Division 05 / Metal Fabrication

Custom sheet metal fabrication in McHenry, Illinois

Custom sheet metal fabrication at Metalmaster Roofmaster stays close to the project team. From design review through 3D modeling, cutting, bending, quality checks, and delivery, the work moves through our 40,000 sq ft dedicated sheet metal fabrication shop inside our 100,000 sq ft McHenry facility. General contractors, building owners, and architects have one point of contact for fabrication and installation.

In-house fabrication lets our project and shop teams coordinate quality and scheduling directly. For complex coping profiles, non-standard panel dimensions, or revised details, the teams can review drawings and field conditions before production.

From design to delivery: how the process works

Every custom fabrication job at MMRM runs through five stages.

• Design. We review drawings, specifications, and field conditions with the project team. Dimensions, material selection, and connection details are confirmed before anything is cut.
• 3D modeling. Components are modeled in three dimensions to verify fit. This can identify coordination conflicts before production starts and reduce field corrections.
• Fabrication. Pieces are cut, bent, and formed to the approved dimensions on our shop floor.
• Quality assurance. Finished components are checked against the approved drawings before they leave the shop. If a component does not match, the team corrects it before delivery.
• Delivery. Material is staged and labeled by zone when phasing requires it. Delivery is coordinated with the installation crew and project schedule.

Equipment

The shop is equipped to cut, rout, fold, and form commercial sheet metal. The equipment supports copings, fascia, flashings, standing-seam panels, ACM/MCM panels, and custom profiles made to approved project dimensions.

Architectural sheet metal we fabricate

Our shop fabricates architectural and commercial sheet metal for roofing and building-enclosure work. If a project calls for a custom profile or an unusual material, contact us to confirm the available options.

• Custom copings and fascia. Shaped to your parapet profile and finished to your spec.
• Standing-seam metal roofing panels. Formed in-house to the specified width, seam height, and project dimensions. See our commercial metal roof installation service for full standing-seam system details.
• ACM/MCM panel fabrication and rout-and-return. Composite panel fabrication for cladding and signage applications. See our ACM/MCM panel service for project examples.
• Metal wall panel systems. Architectural panels for building exteriors, fabricated and installed as part of a complete enclosure scope.
• Flashings, edge metal, gutters, and custom details. Counter flashings, drip edges, gravel stops, gutters, downspouts, expansion joints, and project-specific transition pieces.
• Copper, zinc, aluminum, stainless, and galvanized steel. Material selection is part of the design conversation.
• Interior architectural metalwork. Lobby panels, accent walls, and custom interior metal details for commercial facilities.

The shop behind the work

Our fabrication operation is at 4800 Metalmaster Way, McHenry, IL 60050. The 100,000 sq ft McHenry facility includes a 40,000 sq ft dedicated sheet metal fabrication shop. The shop operates alongside MMRM’s roofing operations, so project management, fabrication, logistics, and installation teams can coordinate from one location.

MMRM has operated since 1977. Estimators, shop foremen, and field crews work within the same organization and share project information from pricing through installation. That continuity reduces the number of handoffs between fabrication and field work.

Projects that show the work

MMRM’s project records include commercial work across the Chicago metro. The selected properties below show the range of building types in that portfolio. Ask our team for the documented sheet metal scope available for a specific project.

• Elfstrom Stadium, Kane County. Stadium and sports venue.
• Six Flags Great America, Hurricane Harbor. Water park and entertainment venue.
• NIU Hoffman Estates. Higher-education facility.
• Life Changers Church. Religious facility.
• Pauly Toyota, McHenry. Retail automotive facility.

Why GCs and building owners choose MMRM for fabrication

General contractors and building owners who specify MMRM work with one shop-and-field team from drawings through installation.

• 40,000 sq ft dedicated sheet metal fabrication shop inside a 100,000 sq ft McHenry facility. Fabrication and installation teams coordinate from the same location.
• In business since 1977. MMRM’s commercial sheet metal record spans multiple building types across Chicagoland.
• Project-specific quality checks. Fabricated components are checked against approved drawings before delivery.
• Union signatory. Metalmaster Roofmaster is signatory to Local Unions #11, #73, and #265.
• Associated roofing scope. Manufacturer approvals and warranty requirements for membrane work are confirmed during bidding.

Frequently Asked Questions

What types of custom metal does Metalmaster Roofmaster fabricate?

Our architectural sheet metal scope covers custom copings and fascia, standing-seam metal roofing panels, ACM panel systems, metal wall panels, flashings, edge metal, gutters, downspouts, custom architectural details, and interior metalwork including lobby panels and accent walls. We work in copper, zinc, aluminum, stainless steel, and galvanized steel.

Why does in-house fabrication matter to my project schedule?

When fabrication is in-house, the project team works directly with the shop instead of coordinating through a separate vendor. We design, model, cut, bend, check, and deliver from our 40,000 sq ft dedicated sheet metal fabrication shop inside our 100,000 sq ft McHenry facility. If a detail changes in the field, our project and shop teams can review it together and adjust the production plan.

What metals do you work with?

We regularly work with copper, zinc, aluminum, stainless steel, and galvanized steel. Material selection depends on the building design, budget, and performance requirements. We advise on alloy and gauge during the design phase, before production begins.

How does the fabrication process work from design to delivery?

The process runs through five stages: Design (we review drawings and specs with your team), 3D modeling (components are modeled in three dimensions to confirm fit before cutting), Fabrication (pieces are cut and formed to spec in our shop), Quality assurance (finished components are checked against approved drawings before leaving the facility), and Delivery (material arrives at your site, coordinated with the installation crew). The same organization handles all five.

Do you fabricate for other contractors and GCs, or only your own jobs?

We primarily fabricate for projects where we are also handling the installation. That means the same team that reviewed the design and built the components is the team installing them on your building. General contractors and building owners who bring us in as their roofing and sheet metal contractor get the full benefit of the in-house model.

What is the lead time for custom sheet metal fabrication?

Lead time depends on project scope, material, and the shop schedule at the time of order. Because fabrication is in-house, our project and shop teams coordinate the production plan directly. Call us at 815-459-6415 to discuss scheduling for your project.

Our fabrication shop is based in McHenry, IL, serving commercial projects across Chicagoland.

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