GreenRiver University

We strongly believe that the more you know about our business, the better you will be at creating your design plan. We hope you find our ‘university’ a valuable resource to help you develop a project that suits your needs and your budget. Please don’t hesitate to call if you have other questions.

Yesterday's Iron

Historically wrought iron was created with what was called "pig iron". It was very porous and not as durable as what we use today. Because of its poor quality, there are very few examples of pig iron left to see from the early Iron Age.

In Colonial times ironwork was used for its strength and utility, but due to its relatively high cost at the time, it also became a status symbol for the homeowner. In fact, iron was considered so valuable during the 1700's that it was actually used as a monetary standard. The Ironworkers or "Black Smithies", as they were called then, held a very high status in their communities. Not only were they relied upon as craftsmen of much needed items, but also as “bankers”, with iron as their currency.

Today’s Iron (used to be Wrought Iron)

Today we are fortunate to have a wide variety of materials to work with; each with specialized physical properties that suit varied applications:

Wrought Iron

The material known today as "Wrought Iron" actually exists in several different forms. It can either be Cast, Forged, or Malleable iron.

Forged Iron offers the most strength of all the irons. Iron is forged by the dual process of heating the material and then condensing the molecules with applied pressure, usually hammering. The longer the material is worked, the more condensed the molecules; the stronger the material becomes. In the early stages of ironwork forging was the most commonly used method, since there was little or no knowledge of casting.

Cast iron is formed by pouring molten iron into molds. This process became widely used because it enabled ironworkers to produce higher volumes of product in a shorter period of time. In addition to volume, casting also provided ironworkers with the ability to replicate exact copies of components. This method is mainly used to manufacture finials, collars and decorative iron inserts because cast iron had limited strength

When iron is poured into molds in a molten state, air pockets form in the material (think foam). Because cast iron in a mold cannot be hammered to condense these air pockets, the resulting product has considerably less strength. It was recognized early on that sand casting could not replace "forged" pieces, such as hinges and other structural elements, because they could not withstand large amounts of weight without fracturing.

Malleable Iron is iron that can be reheated and hammered over and over again. Because of the repeated processes malleable iron is very durable. This type of iron is mostly used for hardware. It can be sand cast and still reheated to make the molecules denser for added strength.

Carbon Steels

Carbon Steels are the materials used today for structural building. There are two types of Carbon Steels; "Hot Rolled" and "Cold Rolled". They are distinguished by the percentage of carbon in each.

Cold Rolled Steel is the denser of the two steels and has the highest carbon content. This density makes it much more difficult to "forge" the steel, but structurally it is the most stable of the two materials. It is mainly used for fixturs and tooling.

Hot Rolled Steel is the best material to use when forging iron. Since it is not as dense as cold rolled steel it is more malleable for bending scrolls and the like. In addition, it also heats much faster in a furnace, allowing it to be worked by hand more quickly, using less fuel. It is the main material used in architectural iron work.

Among all the manufacturing materials available today, Carbon Steels are the most abundant and widely used and most cost effective.

Alloys

Alloy Steels cover a large range of materials used today. The biggest advantage to alloy steel is that they have characteristics that lessen and in many cases eliminate oxidation (or in laymen's terms…rust). Copper, Stainless Steel, Brass, Bronze, Titanium and Aluminum are all alloy steels and each is available in many different grades.

Titanium is generally used only in the aerospace industry due to its exurbanite cost. (Cost is approximately 300% more than iron)

Aluminum is prized for it ratio of strength to weight, and its ability to resist corrosion. Although it can't replace carbon steel in most structural applications it is perfectly suited for light structural and architectural projects. (cost is approximately 30% more than iron)

Stainless Steel is a high grade alloy that is one of the most resistant to corrosion. However, it is a very soft material, often referred to in the manufacturing field as "gummy". This is because it has a completely different make-up from other alloys. While it is very strong, it is one of the easiest alloys to work with. (cost is approximately 30% more than iron)

Bronze and Brassactually fall into the same category. The only difference between the two is their level of copper and tin content. They are most frequently used in ornamental work and decorative and sculptural items. In the last few years, Bronze has become more and more popular as a material of choice for fencing & railing projects. Although it ranges much higher in cost, its beauty and maintenance free qualities make it an attractive alternative. The minimum copper content of Bronze is 70% and Brass is made up of at least 50% copper (Both cost approximately 60%-70% more than iron).

All alloy pricing can fluctuate dramatically, so you should call for the latest pricing!

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Welding

Welding is the process used to join two pieces of iron together. It is imperative to the structural integrity of the finished product that the weld is secure. Regrettably, to save labor & material costs, it is common practice for many ironworkers to "tack" the two pieces together on only two sides. The correct and most structurally sound technique, however, is to weld 360 degrees around the entire seam. The most commonly used methods of welding are Arc Welding, Tig welding and Mig welding.

Arc Welding is performed through a welding rod that is held in a clamping device. To weld using this method you must attach a ground line to the area of the material you are going to weld. Upon contact with the material, the arc welder sends a positive charge through the core of the rod, essentially liquefying the welding rod and forcing it to adhere to the material. This method is favored over others for products that require the strongest possible structural integrity. It is not generally used in ironwork because it requires excessive grinding afterward to clean the weld.

Tig Welding offers the cleanest weld. In this process the welder holds what is called a "pen" in one hand and a welding stick in the other. As they bring the pen to the iron, they depress a foot pedal that controls the amperage going from the pen to the material. This method offers the most control of all the types of welding and allows the operator to add material precisely as needed. In turn, the finished weld has virtually no excess material and no clean up is required. Although most wrought iron companies do not use this type of welding because it is more time consuming and the equipment is much more expensive; at GreenRiver Forge we use Tig welding often.

Mig Welding is the most common method of welding because it is fast and cost efficient. In addition, it allows the operator to always have one hand free to hold the material being welded. During the mig welding process, the operator holds a torch in one hand that has a trigger. By depressing the trigger, the operator can feed the welding wire though the torch and direct it onto the material. Mig welding units hold spools of wire that range from 20 lb to 80 lb reels. These reels provide hours of continuous welding, where other types of welding require the operator to re-supply constantly.

Coatings

Coating is the single most important step in determining the longevity of the work! As with solid metals, there are also a wide range of options for coating materials. For carbon steels there are conventional paints, powder coatings, two part epoxy coatings and plating varieties such as galvanizing, cad and nickel plating. Aluminum can be anodized in many different colors.

Industrial Paints and Primers are the most common coatings used in the wrought iron trade. Although they do offer the greatest color options, they do not have the longevity of other coating materials. We recommend the use of these primers and paints for interior projects only, where they are not subjected to outdoor environments such as "acid rain".

Powder Coating is a unique surface treatment that is unlike any other. The process consists of more steps than conventional painting and is therefore a more expensive process. The best way to describe the powder coating process is to use the term "opposites attract". In this process a negative charge is sent to the product to be coated. The spray gun applies the powder material with a positive charge, which in turn is attracted to the metal. After the product has been powder coated, it is put in an oven or heating room to be baked. Once baked, a hard ‘crust’ of coating covers the entire product.

In our opinion, Powder Coating is best suited for coating aluminum. If used on iron, it must be galvanized first to ensure optimum adhesion. Because powder coating does not flex with seasonal changes in temperature, it tends to crack and allows moisture to get beneath it, causing "bubbling" and "flaking" prematurely. We recommend using aluminum or galvanizing a product prior to powder coating for any outdoor application to assure its longevity.

Two Part Epoxy Coatings using a pre- primer and two epoxy top coats are among the most superior and cost efficient methods of coating. These coatings work very effectively for outside applications. Each item is pre-primed with a liquid coating that seeps into every crevice of the iron over a 24 hour period. A two-part epoxy primer is then applied and allowed to dry. The final coat is an additional two-part epoxy that finishes and seals the item. Once combined, these coatings have a minimum thickness of 120mils and provide a coating that is superior to almost any other method. It is a time-consuming process, but is incredibly effective at preventing rust. Another advantage of these coatings besides their durability is their higher resistance to fading. Epoxy coatings are available in many color choices. This is our main method of coating.

Galvanizing is most often used as an undercoating treatment for other finishes. However in recent years, more customers have requested the galvanized look without the use of an over-coat. The pewter-like finish of uncoated, galvanized iron works well in contemporary applications, but also looks great with a classic cottage style. It can be used in either commercial or residential applications. While many consider galvanizing a lifetime coating solution, it is not. We highly recommend applying clear coat paint over a galvanized product to protect it. Without additional protection galvanized materials will deteriorate over time or develop what is referred to in the industry as "white rust". This is a term used for the white powder that forms on the surface when the compounds found in galvanizing begin to oxidize.

Plating is the most durable, and expensive, coating for products. Although the various plating offers the best longevity, they are better suited for smaller items such as; Hardware, Lighting, Sculptures, etc. The cost associated with large scale items such as fencing and gates are usually cost prohibitive. An important factor for the cost of plating is the preparation. In order to properly plate an item, even the smallest blemish must be eliminated. Where other coatings can effectively cover small inconsistencies, plating will enhance and magnify even the smallest scratch. On the right product, however, plating creates a finish unlike any other.

Anodizing is mainly used with aluminum. Although it offers little help with corrosion it is available in many colors. The anti-corrosive properties of aluminum are so substantial that additional protection is not required. In some cases, a clear coat may be applied to offer additional scratch resistance.

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Installations

Proper installation is critical to a successful product. Whether it’s a simple stair railing, fencing or a driveway gate, how the product is installed will be a determining factor in its stability and longevity. There are several key factors in installation:

Measurement and Design Accuracy is a major determining factor in the quality and fit of the final installation. Variables in stair risers, the grade of the property, or the weight of a gate all need to be considered before the ironwork is even built. To ensure precise dimensions we recommend using Computer Aided Drafting (CAD) for each application. This technology provides an accurate drawing of exactly how the finished piece will look as well as the exact dimensions for lay-out and production.

Hammer Drilling is done with carbide bits that drill into the material with a spiral and hammer action combined. The material is chipped away leaving a hole. While this is an effective way to drill into most bulk material, when you are drilling near the edge of stonework, or into more fragile materials, it is easy to chip or fracture unintended parts of the material. (Bluestone and Brick are good examples of materials that hammer drilling does not work well on.) Hammer Drilling is the most common method of drilling with ironworkers because the tooling and process are relatively inexpensive…unlike core drilling.

Core drilling is done with a carbide tipped Hole Saw with bits that range in size from ¾ of an inch to 30 inches in diameter. The Hole Saw has the ability to inject water through the bit to keep the material cool, and to eliminate any debris from the hole. The biggest advantage of core drilling is that no pressure is transferred from the drill to the material, so the chance of chipping or fracturing the outer edges of the hole is eliminated. For brittle materials such as brick & bluestone, or to drill close to the edge of stonework, core drilling is by far the best choice even though it is more expensive to do.

Sono-tubes are used when materials are being installed directly into the ground. A hole is dug, the sono-tube is placed in the hole, filled with mortar, and then it is back filled. It is important to make sure that the sono-tube is dug to a depth of at least 40” so that it sits below the frost line. (frost line is actually 36”) If not, the expanding and contracting of the frozen ground will cause the tube to settle and become unstable.

Mortar is another key component of a good installation. Most ironworkers use pre-mixed masonry cement also known as “Portland Cement” but this cement has significant drawbacks. We recommend using mortar that contains vinyl. This gives it the capability of expanding and contracting during temperature changes, allowing the plug to stay intact and preventing water from getting under the mortar and pushing it, and the ironwork, outward. It also prevents moisture from surrounding the posts and creating rust. A vinyl based mortar will greatly increase the stability and longevity of an installation.

Conformance

Zoning rules and regulations can change from town to town and state to state. It is important to become familiar with the requirements of each town before the work begins so you can be assured all code requirements are being met. For example, some new changes to the Pool Gate codes are:

All pool gates in Connecticut are now required to have a locking device or magnetic latching system that is at least 54” above grade. If the pool gate has a keyed lock it can be kept at the pool fencing standard of 48” in height, but all ironwork must be no less than ½” apart within 18” of the lock….or 18” Lucite disc must be installed around the lock.

Many towns are now requiring a ‘pinch clearance’ of 6.0” for all driveway gates. This code was recently enacted to prevent a child from being entrapped between a gate and gate column during the operation of an automatic gate operator.

Gate Operators

Gate operators, or automatic gate openers, can vary greatly in operational capabilities and cost…from a simple touch pad to a remote control to a system that can open your gate with a phone call from anywhere.

The actual opening mechanism is determined by the size and weight of your gate…the operating system is determined by your personal needs and your budget. All operators should have a battery back-up system that allows the gate to open in the event of a power failure. 

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Designing your Project

There are endless applications for metals in your interior or exterior projects. From Gates to Fencing, Pergolas & Gazebos, Interior and Exterior Staircases & Railings, to Sculptural Pieces, Furnishings and Decorative Accessories, in Traditional or Contemporary design, there is no limit to the possibilities. If you can imagine it…we can build it.

Historical Accuracy…When first looking at design possibilities, the style of the home or business, features in the landscape and era in which the property was developed are obvious factors. At GreenRiver Forge, we specialize in matching ironwork with location and historical periods and encourage our clients or their architects & contractors to access our resources and consult with us during the design process.

CAD Drawings… we use the latest in Computer Aided Drafting which allows us to design products that are not just aesthetically pleasing, but also structurally sound. Our clients get to see the exact design and proportions of the finished product before it is made…and we know when we fabricate that our products will fit perfectly.

Design Ideas…We have myriad resources for design ideas. From the ideas of our own design team to concept books to component catalogues to manufacturer resources and on and on…we can help you design a project that perfectly suits its surrounding.

We’ll meet with you to discuss design options. Sometimes it is more time efficient to know on the spot what applications are possible and how it will affect costs, etc. Seeing the site first hand also helps us conceptualize what designs will work best for your overall plan.

We Love A Challenge…the creative process is why we do what we do. If you’ve been working on a design and not quite sure if it can work, call and take advantage of our aerospace engineering experience. It often makes the seemingly impossible, possible.

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Cost Structure

When determining the cost of ironwork, as with almost any product, labor is the biggest factor. The more custom hand work…the higher the price. The second issue is cost of materials. Metals are sold by weight, so the more it weighs, the more it costs. Metal pricing also fluctuates regularly, and usually follows crude oil’s pricing ups and downs.

Custom, Hand Forged, Solid Iron is the most artistic…and labor intensive option in iron. Consequently, it is also the most expensive. Custom hand forged iron requires each component of the product to be heated in the furnace to a white metal state and then bent or hammered by hand into form.

Custom, Solid Iron, using Pre-Manufactured Components is the next best option for good design with less cost. The pre-manufactured components are mass produced, but still made of high quality solid iron. In particular, using Finials, Picket Collars & Scrolls that are pre-manufactured are extremely cost efficient. It is still very possible to create a custom look using these mass produced components, and keep costs down.

Custom, Tubular Iron is the next step down in cost. Remembering that iron is sold by weight, the cost obviously lessens by not using solid product. This does not have to mean that the finished product will be flimsy or tinny. There are many different levels of tubular iron depending on how thick the wall of the tube is. What you might commonly find at a warehouse home store is usually from China, and very thin walled. By using a higher grade of tubular iron you can cut cost and still have a very durable product with excellent longevity.

Pre-Manufactured Tubular Ironis what you usually find at warehouse home stores in its lowest grade…and at many fencing companies in a slightly higher grade. Although this is one of the least expensive ways to use iron, it also falls into the category of “you get what you pay for.” This fencing comes in panels that are thin walled, and screwed or bolted together…not welded. There are also few design options, so it has a “cookie cutter” look.

Pricing

It is nearly impossible to have a standard pricing sheet for custom ironwork. Each job must be individually priced according to style, material, coatings and installation requirements. You can be assured that we will use our extensive experience in manufacturing to find the most cost effective methods to create a quality product. We do not charge for estimates, and offer them gladly as needed.

Other Options for Cost Cutting

These high technology options may be able to cut costs by their ability to cut multiple pieces of the material at the same time without the cost of hand forging each piece.

Waterjets are run by a computerized numerical control which is programmed through a CAD drawing. The Jet works by pressuring water, (generally between 50,000 to 60,000 lbs per sq. in.), forcing that water through a nozzle and sending a very small high pressured stream through the material to be cut. Along with water, water jets also use an abrasive grit that is introduced into the water at the point just before the water exits the nozzle, which increases its cutting capacity. Although the grit is not needed for cutting some materials such as plastic or wood, the addition of the grit makes it able to virtually cut any material, from steel to glass to stone, in any form desired. The thickness of the product that can be cut varies with each material. For instance, steel reaches its limitation at approximately a 3” thickness, whereas aluminum can be cut effectively to a 12” thickness. One of the biggest advantages of water jetting is that it cuts the material cleanly, in any design, requiring little or no finish work afterwards. It can also cut several layers at a time, making it very efficient for high production applications.

Laser Cutting uses a very high intensity light that essentially burns though the material. The laser can produce extremely accurate parts, and it has major advantages and disadvantage over a water jet. One advantage of a laser is that it enables the manufacturer to etch into the material. The water jet can only go completely through the material and cannot be used to etch. One of major disadvantages of the laser though, is the thicknesses that it is able to cut. These vary by materials, but for steel that limitation is 1 ½ inches. (half of what the water jet can cut). In addition, if the laser is cutting anything over ½ inch in thickness there is a substantial decrease in accuracy and a substantial increase in the slag build up that requires hand deburring afterwards.

Both of these options can be used to cut a custom design without the cost of hand forging each piece.

Plasma Cutting is done by an electric torch that uses electricity to cut through material. The plasma cutter funnels positive and negative charges, similar to welding, through a plasma tipped electrode. This electrode then funnels the electric current, with the addition of compressed air, through the material to be cut. The biggest advantage of plasma cutting is that it is fast, however that speed is often offset by the labor required to deburr the material afterwards. It is also limited as to what materials it can cut. Plasma cutting is only effective on materials that can carry an electric current…such as steel & some alloys like copper and aluminum. Its main application for ironwork is for cutting out iron for repair and refurbishing, and removing excess material from components. Plasma cutting is generally not used for making parts.

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What Sets Us Apart?

At GreenRiver Forge we pride ourselves on staying ahead of the competition. Our origins in engineering and the aerospace industry have given us an up-dated perspective on an ancient craft. By using old world craftsmanship in combination with new technological advances, we can build products that are more structurally sound and create designs that can stray ‘out of the box’. This opens up the world of possibilities to our clients.

We use Computer Aided Drafting which allows us to draw products to precise specifications. With CAD drawings, our clients can see exactly what their finished product will look like before it is made, eliminating mistakes and misunderstandings in design. Additionally, because the drawings are to scale, we know when we fabricate that our products will fit perfectly.

We use the Best Coatings Available. It took us a long time to find the perfect formula for eliminating rust and ensuring the longevity of our products. Once our items are fabricated, they are sand-blasted to remove any visible rust and to smooth rough surfaces. The next step is to apply the pre-primer which stays liquid for 24 hours so it can seep into and fill every possible crevice. Then we apply the two-part epoxy primer and follow it with the two-part epoxy paint. The result is a finished product that can hold up to whatever Mother Nature throws at it.

We use the Best Installation Tools. By using a Core-Drilling Machine we can install in granite, bluestone, concrete, marble, wood or even cinder block and brick without breakage. Core-Drilling does not transfer pressure to the material it is drilling, allowing us to drill very close to the outer edges of almost any material without fracturing, chipping or breaking. We also take great care leave our work sites spotless.

We use the Best Mortar. Our company uses a specially designed mortar that contains vinyl for anchoring our ironwork. This allows our mortar to expand and contract with extreme Northeastern temperature changes, preventing water from getting under or around the plug or the post. This keeps the "plug" from pushing outward and the post from rusting within the mortar which can both result in a shaking installation. Our installations are ‘rock solid’.

We are very familiar with other fabrication options that can cut costs while maintaining a high quality product and design. Water Jetting, Laser Cutting and Plasma Cutting are a few of these methods.

Mill Work…in addition to an engineer & welders, we have a master carpenter on staff. This allows us to offer mill work for projects that combine wood with metals, such as wood railings with iron pickets, or wood and iron gates or furnishings. We have skilled laborers in all aspects of construction and manufacturing and encourage our clients to consult with us regarding any aspect of the design process.

Engineering…Once again, our experience in the aerospace industry gives us capabilities for creating projects that are “out of the box” in scope. In turn, this allows you the freedom to let your imagination run loose and see it actualized.