O'Brien Metal

The blog of O'Brien Metal

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In its new home, O’Brien Metal evolves the digital process

In March, O’Brien Metal Inc. moved to a new location less than a mile away. Now located at 1442 W. Willow St., O’Brien Metal is the latest addition to the Elston Industrial Lofts, a beautiful newly rehabbed multi-use property on Chicago’s near north side that gives the company not only a bigger fabrication and finishing facility, but plenty of breathing room for the modern front office and architectural detailing space.

Why the move? O’Brien Metal continues to flourish, expand its presence and evolve its offerings. The move was driven by a need for a more state of the art infrastructure necessary to support more sophisticated digital manufacturing processes, along with a more suitable space to attract talent. O’Brien Metal has continued to thrive by investing in technology, top talent, and advanced machinery, building a robust vendor network and unique finishes.

In addition, for the last few months, crews have been demolishing the former north side A. Finkl & Sons steel plant, where O’Brien Metal had a location on the north end of the campus for the past eight years. Plans for the 28-acre site, which sits along the Chicago River’s north branch, are up in the air.

For some photos and discussion of the demolition, see DNAinfo’s article here.

The new atelier area alone gives O’Brien Metal employees ample room to work on the growing list of luxury furnishings and architectural metal projects. Starting in a new space is always a welcome change of scenery, too. Owner John O’Brien anticipates completed projects hence will reflect the company’s fresh perspective originating from a new nexus of modern day technology and age-old artisanal metalworking, which the company typically spends 70% and 30%  of its time realizing a project, respectively.

Tall ceilings, natural light via a multitude of skylights and a lofted office at the front of the building maximize floor space. At the rear of O’Brien Metal's new home is additional square-footage for future space into which O’Brien plans to expand.

The new Willow Street headquarters is strategically located in the Elston Corridor’s Planned Manufacturing District (PMD), near the Kennedy Expressway (I-90/94) at Armitage. Proximity to affluent clients, architects, and designers who reside in Lincoln Park, the Gold Coast, River North with the Merchandise Mart, and the West Loop – makes for a highly collaborative process and gives O'Brien Metal a competitive advantage. 

Each week the company gets a steady stream of architects, designers and clients to brainstorm ideas. They browse the large inventory of mock-ups, finish samples, stock of alloys, and view fabrication processes. Clients review and approve plans, see in-process custom solutions and unique metal finishes.

Here’s a look inside O’Brien Metal’s new home base:

About O’Brien Metal, Inc.:

Founded in Chicago, Illinois in 2007 and are metal fabrication and renovation experts who understand the relationship between design and function, shape and finish. Together with some of the country’s most notable architects, designers, and landscape architects, they have been crafting beautiful interiors and striking exteriors throughout Chicago and New York. The company employs a diverse group of Architectural Detailers, Fabricators, Artists, Metal Technicians, Restorers, Finishing Experts, and Forging and Casting Professionals. They are experts at working with specialty metals such as bronze, brass, nickel, silver, gold leaf, copper, stainless steel, and aluminum. For more information, visit O’Brien Metal online at obrienmetal.com or contact [email protected], 1-888-973-4442. O’Brien Metal is located at 1422 W. Willow St. in Chicago.

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O'Brien Metal featured on cover of FFJournal magazine

In January, O'Brien Metal was featured in FFJournal magazine, a metal fabrication trade publication also HQ'd here in Chicago.

FFJournal's cover story focused on the implications of digital manufacturing, and how there's potential for it to disrupt a metalworking industry accustomed to traditional methods of fabrication.

The article, authored by editor Nick Wright, discusses the nearby Digital Manufacturing and Design Innovation Institute as well, exploring the issues and challenges surrounding digital manufacturing becoming a reality in the metalworking world and related industries. O'Brien Metal is one of the few examples of a fabrication company whose business model is built upon the notion of working in a digital space. The article says:

"In many ways, O’Brien Metal is a textbook example of how a company its size can compete in what’s increasingly a digital age. It has redefined the classic supply chain in leveraging a diverse vendor network and advanced digital tools to fabricate nonferrous precious metals into architectural pieces that adorn universities, libraries and private residences throughout Chicagoland."

Read the complete FFJournal article in its entirety here.

Good read: Digital Future of the Factory

While O'Brien Metal is deploying big tools as a small business, U.K. news site The Engineer takes a look at how Airbus, Lockheed Martin, and Jaguar Land Rover are pushing forward digital manufacturing. The article dives deep with additive manufacturing, virtual reality and advanced data analysis, giving a glimpse of how large OEMs can embrace digital tools.

Read the full article from this month: In touch with reality: the digital future of the factory

News to come: As Old Man Winter has settled in Chicago, there's been plenty of work to go around in the friendly confines at O'Brien Metal. Projects that began in earnest months ago at institutions, residences and high-rises have kept crews busy. In the coming weeks, there will be some big announcements from O'Brien Metal. Stay tuned!

About O’Brien Metal, Inc.:

Founded in Chicago, Illinois in 2007 and are metal fabrication and renovation experts who understand the relationship between design and function, shape and finish. Together with some of the country’s most notable architects, designers, and landscape architects, they have been crafting beautiful interiors and striking exteriors throughout Chicago and New York. The company employs a diverse group of Architectural Detailers, Fabricators, Artists, Metal Technicians, Restorers, Finishing Experts, and Forging and Casting Professionals. They are experts at working with specialty metals such as bronze, brass, nickel, silver, gold leaf, copper, stainless steel, and aluminum. For more information, visit O’Brien Metal online at obrienmetal.com or contact [email protected], 1-888-973-4442. O’Brien Metal is located at 2100 N. Southport Avenue in Chicago’s Lincoln Park.

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Crain’s Chicago Business feature: O’Brien Metal shows the future of UI Labs Digital Manufacturing Institute’s mission.

The Publication describes how O’Brien Metal is helping show how to move manufacturing into the digital age.

“Manufacturing is still very much a paper-and-clipboard type of business,” says Bill King, a mechanical engineering professor at the University of Illinois at Urbana-Champaign and chief technology officer of UI Labs, Chicago's new digital manufacturing hub. “Ten years into the future, it's going to look like Facebook or Snapchat.”

Digital fabrication is a hot topic since Chicago won a $70 million federal grant and $250 million in state, city and private funds to build a digital manufacturing institute on Goose Island. The institute aims to reinvent the region's approach to manufacturing by helping companies big and small think more digitally.

“A small company can behave like a massive company by using these digital tools.”

            Bill King, mechanical engineering professor at the University of Illinois at Urbana-Champaign and chief technology officer of UI Labs

O'Brien Metal started in 2008, an inauspicious year to launch any company, let alone a metal fabricator. But its digital emphasis buoyed it through the recession. Founded by John O'Brien, 45, the firm manufactures custom residential and commercial products ranging from spiral staircases to dining room tables. Its clients include the Driehaus Museum, Northwestern University's Charles Deering Library and high rollers on Michigan Avenue and Astor Street. But before putting a hand to metal, Mr. O'Brien's team of architectural detailers uses 3-D scanners and computer-aided design software to create the project digitally.

Mr. O'Brien has little need to harness big data, but he is devoted to efficiency. A founding member of Braun Consulting Inc. in Chicago, Mr. O'Brien spent 20 years advising companies on how to use technology to cut the fat off their processes. So he was quick to see the wastefulness plaguing most metal fabrication companies. “What a disaster,” he says. “There was no project planning, people used paper copies. It was terribly inefficient.”

In Mr. O'Brien's 7,000-square-foot space in the Lincoln Park industrial corridor, a 10-person team works with architects to orchestrate and fabricate projects ranging from $2,000 to $1.6 million. Between developing the digital designs and the final assembly, O'Brien also uses a network of more than 40 vendors for parts it isn't capable of making. O'Brien uses Basecamp, a Web-based project management software that streamlines communication among vendors and manages versions of shared CAD files. The integrated approach, he says, shaves weeks off the production processes and thousands off the expense.

“It really helps save on cost, and it also helps construction and feasibility in the field,” says Rick Juneau, president of residential and restoration at Bulley & Andrews LLC, a general contractor based in Chicago that works with O'Brien.

To read the article and see the accompanying video in its entirety, please click here:

http://www.chicagobusiness.com/article/20140405/ISSUE01/304059973#

About O’Brien Metal, Inc.:

Founded in Chicago, Illinois in 2007 and are metal fabrication and renovation experts who understand the relationship between design and function, shape and finish.  Together with some of the country’s most notable architects, designers, and landscape architects, they have been crafting beautiful interiors and striking exteriors throughout Chicago and New York.  The company employs a diverse group of Architectural Detailers, Fabricators, Artists, Metal Technicians, Restorers, Finishing Experts, and Forging and Casting Professionals.  They are experts at working with specialty metals such as bronze, brass, nickel, silver, gold leaf, copper, stainless steel, and aluminum. For more information, visit O’Brien Metal online at obrienmetal.com or contact [email protected], 1-888-973-4442.  O’Brien Metal is located at 2100 N. Southport Avenue in Chicago’s Lincoln Park. 

Related Stories:

Digital metal fabrication:  Age-old craft meets cutting-edge technology – turning computerized visions into reality.  http://obrienmetal.tumblr.com/

How Chicago won its biggest research deal in a generation.  http://www.chicagobusiness.com/article/20140224/BLOGS11/140229923/how-chicago-won-its-biggest-research-deal-in-a-generation

The woman who must make Chicago’s new digital manu labs work. http://www.chicagobusiness.com/article/20140301/ISSUE01/303019984/the-woman-who-must-make-chicagos-new-digital-manu-labs-work

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John O’Brien of O’Brien Metal featured on BusinessInterviews.com

BusinessInterviews.com interviews entrepreneurs, founders, and CEO’s from all walks, across all industries, and from around the world. Its reporters focus on their habits and methods; what makes them tick. Its primary focus is to shine a light on the people behind the businesses by sharing some of their stories.

Late last year, a blog post from O’Brien Metal sparked interest in the company’s rise at BusinessInterviews.com.  Their research was thorough and lengthy, and the resulting Q & A interview speaks volumes about how O’Brien Metal has continued to flourish despite the economic and competitive pressures and the price point of its unique metal fabrications.  Here is an excerpt:

“By investing in technology, top talent, advanced machinery, building a robust vendor network and unique finishes we were able to move into the more profitable segment of luxury metal goods and alloys where only a handful of competitors exist in the U.S.”

BusinessInterviews.com: What are some trends in your industry that you’re excited about or think that our readers should be paying attention to?

John: We have integrated high tech into traditional metal fabrication – replacing a lot of cumbersome and time-consuming processes. Modern day tools and techniques allow us to work faster, smarter and more efficiently, while still crafting luxury furnishings that are timeless. We use technology to improve efficiency and enable a more fluid design-build approach – all the while remaining true to the architects’ vision. We’re now partnering with architects and designers early in the process to rapidly help evaluate feasibility and engineer solutions that will far exceed customary functionality, usability, and aesthetic goals.

BusinessInterviews.com: Can you expand on how O’Brien Metal is very well positioned to prosper in the coming digital manufacturing & fabrication revolution?

John: We are very well positioned to prosper in the coming digital manufacturing and fabrication revolution. We have been highly successful in merging an age-old craft with cutting-edge technology – allowing our clients to turn computerized visions into metallic works of art. We pride ourselves in being a leader of a new breed of metal fabricators on the forefront of a digital revolution of technology and artistry that is evolving at a dizzying pace.

To read the interview in its entirety, please click here:

http://www.businessinterviews.com/obrien-metal-john-obrien

More Good Ink for O’Brien Metal

O’Brien Metal was one of the featured team members on a recent Modern Luxury Interiors Chicago article along with Gary Lee Partners Interior Design for a townhome renovation in Lincoln Park.  To read more about this exciting project, click here:

http://modernluxury.com/interiors-chicago/story/strength-numbers

About O’Brien Metal, Inc.:

Founded in Chicago, Illinois in 2007 and are metal fabrication and renovation experts who understand the relationship between design and function, shape and finish.  Together with some of the country’s most notable architects, designers, and landscape architects, they have been crafting beautiful interiors and striking exteriors throughout Chicago and New York.  The company employs a diverse group of Architectural Detailers, Fabricators, Artists, Metal Technicians, Restorers, Finishing Experts, and Forging and Casting Professionals.  They are experts at working with specialty metals such as bronze, brass, nickel, silver, gold leaf, copper, stainless steel, and aluminum. For more information, visit O’Brien Metal online at obrienmetal.com or contact [email protected], 1-888-973-4442.  O’Brien Metal is located at 2100 N. Southport Avenue in Chicago’s Lincoln Park. 

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Attention to detail pays off: O’Brien Metal wins prestigious award for work at Northwestern University.

From left to right:  Attendees of the 2013 Acanthus Awards Ceremony at the Elks National Veterans Memorial. Center; The Acanthus Award presented to O’Brien Metal.  On right; John O’Brien, founder and CEO of O’Brien Metal prepares to receive the award.

The Institute of Classical Architecture recently awarded O’Brien Metal Inc. an Acanthus Award in Allied Arts & Craftsmanship. The Acanthus Awards recognize excellence and distinction in classical and traditional architecture within the areas of architecture, interior design, allied arts and craftsmanship, preservation & restoration, landscape design, and un-built and student work.

The award was given for our role in helping to restore Northwestern University’s Charles Deering Library to its striking historic condition and add period pieces to uphold the collegiate Gothic style of architecture.  The Acanthus Awards 2013 event took place at the majestic Elks National Veterans Memorial on the Chicago lakefront and was attended by a diverse group of notable architects, designers and business leaders.

“We at O’Brien Metal are honored to have received this award and be a part of the ICAA and this special event. This is just one example of the outstanding results we have been able to create in partnership with HBRA Architects,” said John O’Brien, founder of O’Brien Metal.

Blending old with new.

From left to right:  The entrance to the historic Charles Deering Library at Northwestern University.  Center; Glass vitrine case that holds library treasures. On right; The welcome area and turnstile entrance to the library.  

Working closely with HBRA Architects and Northwestern University, the goal of the team was to preserve the intricate elements of the original architecture, most notably the bronze castings and authentic steel forgings inspired by legendary blacksmith Samuel Yellin’s contributions to the library in the 1930s.   They say there is no greater form of flattery than imitation.  At O’Brien Metal, we couldn’t agree more.  Yellin crafted hand-forged lighting fixtures, grillage panels, ornate railings, doors, and intricate bronze castings to replicate the Gothic grandeur of King’s College Chapel in Cambridge.  But time can exact a toll on such metal masterpieces, leading the University to contact HBRA to help restore the Library to its original luster.

We used modern technology combined with authentic blacksmithing techniques to hammer, contour, darken and antique hand-forged vitrine stands that hold library treasures, such as the scribbled lyrics of Eleanor Rigby by John Lennon.  Lamp posts were custom molded, cast and fabricated in bronze, topped off with a statuary bronze patina.  Double-bar exterior bronze handrails were meticulously designed to contrast with the darkened lamp posts, then fabricated out of extruded bronze that was darkened and scuffed back to show the luster of the metal.  Even the way finding signs were hand-forged and designed to mimic the Library’s dramatic interior from the 1930’s. 

About O’Brien Metal, Inc.:

Founded in Chicago, Illinois in 2007. We are digital & artisanal metal fabricators and renovation experts who understand the relationship between design and function, shape and finish.  Partnering with some of the country’s most notable architects, interior designers, and landscape architects, we have been crafting beautiful interiors and striking exteriors throughout Chicago and New York.  We are experts at working with specialty metals such as bronze, brass, nickel, silver, gold leaf, copper, stainless steel, and aluminum. For more information, visit O’Brien Metal online at obrienmetal.com.

About HBRA Architects, Inc.:

HBRA Architects has maintained offices in Chicago since its founding in 1961, and designs buildings for a range of purposes and scales.  They have worked with a prestigious client list, including The Art Institute of Chicago, Lincoln Park Zoo, Princeton University, The Disney Institute, and Yale University.  The firm has been recognized for excellence in design by professional organizations across the country in all categories of building.  In addition to seven National Honor Awards from the American Institute of Architects, HBRA has received over 29 American Institute of Architects Chicago and other local Chapter Distinguished Building and Honor Awards.  For more information, visit HBRA online at HBRA-arch.com.

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Digital metal fabrication: Age-old craft meets cutting-edge technology – turning computerized visions into reality.

When most of us think about metalworking, images of workers beating red-hot rods with ringing hammers, hell-hot forges, and molten liquid pouring from huge looming buckets come to mind.  But gone are the days of the dark, dingy sweat shops with craftsmen in leather aprons shearing, welding and pounding away to wrestle works of art from metal through heat, talent and sheer brute force.

Technology is molding the future.

A new breed of metal fabricators is on the forefront of a digital revolution of technology and artistry that is evolving at a dizzying pace. Take, for instance, O’Brien Metal, Inc. in Chicago’s Lincoln Park.  Their high tech and spacious fabrication and finishing facility bears little resemblance to the black caldrons of old movies and industrial films. Improved methods and processes allows for even the most intricate work to be done to the most exacting standards in a fashion that’s easily repeatable, using state-of-the-art digital mapping, computer-aided dimensional design, and virtual cast engineering.  The more crucial the piece to an architect’s or designer’s vision, the less room for error. 

At O’Brien Metal, most pieces begin in the virtual world of 3D CAD (computer aided design), where ideas come to life and options are explored without ever casting a single mold.  Here, in-house architectural detailers work side by side with metal artisans, mold-making and casting professionals, and creative patina specialists and rely on the new tools of track pads and high-def monitors as much as their predecessors did on the hammer and anvil.

“We have integrated high tech into traditional metal fabrication – replacing a lot of cumbersome and time-consuming processes. Modern day tools and techniques allow us to work faster, smarter and more efficiently, while still crafting luxury furnishings that are timeless,” said John O’Brien, owner of O’Brien Metal.  “We use technology to improve efficiency and enable a more fluid design-build approach – all the while remaining true to the architects’ vision. We’re now partnering with architects and designers early in the process to rapidly help evaluate feasibility and engineer solutions that will far exceed customary functionality, usability, and aesthetic goals.”

Everything old is new again.

Take for instance this highly ornate corner section for a new custom historic bar cart.  Chicago’s HBRA Architects wanted to capture the timelessness of intricate bronze and silver details, with equal scrutiny on how these precious metals would embellish an integrated, highly polished black veneer. CAD modeling was used to produce 3D plastic resin printouts that serve as initial casting patterns. The patterns are then used to create silicon bronze castings inlaid with jewelry quality silver filigree.

When Dirk Denison Architects of Chicago and New York wanted a show-stealer for a client’s dining room, they envisioned an aluminum structure that would support a generously proportioned, sustainable resin top.  Digital 3D CAD modeling was used to produce a 3D plastic resin printout that served as the initial pattern to create cast aluminum dining table bases.  The need for absolute precision was influenced by the structural properties of the multi-radius table base design.  Tight tolerances for the radii had to be kept in order for the base to properly support the LightBlockstm top.

This ornamental grillage and frieze design was specified for a landmark home designed by Eric J. Smith Architects in New York.  Forged from the latest techniques and processes, these intricate ornamental silicon bronze panels look as if they were crafted more than a hundred years ago. Back then, it was a tedious process of hand work and sweat equity.  Instead O’Brien Metal used detailed CAD drawings to replicate the pattern, and water jets to cut entire grillage & frieze panels – bypassing the need to make molds and then extensively chase and grind away any imperfections by hand.  Any size grille can be made at the push of few computer keys, rather than starting anew for each new size.  Then final panels were then hand etched to give them character and finished with a rich historic patina to create an aged bronze appearance. 

Very few in the United States are capable of achieving the type of detail and quality O’Brien Metal can. 

“They are masters at stripping back the ideas to help uncover the how behind the design inspiration. O’Brien Metal is changing the game on their competition and takes a highly intelligent and refreshing approach, unlike traditional cumbersome metal shops that are frequently difficult to work with and produce lackluster results. They are smart, talented, fun to work with and produce the high quality results our clients demand, “ said Aric Lasher, Architect Principle, Director of Design, HBRA Architects.

About O’Brien Metal, Inc.:

Founded in Chicago, Illinois in 2007 and are metal fabrication and renovation experts who understand the relationship between design and function, shape and finish.  Together with some of the country’s most notable architects, designers, and landscape architects, they have been crafting beautiful interiors and striking exteriors throughout Chicago and New York.  The company employs a diverse group of Architectural Detailers, Fabricators, Artists, Metal Technicians, Restorers, Finishing Experts, and Forging and Casting Professionals.  They are experts at working with specialty metals such as bronze, brass, nickel, silver, gold leaf, copper, stainless steel, and aluminum. For more information, visit O’Brien Metal online at obrienmetal.com or contact [email protected], 1-888-973-4442.  O’Brien Metal is located at 2100 N. Southport Avenue in Chicago’s Lincoln Park. 

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Driehaus Museum Garden Entrance

Richard H. Driehaus Museum 40 East Erie Street, Chicago, IL

The Driehaus Museum is housed in the Gilded Age home of banker Samuel Mayo Nickerson (1830-1914). The 25,000-square-foot mansion, built from 1879 to 1883, was one of the grandest residences of nineteenth century Chicago. Between 2003 and 2008, a meticulous restoration transformed the building into the Richard H. Driehaus Museum. Today, the Driehaus Museum preserves and interprets the home in order to promote the understanding and appreciation of historic architecture and design. The Richard H. Driehaus Museum and O’Brien Metal, Inc. collaborated to reproduce three new 7-ft-tall approximately 500-lb cast urns and pedestals as part of the Garden Entrance Restoration.

The Challenge

Due to the large size and intricate detail required to reproduce the original urns and bases, we were faced with complex challenges including a few highlighted below:

Logistics. Transporting 7-ft 500-lb cast urns to and from the museum to our Lincoln Park location. We worked closely with Amy Van Alst (Driehaus Museum) and Roger Machin (Methods & Materials) to ensure great care was taken in handling the urns and pedestals.

Casting size. Limitations of the sand casting process required that we split the urn casts into six separate casts in order to fully weld them back together during the fabrication process.

Extensive chasing. A requirement to accentuate the meticulous details of their counterparts.

The Process

Wax on. To begin fabrication, our Creative Team used a rubber mixture to apply multiple coats over the original cast iron urn.

(L) Rubber application (R) Rubber mold over the original cast iron urn

Mother mold construction. Piece by piece, plaster was applied onto the dried rubber in order to create the mother mold. A mother mold is the shell that supports the flexible rubber mold helping it to retain its shape during the casting process. Clay (shown in grey) was used as dividers to split each plaster application into sections. 

Shims and sections of mother mold construction

  Plaster was applied, dried and repeated until every section of the urn had its own mold.

Mother mold construction by section

  Breaking the mold pt. I. After each section of the plaster was applied and hardened, it was detached and for reconstruction later. The rubber mold was cut in order to remove the original cast iron urn during the pattern making process.

Taking off the rubber mold from the original urn

Mother mold reconstruction. The plaster pieces were put back together and prepared for casting the pattern in plaster.

Pattern making. After the rubber mold is placed inside the mother mold, plaster is poured inside to create the pattern. 

Breaking the mold pt. II. Once the plaster pattern hardened, the rubber was peeled off to reveal a detailed surface. 

Detail of plaster pattern surface after removing the rubber mold

Sand casting prep. Plaster pattern elements are ready for sand casting at the foundry.

After sand casting at the foundry, the aluminum alloy castings were brought back to our shop for extensive chasing, cleaning and welding by our Technology Team. The surface was detailed, primed and finally, faux-painted in a marble finish.

Driehaus Museum urns (L-R): pattern, cast aluminum, faux-painted in marble

Final product. The cast urns as seen in front of the Driehaus Museum in downtown Chicago.

A similar reproduction process for the urns was used in creating the pedestals.

The Result

Presently, the faux-painted urns and pedestals can be seen welcoming visitors through the museum’s East Erie garden entrance in downtown Chicago.

For more photos of the project, please visit www.pinterest.com/obrienmetal. 

Read more on our efforts to expand our restoration services or the Northwestern University Charles Deering Library Restoration project.

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Precious Metal Friezes and Ornamental Grillage Designs by Eric J. Smith Architects, New York.

O’Brien Metal, Inc. beautifully crafts high-end metal accents for the luxurious home. Designed for both function and aesthetics, precious metal friezes and ornamental grillage can accentuate any room or specific element in the home. The process utilizes either custom casting or precision laserjet cutting of brass, bronze, nickel silver, rose red copper and a variety of unique metal alloys. Custom and semi-custom options available to align with individual architect and designer preferences.

For more information, please give us a call at 888.973.4442 or email [email protected].

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The Charles Deering Library Restoration Project

Introduction

HBRA Architects and O’Brien Metal, Inc. collaborated on a project for one of the country’s most prestigious universities. Northwestern University needed to restore the famous Charles Deering Library’s West Entrance to its striking historic condition and add period pieces that uphold the collegiate Gothic style architecture. The goal was to create bronze castings and authentic steel forgings inspired by legendary blacksmith Samuel Yellin’s notable work in the 1930’s.

The Charles Deering Library in Evanston, IL

The Challenge

Vitrines are a glass-paneled case for displaying museum quality artifacts. O’Brien Metal, Inc. created four custom-made vitrine stands in which Northwestern University’s valued collections are displayed. Such collection includes the scribbled lyrics to “Eleanor Rigby” by John Lennon of The Beatles. The vitrine stands are hand-forged antiqued iron with authentic blacksmithing techniques throughout—hammered, contoured, specifically darkened and antiqued.

Custom-made vitrine cases inside the Charles Deering Library

Large historic lamp posts serve as companion pieces to the Gothic façade of the library. The four posts were custom cast and fabricated in bronze with a statuary brown patina and are situated at the entrance of the Charles Deering Library.

Historic lamp posts at the entrance of the Charles Deering Library

The double bar exterior bronze handrails have a smooth finish, designed meticulously to create a contrasting element to the deliberately aged lamp posts. The hand rails are extruded bronze darkened and scuffed back to show the luster of the bronze. Its round rivets and legs have the same chamfered edge on the vitrine stands located inside the library.

Bronze double bar handrails at the entrance of the library

A hand-forged way finding sign system made of iron in natural finish was also designed to match the existing workmanship of the Charles Deering Library interior. Twenty-nine variations of the signs—some hanging, wall-mounted, free standing or with backlit translucent glass to highlight the graphics in which the signs are intended for.

Some of the hand-forged signs for the Way Finding System

  The Results

All components of the project were custom fabricated—either in bronze or steel—designed especially to match the historic metalwork of Samuel Yellin. It was important to maintain the integrity, tradition and history of the Deering Library’s Gothic architecture. O’Brien Metal, Inc. worked closely with Northwestern University, HBRA Architects and WB Olson, Inc. for six consecutive months to complete the restoration project in time for the reopening of the West Entrance Lobby to the Main Library in October 2012.  The finished work can be seen at 1937 Sheridan Road at Northwestern University in Evanston, IL.

As seen in CS Interiors: Winter Issue (January 2013). To view the digital copy, click here. This ad is on pg. 83. A company profile on O'Brien Metal, Inc. is on pg. 154.

About Charles Deering Library

The Charles Deering Library was built in emulation of King’s College Chapel in Cambridge that opened in January 1933 and designed by James Gamble Rogers. Set on higher ground overlooking Deering Meadow, it is recognized today as the university’s most prominent landmark. (Northwestern Library History) The Library’s gates, lighting fixtures, grilles, railings, doors, and ironworks were by the legendary Samuel Yellin who was America's master iron craftsman of the twentieth century. Yellin's work often emphasized traditional styles but he still molded those styles to the needs of the clients and to his own ideas regarding craft. (NYC Architecture)

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Restoring, Reinvigorating, and Conserving Historic Metal Objects

O’Brien Metal, Inc. continues to expand and enhance its Creative capabilities and now provides Restoration services for historical objects both large and small. Within the scope of our capabilities are refinishing of interior and exterior bronze, brass, silver, nickel, and gold leaf gildings along with repairs to damaged castings and recreation of missing elements.

We will continue to invest in people, new technologies, and enhance our facilities to allow for professional restoration and specialty finishing services.

Exterior bronze gate during restoration

Exterior bronze gate after restoration

  Restoration is defined as “bringing back to a former position or condition.” In restoring a historic metal object or architectural element, the most important requirement is the quality and aesthetics of the final product.  We work closely with architects and designers to determine the most desirable period of an object’s life, and then design a treatment necessary to return the object’s appearance to a specific period of significance.

Original British kiosk for restoration at our shop

O’Brien Metal, Inc. offers a variety of services for the restoration and care of metal objects, all based upon our experience, expertise, and knowledge of materials and treatment techniques. The incorporation of traditional metal working methods and contemporary standards for the care and restoration of materials is our upmost goal.

Our services include: 

Condition assessment / documentation / design drawings & specifications

Care and maintenance programs

Treatment design and implementation

Reproduction and repair to damaged and missing elements

Finish stabilization & rejuvenation

Pattern & mold making

Casting

Foundry works

Specialty finishes including: hot/cold patina, paint systems, lacquer, waxing, and platting of a variety of alloys and metals

Leading the Creative team are Ryan Greene and Dawid Czerniejewski, both highly experienced metal artisans and technicians.

Ryan has a master’s degree in Historic Preservation and has worked throughout the U.S. restoring and conserving building facades, monuments, statuary and historic objects. Select projects include the Lincoln Memorial, New York Public Library, Smithsonia, and Metropolitan Museum of Art.

Ryan Greene

Dawid has a master's degree in Sculpture along with a certification in Sculpture and Painting from Accademia di Belle Arti in Italy. His expertise is in metal, stone, cement, sculptures conservation and architectural restoration.

Dawid Czerniejewski

O'Brien Metal, Inc. partners with some of the finest conservation experts in the United States. We are also a proud member of the following organizations: American Institute of Architects (AIA), American Institute of Conservators (AIC), American Preservation Trades (APT) and Society of Architectural Historians (SAH).

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No Shape Is Too Complex: Recreating An Intricate and Historic Design Element

Situation 

For a project at one of Chicago's most prestigious buildings, Eric J. Smith Architect of New York City needed to replicate highly ornate cast iron balcony railings—a defining feature of the century-old residence's unique aesthetic. Originally designed by Benjamin Marshall in 1911, the historic property is a crown jewel of the affluent Gold Coast neighborhood. Its existing railings accentuate the surrounding terra cotta surfaces and underline picturesque vistas of Lake Michigan and Lincoln Park. The new railings had to match every meticulous detail of their counterparts. To achieve this goal, Eric J. Smith partnered with O'Brien Metal and coordinated a unique design solution. 

Goals 

Replicate the style, intricate details,  and nuances of the existing historic railings.  

Develop a creative molding process for use on-site to capture and preserve the railings' unique details and patterns.  

Enhance the railings with new design elements: precision-machined, solid aluminum posts; highly secure, stainless steel mounting inlays to ensure safety; and updated spacing to bring the railing up to current code.  

Integrate the new railings into a pristine built environment.

Results 

Close collaboration led by Eric J. Smith Architects ensured clear project goals for aesthetics, function, and constructability. A series of mock-ups established the most efficient method of crafting the railings, capturing the intricate details, and blending them with the built environment.   

Along with precise architectural detailing, the guideline for this project was a physical object. Molds of the historic railings captured their size, shape, and style down to the most minute detail, allowing them to be recreated exactly.  

 After creating the molds, we were able to cast 3D components in aluminum. O'Brien Metal relied on the shop's fabrication expertise to painstakingly chase and machine each piece—touching up imperfections, and bringing out the subtlest and most eye-catching aspects.  

 The new railings were seamlessly incorporated into the built environment, alongside the historic architectural elements and the surrounding landscape. 

 Client Testimonials 

“The railings are a wonderful addition to the property – a perfect compliment to the building’s historic features.  Eric & John worked well together throughout the process, bringing life to the most intricate details in the design. The results are great and it's a pleasure to work with them.” - Tim Schwertfeger, Owner

"A true collaboration in every way. O'Brien Metal beautifully captured all of our goals for this portion of the project." - Eric J. Smith, AIA

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Architect-led design build approach yields innovative stainless steel railing solution & stand-out results in the built environment

Peter Gluck and Partners Architects, along with their construction arm, ARCS Construction Services, partnered with O’Brien Metal to create an stainless steel railing solution for the exterior of a lakeside Chicago residence. The goal was a railing which would blend with the residence's defining beauty—both its unique architectural design and the neighboring Lake Michigan shoreline.

Photo: LJ Porter/ Courtesy Peter Gluck and Partners

Situation/Challenge:

The Cascade House, designed by New York architecture firm Peter Gluck and Partners, cuts into the Lake Michigan bluff. The property is orientated for panoramic views of the Great Lake. Harmonizing the new railing with both the landscape and the house's unique design required strong, consistent coordination between the on-site design team (ARCS, led by Jim True) and O’Brien Metal.

 Goals:

Translating the new design into architectural details that met the aesthetic, functional, and construction requirements of the existing property and its surroundings.  

Blending into the house's landscaped lawns, terraces, and bluffs, designed by Hoerr Schaudt Landscape Architects.  

Incorporating sophisticated hidden connection details into the design that allowed for a highly secure and safe environment.  

Precise detailing, measurements, and engineering calculations to ensure all elements fit together.  

Ensuring the specialty brush finish would not only aesthetically marry the beauty of the house but also withstand sometimes-harsh lakeside weather conditions.

 Results:

The custom-designed and fabricated railings were created with a stainless steel 304 alloy framework with stainless steel infill mesh. The solution spanned the property's green roof terrace, boat house, and master terrace, as well as the Lake Michigan Bluff.  

Strong coordination and partnering among Peter Gluck and Partners, ARCS, and O’Brien Metal yielded a robust and elegant architectural solution—on time and on budget.

“Working within their architect-led design build methodology was eye-opening and a dramatically smarter way of approaching a project, versus the traditional model. Jim True and his team were great to work with and were side by side with my team to quickly work through any obstacles that came up. It was a highly efficient process that produced stand-out results.” – John O’Brien

Client Testimonial:

“John and his team exceeded our expectations despite the demanding level of detail. The consistent enthusiasm, craftsmanship, and technical knowledge they brought to the table made for a productive working relationship. I look forward to working with John again.”

— Jim True, Architect and Construction Manager, Peter Gluck and Partners/ARCS Construction Services