Substrate—Mio Metals uses FSC-certified wood as a substrate to help support sustainable forestry, and Cain touted, “If I could find an equivalent material with a lower impact on the environment, I would use it.”
products in copper, brass, stainless steel and zinc. “When I bought the business, it primarily focused on custom fabrication of range hoods, chimney caps and flashing for the region,” said Cain. “I created the Mio Metals name to allow us to better market the full range of metals in which we had expertise.” At the time, the founder of the business, John Strong, was retiring and had really relied on just a couple of workers and the company’s reputation rather than strong marketing to bring in business. Zinc countertop demand was very sporadic, and Cain saw it as an opportunity for more business. So, he positioned himself as chief marketer, rather than a fabricator, and established standard designs. He took advantage of the Internet by offering e-commerce and nationwide shipping and pushed his message out through several websites that each focused on a different product line. “In 2008, as the recession was hitting the home improvement market, our range hood business was slowing down, but our Web traffic on zinc countertops was taking off,” explained Cain. “We began making more zinc countertops than ever, and they generated more revenue than our core business of range hoods. Our primary product line is now countertops with zinc being the dominant material. It’s still a niche product with a sticker price that competes with exotic stone, but we’re going through 600 to 1,000 lbs. of zinc per month.” Today, the company’s staff of six is moving into a 70 percent larger building. Only a handful of other companies compete in the zinc countertop market as whole-heartedly as Mio Metals, but there are individuals and small sheet metal shops that attempt countertops or tabletops with the same exotic metals. Of course the number that fabricates stainless steel countertops is larger. However, that’s an area in which Cain doesn’t seek to compete. “We do work with 24-gauge stainless steel in our range hood production, but our shop is geared toward softer nonferrous metals, so we don’t work with thicker stainless steel that is required for countertops,” he explained. “Stainless countertops should be made from 18- or 16-gauge stainless that is dramatically harder than copper or zinc, and we just aren’t set up for it.” Another thing the company isn’t set up for is installation of its countertops. Mio Metals currently only sells its tops directly through its product-specific website, ZincCountertops.net, although it is pursuing authorizing showrooms in select locations. 16 • Vol. 5 / Issue 2 • International Surface Fabricators Association
Figure 3 — Zinc reacts with everything from water to fingerprints to lemon juice, creating a unique patina in every application that is generally part of the appeal. (This countertop is
in El Paseo, a restaurant bar in Mill Valley, Calif., part owned by Sammy Hagar.)
“We rely on professional installers across the country for measurements and installation,” said Cain. “We certify installers in metropolitan and luxury areas we think will be receptive to our product. Keep in mind we produce a high-end, rare product so it would be impossible to staff an in-house crew across the country.” As such, the company has trained installers in locations around the country, including Chicago, Raleigh-Durham, N.C., Baltimore, and New York. But while installation isn’t on the menu for the company, one thing at the forefront is a mind-set of environmental responsibility, and it makes its way into just about every aspect, from the materials to the methods. Green Metal? At its base, the metals industry is not a low-impact one. Between mining, refining and transport of raw materials, there’s a considerable amount of energy being consumed. But from the point the material reaches the shop, Mio Metals is very conscious of how it can lessen the impact of the final products. “As a life-long environmentalist, my goal is to manage my part of the process as efficiently as possible and minimize our carbon footprint,” said Cain. “I buy from local suppliers. I recycle everything in our shop from wood and metal scrap to office paper. I work with freight transporters that use a mix of rail and truck. And, I encourage all of my customers to recycle the metal once it has had a long and productive life.”
Energy consumption—energy usage is one area where Mio Metals makes large strides. “In our shop, we work with softer metals such as copper, brass and zinc on machines that are operated by arms and legs not large amounts of electricity,” explained Cain. “We use a stomp shear—named for the source of power—to cut our sheets and a hand brake to form the bends. Our decorative edges are created with handoperated machinery and skill ,not some large press with large power consumption.” To reduce energy consumption, the company also opts for soldering vs. welding, which is a high-heat, high-energy process. “Soldering is a low-heat, lower-energy method of joining metal,” explained Cain. “In fact, the melting point of the solder is only 400 F.” Even the soldering irons used by the company aren’t connected to the electrical grid, but rather heated by natural gas, and the company doesn’t use any lead-based solder. It’s obvious that Cain takes the business of zinc very seriously, but that begs the question: Why zinc? “Zinc as a countertop material is a design choice first and foremost,” Cain put forth. “It’s cool to the touch and produces a patina that is unique to the situation, which designers love. Through the oxidation process, zinc can change to black, white or charcoal and like most architectural metals, any area that is rubbed or touched on a regular basis, such as the edge of the countertop, will shine with reflectivity. Areas near sinks will show more even oxidation as water stands and evaporates, whereas the zinc adjacent to a cooktop or stove will feature spots from splatters and utensils. Each top is truly unique (see Figure 3). “Another attraction to our countertops is the edge detail,” he continued. “We combine traditional sheet metal techniques with custom hand working to develop edge profiles that recall those found in many French cafes and restaurants. One of my favorite edge details was created for a French café in Florida called Paris in Town. The owner and I talked for a bit, and I offered to create a few designs just for him. He chose the first one I made, and that design was actually reworked for our recent project at French Blue.”