METFAB NEWS - 2012

2012 ---- Our 26th Anniversary Year

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December, 2012 Newsletter

Metfab Metals Reports Another Growth Year

Merry Christmas & Happy New Year
2013
Enjoy a Healthy & Happy Holiday Season

Each month this year we reported in this space Metfab Metals’ milestones, important developments
and some other noteworthy issues in our industry. Take a quick look:

January

Metfab Metals’ Services/Products

February

Brake Metal

March

AESS*BARS at“Ground Zero”

April

Great Engineering

May

Solid Steel-----“Major Mullions”

June

Focus----“Light Gauge”

July

Rome---Stone Anchors

August

Rust on Stainless Steel!

September

AESS*---“Major Mullions”

October

AESS* ---“Coordination”

November

AESS*---“Finishes”

December

Metfab Metals---Growth

As the above chart visually illustrates, we spent a lot of time talking about----while fabricating & supplying---AESS* this past year. But the same Newsletters charted above amply show how we worked for many of our customers, supplying each custom part exactly as ordered, month after month. Even a brief look at our regular “Updates” will give you the flavor of the challenging and innovative parts we made for a stream of mundane, routine jobs and for iconic signature jobs----like the Memorial Pools at Ground Zero!

Now we’d like to talk a little about the future---not the years-away future, but the future in the next twelve months of 2013! We have a lot of 2013 work booked already, Purchase Orders filed chronologically and many “pending” (but not contracted yet) jobs on our “quote” board (of course, not really a board, but a computer screen in our quotation program) that allows us to monitor the developments on jobs and work with you, our customers, to bring them to reality.

Certainly, metal fabrication in 2012 is a competitive business, but we here at Metfab Metals have learned that it is a competition that is not, by its nature, solely price-driven. Rather it’s a business that pivots on value. Our customers come to know-----and expect from us-----true value, not a value based solely on a “numbers game”. True value in construction (as it is always so much a function of time/timeliness) is actually computed from a bevy of factors, including:

  1. getting your supplies for a fair price;
  2. getting them on time;
  3. having them arrive as ordered and designed;
  4. having them arrive at one time or in the increments needed/ specified;
  5. having them labeled for accurate selection and ease of installation;
  6. having all this done without a “thousand” phone calls, emails, “threats” & excuses.
Warren Buffett, the legendary, super-successful investor often called the “Sage of Omaha”, observed
that “Price is what you pay. Value is what you get.”

So that we can grow in 2013, as we did in 2012, here’s what Metfab Metals plans to do for our customers this coming year:

ALWAYS deliver our Metfab Metals products and services in full compliance
with the six factors we just enumerated above. That’s all.

If we do just that, all of our customers will get “true value” on every order,
be it one for a few hundred dollars or millions of dollars.

#################################

UPDATES:

120 E.42nd Street, NYC, NY-----Here we have built a pre-construction VMU, or Visual Mock-Up**, of exterior fabricated parts. This is being done to give the owner, builders and design professionals an opportunity to view the exterior’s appearance and end-products after the building is completed. This is a service we offer many of our customers, especially since we did this so successfully prior to construction of WTC4 at Ground Zero this past year (and on an increasing number of larger jobs each year).

Barclays Center, Brooklyn, NY-----The Barclays Center is open in a newly-developing Downtown Brooklyn. We were happy to do a good deal of this fabrication work in 2012 also. But this is only part of a far larger area redevelopment. We are working to be a continuing part in 2013 of the cluster of high-rises and other development that are the next part of this overall project and the surrounding areas.


Metfab Metals is now your answer not only for quality custom and production Heavy-Gauge AND Light-Gauge metal parts, but also when your job requires AESS*  in all its MANY forms, finishes and applications!

We always offer to work --- FOR FREE --- with our customers at the project concept stage to anticipate issues before fabrication, to suggest better ways to order, extrude, cut, drill, paint, finish, even stage and deliver and always to save time and money. Call me. Come in and talk about pre-construction fabrication concerns

Call me.
Jim Murray, C.O.O.

973-675-7676               jim@metfabmetals.com

As you did in 2012 and soon again in 2013, as in all the past decades with our company,
you can truly count on Metfab Metals for full value for the price you pay.
This is still our pledge and our commitment to all our customers.

* For those still unfamiliar with this acronym, AESS is Architecturally Exposed Structural Steel, and is finely-finished steel members (prepped, welded, filled, blasted, polished, and/or uniquely painted/finished) to be permanently open to the view and touch of all after the job is done. AESS work is never covered by sheetrock or otherwise hidden from public view. Our COO, Jim Murray, has been an integral part of early AESS projects, such as the BWI International Airport [Now BWI Thurgood Marshall Airport]  (erected well over a decade ago)serving the Washington, DC/Baltimore area. There you can see the structural steel space frame with its threads, pipes and connections in plain view-------- and still shining like its original fabricated & installed condition! Since then, Jim has overseen AESS jobs as varied as the American Jewish Heritage Museum a few years back in Philadelphia and the unique roof ladder coverage of an interior courtyard at 51 Louisiana in Washington, DC or the Borgata Casino overhang in Atlantic City, NJ. WTC4 (at the restored Ground Zero in NYC) and VCU (Virginia Commonwealth University, School of Medicine) are even grander and more striking examples of this evolving art form and architectural esthetics at which Metfab Metals is proud to have done the AESS components.


October, 2012 Newsletter

At Metfab Metals, COORDINATION is the key
to Your AESS Delivery Issues Too


[This is an illustration of only ONE of our AESS special shipping processes]

In Newsletters, we have now been writing about our capacities to produce AESS. 1 Major Mullions and other specialty products for years. Last month, we pointed to an excellent resource to help all of our customers---present and future---to most accurately define and specify the exact type or “category” of AESS parts that their job/purchase order actually requires. 2

This CISC Manual is an excellent basic guide to all manner of AESS information. Of course, the first point that most focuses any building contractor is PRICE. What we’d like to highlight in this Newsletter are some of the factors that directly affect that price, sometimes even raising that cost unnecessarily. Some of these factors apply not just to AESS steel, but also to any part with a custom or specialty finish that must be handled with special care---and usually with specialized equipment---once that finish has been applied. We touched on this last month when we wrote about the matrix of AESS categories:

That increased degree of “perfection” decreases the degree of imperfection that can be tolerated and increases the work needed on that part----and thus the price. As we go up the scale to greater “perfection” of cutting and finishing, for example, there is a concurrent need for far more careful handling and shipping---and with that another higher cost. We don’t mention these “real world” considerations to justify unjustifiably-higher bids; we mention this in order to make all of you completely aware of the considerations that go into the value you actually get and the pricing that comes with such increased value for your job. 3

We’d now like to flesh this out a little further. Once any fabricated metal part has been cut, bent, welded, drilled, ground, sanded, filled-in, smoothed, threaded (or whatever else is spec’d to reach its final designed configuration), the next step in the process revolves about what “appearance” is designated for this part. If that part , as is the case with most structural parts, is to be covered over with stone, brick, wood, sheetrock or such, no further concern beyond rust control (if anticipated) is in order. [Earlier this year, we addressed “rust” in a related context. 4

But if the metal part is to be “Exposed” (the “E” in AESS), our work here at Metfab Metals, as a custom fabricator, still leaves much to be done, per the job specs. As you might have inferred already, all these processes, literally from the receipt of your PO require COORDINATION. From this stage until the soon-to-be AESS parts are actually erected and/or installed, an even higher degree of COORDINATION is essential.

And all the remaining steps will require expert handling with every movement of the parts. For now, we’ll pass over the whole subject of “finishes” themselves that might be spec’d and leave this topic to future Newsletters. 5 Suffice it to say, today there are available an entire spectrum of finishes which look great when first applied, but then are readily open to injury , marring and defacement even before they get to the jobsite. As you all know, jobsite damage then is an all-too-familiar event which requires real planning and execution to avoid---or even minimize. Again COORDINATION is an issue to plan throughout. So what does Metfab Metals do to get the “finished” parts to you in the pristine condition you ordered and the Owner demands?

The answer is not as simple as you might think and usually requires a great deal of COORDINATION, even after the parts are properly packed and prepared for shipping from our shops. This answer breaks down into roughly three steps: (1) handling; (2) packing; and (3) shipping.

Handling includes both what is done by machine and what must be done  manually by our workmen. At all points no steel to steel contact can be tolerated; nylon straps and padded handling are mandatory. But packing (at times packaging) is the crucial part. We daily use Styrofoam, plastic sleeving, pink-board, bubble wrap, protective separators, wood dividers and more as we protect and pack these smoothly -finished steel pieces into cartons, wood crates and plastic drums. Alternatively, the larger AESS parts must be protected with an array of these materials and then strapped onto wood pallets or pallets padded with carpet materials.
 
But perhaps the stage in which the parts are most open to damage is the transit stage from loading here at Metfab Metals to unloading at your jobsite. If we have packaged the parts (usually the smaller items), the transit challenge is met by securing the pallet, crate or drum to the delivery vehicle (again usually one of our flatbed trucks/trailers). When the AESS parts are beams, larger parts or major mullions, the starting point is the creation of custom bunks, 6 with carpeted contact points. [This is illustrated above with a picture of these custom bunks we fabricate and install as needed on our delivery trailers.]  Everything then is secured with nylon straps and material tie-downs; no chains, come-alongs or metals fasteners can come in contact with the finished AESS steel as it’s loaded, in transit or during delivery itself. 

The man here at Metfab Metals who orchestrates all of this is our logistics coordinator, Steve Bader. His commitment is to get your parts to you in their finished condition, on time, as made and without glitch or scratch. COORDINATE with Steve to be prepared to accept the parts when they arrive and to handle, move and store them safely so they go into the building erection in the same condition we made them.

We here at Metfab Metals REALLY KNOW how to make AESS, or Architecturally Exposed Structural Steel. We hope that our customers now know our strengths go beyond the fabrication phase itself and even the shipping know-how for these “special” structural items and inhere finally in the timely delivery of the AESS parts you order from us. We must logically mention along with AESS issues here, the evolving building standard in the use of Major Mullions. As we stated last month, the reason is simple: these two are now often coming together as one specification. Architects are designing, so customers are ordering, these mammoth mullions (many weighing in at a ton apiece—or more) with AESS finishes. Again, look back at our earlier Newsletters and you’ll see 20-30-40-50 foot long mullions, finished and polished to look not like a big hunk of plain black steel, but rather with honed edges, finishes & coatings that might deceive the untrained eye to believe these are simple, hollow light-aluminum dividers. But they’re not; they are the incredibly strong, structurally-supporting columns ordered by your architect. Needless to say, these “monsters” multiply the difficulties in handling and delivering them in pristine condition.

Watch for our future Newsletters and emails for more AESS updates.


Call me with all your “Mullions” or AESS questions.
Jim Murray, C.O.O.

973-675-7676 jim@metfabmetals.com

JOB UPDATES:

250 W 55th, NYC, NY--------This Boston Properties commercial building is now substantially complete. We are now filing the required LEED certification for the light-gauge fabrication work we did for the stainless steel exterior fin cladding.

United Nations Building, NYC, NY----- The pre-construction VMU, or Visual Mock-Up** is now done and standing in our customer’s local yard for viewing and to give the owner, contractors and design professionals an opportunity to view the exterior’s appearance and the look of all end-products after the building is completed. This is a service we offer many of our customers, especially since we did this so successfully prior to construction of WTC4 at Ground Zero.

Metfab Metals now also daily makes a whole range of light-gauge steel products. We can fabricate, bend, cut and deliver any light-gauge part your job calls for.

We always offer to work with our customers from the job concept stage to anticipate issues before fabrication, to suggest better ways to order, extrude, cut, drill, paint, finish, even stage and deliver and always to save time and money.

MORE about AESS next month from Metfab Metals
here at www.MetfabMetals.com

-----------------------------------------------------------------------------------
1. AESS, or Architecturally Exposed Structural Steel, is what we have now repeated many times in our literature as finely-finished steel members (prepped, welded, filled, blasted, polished, and/or uniquely painted/finished) to be permanently open to the view and touch of all after the job is done. AESS work is never covered by sheetrock or otherwise hidden from public view.

2.This is from our Canadian friends at Canadian Institute for Steel Construction, 3760 14th Avenue, Suite 200, Markham, Ontario, L3R 3T7 Canada which offers for sale the very useful guide, appropriately entitled “CISC Guide for Specifying Architecturally Exposed Structural Steel, 2nd edition” for the clearly modest current price of $4.95, plus tax, shipping & handling. In all events, we believe this will make your ordering of AESS parts easier---and more accurate---in the future. Their website is: http://www.cisc.ca/publications/technical/codes/aessguide/.

3. Metfab Metals Newsletter, September 2012, “MORE---Yes, More---About AESS”, www.metfabmetals.com/news

4. Metfab Metals Newsletter, August 2012, “Rust on Stainless Steel”, www.metfabmetals.com/news

5. Again, the Canadian CISC Guide referred to above in footnote #2 addresses both “finishes” and “handling”, as well as delivery concerns, in fine detail.

6. A “bunk”is a steel (padded) custom bed or “clip” into which the AESS beam fits snugly so that it cannot shift or bounce around during transit and be damaged.  These are positioned and fastened to the floor of the flatbed. These bunks are set into the flatbed’s floor at intervals along the length of the beam and then the beams are tied down so that they cannot shift laterally or back & forth as the delivery vehicle moves. At the jobsite, the AESS beams must be unfastened and then lifted carefully from these “beds”.


September, 2012 Newsletter

MORE --- YES, MORE --- ABOUT AESS
AND OUR “MAJOR MULLIONS”


[This is an example of AESS steel components]

For those of you that follow our monthly Newsletters and/or have signed up for our ConstantContact emails, you already know that the headlined parts are but TWO of Metfab Metals now-regular products. You have already read our March, 2012 and May, 2012 Newsletters which outlined some of our expertise in these products, as well as our success in delivering these custom-finished items to signature jobs in New York, New Jersey and Virginia. As we post this Newsletter, we are at the PO stage for other such jobs in Pennsylvania & California.

But today we’d like to tell you more about these products that you may not already know. In our May, 2012 Newsletter we told you, in a spare few words the basic function of a mullion---to surround, support and separate glass panels, either for a structural, a safety or an aesthetic reason. Of course, these reasons are most often interwoven with a single design incorporating all these appearance and functional reasons. In our March, 2012 Newsletter, we reiterated a theme we have been telling many of you now for more than a decade. That theme was simply that we REALLY KNOW how to make AESS, or Architecturally Exposed Structural Steel. But now we want to tell you where you can get all the truly expert information on the specifications for AESS. Cut and paste the following site into your browser: http://www.cisc.ca/publications/technical/codes/aessguide/. We offer you this website and its treasure trove of guidelines, data and specs for AESS work, but that offer is not altogether unselfish on our part. We trust that our customers know our strength is beyond the fabrication phase itself and even the shipping know-how for these “so special” structural items and inheres in the timely delivery of the AESS parts they order from us. When you have been working on AESS jobs as long as our COO (Jim Murray) has been, HE is already very well-informed on what varying requirements, types and category limits AESS has. Let me give me give you a small example:

There are five distinct and varied categories (or levels) of AESS that can be ordered, stipulated or “spec’d”, depending upon how you are using this AESS steel on your job. E.g., if the part is going to be “exposed” to view as part of a ceiling 30 feet in the air, logically its “finish” does not have to be as “perfect” as an 8 or 10 foot support column at floor level to be seen by all passersby. That increased degree of “perfection” decreases the degree of imperfection that can be tolerated and increases the work needed on that part----and thus the price. As we go up the scale to greater “perfection” of cutting and finishing, for example, there is a concurrent need for far more careful handling and shipping---and with that another higher cost. We don’t mention these “real world” considerations to justify unjustifiably-higher bids; we mention this in order to make all of you completely aware of the considerations that go into the value you actually get and the pricing that comes with such increased value for your job.

CISC itself holds out this useful Guide as “developed primarily for Architects”. We set all of this out here as our first step (or phase) to inform you of the real industry guidelines so that our customers know what’s available in these specialized processes. The CISC Guide outline more precisely recites the following useful features of these AESS standards as follows:

  • The categories matrix
  • Characteristics
  • Coatings and Finishes
  • Connections
  • Curves and Cuts
  • Erection Considerations

As you Project Managers can surmise just from this list, you can no longer send out a spec that just simply says “AESS”, without more detail. The Project Architect should write this into your project documents, but you are well-advised to review these to see that this is what your customer wants and let that customer know that, with each increase/decrease in the “perfection” of the steel and its “look”, comes a cost adjustment, plus or minus. You also can now better explain the practical reasons for these cost variations.

But, finally, why do we write here today about both AESS and Major Mullions in one Newsletter. The reason is simple: these two are now often coming together as one. Architects are designing; so customers are ordering these mammoth mullions (many weighing in at a ton apiece—or more) with AESS finishes. Again, look back at our earlier Newsletters and you’ll see 20-30-40-50 foot long mullions, finished and polished to look not like a big hunk of plain black steel, but rather with honed edges, finishes & coatings that might deceive the untrained eye to believe these are simple, hollow light-aluminum dividers. But they’re not; they are the incredibly strong, structurally-supporting columns ordered by your architect. Watch for our future Newsletters and emails for more AESS updates.


Call me with all your “Mullions” or AESS questions.
Jim Murray, C.O.O.

973-675-7676 jim@metfabmetals.com


JOB UPDATES:

1050 1st  Street, Washington, D.C.-----On this job, we recently supplied 2,000 custom embeds with studs. Before shipping (and crating) to the jobsite, we filled all of them with foam so no concrete could later get inside during the later pours. [Look in this report in upcoming editions for reports on other Washington, DC jobs too.]

120 E.42nd Street, NYC, NY
-----The pre-construction VMU, or Visual Mock-Up** is now done and standing in our customer’s local yard for viewing and to give the owner, contractors and design professionals an opportunity to view the exterior’s appearance and the look of all end-products after the building is completed. This is a service we offer many of our customers, especially since we did this so successfully prior to construction of WTC4 at Ground Zero.

Barclay Center, Brooklyn, NY
-----The Barclays Center will be opening later this month on 9/28/12 with an initial concert by the Jay-Z. Of course it will be the new home to the National Basketball Association’s Brooklyn Nets in downtown Brooklyn. The arena has cost over $1 billion and presents itself in a unique “weathered” steel appearance---“like a giant rusty bread basket”. (See picture in the NYTimes Sunday September 23, 2012 “Metropolitan” section, p.1.) We were proud to supply so many specialty parts to this iconic, though controversial to its neighbors, building and to add this to our portfolio of successful jobs.

United NationsBuilding, NYC, NY
-----While much of this job is necessarily done under a confidentially agreement, we are free to report that we are making much of the stainless steel cladding and will assemble most of it before shipping to this highly-secure site in the coming months.

Metfab Metals now has modern machinery operating in three (3) diverse buildings, each producing an integrated, but distinct, part of our overall product range. Besides the heavy steel products we discussed above, we also daily make a whole range of light-gauge steel products. We can fabricate, bend, cut and deliver any light-gauge part your job calls for. Call us, email us drawings, come in and consult----we do it all now.

We always offer to work with our customers from the job concept stage to anticipate issues before fabrication, to suggest better ways to order, extrude, cut, drill, paint, finish, even stage and deliver and always to save time and money.

YES, MORE than AESS AND “MAJOR MULLIONS” here at Metfab Metals

973-675-7676 jim@metfabmetals.com

1. AESS, or Architecturally Exposed Structural Steel, is what we have now repeated many times in our literature as finely-finished steel members (prepped, welded, filled, blasted, polished, and/or uniquely painted/finished) to be permanently open to the view and touch of all after the job is done. AESS work is never covered by sheetrock or otherwise hidden from public view.

2. This is the website for our Canadian friends at Canadian Institute for Steel Construction, 3760 14th Avenue, Suite 200, Markham, Ontario, L3R 3T7 Canada which offers for sale the very useful guide, appropriately entitled CISC Guide for Specifying Architecturally Exposed Structural Steel, 2nd edition for the clearly modest current price of $4.95, plus tax, shipping & handling. In all events, we believe this will make your ordering of AESS parts easier---and more accurate---in the future.

3. See page 2 of CISC Publications order form.


May, 2012 Newsletter

“SOLID STEEL "MAJOR MULLIONS"

Just One of Our Custom Products from

Metfab Metals, LLC


[Atrium of the New World Trade Center 4---our window mullions]

What can Metfab Metals do for your company with this type of Major Mullion, shown above at the new WTC4 at the rebuilt Ground Zero?

Of course, a mullion is simply “a slender vertical member that forms a division between units of a window, door, or screen or is used decoratively” often to form such a pattern (at least according to the Merriam-Webster Dictionary). In commercial construction, we often use the term to refer to any member (usually made of hollow metal, such as steel or aluminum), vertical and horizontal,  that divides, supports and surrounds the glass window panes.  We use the newer term “Major Mullion”, in the sense of modern architecture, wherein concerns about safety, structural integrity and a structure’s ability to withstand catastrophes, natural or man-made, require such members to be made of solid steel or filled with solid steel and whose exterior may be finished to match the overall desgn.

Every day we work with plans & specs for modern mullions of all types and intended for a whole spectrum of uses, aesthetics and functions. Presently, we are working on one concept of mullions for the pharmaceutical giant, NOVARTIS, and its new buildings on its extensive campus in Florham Park, NJ. The uniqueness of one building arises, in part, out of its different “look” from solid AESS** steel mullions on its front entrance. We did a similar thing for the new VCU Medical School in Richmond a few months back. We are proud to fulfill all these fabricated metal needs here again for our customer.  Look back in our past monthly Newsletters to see other applications we have fulfilled in this vein.

Ask about these jobs we have done; the others we are now doing;
and the expanded capacity we have to produce any design
your job calls for, including:

Tight-Tolerance Sawing
Exacting Straightening
Milling to Any Spec
Precise Fabrication
Finishing- ALL Kinds

Do you have current metals needs on your pending jobs----
for such mullions or any other esthetic or AESS*?

[Contact our estimator, Chris DeSimone at chris@metfabmetals.com.]

We can quote your work fast; make samples for your hands-on review; and even erect a VMU (Visual Mock-Up)** so your owner, architect, etc can SEE how the finished installation will actually appear. See the 50’ high VMU** we made here in our yard for WTC4 work (at Ground Zero in NYC), so all involved could view/inspect the installed panels from ground level, above, below and even inside.

We always offer to work with our customers from the project concept stage to anticipate issues before fabrication,
to suggest better ways to order, extrude, cut, drill, paint, finish, even stage and deliver
and always to save time and money.

Call me.
Jim Murray, C.O.O.

973-675-7676               jim@metfabmetals.com

* For those unfamiliar with this acronym, AESS, or Architecturally Exposed Structural Steel, is finely-finished steel members (prepped, welded, filled, blasted, polished, and/or uniquely painted/finished) to be permanently open to the view and touch of all after the job is done. AESS work is never covered by sheetrock or otherwise hidden from public view. Our COO, Jim Murray, has been an integral part of early AESS projects, such as Thurgood Marshall BWI Airport (erected over a decade ago) serving the Washington, DC/Baltimore area. There you can see the structural steel ceiling space frame with its threads, pipes and connections in plain view-------- and still shining like its original installed condition! Since then, Jim has overseen AESS jobs as varied as the American Jewish Heritage Museum a few years back in Philadelphia and the unique roof ladder coverage at 51 Louisiana in Washington, DC or the Borgata Casino overhang in Atlantic City, NJ. WTC4  at Ground Zero in NYC and VCU Medical School in Richmondwill be even grander and more striking examples of this evolving art and our shop competencies.

** “VMU” stands for Visual Mock-Up. We have made many of these pre-construction (smaller-scale often) models of building segments so that the design team, owner, GC and others can see first-hand what the erected product will look like, even varying finishes, caulking, fenestration, and the like on such a model so all can better judge what the presented alternatives best suggest. Often we erect these VMU’s right here in our yard as a service to our customers. Or we can make a “portable” VMU so that it can be viewed at the building’s site itself.


April, 2012 Newsletter

“Metfab Metals Together Again With
Great Engineering at
NOVARTIS

Most of what we here at Metfab Metals make ultimately gets incorporated into buildings. But those buildings’ form and content start from the architect and then are the product of the engineer’s many judgments.  We simply fulfill the specialized steel needs in the design & the engineer’s requirements. Engineering often details effectively what to look for in a great building. One who is eminently qualified to tell us about such greatness in engineering is Col. Stephen Ressler, Ph.D., a long-time Professor of Engineering at the US Military Academy at West Point.  Colonel Ressler tells us that greatness in engineering is “not just a matter of aesthetics”. Rather he recalls the “Father of Engineering”, Vitruvius, a 1st Century Roman engineer.

[Most often he is remembered from the later drawing below by Leonardo DaVinci of what has become known as the Vitruvian Man. This drawing has made its way into countless public portrayals today, such as the arm patch for the US Skylab II mission and the Italian One Euro coin.]

  

Col. Ressler writes:
“……great constructions show exemplary form, function or structure. Exemplary form means a sophisticated arrangement of space and harmonious proportions. Exemplary function is a measure of a structure’s practical usefulness or cultural significance. Exemplary structure refers to constructions of unprecedented size or innovative techniques that influence structural engineering for years or decades to come…….”*


[As explained below, the above NOVARTIS “construction” is destined to be “exemplary” in more than one way.]

But what does this have to do with Metfab Metals?

Every day we see plans & specs for modern “great constructions”. Presently, we are working on one for the pharmaceutical giant, NOVARTIS, for its new buildings on its extensive campus of varied research, office and related buildings in Florham Park, NJ. The uniqueness of one building arises out of its various facades, each discretely engineered to project a different “look”. There will be a glass-block wall on one elevation; solid AESS** *steel mullions on its front entrance; and curtainwall support steel on a third elevation, made in a “segmented” fashion, all engineered to make the pieces fit together from tube steel fabricated to sequentially connect like a spliced joint. We are proud to fulfill all these fabricated metal needs here again for our customer. At the end of the day (and the NOVARTIS work), Metfab Metals will again have added great fabrications, including our specialty, AESS*** to a “great construction” in “form, function [and] structure”.

Here are some pictures from the various sections we fabricated for these engineering challenges at NOVARTIS. Notice the glass block VMU**we made early on as well as the miscellaneous AESS*** parts to be used throughout these elevations.



UPDATE:

We now have modern machinery operating in three (3) different buildings, each producing an integrated, but distinct, part of our overall product range. Newest among our operations are the shiny-new brake & shear with which we daily make a whole range of light-gauge steel products. We can fabricate, bend, cut and deliver any light-gauge part your job calls for. Call us, email us drawings, come in and consult----we do it all now.

We always offer to work with our customers from the project concept stage to anticipate issues before fabrication, to suggest better ways to order, extrude, cut, drill, paint, finish, even stage and deliver and always to save time and money.


Call me.
Jim Murray, C.O.O.

973-675-7676               jim@metfabmetals.com

*   Ressler, Understanding the World’s Greatest Structures (The Teaching Company, 2011)

** “VMU” stands for Visual Mock-Up. We have made many of these pre-construction (smaller-scale often) models of building segments so that the deign team, owner, GC and others can see first-hand what the erected product will look like, even varying finishes, caulking, fenestration, and the like on such a model so all can better judge what the presented alternatives best suggest. Often we erect these VMU’s right here in our yard as a service to our customers.
 
*** For those unfamiliar with this acronym, AESS, or Architecturally Exposed Structural Steel, is finely-finished steel members (prepped, welded, filled, blasted, polished, and/or uniquely painted/finished) to be permanently open to the view and touch of all after the job is done. AESS work is never covered by sheetrock or otherwise hidden from public view. Our COO, Jim Murray, has been an integral part of early AESS projects, such as Thurgood Marshall BWI Airport (erected over a decade ago) serving the Washington, DC/Baltimore area. There you can see the structural steel ceiling space frame with its threads, pipes and connections in plain view-------- and still shining like its original installed condition! Since then, Jim has overseen AESS jobs as varied as the American Jewish Heritage Museum a few years back in Philadelphia and the unique roof ladder coverage at 51 Louisiana in Washington, DC or the Borgata Casino overhang in Atlantic City, NJ. WTC4  at Ground Zero in NYC and VCU Medical School in Richmondwill be even grander and more striking examples of this evolving art and our shop competencies.


March, 2012 Newsletter

“Metfab Metals Delivers First AESS*
Bars to "Ground Zero

After we deliver all these bars and they are erected (with the huge glass panes they’ll frame), they will form the lattice-like façade of the fifty-foot high entrance podium which will surround the first floor lobby of “WTC4”. These bars are not only AESS*, they are solid steel, with some individual members weighing as much as 8,000 pounds! This lobby and these framing members are designed to be as “blast-resistant” as 21st engineering can design!


New World Trade Center 4 Lobby 1

Metfab Metals is THE custom and production fabricator of metals, for large and small jobs alike, including specialty items. We now make a whole spectrum of AESS* steel and our shop has a scope of expertise far beyond most fabricators. Here’s the first truckload leaving our shop, located less than ten (10) miles from this now-sacrosanct spot in lower Manhattan.


First truckload of AESS* bars leaves for WTC4 at Ground Zero

Go to the Ground Zero  website at www.wtc.com for even more illustrations and information about this spectacular re-building effort. [We thank all parties for allowing us to reproduce this rendering above.]
We make all types, sizes and designs in AESS* today. You should make Metfab Metals your first call when your job calls for AESS*. We can deliver whatever you need and save you time, aggravation, job delays and more in the process--------and money.
Let us quote your next AESS* job!

Project Update:

Virginia Commonwealth University (VCU), Richmond, VA---School of Medicine---------Another one of our AESS* jobs getting done! Renowned architects I. M. Pei and Ballinger Architects of Philadelphia elected to go with a striking façade and unique Metfab Metals window mullions (solid bars) to frame the glass. While these bars are not as huge as those at WTC4 (Ground Zero, NYC), these will become a distinctive part of this famous medical school for decades to come. In the process, Metfab Metals is contributing to another Silver LEED-certified building.

Come in; meet with us; we can help you with practical details; review your specs; avoid “invisible” glitches that might result in costly re-fabrication to meet original job specs. We always offer to work with you from the project concept stage to anticipate metal “issues” before fabrication, to suggest better ways to
order, extrude, cut, drill, paint, finish, even stage and deliver----- and always to save time & money.

Call me; Email your job info!

Jim Murray, C.O.O.

973-675-7676
jim@metfabmetals.com

* For those unfamiliar with this acronym, AESS is Architecturally Exposed Structural Steel, and is finely-finished steel members (prepped, welded, filled, blasted, polished, and/or uniquely painted/finished) to be permanently open to the view and touch of all after the job is done. AESS work is never covered by sheetrock or otherwise hidden from public view. Our COO, Jim Murray, has been an integral part of early AESS projects, such as the BWI International Airport [Now BWI Thurgood Marshall Airport] (erected well over a decade ago)serving the Washington, DC/Baltimore area. There you can see the structural steel space frame with its threads, pipes and connections in plain view-------- and still shining like its original fabricated & installed condition! Since then, Jim has overseen AESS jobs as varied as the American Jewish Heritage Museum a few years back in Philadelphia and the unique roof ladder coverage of an interior courtyard at 51 Louisiana in Washington, DC or the Borgata Casino overhang in Atlantic City, NJ. WTC4 (at the restored Ground Zero in NYC) and VCU (Virginia Commonwealth University) will be even grander and more striking examples of this evolving art form and architectural esthetics at which Metfab Metals is proud to be doing the AESS components.


February, 2012 Newsletter

“Metfab Metals Makes Brake Metal
---and Much Much More!!

Metfab Metals is a custom and production fabricator of metals, for large and small jobs alike, including specialty items. Our website amply shows that we are an experienced (over 50 years), national and international, well-equipped and well-staffed fabricator. We have long-term relationships with many large contractors that attest to our ability to deliver on-time, every time with parts true to every aspect of your specs! Filling your emergency needs is a particular skill of ours, shipped out immediately on our own fleet of trucks or by common carrier, FedEx, UPS and others, such that we rightly call ourselves a service fabricator. Metal anchors have been our “stock in trade”, but we now make a whole spectrum of related and unrelated parts. AESS* steel is now a common order as our shop has acquired expertise far beyond most fabricators.

2011 was a water-shed year for Metfab Metals, as we grew our business despite a sluggish economy and all the inherent pitfalls of “growing pains”. Now, surely, we had for many years been both servicing the needs of many customers with our signature punctuality (“We always deliver on time.”) and adding incremental changes to our staff, our competences and our equipment. More specifically, over the last two years we have added a massive new 14’ brake, a matching shear to cut the metal for the brake and most recently a new automated “Notcher” to better fulfill the ever-more exacting 21st century specs! In the lingo of this business, it’s “brake metal” that these machines produce!

BUT------What is “brake metal”? Basically, the answer is simple: brake metal is the end-product of sheet metal being cut, then run through and “formed” by a machine called a brake or press brake and thereafter finished/assembled to spec. As this resultant product is most often used to add an esthetic (or architecturally “beautiful”) look to buildings, both on the exterior and in their interior spaces, it is often called “ARCHITECTURAL BRAKE METAL”.


[Our new KNUTH 14' Press Brake 1]

Actually, here at Metfab Metals, we use a series of state-of-the-art machines (most CNC-directed), including a shear, brake, notchers, welders and other equipment to provide micron-accurate custom aluminum and steel shapes per the specific job specs.  Before being bent in our brand-new brake (14'-0 in length, with accuracy to half a degree), the sheet metal arrives at our shop most often in standard sheet sizes (usually 4' X 8' / 4' X 10' / and 4' X 12'), though we can handle longer custom sheets. Standard Architectural Brake Metal finishes include mill, clear, bronze, anodized, painted and other custom finishes. Standard thicknesses are .040, .063, .125, .188. We also work with mild steel, galvanized metal, brushed stainless steel, mirror-polished stainless steel, brass, copper and other custom metals. From our adjacent shop, we can supply curtainwall clips and anchors made in any size, thickness, finish and fabricated with the slots, grooves and holes called for by the design. Throughout production, our staff/shop personnel follow a rigorous Quality Control (QC) manual to ensure that the required fabrication most accurately traces the design provided in the job plans & specs. In this demanding industry, haphazard quality control can cancel the near-perfect production our machines turn out. Make Metfab Metals your first call when your job calls for ARCHITECTURAL BRAKE METAL. We can save you time, aggravation, job delays--------and money.

Let us quote your next Brake Metal job!

Come in; meet with us; we can help you with practical details; review your specs; avoid “invisible” glitches that might result in costly re-fabrication to meet original job specs. We always offer to work with you from the project concept stage to anticipate metal “issues” before fabrication, to suggest better ways to order, extrude, cut, drill, paint, finish, even stage and deliver----- and always to save time & money.

Call me; Email your job info!

Jim Murray, C.O.O.

973-675-7676
jim@metfabmetals.com

* For those unfamiliar with this acronym, AESS is Architecturally Exposed Structural Steel, and is finely-finished steel members (prepped, welded, filled, blasted, polished, and/or uniquely painted/finished) to be permanently open to the view and touch of all after the job is done. AESS work is never covered by sheetrock or otherwise hidden from public view. Our COO, Jim Murray, has been an integral part of early AESS projects, such as the BWI International Airport (erected well over a decade ago)serving the Washington, DC/Baltimore area. There you can see the structural steel space frame with its threads, pipes and connections in plain view-------- and still shining like its original fabricated & installed condition! Since then, Jim has overseen AESS jobs as varied as the American Jewish Heritage Museum a few years back in Philadelphia and the unique roof ladder coverage at 51 Louisiana in Washington, DC or the Borgata Casino overhang in Atlantic City, NJ. WTC4 (at the restored Ground Zero in NYC) and VCU (Virginia Commonwealth University) will be even grander and more striking examples of this evolving art form and architectural esthetics at which Metfab Metals is proud to be doing the AESS components.


January, 2012 Newsletter

Happy New Year!!!!!

Make 2012 Your Best Year Ever!!

Every year at this time, we heartily wish you well in the new year---this time in 2012. [WOW, remember when we all looked forward with anticipation---and with some concern & trepidation also---to this fearsome new millennium in 2000!]

We now truly hope that 2011 was a good year for you, despite all the weaknesses in our national economy. But, even if it wasn’t a “banner year”, 2012 can be that year---and we want to work with you to help.

 

Last year, we wrote at length here that we had completed our part of a rather unique project----the National Museum of American Jewish Heritage, Philadelphia, PA-----where again,Metfab Metals supplied anchors, curtainwall parts and miscellaneous metals on this now-iconic museum that will attract visitors for the rest of the 21st century and beyond. As we recommended then, go visit. We also reported last year on the new World Trade Center, New York City, NY------ Tower #4 with our AESS steel columns that will identify the entrance view to this steadily-rising skyscraper.

However, what we didn’t do and should tell you at the beginning of our work year together----those are just two huge jobs, but we here at Metfab Metals supply small as well as big jobs and supply a whole spectrum of metal parts, now light-gauge (look back just to our last Newsletter in December, 2011) as well as heavy gauge steel parts (aluminum too, as needed).

Look at some of Metfab Metals’ Services/Products:

Products

Stone & Masonry Anchors
Concrete Embeds/Halfen Alternatives
Curtainwall Support Steel
Steel Parts for Glazed Curtainwall
Light Gauge Metals/Fabrication
Complex Metal Operations
Miscellaneous Steel Parts

 

Custom Products

AESS
Wind-Load & Gravity-Load Anchors
Façade Assemblies
Space Frame Assemblies
Stone Truss Fabrication
Trip Carts, Working Platforms, Tool Bins, etc.
Tool & Die Work

Services

Pre-Construction Consultation
25-Years/Industry Experience
Custom Machine Shop Services
State-of-the Art Equipment
14’ Brake & Shear
Plasma Cutting In-House
CNC-Programmed Production
24/7 Services
Licensed Professionals
Computer-Generated Job Documents
LEED-Documentation
WBE/CCR/SBA Accreditation
Material Certifications
MSDS Documents

Outsourcing

“Buy USA” Sources
Fasteners of All Types
WBE “Set-Asides”
Water-Jet Cutting
Laser Cutting
Rolling, Cutting, Straightening
Foreign Supplies

 

Finishes

Anodizing-All types/Colors
Plating-All Types
High-performance Painting
Polishing/Stainless Steel/Alloys
Polishing/Brass & Bronze
Powder coating
Galvanizing
Bead-Blast
Aluminum Abrasives
Kynar
Metallic Finishes
Epoxy

Delivery & Hoisting

Union/Non-Union Deliveries
48 Ft. Trailer Deliveries
Flatbed Deliveries: 16Ft. & 26Ft.
24/7 Misc. Pick-Up Services 
Boom Trucks
Oversize Load Specialists

Misc. Metals, etc.----Ask us
You don’t see it---Ask us

We at Metfab Metals would like to be your supplier
throughout 2012---and years beyond.


Call me. Let me help with all your fabrication needs----and problems!

Jim Murray, C.O.O.

973-675-7676
jim@metfabmetals.com


Happy New Year!
Have a great 2012, working alongside us,
here at Metfab Metals!

NOW, as in all the past decades of our company, you can truly
count on Metfab Metals for full value for the price you pay.
This is still our pledge and our commitment to all our customers again in 2012.


Click HERE for news from 2011

Click HERE for news from 2010

Click HERE for news from 2009

Click HERE for news from 2008

Click HERE for news from 2006 and 2007