The magazine for metal service centers, fabricators & OEMs/end users
Demand for services is breaking loose
getting noticed by gaining mastery over tough materials and air and space artifacts preserved under new roof
January 2021
Black arrow facing downward
Come ride the wave of growth.
VORTEQ is proud to announce a natural expansion to the west coast.
Based in Rancho Cucamonga, the addition of VORTEQ Pacific creates a coast-to-coast service map and boundless coverage for our valued customers.

We’re relentlessly committed to passionate customer service, offering versatile operations and the industries’ most expansive national footprint.

Come ride the VORTEQ wave of momentum for your coil coating needs! Let’s get started at vorteqcoil.com

Vorteq logo
THE NEW FORCE IN COIL COATING.
January2021
trend publishing metals group Volume 77Number 1
Modern Metals: Table of Contents logo
toll processing report
After weathering the virus storm, demand for services is breaking loose
Go big
taking flight
getting noticed
extended life
features
laser technology
A cutting system that can handle large plates increases service center’s efficiency
coil coating
Experts craft a singular roof system for a giant hangar that showcases American air and space history’s artifacts
leveling
Ohio processor gains flexibility, mastery over tough materials with latest capital investment
sawing/cutting
Cutting through hard alloys like butter while saving time, blades and cash helps manufacturer limit downtime and overtime
January2021
trend publishing metals group  Volume 77 Number 1
Modern Metals: Table of Contents logo
toll processing report
After weathering the virus storm, demand for services is breaking loose
features
Go big
laser technology
A cutting system that can handle large plates increases service center’s efficiency
taking flight
coil coating
Experts craft a singular roof system for a giant hangar that showcases American air and space history’s artifacts
getting noticed
leveling
Ohio processor gains flexibility, mastery over tough materials with latest capital investment
extended life
sawing/cutting
Cutting through hard alloys like butter while saving time, blades and cash helps manufacturer limit downtime and overtime
departments
Comprehensive industry coverage anytime, anywhere
front view of the Seattle Opera headquarters
/steel
cutting technology that slashes lead times
/grinding
steel products that allow leaders the space for strategic thinking and planning
/servicecenter
Online
Features
The Seattle Opera headquarters incorporates more than 44,000 square feet of Kingspan KarrierPanels to create a modern, high-performing building envelope
Cutting technology helps company bring parts processing in house, slash lead times
Downtime allows leaders the space for strategic thinking and planning about how best to respond to a paradigm shift
@ symbol
CATSA Lander Mark 1 facebook post
Facebook
The CATSA Lander Mark 1 is a space-themed cat bed made from brushed aluminum
Photo: CATSA
Cor-Ten steel home twitter post
Twitter
A Cor-Ten steel home rocks heavy metal vibes in the Netherlands
ow.ly/U8mw30rm0as
@dwell
Photo: Stijn Poelstra for Zecc Architecten
metal sculpture instagram post
Instagram
#aluminum #hearingnest #noise #concreteart #listen #wallsculpture #gallery #metalsculpture
Corinna Petry headshot
fromtheeditor
BY corinna petry
Priorities
A

newly seated Congress, a changing of the guard within the Congressional Steel Caucus and the long-delayed political effort to finance nationwide infrastructure modernization are among the top-of-mind topics for the new president and CEO of the American Iron and Steel Institute.

“We are excited about the opportunities that a new Congress and administration present,” says Kevin Dempsey, who succeeded Thomas Gibson in the role. Dempsey had served as AISI’s senior vice president for public policy and general counsel since 2009.

“There are big challenges for the country, like beating COVID, before getting the economy running. The steel industry has supported in every way possible [any chance] to be part of the solution in beating COVID.”

facetime
Forward Thinking
Fagor Arrasate’s Peter Swenson discusses the evolution of coil processing equipment to incorporate automation and accommodate high-strength material
Q:
What are some of the changes that you have observed in slitting?
A: In a word—automation. I first observed automation of coil processing lines in Europe perhaps 20 years ago. The goal had been, and continues to be, to take people off lines and to make lines safer and more productive. From entry to exit, automation is making it easier and more efficient to operate lines. For example, there are now affordable coil automatic de-banding and band removal systems. For many years in Europe, they have had robotic setup of the slitter heads and separator tooling. These are both critical points in slitting lines, and long thought only to be able to be set up by a human. Not true! Robots routinely set up slitter heads with correct horizontal clearances every time. They come to work every day and don’t make costly setup mistakes. They can wash the tooling after use, which extends tooling life, and they don’t damage the tooling during routine handling. And they can even inspect the edge condition after each use to determine if a tool is suitably sharp. We are now placing this equipment in forward-thinking U.S. companies.
servicecenternews
Close up of embossed stucco

Coil processor adds embossing line

Andes Coil Processors added embossing services to its Gary, Indiana, facility with the installation of a new 52-inch-wide embossing line. The line produces raised and/or sunken designs into metal without changing the material thickness. Andes Coil Processors’ line provides the non-directional stucco pattern, producing a depth of up to 0.013 inch. Additional patterns will be added as customers’ requirements warrant them.
View of newly installed Mach 700 Dynamic Waterjet System
Stainless distributor installs waterjet
Penn Stainless Products, Quakertown, Pennsylvania, recently installed a new Mach 700 Dynamic Waterjet System from Flow Corp., Kent, Washington. With two independent bridges, four cutting heads, and a 157-inch by 479-inch cutting envelope, this machine is a significant addition to Penn’s waterjet department, which now features six Flow units.
tradetalk
Nippon Steel Corp. and ArcelorMittal S.A. have agreed to build an electric arc furnace
Calvert complex to get new EAF
Nippon Steel Corp. and ArcelorMittal S.A. have agreed to build an electric arc furnace at AM/NS Calvert, LLC, their 50/50 joint venture. The 1.5-million metric ton EAF is scheduled to start operating in the first half of 2023. Calvert now produces steel sheet products by processing slabs procured from domestic and foreign suppliers. With the new melt shop, Calvert will be able to manufacture some of its slabs on site. The goal is to strengthen its competitiveness through integration, such as shortening lead time in slab procurement.
ATI will exit standard stainless products, idle production lines
Allegheny Technologies Inc., Pittsburgh, is exiting standard stainless sheet products, streamlining its production footprint and investing in enhanced capabilities to accelerate the execution of its high-value strategy, primarily in aerospace and defense. “By shedding a low-margin product line and optimizing our footprint, we are redeploying resources to an aerospace and defense-centered portfolio,” said Robert S. Wetherbee, ATI president and CEO. ATI will stop producing standard stainless sheet products by mid-year 2021, and will cease production activities at five locations by year-end 2021. It will also consolidate its finishing operations by investing in its Vandergrift, Pennsylvania, location, creating a more competitive flow path focused on increasing production of high-value, differentiated materials.
newproducts
The Taurus FL is a new large-format, gantry-style fiber laser cutting machine
Laser designed for extra-large sheet capacity
The Taurus FL is a new large-format, gantry-style fiber laser cutting machine engineered for extra-large sheet metal cutting capacity. The machine has a 12-meter bed length and can be expanded in increments of 2 meters to a maximum bed length of 40 meters. The large format allows a diverse range of parts to be cut and efficiently nested, increasing productivity and optimizing material usage. Taurus FL delivers the flexibility to process extra-large sheets or multiple sheets, jobs in varying batch sizes, shapes and material types accommodating workpieces up to 3.3 meters wide and up to 30 mm thick.

LVD Strippit, Akron, Ohio, 716/542-4511, lvdgroup.com.

TOLLprocessing
report
Confidence
rising
After weathering the virus storm, demand for services is breaking loose
By Corinna Petry
B

eing essential to the infrastructure of manufacturing and being able to count on a government program to shore up payroll, toll processors pulled back from the brink of crisis in the last months of 2020. Executives express a cautious confidence that a recovery—for their businesses and the economy writ large—will be realized.

“There is pretty strong demand across all of our divisions: Cleveland, Detroit and Mississippi,” says Ferragon Corp. President Eduardo Gonzalez. “We are very active, especially in 2021, due to the acquisition of AK Steel [Holdings Inc.] and ArcelorMittal USA [Inc.] by Cleveland-Cliffs Inc., and [due to] so many other dynamics,” he says. Gonzalez also predicts there will be “an eruption of activity” for HyCAL Corp., a Ferragon division in Gibraltar, Michigan, that continuously anneals high-yield, high tensile strength steels for the automotive industry.

The recovery in demand from customers of Andes Coil Processors, Gary, Indiana, occurred fairly rapidly during the second half of 2020, says Howard Pena, president and partner. “We started off 2020 with a record first quarter. January to March, we were well above projections. Q2 came in at about 70 percent of our plan. Then we experienced [revenues of] 80 to 85 percent of plan in Q3. In October,” he says, “Andes saw another phenomenal month; we bounced back. But November and December are typically softer.”

lasertechnology
The extra-large-format ByStar Fiber 8025 can process metal sheets with a working area of up to 8 by 2.5 meters.
Go Big typography
A cutting system that can handle large plates increases service center’s efficiency
BY Lauren Duensing
C

utting parts out of extra-large sheets and plates has many benefits, including more efficient nesting and fewer touches throughout the process. However, moving these big, heavy pieces of metal is a challenge, requiring systems that have superior cutting capabilities plus top-notch material handling. For McNeilus Steel’s Morristown, Tennessee, facility, a partnership with Hoffman Estates, Illinois-based Bystronic has allowed the distributor to maximize large-format cutting.

A longtime Bystronic customer, McNeilus employs 700 employees across four warehouses, with its headquarters in Dodge Center, Minnesota. The 100,000-square-foot Tennessee operation is the newest addition to the network.

“We hadn’t expanded geographically in about 10 years,” since opening a warehouse in Fond du Lac, Wisconsin, in 2009, says David Graham, general manager of the Morristown location. “Because the steel industry, including many new mills and a lot of our current vendors, is starting to congregate in the Southeast, it made sense to have a location in East Tennessee.”

coilcoating
Hangar No. 1 of the former Lowry Air Force Base houses the Wings Over the Rockies Air & Space Museum.
For a roofing system that echoed the original material, new metal had to be historic in finish, profile and installation technique.
Art hoy, AH Architecture
Taking flight
Experts craft a singular roof system for a giant hangar that showcases American air and space history’s artifacts
Taking flight
Experts craft a singular roof system for a giant hangar that showcases American air and space history’s artifacts
By Fiona Maguire-O’Shea
T

ransferred from the U.S. Air Force to a volunteer group in 1994, Wings Over the Rockies Air & Space Museum is located in Hangar No. 1 of the former Lowry Air Force Base in Denver. The 182,000-square-foot museum houses iconic aircraft, space vehicles, artifacts, military uniforms and more.

Visitors can experience flight simulators and participate in educational programs and other museum-sponsored events. Each year, the museum welcomes about 160,000 people.

Installed in 1938, the 20-gauge corrugated metal roof on the airplane hangar performed well but had reached its useful life and required replacement. The structure was retrofitted with 92,400 square feet of curved standing-seam roofing. The roof also features ColorGard by S-5!, a snow guard solution made for standing seam metal roofs. This feature is especially critical to have in the Rocky Mountain region.

The challenge was to remove and replace the structure during winter while keeping the museum open. Adding to the difficulty was the shape and height of the roof—curved and more than 100 feet off the ground with a circumference measurement from eave-to-eave over the top of the barrel at 308 linear feet.

For a roofing system that echoed the original material, new metal had to be historic in finish, profile and installation technique.
Art hoy, AH Architecture
leveling
American Utility Processing installed a leveling line that could flatten high-strength steels.
Getting noticed
Ohio processor gains flexibility, mastery over tough materials with latest capital investment
By Benoît Wolff
L

aunched in 2003 and based in Akron, Ohio, American Utility Processing (AUP) works with ferrous and nonferrous coil, sheet and plate. It performs leveling, shape correction, buffing and other services for a range of industries that include trailer, tanker, marine, rail and aerospace. The company operates a 100,000-square-foot plant and recently expanded its capabilities with a wide, heavy gauge leveler.

The secret to success can depend on various factors. For some it is a game-changing product, while others rely on a particularly broad clientele. For AUP, it is sheer presence as well as being noticed.

“We have been here for quite a while, and we offer a broad range of services. The industry found us and we responded,” says Rich Kmiecik, chief operating officer for American Utility Processing.

sawing/cutting
Jawbreaker blades are used at Precision Marshall Steel to cut Inconel, duplex stainless, titanium and hard tool steels.
Extended LIFE
Cutting through hard alloys like butter while saving time, blades and cash helps manufacturer limit downtime and overtime
By Corinna Petry
T

ool steels are carbon and alloy steels that are well-suited to shaping other materials. Their suitability comes from their hardness, resistance to abrasion and deformation, and their ability to hold a cutting edge at elevated temperatures.

Working with hard, tough alloys requires other tools that are even harder and more resistant to breakage and erosion. When Precision Marshall Steel sought to reduce downtime due to frequent band saw blade changes and to lower the amount of man hours needed to operate its saws, the company learned about The M. K. Morse Co.’s newest blade, Jawbreaker.

“Jawbreaker is designed to cut superalloys and other very hard-to-cut materials,” says Bruce Woodruff, marketing director for Morse. “It takes advantage of two innovations. The first is patented KerfLock technology,” Sekhar Rakurty, head of Morse research, explains. “Most band saw blades create the kerf by bending the teeth side to side. Premature tooth wear can result as the bend relaxes through the life of the blade.”

partingshot
Rhythmic Gymnastics Palace
Moscow
Inside the Luzhniki Olympic Complex in Moscow sits the Irina Viner-Usmanova Rhythmic Gymnastics Palace. The external appearance conveys the connection between the design of the building and its purpose: the shape of the roof resembles the wave of a gymnastic ribbon in flight. A total of 15,200 square meters of Riverclack 550 mill-finish 0.8 mm-thick aluminum panels covers the palace as the main standing seam system plus decorative panels. The center, which opened in 2019, hosts rhythmic gymnastics competitions as well as training, cultural and recreational activities.
Photo: Creative Production Union PRIDE
ModernMetals
President/Publisher Michael D’Alexander
Editorial
Editor-in-Chief
Corinna Petry
Senior Editor
Gretchen Salois
Senior Editor
Lynn Stanley
Senior Contributing Editor
J. Neiland Pennington
Contributing Editor
Lauren Duensing
EDITORIAL OFFICES
Trend Publishing Inc.
123 W. Madison St., Suite 950, Chicago, IL 60602
312/654-2300, Fax: 312/654-2323
www.modernmetals.com
pRODUCTION & Design
VP Production
Carlotta Lacy
VP Creative
Matt LaFleur
Digital
Digital Manager
Mark Koenig
CORPORATE
President/Publisher
Michael D’Alexander
Vice President
Jim D’Alexander
VP Finance
Wayne Krusen
Business Manager
Traci Fonville
Circulation
Bill D’Alexander
advertising sales territories
Michael D’Alexander, President/Publisher
312/654-2309, Fax: 312/654-2323
mdalexander@modernmetals.com
Alaska, Arizona, Arkansas, California, Hawaii, Idaho, Montana, New Mexico, North Dakota, Wyoming

Jim D’Alexander, Vice President
770/862-0815, Fax: 312/654-2323
jdalexander@modernmetals.com
Alabama, Colorado, Florida, Georgia, Louisiana, Minnesota, Mississippi, W. New York, North Carolina, Oklahoma, Pennsylvania, South Carolina, South Dakota, Tennessee, Texas

Bill D’Alexander, Principal/Sales Manager
203/438-4174, Fax: 203/438-4948
bdalexander@modernmetals.com
Connecticut, Delaware, Kentucky, Maine, Maryland, Massachusetts, Missouri, Nevada, New Hampshire, New Jersey, E. New York, Ohio, Oregon, Rhode Island, Utah, Vermont, Virginia, Washington, West Virginia; International

Bob D’Alexander, Principal/Sales Manager
616/916-4348, Fax: 616/942-0798
rdalexander@modernmetals.com
Illinois, Indiana, Iowa, Kansas, Michigan, Nebraska, Wisconsin

Valerie Treiber, National Sales Manager
203/894-5483
valerie@modernmetals.com

Traci Fonville, Classifieds, Logos and Reprints
312/654-2325, Fax: 312/654-2323
tfon@modernmetals.com

Modern Metals® (ISSN 0026-8127, USPS 357-640) January 2021, Vol. 77, No. 1 is a registered trademark of Trend Publishing Inc. Modern Metals® is published 11 times a year 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 J. D’Alexander, President, Trend Publishing Inc. Copyright 2021 by 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. This publication is sent free of charge to qualified subscribers. Single copies $14. Paid subscriptions in the U.S. $125/year. Canada, $145/year. Foreign subscriptions, $180/year surface mail and $260/year air mail. If interested in a free subscription go to www.modernmetals.com to see if you qualify. Periodicals postage paid at Chicago and additional mailing offices. POSTMASTER: Send address changes to Modern Metals® c/o Creative Data Services, Inc., 440 Quadrangle Drive Suite E, Bolingbrook, IL 60440. Printed in the USA.
The magazine for metal service centers, fabricators & OEMs/end users
Thanks for reading our January 2021 issue!