40,000 Square Feet of Dedicated Architectural Sheet Metal Fabrication in Illinois

Architectural sheet metal at Metalmaster Roofmaster starts and ends in one facility. From the first design review through 3D modeling, cutting, bending, quality inspection, and final delivery to your site, every piece is made in our own shop at 4800 Metalmaster Way in McHenry, Illinois. General contractors, building owners, and architects who need architectural sheet metal on schedule get a single point of accountability, not a chain of vendors.

In-house fabrication means we control quality and schedule directly. When a project calls for a complex coping profile, a non-standard panel dimension, or a tight delivery window, we do not negotiate with an outside shop or absorb their backlog. We set the production schedule and own the result.

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 and catch conflicts before production starts. This is where costly field corrections get caught instead of discovered on-site.
• Fabrication. Pieces are cut, bent, and formed to spec on our shop floor. Tolerances held in fractions of a millimeter, it shows in the sight lines and joints on the finished building.
• Quality assurance. Every finished component is checked against the approved drawings before it leaves the shop. If something does not match, it is remade, not shipped.
• Delivery. Material arrives site-ready, staged and labeled by zone when phasing requires it. Delivery is coordinated with the installation crew, often the same people who reviewed the design drawings at the start.

Equipment

The shop runs on equipment sized for commercial work at scale. Our floor includes three Schechtl shears and folders, a CNC table router for ACM panels, a standing-seam panel roll former, and a flush-seam panel roll former. Schechtl machines are the professional standard for architectural sheet metal: precision folding, consistent brake pressure, and production throughput that lets us run a coping package for a large commercial project alongside custom detail work without one scope holding up the other.

Architectural sheet metal we fabricate

Our shop handles the full range of architectural and commercial sheet metal for roofing and building enclosure. If a project calls for a custom profile or an unusual material, call us before assuming it is unavailable.

• Custom copings and fascia. Shaped to your parapet profile and finished to your spec.
• Standing-seam metal roofing panels. Bent in-house to match your slope, width, and seam height. See our commercial metal roof installation service for full standing-seam system details.
• ACM panel fabrication and rout-and-return. Full aluminum composite material fabrication for cladding and signage applications. See our ACM 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 any custom transition piece your drawings call for.
• Copper, zinc, aluminum, stainless, and galvanized steel. We work in all common architectural metals. 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 facility includes 80,000 sq ft of shop, with 40,000 sq ft dedicated to sheet metal fabrication, roughly three times the dedicated footprint of a typical architectural-metal specialist. The 40,000 sq ft fabrication shop operates alongside MMRM’s roofing operations within the same 100,000 sq ft McHenry facility, allowing both divisions to share logistics, equipment support, and project coordination under one roof. That capacity is why we can run a major coping package for a high-rise and a complex custom-detail scope for a mid-size building at the same time, without one project sitting behind the other.

MMRM has operated continuously since 1977. The 49 years of fabrication experience are in the people who run our equipment and read our drawings. Estimators who price a job, shop foremen who oversee production, and field crews who install the finished pieces share the same project history. That continuity is what cuts the hand-off errors that happen when fabrication and installation are two separate organizations.

Projects that show the work

MMRM has fabricated and installed custom sheet metal on commercial projects across the Chicago metro for nearly five decades. The projects below are representative. Full details are available on request.

• Elfstrom Stadium, Kane County. Architectural sheet metal scope for the Kane County Cougars stadium, including custom copings, fascia, and edge metal fabricated and installed by MMRM.
• Six Flags Great America, Hurricane Harbor. Commercial roofing and sheet metal fabrication on the water park facility, requiring non-standard profiles for a large-scale entertainment venue.
• NIU Hoffman Estates. Sheet metal fabrication for a higher-education facility, including custom architectural details coordinated with the architect of record.
• Life Changers Church. Custom roofing and sheet metal scope for a large commercial religious facility, requiring fabricated transitions across multiple roof sections.
• Pauly Toyota, McHenry. Retail automotive facility with custom fascia and coping profiles fabricated to match the dealer’s brand specifications.

Why GCs and building owners choose MMRM for fabrication

General contractors and building owners who specify MMRM get a fabrication operation with a verifiable safety record built into the price.

• 40,000 sq ft dedicated fabrication shop inside a 100,000 sq ft facility. One location, one team, one quality standard from raw stock to finished installation.
• 49 years in business, since 1977. Commercial sheet metal experience built across generations of projects in the Chicagoland market.
• EMR 0.66. Our Experience Modification Rate is 0.66. On workers-comp insurance, that means we pay 66 cents on the dollar compared to a contractor at 1.0, a direct, auditable read on our safety record, not a marketing claim.
• ES-1 tested and NRCA member. Our shop-fabricated edge metal systems are ANSI/SPRI ES-1 tested, and Metalmaster Roofmaster is a National Roofing Contractors Association member.
• OSHA 10 & 30 trained crews. All field personnel carry OSHA training cards. Our full-time safety director makes regular site visits.
• Union shop. Disciplined apprenticeship training, journeyman-level craft standards, and consistent crew quality across projects.
• Authorized applicator. Johns Manville, Elevate, and Versico authorize MMRM to install their systems. That matters when a project needs a manufacturer-backed warranty on membrane work running alongside the sheet metal scope.

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, there is no outside vendor to wait on and no lead time gap between design approval and production. We design, model, cut, bend, quality-check, and deliver from our facility in McHenry, faster turnaround, single point of accountability. If a detail changes in the field, we adjust production without going through a third-party shop’s change order process.

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 the right 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 to 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 shop schedule at the time of order. Because fabrication is in-house, we can often turn around standard items faster than an outside vendor. Call us at 815-459-6415 to discuss scheduling for your specific project.

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