The Plating and Coating Industries’ Technology Magazinewww.metalfinishing.com

Jan./Feb. 2013Vol. 111

No. 1

Technically SpeakingElectroless nickel/immersion

silver for PCB applicationsNew developments in DC acid

copper for vertical plating tanks

On the surfaceCritical cleaning for

electronic components

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‘Iron Clad’

Henderson, Nev.-based AR Iron LLC supplementsits sought-after decorative forging capabilitieswith in-house powder coating services.

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In Henderson, Nev., in a grittyindustrial park about 20 milesremoved from the glitter andglitz of downtown Las Vegas,employees toil away at AR Iron

LLC. There, metal workers literallygrind out reams of linear feet of cus-tom-fabricated ornamental wroughtiron creations. Many of these intri-cately designed fabrications—ironsecurity doors, bars, gates, fencing,to name a few—will find their way

into high-end commercial installa-tions on “The Strip” or in residentialcommunities across the state ofNevada.

AR Iron’s list of custom-fabricatedspecialties reads like a designer’sarchitectural shopping list: customhand forgings, iron balusters, bas-kets, scrolls, twisted pickets, bellypickets, hammered material,embossed railing—you name it, ARIron can probably bring it tofruition. In fact, the more complexthe job, the more AR Iron seems torelish in it.

“It is our goal to satisfy our cus-tomers with beauty and efficiency onevery job,” says Tony Sclafani, ARIron’s general manager. Whether it’sa one-off residential job, a high-vol-ume home builder contract, or a sig-

nature commercialinstallation, ARIron’s approach toquality is essential-ly the same. “Weoffer residentialand commercialclients quality, cus-tom fabricatedo r n a m e n t a lwrought iron, while providing secu-rity that is beautiful, yet strong anddurable.”

AR Iron’s metal working capabili-ties entail a blend of both the time-honored tradition of hands-oncraftsmanship and state-of-the-artcomputer technology. While thecompany’s electronic database storessome 5,000-plus plasma art finialand scroll designs, it still requires thehuman touch of an experiencedwelder or metal worker to assemblethe various components and forgethe final design. Computer-aidedplasma cutting services, which cangreatly expand the design possibili-ties, are also available.

The depth of these capabilities,according to Sclafani, provides acompetitive advantage. As an exam-ple, he said AR Iron workers can“miter-cut” the top corners of gates(as means to deter water intrusioninto the railing or post). Such a serv-ice, he notes, would incur premium

up-charges by other companies spe-cializing in custom iron work.

Attention to detail isn’t the onlypoint of distinction for AR Iron. Thecompany also prides itself on rapiddelivery times without compromis-ing product quality. “Unlike mostiron companies, we have a turn-around of 5–7 business days for moststandard work, with custom forgingstypically requiring 7–10 businessdays,” Sclafani notes.

It’s capabilities such as these—aswell as an ingrained commitment toproduct quality—that’s drawing theattention of new, prospective clientswhile keeping existing customerscoming back for more. Sclafani rat-tled off an impressive list of majorbuilder partners (Lennar Homes,Pulte Homes, Ryland Homes, toname a few) as well as establishedgeneral contractors that providelucrative leads. “We proactively lookfor business,” said Sclafani, who

BY REGINALD TUCKER

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AR IRON LLC/AR POWDER COATING1425 Athol Ave. Henderson, Nev. 89011Tel.: 702-565-7161Fax: 702-565-6500E-mail: tonys@arironllc.comwww.arironllc.com

AT A GLANCE ✪

AR Iron has the capability to deliver intricate,detailed designs in a relatively short time frame.

Father & son: Fred Sclafani (left) owns AR Iron LLC with his wife, Sylvia. Their son Tony (right) servesas general manager.

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ing that was alsoin keeping withthe Venetian’sartistic flair. ARIron stepped up tothe challenge, cre-ating railing thatfeatured morethan 8,000 hand-forged solid barscrolls comple-mented by 16,000deco rosettesattached to thefinials.

Greg Bachnick,project manager,The VenetianHotel & Casino,recalled the com-plex requirementsof the job. “AR Iron was the onlycompany that went through the timeand expense to create a sample panel,and that was very impressive to us,”he explained. “The design was criti-cal, and delivering the product in atimely manner while maintainingthe consistency in design and qualitywere a major concern, but AR Ironmade us feel very comfortable withtheir ability to accomplish the job.This installation took a great deal ofdetail work and layout and, as youcan see from the final result, AR Ironperformed flawlessly.”

Sclafani attests to the challenges ofthis particular installation—a projectspanning eight floors. “The open-ings were not square, so it was diffi-cult to pre-fit every panel,” heexplained. “This required measuringeach individual opening on site toensure the panels lined up.” Theentire job, from fabrication to instal-lation, took 90 days.

BRANCHING OUTAR Iron’s expertise is not limited tothe custom manufacture of decora-tive iron railings. Having addedenamel painting and powder coatingcapabilities to its repertoire aboutfive years ago, AR Iron expanded itsoperation to offer customers a morecomplete array of services. To that

always has his fingers on the pulse ofthe local residential/commercial realestate market. “We’re also seeing afair amount of repeat business.”

And then there are those “mega,”high-profile jobs that showcase thefull breadth of AR Iron’s capabilities.One such project entailed the park-ing garage structure attached to theVenetian Resort Hotel & Casino, thesprawling complex boasting 6,000luxury suites, 200,000 sq. ft. of casi-no space, and 500,000 sq. ft. of retailspace. The hotel’s parking garage—which can accommodate space for7,500 cars—required protective rail-

end, the Sclafani family added10,000-square feet, purchased paintand powder coating equipment andsupplies, and invested in trainingand education for its employees.Thus, AR Powder Coating was born.

With the addition of the powdercoating operation, the total facilitycovers 20,000 square feet. The exten-sion boasts an 8-gun automatedpainting station paired with a down-draft system; an energy-efficientbatch oven with an enlarged openingto accommodate oversize parts; anda new batch spray booth. What’s

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PRIMARY VENDOR PARTNERS ✪AkzoNobel—www.akzonobel.comCarpenter Chemical—www.cc-lc.comCoral Chemical—www.coral.comParker Ionics—www.parkerionics.com Prismatic Powders (div. of NIC Industries)—www.prismaticpowders.com Sherwin-Williams—www.sherwin-williams.com

Tony Sclafani demonstrates what’s possiblethrough design and fabrication. Here, heinspects a set of security gates after coatingand curing.

AR Powder Coating features an 8-gun auto-mated painting station paired with a down-draft system.

The owners of AR Iron invested in an energy-efficient batch oven with an enlarged openingto accommodate oversize parts.

CAPABILITIES & CERTIFICATIONS ✪Custom Iron ForgingParts Cleaning & Priming Powder CoatingEnamel Painting CAD Part DesignComputer-Aided Plasma Cutting

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Iron LLC is also hoping that factorsoutside its sphere will translate intoeven more business for the company.Namely, the tepid upturn in theeconomy. “The local economy iscoming back slowly,” Sclafani con-firmed, reflecting on the 2008–09economic downturn that essentiallyput a halt to the construction boomthat had become to define Las Vegasand its surrounding counties.

Sclafani is also seeing positive signsresulting from Las Vegas MajorOscar Goodman’s revitalizationplan, which has fostered the develop-ment of single- and multi-familyhousing units as well as new, large-scale commercial development. Withhome ownership rates hovering

more, all material is thoroughlycleaned and primed using advanced,environmentally friendly pretreat-ment chemistry1 prior to finishapplication. All totaled, AR Iron/ARPowder Coating has the capacity toput out 4,000–5,000 linear feet perweek.

Sclafani also attributes the compa-ny’s high level of production to thetalents and commitment of hisworkforce, which now stands atabout 22 employees. “These skills arehard to teach,” he said, singling out aworker performing a visual inspec-tion of a finished product. “One ofthe main reasons we are successful isbecause our employees take owner-ship in the business.”

AR Iron’s clients tend to agree. “ARIron has an amazing facility/teamand, thus, the ability to create anddeliver a product that ultimatelywould meet our high standards,”The Venetian’s Bachnick said. “Iwould reach out to AR Iron for anyopportunity to bid that comes ourway where we would need theirexpertise on a project. I would alsorecommend them to anyone who islooking for custom/quality metalfabrication.”

OUTLOOKBeyonds its technical prowess, AR

around 60% (only slightly below thenational average) and 2012 permitsabove year-ago levels, there’s reasonto be cautiously optimistic.“Building permits are starting tocome back,” Sclafani notes, “andthat’s always a good sign.”

REFERENCES1. Carpenter Chemical’s one-step

pretreatment process. “The adhe-sion is phenomenal with theCarpenter chemistry,” said TonySclafani, general manager, ARIron LLC. “If you’re putting ongood powder, you’ve got to havegreat pretreatment.”

Racked and ready. AR Powder Coating has thecapacity to put out 4,000 –5,000 linear feet perweek.

The installation AR Iron completed for the garage structure at the Venetian Resort Hotel & Casinoentailed 8,000 hand-forged solid bar scrolls complemented by 16,000 deco rosettes attached to thefinials. The entire job, which spanned eight parking levels, took 90 days.

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