MCM and ACM Panel Fabrication in Chicago, IL

Metalmaster Roofmaster fabricates and installs metal composite material (MCM) and aluminum composite material (ACM) panels, also called metal plate panels, for commercial building facades and interior metalwork across Chicago and the Chicagoland suburbs. We have served the region for 49 years, operate a 40,000 sq ft in-house fabrication shop, and carry a 0.66 EMR safety rating. The lower the EMR, the stronger the safety record: ours means we pay roughly 66 cents on the dollar in workers’ compensation costs compared to the industry average.

What ACM is, structurally

Aluminum composite material is a panel built from two thin aluminum skins bonded to a solid core. The core is either a polyethylene compound for standard commercial applications or a mineral-filled, fire-rated compound for assemblies where NFPA 285 compliance is required, typically multi-story facades and taller buildings under state and local fire codes.

That sandwich construction is what gives ACM its performance profile: the aluminum skins provide a flat, finished metal surface; the bonded core adds rigidity, absorbs sound, and keeps the overall panel weight well below solid aluminum. The panel arrives at the job site as a pre-finished unit. There is no field painting, no field assembly of skins and substrate, and no waiting on a secondary supplier.

For specification purposes, we work with ALUCOBOND-class aluminum composite panels. ALUCOBOND is the category benchmark that architects and specifiers reference when writing exterior cladding specifications. If your project calls for a specific product, we can match it. If the spec is open, we will recommend the correct panel and core type based on building height, occupancy, and finish requirements.

Four reasons architects and building owners specify ACM

• Appearance. ACM produces a flush, flat metal surface across large facades. Color stays consistent panel-to-panel because every panel comes from the same coil stock and finish run. PVDF and anodized finishes come in hundreds of standard colors, and custom matches are possible. You get the look of premium metal cladding without the cost and weight of solid aluminum.
• Installation speed and cost. ACM panels are much lighter than solid metal, and a pre-fabricated rout-and-return unit arrives on site ready to mount. That cuts labor hours and shortens the schedule for the GC compared to built-up metal systems assembled in the field.
• Durability. The aluminum skins resist corrosion, PVDF coatings hold color and gloss for 20 to 30 years, and the bonded core does not rot, swell, or absorb moisture. Chicago freeze-thaw cycling is well within the performance range of a properly detailed panel.
• Noise reduction. The bonded core attenuates sound transmission through the panel, which matters on facades next to mechanical equipment rooms, elevated train lines, or parking decks, and on interior accent walls where tenant separation is a factor.

How we fabricate ACM: rout-and-return vs. field-fastened

There are two primary methods for installing ACM on a commercial building. The method that belongs on your project depends on the geometry, the specified panel system, and how the architect has detailed the reveals and returns.

Shop-fabricated rout-and-return panels

Rout-and-return is the method used for premium panel systems where the finished edge matters as much as the face. Here is what happens in the shop: a CNC router cuts a precise groove into the face of the ACM panel along the fold line. The aluminum skin is then folded back along that groove, which wraps the skin around the panel edge and creates a finished return that conceals the core. The result is a rigid, self-contained unit with clean architectural edges on all four sides.

The panels are fabricated in our 40,000 sq ft fabrication shop to project-specific dimensions before they leave the building. Reveals, corner conditions, column wraps, curved returns, and custom shapes are all handled in the shop. When the panels arrive on site, the crew mounts them. There is no field fitting, no field cutting of returns, and no improvising at the perimeter. Architects and general contractors specify rout-and-return systems because the tolerances are tighter and the finished product looks the way the drawings intended.

Field-fastened flat sheet

For simpler geometries, retrofit cladding, and projects where a full panel system is not specified, ACM can be installed as flat sheet secured directly to the substrate. This method works well on single-plane facades, canopy soffits, and column cover applications where the panel edge condition is straightforward. It is a faster and lower-cost installation than a full rout-and-return system and still produces a flat, finished metal surface.

The distinction between these two methods is something specifiers and GCs use to evaluate subcontractors. A contractor who only does field-fastened flat sheet is a different operation from a fabricator who can rout, fold, and deliver a complete panel system. We do both, in-house.

Interior ACM: lobbies, accent walls, and elevator surrounds

ACM is not limited to exterior facades. Architects and interior designers specify ACM for interior metalwork on projects where they want a modern, flat metal finish without the cost of solid aluminum or stainless cladding. Metalmaster Roofmaster fabricates and installs ACM for interior applications including:

• Lobby feature walls and reception cladding
• Elevator surrounds and hoistway enclosures
• Accent panels and column covers
• Corridor bulkheads and ceiling soffits
• Interior retail display walls and brand feature elements

General contractors often source interior metalwork separately from the exterior panel system. There is usually a simpler path: one fabricator, one shop. We handle both scopes. For adjacent metal wall panel systems, see our metal wall panels page.

Building types where ACM is specified

ACM appears across nearly every commercial building category in Chicagoland. The owner or architect wants a premium metal exterior without the cost and lead time of solid aluminum, stainless, or zinc. Projects we work on include:

• Office buildings and corporate headquarters. Class A and Class B specifiers write for the flat, contemporary facade ACM delivers. Custom colors let a campus maintain consistent branding across multiple buildings.
• Healthcare facilities and hospital campuses. Multi-story healthcare facades typically require NFPA 285 compliance, which calls for fire-rated mineral-core panels. Color consistency matters too when the architect is matching a campus identity across a large panel run.
• Retail storefronts and shopping centers. Big-box, strip center, and inline storefront work often requires color-matched panels across multiple tenant facades. The finish needs to hold up under heavy foot traffic and repeated signage installation.
• Hotel and hospitality exteriors. Hospitality brands carry tight exterior finish standards. ACM keeps the facade consistent and maintainable across properties, which matters to ownership groups managing multiple locations.
• Education campuses and schools. Schools and universities put ACM on facades, entry canopies, gymnasium exteriors, and interior accent walls. Hyde Park Day School is one example of this scope in our portfolio.
• Industrial facilities with office frontage. Manufacturing and distribution buildings increasingly spec ACM on the office facade and entry features when the ownership group wants the building to reflect the brand.

In-house fabrication: what it means for your project

Every ACM panel on a Metalmaster Roofmaster project is fabricated in our 40,000 sq ft fabrication shop in McHenry, Illinois. We do not send your panels to a panel house and wait for delivery. We cut, rout, fold, and finish them to your project’s exact dimensions on our own equipment.

There is no supplier lead time sitting between shop-drawing approval and the first panel arriving on site. When a field condition comes up, a revised panel ships without a purchase order to a third party. Custom shapes, radius corners, and non-standard reveals are a normal part of the shop’s work, not a premium add-on or a special order.

We have been operating this shop for 49 years. The equipment and the people who run it are the reason architects specify us on projects where fit and finish matter.

Selected ACM projects

Hyde Park Day School, Chicago, IL. Exterior ACM cladding and interior metalwork as part of the school’s new campus construction. The finished project drew consistent praise for workmanship and attention to detail from school leadership and the surrounding community.

Why Metalmaster Roofmaster

• 40,000 sq ft in-house fabrication shop. Panels are cut, routed, folded, and finished to your project dimensions without going through a third-party panel supplier.
• In business since 1977. GCs, architects, and building owners across Chicagoland have worked with us on multiple projects and projects cycles. That track record is easy to verify.
• No supplier lead times on custom shapes. Fabrication is in-house, so revised panels and non-standard dimensions run on our schedule, not a vendor’s.
• 0.66 EMR safety rating. The lower the EMR, the stronger the safety record. We pay roughly 66 cents on the dollar in workers’ comp compared to the industry average of 1.0, an independently calculated number based on our actual claims history.
• Union crews, OSHA 10 & 30 trained, Top 100 U.S. roofing contractor. Full-time safety director on staff, not just on paper.
• Associated roofing scope available. If your project includes a low-slope roof alongside the ACM work, we are an authorized installer for Johns Manville, Elevate, and Versico and can carry both scopes under one subcontract.

Frequently asked questions

What is ACM and how is it different from solid aluminum?

ACM is a panel built from two thin aluminum skins bonded to a solid core. The core is either polyethylene for standard commercial applications or a mineral-filled compound for fire-rated assemblies. That layered construction gives you the flat metal look of solid aluminum at a fraction of the weight and cost. Solid aluminum panels are heavier, more expensive, and add structural load to the substrate. ACM gets you the same finished surface with lighter installation and better acoustic performance.

Is ACM fire-rated?

Yes. ACM with a mineral-filled fire-rated core is available for assemblies that must comply with NFPA 285, which covers multi-story facades and code-regulated building types. Standard polyethylene-core panels are used in low-rise and interior applications where fire-rated assemblies are not required. We specify the correct core type based on your building height, occupancy, and local fire code.

What is rout-and-return fabrication?

Rout-and-return is a shop fabrication process where a groove is routed into the face of the ACM panel along the fold line and the aluminum skin is folded back along that groove. That fold wraps the edge and creates a finished return that conceals the core. The panel arrives on site as a complete unit with clean architectural edges, ready to mount. All of this happens in our fabrication shop, not in the field, which is why the tolerances are tighter and installation goes faster.

Where can ACM panels be used?

ACM is specified for exterior building facades, storefront systems, canopies, soffits, and column covers. It is also used for interior applications: lobbies, reception walls, elevator surrounds, and architectural accent features. Metalmaster Roofmaster fabricates and installs ACM for both exterior and interior scopes on the same project.

How long do ACM panels last?

ACM panels with a PVDF coating are rated to hold color and gloss for 20 to 30 years under normal exterior exposure. The aluminum skins resist corrosion, and the bonded core does not rot, swell, or absorb moisture. Chicago freeze-thaw cycles, UV exposure, and wind loading are all within the performance envelope of a properly specified and installed panel system. Periodic cleaning is the primary maintenance requirement.

Can Metalmaster Roofmaster fabricate ACM in custom colors or shapes?

Yes. We fabricate ACM panels in our 40,000 sq ft fabrication shop to project-specific dimensions, including curved panels, radius corners, reveals, and non-standard shapes. Custom color matching is available through PVDF and anodized finish options from ALUCOBOND-class panel stock. Because we cut, rout, fold, and finish panels in-house, custom work does not require a third-party supplier or additional lead time from an outside panel house.

Metalmaster Roofmaster fabricates ACM and architectural sheet metal for commercial buildings across Chicagoland, including Oak Brook and Chicago.