to: Association for the Help of Retarded Children (Nassau).

January / February 2015 n O&MM Fabricator

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In Memoriam

Letter to the Editor Strength of square tubing vs. square solid I’m reading the November/December 2014 O&MM Fabricator, and the article on testing railings is quite good.

However, I’d like to point out an inaccuracy. A statement made in the article says that square tubing is stronger than square solid. It’s a common misconception and an argument I’ve faced multiple times. This isn’t true when comparing apples to apples.

For instance, people should not assume that a hollow of a same alloy and temper as a solid, will be stronger.

The opposite is true.

Where it gets tricky is that steel tubes under 2 inches are manufactured to ASTM 513 and are made from a different steel composition than standard hot rolled solid bars. They have a minimum yield strength of 72,000 psi and tensile of 87,000 psi with 10 percent elongation, whereas A36 steel has a yield strength of only 36,000 psi and tensile of 58,000 to 80,000 psi with 20 percent elongation.

Now, if someone takes the same grade of material, such as architectural bronze, and compares a 1-inch solid square versus a 1-inch square tube, (no matter what thickness tube) the solid will almost always win.

For details on the actual calculations for this, see http://bit.ly/1tuQSpd Kendall Shrock Shrock Fabrication Author, Jeff Fogel, responds This tube vs. solid strength is an old debate. Engineers and physics students fight about it in pubs.

A tube can be at least as strong, if not stronger, than solid stock provided we are talking about similar mass and not similar diameter.

What this means is that hollow tube has a higher strength to mass ratio than solid. But when you’re comparing equal diameters, the solid wins hands down.

Having said that, Kendall Schrock is considered one of the most knowledgeable people in the industry. I’d go with his opinion (which, unlike a physicist, is predicated on real life). I have no problem being corrected by him.

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NOMMA Education Foundation

In partnership with the National Ornamental & Miscellaneous Metals Association

Foundation names new leadership team The NOMMA Education Foundation would like to congratulate its new officers.

Chair, Lynn Parquette, Mueller Ornamental Iron Works Inc., Elite Architectural Metal Supply (pictured, left).

Vice Chair, Rob Rolves, Foreman Fabricators Inc. (pictured, center).

Treasurer, Mike Boyler, Boyler’s Ornamental Iron Inc. (pictured, right).

METALfab2015 education highlights

Along with the outstanding lineup of NOMMA members presenting at METALfab2015, NEF is providing a very special presenter, Tyler Pare, a consultant with FMI Corporation.

Pare will present a series of classes for the METALfab2015 education program on Wednesday, March 11 and Thursday, March 12.

As a consultant with FMI, Tyler focuses on leveraging his construction experience and his knowledge of business mechanics to help clients mitigate risks and improve productivity. The topics that Tyler will be covering include: n Leveraging Your Competitive Advantage by Improving Productivity n Connecting Actual Job Costs Back to Estimating n Key Performance Indicators that Drive Best Practices n Keys to Effective Management n Driving Best Practices in Business Development n How to Avoid Confrontation with Change Orders

field measuring, shop drawings, and shop and field layout.

History of Metalwork. Eric Cuper, Cuper Studios LLC, will focus on history of metal emphasizing blacksmithing and decorative work, and how technology and modern design have impacted it.

Under 40 — Hammering Out Your Course in Metalwork. Discover how the under-40 group see its future path to success.

Video Shop Tours. This is your chance to see in-person how other fabricators set up shop.

Women in the Business. A roundtable discussion for women about their challenges and successes, and what the future holds.

ListServ Live. Meet the people who participate in the NOMMA ListServ discussions and ask them more questions, in person.

Other classes will be announced; be sure to check the NOMMA website at www.nomma.org.

For more information: See the METALfab2015 Convention Guide included in this issue after page 34.

Special NEF events at METALfab2015

Don’t forget to consider making a tax-deductible contribution for our Live and Silent Auctions set for Thursday, March 12, 2015, during METALfab2015.

The Auction Committee is requesting donations of auction items, which may include, but are not limited to: Other useful sessions n Metal sculpture, a garden gate, hand-forged furniture, Where’s The Cash? Dave Filippi, FabCAD will present a books, artwork or antiques; practical and unconventional look into small business mann Non-metal items such as tools, gift baskets, gift certifiagement cates/coupons, jewelry, electronics, clothing, food/wine, Hedging Your Bets on Hiring the Right Employee for presentation drawings, the use of a condo at the beach or airYou. Roger Carlsen, Ephraim Forge, will lead a discussion on line tickets; how to design an employee search paradigm, including, but n Specialized services to create a custom one-of-a-kind not limited to: item for the winning bidder; n Where to look for possible candidates. n Or, be creative– the sky’s the limit! n Some first impressions insights.

Donation forms are available at www.nomma.org under n Designing the right written test to fit your specific needs. the education tab. Thank you in advance for your contribun Thoughts on actual hands on task testing. tion to NEF. n Making the final decision.

Finally, please join the NEF trustees at the Partners in Measuring Made Easy. Mark O’Malley, O’Malley Welding Education Reception on Friday, March 13. & Fabricating Inc. and Terry Barrett, Pinpoint Solutions will This event is sponsored by NEF to thank you for your conshow attendees the tools, technology, and methodology for tinued support of the foundation.

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.

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O&MM Fabricator n January / February 2015

Shop Talk

Structural Material Manager

What estimating app works for you? n

Whatever tool you use for estimating the costs from job to job, make sure your method is consistent. Software helps you achieve this. While sometimes tedious to learn, software can also save you time and cut down on mistakes. Here’s what fabricators say about 13 programs.

Editor’s note: For this article, O&MM Fabricator looked at a 13 estimating software programs used by fabricators.

We sought to interview at least one fabricator for each app and talk to the vendor as well. If one of the two sources are not mentioned in a description, it was because we could not reach the source.

Due to the numerous products and features, and space limitations in the magazine, we cannot describe each comprehensively. Instead, we attempt to give you a “sense” of the product.

By Linda M. Erbele Sometimes it’s an RFP for a job. Some-

times it’s a customer with a sketch for complicated work. Regardless of the way the job comes in, you create an

14

estimate for the cost of the work.

Estimators likely build a job in their mind to some degree from start to finish — every weld, pipe and sheet, cutting to finishing. What machines are used for each step? The purchase price for each piece of material, as well as shipping costs, are included.

The labor hours for every process required to turn raw materials into a final job is accounted for. Plus hours for installation. If that requires an overnight at the customer’s location, per diem for the employees might be part of the cost. If a truck is rented, its cost and that of gasoline is factored in.

Thus, an estimate would include all costs for design, field measuring, materials, labor, finishing, installation, travel, machine rental, subcontractors,

overhead, and profit as a percentage.

Kevin Hill, administrator with Owens Welding in Cleveland, GA, says that after the material and labor costs he adds in the costs to run the machines and the use of other consumables, such as welding rods and wire, gas, and power. Like most fabricators, he says the shop uses a lot of electricity.

“Basically, an estimate is an educated guess,” says Hill.

Sometimes, experience tells him the cost of a job. Sometimes, it’s a blind bid or a price by the hour.

“When you find that an estimate was too low, you can’t go back to the customer and ask for more money,” he says. “You just eat it and move on.

But you learn from it.”

Michael Stone, author of Markup and O&MM Fabricator n January / February 2015

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Profit, A Contractor’s Guide Revisited, says you rarely see an estimator who has made the mistake of overestimating. If a mistake has been made, it’s usually the other way around. Maybe you accidentally left out an item. Easy to do.

You’ve got to use a system

Stone teaches a course on estimating (see www.markupandprofit.com). What is important in a takeoff, he says, is the use of a consistent system.

“Too many people get hung up on how to get the numbers,” he says.

“What’s important is using the same system every time. You do the same thing, the same way, every time. That’s how you stop things from falling through the cracks.”

The consistent system must also be a good system. Stone says that two mistakes people make with estimating are not using a system that covers all the variables, including profit and overhead — and the second is guessing. “It’s very boring and tedious, but it has to be done right or you lose money,” he says.

For some fabricators, creating an

of custom work. Partner Rachel Miller, who does most of the estimating, recently began using an Excel spreadsheet to track time on a job.

“If we get a similar job, I can occasionally pull labor from (an older job,) but it’s never the same,” she says, because each job is different. A look at older jobs can at least give her an idea of labor hours per operation.

Structural Material The advantage to a spreadsheet is Manager it can be as simple as a list of prices or as complex as you can make it.

With rows and columns, items of material can be listed and the various labor functions (cutting, welding, estimate requires a sharp pencil with an eraser, maybe graph paper, or a legal sanding) can be listed beside them. pad — and a long night.

Once set up, a spreadsheet can serve as For others, it’s a spreadsheet with a checklist of materials and processes. fields for quantities of materials, then Because it can calculate, columns the labor: hours for cutting, weldcan be totaled and the percentages for ing, sanding, polishing, yadda, yadda, overhead and profit factored in. yadda. . . . Then columns for additional However, spreadsheets are twohours of installation. dimensional. They can’t make an association between much more than the rows and columns. Scrolling through Using a spreadsheet multiple pages of material and other Like many, Spirit Ironworks in Baydata can be tedious. port, NY, is a small shop that does a lot

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Using software

Estimating programs typically can be customized by the user. All the programs we review are Windows-based, but ask the vendor if there is iPhone, iPad, or Mac functionality.

Many fabricators, even small shops, use a software application, which may be available either on-premise — meaning you own it, and the program has been loaded onto your computer; or it is in “the cloud” — meaning the application and sometimes a materials database are accessed on the Internet and live on a provider’s server. Variations can exist, such as the application on your computer and the database in the cloud.

Most software vendors offer complimentary training when you buy the product, and online help documents for later. Many of the larger software packages have videos online showing how they work. Look for the best training deal after the “new” wears off.

Software is sold typically as “licensed users,” sometimes referred to as “seats” — the number of people at the company

they have an estimating function and can also help you manage other business operations from production to purchasing and accounting. Some can do multing and nesting — combining lengths of the same materials to create the most efficient cuts to reduce overages of materials. This can extend to telling the shop how to best use the sheet or bar most economically. Some can even track price Structural Material breaks by quantity, knowing when Manager buying 50 of something will cost less than buying 46. authorized to use it. Prices start with the first user, and most go up with each seat. Sales people can sometimes discount the cost when more licenses are purchased, so don’t hesitate to negotiate.

Many programs include a database of material items. Depending on the volatility of prices for the particular metal a fabricator uses, a database of costs by sheet or length can be helpful.

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Bluebeam

Jim Toney, general manager at Southwest Architectural Metals in Henderson, NV, uses Bluebeam.

“We use it in doing takeoffs for a project in preparation for proposals,” he says. “It is primarily used in lieu of paper documents and can be passed electronically to share information.

We pass the marked up electronic files between the different divisions of our companies: structural steel, miscellaneous steel, stair structures, and architecturally exposed metals and glass.”

The software is cloud-based and everyone can work in the same file.

Southwest Architectural Metals doesn’t use it to produce the final document the customer sees, but if they are successful with the bid, the Bluebeam file can be transferred to the operations side so they can understand the project’s scope.

Bluebeam costs $219, and customers can buy a $79 annual training package.

“Bluebeam Revu allows users to perform many types of digital takeoffs; they do not need to own any additional Bluebeam software,” says Steve Jones, senior channel sales specialist. “While Revu is an extremely powerful tool (especially for the price point), it is not a 100% apples-to-apples replacement for dedicated on-screen takeoff solutions, which cost substantially more and are more specialized. However, for many of our customers, Revu has all of the features they need to get their job done efficiently.”

He adds that Bluebeam doesn’t have a material or labor cost database.

“Users can add costs [of materials] to their measurement markup tools by using custom columns in the markups list, but this information does need to O&MM Fabricator n January / February 2015

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Overview of software programs for estimating cost of jobs Application Strengths* Weaknesses*

Improvements coming

Cost (basic plan)

Training

Blue Beam with OST

None identified

Spring 2015

$219

$79 per year

Learning curve

Spring 2015 — metrics

$1,995

Free

FabMate Customized None

by shop

Early 2015

$3,000

Free

FabSuite

Comes in Complexity modles

First quarter 2015

$5,000

5 hours free

FabTrol

Calculates labor per operation based on previous inputs

Fields a bit limited, requires abbreviations

Rewrite in Spring 2015 to address field size

$3,500

Free

Fast Track

Low cost

None identified

None expected soon $295

Relatively inexpensive

E2 Shop Comes in System modules

Free manual

JobBoss Job tracking

None Feb identified 2015

$2,750; $299/month

MIE Quote-It Adaptable

Learning curve

Jan 2015

$2,500 w/initial training free; $1,500 + $215 for training

PlanSwift

Figures linear footage on screen from PDF, CAD dwg

Learning curve

Mid-2015

$950

ProEst

Detailed estimates from on-screen plans

None identified

Spring $1,295 2015

$695 for online class

Structural Multing, nesting None Material identified Manager

Spring 2015 — metrics

$1,495 + $795 estimate module

Free manual

Visual EstiTrack Cost tracking Complexity

New release issued Dec 2014

$3,000

Free

WinEst Pro

2015

$3,500

$1,000

Ability to view and sort data

None identified

Free

$295

* Strengths and weaknesses are based on interviews with fabricators who use the software.

be added manually,” Jones says.

Training videos are available.

Contact www.bluebeam.com E2 Shop System

Rob Rolves of Foreman Fabricators in St. Louis, MO, uses the E2 Shop System by ShopTech.

“No software takes away the art and intrinsic knowledge needed for estimating, but it helps,” he says.

One big time-saver in using software is the ability to quickly search other jobs that are similar.

“If the powder coating on this job is like another one, that speeds up your time to quote,” he adds.

An ERP product, the software can do more than simply create estimates. It tracks inventory and schedules produc20

tion. It compares the actual costs to the estimated costs. People in the shop scan a piece of paper associated with the job (called a job sheet or router) with a barcode reader to track their hours spent on each part of the job.

In addition, Rolves says, they generate shipping tickets, purchase orders, and invoices with the software. It tracks the bids that turn into orders and allows the estimator to record notes so that someone else can see how the estimator envisioned the product being made.

The E2 Shop system has an optional database of materials that the user can choose from, and can create reports based on customer or product. The user can add prices based on experience and update them as they change.

The program’s calculator helps break

down how much of a sheet or bar each part (or a job) is using, and it can calculate quantity price breaks — the change in price if 10, 25, or 50 are purchased.

“You create your own work centers (in the software,)” he says. “If you want to consider coping a pipe to be a different operation from cutting a pipe, you can set up it that way. We’ve changed the design set up in the software over the years as we’ve learned things.”

For example, he says they initially set up a unit for welding and a separate unit for layout for the welding. But the welders had to stop work to record time for layout before they went on to welding, and so it made sense for the two operations to be combined.

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training several times over the years, and learned more each time.

“Like any software, if you get training on every part of it at the begin­ ning, you won’t retain it,” he says.

Paul Ventura, ShopTech’s vice president marketing says the product is designed so that a small fabricator can purchase just the estimating portion and download to QuickBooks, or buy the accounting part of the software in addition to the estimating portion.

The E2 Shop System is available onpremise or in the cloud. Employees can report their time with a bar code scanner or a tablet, where they can also view the drawings or pictures of the job.

“We have a basic (starter) system priced for the smaller guy,” he says.

The starter system costs $1,995 for each license including free three-day classroom and Internet training, both pre-recorded and live.

Ventura says the basic system can create estimates, track the job, and perform purchasing and shipping functions. The next level of the software adds shop floor system management.

labor costs in the manner you want to compile them,” he says. “Make sure the program puts the estimate together the way you want it done. Don’t adjust your operation to the way the software works.”

Miller says he couldn’t find a program that fit those needs, so he hired Michael Babcock of MB Software Solutions to create it.

“It is basically a compiler. It’s a Structural Material very good compiler as opposed to Manager a spreadsheet,” he says. “It does an excellent job of taking our inputs and compiling them in the manner we asked him to do. It prepares Higher levels of management are availa summary sheet, a list of individual able above that, such as accounting and items, then a proposal sheet in a very quality control. slick fashion.”

Contact www.shoptech.com/ Miller says the software has a material and labor database, that can be cusproducts/estimating tomized by the user to add costs. They have been using the system since 2003.

FabMate MB Software Solutions president Bill Miller, president of Ebinger Iron Mike Babcock says he’s re-writing the Works in Schuylkill Haven, PA, believes software to bring it to current technical the most important thing about an estistandards and expects that re-write to mating program is that it works the way be complete about mid-2015. It creates your company does business. estimates, and hours collected by the “See if it compiles your material and

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shop foreman can be input manually to be compared against the estimate.

“The beauty of this software is it’s as simple or as complex as you choose to make it,” Babcock says. “What I’ve heard from my customers is that the other softwares do all this whizbang stuff, and they only use 20% of it. FabMate provides a simple, clear way for consistent estimating, taking the routine out of one’s head and tracking it in a database, so that knowledge is preserved and able to be re-applied for future estimates.”

It has a materials database, and the ability to factor in labor and installation costs, such as a hotel stay.

“You shouldn’t need a manual for this software,” he says, although a 52-page book comes with it. “You should be able to pick it up, just common sense.”

The price begins at $3,000, and the current version has no additional cost for other users, at this point.

“It’s all you can eat,” Babcock says.

He offers a 30-day money-back guarantee and says he’s happy to discuss customization of the product.

“I’m a small company that started 10 years ago. I’m willing to listen and put something together that will help you work smarter not harder,” he says.

Contact www.mbsoftwaresolutions. com

FabSuite

Brad Landry, division manager with Grunau Metals in Oak Creek, WI, uses FabSuite for estimating, project management, and production control.

“It puts together a material list, connects to Outlook, and sends (the list) to vendors,” he says. “You can send a spreadsheet out for them to fill out so you don’t have to do any keypunching.”

The software has multing and nesting functions to minimize overages and suggest the best cut from sheet material.

“They have a very open minded development team that listens to customers and implements things when we ask,” Landry says. “They listen to us fabricators and have made some really good changes.”

Bill Issler, FabSuite president, says fabricators can purchase just a module to create estimates or larger modules that do project management, produc24

York says that once it goes to the shop, the program tracks the labor for the project, which can then be compared to the estimate.

Brian Williams, FabTrol’s general manager, says the program allows the fabricator to build a model of the shop operations within the software.

“We have the ability to set up formulas to derive time based on the Structural Material length, the type of material, the Manager weight of materials, or the perimeter of a plate,” he says. “As you’re doing your material takeoff, we have automation that determines tion management, purchasing, and what types of operations needs to hapinventory control. pen for certain types of material, then FabSuite integrates with modeling how long those steps should take.” systems such as Tekla and SDS/2, as Williams estimated that it could well as AutoCAD-based systems such take a fabricator new to the software an as Advance Steel. Thus, a CAD design entire day to create a model of the shop can be imported, and estimates and within the software. But a person just production control information can using it for its estimating capabilities be generated. An included web-based could get going with little training in interface enables remote access to data just a few hours. as well as recording of shop activities He says that the software will calculate buyouts and sub-outs, freight, on tablets or smartphones. markups, overhead, and profit. FabTrol Issler says a detailed inventory syscomes in three levels, FabTrol Shop, tem allows the user to add the costs of materials. Fabricators can maintain that for small shops, FabTrol MRP for more management, and FabTrol Pro. database as their pricing changes.

Contact www.fabsuite.com/ FabTrol Pro maintains a material cost database that is updated automatestimating ically for users who also use the purchasing system. Users have full conFabTrol trol over material pricing. The latest David York of York Metal Fabripricing for a given bid can be saved cators, Oklahoma City, OK, has used and re-used, and/or each job can have FabTrol since it was a DOS program, custom pricing. FabTrol tracks labor, pre-Windows.

“Inside Fabtrol, there are abilities to for those using the production module, build pre-fabricated units and calculate and can provide feedback about manhow many inches of weld go on a piece hours per assembly type. of metal,” York says.

Williams adds that FabTrol Pro The software offers a field to put in was re-written and released in the fall the material, with an associated field (or of 2014, and the estimating module more) for the labor that will be required. is being re-written with an expected Spring 2015 release date.

For a railing, for example, he puts in the A common complaint about FabTrol welds, the core drills, brackets, and pickhas been the limited field size, and Wilets, each with the associated labor. liams says a re-write will address that.

“When I’m done, it tells me how Contact many hours I have per post,” York says. www.fabtrol.com/software/ “If we sell the job, then I give it a job fabtrol-pro-enterprise/ number. When engineering details the estimating.html job, it gives them a bill of material. Then they hit a button that says ‘optimize.’ It Fast Track Estimating tells purchasing they will need to order Fast Track Estimating was created by 376 pieces of pipe.”

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profitable estimating. His simple estimating software is $295. It breaks down parts of the job as “assemblies” (a group of labor and material steps to perform a single unit of work) and allows the fabricator to enter materials, labor, and subcontractor costs. Then the percentage for overhead and profit is applied to create the final price.

Stone says that the “assemblies” can be adjusted to match the needs of the shop, and some are already built in that are applicable to fabricators.

“It’s a small, bare-bones, get-the-jobdone type program,” he says. “Our target market is the smaller company.”

The software includes a database of materials, labor, and assemblies that are easily customized, Stone says. The estimator enters the quantity of each assembly; material, labor hours, and other costs can be adjusted for each project as needed.

They can also easily create new assemblies by cloning an existing assembly and adjusting. The software then creates an estimate document.

Stone says it is so simple that a training class isn’t really necessary, but he’s personally available to help anyone get started.

“I always take support calls, and they usually last about two minutes,” he says.

Contact www.markupandprofit. com/products/ estimating-software

JobBOSS

Tony Martinez, production coordinator with Big D Metalworks in Dallas, TX, has a mantra about the fabrication business: You can’t manage it if you don’t measure it.

“How do you know you made money on it if you don’t track the hours?” he says.

He uses JobBOSS by Exact America for purchasing, job tracking, and cost analysis.

The program also has estimating and scheduling functions. Big D doesn’t use those functions because the company has spreadsheet processes they have used for years, he says.

He has advice about any software though.

“With any program, you’ve got to factor in human errors. Garbage in, 26

up, but the MIE support people have always been quick to fix it.

MIE Quote It is the quoting and estimating software part of MIE Trak Pro, created by MIE Solutions. It integrates with QuickBooks as an on-premise software.

It does not contain prices for material, but users can add them to the database.

MIE Quote It prices start at Structural Material $2,500 for the first seat with training Manager included, or $1,500 with training priced separately. Additional seats are $1,500 each. MIE Trak Pro costs $5,995 for the first seat and $2,995 for additional seats. garbage out,” he says. “People will It is available on-premise for both punch in the wrong job number, or the application and database, or forget to punch out so it looks like they on-premise applications with cloudhad 90 hours on one job in a week.” based database at $50 per month or JobBOSS is available in the cloud or both in the cloud. on-premise. Marketing director Mike Contact www.mie-solutions.com Stadelman says an on-premise seat license is $2,750 or the Internet subscripPlanSwift tion is $299 per month for the first user SRS, in Metuchen, NJ, has been and $19 per month for the next user. using PlanSwift for about two years to On-line training guides are available do takeoffs for railings. The software for free and regional training sessions imports drawings from PDF, JPG, or available at a cost. The cloud version CAD formats. comes with 30-days of free consultation One feature of the app is that the training. user can click on the beginning of a line A material cost database is available that indicates a rail or wall, for examand can be updated by the user.

Currently, shop hours can be tracked ple, then click on the other end, and the software estimates linear footage or with a smartphone or tablet in the square footage, even gallons of paint for online version and that will be availan area. able in the future with the on-premise It also imports data from a spreadversion. sheet, so if you had, for example, footContact www.jobboss. age of various pieces of metal, it can exactamerica.com add that in as you direct it, says Lou MIE Trak Anelli, PlanSwift’s vice president marJoe Skelton owner, of Nemesis Metketing. The software can figure labor als in Fond Du Lac, WI, uses MIE Trak based on the data you give it. software, another ERP system.

“It integrates fully with Excel and a “It quotes our projects, and breaks variety of accounting software applications,” he adds. down material costs,” he says. “It SRS lead estimator Lin Huang says (defines the order of) all the operashe can import the drawings from a job tions when they hit the floor. We tell and create the takeoffs by clicking on it dimensions, and it does the math the beginning and the end of the railon that piece of material. The system’s ings to develop the linear footage. pretty adaptable.”

“It’s very convenient to separate the The app helps with the repetitive parts of estimating and keeps track types of railings,” she says. of materials and labor, he says. Shop In the past, she had to keep track workers can track their time by scanof the footages on each page of a job ning a job sheet or tapping it in on manually. PlanSwift can show her a a tablet. He adds that occasionally summary of the pages on one side of an issue with the software has come the screen and on the other, a totaled O&MM Fabricator n January / February 2015

list of footages, by page.

“That saves a lot of time,” she says.

She says the software has other functions that she has yet to explore. Currently, SRS uses an internally generated spreadsheet to add the labor and material costs to the material list that is generated by PlanSwift, then the spreadsheet adds in overhead and profit.

The software itself does not come with a material cost database, but users can add the prices and update them as necessary.

“It has a lot functions, and PlanSwift has a good team to develop other functions,” she adds.

User licenses are $950 for PlanSwift, and the company offers a 14-day free trial download. A $200 annual support plan includes all upgrades. The first hour of training is free and the company offers a $295 training package in addition that includes personalized webinars.

Contact www.planswift.com ProEst

At press time, Gale Schmidt with A2 Fabricators, Milwau­kie, OR, had just begun working with ProEst construction estimating software to customize a database.

“Seems like most software out there having to do with steel focuses on structural members. ProEst is more universal and they seem willing to customize for miscellaneous metals,” she says.

ProEst president Jeff Gerardi says the ProEst database is easy to maintain and fabricators can add their costs to the materials in the database.

“The ProEst software is very easy to use and operate,” he says. “It automatically calculates the total pounds and labor necessary to install and fabricate any type of metal.”

ProEst comes in three levels of annual subscription (standard, professional and enterprise) starting at $1,295 per year.

Training requires an additional fee. The company offers three types: Web-based, classroom, and on-site.

Contact www.proest.com Structural Material Manager

Custom Fabrication builds a lot of steel tanks, and co-owner and president Roger Rhoades says he has the estimates from jobs the company built 15 years ago stored in his files in the Structural Material Manager software. That saves a lot of time for him.

“Hardly any of our stuff is the same, but a lot of it is similar,” he says. “You may get four or five hours to bid a job.”

But even estimates from scratch are easy to create with the software.

“If you type in something in wrong, it will tell you and you go back figure out what you did wrong,” he says. “There is a place in the program you can put in hours (to create the estimate.) Then you can go in the program to print the materials to a [Microsoft] Word document and send it out as a inquiry for material to the vendor.”

Another feature Rhoades likes is that it reports the square footage inside and out, which tells him costs for painting and finishing.

January / February 2015 n O&MM Fabricator

27

CELEBRATING

75

YEARS! Est. 1939

SPIRAL, CIRCULAR & HELICAL BENDING Pipe, Tube, Plate & Structural Members -Stringers, Staircases & Handrails - Decorative Gates, Fences & Signage -Handrail Kits Available: Bent and trimmed per drawing, mid-rails trimmed and coped, assemblies supplied as individual parts or fabricated complete!

For Custom Fabrication’s type of work, Rhodes says an estimating program must know the weights of materials precisely to generate accurate prices. In addition, the program has a nesting and multing capability, so it tells the shop how to cut.

“It will add up all your cuts and give you the best size to buy to cut your pieces of it,” Rhodes says. “If you’re buying 60-foot beams, it will tell you how to cut all your pieces to cut waste.”

Structural Material Manager is not full-blown ERP software, says Edward Easterday, software sales and support with EJE Industries.

“That is actually what so many people find attractive about the product, is that it does not strive to be all things to all people or to handle every conceivable task,” he says.

“Instead, it focuses on a few areas and does them extremely well (such as nesting and multing.)”

Another difference from generalized ERP is that Structural Material Manager “speaks” steel.

“By that I mean that an angle can be entered as L 2 x 2 x ¼ x 10’-6, exactly as a fabricator is accustomed to writing it by hand,” Easterday adds. “We don’t require the item to be given some strange part number but, rather, accept it in industry-standard nomenclature. In keeping with the above statement, simplicity is our claim to fame in the steel software industry. Our customers are expected to be literate in fabrication-related matters rather than computer-oriented ones.”

The software comes with a materials cost database that must be updated by the fabricator.

The software is on-premise and costs $1,495 for the main system plus an additional $795 for the estimating module.

Easterday says there is no training cost because the manual is “very complete” and training videos are on the website.

Contact www.ejeindustries.com Visual EstiTrack

12080 SW Myslony St. Tualatin, OR 97062

Toll-Free: (866) 252-4628 info@albinaco.com

www.albinaco.com 28

As an ERP shop management software, Visual EstiTrack

by Henning Software not only creates estimates but also tracks and manages jobs.

Tom Zuzik Jr., vice president of sales and design with Artistic Railings in Garfield, NJ, has been using EstiTrack for shop management for nine years.

“We’ve built our materials and labor into the software,” he says. “It produces a list of our costs, then we are able to compare the estimate against the actual. It’s fabulous for tracking costs.”

The material office enters material purchased into the software, and employees in the shop scan their time on a work order sheet the software prints per job.

He’s happy with the software, but when asked about weaknesses, he says that it is not a simple system.

“For people who have never used a system, it’s not a small jump,” he added. “As with any of the larger software packages, it takes someone in the company to manage it. Someone has to do the input and the checks. The biggest thing with time and material tracking is — it’s only as good as your input.”

The software does not come with a material cost database.

O&MM Fabricator n January / February 2015

henningsoftware.com/ products/ visual-estitrack/overview

WinEst Pro

WinEst Pro comes with a starter construction database and will work with most other databases. It works with most accounting, scheduling/ project management, and CAD softwares. The user can build a template of standard questions that go with every estimate (Travel time? Overhead? Machine rental?) and use it as a checklist.

Robert Aquilera, drafting manager at JSR Incorporated in Schertz, TX,

January / February 2015 n O&MM Fabricator

Structural Material Manager

says the company uses it and an existing spreadsheet to create estimates.

They input raw materials to the company spreadsheet, which they adjust on a per-job basis, to get prices by pound or foot, then add that information to WinEst to calculate the labor. WinEst can track materials as well.

“We plug in our numbers and it builds our percentages” to create the final estimate, he says.

He added that the company’s owner uses it to review costs.

“WinEst sells the RS Means Construction Cost Data in a WinEst database format,” says Steve Watt, segment manager for the General Contractor/Construction Manager Division of Trimble Buildings.

(WinEst was recently acquired by Trimble.) “A customer can choose to subscribe to annual price updates, which would include updated material prices.”

The first user license starts at $3,500. Training is in addition and can be done on-line for $1,000.

Contact http://buildings.trimble. com/products/winest

For your information

n

Billie Henning, vice president with Henning Software, says the software is an on-premise purchase. It will download to QuickBooks or a customer can buy the Visual Books accounting system. Time spent on the job can be tracked with bar code scanners in the shop or a smartphone.

The first user license starts at $3,000.

Contact www.

About the author Linda Erbele, an Atlanta-based writer with 15 years of journalism experience, specializes in business and travel writing.

29

Shop Talk

■

30

N E G F F

You can find bending tips in a variety of places, including the NOMMA ListServ.

But when O&MM Fabricator wanted to find a few, we spoke directly to the fabricators.

Here’s a baker’s dozen of ideas.

S

O

n e t BRI

By Jeff Fogel

Chapala Iron Company’s homemade scroll bender receives multiple custom dies and is adjustable for larger scrolls. It was built based on information gleaned from O&MM Fabricator articles. See Tip 13.

In the world of bending, two types of people do this work: Those who bend for fabricators and those fabricators who bend for themselves. So to speak.

Whereas the first category may not be willing to share what is essentially their trade secrets, the second group has no such restrictions.

Because bending is part of so many fabrication jobs, one thing is for sure: Fabricators have plenty of experience and are just fine with sharing it.

Read on for 13 ideas.

O&MM Fabricator n January / February 2015

1 Bend first,

tages of being a fabricator. You can make your own dies.

For instance, Eugene Evans of Eugene L. Evans Mfg. Co., Anniston, AL, was working with a Bentec that came with a wedge for 90-degree bends. He wanted something softer for a 12-inch bend on a 6-foot set of steps.

He yanked out the wedge and replaced it with a blunter U-shaped die.

Once you make a new die, hang on to it.

Chances are you’ll use it for another job.

cut later

Cutting the right length can be a Sisyphean task owing to the material nature of a bend.

The outside of the bend has a tendency to stretch while the inside of the bend is compressed. This results in a distortion of the overall length of the piece.

Worse, it’s not always uniform so the bend can wind up somewhere other than you planned.

Absent software, you Bending cap rail. Eugene L. Evans Mfg. Co. replaced this bender’s original have to calculate to allow wedge shaped die for sharp 90° bends with a home-made bullnose die for the for the distortion of the continuous long curves you’d normally need a rolling machine for. Note the marks on the cap rail for 1-inch increments. See Tip 3. bend. This might involve math you’ve either forLet software do it for you gotten or have been scrupulously avoiding since To create drawings high school. and figure lengths for Here is a simple and bending, good softeffective solution from ware can help. For Bill Mike Stylski of Accent Bendinelli of BenFab Ornamental Iron & PowInc., Lansdowne, PA, der Coating Co., CamFabCAD is his go-to bridge, MN: program. It’s essentially Start with stock that is AutoCAD modified for longer than your drawmetal fabrication.

Remember the sticky ing calls for. Let’s say you problem of bends changneed a piece that is 24 ing the length of your inches with a bend dead piece? That’s where center at 12 inches. Use FabCAD shines. Rather a stock piece that is 28 Heating the bend with a torch. Oxygen and acetylene provide motivation to give this cap rail a nice 12-inch outward flair at its end. than resort to math, inches, or so. or just wing it with a Mark the center of guesstimate of the length, the software your bend at 14 inches. After your bend a crescent wrench welded to the end of a length of pipe provides the necessary measures along the centerline of the is finished, simply cut off the ends 12 incentive for the bend to keep itself on bend and automatically calculates and inches from the center of the bend. the straight and narrow. accommodates the amount of stretch Keep it on the level This involves a second pair of hands and compression in the bend.

Warping is another unintended and applying counter pressure to the errant You simply set the software for the unwanted consequence of bending a movement as determined by vigilant radius of the bend, the diameter of piece of steel. Sometimes, a bend can checks with the torpedo level. the stock, and the length. Voilà, a fintake off in a direction of its own, outished drawing that is dead on accurate side the plane of the bend. Stylski has a Fabricate your own dies for length. simple fix for this problem as well.

A number of reasonably priced A basic program that might serve Check your work with a torpedo bending machines are ready for purmany of your bending needs costs level to make sure it’s staying in the chase. But, at the lower end of the about $1,800. same horizontal (most bending is done price spectrum don’t expect them to be Mark O’Malley of O’Malley Welding & Fabricating, Yorkville, IL, is also big on the horizontal dimension) plane infinitely adjustable or awash with dies on software. you’re working in. for every occasion.

“Using a bender without software If it starts to have a mind of its own, No problem. That’s one of the advan-

4

2

3

January / February 2015 n O&MM Fabricator

31

is like buying a Cadillac Sytlski’s method is without air conditionto under bend, bring it ing,” says O’Malley. close to where you want He uses software to it, then bend it just a hair create drawings and temmore. plates for rail shapes and In bending, patience practically anything else is a virtue. that involves a bend.

“The software,” he Math saves drawing time says, “gives you three basic advantages. You If you don’t have can use it to determine calculating software or the required length the don’t care to guess, you pipe blank needs to be. might want to brush You can use it for the up on your math. Basic layout where each of the algebra, geometry, and bends stop and start; and trig will get you through it lets you determine the The making of a pattern. James Gunnell of Antietam Iron Works LLC, any calculation you’re angle and orientation likely to need for a bendMcConnellsburg, PA suggests marking off at one inch increments with an of each bend. It lets you arrow at the one that lines up with the starting point on the die. See Tip 5. ing problem. do these things quickly Bill Bendinelli and accurately, so your unabashedly likes math. waste from guessing and He even uses Exel to reworking is eliminated. make his own spread“The software even sheets. “I calculate the prompts you with warnlength and bend lines, ings when the input using good old fashassembly won’t work ioned math and make up with the machine you’re a spreadsheet.”

This approach may using. You don’t need any not be practical for mulreal experience to use tiple bends, but it works the software either, so it like gangbusters for a job opens the bending operwith many repetitions of ations up to a lot more one or two bends. shop employees,” he says.

“It cuts out lot of It means you can give drawing time,” attests the job to someone in Bendinelli. the shop with less expeSo, he simply bends one piece at 90 rience, and it shortens the bending and then uses another scrap piece to Watch videos learning curve. form a 180.

The fact is, it’s astonishing how Inch up on it The patterns are saved; he figures much technical know-how can be James Gunnell of Antietam Iron he’s been referencing these same patfound on YouTube.

Works LLC, McConnellsburg, PA, has terns for years now and always has at A little known fact of modern medan interesting method for figuring out his fingertips the amount of pipe used icine is that even surgeons are learning how much pipe is used up in a bend up in the bend, how much space the new techniques from videos. So why without software or math. bend will take up, and how much extra not fabricators?

First, he takes a scrap of whatever length is needed after the bend.

Why not, indeed, says Eugene diameter pipe he’s using in his layout, Evans. He discovered a new bending and marks lines in 1-inch increments Don’t overdo it machine that has great versatility. before setting it up in his pipe bender.

A common bending faux pas is “I was doing some research online Next, he lines up one mark on the overbending, Mike Stylski says. recently and discovered a YouTube pattern with the starting point marked Once a piece is overbent, the tenvideo on this small, portable bender. It on the die. A note here: Make sure dency is to try to pull it back into was simple, really, and could be used you’ve made a mark or arrow at this shape. This causes more problems. on site or in the shop. increment on the pattern so you can “Pulling back will damage the “It had two stops and a hydraulic remember which line you used. piece,” Stylski says, “then you’ll have to jack exactly like you’d use to change a His most commonly used bends for go back and reconfigure your set up on tire on your car. It did short bends — railings are 90 degrees and 180 degrees. the machine.” about two or three inches at a time, and

7

8

5

6

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O&MM Fabricator n January / February 2015

it was only about $500,” Evans says.

YouTube. It’s not just for cats anymore.

9 Turn on the coals

If you have a recalcitrant piece of pipe that no amount of muscle will move, you probably need a bigger bender.

A cheaper solution is to heat the material. For a short, sharper bend, a propane torch will work just fine. But for lengthier bends, you’re going to have to go to a forge.

John McLellan of McLellan Blacksmithing, Loomis, CA, says that gas forges favor a longer bend while coal is fine for medium-length bends.

“I take it to about 1,650 degrees, about orange, so it’s just workable,” explains McLellan. “For a slighter bend, I can go with red.”

Diameter plays a role here, as well. “For ¼-inch (stock), you can go to red or even cold bend it. But for stuff like 1½ inches you’d need to go to yellow.”

Heating the piece also tames warping, or bending out of the plane, notes McLellan. “If you heat it, it pretty much stays flat.”

And if it doesn’t, he just lays it flat on a table, and taps the still malleable piece flat with a hammer.

10 Make a magic mandrel

When we talk about heating for bending, we’re referring strictly to solid pieces. Try it with a hollow piece and it can collapse. That’s why you generally bend a hollow pipe cold.

Of course, you can always heat hollow pipe to bend it if you’re using a mandrel. But benders with mandrels are strictly on the high end of the price spectrum.

Here’s a trick John McLellan uses to fashion his own mandrel: First, he welds a cap on one end of the hollow pipe.

Then he starts filling it with sand. The trick is to pack it in very tightly. Use dry sand; any moisture in the sand will quickly translate to steam when the piece is heated. Steam translates to pressure inside the pipe, and well, you can see where that’s going. Make sure the sand is absolutely Saharan.

Once the pipe is packed with sand, just weld a cap on the other end of the pipe.

You now have a hollow pipe that can be heated just like a solid piece, making the bending a lot easier.

11 Buy pipe by the bundle

Springback. No, it’s not a South African rugby team; it’s bending’s propensity for deflection. It’s simply when the piece you’ve just bent returns toward its original shape.

Obviously, the bend won’t flatten out entirely, but it will move back a few degrees out of its desired shape.

While some of the higher-end benders have a computer that calculates expected springback and tells you how much to overbend, you can deal with this problem in other ways.

McLellan’s method is to avoid it entirely, which can be done by heating the bend. But if you’re cold bending, McLellan says it’s a matter of trial and error.

“There’s no mathematical formula for figuring springback,” says McLellan. You have the estimate, allow for it, and then overbend by the estimated amount.

January / February 2015 n O&MM Fabricator

33

A good way to make your estimates more accurate is to try a few practice bends on a similar piece of stock.

Bruce Berg of Outland Steel Inc., Caldwell, ID, says the key to managing springback is to have all your steel from a similar batch.

“Steel properties change slightly from bundle to bundle,” Berg says, “so I try to buy by the bundle so all the steel (pipe) is from the same rolling. I’ll just save the rest for another job.”

When bending a repeat pattern, the seam should be

in the same place for each bend.

It matters little where the seam is in the first bend, as long as it’s in the same position for all the others.

Bruce Berg

Outland Steel Inc. Caldwell, ID

12 Seams right

installation sites to straighten railings.

Another NOMMA-sourced idea was about using an old homebuilt scrolling machine in the shop.

Designed to accept a variety of dies, the scroller is adjustable for larger diameter scrolls.

A hefty 3-inch pipe provides the leverage to muscle up to 2-inch solid iron rounds or squares.

Although he has two store-bought benders in the shop, Davis says the two home-builts still see service everyday.

Berg also advises to be conscious of the same place for each bend. It mat12/19/07 9:44 AM Page 1 where the seam is in your bend. ters little where the seam is in the first Pipe begins its life as a flat sheet of bend, as long as it’s in the same posisteel. It’s rolled up, and the two edges tion for all the others. Be aware of the are attached by a resistance weld at seam when setting up the pipe.

About the author the factory.

Jeff Fogel began writing as It’s the welding process, however, Read O&MM Fabricator a journalist with the New that gives the seam different properties Paul Davis of Chapala Iron ComYork Daily News. He has than the rest of the pipe when being pany, Ventura CA, says his company been a copywriter and bent. The heat from the weld actually built its own portable bender from associate creative director for advertising agency Ogilgives it a slight degree of temper — information gleaned from O&MM vy & Mather. Jeff now lives even on mild steel — and this makes it Fabricator articles. in New Hampshire where the weather’s a little more resistant to bending.

A rudimentary machine, it was origbad, the skiing’s better, and blacksmithThus, Berg says that when bending inally used to create templates. Nowaing’s a respectable way to keep warm.

PROOF - 45-3454-ACF-121807-V2 a repeat pattern, the seam should be inAD days, it’s usually pressed into service at

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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

Education sessions

Page B Pages C–D

NOMMA METALfab2015 Guide

Sponsors, Hotel information Pages E–F

Registration form Pages G–H A C

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 1 1:15 am–12:30 pm Lunch Break Lunch on your own 1 2:30 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 1 0:00 am–2:00 pm Spouse Classes 2 classes for attendees with a spouse registration 1 2:30 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 1 0:00 am–1:00 pm Exhibits Open Another chance to visit exhibitors and vote in Top Job contest 1 0:30 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 D B

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.

NOMMA METALfab2015 Guide

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 E

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.

F 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 its 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. Dis­ cussion 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 par­ ticipant 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 NOMMA METALfab2015 Guide

Keynote Barry Willingham Ameristar Perimeter Security USA

Using Adversity and Challenges as an Opportunity for Positive Change 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.

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 1/13/2015 Platinum Silver Contributor Industrial Coverage Corp.

Lawler Foundry Corp.

Sculpt Nouveau

Silver M.Cohen & Sons Inc./The Iron Shop

Exhibitors as of 1/13/2015 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 Compass Software GmbH . . . . . . . . . . . . . . . . . . . . www.compass-software.de 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 ETemplate Systems . . . . . . . . . . . . . . . . . . . . . . . . . . www.etemplatesystem.com Feeney Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.feeneyinc.com Hartford Standard Company Inc. . . . . . . . . . . . . . . . www.hartfordstandard.com Industrial Coverage Corp. . . . . . . . . . . . . . . . . . . . . www.industrialcoverage.com Jerith Mfg. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.jerith.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 Nationwide Industries . . . . . . . . . . . . . . . . . . . . . . . www.nationwideindustries.com NOMMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.nomma.org NOMMA Chapters . . . . . . . . . . . . . . . . . . . . . . . . . . www.nomma.org NOMMA Education Foundation . . . . . . . . . . . . . . . . www.nomma.org/nef Regency Railings Inc. . . . . . . . . . . . . . . . . . . . . . . . . www.regencyrailings.com Sculpt Nouveau . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.sculptnouveau.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

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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 Regular Fee

9/1/14–2/19/15 2/20/15–3/4/15 ❑ Full Conference — NOMMA Member $450 $580 Education Program/Opening Session/Exhibits/Thursday Party with a Purpose & NEF Auctions/NEF Reception/Shop Tours/Awards Banquet ❑ 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

G

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

✂

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 ❑ Below $1 million ❑ Fabricator ❑ $1–$2.5 million ❑ General Supplier ❑ $2.5–$5 million ❑ Contractor ❑ Over $5 million ❑ Other_____________________

3) Your role in purchasing 4) Job description ❑ Final Say ❑ Owner ❑ Recommend ❑ Manager/Foreman ❑ Specify ❑ 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: Questions?

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

H

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

✂

Knowledge to enlighten the industry METALfab2015

M. Cohen & Sons shop tour M. Cohen & Sons Inc. and The Iron Shop of Broomall, PA have been named a tour stop for our Saturday, March 14 shop tours.

This fourth generation NOMMA member has more than 200 employees and a 130,000-square-foot facility with state-of-the-art technology.

During the tour, a series of mini-demos will be presented, including one on Samuel Yellin and his work.

M. Cohen is known for its quality ornamental work; they regularly win awards in the NOMMA Top Job Contest.

Exploring Valley Forge and Montgomery County, PA While in King of Prussia for METALfab2015, be sure to schedule in extra time to explore the area. 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. You’ll see the Muhlenberg Brigade, an historic camp, the National Memorial Arch, Washington Memorial Chapel, and the von Steuben Monument. 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. 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 a zip in the park.

You’ll actually ride on a course of zip lines, including one that’s 340 feet (you are requested to scream). Speeds 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.

Boyertown Museum of Historic Vehicles.

January / February 2015 n O&MM Fabricator

In 2010, The Iron Shop and M. Cohen hosted the Northeast Chapter for a meeting and tour. 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.

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. You’ll see some 100,000 collectibles, including props, posters, magazines, toys, and personal items.

Chanticleer gardens, left; downtown Pottstown.

43

KNOWLEDGE to enlighten the industry.

METALfab 2015

MARCH 11 – 14

Valley Forge Casino Resort, King of Prussia, Pennsylvania

Come Join Us‌

at the beautiful Valley Forge Casino Resort in Pennsylvania for the NOMMA Event of the Year! Meet and interact with the best and brightest in the ornamental and miscellaneous metalworking industry. Network at the social events, shop tours and see the Top Job Awards. Get the latest trends and technologies firsthand by attending the Education Sessions.

Learn about hundreds of the best products and resources available that you can touch, explore and evaluate at the Exhibits.

Visit www.nomma.org Today to register for the METALfab 2015 Convention Exhibit ONLY Registration is FREE!

Join NOMMA Today and Save $100* off your Membership Plus receive discounted registration for METALfab 2015!

Visit us online at www.nomma.org and enter promo code: DM2-2014 First time members, offer expires March 1, 2015

*

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

2014 Top Job Gold Award: Non-forged, exterior railing and fence

Making stainless look lıke forged steel n

Stainless steel is harder to bend and more finicky to weld. Falling Hammer Productions took extra care during design and fabrication of this Top Job gold-winning railing.

By Peter T. Swarz-Burt About 10 years ago, we took on a challenging

interior railing project that involved ovals that were overlapped, offset, collared, and riveted.

Although this project has generated a lot of interest on our website since, it never led to using the design in another project. The design meant such a project would be time intensive, and thus, more expensive.

What was different in the case of our 2014 Top Job gold award project (a non-forged, exterior railing and fence) was that the customer wanted an exterior rather than interior railing.

This allowed us to discuss changes to our original design that would make it more suitable for outdoor use in New England.

Corrosion issues lead to design change

The 125-foot, 304 stainless steel railing was for a large, private residence that was under construction in one of the Boston suburbs, and as is often January / February 2015 n O&MM Fabricator

the case, we worked with both the contractor and the homeowner at every step. Both of them liked the original oval design, but they were rightfully concerned about corrosion issues: the appearance of the railings themselves and the “bleeding” that would occur onto the expensive imported granite that the rail would be mounted into.

Early in the discussion, I suggested that we go with painted stainless steel because this would provide the same look as painted steel and would hold up better to weather.

To improve the corrosion resistance more, I suggested that we remove the rivets because these would create pockets where moisture could linger; crevice corrosion is an issue with stainless, and I did not want to create an ideal environment for it.

Balancing design with price. Although seemingly interested in the concept, the customer was not pleased with the higher price tag that stainless brought to the table. I then suggested a few more changes to simplify the fabrication without changing the basic appearance.

The original oval railing design, left, and the new version, right.

Falling Hammer Productions simplified the original rail to meet the customer’s needs.

45

The most important change was to switch from overlapped, offset ovals to a two-layer approach in which one layer of ovals simply laid in front of the other, offset by the width of half an oval (see photos, page 45) This created the same silhouette as the original design but was much easier to create.

Another change was to weld the “pegs” in place rather than have them wrap around as they did in the original.

In the end, these simplifications brought the price for the stainless design in line with the price of the original, forged-steel design, which was enough to seal the deal.

Weather, masonry affect field measuring

The primary characteristic of the project was three arcs that defined the perimeter of a stone terrace. Measuring the arcs was complicated by temperatures in the low 30s, which not only made the measuring uncomfortable, but also meant that the masons had set up makeshift tents over portions of the terrace.

The masons also had equipment and materials scattered around the terrace, and this made striking straight lines a challenge.

Additionally, the capstones that we would be mounting to were placed on some areas and not in others, leaving us to “guestimate” where the remainder of the cap stones would be placed.

During our conversation with the head mason, it became obvious that we were dealing with a fluid situation since the wall foundation had been set incorrectly and the mason was correcting the curve as he placed the cap stones.

Because of this we needed to be certain that we allowed extra time for on-site alterations during installation.

To account for this, we left one panel on each run of railing over-long, so that we could trim it on-site to fit the final stonework perfectly.

Templates not needed. For the measurements, we used a Bosch laser level and a long tape measure. Since all of the sections were simple arcs rather than irregular curves, we worked entirely from measurements; we did not need to take templates because the 46

Top, the main terrace was constructed in multiple panels and welded on-site. The project included two balconies, above, that were installed using a lift borrowed from the general contractor.

Bottom drawing, an illustration of how to measure a uniform radius.

arcs could be mathematically derived at our shop.

We measured the distance across the arc, then found the center point and measured the “height” of the arc at that point using the laser level as the straight line across the arc. The drawing above shows the method of measurement and the layout of the terrace. We took the same measurements for all

of the arcs, then simple tape measurements for all of the straight areas.

Where we could, we used a Bosch digital protractor to establish whether the corners were truly 90° angles, and if not, we noted the actual angle measurements. At those areas where we were interacting with the exterior walls of the house, we used the digital protractor to determine if the walls were actually vertical or had a slight lean in or out.

At the shop, we created digital versions of the different areas using TurboCAD (See drawing, page 47), a program less powerful, but cheaper than AutoCAD or FabCAD. Then it was relatively quick work to lay out the railing centered on the cap. This was then broken down into panels that could fit on our 16-foot welding table, with various details for each panel spelled out on its own sheet of paper.

Fabrication begins

Meanwhile, two other aspects of the project were working.

O&MM Fabricator n January / February 2015

1 Modifying a hydraulic log splitter made by Ramsplitter into a hydrau-

lic forming table (see photos below).

The modification was the addition of attachment points for the forming dies, which were designed in TurboCAD and water-jet cut from ž-inch mild steel plate at our normal steel supplier, Chapin & Bangs, Bridgeport, CT (see drawing, photos, this page).

We added some simple rollers to the basic form of the dies so that the stainless bars would feed nicely, but otherwise the dies were essentially ready to use as-delivered.

2 Annealing the stainless steel so it could be easily and consistently press-formed into the halfovals. To accomplish this, a stackable

electric Econo Kiln with an AutoFire digital controller allowed us to program a ramp-up to 1,500° F and hold there for as long as necessary, which meant we could anneal up 100 cut-to-length pieces at a time.

Annealing the stainless bars had two effects: 1 To make them soft enough to bend and stay bent.

2 To burn the layer of oil that stainless is always shipped with. We have found that burning off is by far the best method of degreasing bar stock that will later be painted because most other methods tend to leave, at least, some residue.

One great thing about having the digital controller for the kiln was the ability to set the program and walk away. In most cases, we unload one batch of stainless steel, load another, and then press the annealed pieces with our new forming table while the kiln annealed another batch.

With so many pieces in the kiln at one time, it generally was not until the following day that the pieces were cool enough to unload. But that was OK; we had plenty of other work.

Once the pieces were annealed and pressed, they still needed a little final shaping by hand to achieve a pleasing parabolic shape. The center of the parabola shaped quite nicely, but the ends needed to be curved and adjusted cold with hammer and anvil (see photos, page 48).

Once each piece was matched up to a master, two pieces were trimmed and January / February 2015 n O&MM Fabricator

TurboCAD drawing of the ovals, left, at top, centered on the cap rail.

To make the forming dies, the design created in TurboCAD, left, below, was sent to a steel supplier for water-jet cutting.

TIG-welded together with a Miller Syncrowave 200 to form a complete oval (see photo, top right, page 46).

Welding jig make process easier. We also attached the two stain-

Holes, diamter 0.625�

Cutout 3 x 8.125"

Left, outside dimension 12 x 17" Right, outside dimension 6 x 15.5"

less steel pegs that connected the ovals to the stringers. To simplify the process, we created a welding jig on one of our spare tables. While one person tacked the oval parts together in the welding jig, a second person used another TIG welder on a separate welding table to finalize all of the welded joints. Welding on electrically separate tables keeps electricity from traveling to the wrong grounding clamp.

Curved panels assembled. After grinding all of the welds flush, we assembled the panels. The majority of the panels were curved, but the curves were so slight that it was much easier to create them on the anvil than by using our Eagle Bending Machines pyramid roll. The necessary radius was laid out on the table and matching top and bottom stringers were created.

For curved panels, we always build with the panel standing upright and upsidedown (see photos, page 48) and in this case, we tacked in temporary posts since the oval design was to be unbroken except at corners.

We started by welding in the inside layer of ovals across the full width of the panel, then welded in the outside layer of ovals. After the fabrication of the ovals, the finished width had some variation. We organized the ovals by width since we knew that the ovals in the outside layer would need to be slightly larger than those in the inside layer.

Backing tool had multiple uses.

A modified log-splitter, top photo, served as a hydraulic press to mass produce the half-ovals.

Custom dies, photo above, were used to press the half-ovals efficiently after being modified with rollers and attachment points.

Once all of the ovals were welded into each panel, the ovals themselves were welded at the point of contact. This weld was then covered with forged collars that we tacked in place and then hammered closed while cold. A special backing tool we made supported the collars during this process; the panels 47

Stacks of half ovals, top left, ready for welding.

After being welded together, tabs were added to the tops and bottoms, top right.

welded closed both ends of all posts. In cases where hollow products are used, one must consider what would happen if water gets inside. Rusting from the inside out at ground level is the most common way for railings to fail.

The most extreme case we have seen involved a 11/4 x 1/4-inch wall post that had been capped at the bottom and not at the top. Water built up in the tube, and when it froze in the winter, it not only expanded and exploded the pipe, but it also blew the corner right out of the homeowner’s step. Known for its quality work, the company that installed this railing repaired it and the step at its expense; the cost to their reputation was hard to quantify.

For curved panels, Falling Hammer always builds with the panel standing upright and upside-down, above. In this case, the company tacked in temporary posts because the oval design was to be unbroken except at corners.

The rolling dies, right, used to turn stainless flat-stock into curved cap rail.

needed to remain upright throughout the setting of the collars. The same tool was later used on the job site when we needed to join panels together.

The cap rail was perhaps the most complicated aspect, and one which we initially expected to be straightforward.

The original proposal called for purchasing a stainless cap on the market, but this proved to be far more costly for the client. We decided to chance making our own cap rail from bar stock.

Making a rolling mill. The client did not want a hammer-beveled design, instead something with a nice radius across the top. We then built a rolling mill that was capable of cold rolling 3/8 x 21/2-inch stainless 304 from flat 48

bar into bar with a 4-inch radius (see photo directly above). After adjusting the resulting bars with table-mounted forks, they were curved to match the panels using new dies on the modified log splitter.

A different solution on our more recent stainless railings has been to use aluminum cap rail in the same fashion that we do with bronze cap rail; the variety of available cap profiles is much better than for stainless.

Closed the ends of tubing posts.

One particular note is that we typically only use solid material for our posts, but given the expense of stainless steel, we used tubing posts instead. To avoid issues with water and ice build-up, we

Finishing with easy-to-find, water-based product

All parts were painted with Rusto­ leum Professional water-based exterior acrylic enamel before installation. We’ve been using this line for several years after trying a variety of products.

However, our two main considera­ tions for using this product were: 1 It is water-based and thus easy to spray at the shop and easy to clean up at the job site.

2 It is an over-the-counter product.

The customer can easily find touch-up spray cans that match the paint well.

Included as part of our installation fee is a second visit to do a final round of touch-up painting any time in the first year after the railings are installed.

O&MM Fabricator n January / February 2015

A bit of simple chisel-work detail on these bolts help give a railing a “custom” feel.

grade with the cement; this system makes use of the superior strength and fast cure time of the Rockite, while the cement cap can be shaped with a wet sponge to ensure that water drains away from the base of the post.

Drilling granite was difficult.

before fabrication. However, we had some trouble with paint peeling on these parts indicating that a residue remained.

Additional degreasing and repainting on site was not fun. As a result, we now degrease all oily parts with heat, except in cases where this would be impossible or detrimental to other qualities of the material.

Installation was frustrating

For installation, we used a wet diamond core drill to make 2-inch diameter x 4-inch-deep holes and then secured the panels in place with Rockite capped with Quikrete fast-drying cement.

We always pour the Rockite to just below grade and then fill just above

Tips If stainless is annealed at about 1500° F, it can readily be bent cold. The strange heat-conduction properties of the material means it is often easier to get an even bend when it is cold rather than hot.

When welding stainless steel, the joint will always pull due to expansion and contraction of the material during heating and cooling. This movement during fabrication must be controlled.

Sometimes the easiest solution to a welded joint pulled out of alignment is to simply weld the other side and see if it pulls back in line.

When trying to account for weld-pull, think of the weld as shrinking. Look at the fixed points (other welds, points of contact, tack welds) and imagine what will happen when you weld in a particular location.

When fabricating with stainless steel, getting an entire panel “tacked” together on one side, then flipping it over, re-clamping, and welding the other side solidly is generally best. This provides the most structure before welding and helps minimize overall distortion in the panel.

January / February 2015 n O&MM Fabricator

For your information

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We generally suggest that customers have us come back after the first winter because in the Northeast this is by far the most trying time for the paint. This service helps keep our customers happy, but it also allows us a chance to see if our processes have any weaknesses that we need to fix for future work.

Oily residue issues. Probably the most frustrating aspect of this project was the level of oily residue on all of the stainless bar stock when it came to us from our supplier.

Much of the material was annealed or heated for one reason or another, and these were nicely degreased. All of the parts that did not get heated were degreased chemically with Simple Green

The stone that we mounted into was custom-cut granite from China, which was remarkably hard to drill through. It was not the hardest stone that we have faced, but drilling 20 holes made it frustrating. The low wall that the granite capped also had some voids inside that needed to be filled with Quikrete before we could mount the railings.

The final frustration was that the wall also contained periodic pieces of 1/8 x 1-inch stainless bar that the masons used to position the granite while the mortar was setting. We only hit two of these during the installation, but each one added roughly 20 minutes to the drilling time.

In the end, this was an interesting, challenging, and rewarding project. The techniques and tools that we developed for this job have been put to good use on other projects. If another customer is ever interested in this or a similar design, we’ve worked out the kinks, and the new job would be smooth sailing, which means we will probably never get another call for this design.

About the author Peter T. Swarz-Burt, one of the founding partners in 2005 of Falling Hammer Productions, LLC, Wolcott, CT, has been smithing since 1991 when he built his first forge in his parents’ backyard. He has been a full-time metalworker since 1994. Since founding the company, his main focus has been developing better techniques for making high-quality railings.

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O&MM Fabricator n January / February 2015

Biz Talk

The current face of tech school apprenticeship ■

Trade schools depend on advice from local companies to help build their programs. Here’s what Savannah Technical College has learned.

Collection of blacksmithing tools used in the Savannah Technical College programs.

Welding and historic preservation students created this mild steel decorative tree sculpture using cold bending and MIG welding.

By Steve Hartley Historic Preservation Savannah Technical College William Burns Welding and Joining Technology Savannah Technical College The fabrication world and the greater realm of trade skills need experienced workers to supplement an aging workforce.

But the rules and systems in which new workers are being trained are drastically different now than they were.

Traditional apprenticeships are virtually non-existent in many areas of the country given the costs and time needed to train apprentices within the current economic climate.

Apprenticeships still exist in some areas in the country, primarily in the Northeast and Great Lakes regions where the union system is the strongest. These apprenticeship programs are commonly oversubscribed with applicants for training spots, leaving many potentially high quality welders and fabricators outside the system.

Rapidly expanding technical colleges are working diligently to dispel the long-standing negative perception of technical education, both within industries and with the public.

January / February 2015 n O&MM Fabricator

Student cuts mild steel plate, top.

Another student, above, MIG welds a butterfly bench. Both used a Torchmate CNC plasma cutting table.

Fabrication shops are traditionally small, meaning the cost for taking on a new employee must be offset with the amount of work that the new employee can produce.

Advancements in the fabrication field also means that the new employee must balance traditional skills, such as stick, MIG, and TIG welding with new technologies such as 3D printing and CNC programming skills to contribute positively to their new employer’s business.

This article examines how local metal fabricators help shape Savannah Technical College’s Welding and Joining Program in conjunction with its Historic Preservation Program to ensure graduates are prepared for the evolving job market. We hope to demonstrate clearly how the training delivery at the college produces graduates that are highly desired especially in the regional job market.

Savannah Technical College is located in Savannah, GA. A unit of the Technical College System of Georgia, it serves a four-county region encompassing the greater Savannah area.

Within this region lies the second largest container port in the eastern United States, large manufacturing companies, two military bases, and seven historic districts comprising one of the largest collections of decorative ironwork in the U.S. Ironwork of Savannah (Writeplace Press, electronic edition, 2013) by Savannah native T.D. Conner has brought new focus on the history of ironwork in the region, and the 51

Sampling of courses offered For complete list of all courses and their descriptions: n

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Drafting: www.savannahtech.edu/academics/ all-programs/drafting/ Historic Preservation: www.savannahtech.edu/ academics/all-programs/historic-preservation/ Welding & Joining: www.savannahtech.edu/academics/ all-programs/welding-joining-technology/

Foundations of Mathematics

Technical Drawing (5 courses) Engineering Graphics Blueprint Reading-Tech Drawing (3 courses)

Introduction to Welding Technology Flat Shielded Metal Arc Welding Horizontal Shld Metal Arc Welding Vertical Shield Metal Arc Welding Overhead Shield Metal Arc Welding Gas Metal Arc Welding Gas Tungsten Arc Welding Oxyacetylene Welding Advanced Gas Tungsten Arc Welding Fabrication Processes Pipe Welding Flux Cored Arc Welding Metal Welding/Cutting Tech Oxyfuel Cutting Plasma Cutting

catalog of work created by companies like the Kehoe Ironworks, founded in Savannah in 1830, can be found throughout the southeast.

Savannah Technical College currently has five campuses with an enrollment of roughly 4,500 students.

200 welding students a year

One of the fastest growing programs at Savannah Technical College, the Welding Department is associated with The American Welding Society (AWS) SENSE (School Excelling through National Skills Standards Education) program boasting a full day-and-night program at the main campus in Savannah, as well as night programs in two satellite campuses and high school dual 52

Advanced Material Sciences/Metals in a preservation setting including history of the medium, project characteristics and properties of metal, layout, material and cut list, metal failure, metal stabilization, as well as cleaning, repair, and replication.

Advanced Preservation Skills, including advanced blacksmithing, advanced mold making and casting, decorative ironwork, material replication, as well as project managing and estimating.

CAD Fundamentals

Blueprint Reading-Welding Tech

Ornamental Iron Works emphasizes safety practices for equipment and ornamental ironwork techniques. Includes use of scroll machine and bar twister.

Field Techniques/Documentation, including field measurement, photography, photogammetry, and surveys Print Reading for Architecture emphasizes skills in reading, producing and interpreting construction drawings.

Topics include reading and measuring plans, identifying and understanding lines, symbols, dimensions, materials, schedules, and specifications.

Manual Drafting Fundamentals emphasizes the essential techniques of basic manual drafting. It introduces drafting tools and equipment, scale and measurement, line relationships and lettering, and geometric construction concepts.

Architectural Fundamentals introduces architectural fundamental principles and practices associated with architectural styles and drawing. Fundamentals residential and commercial practices will be covered. Topics include: specifications and materials; architectural styles, construction drawing practices and procedures, dimensioning and scales.

Architectural 3D Modeling covers concepts of the software related to Parametric modeling for Architectural drafting. The student will develop the skills necessary to create 3D models and presentation/constructions drawings.

Advanced 3D Modeling Mechanical covers concepts of the software related to Sheet Metal modeling

enrollment programs with local school districts.

Being listed as a SENSE school, the program adheres to AWS standards, primarily structural welding code D1.1.

Students can take classes in shielded metal arc welding, gas metal arc welding, flux cored arc welding, and gas tungsten arc welding, passing proficiency tests in flat, horizontal, vertical, and overhead applications.

The students are also required to study basic blueprint reading, focusing on AWS welding symbols.

The program is above capacity, currently training 200 welders per year, with a waiting list of 50 every year.

Placement rates are high with 97.2% of jobseekers finding employment within

six months, and many of the graduates work within the growing welding and fabrication industry in the region.

Larger employers such as JCB (manufacturers of equipment for the agriculture, construction, industrial and waste/recycling markets) and the Port of Savannah hire many of the graduates, while others work for specialized companies such as CST Coverings (design, manufacture and construction of custom aluminum covers and structures for architectural, environmental and industrial applications) and local fabricator shops such as Dixie Machine & Fabrication and Savannah Mobility Concepts (wheelchair accessible vans).

Growth in ornamental shops.

While many of the students work in O&MM Fabricator n January / February 2015

the industrial sector, a growing number, roughly 25% are finding employment in ornamental and fabrication companies, and these are some of the most highly desirable placements after graduation.

Other equipment used. The program has state-of-the-art labs with welding machines, CNC plasma tables, track torch cutting tables, as well as scrolling and decorative metals equipment.

The program is currently exploring the use of virtual welding machines to supplement traditional training.

A full drafting program and lab, equipped with AutoCAD, Revit, and CATIA programs, plotters, and 3D printers also are used.

Savannah as a metal preservation lab

The department was founded in 2006 in response to local industry desires to have a construction and craft workforce trained in traditional building arts to repair and replicate historic architectural elements.

The program is a generalist curriculum, where students learn a variety of trades including blacksmithing and ornamental metals fabrication, specifically fencing, gates, and window grilles.

Students enrolled in the historic preservation program also study flat and ornamental plaster, masonry, stained glass, decorative finishes, and carpentry trades, while taking classes in architectural history, structural theory, and pathology, as well as material sciences.

This desire to replicate Savannah’s history is reflected in the desire for new housing communities and businesses to embellish their properties with ornamental metalwork, sometimes hundreds of pieces at a time.

Testing ABANA curriculum. Currently, the school is experimenting with portions of the new ABANA curriculum for blacksmithing education, and it is considering adapting the entire program once the experimentation is completed.

The Savannah Tech program has gained international fame, making products for many regional and national organizations, including replicating 32 cast iron finials for the Smithsonian Arts and Industries Building restoration project in Washington, DC, during in the spring of 2012.

January / February 2015 n O&MM Fabricator

Student sets mild steel fence pieces in a jig to prepare for welding.

The Drafting Department is an integral part of the collaborative projects performed by the school. Here, the department’s MakerBot 3D printer creates a model for future use.

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The historic preservation and welding programs share a close relationship, with many students enrolling for classes in both courses to further enhance their career prospects.

Currently, the Historic Preservation department enjoys a 100% placement rate for graduates, with 90% of students finding employment by the end of the first year of the two-year program.

About 25% of these graduates are employed in the fabrication and repair of decorative metal components and commercial and residential structures.

Both programs have experienced success through the formation and active participation of their individual external advisory boards.

Industry advisory boards

As required by Technical College System of Georgia guidelines, each department must maintain an exter-

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nal advisory board of industry partners to ensure that the training delivered by the program meets the needs of the local economy and to keep departments abreast of upcoming changes within industry. Boards meet twice a year at the school. Informally, advisory boards assist departments in the placement of their students, material donations, and upcoming plans for their businesses.

Board members are expected to attend meetings and offer constructive criticism and guidance on the direction of the program. Within each board also sits an Executive Board that serves as representation in greater divisional or school-wide advisory meetings. Companies of any size are welcome to join, provided they can assist the department.

The welding board. Companies on the welding advisory board reflect the larger welding field within the region.

Some, such as JCB, represent large

manufacturing firms. Small companies, such as Thunderbolt Marina that repair and fabricate specialized equipment and railings for luxury yachts, are also active members of the board. On a national level, unions, such as the Ironworkers and Pipefitters also have representatives on the board.

The preservation board. The Historic Preservation board consists of public entities, including the National Park Service, and private restoration firms, such as J.T. Turner Construction and Tidewater Preservation. While none of these companies focus specifically in metal fabrication, many are employed in fabrication work throughout the region and some, including The Coastal Heritage Society have dedicated fabrication teams within their employee structure.

For their dedication, advisory board members enjoy an inside look at the next generation of welders and fabricators being trained, and a growing number of board members develop welding and fabrication tests that are geared specifically to their business.

Several companies give welding tests to students during class, saving them time finding the right fit for their firm.

These collaborative partnerships allow the schools to better educate their students and reduce cost for employers through less in-house training time.

Benefits of collaboration. Working with advisory boards can sometimes have unexpected dividends. At this writing, the two programs are engaged in a project to replicate a fence and gates for the historic Liberty County Jail. The Jail, constructed in 1892 and on the National Register of Historic Places, now houses a museum as well as the Hinesville Downtown Development Authority. Working with advisory board member Tidewater Preservation, and using historic documents and field measurements, students will layout, fabricate, finish, and finally install the pieces back onto the newly restored grounds.

Besides giving the students invaluable real world experience, the project will also save thousands of dollars in material costs for training and provide a valuable service for a local historic site.

O&MM Fabricator n January / February 2015

5 ways you can help get students the training they need for you?

Getting involved with a technical school or training organization can be a rewarding experience. Operational standards and guidelines vary by state.

But regardless of a school’s framework, here are ways you can help guide the training of the next generation of fabricators.

1 Contact your local community or technical college. Study the local training programs carefully and then talk to the instructors at the appropriate department. The instructors share the same love of fabrication that you do, and they should be willing to listen to you. Tell them what you as an employer expect from a new hire and how the program can adapt to those requirements.

2 Help the program connect to real-world projects. If the program doesn’t have an external advisory board, help them form one. If the program does not have an outside-of-classroom internship program, help them build one. If the program does not have real-world projects as part of classtime training, help them find some.

3 Tour the school shops. See what type of equipment they are working with. Offer advice for what they should have to bring their training facility up to industry standards. A graduate can’t operate your machine properly if they’ve never seen it before.

4 Talk to the students. Let them know the realities of the fabrication world. Tell the students about the pay scales. How do you make the work environment safe and nurturing. Do you offer continuing education? Is there room to grow? Open your shop for tours. Tim Henston says many think they can fabricate hot rods in record time. Let them know the difference between reality and television. You will see quickly which ones are still interested.

5 Volunteer. Time, money, material, expertise. Whatever you choose to do will be greatly appreciated. Schools are under considerable financial strain, given the massive influx of students and budget cuts from typical funding streams. Fabrication is a material intensive trade to learn; donations are happily accepted and often tax deductible.

Schools are tasked with training students to enter the workforce in their chosen field. This task can only be completed with the assistance of those who will employ these students after graduation. The school must listen to industry and react accordingly. Without your guidance, they cannot adequately serve those students. Industry can and should shape the training of its workforce, but industry needs to get involved.

Advantages of your involvement Direct Indirect Having direct access to training suppliers

Networking with others in your field

Meeting the next generation of fabricators

Regular meetings with suppliers

Staying abreast of major developments in the regional economy

Building a rapport with the faculty and staff

Keeping updated on changes within the field

Watching students evolve into professionals

Shaping fabrication education for the future, therefore shaping the future of the fabrication world

January / February 2015 n O&MM Fabricator

This type of collaboration addresses another issue within the educational world. Since the economic downtown, states have been forced to make difficult decisions in regards to funding.

Decreased budgets have required programs to develop new directions for education, including real-world projects such as this. These types of collaborations could not be possible without the support of our advisory boards.

Success stories

The collaboration between the two departments and their respective industry partners have borne fruit for the students in which these partnerships are meant to benefit.

Welding graduate Brian Moyo currently works at Thunderbolt Marina, working on custom railings and fittings for luxury yachts.

Brian is enrolled in the nighttime Historic Preservation Program to further his side business, producing ornamental fixtures for private individuals.

Leron Brooks, a home-schooled student entered the welding program at age 16. After taking the blacksmithing class in the Historic Preservation department, he dual enrolled in both programs.

Upon completing his coursework in the summer of 2013, he was employed as a welder and fabricator for the Coastal Heritage Society, an organization involved with the preservation of the Savannah Roundhouse Railroad Museum, the nation’s largest antebellum industrial site. Leron works with both the construction department and rail operations to fabricate fencing, window grilles, and parts for a variety of components of the Roundhouse complex.

Both students were hired directly from communication between advisory board members and faculty.

New degreed programs

Because of the strengths of the two programs’ advisory boards, within the next five years the school will offer new degrees in pipe welding, CNC fabrication, as well as forged and ornamental metal work.

These programs have been identified as areas that will require more trained workers in the near future, according to data supplied by the U.S. Department 55

of Labor as well as requests from local labor boards and industry partners.

With technology changing so rapidly, it is difficult to predict what will occur in the next few years, and the programs are relying heavily on these external boards to keep them abreast of what is desired in an employee.

With this expansion, more companies with specializations in these areas will likely be on board. These companies, which are being identified with the assistance of the advisory board members, will help shape the specific classes in which they are focused.

In his article “Where the Best Welders Go and Why: How schools and companies are fixing a broken skilled-labor pipeline,” for The Fabricator magazine (January 2014), Tim Heston says a gluttony of entry level welders exist, but those with specialized skills and experience are difficult to find. The opportunity exists to develop the skills that are in high demand while the entry-level welders are still in training. If schools, working with industry, can re-imagine how training should be delivered and partnerships can be established, all parties will benefit.

Technical colleges can offer industry a unique avenue into shaping the training of the next generation of welders and fabricators. Successful programs are based entirely on the relationship they formed with industry partners.

Savannah Technical College’s success both within the welding and historic replication fields demonstrates that collaborative partnerships between those working in the field and training organizations can form a working relationship that will benefit all involved.

A close relationship with your local training organization can help you build a rapport with the instructors, permitting the correct placement of graduates into industry partners in which they will be the best fit.

Direct and indirect results of getting involved with your local training provider are numerous (see table, page 55).

In purely financial terms, the proper cutting-edge trained students who are about to enter the field translate into less time spent on in-house training 56

Steve Hartley, Savannah Technical College’s Historic Preservation and Restoration Department Head, demonstrates blacksmithing techniques.

and a quicker return on the investment you make by hiring a new employee.

The overall fabrication field is changing dramatically, given the increased use of computerized CNC programing and the introduction of affordable 3D print­ing technology into the arena. The growing desire of customers to have custom products of high quality will also spur a growth

For your information

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Industry helps determine success

Bill Burns, Savannah Technical College’s Welding and Joining Technology Department Head, demonstrates oxyfuel beveling techniques on mild steel.

About the authors Stephen Hartley is the department head of Historic Preservation at Savannah Technical College.

He has 10 years of experience within the restoration and replication fields, and has won awards from the American Institute of Architects, Historic Savannah Foundation, and other organizations.

Hartley is a member of the Artist Blacksmith Association of North America and Preservation Trades Network. He is also

within the fabrication field, as demonstrated by the growth of “niche” crafts and “buying local” campaigns with the greater sustainability field.

Building relationships with schools can ensure that the employees you desire are available when you need them, and that these employees have the skills to help you compete in a competitive market. a member of the International College of Traditional Practitioners, which is under the patronage of His Royal Highness the Prince of Wales.

Contact shartley@savannahtech.edu.

William Burns William “Bill” Burns is the department head for Welding and Joining Technology at Savannah Technical College.

Burns has 30 years of fabrication experience working for a variety of companies within the Savannah region.

He is a member of American Welding Society and is a certified instructor through the Hobart Institute of Welding.

Contact atwburns@savannahtech.edu.

O&MM Fabricator n January / February 2015

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NOMMA Nationwide Supplier Members Albina Pipe Bending Co. Inc. dba Albina Co. Inc. (503) 692-6010 Allen Architectural Metals Inc. (800) 204-3858 Alloy Casting Co. Inc. (972) 286-2368 American Punch Co. (216) 731-4501 Ameristar Fence Products (918) 835-0898 Architectural Iron Designs Inc. (908) 757-2323 Atlas Metal Sales (800) 662-0143 AZZ Galvanizing (815) 618-8440 Banker Wire (800) 523-6772 Big Blu Hammer Mfg. (828) 437-5348 Julius Blum & Co. Inc. (800) 526-6293 Bridgeton Drafting Co. LLC (856) 205-1279 C.R. Laurence Co. Inc. (800) 421-6144 Cable Art Inc. (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. (718) 324-6871 DAC Industries Inc. (800) 888-9768 DKS, DoorKing Systems (800) 826-7493 Eagle Bending Machines Inc. (251) 937-1947 Eastern Metal Supply (800) 343-8154 Elite Architectural Metal Supply LLC (847) 636-1233

ETemplate Systems (919) 676-2211 FabCAD Inc. (800) 255-9032 The Fabrication Store (866) 79-FAB-4-U FabSuite LLC (757) 645-0842 Farris Fab & Machine Co. (704) 629-6879 Feeney Inc. (Feeney Architectural Products) (800) 888-2418 Geo. Bezdan Sales Ltd. (604) 299-5264 The G-S Co. (410) 284-9549 Hartford Standard Co. Inc. (270) 298-3227 Hayn Enterprises LLC (800) 346-4296 Hebo/Stratford Gate Systems Inc. (503) 722-7700 Heritage Cast Iron USA (918) 591-1700 Indiana Gratings Inc. (800) 634-1988 Industrial Coverage Corp.

(800) 242-9872 Interstate Mfg. Associates Inc. (800) 667-9101 The Iron Shop (800) 523-7427 Kammetal Inc. (718) 722-7400 King Architectural Metals (800) 542-2379 King Architectural Metals - CA (714) 670-8980 King Architectural Metals - MD (410) 644-5932 Krando Metal Products (610) 543-4311 L.E. Sauer Machine Co. (636) 225-5358 Lavi Industries (800) 624-6225 Lawler Foundry Corp.

(800) 624-9512 Lewis Brass & Copper Co. Inc. (718) 894-1442 Locinox USA (708) 579-0286 Mac Metals Inc. (800) 631-9510 McNichols Co. (847) 635-5100

January / February 2015 n O&MM Fabricator

Mittler Bros.

Machine & Tool (800) 467-2464 Multi Sales Inc. (800) 421-3575 Nationwide Industries (813) 988-2628 NC Tool Co. (336) 674-5654 O.K. Foundry Co. Inc. (888) 592-2240 Ohio Gratings Inc. (330) 477-6707 Orleans Orn. Iron & Casting Dist. Inc. (800) 824-3608 Pacific Stair Corp.

(503) 390-8305 Powder-X Coating Systems (888) 326-4840 Praxair Mid-Atlantic (609) 882-1300 Precision Glass Bending Corp.

(800) 543-8796 ProCounsel (214) 741-3014 Ransburg (419) 470-2000 Regency Railings Inc. (214) 742-9408 Robinson Iron Corp.

(800) 824-2157 Rockite, Div. of Hartline Products Co. Inc. (216) 291-2303 Rogers Mfg. Inc. (940) 325-7806 Sculpt Nouveau (800) 728-5787 SECO South (888) 535-SECO Sharpe Products (800) 879-4418 South Camden Iron Works Inc. (856) 423-1107 Stairways Inc. (716) 680-3110 Suhner Industrial Products Inc. (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

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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 December 26, 2014.

A&E Arte Di Ferro Inc. Sead Steta Santa Clara, CA Fabricator Artistic Metal Works Corp.

Julius Minervini Hawthorne, NJ Fabricator Bauer Custom Welding Amy Bauer St. Paul, MN Fabricator

Everlasting Iron Works Anthony Anagnostou Keillor East, Melbourne, Australia Fabricator FabSuite LLC Bill Issler Williamsburg, VA Nationwide Supplier Granite City Steel LLC Jason Keblish Royston, GA Fabricator

Hudson Welding Dave Willbanks Hudson, CO Fabricator Praxair Mid-Atlantic Gerard Guarino Trenton, NJ Nationwide Supplier Red Hawk Forge Dan Nibbelink Berthoud, CO Fabricator

We are proud of our members!

NOMMA 2015 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. n

Capitol City Iron Works Inc., Indianapolis, IN

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Carfaro Inc., Hamilton, NJ

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Custom Ornamental Iron Inc., Glen Allen, VA

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Eagle Bending Machines Inc., Stapleton, AL

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Gates That Open LLC (GTO), Tallahassee, FL

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Gator Welding Inc., Jupiter, FL

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Iron-Works International Inc., Atlanta GA

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Majka Railing Co. Inc., Paterson, NJ

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Moore & Morford Inc., Greensburg, PA

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R & F Metals Inc., Clinton, MD

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Raysteel Inc., Albuquerque, NM

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Sippel Co. Inc., Sewickley, PA

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

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

Alloy Casting Co. Inc., Mesquite, TX

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Artistic Railings Inc., Garfield, NJ

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Julius Blum & Co. Inc., Carlstadt, NJ

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Bridgeton Drafting Co. LLC, Vineland, NJ

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Locinox USA, Countryside, IL

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O’Malley Welding & Fabricating, Yorkville, 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.

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

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.

Cost: $120 + shipping Payment: Checks only Contact: Frances Kinsey (fmkinsey@bellsouth.net, 770-971-2701) Note: We have discontinued the interior banner due to slow orders and durability concerns.

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AD PROOF 4566845-4352A

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Doug Bracken, Wiemann Metalcraft, Tulsa, OK

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Chet Dinkins, Sumter Coatings Inc., Sumter, SC

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Dave Filippi, FabCAD Inc., White Stone, VA

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Mason Hains, MoFab Inc., Anderson, IN

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

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

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

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Allyn Moseley (2), Heirloom Stair & Iron, Campobello, SC

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

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

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Jan Allen Smith, Allen Iron Works & Supply Inc., Birmingham, AL

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John Steel, Steel Welding, Freedom, PA

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

O&MM Fabricator n January / February 2015

What’s Hot? n News Brief Mazak Optonics partners with southeast distributor Mazak Optonics Corporation has partnered with ProMac Technologies as its new southeast region distributor, based in Charlotte, NC. The company Mazak Optonics will serve manu- Vice President/ facturers and job GM Al Bohlen, left, welcomes ProMac shops in North President Bob Carolina, South Lauer to the team at FABTECH Carolina, and in Atlanta.

Virginia, focusing on Mazak’s lineup of CO2 and fiber lasers, automation, tube-cutting systems and turnkey solutions.

Combining Mazak’s laser products with ProMac’s laser experience, the partnership is expected to enhance consultation in manufacturing solutions geared specifically toward customer application requirements, increased productivity, and overall profitability.

Mazak names southeast sales manager Mazak has named Art Weinerman as a new regional sales manager. His territory includes Virginia, North Carolina, South Carolina, Tennessee, Mississippi, Alabama, Georgia, and Florida.

Weinerman has 38 years in the precision metal fabrication industry, including sales and manufacturing.

Contact 847-252-4500 www.mazakoptonics.com

Industry News

Demand softens, but ABI outlook remains positive “Architecture firms are expecting Buoyed by sustained demand for solid mid-single digit gains in revenue apartments and condominiums, coufor 2014, but heading into 2015, they pled with state and local governments are concerned with finding quality moving ahead with delayed public contractors for projects, coping with projects, the Architecture Billings volatile construction materials costs, Index (ABI) has been positive for and finding qualified architecture staff seven consecutive months. for their firms, ” says AIA Chief EconoThe ABI reflects the nine to 12 mist Kermit Baker. month lead time between architecture billings and construction spending.

The American Institute of ArchiNovember highlights tects (AIA) reported the November n Regional averages: South (57.9), ABI score was 50.9, down from a mark West (52.7), Midwest (49.8), Northeast of 53.7 in October. This score reflects a (46.7) slight increase in design activity (any n Sector index breakdown: score above 50 indicates an increase multi-family residential (56.8), mixed in billings). The new projects inquiry practice (52.6), institutional (51.3), index was 58.8, following a mark of commercial / industrial (50.6) 62.7 the previous month. n Project inquiries index: 58.8 The AIA has a new indicator mean Design contracts index: 54.9 suring trends in new design contracts The regional and sector categoat architecture firms that can provide a ries are calculated as a three-month Proof signal of the direction of Ad future archi-77035-CB-4829-08 moving average, whereas the national tecture billings. The score for design index, design contracts, and inquiries contracts in November was 54.9. are monthly numbers.

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Gas Forges January / February 2015 n O&MM Fabricator

Tongs

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What’s Hot? n Events March–September 2015 Blacksmithing classes The John C. Campbell Folk School in Brasstown, NC, offers an ongoing selection of classes, workshops and events in blacksmithing, as well as numerous other crafts.

Upcoming classes include: March 15–20, First Time at the Forge: Beginning Blacksmithing May 1–3, Basic Blacksmithing: Good Habits May 24–30, Basic to Intermediate Blacksmithing June 7–12, It’s Time to Try Blacksmithing June 12–14, The Basics of Moving Metal

60

Industry News

Yearly construction employment increases in 37 states and DC Construction firms added jobs in 37 states and the District of Columbia between October 2013 and October 2014 while construction employment increased in 28 states and the District of Columbia between September and October, according to an analysis by the Associated General Contractors of America (AGCA).

The sector’s recovery is erratic and remains vulnerable to growing labor shortages, new regulatory burdens, and stagnant public sector demand.

Florida added the most construction jobs (38,900 jobs) between October 2013 and October 2014. Other states adding a high number of jobs for the past 12 months included Texas (38,500 jobs), California (34,300 jobs), Illinois (14,800 jobs) and Utah (11,000 jobs).

North Dakota added the highest percentage of new construction jobs during the past year, followed by Utah, Florida, Illinois and Wisconsin.

Twelve states shed construction jobs during the past 12 months, with employment unchanged in Hawaii.

The largest percentage and total losses occurred in New Jersey (-8.1%, -11,100 jobs), Mississippi (-7.7%, -4,200 jobs), West Virginia (-7.6%, -2,600 jobs) and Kentucky (-7.6%, -5,200 jobs).

Twenty-eight states and D.C. added jobs between September and October. Texas (9,200 jobs) added the most jobs, followed by Florida (6,200 jobs), Utah (2,800 jobs) and Colorado (2,600 jobs). Idaho had the highest percentage increase for the month, followed

by Utah, D.C. and South Dakota.

O&MM Fabricator n January / February 2015

What’s Hot? n

Media

Ironwork Today 4: Inside and Out Schiffer Publishing Ltd. Several NOMMA member firms are featured in a new hard cover book, Ironwork Today 4: Inside and Out, including Heirloom Stair & Iron, Steel Welding, and Grizzly Iron Inc. Compiled by Catherine Mallette, an editor who regularly works on art publications for the book’s publisher, Schiffer Publishing Ltd., she is also the author of Art Jewelry Today: Europe.

The book features hundreds of beautiful projects from some 90 metalsmiths. Projects featured include railings, gates, furniture, doors, and sculptures.

Ironwork Today 4 is the fourth in an ongoing series. It presents the works alphabetically by artist, allowing readers to see the full scope of each artist’s work on adjoining pages.

Each listing includes a descriptive paragraph and several photos.

Schiffer Publishing produces other books on metalworking and has promoted the metal industry for many years. NOMMA has assisted the company in the production of past titles.

300 pages, 300+ photos, $50.

Contact 610-593-1777 www.schifferbooks.com

As the user moves through the process, PDT records each step. At the end of the process, users can add details to any step to provide a full description of the process.

“PDT gives our customers unprecedented ease and simplicity of process tracking,” says Chris Okamuro, vice president and chief technology officer for Global Shop Solutions. “Whether it’s a simple process like generating a sales order or a highly complex one such as building multi-level bills of materials, PDT records and electronically stores the entire sequence of events in a fraction of the time required with traditional documentation processes.”

PDT also identifies whether any existing recordings have changed when Global Shop Solutions updates a program or issues a new software release. To protect documentation ver-

sion integrity, managers may accept the new recording as is or mark it as replaced with another one.

“Even though PDT runs inside our software, it’s flexible enough to be used with any program that runs in Windows,” says Okamuro.

“Customers can also use PDT to record any service issues they’re having, allowing our customer service team to provide faster, more accurate technical support,” he says.

Contact 888-851-1248 www.globalshopsolutions.com

Process documentation and training product Global Shop Solutions A fully integrated product within Global Shop Solutions’ software package, Global Shop Solutions’ Process Documentation and Training (PDT) automatically records the operation of any task, process, or program performed within the software.

January / February 2015 n O&MM Fabricator

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What’s Hot? n

Products

Modular cast iron railing system Wiemann Metalcraft/ Heritage Cast Iron USA Through its subsidiary, Heritage Cast Iron USA, Wiemann Metalcraft has introduced a new modular,

code-compliant, castiron railing system.

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

When 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 tradi-

tional mortise-and-tenon detail and do not require welding for satisfactory installation, says the company.

Molded cap railing or sidemounted ADA grab rails may be added by the fabricator/installer to suit a wide range of applications.

Contact 918-592-1700 www.heritagecastironusa.com Hole saws for hand drilling CS Unitec CS Unitec’s new hole saws are designed for applications where cutting with a magnetic drill is not feasible, such as tight spaces where a magnetic drill cannot easily fit and where material is too thin for the magnet to attach.

Designed for use with hand-held drills, the 1-Series and 2-Series Tungsten Carbide-Tipped (TCT) Hole Saws cut clean, fast holes, without grind-

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 TUBING 1BENDERS Tubing $499.95$499.95 1(1/2 1/2”  1 xSquare 11/2” Rectangular Tubing Hand 1/2” Flat Bar x 1Square 1/2” & Tubing smaller)  1xPipe 1/2” Tubing Rectangular 1 x(1/2 1 1/2” Rectangular 1Flat x 1 1/2” & smaller)Tubing &Bar Tubing Hand Tube Bender Rolls: Tube  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 Bender Rolls: Magnum Pipe & Tubing  Hand Pipe & Tubing Bender  1 x 1 1/2” Rectangular Tubing Magnum Hand Tube Bender Rolls:

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$649.95 Square Tubing  2”Rolls:  Flat Bar (1/2 x 1 1/2” & smaller) Magnum Hand Tube Bender Magnum Hand Tube Bender Rolls: $649.95 2” TubingTubing 1 x 2”Square  Pipe & Tubing Rectangular $649.95$649.95 2” Square Tubing 2” Square Tubing   1 xBar 2” Rectangular Tubing Flat (1/2 x 2” & smaller) Magnum Hand Tube Bender Rolls: : 1 x 2” Rectangular Tubing s 1 x 2” Rectangular Tubing l l Ro Flat&Bar (1/2 x 2” & smaller)  Pipe Tubing $649.95 Flat Bar (1/2Flat x 2”Bar & smaller)  2” Square Tubing (1/2 x 2” & smaller)  Pipe & Tubing  Pipe & Tubing  1 x 2” Rectangular Tubing Pipe &Available Tubing Additional Rollers Flat Bar (1/2 x 2” & smaller) Additional Rollers Available Additional Additional Rollers Available Rollers Available  Pipe & Tubing

1-800-200-4685 1-800-200-4685 UNIQUE1-800-200-4685 ROLLING SYSTEM 1-800-200-4685 Works with both hand tubing benders

UNIQUE ROLLING SYSTEM Additional Rollers Available Cap Rails Works with both hand tubing benders UNIQUE ROLLING SYSTEM $599.95 UNIQUE ROLLING SYSTEM Works with both handwith tubing benders Works both hand tubing benders Cap Rails Channels $599.95 ® CML USA, Inc. Ercolina Cap Rails Rails Channels $599.95  Flat Bar Cap (on edge hard way)$599.95 UNIQUE ROLLING SYSTEM Channels Channels  Flat Bar (on edge hard way) ercolina-usa.com Phone 563-391-7700

1-800-200-4685

R&benders D Hydraulics, Mfg. and Machine Co. Works with both hand tubing Bar (on edge Bar hard way) 1431 West 5th St. Chico, CAFlat 95928 www.rdhs.com  Flat (on edge hard way)

For the latest bending technology – www.bendsoveramerica.com 62

Cap Rails R&D Hydraulics, Mfg. and Machine Co. $599.95

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 O&MM Fabricator 2015 n January 1431 West 5th St.West Chico, 1431 5thCA St.95928 Chico,www.rdhs.com CA 95928 / February www.rdhs.com  Flat Bar (on edge hard way)

What’s Hot?

Products

ing the core, says the company. The TCT cutting edges are designed to last longer than bi-metal edges and can be run at higher speeds and feeds to create holes accurately.

The 1-Series Hole Saws include a center pilot drill for cutting holes up to 1-inch deep, with diameters ranging from 9/16 inches to 4 inches. Cutters up to 31/4 inch in diameter feature a 3/8-inch shank, while cutters 35/16

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

inches in diameter and larger feature a ½-inch shank.

The 2-Series heavy-duty Hole Saws feature a spring-loaded pilot pin to easily eject the slug. The milled 3-flat shank fits ½-inch chucks. The 2-Series Hole Saws are available in diameters from 9/16 inches to 13/8 inch and drill up to 9/16 inches deep.

The hole saws are designed for use with CS Unitec’s line of handheld electric drills, such as the EHB32 series.

Contact 800-700-5919 www.csunitec.com Glass mounting clips The Wagner Companies The Wagner Companies has expanded their product line with four new, stock glass mounting clips in corrosion-resistant type 316 satin stainless steel. They are available for

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January / February 2015 n O&MM Fabricator

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

15/8-inch to 2-inch diameter round posts or flat posts.

The clips are supplied with an optional security pin and are suitable for ½-inch through 5/8-inch tempered glass or laminated glass panels.

Contact 414-214-0444 www.wagnercompanies.com Heavy-duty shrinker/stretcher Mittler Brothers Machine & Tool Mittler Brothers Machine & Tool

FIRE YOUR FORGE TODAY!

Proven design Efficient-Reaches 2350 Degrees Versatile Portable Many Models Available

Call for Free Catalog - 800/446-6498

NC Tool Company Inc 6133 Hunt Road Pleasant Garden, NC 27313 336/674-5654

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What’s Hot? n

Products

has announced the newest addition to its ongoing list of metal fabrication tools — the new Jamey Jordan Signature Series Shrinker/Stretcher, Model #570.

This heavy-duty shrinker/stretcher has a 7-inch throat depth, heavy-duty construction throughout, ball bearings at all pivot points for smooth operation, and a cam that allows up or down action for the handle.

Interchangeable dies are available for shrinking or stretching of steel or aluminum up to .060 thick. The dies are heat treated and designed to minimize marking of the material.

The machine is another in the line produced by Mittler in conjunction with Jamey Jordan, including several bead rollers, oval and triangle punch and flairs.

Contact 800-467-2464 www.mittlerbros.com

Hydraulic precision leveler ARKU A new control on the FlatMaster 55 allow users to easily produce dead-flat, stress-free metal parts, the company says, by entering as few as two values: the material type and thickness.

A touch-screen interface with icons uses a database of material properties, “expert knowledge,” part thicknesses, operating parameters, and plausibility checks, which help new users to run the machine quickly with minimal training.

The new control’s built-in “optimal leveling parameters” can be fine tuned by the operator and saved as a part program for future use. The control can store up to 1,500 part programs.

ARKU’s FlatMaster hydraulic precision leveler is designed to quickly deliver leveled and nearly stress-free punched, laser-cut, and flame-cut

abana.org

sheet metal parts from 0.5 mm to 60 mm thick and up to 118 inches wide.

The FlatMaster makes subsequent processes, such as welding or bending, faster and more reliable, says ARKU. Other features of the FlatMaster: n Leveling gap control, providing good leveling results even on parts with cut-outs. n Intuitive control, with a digital control screen that features a value database for saving individual job settings and provides recommended inlet/outlet values based on material thickness.

Contact 512-985-0500 www.arku.com

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

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RegisteR Now! www.traditionalbuildingshow.com registration inquiries: Carolyn Walsh 781.779.1560 cwalsh@aimmedia.com

Artist-Blacksmith’s

education inquiries: Judy Hayward 802.674.6752 jhayward@aimmedia.com

sponsorship inquiries: Peter H. Miller 202.339.0744, ext. 104 pmiller@aimmedia.com

Produced in collaboration with

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O&MM Fabricator n January / February 2015

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

Pg Company

Website

64 ABANA.........................................................www.abana.org 28 Albina Co. Inc.....................................www.albinaco.com 16 Big Blu Hammer Mfg. Co. / Oak Hill Iron Works...............www.bigbluhammer.com 59 Blacksmiths Depot / Kayne & Son Custom Hardware Inc.................... www.blacksmithsdepot.com 57 Julius Blum & Co. Inc....................www.juliusblum.com 19 The Cable Connection.................... www.thecableconnection.com 60 Carell Corporation.......................... www.carellcorp.com 17 Chicago Metal Rolled Products Co................................. www.cmrp.com 62 CML USA Inc................................www.ercolina-usa.com 25 D & D Technologies (USA) Inc.......... www.ddtechglobal.com 22 DAC Industries Inc....................www.dacindustries.com 15 DKS, DoorKing Systems.................. www.doorking.com 61 Eberl Iron Works Inc........................www.eberliron.com 6 FabCad Inc.............................................. www.fabcad.com 23 Hebo - Stratford Gate Systems Inc....................www.drivewaygates.com 22 Hougen Mfg. Inc................................. www.hougen.com

Pg Company

Website

63 John C. Campbell Folk School.........................................www.folkschool.org 68 King Architectural Metals........... www.kingmetals.com 13 Lawler Foundry Corp..............www.lawlerfoundry.com 2 Lewis Brass & Copper Co. Inc................................ www.lewisbrass.com 9 Locinox USA.......................................... www.locinox.com 29 Marks U.S.A........................................www.marksusa.com 18 Mittler Bros.

Machine & Tool.............................. www.mittlerbros.com 63 NC Tool Company Inc......................www.nctoolco.com 62 R & D Hydraulics Mfg. & Machine Co....................................www.rdhs.com 54 Regency Railings....................www.regencyrailings.com 27 Sharpe Products................... www.sharpeproducts.com 33 Spiral Stairs of America LLC.............www.spiralstairsofamerica.com 67 Stairways Inc................................www.stairwaysinc.com 50 Sumter Coatings Inc............www.sumtercoatings.com 64 Traditional Building...... www.traditional-building.com 34 Tri-State Shearing & Bending.................. 718-485-2200 21 The Wagner Companies.......................www.wagnercompanies.com

53 International Gate Devices...............www.intlgate.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 January / February 2015 n O&MM Fabricator

Advertise in the 2016 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 27, 2015 Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; stheien@att.net 65

n

Metal Moment

Dragon Forge has the passion to do it for TV

By Rory May Dragon Forge Ltd. The television show hosted by

CNN’s Mike Rowe is about people with a passion.

Dragon Forge Ltd., a Pine, CO, blacksmith studio has such a passion, and it will be the subject of Rowe’s “Somebody’s Gotta Do It” program this spring on CNN. Last August, Pilgrim Films, the program’s production company, called us to confirm that our family-owned and operated company, run by me and my dad Craig, was a good fit for this new type of reality show.

During the filming, we shared forging techniques with Mike and let him try some equipment, such as our 250-pound Little Giant power hammer, torches, forges, and hand hammers. He helped us with a few tasks left to forge for the sign.

We saw Mike’s perspective broaden as the day went on.

He grasped the broad definition of “blacksmith” — the many specialties a smith could pursue in this craft — much more than just swords and horseshoes.

Keeping the work alive

We were excited for the chance to not only represent a modern blacksmithing studio, but to also share what that Craig May, black shirt, works with show host Mike Rowe, light blue T-shirt, during filming. Craig is riveting the lower scroll detail means through the demonstration of our daily effort to that gets attached to the bottom of the sign. Mike was talking about the uncomfortable burn on his thumb.

The host works, too keep the tradition alive in the An important component of the proform of custom railings, lighting, fireplace gram is that as host, Rowe gets directly doors, kitchen stove hoods, custom hardinvolved in the work of the featured indiware, and the list goes on. viduals. After a few more phone meetings, The crew stayed all day, never slowing.

The final sign of the show name is 5 feet the production company was encouraged long, 6.5 feet from the end of the points, that we could forge something with Rowe and 34 inches tall. It weighs 110 pounds. that would demonstrate our blacksmithThe orange “Somebody’s” is copper and ing work. But we weren’t sure exactly what the rest is metal. We delivered it to the we’d do and how long the program crew production company in November. would be at our shop.

A CNN press release about the show After a weekend of brainstorming, we They had to do it. Rory May, left, son of decided to forge a business sign for the Craig May, right, owners of Dragon Forge indicates viewers will be “face-to-face with Ltd. Mike Rowe, center, host of CNN’s show. “Go big or go home” was our attimen and women who march to the beat of “Somebody’s Gotta Do It.” tude. If we were going to be part of this, a different drum.” we wanted to leave our mark.

It continues: “In each episode, Rowe visits unique individThe day before the filming, a small production team met uals and joins them in their respective undertakings, paying us and scouted our shop. We thought they’d be with us for tribute to innovators, do-gooders, entrepreneurs, collectors, only a couple of hours; they stayed for four, interviewing us fanatics — people who simply have to do it. This show is and getting secondary, b-roll footage. We also gave a small about passion, purpose, and occasionally, hobbies that get a demonstration of what are known for doing — forging. little out of hand.”

After putting on our little show, they said they would For more information arrive at the shop the next morning and stay however long n Mike Rowe’s website: they needed to do the episode. http://profoundlydisconnected.com The next day, Mike Rowe, the show’s host, showed up n Mike Rowe’s Facebook page about the filming: ready to do what he does best: talk, crack jokes, and particihttps://www.facebook.com/TheRealMikeRowe pate in some work. n Dragon Forge website: www.dragonforgeltd.com 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.

66

O&MM Fabricator n January / February 2015

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