Title of article
From homeless shelters to mixed-use spaces, prefab steel microhomes are changing how Americans live and work
Title of article
Title of article
Joss Hudson, President EcoSteel Building Systems
Title of article
From homeless shelters to mixed-use spaces, prefab steel microhomes are changing how Americans live and work
Title of article
Title of article
Joss Hudson, President EcoSteel Building Systems
July 2021
July 2021
trend publishing metals group  Volume 18 Number 06
July 2021
trend publishing metals group  Volume 18 Number 06
Logo
steel fabrication
Home sweet home
steel fabrication
Home sweet home
steel fabrication
Home sweet home
From homeless shelters to residential communities, eco-friendly, prefab steel is changing the face of an industry with attractive, affordable housing
features
Man going to work
bending/folding
During a difficult period, wise capital investment turns business around
Collaborative approach allows fabricator
material handling
A collaborative approach allows fabricator to adjust its inventory strategy
features
Man going to work
bending/folding
During a difficult period, wise capital investment turns business around
Collaborative approach allows fabricator
material handling
A collaborative approach allows fabricator to adjust its inventory strategy
A new customer expedites fabricator’s decision to invest in new equipment
Bending technology helps fabricator produce precision parts while staying a step ahead of demand
Servo presses with large bed sizes raise throughput, reduce die wear
Wheels
cutting technology
A new customer expedites fabricator’s decision to invest in new equipment
press brake tooling
Bending technology helps fabricator produce precision parts while staying a step ahead of demand
stamping
Servo presses with large bed sizes raise throughput, reduce die wear and deliver tight tolerances
deburring
Abrasives manufacturer looks ahead to an expanded product offering and wider geographical footprint
A new customer expedites fabricator’s decision to invest in new equipment
cutting technology
A new customer expedites fabricator’s decision to invest in new equipment
Bending technology helps fabricator produce precision parts while staying a step ahead of demand
press brake tooling
Bending technology helps fabricator produce precision parts while staying a step ahead of demand
Servo presses with large bed sizes raise throughput, reduce die wear
stamping
Servo presses with large bed sizes raise throughput, reduce die wear and deliver tight tolerances
Wheels
deburring
Abrasives manufacturer looks ahead to an expanded product offering and wider geographical footprint
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Cutting machine in use
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Online
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customfabricator
Atmospheric Wave Wall, designed by artist Olafur Eliasson, covers the wall outside Chicago’s Willis Tower with a pattern of powder coated steel tiles based on Penrose tiling
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plasma
Cutting machine manufacturer equips fabricators with the right tools to reduce scrap and gain higher throughput
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facetime
Softening the blows for high-end component shipping
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Welding robots to take over hard work in shipyards
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Welding contest aims to show students paths forward, strengthen the pipeline of skilled workers
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Photo: David Lane/Union Leader
Portrait photo of Lynn Stanley

From the Editor

lynn stanley, senior editor

Sustainable steel

A

ccording to the American Institute of Steel Construction (AISC), steel remains the leading green construction material. When it comes to environmentally safe phrases, it seems that more and more products are being touted as “green,” “eco-friendly” or “sustainable.” I wondered if the terms were interchangeable so I looked them up. Oxford Languages defines the word green as a label that refers to all aspects of environmentally friendly products from fashion to buildings. The term eco-friendly is attached to products or practices that won’t hurt the environment. Sustainability speaks to the idea that what we do today won’t exhaust resources for future generations.

Fabricator’s POV
BY STEVE GUISGOND, GENERAL MANAGER, CI METAL FABRICATION
Jacks of all trades
Cross-training can equip employees with the necessary tools for individual—and shop—success
B

ehind every great custom fabricator is an even better training program set in motion by the senior fabricators and shop managers. Ci Metal Fabrication, a custom industrial metal fabrication shop based in Meridian, Mississippi, has long relied on detailed training and education programs within its shop.

Ci Metal Fabrication uses talented and experienced mentors, averaging more than 30 years of industry experience in presswork, power forming, welding, cutting and shearing, to usher in the next generation of metalworkers.

Training & Education

By Lauren Duensing, Contributing Editor
Sawblade University moves the reference library to video
Cooperative Learning
Sawblade University moves the reference library to video
W

hile working, people often run into problems. And those problems need solutions. This basic concept is at the root of Sawblade.com CEO Chris Luke’s new online manufacturing training library, Sawblade University. Luke says he began to assess the idea of a collection of educational videos when talking with students at trade shows. “They’re a pulse on what’s going to happen in the future.”

Sawblade.com was already producing videos for customers detailing how best to cut specific materials, Luke says. For instance, if an aerospace manufacturer showed interest in how to successfully cut a specific grade of titanium, “they send us a small piece, we put it on the saw and produce an entire video for that company—a video they can keep and review and show employees.

Guest Editorial
By ALESSANDRO SOFFRITTI, PRESIDENT AND CEO, DAVI INC.
Offshore wind energy industry Davi machine
MCD/Davi machine
Harness the wind
Fabricating offshore foundations is a challenging and time-consuming rolling operation that requires the right skills and equipment
T

he offshore wind energy industry will be a “major contributor” to the post-COVID-19 economic recovery worldwide, according to the Global Wind Energy Council. Through 2030, the council forecasts that more than 205 gigawatts of new offshore wind capacity will be added globally—a 15-gigawatt increase from GWEC Market Intelligence’s pre-pandemic forecast.

However, the development of new technologies, manufacturing and construction procedures, and the increase in the size of wind farms and turbines, means new installations are being set up farther from the coastline. As a result, the design for the structures that support the turbines has evolved to become bigger, thicker, longer and heavier to accommodate these great ocean depths.

Hot Sheet
Supply chain disruption illustration
industry
Talent gaps, cost, lack of flexibility and IT systems over-reliant on legacy technologies are creating financial and operational challenges for U.S. supply chains.
Supply chain disruption
For fabricators and stampers battling wide-scale shortages, there are steps that can help hedge the drain

The pileup between supply chain bottlenecks and vigorous demand is putting the brakes on U.S. manufacturing. In May 2021, the Institute for Supply Management (ISM) reported “record-long lead times, wide-scale shortages of critical basic materials, rising commodities prices and transportation difficulties.”

Steel fabrication
By Lynn Stanley, Senior Editor
Home Sweet Home
From homeless shelters to residential communities, eco-friendly, prefab steel is changing the face of an industry with attractive, affordable housing
I

n the U.S., San Francisco is the undisputed king of tech IPOs with startups securing more than $31 billion in early stage venture capital funding between 2010 and 2020. Last year, the city was also recognized by the Wealth-X report as the third city in the world with the most billionaires—77 to be exact. Iconic landmarks like the Golden Gate Bridge and the former Alcatraz Federal Penitentiary, along with Chinatown, the San Francisco Giants, Fisherman’s Wharf and the Maritime National Historic Park make the Bay Area an eclectic mix of cultural, entertainment and commercial attractions. The city is also a dichotomy of the rich and homeless.

bending/folding
By Robert J. Kolcz, Prima Power North America Inc.
Wearhouse
The E5x servo-electric turret punch press can process full 1,250 mm by 2,500 mm sheets without repositioning and makes part nesting more efficient.
Power ahead
During a difficult period, wise capital investment turns business around
H

ow many job shops could lose a customer that accounted for 98 percent of their business and recover in just a few years? Elm Machining was faced with that scenario several years ago. The company confronted this threat by making some hard decisions, placing additional emphasis on fabrication, investing in the proper equipment and dedicating itself to the hard work that it took to not only survive but also prosper.

material handling
By Gretchen Salois, senior editor
Aisle view of the stacker crane for the Fehr honeycomb system
Aisle view of the stacker crane for the Fehr honeycomb system.
Future Proof
A collaborative approach allows fabricator to adjust its inventory strategy
I

n March, the Denver area was devastated by a record-breaking snowstorm that razed structures, forced businesses and schools to close, and left thousands of residents without electricity. A portion of Triple-S Steel Holdings Inc.’s Colorado facility was no exception. About 40,000 sq. ft. of its 234,000-sq.-ft. facility collapsed.

Cutting Technology
by Gretchen Salois, Senior Editor
Roto Hornet 1000 CNC plasma pipe cutter at work

Hornet Cutting Systems’ high-performance CNC plasma pipe cutting machines are built for speed and accuracy.

Roto Hornet 1000 CNC plasma pipe cutter at work
Hornet Cutting Systems’ high-performance CNC plasma pipe cutting machines are built for speed and accuracy.
Prepped & Ready
A new customer expedites fabricator’s decision to invest in new equipment
I

n September 2020, while much of the world remained shut down and in limbo, Fab Tech Wastewater Solutions LLC invested in a new Roto Hornet 1000 CNC plasma pipe cutter to meet a new customer’s demand. “We have a new customer that is going to send a volume of pipes to work on—plus, [we wanted] a general upgrade as well,” says David Umphenour, administrative services manager at the Warrenton, Missouri-based fabricator.

PRESS BRAKE TOOLING
By Lynn Stanley, Senior Editor
A different path
Bending technology helps fabricator produce precision parts while staying a step ahead of demand

A robot-operated Ermaksan 6-axis Speed Bend press brake provides production rates twice that of conventional machines.

robot-operated Ermaksan 6-axis Speed Bend press brake
A robot-operated Ermaksan 6-axis Speed Bend press brake provides production rates twice that of conventional machines.
A

sales call, a downpour and a missed cutoff outside Greenville, Texas, changed the course of events for Steve Lester, his wife, Sherrill, and his father, Pat.

“I was in the metals business at the time,” says Steve Lester. “I worked for a mill. I decided to visit QMF Steel Inc. It was a mom-and-pop operation with two barns full of metal. A terminal cancer diagnosis prompted the owner’s wife to try and persuade me to buy their business. At the time, I thought it was the worst idea I’d ever heard.

STAMPING
By lynn stanley, senior editor
Nidec Minster’s servo press technology allows HSI to run a variety of metals while boosting throughput and minimizing die wear.
Nidec Minster’s servo press technology allowing SI to run a variety of metals
Nidec Minster’s servo press technology allows HSI to run a variety of metals while boosting throughput and minimizing die wear.
Stepping up
Servo presses with large bed sizes raise throughput, reduce die wear and deliver tight tolerances
H

enderson Stamping & Production Inc. has been making decorative and non-decorative parts and assemblies for carmakers and appliance brands for 40 years. On any given day, 20 production lines hum with presses (110 tons to 1,375 tons) stamping everything from small automotive brake components to deep drawn cook tops out of stainless, carbon, high-strength and aluminum steels. Three plants total 165,000 sq. ft. of manufacturing space. Plant 1 also houses a tool room and a five-stage powder coating system. Plant 3 is used for warehousing and value-added assembly processes.

Deburring
BY gretchen salois, SENIOR EDITOR
Strategic
gains
We’re planning on adding more customers into the fold as we get our four points of distribution to full speed.
Graydon Greiwe, Continental Abrasives
Strategic gains
Abrasives manufacturer looks ahead to an expanded product offering and wider geographical footprint
W

hen Bill Taylor founded Continental in Los Angeles in 1960, the company became a go-to abrasives manufacturer for distribution houses across the west. Years later, the company was sold and subsequently, dissolved. In 2013, Taylor’s daughter Cindy; son-in-law Gary; and his grandsons, Graydon, Gavin and Garrett, relaunched Continental Abrasives, thus reestablishing its presence on the West Coast with plans to go nationwide.

Toolbox
Software expands integration graphics
SOFTWARE
Software expands integration
SigmaSUITE continues to close the loop on manufacturing connectivity targeting “The Connected Shop,” scheduling, quoting, and logistics informed by nesting intelligence. This focus, along with CAD/CAM enhancements centered on simplicity and best manufacturing strategies, continues to strengthen SigmaNEST capabilities. The aim of the Connected Shop is to bridge CRM, Ordering, Inventory, Production, Delivery, and Accounting. New software products and enhancements to the Business Systems and Shop Floor products have expanded this integration for customers.
SigmaNEST, Cincinnati, 513/674-0005, sigmanest.com.
Custom Fabricator
The Sound that Light Makes

The Sound That Light Makes by Australian artist Alexander Knox forms the exterior screen to the newly developed 300 George Street precinct in Brisbane, Australia. The work creates an iconic visual signature wrapped around the podium at the base of the three-tower site. Spanning 2,660 sq. m. and composed of over 2,500 3D-pressed and planar aluminum panels, the future landmark for the soon-to-be-completed high-end commercial area uses geometric and organic shapes to explore the effect of light shimmering on the surface of water. Its 3D metallic surface is designed to catch and mimic the kinetic nature of light on water, bringing the influence of natural forces into the highly urbanized setting of Brisbane’s central business district. The art façade’s title refers to the shimmer of light on water as a whisper from the site’s pre-urban epoch.

Photo: Alexander Knox, Cian Sanders and UAP
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator.
The Sound that Light Makes

The Sound That Light Makes by Australian artist Alexander Knox forms the exterior screen to the newly developed 300 George Street precinct in Brisbane, Australia. The work creates an iconic visual signature wrapped around the podium at the base of the three-tower site. Spanning 2,660 sq. m. and composed of over 2,500 3D-pressed and planar aluminum panels, the future landmark for the soon-to-be-completed high-end commercial area uses geometric and organic shapes to explore the effect of light shimmering on the surface of water. Its 3D metallic surface is designed to catch and mimic the kinetic nature of light on water, bringing the influence of natural forces into the highly urbanized setting of Brisbane’s central business district. The art façade’s title refers to the shimmer of light on water as a whisper from the site’s pre-urban epoch.

Photo: Alexander Knox, Cian Sanders and UAP
Learn more about this and other Custom Fabricators at www.ffjournal.net/customfabricator.
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FFJournal® (ISSN 1551-1006) July 2021 (Vol. 18, No. 6) is a registered trademark of Trend Publishing Inc. FFJournal® is published 11 times by Trend Publishing Inc., with its publishing office located at 123 W. Madison St., Suite 950, Chicago, Illinois 60602, 312/654-2300; fax 312/654-2323. Michael D’Alexander, President, Trend Publishing Inc. Copyright 2020 Trend Publishing Inc. All rights reserved under the United States, International and Pan-American Copyright Conventions. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means—mechanical, photocopying, electronic recording or otherwise—without the prior written permission of Trend Publishing Inc. Opinions expressed in articles are those of the authors and do not necessarily reflect those of Trend Publishing Inc. Published free of charge for those who qualify. It is mailed at no cost to these qualified readers in the U.S., Canada and U.S. possessions. Single copies $14. Paid subscriptions in the U.S., $120/year. Canada, $140/year. Foreign subscriptions, $175/year surface mail and $255/year air mail. For subscription information, go to www.ffjournal.net or call 312-654-2300. Periodicals postage paid at Chicago and additional mailing offices. Postmaster: Send address changes to FFJournal® c/o Creative Data Services, Inc., 440 Quadrangle Drive Suite E, Bolingbrook, IL 60440. Printed in the USA.
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