March 2019 Volume 25.3
The Beacon of the Stone Industry www.slipperyrockgazette.net United Marble Fabricators: Providing Distinctive and Award-Winning Stone Projects Since 1987
estled within a vast array of buildings in histor- Peter Marcucci Nically rich Watertown, Photos Courtesy Massachusetts stands United United Marble Fabricators Marble Fabricators. President John Kilfoyle leads the fami- ly-owned company. A growth machine from its onset, United that could make them. Tired of Marble has become successful waiting weeks for his parts, he by consistently going beyond decided that he wanted to begin “just good enough,” past “is this cutting them on his own. At that our best effort” — resulting in time, stone importers and dis- outstanding projects installed tributors would only sell slabs throughout much of New to companies that had a bridge England’s affluent residential saw, so in 1987 he bought a saw market. and incorporated under the name United Marble Fabricators.” John Kilfoyle, like many of the The bridge saw was a sim- business leaders interviewed in ple and beautiful fully manual the Slippery Rock, grew up being Terzago, and it became a great involved in his father’s shop. and reliable workhorse when While other kids were spending later fitted with a laser, but was time off from school traveling retired in 2015 to make room for with family or having summer the company’s next growth stage, The United Marble Fabricator showroom is a showcase of the art of bookmatching. fun with friends, John was busy as well as for one big safety rea- learning stone fabrication from son: it didn’t have a tilt table, and the ground up. Coming into the every once in a while when load- company as a full-time employee ing or unloading, a marble slab in 2008, he already knew how would bite the dust. Natural Stone Institute Announces to produce and estimate projects from his years spent in the shop Building Success in a Luxury 2018 Grande Pinnacle Award helping out wherever he could. Residential Market This story recounts those days, According to Kilfoyle, United he winners of the 2018 a light and airy feel, a startling and what it took to get the com- Marble Fabricators is very fortu- Pinnacle Awards were juxtaposition to what one typi- pany to where it is today. nate to be in the Massachusetts T announced during the cally associates with heavy, rug- “United Marble Fabricators market, because the housing Natural Stone Institute Awards ged stone. was started in Somerville, growth over the last eight years Ceremony at TISE 2019 in Las The stone needed to be Massachusetts by my father, Tom has been remarkable. “Even Vegas, Nevada. Fourteen proj- solid and dense enough to re- Kilfoyle, in 1987. My father was through the Great Recession, ects were honored with Awards tain structural integrity when a tile installer by trade and came the growth rate in suburban of Excellence, and the best carved thinly with a lot of neg- into the natural stone industry by Massachusetts was unrivaled. overall project was selected for ative space. An eight cubic foot, way of needing stone for the tile Overall, clients who live in this the Grande Pinnacle Award. half-ton block of statuary grade projects he was doing. Shower market have a lot of concentrated The 2018 Grande Pinnacle Award was presented Bianco Carrara C marble was sourced in Pietrasanta, seats, thresholds, jamb kits and wealth, are educated, know what to Mario & Son (Liberty Lake, Washington) for Italy and meticulously tested for any fissures. It soap shelves all needed to be fab- they want, and have a very dis- their work on Aura — the first time a sculpture has would ultimately be reduced down to a mere eighty ricated. At the time, there were tinctive style. been awarded the Grande Pinnacle. pounds, while retaining most of the original volume. only a few shops in New England Please turn to page 2 Carrara marble conjures thoughts of elegance, Inside this framework is a continuous band, weav- timelessness and refined taste, begging to be ca- ing in and out of itself, playing with light and shadow ressed and admired. Aura is as much about the among suggestively feminine curves. marble as it is the spaces in between, conveying Please turn to page 5 | 2 March 2019 Slippery Rock Gazette United Marble Fabricators
Continued from page 1 there’s a single source and only one company that they need to go “We fabricate many materials, to. From the general contractor’s but the core of our business is still standpoint, it serves them very marble. We’ve been able to create well, because we understand the a niche for ourselves within a lux- entire scope of the project and can ury residential market, and don’t schedule accordingly. An exam- have to worry about how many ple of this would be prioritizing kitchens we are doing this week finishing the master bathroom to because we are mostly working open it up for the wallpaper crew. on custom projects. It’s not un- common for us to be hired by a “So we have the ability to create custom builder on referral from a schedule that works around the an architect or interior designer overall build schedule, because and be brought in during the plan- we are providing our own project ning stage. Early on we are in- management for the job. This is volved in the conversation about a huge bonus for the homeowner what the client wants, such as an and is probably our biggest ad- extra thick mitered edge, or the vantage. When we’re involved in builder saying, ‘We are thinking a bid and there’s multiple compa- about using this type of material. nies also bidding, oftentimes the What would you recommend?’ reason we get the job is because of our project management ability also created a lot of loyalty from Mitered Calacatta master vanity countertop with matching back- “We also continue to do tile in- and somebody’s confidence that our clients, because it eliminates splash and mirror frame designed by Lewis Interiors and built by Adams & Beasley Associates. stallations. A typical project for we can effectively manage the the fear of the unknown for them. us is a new custom build, and we scope in a way that will get them They know what they are going to High Tech to the Rescue too, is packed with buildings. So will handle all hard surface for what they want, when they want get, and if a designer has a partic- If you’ve ever visited Boston, much so, in fact, that the United the entire project; kitchen, pan- it. You would think that in a ser- ularly difficult client who is picky you know it is one heck of a big Marble Fabricators’ long, skinny try, wet bars, fireplaces, master vice society where everything is about finishes, they know our city, with every inch of concrete building covers 90 percent of its and kids’ baths – basically all about price, price, price, it would build quality is always a priority. and pavement packed with build- lot. Needless to say, a prudent, ef- the stone and tile throughout the hurt our volume, but there’s a So that service and intangible as- ings of all sizes. To say that space ficient plan was needed when di- house. This has let us provide a surprising amount of people who suredness that we provide is very is at a premium would be an un- viding up floor space for its 1,500 lot of accountability for a general understand value and are willing important.” derstatement. Watertown is just square foot showroom, and 7,000 contractor or an architect, because to pay for the value we offer. It’s beyond Boston’s outskirts, and it, square foot shop and warehouse. Moreover, production equip- ment and protocol needed to be super-efficient, too, continued Kilfoyle.
“We went from a manual shop to a fully digital shop within one year. It was a hairy year, but it happened and it taught us a lot, because when using technology you need to have a very defined process and need to have very defined roles or, essentially, the project doesn’t move. I think that these were our biggest challenges in adopting new technology. I also think that once we were able to create that process, technology helped our projects come together faster and actually reduced our re- work rate by a lot. Quality wise, we are able to produce very, very complex things that we weren’t able to produce when we were a purely manual shop. An exam- ple of this would be our ability to bookmatch slabs. This is a really big thing for us, and the ability for us to do the layout work up front was not something we could easily do when we were manual. Honed Sea Pearl Quartzite kitchen countertops designed by Please turn to page 7 Lewis Interiors and built by Adams & Beasley Associates. | Slippery Rock Gazette March 2019 3
Now available at braxton-bragg.com | 4 March 2019 Slippery Rock Gazette In This Issue DEPARTMENTS: Industry Spotlight United Marble Fabricators: Providing Distinctive and Award-Winning Stone Projects Since 1987, by Peter Marcucci ...... Begins on 1 Meet St. Henry Granite: The Mega-Crystal Marvel, by Steven Schrenk ...... Begins on 32 The 2018 Pinnacle Awards ...... Begins on 13 Creative Stone Worx Owner Robert Foster Receives Patriot Award from ESGR ...... Begins on 15 Slab racks John Huarte, University of Notre Dame Alumni, Gives Back ...... 23 Material Handling Training and Education Sponsored by Braxton-Bragg What It Takes to Be a “10”, by Ed Hill ...... Begins on 5 Are You Complying With Crane Safety Regs?...... 11
Industry Topics, Tips and Regulars Home Shows: Yes or No? by Sharon Koehler ...... 11 Seam Setter The Stone Detective, by Frederick M. Hueston ...... Begins on 12 Stone Restoration and Maintenance Corner, by Bob Murrell ...... Begins on 14 A-Frames Safety First, by Codiak San Herrell ...... 16 Safe Driving 101, by Sam Venable ...... 17 What Have You Gained? by Sharon Koehler ...... 20 What Do You Do With Your Stone Remnants? by Stephanie Vierra ...... Begins on 26
Stone and Tile Industry News Stone Interiors Employee Mark Blanda Jr. Awarded Stone Scholarship ...... 8 Creative Edge Master Shop Sold to Iowa Investor Weaton Capital ...... 12 Alpha Introduces New EZ Leveling Systems for Tile ...... 15 Peter de Kok Receives 2018 Migliore Award for Lifetime Achievement ...... 20 LPI Announces New Version Laser Templater is Fastest Ever...... 35 Debate on Chinese Quartz Duties / Tariffs Continues ...... 35
Telescoping Classifieds and Marketplace ...... 30, 31 Forklift Boom
® Clamping Dolly Carry Clamps “It is important that we know where we SLIPPERY ROCK GAZETTE The Beacon of the Stone Industry come from, because Visit our online edition www.slipperyrockgazette.net to if you do not know place a classified ad and to view current and back issues. where you come Rick Stimac Publisher Larry M. Hood Editor and Design Director from, then you don’t G. William Brown Graphic Designer know where you Codiak San Herrell Stone Industry Consultant Fabrication Fabrication Table Ed Hill Synchronous Solutions Stand are, and if you don’t Frederick M. Hueston Stone Forensics Consultant know where you are, Sharon Koehler Artistic Stone Design then you don’t know Rufus B. Leakin Guru of Urban Folklore Peter J. Marcucci Special Contributor
INTRODUCING A NEW LINE OF PRODUCTS where you are going. Bob Murrell Restoration Consultant And if you don’t Steven Schrenk Polycor know where you are Sam Venable Department of Irony going, you’re proba- Stephanie Vierra usenaturalstone.com bly going wrong.” Read our online edition at www.slipperyrockgazette.net . Use the department tabs to place a classified ad and to view current and back – Sir Terry issues. Send address updates to [email protected], and Call 1-800-575-4401 or Order Online comments c/o editor [email protected] . Subscription Pratchett requests, a classified ad submission form and our 2019 Ad Guidelines are www.braxton-bragg.com available online at www.slipperyrockgazette.net . | Slippery Rock Gazette March 2019 5 Training & Education What It Takes to Be a “10’ Free Online Training Tools for lients often ask Ed Hill opportunities to improve me, “How are we Synchronous Solutions both financial and quality Cdoing? Are we on of life metrics for the com- Stone Industry Professionals track? How do we compare pany and its people. The to other companies who …There are always op- degree to which a com- have done this?” pany practices those prin- portunities to improve ciples with diligence and They are referring to the both financial and discipline will define the practice of Synchronous quality of life metrics performance of the opera- Flow. They ask this upon tional system. completion of the initial for the company and its While the basic elements implementation of the people. This should be of Synchronous Flow can Synchronous Flow princi- be implemented in a matter ples, when their score on a the driving philosophy of months, the time frame scale of ten would be about of the organization. from the initial introduc- a three. And they continue tion to a consistently good to ask it as their use of the Point, and all other functions level of operational per- principles matures over the work to serve that point. The formance will probably be years. These people un- primary metric is throughput least one year. It takes that derstand that Synchronous ($T), which is the measure long to instill all the disci- Flow is all about continu- of value added by the com- plines of the Synchronous ous improvement, so they pany. Planning, scheduling Flow business process. are always looking for bet- and tracking the business is Moreover, it takes that ter ways to do business. accomplished daily using long to change the cul- They also understand that $T as the common metric. ture of the organization practicing Synchronous Protective buffers of or- to one that follows the Flow is more a matter of ders-in-process are man- Synchronous Flow princi- www.uofstone.com behavioral discipline than aged constantly to achieve a ples habitually as the basis just following a set of tech- smooth flow of information for all routine procedures niques. It is a new way to and materials through the and decision-making. The do business. It is a new lan- system from the sale through driving principle of the guage of operational con- the completion of each order. business should be the cap- 2018 Grande Pinnacle Award trol. Used most effectively, The company uses the in- ture of every opportunity it can be a transformational formation from the various for continuous improve- Continued from page 1 a small metal ribbon bent modeling program, and journey in the operational Synchronous Flow reports ment toward operational into a pleasing, asymmetri- eventually 3D printed to performance of a company. to identify and address the excellence. The luminous nature of cal shape, capable of being scale in plastic. An Old- Synchronous Flow is a most advantageous op- To be scored a “10” the stone allows light to displayed and viewed from World measuring device, common sense approach portunities for continuous would require excel- penetrate the thin edges multiple perspectives, with the Macchina di Punta, to business management. improvement. lence in all the principles producing a glowing halo no defined “base.” Utilizing was employed to mark spe- The process flow is syn- The driving philosophy of Synchronous Flow. effect, hence the title of the modern technology, this cific points on the model chronized around a stra- of the organization should sculpture, Aura. metal prototype was digi- that were transferred to the tegically selected Control be that there are always Please turn to page 8 The sixteen month execu- tally scanned and refined block, allowing the shape to tion of this work began as within a 3D computer be copied into the marble by hand, in the tradition Six Day Lead Time from Template through Install Joey Marcella with Aura, 2018 Grande Pinnacle winner of the Old Masters. Manufacturing Engine Hammer and chisel methods eventually INSTALL had to yield to hand- RED held, rotary abrasives, YELLOW ONE ONE TEMPLATE as the piece became GREEN ONE Please turn to page 8 thinner and more frag-
ile. The entire piece Approval Programming Cut and Polish Ready by 2 pm was meticulously hand 24-Hour Rule through QC { { sanded to achieve the { { { deepest and most 1 Day 1 Day 1/2 Day Shop Floor: 2-1/2 Days 1 Day { { { spectacular polished { { finish. Template Green one Yellow one Red one Install 1 Day 1-1/2 Days 1-1/2 Days 1 Day 1 Day { Please turn to page 13 6 Days – Approval through Install for additional coverage of the 2018 Pinnacle Awards. Synchronous Flow production chart of a stone shop shows optimization of time and scheduling to build maximum efficiency. | 6 March 2019 Slippery Rock Gazette
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