Division 07 / ACM Systems

ACM and MCM panel fabrication and installation in Chicago

Metalmaster Roofmaster fabricates and installs metal composite material (MCM) and aluminum composite material (ACM) panels for commercial building facades and interior metalwork across Chicago and the Chicagoland suburbs. MCM is the broader product category; ACM uses aluminum skins bonded to a core. Solid metal plate panels are a separate system. We have served the region since 1977 and operate a 40,000 sq ft dedicated sheet metal fabrication shop inside our 100,000 sq ft McHenry facility.

What ACM is, structurally

Aluminum composite material is a panel built from two thin aluminum skins bonded to a core. Core types include polyethylene and mineral-filled products used in some fire-rated wall assemblies. Whether a project requires an NFPA 285-compliant assembly depends on the building height, wall construction, occupancy, and applicable code. The project architect and code team should confirm the required tested assembly.

The layered construction gives ACM its performance profile: the aluminum skins provide a flat, finished metal surface, while the bonded core adds rigidity and keeps the panel lighter than solid aluminum. Panel sheets arrive prefinished. Rout-and-return fabrication moves cutting and forming into the shop before installation.

We work with composite panel products selected in the project specifications. When the documents name a manufacturer and system, our team reviews the fabrication and installation requirements for that product. When options remain open, the design and code teams should select the panel, core, tested assembly, and finish that fit the building and applicable code.

Four reasons architects and building owners specify ACM

• Appearance. ACM creates a flat metal surface across large facades. Available PVDF and anodized finishes depend on the manufacturer and product line. The panel schedule can coordinate color and finish across the facade.
• Shop preparation. ACM panels are lighter than solid metal, and a prefabricated rout-and-return unit arrives on site ready to mount. This reduces the amount of cutting and forming required in the field.
• Durability. Service life depends on the selected panel, coating, exposure, detailing, installation, and maintenance. The specified manufacturer’s current technical data and finish warranty set the project-specific expectations.
• Design flexibility. Rout-and-return fabrication supports project-specific reveals, corners, column wraps, and other formed details. Available shapes and dimensions depend on the selected product and system requirements.

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 used for panel systems where the finished edge matters as much as the face. In the shop, a CNC router cuts a groove into the panel along the fold line. The aluminum skin is folded back along that groove, wrapping the edge and creating a finished return that conceals the core. The result is a formed unit with clean architectural edges.

The panels are fabricated to project-specific dimensions in our 40,000 sq ft dedicated sheet metal fabrication shop inside our 100,000 sq ft McHenry facility. Reveals, corner conditions, column wraps, curved returns, and custom shapes are handled in the shop. Panels arrive with returns formed and dimensions checked against shop drawings, which reduces field fabrication at the perimeter.

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 can suit single-plane facades, canopy soffits, and column-cover applications where the panel edge condition is straightforward. Cost and schedule depend on the selected assembly and project conditions.

Rout-and-return panels and field-fastened sheet serve different details. Our shop and field teams handle both methods, subject to the specified system and project scope.

Interior ACM: lobbies, accent walls, and elevator surrounds

ACM is not limited to exterior facades. Architects and interior designers also specify it for interior metalwork that calls for a modern, flat metal finish and formed composite-panel details. 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

When interior and exterior panels are part of the same project, our shop can coordinate both scopes. For adjacent metal wall panel systems, see our metal wall panels page.

Building types where ACM is specified

ACM is used across commercial building categories in Chicagoland. The system, finish, and attachment method depend on the building design and project requirements. Project types include:

• Office buildings and corporate headquarters. Class A and Class B office projects may use ACM for flat, contemporary facade zones, entries, and brand-specific color programs.
• Healthcare facilities and hospital campuses. Panel and wall-assembly selection depends on the building, applicable code, and tested system requirements. Finish schedules may also coordinate colors across a campus.
• Retail storefronts and shopping centers. Big-box, strip-center, and inline storefront work can use color-coordinated panels across tenant facades. Panel joints and support details must account for storefront layouts, signage, and service openings.
• Hotel and hospitality exteriors. ACM can provide a coordinated finish across entries, canopies, and facade zones while meeting the project’s selected panel-system requirements.
• 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. ACM can distinguish the office entry and customer-facing facade from the surrounding warehouse or manufacturing envelope.

In-house fabrication: what it means for your project

ACM panels for MMRM installation scopes are fabricated in our 40,000 sq ft dedicated sheet metal fabrication shop inside our 100,000 sq ft McHenry facility. Our shop team cuts, routs, folds, and finishes the panels to approved project dimensions.

Keeping fabrication in-house removes a separate panel-house handoff after shop-drawing approval. When a field condition requires a revision, our project and shop teams can coordinate the updated panel directly. Custom shapes, radius corners, and non-standard reveals are part of the shop’s work.

MMRM has operated since 1977. Our fabrication and field teams coordinate within the same company when fit and finish matter.

Selected ACM projects

Hyde Park Day School, Chicago, IL. The project included exterior ACM cladding and interior metalwork for the school’s new campus.

The following comment refers to the completed school project as a whole.

Why Metalmaster Roofmaster

• 40,000 sq ft dedicated sheet metal fabrication shop inside a 100,000 sq ft McHenry facility. Project and shop teams coordinate panel dimensions and production from the same location.
• In business since 1977. MMRM’s commercial project record spans multiple building types across Chicagoland.
• Direct shop coordination for custom shapes. Project and shop teams coordinate revised panels and non-standard dimensions directly. Lead time depends on material availability, scope, and shop schedule.
• Union signatory. Metalmaster Roofmaster is signatory to Local Unions #11, #73, and #265.
• Associated roofing scope available. When a project includes low-slope roofing alongside the ACM work, manufacturer approvals, warranty requirements, and contract scope are confirmed during bidding.

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 used in some fire-rated assemblies. The layered construction creates a flat, finished metal panel that is lighter than solid aluminum. Final material and assembly choices depend on the design, code requirements, and project budget.

Is ACM fire-rated?

ACM is available with different core types, including mineral-filled products used in fire-rated wall assemblies. Whether a project requires an NFPA 285-compliant assembly depends on the building height, wall construction, occupancy, and applicable code. The project architect and code team should confirm the required tested assembly.

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. The shop completes this work before installation, which keeps the formed edges and project dimensions under one fabrication process.

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 service life depends on the specified panel, coating, exposure, detailing, installation, and maintenance. Review the panel manufacturer’s current technical data and finish warranty for project-specific service-life expectations. Periodic cleaning and inspections help identify sealant, joint, or finish issues.

Can Metalmaster Roofmaster fabricate ACM in custom colors or shapes?

Yes. We fabricate ACM panels to project-specific dimensions in our 40,000 sq ft dedicated sheet metal fabrication shop inside our 100,000 sq ft McHenry facility. The shop can produce curved panels, radius corners, reveals, and non-standard shapes. Finish options depend on the specified panel manufacturer’s current color range and project requirements. In-house fabrication keeps custom work with our project and shop teams; lead time depends on material availability, scope, and shop schedule.

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

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