Specifying Guide Decorative Custom Wood Moulding & Decorative Custom Metalwork

Transcription

1 Specifying Guide Decorative Custom Wood Moulding & Decorative Custom Metalwork An Essential Reference Manual for Architects, Interior Designers & Contractors Important considerations, factors & variables that affect quality & cost of custom decorative wood moulding and metalwork for residential & commercial design projects

2 This manual will enable you to: Identify the best material & design options to fit your unique project needs Select the best quality & cost options available for your specific applications Recognize the innate characteristics of both raw wood & metal materials Simplify the specification process & avoid installation challenges Provide your clients with a better understanding of custom craftsmanship Ensure the finest quality outcomes for your residential & commercial projects Contents Decorative Lineal Wood Mouldings Factors affecting quality & cost... 1 Popular Species for Carved & Embossed Decorative Lineal Moulding... 2 Popular Hardwoods for best yield & quality finish for carving... 2 Hard Maple face grain White Oak face grain Hard Maple end grain White Oak end grain Popular Hardwoods with distinctive open grain structure Popular Hardwoods for embossing Best Species for Production of Carved & Embossed Decorative Lineal Moulding... 3 Egg & Dart Hard Maple Sample Moulding; Egg & Dart White Oak Sample Moulding Hardness of Popular Wood Species... 4 Janka Scale of relative hardness; Klise Warehouse - Lumber Bunks Color of Popular Wood Species... 5 Wood Species with Significant Color Variation Walnut samples showing color variation Cross Section View of a Tree Trunk... 6 Frequently Asked Questions RE: wood Mouldings... 7 Q: What are the best wood species to select for carved mouldings? Q: Are Basswood and Poplar less expensive than Hard Maple or Cherry? Q: What is the normal color of wood species such as Poplar and Walnut Species? Quality Rating of Lumber... 8 Standard Hardwood Lumber Grades National Hardwood Lumberman s Association Time-Honored Production Processes... 9 Carving Wood Turning Embossing CNC Carving 1890s Carving Machine Klise custom carved pattern D1024 Wood Turning Machinery Klise G73 bamboo shaped moulding; Klise G20 bead moulding Embossing Machinery Embossed design on lineal moulding CNC (Computer Numerical Control) Carving Machinery CNC Tool Close-up ii

3 Custom Hand-Crafted Wire Mesh Grillework Sample Grille Installations Factors affecting quality & cost Raw Material Pre-Production of Wire Mesh Grilles Template for a custom formed #403 Formed wire grille Material, Wire Type/Size & Decoration Material: Steel & Brass Wire Size / Wire Type Round Wire; Reeded Wire (one side only); Plain/Flat Wire; Square Wire; Distressed Wire (one side only) Rosette Type / Placement Rosette Options #311 Grille Shown with #2002 Rosettes Woven Wire Mesh Grilles Crimping Methods Single-Crimp; Double-Crimp; Press-Crimp Wire Spacing for Woven Wire Mesh Grilles Formed Wire Grilles Pattern Variation #503 Style Grille Pattern with 1/4 bracket clips Formed (non-standardized) Wire Grilles Klise Custom formed #503 style, Neo-Moorish Grille design Formed Wire Grille Samples #540 scallop; #600 custom vert. w/rosettes; #403 diamond w/rosettes; #600 custom; #660 ovals w/tabs Measuring Formed Grilles Dimension / Orientation of Formed Wire Pattern Grille #522 custom hexagonal pattern Reveal and Repeat of Formed Grilles Expected Reveal & Repeat Balanced vs. Unbalanced Reveal #403 style grille with #2002 rosette Mounting Techniques for Grilles Rubber Gasket; Quarter-round Moulding Tabs; Integral Frame Frequently Asked Questions RE: Wire Grilles Q: Can Klise determine the best size, repeats & spacing for my custom formed grilles? Q: Is it normal to have slight variations in my hand-made formed grille patterns? Q: Why are Reveal Area and Overall Grille Size details important? Q: What is the Reveal Area? Q: What is a Rabbet? Q: Why doesn t the color finish of my grilles look like the samples on the Klise website? Q: What is the best way to match grille finish to other metal hardware, faucets, etc.? Q: Is it normal to have the color finish on my mesh grilles show ligher & darker areas? Q: Will my electroplated grilles be susceptible to rust? iii

4 Decorative Lineal Wood Mouldings Patrick Mulcahy Photography J. McLaughlin Lexington Avenue Women s Store, New York, NY Klise G73 Bamboo & D2231 Basketweave Kitchen cabinetry accented with Klise carved lineal mouldings P2015 Crown, D1441 Reed/Wrap, T2072 Beaded ColumnTrack Armoire/dresser with Klise decorative wood mouldings A1 Carved Rope & T1572 Beaded ColumnTrack iv

5 Decorative Lineal Wood Mouldings Important Factors Affecting Quality & Cost of Carved & Embossed Lineal Wood Moulding The innate characteristics of any wood species will have a significant impact on quality and cost of all projects that require detailed carved or embossed lineal decorative moulding. Many challenges come from the wide variance in the properties of all wood species including its durability, grain structure and color. Successful carving and/or embossing of wood mouldings will vary significantly based upon the specific wood chosen for the application and the process used to create the decorative lineal moulding. Four of the most important factors that affect quality and subsequently cost are: 1. Wood Species 2. Color Requirements 3. Quality Rating of the Lumber 4. Production Process Stundwar-Flemming Pool Table, Camp David, MD Includes a multitude of Klise custom lineal wood designs, most notably; K6810 Guilloche/Running Coin (top right) & D2484 Diamond (bottom right) Sleigh bed with Klise carved lineal moulding pattern D1116 Fluted 1

6 Most Popular Wood Species Used for Carved & Embossed Decorative Lineal Moulding Popular hardwoods that typically provide the best yield & quality finish for carving More durable woods with tight close and smooth grain structure (smooth) are the best choices for use in intricate carved applications. Some of the most popular durable woods used for decorative carving are: Hard Maple, Cherry and Walnut (see image on page 5). These species typically will have relatively straight grain. Historically, Hard Maple and Cherry have been the most popular wood species used in kitchen cabinetry. Other popular hardwoods with distinctive open grain structure Wood species including; White Oak, Red Oak and to a lesser extent, Genuine Mahogany, although very durable (hard) also have an open and rather coarse grain structure (see images at lower right). White Oak is especially difficult to carve given the varying grain, porous structure and overall hardness. As a result, it is very common to have tear-out or cracking (see next page) along the open grain when carving intricate patterns into these wood species. Hard Maple Face Grain notice the tight smooth & rather straight grain structure White Oak Face Grain notice the open & varying grain structure Hard Maple end grain White Oak end grain Popular hardwoods for embossing: Many species can be successfully embossed, however, the softer hardwood species including Basswood, Poplar and Soft Maple tend to be frequently used, mostly due to cost considerations. However, very hard woods (see hardness scale, page 4) such as White Oak are too hard to use for most embossing processes and can damage embossing dies. 2

7 Wood Species that Provide Best Results for Production of Carved & Embossed Decorative Lineal Moulding 1. Wood species that have a tight close, smooth and straight grain structure will yield the best results when being intricately carved. 2. Species of wood that have an open, coarse and varying grain structure offer unique aesthetics, but when carved, can often result in significant tear-out or chipping. 3. Softer wood species tend to work best for the embossing process and also tend to be the most costeffective option. Tight close grain structure of Hard Maple is shown in this carved Egg & Dart moulding Note the smooth lines and consistent grain providing a clean appearance and high detail. tear-out due to coarse & open grain structure Coarse open grain structure of White Oak is shown in this carved Egg & Dart moulding. Note the varying and open grain, tear-out and the jagged lines resulting in less detail. 3

8 Hardness of Popular Wood Species Basswood Poplar Gen Mahogany Cherry Walnut Wood Hardness Red Oak White Oak Hard Maple Source: USDA / Forest Service, Forest Products Laboratory Research The Janka scale rates the relative hardness of wood, with the higher number values representing harder wood species. The diagram above shows some of the most popular wood species used for creating carved and embossed decorative lineal moulding and are listed for reference and comparison. These ratings established by using the Janka Hardness Test, measure the force required to embed a.444 inch steel ball to half its diameter into the wood. (Although the Janka Scale was created for the wood flooring industry, it provides a good general reference point for the relative hardness of many wood species.) Bunks of various species of hardwood stock awaiting production orders in Klise warehouse. 4

9 Color of Popular Wood Species The color of most wood species can vary greatly. Much of this will be dependant upon the region of the country in which it is harvested, amount of light the tree receives, soil it is grown in, etc. Color may vary slightly or significantly from wood within any bunk of lumber or even in an individual lineal piece of wood. Within the lumber industry, color is not rated in any definitive way, so color range is rather subjective and is spread over a broad spectrum of shades; as a rule, heartwood is darker than sapwood (see image, page 6). At an additional charge, Klise can provide an advanced color sort to fit within a range or limited spectrum of color, however, as with any natural product, the color of wood will not be exact or uniform. Several Wood Species with the Most Significant Color Variation: Hard Maple Typically has creamy white sapwood with slight reddish brown tint, while the heartwood varies from light to dark reddish brown. This color can differ greatly based upon the growing region it was harvested from. Walnut This species has an off-white sapwood with light brown to dark chocolate colored heartwood. Often times there will be darker or purple color striations in this species. Generally, Walnut will darken over time. Cherry Often times this wood will have a yellowish-pink sapwood with reddish to deep red heartwood. Pitch pockets and pin knots are common in the darker sapwood of this species. Cherry wood will darken with age and exposure. Poplar A popular cost-effective wood, varies significantly in color from creamy white and/or streaked sapwood to heartwood which varies from yellow, brown, green or purple. Below is photo showing two boards from a single bunk of Walnut. This color striation is typical for Walnut and other species. As with any product coming from nature, trees vary significantly in size, color and density, based upon growing region, climate, seasonal climate changes and other environmental factors. Two boards cut from a single bunk of Walnut (already steamed for better color consistency) showing color variation. There is no default color for any wood species and color throughout an individual tree will at times vary significantly. Color sampling, however, can be offered to determine a general range of acceptable color. At the point that a color range is agreed upon, a custom quote can be offered factoring in the labor-intensive process of color sorting. 5

10 Cross Section View of a Tree Trunk Sapwood (lighter in color) Heartwood (darker in color) Pith Bark photo emer - Fotolia.com 6

11 Frequently Asked Questions Regarding Wood Moulding Q: What are the best wood species to select for carved mouldings? A: Typically harder woods with tight grain structure provide the best finished results when carved. Choice of wood species is a decision best left to the architect/designer and their client. Q: Are Basswood and Poplar less expensive than Hard Maple or Cherry? A: Yes, in their raw form species of Basswood and Poplar are in fact cheaper. These species are considered utility woods, typically used for non-aesthetic purposes. Despite being less expensive as raw lumber, these softer wood species carve rather poorly and are subject to fuzz or tear-out. With this in mind, the yield of good carved finished product is drastically reduced. It is not uncommon that using softer wood (for example; Basswood or Poplar) may require 3x more raw material to produce 100 lineal ft. of carved moulding, than if a harder more dense wood such as Hard Maple was used. Q: What is the normal color of wood species such as Poplar and Walnut Species? A: As with any natural material, wood may vary significantly in color within a tree (see image at left), from tree to tree or lineal piece to lineal piece. There is no normal color for wood but rather a general color range that may vary significantly from species to species. Wood can be sorted for color, which means that Klise can send color samples to architects, designers, etc., which show color variance/range (typically 5 different samples). Once a color range is determined, the bunks of raw lumber boards can be sorted to fit within the specified range. Color sampling can be a very labor intensive process. Poplar, unless specified to be SORTED FOR COLOR, will vary significantly. Typically, unsorted Poplar will have green or gray tinges or striation, amongst a light yellow /cream color. As with any natural product, wood will vary from piece to piece, with regard to color, grain texture, with no uniformity. Walnut has a wide range of color variability. It may contrast from a cream-colored sapwood to a light brown to dark brown heartwood (see image at left). Unless specified, Klise can quote Walnut STEAMED FOR COLOR, which only means that the wood used is steamed to allow for greater consistency in color. Sorting for Color or Steamed for Color will add additional expense to the project. 7

12 Quality Rating of Lumber The quality of lumber is defined by standards established by the National Hardwood Lumbermen s Association (NHLA). This non-profit organization was created in 1898 to implement standard rules for grading, inspection and measurement of hardwood lumber. Hardwood grades are based on the size and number of clear pieces that can be obtained from a board when it is cut to be used to make a product. Grades are determined by specific measurements of clear sections & definitions of defects. Klise uses only Selects (SEL) & better (F1F and FAS) lumber to create our custom lineal wood moulding. Klise also imposes additional quality specifications (dimensional tolerances and color, knot & mineral allowances) which vary based upon the unique production processes, customer requests and species of wood used. A Summary of Standard Hardwood Lumber Grades: Best Quality Firsts and Seconds (FAS) The best and most expensive grade. Boards 6 and wider, 8 and longer. Yields 83.3% of clear face cuttings with minimum sizes of 4 x 5, or 3 x 7. Board is graded from the poorer face. Suitable for fine furniture, cabinetry and applications where clear, wide boards are needed. FAS One Face (F1F) The same as FAS except the board is graded from the better face. Selects (SEL) Face side is FAS, back side is No. 1 Common. Boards are 4 and wider, 6 and longer. Yields 83.3 % percent clear face cuttings with minimum sizes of 4 x 5, or 3 x 7. A cost effective substitute for FAS when only one good face is required or smaller cuttings are acceptable. Lesser Quality No. 1 Common A typical thrift or shop grade. Boards are 3 and wider, 4 and longer. Yields 66.6 % clear face cuttings with minimum sizes of 4 x 2, or 3 x 3. Provides good value, especially if relatively small pieces can be used. No. 2A & 2B Common Boards are 3 and wider, 4 and longer. Yields 50 percent clear face cuttings 3 and wider by 2 and longer. Suitable for some paneling and flooring applications. No. 3A Common Boards are 3 and wider, 4 and longer. Yields 33-1/3 percent clear face cuttings 3 and wider by 2 and longer. Economical choice for rough utility applications:, crates, palettes, fencing, etc. No. 3B Common Boards are 3 and wider, 4 and longer. Yields 25 percent clear face cuttings 1-1/2 and wider by 2 and longer. Applications same as No. 3A Common. Klise uses Selects (SEL) and better-rated hardwood grades (which includes; F1F and FAS). These top grades provide the most consistent and highest quality raw lumber, resulting in the best final aesthetic quality of carved & embossed decorative lineal moulding. 8

13 Time-Honored Production Processes Carving Wood Turning Embossing CNC Carving Carving Machinery A series of intricate tools (knives), hand-set in a specific order to achieve a specific design pattern. 1890s Carving Machine (pattern setup: D1024) Klise custom carved pattern D1024 This 1890s era carving machine is still in use today, and creates a multitude of carved lineal mouldings with both precision and unmatched detail. Tools are hand-set, with some patterns requiring more than 13 different knives. Modern machinery, including CNC rotary tools cannot duplicate the clean angles obtained on these old-world machines. Very few of these machines remain in existence and Klise has most of them. 9

14 Wood Turning Machinery Klise G73 bamboo shaped moulding Klise G20 bead moulding Woodturning is a carving process that involves mounting and securing a lineal wooden dowel at two end points in the machine. Once secured, the wooden dowel is rotated or turned in a circular fashion at a relatively high rate of speed, while a stationary tool is used to cut and shape it. Many intricate shapes and designs can be made by turning wood, including lineal bead patterns. 10

15 Embossing Machinery Embossing Die Embossed design on lineal moulding Heated dies press patterns onto lineal wood moulding Embossing Machines create detailed designs on moulding by using a hot die to make an imprint in the wood. An embossing die or wheel is made of a brass alloy or carbide and contains a specific pattern or design. This embossing die is then affixed to the embossing machine and heated to approximately degrees Fahrenheit. Once the die reaches the optimum temperature (determined by hardness of the wood, and burnishing needed), it is then rolled over the face of the lineal wood profile to create a unique and consistent indentation. The pattern is pressed or embossed into the wood. Embossed Lineal Moulding Pattern #K602 Embossed Lineal Moulding Pattern #K981 Embossed Lineal Moulding Pattern #K

16 Computer Numerical Control (CNC) Machinery CNC Carving Machinery CNC tool close-up CNC (computer numerical control) Machines extract programmed commands in order to produce lineal mouldings that will closely match a CAD design. Depending upon the wood product being produced, the process may require the use of a number of different tools, including saws or drills. Although Klise does not use much CNC technology in our production process, we do utilize a 3-axis CNC machine for select jobs. 12

17 Custom Hand-Crafted Wire Mesh Grillework Louis Benton Steakhouse, Grand Rapids, MI McGraw Construction Klise Style #212 Press Crimp Custom Wire Grille Benchmark Wood Studio Bathroom Cabinet Klise #403 Grille with #1533 Rosette Parade of Homes Entry Tim Schollaart Builder LLC Michigan Cabinet Supply Klise Style #212 Press Crimp Custom Wire Grille in Cabinets 13

18 Important Factors Affecting Quality & Cost of Custom Hand-Crafted Wire Mesh Grillework Decorative Wire Mesh Grillework provides an excellent way to distinguish and enhance cabinetry, wine cellars, furniture and other architectural designs. The process of creating hand-made, intricate custom formed or woven wire grilles is a dying art form. There are very few remaining metalwork artisans. Unlike mass-produced/machine made products on the market, Klise artisan metalworkers hand craft grilles using century-old techniques, which gives our grillework its old-world, one-of-a-kind character. The success of any custom metalwork project is determined by the amount of detail provided by the architect, designer or client. Many factors will impact quality and cost of custom grillework. The most important information needed in order to obtain an accurate production quote for your client includes: 1. Grille Design (Woven or Formed) 2. Material (Steel Wire or Brass) 3. Wire Type / Wire Size / Rosette Options 4. Finish Options* 5. Wire Spacing or Formed Pattern Dimension & Orientation 6. Expected Reveal & Repeat and Orientation 7. Overall Grille Dimensions & Rabbet Width 8. Production Quantity * NOTE: Klise does not perform the actual finishing of product. This is done by outside resources. For critical finish matching, unfinished grilles may be ordered and finished by sources local to the architect, designer or client to enable final, on-site inspection. 14

19 Raw Material Klise purchases raw steel and brass, which comes to us in large spools. Each spool is roughly the size of a car tire and weighs several hundred pounds. These spools are sorted according to size/type, and are then pulled for each individual application. Klise s metalworkers will cut enough metal for each specific job, then prepare to bend, press, crimp, weave and/or weld the metal into a custom wire grille that meets our customers specifications. Pre-Production of Wire Mesh Grilles For each individual custom wire grille that is ordered, the Klise metalwork team will build a template using a wooden base with metal pins/clips. This template will enable the metalworkers to weave or form a grille pattern to the specific dimensions requested, while maintaining the overall form, shape and spacing required. Shown is a template for a custom formed #403 Formed wire grille. #403 formed wire grille with #1533 rosette. 15

20 Material: Steel & Brass Material, Wire Type/Size & Decorations Cold-Rolled Steel is the most common material used (1008 alloy) for creating wire mesh grillework. This type of steel is much smoother than hot-rolled steel, which results in a cleaner more consistent finish after electroplating. Brass is another alloy which is used for creation of Wire Mesh Grillework. Brass is much more resistant to oxidation, so often times it is requested for outdoor use. In addition, Brass can be gold plated, however cannot be welded or electroplated, given its properties. Wire Size/Wire Type The size, type and spacing of the wire will have a significant impact on aesthetics and cost. Many types of wire can be used for creating custom hand-crafted grilles, here are some examples: Round Wire reeded Wire (one side only) Plain/Flat Wire square Wire Distressed Wire.050, 1/16, 3/32 & 1/16 x 1/8, 1/16 x.040 x 1/8, 1/16 x 1/16 x 1/16, and (one side only) 1/8 Diameters 3/16, 1/16 x 1/4, 1/8, 1/16 x 3/16, 3/32 x 3/32 1/16 x 3/8 and and 1/16 x 5/16 1/16 x 1/4, 1/16 x 1/16 x 1/2 5/16, 1/16 x 3/8, and 1/16 x 1/2 Rosette Type / Placement Rosettes are typically decorative furniture/upholstery nails, which are made of steel. They can be affixed to intersections of any formed grille (and in some infrequent instances also to woven grilles). The shape, size, quantity and placement of the rosettes will affect both cost and aesthetic outcome. Shown below are some examples of rosettes that can be used. #16 ESCUTCHEON PIN #6005 (3/16" dia) #2002 (7/16" dia) #4 Cone (7/16" dia) #1533 Rosette (3/8" dia) #6 Cone (9/32" dia) CLOVERLEAF (1-1/16") #311 Grille Shown with #2002 Rosettes 16

21 Woven Wire Mesh Grilles The most common type of decorative metal grillework is woven. Much of the high-quality metalwork used in homes of distinction, luxury yachts and 5-star hotels are more than likely made by custom metalwork artisans. Although custom made grillework carries a premium cost, there is no replacement for the unique, old-world character of artisan craftsmanship. Klise s custom metalwork shop has decades of experience within the Kitchen Cabinet, Luxury Furniture and Hospitality markets, so we can help put the architect, designer or clients project needs into a greater context. Although, other manufacturers offer commodity options for woven grilles, made by on industrial looms, these leave very little opportunity for customization of design, color plating or unique mounting options. Crimping Methods Three basic wire crimping methods are used for most wire mesh grillework; Single Crimp, Double Crimp and Press Crimp. Each method of crimping can be applied to wire types including; round wire, flat wire, square wire and reeded wire. flat wire flat wire Single-Crimped Double-Crimped flat wire Press-Crimped 17

22 Wire Spacing for Woven Wire Mesh Grilles Confirming the desired wire spacing for Woven Wire Mesh Grilles is important to determine how much material is used in creating the custom wire grille. Due to the various sizes of different wire material, woven grille spacing is measured from the center line of one wire to the center line of the next wire running parallel to it (not by opening size). Wire Mesh Grille Spacing is Measured by Center-to-Center Distance #311 grille - press crimped flat wire 18

23 Pattern Variation Within Formed Wire Grilles Formed Wire Grilles Unlike Woven grilles, which as their name implies are literally hand-woven together, Formed Grilles are made much differently; with wires that are formed into a particular shape (ovals, hexagons, elongated diamonds, etc.). Once formed into the desired shape, the grilles are welded at the wire intersections. Rosettes, frames, tabs and brackets may also be incorporated into the design. Formed grilles are not standardized. Therefore the design details must be provided to the metalworkers by the architect, designer and/or client. Klise will be happy to offer suggestions and make recommendations. Generally speaking, Formed Wire Grillework is more labor intensive, thus typically more expensive than less complex Woven Wire Grillework. Please Note: It is important to recognize that pattern variation within unique ovals, scallop or diamond shapes is unavoidable. Like any artisan creation, slight pattern variation is something that gives unique custom formed grilles their old-world, one-of-a-kind character. #503 style Neo-Moorish grille pattern with 1/4 bracket clips 19

24 Formed (non-standardized) Wire Grilles Klise custom formed #503 style, Neo-Moorish grille design shown above Shown above, is a Klise metalworker, affixing bracket clips to the intersecting wires of a formed wire mesh grille. These brackets are applied to this grille after it is formed into a specific shape and welded together. The clips provide added strength to the grille at each intersection, while also providing a pleasing aesthetic texture. As with any custom formed grille, it is impossible to stock standard sizes, so it is important for the architect, designer and/or client to provide Klise with specific, detailed specifications prior to quoting or production. Examples of Custom Formed (non-standardized) Wire Grilles Style #540 custom scallop pattern Style #600 custom with rosettes Style #403 with #2002 rosette Style #600 custom pattern variation Style #660 oval with tabs 20

25 Measuring Formed Grilles: Shape, Sizing and Orientation Dimension / Orientation of Formed Wire Pattern Grille The Dimension of the formed wire grille pattern is essential to determining the overall repeat to ensure a balanced reveal. Height & width of the pattern (in this instance, measured point-to-point (at intersecting wires) and center-to-center in the pattern shown below. Horizontal Orientation vertical Orientation #522 custom hexagonal pattern Reveal & Repeat of Formed Grilles Reveal is defined as the viewing area, or the part of the cabinet door or other framed opening which is visible. A symmetrical (or balanced ) reveal provides the best aesthetic results. Repeat refers to the layout of a grille which defines a specific number of repeated patterns (shapes or designs) in the given viewing area. Since Formed Grilles are of a fixed dimension with intersections welded together (with or without decorative hardware) it is of extreme importance that the architect, designer and/or client provide instructions for the expected reveal and repeat dimensions. 21

26 Expected Reveal & Repeat of Formed Grilles Having the architect, designer and/or client clearly define the expected reveal (how the grille pattern fits inside its frame) and repeat will ensure customer satisfaction and eliminate costly re-works. Identifying the repeat, will allow the metalworkers to confirm the dimension of the formed wire pattern. Providing reveal information in a simple shop drawing or CAD drawing will ensure that the reveal will be proportionally balanced. balanced Reveal Unbalanced Reveal #403 style flat wire grille with #2002 rosette 22

27 Rubber Gasket/Quarter-round Moulding Mounting Techniques for Grilles Often times, woven grilles will be inset into the rabbet from behind a cabinet door, and held in place with a rubber gasket or a piece of quarter-round moulding. Rubber Gasket is pressure fit into Rabbet to hold grille in place. Back of Cabinet Frame Cabinet Door (rear view) with chromed grille edge mounted in rabbet behind this kitchen cabinet door is held in place with a rubber gasket Quarter-round Moulding Antiqued wire mesh grille held in place between rabbet and quarter-round moulding affixed to the back of the cabinet door 23

28 Mounting Techniques: Tabs For more intricate Formed Wire Grilles, a mounting tab is usually a better option. These tabs are small welded metal pieces affixed to the grille and are intended to fit within a rabbet opening. Usually, cabinet makers will place a quarter-round piece of moulding in place from behind the cabinet and micro-pin it in place. Circle Grille with mounting tabs Mounting Tabs Walnut-colored Oak Frame with Hexagonal Formed Wire Grille Pattern #522 Mounting Techniques: Inset Formed Grille Frame On other occasions, contractors or cabinet makers may wish to build cabinet doors around the metalwork. To ensure proper production of the intricate wire grilles, mounting expectations should be discussed at the beginning of the design process. Grille with integral frame inset Front view of Kitchen Cabinet Door with inset Formed Wire Grille style #

29 Frequently Asked Questions About Klise Custom Wire Mesh Grilles Q: Can I order Klise s custom formed grilles in standard spacing or opening sizes? A: Unfortunately not. Klise formed wire grilles are hand-crafted into a particular shape or design (ovals, elongated diamond, scallop, etc.) which is specified by the customer or design professional based upon their unique demands. It is essential that the formed shapes fit into the reveal area (see page 22) of the cabinet or door opening. Q: Can I have Klise determine the best size, number of repeats and spacing of shapes for my custom formed grille? A: Yes, Klise will be happy to have our team provide a CAD drawing or shop drawing suggesting particular size/ openings, repeat of shapes to fit the reveal and overall grille dimensions for your project. As with any design work, there will be a design fee associated with each requested drawing that Klise creates. Please check with our estimator on applicable fees. Q: Is it normal to have slight variations in my hand-made custom formed grille patterns? A: Yes, this is typical. Klise s custom grilles are hand made so slight pattern variation with unique ovals, scallop or diamond shapes is unavoidable, and like any artisan creation, slight pattern variation is something that gives these unique custom formed grilles their old-world, one-of-a-kind character (see page 19) Q: Why are details of Reveal Area and Overall Grille Size important? A: Providing us with both reveal area and overall grille dimensions (see page 22), will help ensure Klise s metalworkers are not only making the grilles to the appropriate size, but that they are also factoring in the rabbet width, depth and balance of the reveal for the best possible aesthetic appearance. This will also help us account for all mounting needs within the rabbet so that the grille fits appropriately into the cabinet or other casegoods. Q: What is the Reveal area? A: The reveal area is the visible area or opening in your cabinet or other casegood. Q: What is a Rabbet? A: The rabbet is the recess on the back inside edge of a framed cabinet or other casegood, which the wire mesh grille will fit into. The most important information for Klise will be the rabbet width, so that Klise can factor the reveal of your wire mesh grille. See diagram below showing rabbet. Rabbet Width... continued on next page 25

30 Frequently Asked Questions About Wire Grilles... continued Q: Why doesn t the color finish on my grille look like the pictures/images on the Klise website? A: Images on any website do not provide an accurate depiction of true color. An image may take on a completely different hue or tint depending upon lighting, resolution of the photo or any enhancement done to the image. The pictures on Klise s website (and printed material) are intended for general reference only and should never be used as a guide to match any specific color finishes. Q: Why are there so many confusing names for different color finishes? A: We don t actually know why this is. Most manufacturers or designers use their own marketing terms and descriptions for various colors. We do know that many manufacturers frequently use general color descriptions/terms such as; Bronze, Brass or Nickel, however, the actual color of the electroplated product often differs significantly from one manufacturer to another. Simply put, color terms or descriptions used by any manufacturer do not equate to a universal color or finish. Q: What is the best way to match the color finish of my Klise wire mesh grilles to other metal cabinetry knobs, faucets, etc.? A: Since color finishes have many different names, there is no standard term to identify a particular color. For projects where color matching is important, you should have your design professional send a color sample to us, or Klise can send a small assortment of color chips for review and customer approval. It is also important to note that the electroplating process for producing any color finish is part art and part science, so it is important to expect slight color variations. Once we receive your written confirmation of the approved color chosen from our samples, we can begin production and then plating of your wire mesh grille. * NOTE: Klise does not perform the actual finishing of product. This is done by outside resources. For critical finish matching, unfinished grilles may be ordered and finished by sources local to the architect, designer or client to enable final, on-site inspection. Q: Is it normal to have the color finish on my wire mesh grille show lighter and darker areas? A: Yes, these lighter and darker areas are referred to as highlights. It is important to note that all wire grillework which has reeding or crimping (peaks and valleys) will show highlights of darker and lighter color finish. This is due, in part, to how the color plating settles on to the grille. All grilles will have some highlighting. Q: Will my electroplated grilles be susceptible to rust? A: Klise grilles are made of cold rolled steel, and as with all products made from this material, they will be subject to eventual oxidation/rust if exposed to the elements, despite being electroplated. Klise recommends that our grillework be used for indoor applications only, and we can make no assertions to the extent of rust/corrosion that might occur over any given time, due to many environmental factors involved. Klise can offer to quote custom grilles using brass alloy. Klise uses 60/40 brass, which cannot be electroplated nor welded, but has been a good option for customers who have applications where rust is a concern. Although brass will not rust, it will tarnish, which will ultimately cause discoloration. The cost of woven grilles made of brass alloy is more expensive than cold-rolled steel, but we ll be happy to offer custom quotes to fit the customers needs. 26

31 Klise Architectural Details Stundwar-Flemming Pool Table, Camp David, MD J. McLaughlin Women s Store, New York, NY Patrick Mulcahy Photography Louis Benton Steakhouse, Grand Rapids, MI McGraw Construction The Breakers Palm Beach Details make the Difference Klise understands that when it comes to creating a design that s apart from the others, it s all in the details. That s why we have been an industry leader in decorative wood components and hand-crafted metalwork for over a century. We provide you over 6,000 unique ways to make a difference in your designs. Klise makes it easy to create a customized look that is truly unique. Our products are manufactured-toorder, with many of these designs exclusive to Klise, giving you that distinctive style your customers demand. Over a Century of Attention to Detail, Klise has manufactured decorative lineal wood mouldings with the more recent addition of artisan metalwork, both of the highest quality. We continue to serve architects, designers, kitchen cabinet & furniture manufacturers, architectural millwork firms and the design-build industry at large. As you can see from the small sampling here, Klise s unique wood and metalwork designs can be found in a broad spectrum of commercial and residential applications including 5-star hotels, retail locations and homes of distinction throughout the world. Merger of Old-World & New Much of Klise s carved lineal wood patterns are still made on our unique carving machines, which date back to the 1890s (page 9). When details are important, we ve found that even new machinery cannot provide the same unique depth or distinction within carved wood. We of course combine these old-world processes with the use of newer state-of-the-art machinery, engineering and CAD capabilities to further help our customers achieve their design goals. Hand-crafted wire mesh grillwork (page 13) is an additional way to distinguish and enhance your creations. Our factory artisans (page 20) have over four decades of experience producing intricate, American-made metalwork and are a great resource of creative suggestions and design ideas to distinguish any project. Beginning with the Best Raw Materials Klise uses only the highest quality materials to craft our decorative lineal wood designs. We work with an array of North American and Exotic wood, using Select & Better rated hardwoods (see page 8) to create our unique carved and embossed lineal designs. Our wire mesh grillework is created from either mild steel or brass (page 15), with our artisans using time-tested, old world production techniques. Our metalworkers carefully craft, weave, crimp (page 20), form and finish intricate wire patterns to the custom specifications of architects and designers. All of our products are made in the USA at our factory in Grand Rapids, Michigan. The Breakers Hotel Boardroom, Palm Beach, FL 27

32 Parade of Homes Entry, Tim Schollaart Builder LLC, Michigan Cabinet Supply, Klise Custom Wire Grille Style #212 Armoire/dresser with Klise decorative wood mouldings A1 Carved Rope & T1572 Beaded ColumnTrack Extensive Design Library Options With a design library of over 6,000 unique patterns, Klise offers Architects and Designers virtually limitless custom make-toorder design options in wood and metalwork. Our unique designs provide artistic flair and relevance to traditional, contemporary and transitional design styles for both residential and commercial projects. Responding to Demands from the Design-Build Community We realize that the needs of the design-build community have changed significantly over the past few years. Many architects, designers, builders and contractors are faced with ever shorter deadlines. Klise has responded by updating our limited offering of ready-to-ship stock products, which have been increasingly popular with builders and artisans who demand high quality products for cost-sensitive projects with just-in-time availability. Unmatched Experience & Superior Customer Service Attention to detail embodies our quality statement; attention to service ensures long-lasting client relationships. The Klise team is dedicated to offering their extensive knowledge and providing creative and consultative advice to ensure you the highest degree of customer satisfaction. Our wood experts, engineers and estimators are here to understand your design needs, with an attention to detail. A Strong Finish Klise s goal is to offer you the highest quality product possible. When aesthetic details are most important, Klise provides wood products that have tight and consistent lineal tolerances, which are finish-ready requiring little or no additional processing. Klise s metalwork offers the same attention to detail with an added flair of noticeable old-world craftsmanship. American-made products with a distinguished reputation and a wealth of creative application what more could you ask for? Resources are Critical to Your Success; We Want to be One of Them. For over 100 years Klise has been a proven, detail-oriented resource contact us today so we can start the next century as a resource to you. r Klise is a proud member of these fine organizations: National Kitchen & Bath Association Klise products featured on Maryland Ave., N.E. Grand Rapids, MI P: F: Quality Products Proudly Made in the U.S.A. Visit our website to see our complete line of custom design options and popular stock products. Klise custom formed Asian Tropical Wire Grill ADEX Platinum Award Winner, Design Journal Magazine (adexawards.com)