Nov 2014 O&MM Fabricator

Case for detailing, part 2, page 24

Shop Talk

The offi cial publication of the National Ornamental & Miscellaneous Metals Association November / December 2014

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Biz TalkMeasuring bending under load, page 14

Shop Talk

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2014 Top Job Awards

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Greg Bailey tests rural tastes, page 47

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Membership in the National Ornamental & Miscellaneous Metals Association (NOMMA) offers a unique opportunity to meet and interact with the best and brightest in the ornamental and miscellaneous metalworking industry. The connections you make here will serve you in the future when questions arise, you’ll know what colleagues to call. NOMMA interactions lead to profitable collaborations, new jobs, and lifelong friendships.

NOMMA serves its members and advances the industry through education and the promotion of a positive business environment. By becoming involved in NOMMA, you have a chance to add your voice to the conversations that shape and grow the industry. There is no better way to ensure your business’s needs are part of the discussion than by being at the table with the leaders and technical minds that are shaping the future.

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

Visit www.nomma.org today to discover many more compelling reasons to become part of NOMMA family.

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

President’s Letter .......... 7Architects, codes, members, and education.

Exec. Director’s Letter ... 8Usable information ready for you.

NEF .................................. 12Donate items for NEF’s auction at METALfab15.

Metal Moment ...............74Templates for cutting pipe.

News ........................................................67n Feeney, King Architectural Metals

sign marketing deal.n Cole-Tuve named distributor

for Apollo machines.

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

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

What’s Hot!

NOMMA Supplier Members .........65

New NOMMA Members ..................66

Ad Index .................................................73

The case for detailing, part 2 .......24Economic and liability issues rising over the years have changed construction documents. We examine the detailer’s role today with specs and drawings and their eff ect on fabricators.Also: A construction lawyer writes about the KC Hyatt hotel tragedy and shop drawings as a legal document. ..34

Shop Talk

Bailey stretching rural tastes ......47Bailey Metal’s locale shapes its busi-ness model. But the company hopes its diversifi cation test will pay off .

By Molly Badgett

Member Talk

Affordable Care Act’s SHOP for small business comes online .......60Open enrollment for the Small Busi-ness Health Options Program under the Aff ordable Care Act for employers with 50 or fewer full-time workers is expected to begin November 15.

By Mark Battersby

Also: What’s new and updated ...........61

Biz Talk

Inside

n

November / December 2014 Vol. 55, No. 6

The only show exclusively for ornamental & misc. metal fabricators .........after 36NOMMA and the NOMMA Edu-cation Foundation have devel-oped a METALfab2015 program that demonstrates the value of peer networking and continuing education:

n Education program n Exhibits n Awards banquet n Shop tours n Business classes, presented

by Tyler Pare, a consultant with FMI Corporation, Raleigh, NC, will off er a substantial number of how-to tips.

n Keynote speaker, Barry Willingham, is the vice president/general manager of Ameristar Perimeter Security USA Inc.

METALfab2015 GuideBest in class: fences, rails ..............54A showcase of the winners in the 2014 Ernest Wiemann Top Job Contest.

Top Job Gallery

Shop Talk

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

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

By Jeff Fogel

Knowledge to enlighten the industryKnowledge to enlighten the industryKnowledge to enlighten the industryMETALfab2015

Knowledge to enlighten the industryKnowledge to enlighten the industryMETALfab2015

Knowledge to enlighten the industryMETALfab2015






































































Knowledge to enlighten the industryKnowledge to enlighten the industryNOMMA announces slate for 2015–16 board of directors .........10

Also: NOMMA chapter meeting and workshop roundup. .....................10

NOMMA Network

Upper Midwest Chapter meeting attendees

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President’s Letter

Architects, codes, and membersIn January, NOMMA will cel-ebrate its 57th birthday. I’m excited about the new initiatives that our association is bringing into the new year.

METALfab for architectsA strategic goal for many

years, NOMMA’s AIA mar-keting team held a successful continuing education event for architects and designers at METALfab2014, and they are doing it again at METAL-fab2015.

Th is program helps the design community learn about our industry’s products.

When architects attend this continuing education program at METALfab, they not only earn CEU credits, but they also see our exhibits and Top Job gallery.

Th e education we off er provides two advantages:

1 It exposes design professionals to new ideas and options.

2 Th e more versed they are with our products, the more likely they are to spec them.

Th e end result is a greater demand for our products.

Need volunteers for code workSince the 1980s, NOMMA has

earned respect for its work with stan-dards development, building code advocacy, and manual creation. At our past two board meetings, we’ve brain-stormed ways to further strengthen this program.

Some of our current volunteers need a break or more volunteer sup-port, and the board wants to help the technical team get what they need. We are delighted to have three new volun-teers on this team, but we can always use more.

A new ICC code cycle begins next year, and we anticipate that we’ll need a team at the Committee Action Hear-

ings this spring in Memphis, TN, and another team for the fall Public Comment Hearings in Long Beach, CA.

If you’re not comfortable speaking, we could still use your help for behind-the-scenes logistical support during the hearings.

More active members soughtOur membership remains

a critical concern. Without a vibrant and growing member-

ship base, we’re unable to support the two programs above, as well as our other initiatives.

As a member you can help our 2014–15 membership drive in two ways:

1 Encourage prospects to join, and when you do, be sure to tell them to put your name on the application form’s “Sponsored By” line.

2 Send the NOMMA offi ce leads for prospective members.

A thanks goes to James Minter Jr. for his leading this committee, and the two new volunteers. And we’d love youto volunteer for this eff ort, too.

METALfab info in this issueAs I write this column, METALfab

is only four months away. I encourage you to plan now for our biggest event of the year.

If you’ve never attended a conven-tion before, I assure you that you’ll be in for an amazing treat. Th e conven-tion will fi ll you with ideas, give you new business connections, and pro-vide you with great education. Th e shop tours particularly are a gold mine because you see how other fabricators run their operations and the equip-ment they use.

For full METALfab details, see the section aft er page 6.

See you there!

Mark Koenke, Germantown Iron & Steel Corp, is president of NOMMA.

Dedicated to the success of our members and industry.

NOMMA OFFICERSPresident

Mark Koenke, Germantown Iron & Steel Corp. Jackson, WI

President-ElectAllyn Moseley, Heirloom Stair & Iron, Campobello, SC

Vice President/TreasurerKeith Majka, Majka Railing Co. Inc., Paterson, NJ

Immediate Past PresidentJ.R. Molina, Big D Metalworks, Dallas, TX

FABRICATOR DIRECTORSGreg Bailey, Bailey Metal Fabricators, Mitchell, SD Max Hains, Mofab Inc., Anderson, INMaciej Jankowski, Artistic Iron Works, Norwalk, CTTina Tennikait, Superior Fence & Orn. Iron,

Cottage Hills, IL Cathy Vequist, Pinpoint Solutions, Jupiter, FLHenry Wheeler, Wheeler Ornamental Metals, Dothan, AL

SUPPLIER DIRECTORSBill Schenke, Ameristar, Tulsa, OKMark Sisson, Mac Metals Inc., Kearny, NJDave White Jr., Locinox USA, Countryside, IL

NOMMA EDUCATION FOUNDATION OFFICERSCo-Chairs

Roger Carlsen, Ephraim Forge Inc., Frankfort, ILLynn Parquette, Mueller Ornamental Iron Works Inc., Elite Architectural Metal Supply LLC, Elk Grove Village, IL

TreasurerMike Boyler, Boyler’s Ornamental Iron Inc., Bettendorf, IA

NEF TRUSTEESHeidi Bischmann, Hartland, WICarl Grainger, Grainger Metal Works, Nichols, SCMark Koenke, Germantown Iron & Steel Corp., Jackson, WI

Christopher Maitner, Christopher Metal Fabricating,Grand Rapids, MI

Rob Rolves, Foreman Fabricators, St. Louis, MOGreg Terrill, Division 5 Metalworks, Kalamazoo, MI

NOMMA CHAPTERSChesapeake Bay

Patty Koppers, President, Koppers Fabricators Inc.Forestville, MD 301-420-6080

FloridaMarco Vasquez, President, Vasquez Custom Metals Inc., Tampa, FL, 813-248-3348

Gulf CoastRandy LeBlanc, President, Metal Head Inc., Lafayette, LA, 337-232-38383

NortheastKeith Majka, President, Majka Railing Co. Inc., Paterson, NJ, 973-247-7603

Pacific NorthwestGale Schmidt, President, A2 Fabrication Inc., Milwaukie, OR, 503-771-2000

Upper MidwestMark O’Malley, President, O’Malley Welding & Fabricating Inc., Yorkville, IL, 630-553-1604

NOMMA STAFFExecutive Director, J. Todd Daniel, CAE Meetings & Exposition Manager; NEF Executive Director, Martha PenningtonMember Care & Operations Manager, Liz HarrisSales Director, Sherry Theien Editor, O&MM Fabricator, Robin Sherman

FABRICATOR EDITORIAL ADVISORY BOARDTerry Barrett, Pinpoint Solutions, Jupiter, FLDoug Bracken, Wiemann Metalcraft, Tulsa, OKBill Coleman, Arc Angels, Dunedin, FLNancy Hayden, Tesko Enterprises, Norridge, ILChris Holt, Steel Welding, Freedom, PARob Rolves, Foreman Fabricators, St. Louis, MO

O&MM Fabricator n November / December 20148

I am continually amazed at the quality of discussions on the NOMMA ListServ, and the question I ask myself is, “How can any fabricator aff ord NOT to be a NOMMA member?”

Th e ListServ is a 24/7 fi re hose of knowledge, and just a few sips will more than repay your annual dues.

Sample formsOne of the golden nuggets on the

ListServ is when a member shares with their fellow members a model docu-ment that they created.

At the request of several members, I am collecting and placing these in a new area on our website. Called “Mod-els & Samples,” it will hold estimating worksheets, sample contracts, check-lists, and more. Eventually, I’d like sam-ple warranties and internal workfl ow forms here, too.

Th e idea is to make your work easier by using someone else’s form as a start-ing point for your own document.

Th e new section is a member’s-only benefi t, and contributions to this pool of information are welcomed.

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

Literature GuideOccasionally, members mention

books and manuals on the ListServ; we are harvesting this information as well.

For instance, Rachel Miller at Spirit Ironworks shared a book called Forged Architect ural Metalwork by Peter Parkinson. For me, it was a surprise to learn that this book has a chapter

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

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

How to fi nd itSince 2004, we have dreamed of cre-

ating the ultimate “knowledgebase” for our industry. Many components of this project are already on our website.

For instance, you can go online to search the O&MM Fabricator and List-Serv archives to fi nd a massive amount of information.

To help members navigate through our various online resources, I do an online webinar on the fi rst Wednesday of each month. On even months, I do a NOMMA 101 class that covers basic resources and reviews member ben-efi ts. On odd months, I do a Not-So-Dirty-Dozen webinar about 12 online resources off ered by both NOMMA and related associations.

To sign up for the next class, contact Liz Harris at [email protected] or 888-516-8585, ext. 101.

SummaryI am a member of the American

Society of Association Executives. Th ree benefi ts make my dues worth-while: their magazine, discussion lists, and their sample forms collection. My hope is that the new “Models & Samples” section of our website will grow into a vital resource for all NOMMA members.

How to reach usOrnamental & Miscellaneous Metal Fabricator (ISSN 0191-5940), is the offi cial 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: [email protected].

Advertise Reach 8,000 fabricators For information, call Sherry Theien, Ph: 815-282-6000. Email [email protected]. Ads are due on the fi rst Friday of the month preceding the cover date. Send ads to: Fabricator at address above. Email ads to: [email protected] (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 benefi ts as a NOMMA member. To join, call 888-516-8585, ext. 101. For a list of benefi ts, see membership ad in this issue.

Exhibit in METALfab Exhibit at METAL-fab, NOMMA’s annual convention and trade show. For more information, con-tact Martha Pennington at 888-516-8585, ext. 104, or [email protected].

Subscriptions Subscription questions? Call 888-516-8585. Send subscription address changes to: Fabricator Sub-scriptions, 805 South Glynn St., Ste. 127, #311, Fayetteville, GA 30214. Fax: 888-516-8585, or [email protected].

1-year: U.S., Canada, Mexico — $302-year: U.S., Canada, Mexico — $501-year: all other countries — $442-year: all other countries — $78

Payment in U.S. dollars by check drawn on U.S. bank or money order. For NOM-MA 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 [email protected].

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

© 2014 National Ornamental & Miscellaneous Metals Association

n

Executive Director’s Letter

Usable information ready for you

Todd Daniel is executive director of NOMMA.

Are you a NOMMA Top Job winner? Do you have how-to, step-by-step tips to share? Have you solved an interesting fabrication problem? Write for Fabricator. Contact Editor Robin Sherman at [email protected].

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The NOMMA Network


NOMMA names 2015–16 board slateThe NOMMA Nominating Com-

mittee, chaired by Immediate Past President J.R. Molina, has announced its 2015 slate of officers and directors, which will be presented at the member meeting at METALfab2015 next Marchn President, Allyn Moseley, Heir-

loom Stair & Iron, Campobello, SC.*n President-Elect, Keith Majka,

Majka Railing Co. Inc., Paterson, NJ.n Vice-President/Treasurer, Cathy

Vequist, Pinpoint Solutions, Jupiter, FL.n Fabricator Director (1-year term),

Tina Tennikait, Superior Fence & Orn. Iron, Cottage Hills, IL.n Fabricator Director (3-year

term), Tony Martinez, Big D Metal-works, Dallas, TX.n Supplier Director (3-year term),

Stacey Lawler Taylor, Lawler Foundry Corp., Birmingham, AL.

Their term begins after the swearing in ceremony at the METALfab awards banquet on March 14, 2015.

Voting takes place during the METALfab2015 opening session, March 11, at 9:15 a.m. at the Valley Forge Casino Resort, King of Prussia, PA.

All current Fabricator and Nation-wide Supplier members are entitled to one vote per company on items pre-sented to the membership.

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

Jankowski, Artistic Iron Works, Nor-walk CT. n Fabricator Director, Henry

Wheeler, Wheeler Ornamental Metals, Dothan, AL.n Fabricator Director, Max Hains,

Mofab Inc., Anderson, IN.n Fabricator Director, Greg Bailey,

Bailey Metal Fabricators, Mitchell, SD. n Supplier Director, Dave White Jr.,

Locinox USA, Countryside, IL. n Supplier Director, Bill Schenke,

Ameristar, Tulsa, OK.n Immediate Past President, Mark

Koenke, Germantown Iron & Steel Corp, Jackson, WI.

Retiring board membersA “thank you” goes to the following

retiring board members for their years of outstanding service:n Mark Sisson, Mac Metals, Kear-

ney, NJ, is rotating off the board after three years of service.n J.R. Molina, Big D Metalworks,

Dallas, TX, is rotating off the board. after seven years of service.

Meet the new candidatesn Stacey Lawler Taylor of Lawler Foundry Corp., Birmingham, AL, is a candidate for Sup-plier Director.

She is active with the Gulf Coast NOMMA Network and served as a NEF trustee from 2007 to 2010.

Her company joined NOMMA in 1960.

n Tony Martinez of Big D Metalworks, Dallas, TX, is a can-didate for Fabricator Director.

He is a past presenter, both at METALfab and at NEF’s 2013 continu-ing education event in Dallas.

His firm, which joined NOMMA in

1977, has won many Top Job awards.

Stacey Lawler Taylor, left, Lawler Foundry Corp., and Tony Martinez, Big D Metalworks.

*The president-elect advances to president.

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

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


NOMMA and the Stairway Manu-facturers’ Association (SMA) held their first combined event on October 17 in southeastern Pennsylvania. Ninety people attended the event, including 65 attendees from the SMA and 25 from NOMMA.

The daylong workshop started with a breakfast and social at NOMMA member shop Crystal Metalworks of Hatfield, PA. NOMMA Executive Director Todd Daniel and Vice Presi-dent Keith Majka welcomed the crowd with opening remarks.

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

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

Of particular interest was the demonstration of an Amada Promecam press brake, which could create stair pans with a minimal number of steps. Members were also treated to a demon-stration of a Messer EdgeMax CNC high-definition plasma cutting system, which the company uses to cut custom shaped parts.

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

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

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

Lunch featured traditional Philadel-phia fare, including Philly cheesesteaks

and pretzels.Afternoon events at Advanced

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

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

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

NOMMA and SMA hold daylong stair workshop

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

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

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

n

NOMMA Education FoundationIn partnership with the National Ornamental & Miscellaneous Metals Association


DONATE!

For more information on donating to the NOMMA Education Foundation Contact NEF Executive Director Martha Pennington, 888-516-8585 x104, [email protected].

Don’t miss METALfab2015 program in this issue

Among the outstanding NOMMA members presenting at METALfab2015, is our special presenter Tyler Pare, a consultant with FMI Corporation, which provides management consulting and investment banking for the engineering and construction industry.

Tyler’s classes will cover topics such as Leveraging Your Competitive Advantage, Connecting Actual Job Costs Back to Estimat-ing, Key Performance Indicators that Drive Best Practices, Driving Best Practices in Busi-ness Development, and How to Avoid Con-frontation with Change Orders.

Check out the education program for METALfab2015 that is included in this issue of the Ornamental & Miscellaneous Metal Fabricator beginning after page 36. More details will come later, so continue to check the NOMMA website.

NEF Auction donationsWe’re also beginning work on one of our favorite fundrais-

ing projects — the Silent & Live Auctions held at METAL-fab. Whether you donate of an item for auction or you bid on items, both are critical to the success of this project.

We have had fabulous items donated through the years and depend on you to help us continue this great tradition. Among the items the Auction Committee asks you to donate as auction items may include the following:

n Metalwork, such as sculptures, garden gates, or hand-forged furniture.

n Non-metal items, such as tools, gift baskets, gift certifi-cates/coupons, jewelry, electronics, clothing, food/wine, pre-sentation drawings, the use of a condo at the beach, airline tickets, books, artwork, or even antiques.

n Specialized services, such as offering to create a cus-tom, one-of-a-kind item for the winning bidder.

Or be creative — the sky’s the limit! Every donated item will help the Foundation provide qual-

ity education for our industry through the following platforms:n METALfab education program, n continuing education classes, n video productions, n educational publications, andn other special projects.

If you wish to contribute an item(s) for this event, please go to www.nomma.org. for a donation form. Questions? Call the NOMMA office at 888-516-8585, ext. 101, or contact Liz Harris at [email protected].

Todd Kinnikin Memorial METALfab Scholarship

Applications for the Todd Kinnikin Memorial Scholarship are now available. The scholarship is given by the NOMMA’s Upper Midwest Chapter to honor the mem-

ory of Todd Kinnikin of Eureka Forge, Pacific, MO. This scholarship provides the recipient with a full and

spouse registration for METALfab2015. Go to www.nomma.org for a copy of the scholarship application. Application deadline is January 9, 2015.

If you would like to donate to the Todd Kinnikin Memo-rial METALfab Scholarship fund or need mre information, please contact Martha Pennington, NEF Executive Direc-tor at [email protected] or 888-516-8585 x 104, or Mark O’Malley, Scholarship Chair at [email protected] or 630-553-1604.

NEF curved stairs continuing education classThe NOMMA Education Foundation sponsored a con-

tinuing education class: Curved Stairs — How to Measure, Detail & Fabricate. This class was held Saturday, September 27, at Germantown Iron & Steel Corp., Jackson, WI.

The NEF trustees are grateful for the wonderful presen-tations by Mark Koenke, Germantown Iron & Steel Corp. of Jackson, WI, and Mark O’Malley, O’Malley Welding & Fabri-cating Inc. of Yorkville, IL.

A special thank you goes out to Germantown Iron & Steel Corp. owners and employees for all their efforts to make this class a success and to Chicago Metal Rolled Products, Chi-cago, for donating time and material for the class.

Some attendees had to brave the confusion and delays caused by the fire at the FAA facility in Aurora, IL, to get to the class, but they were rewarded for their efforts with an out-standing presentation.

We look forward to seeing you in King of Prussia.

Donate items for the NEF auction at METALfab

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


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

Shop Talk

n Consider this. You’re building a railing. Who’s the cust omer? Doesn’t matter. Th e design, the measurements, the materials, only matter. And one more thing. Th e cust omer insist s the vertical post s be kept thin. So, here’s your problem. How thin can you go and st ill have post s capable of withst anding the attendant loads of said railing? Well, you’ve just entered the . . .

By Jeff Fogel

What is defl ection? Imagine a metal rod, fi xed in place at one end. If you were to push sideward on the rod, it would fl ex in the direction you are pushing. If you suddenly stop pushing, letting go of the rod, it will return to its original position. Roughly speaking, the amount you can bend the rod and still have it return to its upright position is called its defl ection.

Th e NOMMA Metal Rail Manual is more concise. It defi nes defl ection under load this way: “Aft er the application and release of the required test load, the anchored railing system shall return to within one-half inch of its original position.”

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


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

What happens to the rail if it’s bent beyond that distance? Bad things. “The chemical bonds between the molecules in the steel lattice are rup-tured,” says Coviello, “and the steel is damaged. There may be some residual strength, but it is still compromised.”

A curve indicates the yielding por-tion of deflection. Coviello says: “The

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

Three ways to measure bending under load

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

1 Old school methodAssuming we’re dealing with square

tubing, (and we are), measuring the

bend deflection mainly depends on n what your material is, n the width of the tubing, and n what the wall section thickness is.Here’s why. Newton’s first law of

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

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

This gives us:

M = f x S.

Now we can get more specific with M. In practical applications, M refers to the sideward load applied to the post. Because the principle of lever-age would make the load greatest at the top of the post, we designate that P; the length of that “lever” is h, the height of the post.

Now we get:

M = P x h.

If M is the bending moment, the resisting moment has to equal M, and the resisting moment is com-prised of the allowable stress fs, and the cross-section size S, then we can set up:

P x h = fs x S.

Hang in, we’re going to use this handy formula for a real-life problem involving a railing.

Say a design (or maybe the code) calls for a square tube post that is 36 inches high and must withstand a hor-izontal load of 100 pounds. We’ll use square tube C1020 steel as a material. How thick does the post have to be?

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

S = P x h = 100 x 36 = 0.180 in³ fs 20,000



22144 NOMMA Sep NOV 2014.ai 1 10/10/14 12:00 PM

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

2 Use an Internet calculatorA new school way can skin this cat.

Use the Internet. Just go to a website that does metal defl ection calcula-tions. Metalgeek.org will do fi ne (see image on page 20).

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

All the metal defl ection calculator websites work much the same way. None of them involve the slightest mathematical eff ort on your part.

Curiously, no fabricators we spoke with had used any of the on-line cal-culators even though they were aware of them. Why would anyone use the

mathematical formula with its atten-dant risk of miscalculation? We asked several fabricators.

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

3 The simple ways“Real life, and that means KISS

(‘keep it simple, stupid’),” says Amos Glick of Compass Ironworks, Gap PA. “Code [in the geographic area where Compass is located] says every railing has to withstand a 50-pound horizontal load in either direction. We don’t use formulas. We’ll literally hang a weight on the railing to see if it can bend and return to its original position.”

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

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

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

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

Zuzik’s method is to clamp a piece that is to be tested at a fi xed point. Th en he hangs a barbell weight at the opposite end. He then measures the distance the piece will move and still revert to its initial conformation.

Sometimes Zuzik uses testing equipment. Th is consists of load sen-sors and soft ware. A basic set up, Zuzik says, would run between $250 and $500.

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

A couple of things. You can use a trick that James

Rucker of York Metal Fabricators in Oklahoma City employs. Simply run a steel insert inside the square tubing.


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

Or you can do as Amos Glick does. Find a harder material in the same alloy family. Often this simple substi-tution does the trick.

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

load requirements for deflection. “So we poked around here and

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

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

Trust but verifyThe modern mariner avails himself

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

This is sound advice for the fabrica-tor who seeks to determine deflection of square tubing.

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

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

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

“Use at your own risk. Or you’ll be sorry,” Eckhart says. Formulas and data gleaned from the “Elastic Beam Deflector Caluclator” at: http://1.usa.gov/1xVAjQO

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as well, he’ll run “real life” tests, a la Amos Glick’s method.

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

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

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

“We don’t have an engineer on staff , and I’m not an engineer,” says Mike Stylski of Accent Ornamental Iron and Powder Coating Co. in Cambridge, MN. “So we tend to overbuild things. Th e code here is very specifi c about loads. I believe it allows for a 1/4-inch defl ection for a top railing. So, we’ll select a tube with enough wall.

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

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

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

Stylski recalls a recent job that used a rectangular tube of massive propor-tion; its cross section measured 2 by 12 inches, with an 11-gauge wall (⅛ inch), and weighed a heft y 16 pounds per foot. Th e rails spanned 167 inches. “Th e more it weighs,” says Stylski, “the less bracing you’ll need.”

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

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

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

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

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

But what do engineers think about not using engineers? You might think they’d respond with a litany of cata-strophic results: failed railings, col-lapsed stairs, fl ood, fi re, and famine.

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

“You don’t always have to test. In fact, you don’t always need an engi-neer,” fl atly states Tony Coviello, part-ner with Summit Engineering, Ports-mouth, NH. “Th ere’s the ideal world, and then there’s reality. Sometimes simply adhering to known constraints (i.e. code) is suffi cient. It all depends on the project, the budget, etc.”

Th ere you have it. Allowing for defl ection in square tubing is not fraught with arcane math and physics. If you’re a bigger shop, you can simply dump it in an engineer’s lap. Or, if you’re comfortable with some simple arithmetic, you can do some DIY cypherin’. For smaller shops or those less numerically capable, there are simple testing methods, or even intuition.

For your information

ResourcesAccent Ornamental Iron & Powder CoatingCambridge, MN 763-691-8500www.accentornamentaliron.com

Artistic Railings Inc.Garfi eld, NJ 973-772-8540www.artisticrail.com

Berger Iron Works Inc.Houston, TX 713-869-7386www.bergeriw.com

Compass IronworksGap, PA 717-442-4500www.compassironworks.com

Summit EngineeringPortsmouth, NH 603-319-1817www.summitengineeringinc.com

Vasquez Custom Metals Inc.Tampa, FL813-248-3348www.vasquezcustommetals.com

York Metal FabricatorsOklahoma City, OK800-255-4703www.yorkmetal.com

NOMMA Metal Rail ManualFor NOMMA members onlywww.nomma.org

About the authorJeff Fogel began writing as a journalist with the New York Daily News. He has been a copywriter and associate creative director for advertising agency Ogilvy & Mather. Jeff now lives in New Hampshire where the weather’s bad, the skiing’s better, and blacksmithing’s a respectable way to keep warm.

n

‘You don’t always have to test. In fact, you don’t always need an engineer,’ fl atly st ates Tony Coviello, partner with Summit Engineering, Portsmouth, NH. ‘Th ere’s the ideal world, and then there’s reality. Sometimes simply adhering to known const raints (i.e. code) is suffi cient. It all depends on the project , the budget, etc.’

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

Editor’s note: In the March/April 2014 issue of O&MM Fabricator, detailer David Busarello, Bridgeton Drafting Company LLC, Vineland, NJ, began a two-part article on the benefits a fab-ricator can receive from using the ser-vices of a miscellaneous metals detailer. The article examined what a detailer provides, the detailing process, and briefly, some of the industry changes that occurred in the past 100 years that make the services of a detailer all the more important.

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

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

Let’s begin with a deeper examination of the current state of construction documents (CDs), how and why they

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

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

cal Services, Scottsdale, AZ, says The Construction Specifications Institute (www.csinet.org/store) defines CDs as “the written and graphic documents prepared or assembled by the [archi-tect and/or engineer] for communicat-ing the project design for construction and administering the construction contract.”*

CDs may include thousands of pages of drawings and specifications for a skyscraper, or one, letter-sized sketch with a few notations for a res-idential step rail. Either way, the pur-pose of the CDs is to convey enough information that:

“These two images show

the hand sketch I worked

from and the installed rail. Stoop is what

Philadelphians call their small

front steps.” — David

Busarello

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

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n the project owners can see what they are getting,

n the code officials can certify that the project meets local codes, and

n the contractors can bid and build the project.

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

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

We know how large a stairway should be and how many are needed to get everyone out of a high-rise. Government building code officials, with support from trade groups like NOMMA, develop codes that make buildings safer and more efficient to use.

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

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

Two causes for the change in construction document

1 EconomicsWe’ve all seen insurance companies

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

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

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

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

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

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

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

“While inherent in the mind-set of the responsible engineer, compe-tent engineering may be reinforced by an environment that promotes responsible use of computer software. The opportunity to check for error is inherent in the process. Engineers should consider the loss of this review time and make special effort to build confidence in the procedures per-formed by the software.”

2 LiabilityProtection from liability is another

cause. In the book Construction Bud-get Management by Richard Lin-

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

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

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

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

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

This creates new risks and responsi-bilities on the fabricator.

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

In short, the fabricator bears the risk to ensure the design and fabrica-tion meet requirements.

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

Here is one such comment from the Board:

“Apparently, there is a trend for archi-tects to do nice renderings for their clients, but have little detail. They are


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

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

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

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

How this issue applies to stairs and rails. How many times have you, as a

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

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

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

Providing a set of plans and sec-tions, prepared by a detailer and pre-

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

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

“This provides us with a document that serves many purposes. To our cli-ent, it defines what we are providing. To our shop, it specifies exactly what materials we need to order, and how to fabricate it. To our erectors, it provides direction on how to build it. Finally, it provides a record for future use, be it future work in the same building or defense from litigation. Our firm is more efficient fabricating and erecting it, the customer is happy, and we make a nice profit.”

Shop drawings vs. architect specsThat Maltese’s engineer verifies that

a fabricator’s design will structurally work leads to another comment by the O&MM Fabricator Editorial Board:

1) “Do shop drawings always have to follow the architectural plans and specifications.”

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

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

Can a fabricator substitute an alternate design? A quote from the movie, “The Towering Inferno,” in which a fire starts in a high-rise office/condo building, addresses this. At one point, the architect, played by Paul Newman, accuses the general contrac-tor, William Holden, of installing a substandard electrical system, at which time the GC gets in his face and says:

“Now listen. Any decisions that were made for the use of alternate build-ing materials were made because I as a builder have a right to make those deci-sions, if I remain within the building code and (bleep-bleep), I did!”


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

We all have an ethical responsibil-ity to build something that is struc-turally safe or clearly going to serve the purpose for which it was designed. Design professionals are human and make mistakes as we all do. We serve our customers well and keep our good reputation by doing what is right.

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

Two examples1 Library stair and rail designOn a Washington D.C. library proj-

ect I worked on for Maryland Fabrica-tors, Millington, MD, I submitted an alternate stair and rail design for a ser-vice stair in the back of the building, to be used for employees only, not the public, therefore it’s appearance was less important.

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

The contractor told us early the owners were looking to save money. We provided an alternate with 12-inch junior channels (MC12x10.6), and a steel pipe handrail on a two-line, steel pipe guardrail. Our engineer also provided calculations. The project architect accepted it, and it saved the customer considerably.

2 Shrine structureThe Malvern Retreat House, a 125-

acre complex in Malvern, PA, hosts weekend retreats for thousands of peo-ple every year. For their 100th anniver-sary, the Retreat House leaders wanted to replace the existing Shrine to Our Lady of Fatima that was in disrepair.

An architecture firm provided a beautiful design. Unfortunately, the

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

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

When contract requires the fabricator to hire an engineer The O&MM Fabricator Editorial

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

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

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

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

ApprovalsThe editorial advisory board

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

the March/April 2014 issue of O&MM Fabricator, we explained the process. Now, we will discuss how various end results of this process affect the fabricator.

For many miscellaneous metals fabricators, shop drawings provide a clear format to show the architect what you intend to provide, and a plat-form to ask questions generated due to conditions not covered in the con-struction documents. When the draw-ings are returned, here’s what you may and may not find:

A stamp with language similar to the following: “This review is only for the general

conformance of the design concept and does not relieve the contractor from its responsibility to comply with the requirements of the plans.”

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

Later, he continues: “There are situations in which the project engi-neer can assign design responsibility, . . . to a fabricator . . . who provides a metal stairway that collapses [and who] would face significant liability.” (See AIA Document 201, § 3.12.4; http://bit.ly/1fuBNum)

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

Here you will learn the position the architect and owner will likely take, should you find yourself in a dispute. I encourage you to read it. It’s part of just about every project you have.


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Answers to the questions you asked about the shop drawingsDocument AIA 201, section 4.2.12 explains that the

architect shall review properly prepared requests for infor-mation submitted by the contractors and prepare and dis-tribute supplemental drawings and specifications to the contractors in response. This is part of the architect’s Con-tract Administration Services Agreement with the client, what the architect agrees to provide (From The Architect’s Handbook of Professional Practice, 13th edition ©2000: http://bit.ly/1nm2FTt).

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

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

Additional information that add cost or impact schedulesAIA Document 201, section 3.2.3 address this, stating

the “contractor is not required to ascertain that the con-tract documents are in accordance with applicable laws, statutes, ordinances, codes, rules, and regulations.”

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

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

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

No comments at all by the architect, engineer, or GC.Section 3.12.14 states review by the architect is limited to

section 4.2.7 and that “submittals that are not required by the contract documents may be returned by the architect without action.”

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

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

What does it mean to the fabricator? It means know your obligations on each project. My experience shows shop drawings are almost universally required on each


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

How the courts have ruled on liability

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

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

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

1 Jaeger v Hen ning son, Durham, and Richardson Inc.Powers says that in Jaeger v

Hen ning son, Durham, and Richardson Inc, the contractor used 14-gauge- steel stair pans instead of the stronger 10-gauge pans specified by the archi-tect. Ironworkers were injured during construction when the weaker pans failed.

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

2 Waggoner v. W&W Steel Co.However, in Waggoner v. W&W

Steel Co., two ironworkers were killed and another injured when a structure under construction collapsed. The claim alleged the architect was negli-gent for approving shop drawings that

How to find a qualified detailer

Industry organizationsFirst, go to industry organiza-

tions like NOMMA and NISD. The detailers who belong to these groups are active in the industry. They care about their customers enough to invest the time and money to con-nect and improve their skills.

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

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

Other fabricatorsA great referral can come from

a fabricator with whom you have a good working relationship. Be pre-pared for some resistance; some fab-ricators might be possessive about their detailers, and they often have a close relationship.

YahooAn excellent Yahoo Group for

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

How to pare down your listAs experienced business own-

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

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

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

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

“Detailers use the draw com-mand. Fabricators use the edit com-mand because they are always work-ing the design. Designers should have shop and field experience. Ask them if they know what GoJo is [We’re not telling. — The Editor]. If not, they probably have no shop experience,” he says.

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

Finally, if you find yourself work-ing with the same engineers and architects, ask them, because they review detailers’ drawings nearly every day. They know the good ones. They’re the ones who call the archi-tect to discuss a job before begin-ning their detailing so the approval process is quick and efficient.

— David Busarello


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did not show temporary connections. The Oklahoma Supreme Court upheld that the contractor, not the archi-tect, was responsible for construction means and methods.

What is a fabricator to make of this? Shop drawings can be your friend

or your albatross. It all depends on who is preparing them.

As Heideck states in his sidebar:

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

John Hladczuk, Craft Ornamen-tal Metals LLC, Philadelphia, PA, has stated many times:

“My detailer is like my shield. He protects me from making assumptions about the designer’s intent. He gets on the phone with the architect, irons out the issues, and documents everything

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

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

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

The architect, a one-man firm in New Jersey, provided a huge set of specifications covering an assortment of items that were not in the project. Small architectural firms commonly do this because they do not have the time to assemble a 600-page spec book for every small job. We detailed the stair as designed, and it was built and installed with no issues. The building inspector even approved it.

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

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

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

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

Detailer can help you stay technologically current

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


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

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

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

Two forms of CAD/CAM 1 Computer numerical control

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

A great quote from the article described the relationship between the CAD program that creates the design and the CAM program that takes the CAD files, interprets it, and drives the machine:

“The happy result of these two soft-ware programs, harnessed in tandem, is the satisfying clicks and whirrs of the router’s servos as it guides the tool-ing heads along its merry way while you go have a cup of coffee.”

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

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

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

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

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

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

“Modeling it in a 3D CAD pro-gram, making it with a 3D printer, and coating it with epoxy paint would pro-vide you with an identical match at a much lower cost and that will last just as long as the original did,” he says

Dave summed up one example like this: “Say you need three spears for a fence renovation and the foundry long out of business. Take a picture of the spear, scan it, draw over it, add depth to it, send to 3D printer, make it, coat it, color it, done.” It’s getting to be just that simple.

Building Information Modeling (BIM)One of today’s most overused

acronyms is BIM. I found dozens of definitions for this concept, seemingly misunderstood by just about everyone in the trade.

The National Building Information Model Standard Project Committee defines BIM as:

“Building Information Modeling (BIM) is a digital representation of physical and functional characteristics of a facility. A BIM is a shared knowl-edge resource for information about a facility forming a reliable basis for decisions during its life-cycle; defined as existing from earliest conception to demolition.

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

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

Architects used to provide this depth of service years ago when all the details of a building were coordinated before the job was released for bid. Most of us old-timers also remember the red line set of contract drawings in the job site trailer that all the trades marked up with any changes they made so the architect could produce a set of “as-builts.”

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

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

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

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

Don’t be surprised when the archi-tects/GCs in your area start request-ing bids on these larger and mid-sized jobs before the CDs are even done. They want the fabricator’s early input on these miscellaneous items, and BIM is leading the way. Your detailer is the one who can help you.

Early steel detailingGetting on the job early is addressed

by a process growing slowly but surely: “early steel detailing.” This brings the fabricator and the detailer into the pro-cess during the design phase.


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

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

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

In his paper “Procuring Steel through an Early-Release Steel Package” (http://bit.ly/1aIxFHi) Auburn University’s C. Ben Farrow, MSCE, MBA, PE, concluded that:

“Procurement of steel through the use of ‘early-release’ shop drawings can provide an effective way to shorten time, save money, and reduce errors on certain construction projects. The use of ‘early-release’ shop drawings paves the way for a paradigm shift where a single owner owns a complete data-base for a project.

“In this future scenario, the 3-D model will be shared by designers, detailers, builders, and facility managers through the design, construction, and service life of the building. However, resistance to change in the way buildings are delivered exists among designers, fabricators, and facility managers. . . .”

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

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

In closingMy hope is that the two articles, “The case for Detail-

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

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

The industry has changed. The need for a fabricator


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

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

My relationships with my miscel-laneous metals clients are diff erent from my structural clients. Th e rela-tionship is much more personal with the miscellaneous metals fabricator because we talk almost daily when I have a project from them. During my research for this article, I’ve learned my customers feel the same way, and this humbles me greatly.

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


Bridgeton Drafting Company LLC520 North. West Ave.Vineland, NJ 08360856-205-1279856-205-1283 [email protected]

About the authorDavid Busarello began working in his father’s sheet metal shop as a teenager. He has been in the detailng busi-ness since 1978, fi rst employed by a structural fabricator, then as chief draftsman of a miscellaneous metals shop.

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

n

Shop Talk

The case for detaılıngPart 2

An attorney’s views on Hyatt hotel tragedy and shop drawings as a legal documentEditor’s Note: Th is article represents the views of the author, and does not nec-essarily represent the views of Pepper Hamilton LLP, its clients, or NOMMA. Th is article is published solely for gen-eral informational and educational purposes and is not intended to adver-tise any services, legal or otherwise. Th e article should not be considered a subst itute for legal advice, and it does not est ablish an attorney-client rela-tionship. For legal assist ance, contact an attorney licensed to pract ice in your jurisdict ion.

By Robert E. Heideck* Pepper Hamilton LLP

For many in the construction industry, the single major event which raised the importance of shop drawing review was the collapse in 1981 of the skywalk at the Hyatt Regency Hotel in Kansas City in which 114 people were killed.1

Th e collapse was caused by the failure of the box beam hanger rod connec-tions supporting the atrium walkways.

Th e original design contemplated continuous hanger rods that would be attached to the roof, pass through the fourth fl oor box beams and then through the second fl oor box beams.3

Th e drawings supplied to the steel erec-tor provided what appeared to be full details for these connections, but could be read as showing that the rods termi-nated below each walkway box beam.4

Th e shop drawings prepared by the fabricator showed a double rod con-fi guration with one rod extended from the fourth fl oor to the roof and the sec-ond rod from the second to the fourth fl oor.5 Also, the box beams were not extruded rectangular tubes but were shown to be created by welding the toe edges of two channel sections together

along the fl ange lengths. No stiff eners or bearing plates were shown either on the structural drawings or on the shop drawings. A copy of the confi guration is set forth above.

No loads were provided on the drawings sent to the fabricator and no calculations or other analysis were per-formed or provided by the fabricator.

Th e structural engineer for the project stamped the drawings as reviewed but this was not based upon any calcula-tions of the anticipated loads.9

Th e changes created a doubling of the load on the fourth fl oor walkway beams because those beams now also carried the entire load of the lower walkway.10 Also, the off set of the two rods created a concentrated load at the end of the box beam section of the fourth fl oor, which created a “structural eccentricity.”11 Under load, it appears that the more heavily loaded outer rod tore through the fl anges of the box beam, causing the entire walkway to fail with the resulting deaths and inju-ries. A copy of a photograph of one failed section is below.13

As might be expected, a myriad of lawsuits were fi led and a criminal grand jury was enpaneled. No crimi-nal indictments were issued. Th e major source of the “lessons learned” is the 442-page opinion of the Missouri Board of Architects, Professional Engi-neers & Land Surveyors, published in 1985.1 Among many conclusions reached by the Board was that the structural engineer for the project had ultimate responsibility for reviewing all shop drawings to ensure that the struc-tural members and connections were adequate for the loads.13 As the Judge stated: “Shop drawing review allows the engineer to provide the fi nal, unre-


viewable determination and verifi ca-tion of strength for the protection of the public. . . .”14

Th e State of Missouri revoked the licenses of the two project structural engineers. Th at same year, the Ameri-can Society of Civil Engineers issued a policy statement:15

Th e engineer of record should have responsibility and authority for all aspects of the structural design and his/her contract should specify that he/she either (a) designs the connec-tions or (b) reviews and approves all shop drawings, including connections selected and detailed by the fabrica-tor. During construction, the engineer of record should make appropriate on-site observations.

Since the Hyatt case, the law relat-ing to shop drawings has generally developed as follows:

With respect to the contractor (and/or the erector), the major pur-pose of the review of the shop draw-ings is to confi rm means and meth-ods of construction, to ensure proper sequencing of the trades, and to ensure that the proposed activities can be accomplished in a safe and eff ective manner. If, for example, a worker gets injured because of insuffi cient attach-ments for temporary scaff olding, the

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

As to the architect/engineer, the purpose of the review of the shop drawings is to confi rm that the pro-posed items meet “the design concept of the Project.” Th is generally means that if the overall structure as designed fails or if the work does not meet the overall design, then the architect/engi-neer face liability even through the drawings were prepared by others.

As to the fabricator, the fact that the Board in the Skywalk matter placed ultimate responsibility on the project structural engineer, as opposed to the steel fabricator, does not mean that fabricators have no liability for “design” decisions. Th ere are situa-tions in which the project engineer can assign design responsibility for connections, etc., to the fabricator. In any event, a fabricator who pro-vides a metal stairway that collapses would face signifi cant liability, even if the shop drawings were reviewed and approved by others.

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

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

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

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

This created a zipper-like weak spot, see photo. Vibration due to human movement, like dancing on the walkways, caused the channels to fail, the nut tearing through the seam.Photograph by Dr. Lee Lowery, Jr., P.E., Zachry Department of Civil Engineering, Texas A&M University. More photos at: http://bit.ly/1zjKjYF.

2nd fl oor walkway channel box beam

5th fl oor steel5th fl oor steel

Hanger rod to support 4th fl oor

4th fl oor walkway box beam

4th fl oor box beam

supporting itself &

2nd fl oor walkway Hanger rod

to support 2nd fl oor2nd fl oor

walkway box beam

Hanger rod to support 2nd fl oor (beyond)

4th fl oor walkway channel box beam

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


2nd fl oor walkway tube box beam

5th fl oor steel5th fl oor steel


4th fl oor walkway tube box

beam

Rod passes through

box beam with no

connection

Hanger rod to support

2nd fl oor

2nd fl oor walkway tube box

beam

Hanger rod to support 2nd fl oor (beyond)

4th fl oor walkway tube box beam

8x5-inch tube box beam as designed



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

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

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

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

In addition to its benefi ts, however, the virtual blank slate also creates new risks and responsibilities. Th e lack of detail oft en creates a “performance” specifi cation by describing the item to be supplied in extremely general terms and adding performance require-ments.

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

If the design is a “performance” specifi cation, for example, “design, fab-ricate and erect a circular metal stair-way installed at point x, capable of load y and meeting all applicable codes,” the fabricator bears the risk and responsi-bility to ensure that its design and fab-rication will meet those requirements.

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

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

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

Use of an experienced detailer as the “bridge” to facilitate communica-tion could help the shop drawing and fabrication process by bridging the gaps in many ways. For example, the detailer can help to avoid the frustrating delays caused by shop drawing “ping-pong” in which the same drawings are repeat-edly stamped “revise and resubmit” but there is no eff ective communication to identify and solve the real prob-lems and ultimately close the gap to approval. Th e use of the detailer can also avoid the costly rework and delays resulting from a failure to commu-nicate eff ectively and early about the hidden gaps between the designer’s concepts and the fabricator’s standard details which might, unfortunately, only become clear aft er fabrication or even erection commences.

References1 Most of the fact s described here are taken

from the 442-page published opinion of the Administ rative Hearing Commission of the State of Missouri in “Missouri Board for Architect s, et. al. v. Duncan, et. al,” published in November 1985. Hereaft er cited as “1985 Missouri Board Decision.”

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

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




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

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

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

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


12 See Footnote 1.13 See 1985 Missouri Board Decision at

p. 76.14 See 1985 Missouri Board Decision at

p. 216.15American Society of Civil Engineers

Policy Statement “Authority and Resp onsibility for Design of Steel Struct ures” (as adopted on Oct ober 20, 1985).

16 See 1985 Missouri Board Decision at p. 234.


About the authorRobert E. Heideck is a partner in the Litigation Department of Pepper Hamil-ton LLP, www.pepperlaw.com.

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

n

Top Job Contest InformationDeadline: December 31, 2014Late Deadline: January 16, 2015*

Entry details: Entrants enter by submitting 1-3 photos of their work plus a 160-word description. During the annual METALfab event, all images are displayed in a gallery and each NOMMA member firm is allowed one vote. Results are announced during the METALfab banquet.

Enter your work in NOMMA’s annual awards contest!

Complete rules are available on the NOMMA home page — click on “Top Job Awards.” Note: You must be a NOMMA member at the time of entry.Justin L. Pigott, Top Job Chair * Late fee required.

METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015Knowledge to enlighten the industry

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 vol-unteered 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.

Celebrating 57 yearsMarch 11–14, 2015Valley Forge Casino ResortKing of Prussia, PA

Join Us for a revolutionary experience at METALfab2015!

As the president of NOMMA and the chair of METALfab2015, please join me at the Valley Forge Casino Resort, King of Prussia, PA (a suburb of Philadelphia) for METAL-fab2015.

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 pro-vide 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 experi-ence, 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.

Mark KoenkeNOMMA President 2014–2015METALfab2015 Convention Chair

Conference highlightsProgram at a glance Education sessions Sponsors, Registration

Page B Pages C–D Hotel information form Pages E–F Pages G–H

NOMMA METALfab2015 Guide A


METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015Knowledge to enlighten the industryProgram at a glance

8:00 am–9:00 am First Time Attendee Orientation New attendees get overview of NOMMA and METALfab

9:15 am–11:15 am Opening Session NOMMA annual membership business meeting and keynote

11:15 am–12:30 pm Lunch Break Lunch on your own

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

8:00 am–9:30 am NEF Education Sessions 2 sessions: 2 classrooms with 1 session each

9:30 am–2:30 pm Exhibits Open Visit with exhibitors and vote in Top Job contest

10:00 am–2:00 pm Spouse Classes 2 classes for attendees with a spouse registration

12:30 pm–1:30 pm Lunch with the Exhibitors Enjoy lunch while you visit with exhibitors

2:45 pm–6:00 pm NEF Education Sessions 4 sessions: 2 classrooms with 2 sessions each

7:00 pm–10:30 pm Party with a Purpose Network, bid at the auction, enjoy entertainment, food, drink

8:30 am–10:00 am NEF Education Sessions2 sessions: 2 classrooms with 1 session each

10:00 am–1:00 pm Exhibits Open Another chance to visit exhibitors and vote in Top Job contest

10:30 am–12:30 pm Spouse Class 1 class for attendees with a spouse registration

1:00 pm–4:15 pm NEF Education Sessions 4 sessions: 2 classrooms with 2 sessions each

4:30 pm–6:00 pm Top Job Jamboree Learn from the members who entered the Top Job contest

6:00 pm–7:00 pm NEF Partners in Education Reception Thank you for your continued support of NEF

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 of� cers, present Top Job awards, closing remarks

WEDNESDAY, MARCH 11, 2015

THURSDAY, MARCH 12, 2015

FRIDAY, MARCH 13, 2015

SATURDAY, MARCH 14, 2015

NOMMA METALfab2015 GuideB


METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015Knowledge to enlighten the industryEducation session descriptions Business classes withR. 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 con-struction estimating, both in negotiated and hard-bid envi-ronments and has operations experience, serving as proj-ect manager on commercial and industrial projects.

Pare has a master’s in business administration, con-centrating in � nance and real estate, a master’s in man-agement, and a bachelor’s in building construction from the University of Florida. He is a LEED accredited profes-sional.

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 � eld problem, but rather a management and leadership issue.

In this session, you’ll learn how to improve productivity to address market challenges by:

R. Tyler PareConsultantFMI Corporation

NOMMA METALfab2015 Guide C

n understanding how a minimal improvement in pro-ductivity will make you more competitive.

n implementing FMI’s P3 model: Process, Productivity Tools, People.

n determining the best practices and the new technolo-gies 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 pro� tability by:

n incorporating � eld input into estimates and budgets,n determining the healthy differences between an esti-

mate and a budget,n recognizing why and how actual job costs should be

tracked, and n using job-cost information to improve estimating

accuracy.

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 pro� t. 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 over-all company performance on a timely basis so you can make corrections to keep your team on course.

n Measure your business’s processes to de� ne success factors and measure progress toward strategic goals.

Keys to Effective Management Why is it so dif� cult to work and get along with cer-tain 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 work-ing 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 pref-erences, 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 pro� le.

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 mar-kets around them, many are putting new effort into their approach to business development.

After observing a signi� cant shift in this direction, FMI conducted a survey of contractor CEOs and top execu-tives 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 � rms. 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.

METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015Knowledge to enlighten the industry

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 pro� t, but where is the cash?

n Primary sources of cash.n How to � nd 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-on-

hand 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, � rst impressions insights, designing the right written test to � t your needs, thoughts on actual hands-on task testing, and making the � nal decision.

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

The � rst 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 speci� c challenges for address-ing in the hands-on section.

History of Metalwork Eric Cuper, Cuper Studios LLCThis 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 MetalworkDiscover how the under-40 group see their future path to success. In past years, you’ve heard from veteran fabri-cators 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 ToursDuring 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 ToursWith 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 fabrica-tors.

Women in the BusinessA roundtable discussion for women in the metals business. Discuss chal lenges, successes, and where to go in the future. Great networking for women in the industry.

ListServ LiveMeet 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 GuideD

How To Avoid Confrontation with Change Orders Change orders are a way of life in construction and, unfor-tunately, so is the dif� culty 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.


METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015Knowledge to enlighten the industry

KeynoteBarry WillinghamAmeristar Perimeter Security USABarry 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 perim-eter security, � re protection, and construction tech-nology. He has held positions in manufacturing and security construction installation, with additional responsibilities involving training, organizational devel-opment, leadership, and operational excellence.

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

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 Founda-

tion 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 enjoy-ing a wonderful luncheon.

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.

n All hotel reservations must be guaranteed with a major credit card or guaranteed and accompanied by a � rst night’s room deposit including sales and occu-pancy tax.

n Reservation cancellations must be received 3 days before arrival to avoid the billing of the � rst 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.

Gambling Problem? Call 1-800-GAMBLER

METALfab2015 Registration instructionsTwo ways to register for METALfab2015.1 Go to the NOMMA website www.nomma.org and regis-ter 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 RegisterThe 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, Regu-lar $580; Deadline 3/4/2015.

Non-members: Save money on your registration by becom-ing 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, [email protected].

Conference Hotel information — Valley Forge Casino Resort

NOMMA METALfab2015 Guide E

METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015METALfab2015Knowledge to enlighten the industry

Platinum SilverIndustrial Coverage Corp. Lawler Foundry Corp.

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

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

Big Blu Hammer Mfg. Co. . . . . . . . . . . . . . . . . . . . . . . . www.bigbluhammer.com

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

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

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

Custom Orn. Iron Works . . . . . . . . . . . . . . . . . . . . . . . . www.customironworks.com

D.J.A. Imports Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.djaimports.com

Elite Architectural Metal Supply LLC . . . . . . . . . . . . . . . www.elitearchitecturalmetal.com

Ercolina — CML USA Inc. . . . . . . . . . . . . . . . . . . . . . . . www.ercolina-usa.com

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

Hartford Standard Company Inc.. . . . . . . . . . . . . . . . . . www.hartfordstandard.com

Industrial Coverage Corp.. . . . . . . . . . . . . . . . . . . . . . . . www.industrialcoverage.com

King Architectural Metals . . . . . . . . . . . . . . . . . . . . . . . . www.kingmetals.com

Lavi Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.lavi.com

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

Locinox USA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.locinox.com

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

NOMMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.nomma.org

NOMMA Chapters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.nomma.org

NOMMA Education Foundation . . . . . . . . . . . . . . . . . . www.nomma.org/nef

Regency Railings Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . www.regencyrailings.com

Sumter Coatings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.sumtercoatings.com

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

ABANA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . www.abana.org

American Fence Association. . . . . . . . . . . . . . . . . . . . . . www.americanfenceassociation.com

Exhibit ScheduleThursday, March 12 .......................................................... 9:30 am–2:30 pmFriday, March 13 ............................................................... 10:00 am–1:00 pmGo to www.nomma.org for an up to date list of exhibitors and sponsors.

Sponsors as of 9/26/2014

Exhibitors as of 9/26/2014

NOMMA METALfab2015 GuideF

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

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.”

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

METALfab2015 Registration Options Special Fee Regular Fee9/1/14–2/19/15 2/20/15–3/4/15

❑ Full Conference — NOMMA Member $450 $580Education Program/Opening Session/Exhibits/Thursday Party with a Purpose & NEF Auctions/NEF Reception/Shop Tours/Awards Banquet

❑ Full Conference — Non-Member $650 $780Education Program/Opening Session/Exhibits/Thursday Party with a Purpose & NEF Auctions/NEF Reception/Shop Tours/Awards Banquet

❑ One Day — NOMMA Member $350 $480Events scheduled for day except Spouse classes and tour (check day): ❑ Wednesday ❑ Thursday ❑ Friday ❑ Saturday

❑ One Day — Non-Member $550 $680Events scheduled for day except Spouse classes and tour (check day): ❑ Wednesday ❑ Thursday ❑ Friday ❑ Saturday

❑ Spouse Registration $380 $480Spouse Classes/Opening Session/Exhibits/Thursday Party with a Purpose & NEF Auctions/NEF Reception/Spouse Tour/Awards Banquet

❑ Exhibits Only Registration $0 $0Visit the suppliers on the show � oor.

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 packetSpouse Registrant Name__________________________________________________ ❑ New Member

❑ First Time AttendeeCompany _______________________________________________________________ ❑ Fabricator Member

❑ NW Supplier MemberAddress:_________________________________________________________________ ❑ Regional Supplier Member

❑ Local Supplier MemberCity: ____________________________________________________________________ ❑ Af� liate Member

❑ Committee ChairState: __________Zip:_________________Country:_____________________________ ❑ Committee Member

❑ Chapter PresidentEmail:____________________________________________________________________ ❑ Chapter Member

❑ NEF ContributorPhone:_____________________________ Fax:__________________________________ ❑ Gold Member 20+ years

❑ Past PresidentEmergency Contact Number:_______________________________________________ ❑ BOD ❑ Of� cer

❑ NEF Trustee/Of� cerName of Emergency Contact:_______________________________________________ ❑ Speaker/Presenter

Registration form continued on page H

METALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee Registration FormMETALfab2015 Attendee 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NOMMA METALfab2015 Guide G

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




Attendee Pro� le Tell us about your businessThis 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 3) Your role in purchasing 4) Job description ❑ Fabricator ❑ Below $1 million ❑ Final Say ❑ Owner ❑ General Supplier ❑ $1–$2.5 million ❑ Recommend ❑ Manager/Foreman ❑ Contractor ❑ $2.5–$5 million ❑ Specify ❑ Other_______________ ❑ Other_____________________ ❑ Over $5 million

Important InformationRegistration 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.

Con� rmation & Updates Your con� rmation 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 [email protected] 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 Call 888-516-8585 extension 101 or email [email protected]. O. Box 124 For updated information go to www.nomma.orgDelcambre, LA 70528 Online Registration is available on the NOMMA website: www.nomma.org Fax: 888-279-7994 Mail checks to the “Return to” address at left.Email: [email protected] Be sure to include your registration form when mailing or faxing your payment.

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NOMMA METALfab2015 GuideH


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Here’s a list of things to do and see:

n Valley Forge National Historical Park. This 3,500-acre park is a must-see. It contains 19.5 miles of trails for hiking, running, or cycling. If you want to see all the main monuments, walk on the Joseph Plum Martin Trail, which is a 6.6 mile loop. On this walkway you’ll see the Muhlenberg Brigade, an historic camp, the National Memorial Arch, Washington Memorial Chapel, and the von Steuben Monument overlooking the Grand Parade.

n King of Prussia Mall. The second biggest attrac-tion in the area is the King of Prussia Mall. Oh, sure you may say that malls are everywhere, but this is no ordi-nary mall. With 400 stores and three food courts it’s one of the largest shopping centers in the U.S. The mall has more than 2.6 million square feet of retail space and welcomes 25 million visitors a year. If you want to take a break from shopping, try the IMAX theater.

n Spring Mountain. If you enjoy living on the edge, check out the canopy tours at Spring Mountain Adven-tures. Excuse the pun, but this place is no zip in the park. You’ll actually ride on an entire course of zip lines, including one that’s 340 feet (you are requested to scream the entire time). Speeds on some of the lines can get up to 45 miles an hour, which is no big deal in a car, but a bit dicey when you’re � ying over treetops.

n Historic sites. There’s plenty more history in the area in addition to Valley Forge park. Recommended places to visit include the Beth Sholom Synagogue, designed by Frank Lloyd Wright, and the Bryn Athyn His-toric District, which features Gothic architecture. Also, Pottsgrove Manor, a 1752 Georgian mansion, and Penny-packer 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 fea-tures an 18th century German kitchen garden, gift shop, and adorable farm animals.

n Arts & culture. Visit the John James Audubon Cen-ter 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 scienti� c studies and bird research.

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

Finally, take in The Stoogeum, North America’s only museum devoted to the Three Stooges. At the facility you’ll see some 100,000 collectibles, including props, posters, magazines, toys, and personal items.

n Restaurants. The Valley Forge area features a wide variety of restaurants, providing cuisines that range from hamburgers to steaks. One restaurant of interest is Savona in Gulph Mills, which features world-class cook-ing and the largest wine cellar in Pennsylvania, with 1,200 available selections. The restaurant building was used as a lookout post during the encampment of Valley Forge during the winter of 1777. Two microbreweries are in the area, including the Rock Bottom Restaurant & Brewery in King of Prussia.

n Nightlife. Looking for some evening entertainment? You can � nd it at our own host hotel, Valley Forge Casino Resort. The facility offers more than 35,000 square feet of action on its casino � oor, with 600 slot machines and 50 live gaming tables. The casino has several restaurants, including Paci� c Prime, Valley Tavern, Viviano, and the American Grill, which features good ol’ burgers and hotdogs.

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


Boyertown Museum of Historic Vehicles. Chanticleer gardens, left; downtown Pottstown.

2015KNOWLEDGE to enlighten the industry. 2015KNOWLEDGE to enlighten the industry.

METALfab

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Member Talk

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

S T R E T C H I N G S T R E T C H I N G S T R E T C H I N G rural sensibilitiesrural sensibilitiesrural sensibilitiesS T R E T C H I N G rural sensibilitiesS T R E T C H I N G S T R E T C H I N G S T R E T C H I N G rural sensibilitiesS T R E T C H I N G rural sensibilitiesS T R E T C H I N G rural sensibilitiesS T R E T C H I N G S T R E T C H I N G S T R E T C H I N G rural sensibilitiesS T R E T C H I N G

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

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

By Molly Badgett

In Mitchell, SD, Greg Bailey has a cus-tomer base that’s largely conserva-tive when it comes to ornamental and miscellaneous metals. Few people are willing to spend a lot of money on highly decorative pieces. Most of Bailey Metal Fabricators’ customers go for the highly functional.

Th is market has served the com-pany well since it became the family business in the 1960s. Now, however, Greg Bailey is looking to forge, so to speak, a new direction for the com-pany, to see what happens if the met-als took on more aesthetic appeal. It wouldn’t replace the core business. Rather, it’ll create another basket for some eggs.

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

O&MM Fabricator How is your busi-ness divided between residential and commercial work?

Greg Bailey We do so many diff er-ent things; it’s hard to break it down. We do residential railing and stairs, and commercial railing and stairs. On the commercial side, we do all kinds of things like structural steel, railing, gar-bage gates, sunshades, drive gates, lad-ders and trench drains — pretty much anything metal (a customer) could use on a commercial site. On the residen-tial side, we do railing, garden gates, curved stairs, spiral stairs, drive gates, sunshades, and curtain rods.

We also do a lot of industrial fabri-cating; we make concrete forms for box


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

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

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

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

room to expand into other areas of fab-rication that have larger profit margins. The downside is that sometimes we are busy with lower-margin items that take up some of our shop capacity.

Fabricator How do you go about get-ting business?

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

Sometimes, the better work that we would like to have, we have to go out and get it. We get work in a variety of ways; we use a builders’ exchange, architects, our Web page, Facebook. And, we have a lot of word-of-mouth advertising. It’s stuff with a little bit more margin.

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

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

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

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

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

We’re pretty good at a lot of differ-ent things, and there are some things that we’re not as good at as we’d like,

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


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

The biggest challenge for Bailey Metal Fabricators was that none of the company’s steel saws was capable of making the compound miters needed at the corners. Bailey Metal did have a small wood table saw, however, so the miter gauge was replaced with a custom designed and fabricated jig. That held the bull-nose fascia at the correct angle to make a compound miter. The result: tight-fitting compound miters for the bolted connections.

but we pride ourselves in doing the best job we can on everything we do. It doesn’t leave our place until I’m satis-fied with the workmanship; that some-times costs us in the end. I’m fussy that way, maybe too fussy.

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

Sometimes we’re not even bidding against anyone (for a job). Because of our reputation, some of the contrac-

tors bring us the work, regardless of where we’re at with the price. They know we’re going to give them a fair price and very good quality.Fabricator Do you ever do work for the Corn Palace* there in Mitchell?

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

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

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

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

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

Bailey The shop was started in the 1940s; we don’t know exactly when. My dad, when he got out of the ser-vice, worked for the son-in-law of the guy that started the business and went into a partnership with the son-in-law.

* The iconic Corn Palace in Mitchell, SD, dates back to 1892 as a tribute to South Dakota’s thriving agriculture industry, and today is a site for the annual Corn Palace Festival, exhibits, and civic events. Drawing a half-million tourists a year, the building features Moorish minarets and annually designed murals made of natural corn in multiple colors.


My dad took it over around 1960.Since I was a little kid, I hung

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

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

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

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

We usually have three or four oth-ers, not including family. Typically, we have between eight and 10 on board. We just hired another employee.

Fabricator How do you fi nd qualifi ed help?

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

Usually, it’s people not typically looking for a job. Th ey’re working for someone else until they hear our ad. Th e ads run on FM, all hours of the day and night. We have a good rela-tionship with the station.

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

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

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

We don’t spend more than $400 to $500 a month. We’re right in the prime time, when people are driving to work. We have a Web page link to our site on the radio station Web page when they do Internet broadcasting. It helps to know people, too, who work at the station. We’ve been doing it for seven, eight, maybe nine years.

Th ey’re 30-second spots. We let lis-teners know that we are a small com-pany with competitive pay and benefi ts and with a good working environment, and that they won’t be stuck doing the same thing every day; the projects are always changing from day to day. No production-line jobs here!

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

Typically, within a couple of days of running those ads, we have applicants. I fi nd that they’re better-quality appli-cations than we had before I started doing that.

We were one of the fi rst to do that kind of advertisement, and now I know at least three manufacturers who advertise on the radio for applicants, and one of the automotive dealerships. Now quite a few more are doing it.

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

Fabricator What else do you advertise for besides new hires?

Bailey Th e radio advertising is not great for commercial work, but it does work for our residential business. Th e homeowner is the one we’re trying to draw in. Th e target market appears to be right in that 35-to-65 age group. Th is is the market spending the money with us. For some of the things that we do, it works pretty well.

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

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

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

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

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

Fabricator Do you sell a lot to the farmers in South Dakota?

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

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

We do service some of the farmers, but not nearly as many as we used to. That market has changed considerably over the years. When I started, that was 75% of what we did. Now, it may be less than 10%.

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

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

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

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

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Fabricator How is business?Bailey We had a slower year last

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

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

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

We didn’t see much change until about 2008 or 2009. We didn’t slow down until about the end of 2010. When everyone else was bad, we were a year behind that.

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

I don’t think we saw it coming; it never got that bad for us anyway. We’re really diversified; we don’t see the market just drop out from under us.

Fabricator Are you hoping to get into more artistic work?

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

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

We’re getting into copper some. We’re trying to add a few elements to some of our railings. Again, we’re dab-bling, trying to create a market for it. People here are pretty conservative.

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

bronze, copper, nickel, and silver.We don’t do much blacksmithing to

speak of, either. We’re thinking we can create a market for that, too, mainly because no one around here does that type of work — the more decorative and artsy pieces. Blacksmithing tends to be more on the creative and artsy side, in my opinion. It is functional but typically more high-end.

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

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

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

Fabricator What else do you get out of NOMMA?

Bailey A lot of things. The one thing that I’d say to most members is that unless you go to the METALfab


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

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

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

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

Get on the NOMMA ListServ [dis-cussion forum] at the very least; mem-bers will help you with the day-to-day problems you encounter. I will guaran-tee that membership fee will pay itself back if all you do is seek out informa-tion on the ListServ. Don’t be shy, ask

the questions!Until you actually network with

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

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


Greg BaileyBailey Metal Fabricators Inc.Mitchell, SD605-996-4306605-996-6748 fax605-999-4306 [email protected]

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

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n Th e Top Job Gallery features entries in our 201 Ernest Wiemann Top Job Contest . Information about the annual competition, open to all NOMMA members, is post ed at the NOMMA website, www.nomma.org.

Fences &Bestın Class

Top Job GalleryTop Job GalleryTop Job Gallery n

RailingsCategory: Exterior railings & fences — nonforged

Falling Hammer Productions LLC — Gold

Wolcott, CTDesigned by the fabricator, this job

is roughly 125 feet of custom railings and balconies made entirely from 304 stainless steel.

Th e ovals were made from 1/2 -inch square material that were annealed and then bent cold in halves using cus-tom press-plates.

Th e resulting half-ovals were then adjusted cold to match a master and assembled into full ovals before fi nal

fabrication of the railing. Small, forged collars were ham-

mered on cold to cover the welded joints between the ovals.

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

Th e fi nal fi nish was satin black paint.

Th e greatest challenge was making the cap rail, which began as 3/8 x 21/2 inch 304 fl at stock that the fabricator annealed and ran cold through a cus-tom roller to create a domed cross-section.


c

Allen Iron Works & Supply Inc. — Silver

Birmingham, ALThe castings used in this step railing

offer design and detail that would have taken extensive work and time to com-plete if forged by hand.

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

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

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

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

The finish is oil base enamel. The difficulty was to keep the integ-

rity of the design while shortening it. Approximate labor time: 82 hours.


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Allen Architectural Metals Inc. — BronzeTalladega, AL

Th is architect-designed, exterior custom rail for New York’s Park Avenue Armory created challenges due to the combination of mixed materials and fi n-ishes. Th e cap railing was free-formed, draped, and created from 41/2-inch OD copper pipe and custom copper castings.

Th e rail span due to inconsistent site condi-tions would not allow the use of a single length of copper, thus requiring castings and standard pipe. Th e challenge was to create seamless joints in the copper top rail that was neither visible nor detect-able to the touch.

Th e fi nishing of the copper was labor intensive; the custom heat applied patina required about 80

hours and three diff erent color com-binations to achieve the fi nish.

Th e fabrication and fi nishing of this complex railing system took about 400 hours, the end result pos-itively accepted by the client and architects and now the focal point at the entrance to this newly renovated New York Landmark.


M. Cohen & Sons Inc. — GoldBroomall, PA

This job is an ornate bronze sculp-tural frontispiece designed by a Palm Beach-based architecture firm. The entire piece is made of bronze, which was moderately antiqued during finishing.

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

The piece was installed using invisi-ble fasteners into marble.

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

Approximate labor time: 800 hours.

Category: Exterior railings & fences — forged



Rod Iron Rod Inc. — BronzeOdessa, TX

Th e fabricator designed all the gates and the fence (see top photo on next page and on magazine cover) for the customer in AutoCAD. Th ere was 210 feet of fence with this job and two sets of entry gates.

All the scroll work is hand forged. Th e frame is 11/2 -inch square tubing with hand forged C scrolls.

Th e fi nish is Penny Vein powder coat.

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

Approximate fabrication time: 680 hours.

Iron Touch LLC — SilverLouisville, KY

Th is hand forged railing depicts the customer’s fl ower garden and favorite plants.

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

blooms, all with fully textured vines. Th e railing is fabricated by hot tex-

turing and shaping of both fl at and round iron with forged leaves.

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

Materials include 16-ounce copper

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

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

Th e railing fi nish is a layer of primer base coat, primary color, a bur-nished, secondary darker color, and a fi nal UV resistant clear coat.


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Compass IronworksGap, PA

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

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

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

Requirements specified there be no equipment over 7 PSI of turf compac-tion and zero damage to trees or roots. The property had more than 100 trees, and many holes had to be air-spaded.

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

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

Approximate labor time: 3,133 hours.


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

ACA blueprint for small business comes online

Biz Talk

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

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

By Mark E. Battersby

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

Small business optionsOne important development

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

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

Businesses with 50 or fewer employeesWhile many employers under-

stand the value of providing health insurance to their employees, doing so can be challenging for small businesses that lack the purchas-

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

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

Each state is expected to have a SHOP Marketplace. A business must have an office or employee work site within the SHOP’s service area to use that particular SHOP.

To use SHOP, a business must offer coverage to all of its full-time employees — generally those work-ing 30 or more hours per week on average. In many states, at least 70% of your full-time employees must enroll in your SHOP plan. (Employ-ers who apply for SHOP coverage between November 15 and December 15 each year can enroll without meet-ing this requirement.

Source: https://www.healthcare.


gov/what-is-the-shop-marketplaceStarting in 2016, all SHOPs will be

open to employers with up to 100 full-time employees. The process for enroll-ing in SHOP plans varies by state, but in most states, it will be handled through an insurance agent, broker, or preferred insurance company.

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

Tax credits for business with fewer than 25 employeesSome small businesses, notably those

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

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

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

You can still deduct from your taxes the rest of your premium costs not cov-ered by the tax credit. This tax credit is to be available only for plans purchased through SHOP.

Source: https://www.healthcare.gov/will-i-qualify-for-small-business-health-care-tax-credits

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

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

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

Self-employed, no employeesIf you are a self-employed business

owner with no employees, you cannot get coverage through the SHOP. You must instead turn to the individual market Health Insurance Marketplace

What’s new and updated SHOP for small businesses

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

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

Tax credit for very small employers

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

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

The employer mandate for larger businesses

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

Expanded W-2 reportingThe ACA requires employers

to include on Form W-2 the total cost of employer-sponsored health insur-ance coverage.

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

For IRS-related ACA infohttp://www.irs.gov/uac/

Newsroom/Questions-and- Answers-on-Employer-Shared- Responsibility-Provisions- Under-the-Affordable-Care-Act


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

The large business ‘employer mandate’ The ACA requires large employers of 50 or more

employees to provide health coverage or pay a penalty. Four years later and after repeated delays, the so-called “employer mandate” has become something of an orphan. Twice in the last two years, the administration has delayed the penalties, citing difficulties enforcing the mandate.

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

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

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

Employer responsibility provisionThe Treasury Department has issued the following state-

ment regarding 2015: “The employer responsibility provision will generally

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

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

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

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

Phasing in scheduleAlthough there are only scattered reports of this hap-

pening so far, businesses are reviewing the option as they plan for 2015, when the mandate requirement is scheduled to be phased in — unless the administration delays them further.

Beginning in 2015, the penalties are scheduled to go into


effect on employers with more than 100 workers.

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

The great unknownPotentially impacting all this is that

the Affordable Care Act has faced legal challenges. In July, two federal appeals courts issued contrary opinions on whether subsidies for qualifying indi-viduals are legal, which might throw the individual subsidy issue before the U.S. Supreme Court.

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

Expanded W-2 reporting In March 2014, the IRS issued final

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

employers that are required to file more than 250 W-2 forms must report.

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

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

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

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

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

Coming later? The excise tax on high-end plans

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

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

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

“The employer responsibility provision will generally apply to larger firms with 100 or more full-time employees starting in 2015 and employers with 50 or more full-time employees starting in 2016.”

— U.S. Treasury Department Fact Sheet


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

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

And don’t forgetMedicare tax withholding The Medicare part A tax is paid by

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

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

Small businesses making under $250,000 are exempt from the tax. Employees, even the shop’s owner mak-ing less than $200,000 as an individual or $250,000 as a family, are also exempt.

Health Flexible Spending Arrangements (FSA) Limits on contributions to FSAs,

used by many self-employed and small business owners, are now $2,500 (pre-tax employee contributions) adjusted for inflation.

The individual mandate The mandate requiring most indi-

viduals to either obtain qualified health care coverage or pay a fee or “penalty” went into effect Jan. 1, 2014. The pen-alty in 2014 is calculated one of two ways. If you or your dependents don’t have insurance that qualifies as min-imum essential coverage, you’ll pay whichever of these amounts is higher:

n 1% of your yearly household income. Only the amount of income above the tax-filing threshold, $10,150 for an individual, is used to calculate the penalty. The maximum penalty is the national average premium for a bronze plan.

n $95 per person for the year ($47.50 per child under 18). The max-imum penalty per family with this method is $285.

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

Source: https://www.healthcare.gov/what-if-i-dont-have-health-coverage

ConclusionSmall business owners with fewer

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

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

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

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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

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

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

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


We are proud of our members!

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

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

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

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

n Dave White Jr., Locinox USA, Countryside, IL

The Rust-Free Club

Individuals who have provided the NOMMA office with a member lead for the 2014–15 membership year, which began July 1.

n Chet Dinkins, Sumter Coatings Inc., Sumter, SC

n Dave Filippi, FabCAD Inc., White Stone, VA

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

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

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

n Allyn Moseley, Heirloom Stair & Iron, Campobello, SC

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

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

n John Steel, Steel Welding, Freedom, PA

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

Meet our membersNOMMA is proud of its 550+ members. As members, fabricators and suppliers show support for both the association and entire industry.

To get contact information on a member, please see our Member Locator at www.nomma.org.

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

NOMMA 2014 Gold MembersNOMMA 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 Architectural Iron Designs Inc. ......... Plainfield, NJn Berger Iron Works Inc. ......................... Houston, TXn Creative Forge — Reichert Corp. ....... Telford, PAn D’Agostino Iron Works Inc. ................. Rochester, NYn DAC Industries Inc. ................................ Grand Rapids, MIn Emerald Ironworks Inc. ........................ Woodbridge, VAn Historical Arts & Casting Inc. ............. West Jordan, UTn Jesco Industries Inc. — Wire & Iron Products Div. .................. Litchfield, MIn Keystone Metals Inc. ............................ Pittsburgh, PAn Liberty Home Products ........................ Denver, COn Louis Emmel Ornamental Iron Inc. ........................... Coraopolis, PAn Mac Metals Inc. ....................................... Kearny, NJn New Hampshire Steel Fabricators Inc. ........................... Goffstown, NHn Outland Steel Inc. .................................. Caldwell, IDn Pinpoint Solutions ................................. Jupiter, FLn Van Dam Iron Works ............................. Grand Rapids, MIn Van Linda Iron Works Inc. ................... Lake Worth, FL

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

n

New NOMMA Members

A1 Fire Escape* Thomas Curran Quincy, MA

Local Supplier

Borrelli Steel Fabricators Jay Price Vineland, NJ

Fabricator

Craft Ornamental Metals John Hladczuk Merion Station, PA

Fabricator

DDM Steel Construction Rich Muckenfuss Vineland, NJ

Fabricator

EH Iron Works Ed Hladczuk Philadelphia, PA

Fabricator

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

Fabricator

Evolution Ironworks* Andrew VanSchoick Albany, NY

Fabricator

Frederic Zimmer Sculptor* Frederic Zimmer Honolulu, HI

Fabricator

Glenn’s Custom Metals Inc. Glenn Raulfs

Red Lee Draper, VA

Fabricator

JSR Inc. Danny Frias Schertz, TX

Fabricator

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

Fabricator

Railing Systems Hawaii LLC Bob Tremain Kailua Kona, HI

Fabricator

Ranch Services LLC* Jeffrey D Hanneken Kamuela, HI

Fabricator

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

Fabricator

T & W Fabricating Tony Mertens New Holstein, WI

Fabricator

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Industry NewsHot?nWhat’s

Feeney, King Architectural Metals sign marketing dealFeeney Inc., known for

its CableRail stainless steel railings and DesignRail alu-minum railing systems, has joined King Architectural Metals in a service and marketing agreement.

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

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

president of business devel-opment, Del Leutbecher. “Feeney will directly ben-efit from the prolific mar-keting efforts performed year-round by King Metals,

including both digital and direct market-ing campaigns in the form of quarterly and annual product catalog and catalog update mailings; and newsletter distribu-tion to tens of thou-sands.”

In return, King Metals can now offer “a high-quality, com-petitively priced, stylistically versatile cable railing product,”

according to a news release. Feeney’s CableRail and

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

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

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

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201307-404-A

Cole-Tuve named new distributor for Apollo machines

Cole-Tuve Inc., of White Marsh, MD, has been appointed as the exclusive distributor in the U.S. and Canada by Apollo s.r.l., a prominent Italian manufac-turer of high-speed CNC tube and pipe punching and drilling machines.

Apollo manufacturers 22 different hydraulic punching machines. Models are avail-able for accurately punching and drilling pipes, as well as round, square and rectangu-lar tubes in a variety of holes and shapes.

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

the first to the last hole on a tube 3 meters long.)

Material can be placed in the machine manually and then processed auto-matically, or fed automati-cally from a bundled storage component and processed through the machine in as little as one meter per sec-ond, says the company.

Cores are available for inside the material, and they expand each time a hole is punched to keep it free of fall-off. An alpha-numeric programmer is standard equipment. Computer sup-port is available to guide repair in case of breakdown.

Contact 877-989-0700;www.coletuve.com


MediaWhat’sHot? n

New abrasive saws, sanders, and grinders in catalog

Kalamazoo IndustriesKalamazoo Indus-

tries is off ering a new, updated full-line cata-log of its abrasive saws, sanders, grinders and other components, including new additions to its line of abrasive cutoff saws.

Th ese saws include:n the Model K12-

14MS metallurgical saw, which produces mir-ror-surface cuts;

n the Model K26E large-capacity abrasive saw designed for foundries and other metal working operations handling large work pieces; and

n the Model K10SW 10-inch wet saw designed for cuts in smaller work

pieces, even when cutting high alloy steel.

Other new products include:n the Model BSG14

back stand grinder for foundries needing to rapidly remove metal;

n the Model S272V multi-purpose belt grinder for grinding, shaping, contouring, or other work on small parts or short-runs; and

n the Model KVF3 vibratory fi nisher that is less expensive than hand fi nishing small parts.

Contact Th e new Kalamazoo Industries cata-

log is available online at www.kalamazooindustries.com;

or call 269-382-2050

Underwood named president of Tampa Steel & Supply

Troy Underwood has been named the new president of Tampa Steel & Supply, a metal service center with long-standing roots in the Tampa Bay area.

Th e company off ers and invento-ries a full line of prime, secondary, surplus, and ornamental metals.

Features include on-hand inven-tory, cut-to-size services and accesso-ries, next-day delivery capability, and a no-minimum-purchase benefi t. Industries served include welding, construction, fabrication, ornamen-tal, and machine shops.

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

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Magnetic drill pilot light

Hougen ManufacturingHougen Manufacturing,

inventor of the mag drill annular cutter and a lead-ing manufacturer of mag-netic drills, has added the first-ever pilot light to the magnet of their new drill models.

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

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

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

This increases opera-tor productivity and hole location accuracy, says the company.

The new light improves visibility in two ways:

1 in low-light to no-light conditions it sheds light on the pilot point, and

2 in brighter condi-tions the LED light helps to counteract the shadows from the light.

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

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

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

Contact 810-635-7111;www.hougen.com

Heavy-duty wire straightener

Electron Beam Technologies

Electron Beam Technol-ogies, Inc., has announced a new, larger Straight ’N Easy Heavy-Duty Wire Straight-ener (Part #A-2251).

The Heavy-Duty Wire

Straightener features a modular design with sev-eral mounting options — face, end, and traditional.

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

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


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friction systems, the com-pany says.

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

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

Contact 815-935-2211;www.electronbeam.com

Modular cast-iron railing system

Wiemann Metalcraft /Heritage Cast Iron

Th rough its subsidiary, Heritage Cast Iron, Wie-mann Metalcraft is intro-ducing the world’s fi rst modular, code compliant

cast-iron railing system.Designed and engi-

neered to meet height, load and opening require-ments defi ned 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 Col-lection and are supplied ready to install.

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

Additionally, they interlock from one panel to the next, with a traditional mortise- and-tenon detail and do

not require welding for sat-isfactory installation, says the company.

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

fabricator/installer to suit a wide range of applications.

Contact 918-592-1700;www.wmcraft .com

Internet-enabled outdoor access-control system

Lift MasterAccess-control man-

ufacturer Lift Master, has introduced IPAC (Internet Protocol Access Control), the fi rst Internet-enabled outdoor access-control sys-tem with voice-over-Inter-net protocol (VoIP).

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


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IPAC allows property managers to access their system’s data from any browser or device, any-where, and at any time.

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IPAC also stores infor-mation for up to 50,000 residents.

IPAC also includes Lift Master’s Security+ 2.0 patented technology, which ensures a strong and reli-able signal to access prop-erty quickly and safely, says the company.

A large, color touch-screen interface provides easy and familiar naviga-tion for customers, resi-dents and guests, and a

full keyboard search lets guests quickly fi nd resi-dents without having to scroll manually. Anti-glare coating and auto dimming make it easy to read the screen in any light.

IPAC off ers a contem-porary design, and durable scratch and dent-resistant materials that can with-stand constant use, says the company.

Lift Master’s IPAC is also designed to deal with envi-ronmental extremes. When enclosed in a custom IP65-rated weather-tight enclo-sure, IPAC can operate in temperatures from -20°F to +130°F — providing customers with year-round protection.

Contact 800-528-5880;www.Lift Master.com/

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Auto-darkening welding helmet

Victor Technologies

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education inquiries: Judy Hayward 802.674.6752

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Product sWhat’sHot? n

amps, says the company. Th e helmet has a large

viewing area of 3.86 x 1.69 inches, weighs 16 ounces, uses solar power to elim-inate the need to change batteries, and comes in three styles.

When switching from light-to-dark, this helmet darkens in 33 microseconds (or ⅓ of a second).

When switching from dark-to-light, users can select from three switching speeds: short (0.25s to 0.35s), medium (0.35s to 0.50s) and long (0.50s to 0.80s).

Designed to combine safety, strength, fl exibility, and comfort, the Tweco WeldSkill four-sensor hel-met passes all of the 49 tests required under the ANSI Z87.1-2010 standards, the company reports. Th is

includes the ability to retain its auto-darkening per-formance even aft er high impact by a steel ball, the company says.

Th e sensitivity and delay knobs are on the outside of the helmet shell so that operators can make adjust-ments while welding. When setting the helmet down, a recessed lens design pre-vents the faceplate from touching the table, protect-ing it from scratches.

Contact 636-728-3000; www.victortechnologies. com

Vertical lifterKonecranes

Konecranes, global man-ufacturer of lift ing tech-nology, off ers the dynamic ATL Vertical Lift er to meet the handling requirements of a variety of industries.

With a lift ing capacity of up to 1,600 kg and absorp-tion of torque up to 4,000 Nm, the ATL Vertical Lift er off ers diverse, high-qual-ity drive concepts, says the company, along with pneu-matic balance controls or electrical chain hoists.

Konecranes’ pneumatic manipulators are ceil-ing-based solutions made up of an XA crane sys-tem and a telescopic lift ing device combined with a customized gripping unit.

Th e design is modular for fl exibility and adapt-

ability to meet the needs of individual operations.

Unlike chain or rope hoists, the ATL Vertical Lift er can lift loads outside the center of gravity, and its balancing mode makes the handling of parts feel nearly weightless, the company says. High-qual-ity telescope guides are designed to enable precise, sway-free lift ing and verti-cal manipulating.

Contact 937-525-5533; www.konecranes.com


Advertiser’s Index

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

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Pg Company Website Pg Company Website 70 Hougen Mfg. Inc. ........................................... www.hougen.com

58 International Gate Devices ..........................www.intlgate.com

76 The Iron Shop ........................................www.theironshop.com

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

75 King Architectural Metals ...................... www.kingmetals.com

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

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

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

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

48 Pat Mooney Inc. .............................www.patmooneysaws.com

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

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

55 Regency Railings ..............................www.regencyrailings.com

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

31 Scotchman Industries ............................www.scotchman.com

33 Sharpe Products ............................. www.sharpeproducts.com

59 Simonian Bender ..........................www.simonianbender.com

25 Stairways Inc. ..........................................www.stairwaysinc.com

52 Sumter Coatings Inc. ......................www.sumtercoatings.com

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

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

23 TS Distributors Inc. ..............................www.tsdistributors.com

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

19 The Wagner Companies ..........www.wagnercompanies.com

53 Weaver’s Iron Works................. www.weaversironworks.com

Sherry Theien Advertising Director8392 Leesburg Ct. Rockford, IL 61114815-282-6000 815-282-8002 [email protected]

CONTACT

Your advertising contact forO&MM FabricatorNOMMA Buyer’s GuideNOMMA website

Advertise in the 2015 NOMMA Buyer’s GuideYour one-stop resource for shop and office personnel

The Buyer’s Guide is available in 3 versions:

1) print, 2) online, and 3) database.

Closing date November 28, 2014Contact Sherry Theien, 815-282-6000; 815-282-8002 fax; [email protected]

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

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

69 Atlas Metal Sales ...................................... www.atlasmetal.com

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

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

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

4 The Cable Connection ..........www.thecableconnection.com

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

16 Carell Corporation .................................... www.carellcorp.com

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

70 CML USA Inc. ..........................................www.ercolina-usa.com

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

64 Colorado Waterjet Co. ................www.coloradowaterjet.com

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

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

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

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

13 FabCAD Inc. ...................................................... www.fabcad.com

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

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


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Metal Moment

Templates for cutting pipe

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 [email protected].

TALK TO US

From the NOMMA ListServJoin NOMMA to get your questions answered free.

NOMMA member Kurt Lents of Alamance Iron Works posted this question on the NOMMA ListServ:

Does anyone have a FabCAD template for cutting 11/4-inch pipe where three pipes come together for a level, 90° corner with post? All three ends should be cut in a heart shape. Many shops just make the handrail 45° and weld a post underneath. It could be done better. I’m trying to teach new guys with a sample but can’t quite figure the cuts out.

Angela D. Hertl, Big C Steel:We’ve used a website www.harderwoods.com/pipetem-

plate.php (see screenshot at right) to create a template with the proper angles to join pipes. Pop in the details, and it will create the cut template for you. Might help.

Stan Harder, digitalpipefitter.com:The joint in question is two miters, one rotated 90° com-

bined on the same template. The Digital Pipe Fitter applica-tion does the combining with a union joint. This joint can be done as shown below at http://digitalpipefitter.com.

Digital Pipe Fitter supports many simple and complex joints. Experienced fabricators can lay out the simple joints manually but many customers are pleased not to do manual layout even on the simple joints. The software saves time and is much more accurate than most manual layout techniques.

Instructions at digitalpipefitter.com: Choose the type of joint you want, enter pipe sizes and desired dimensions, print a template on your printer, wrap the template around the pipe, and cut on the line.


Photos submitted to our Facebook page by TopHand Fence, Lawton, OK.Photos submitted to our Facebook page by TopHand Fence, Lawton, OK.Photos submitted to our Facebook page by TopHand Fence, Lawton, OK.

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