Sheet Metal Supply LTD. Replaces Wood Pallets and Cantilever Racks with Efficient Sheet Metal Storage

Ben and Zach had the pleasure of sitting down with STEELSTACK to discuss why Sheet Metal Supply LTD. chose STEELSTACK and how it has completely transformed our workflow.

Article Credit – STEELSTACK USA (Click here for the original article)

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As our shop grew, so did our challenges with space, safety, and efficiency. What started as a storage struggle with wood pallets and cantilever racks quickly became a story of innovation and productivity once we switched to STEELSTACK.

Below, we share our firsthand experience on how the right storage system completely changed the way we handle sheet metal.

Q: What challenges were you facing with your previous storage setup?

“When we expanded from 30,000 sq. ft. to 80,000 in March of 2020, we quickly realized how much shop space we really needed. Our old cantilever racks hit a tipping point. We were constantly fighting space constraints, balance issues, and inefficiencies. With wood pallets, materials were often off-center, which made handling unsafe and slowed us down. Switching to STEELSTACK cassettes solved that — they gave us fork pockets for guaranteed balance, reduced the number of skids we needed, and created a much safer and more efficient workflow.”

Q: What made you choose STEELSTACK over other options?

“We looked at a lot of different systems, but STEELSTACK was the best value by far. The racks are stronger, heavier-duty, and designed with integrated forklift channels that make handling faster and safer. What really stood out was how the racks and carts all work together as one system. That integration gave us more space, better efficiency, and ultimately a smarter investment compared to cantilever racks.”

Q: What improvements have you seen since implementing STEELSTACK?

“Before, we needed four skids to do the same job we can now handle with just one cassette. That alone cut down on material handling and saved us time every day. The stationary carts have also been a big win for staging — it’s simple to move a cassette from rack to cart without the guesswork. Overall, we’ve reclaimed a huge amount of shop space, eliminated wasted lumber, and doubled the amount of sheet metal we can store on a single cassette compared to wood pallets.”

Q: If another shop is struggling with storage inefficiencies, what advice would you give them?

“Investing in STEELSTACK gave us our space back. Instead of spending money on an expensive building addition, we maximized the square footage we already had. The racks make organization easy — every material has a dedicated spot, nothing is hanging off edges or causing safety issues, and it’s much easier to see and track inventory. It’s a safer, more sustainable way to work, and it saves both time and money.”

Click HERE for more information on STEELSTACK.

Sheet Metal Supply adds Kohler equipment to flatten metal

Grayslake, Ill., August 21, 2025 — With the purchase of a Kohler 60P. 1600 Peak Performer, Sheet Metal Supply has made a major investment and commitment to fabricating the highest quality metal products.

The Peak Performer part leveling machine reliably levels and relieves stress from sheets and part blanks 0.024 to 0.669 inches thick, providing downstream production processes a higher quality of leveled parts and sheets, eliminating time-consuming manual rework.

“With the acquisition of this machine, we’re setting ourselves up as a fabricator committed to unmatched quality,” says Zach Timmerman, Project Manager at Sheet Metal Supply. “These capabilities elevate SMS products to a quality level few others can compete with.

“Our Kohler saves us not only time, but also money in being able to run machines at full speed, save warped sheets and create more consistent bends. The Peak Performer ensures tighter tolerances and higher-quality end products, while contributing to better part nesting. It also levels perforated sheets.”

Timmerman says the versatile flattener is not only used for SMS products, but for toll processing inside and outside the building envelope community.

“We have the capabilities to position ourselves as a serious player in the façade market, specifically the plate arena, where panels are bigger and need to be flatter,” he added. “It also helps process incoming material that may have arrived in not-so-perfect condition.

With the new machinery, SMS can flatten ¼-inch thick aluminum up to 60 inches wide, 304 Stainless Steel ½-inch thick up to 13 inches wide and a vast array of materials within those parameters.

Timmerman says the machine’s energy-efficient servo-electric drive system aligns perfectly with SMS’s sustainability goals. “Operators find the machine intuitive and user-friendly, with seamless integration of powered infeed and outfeed tables that streamline production and reduce labor requirements,” he says. “The ease with which the machine can be cleaned is an additional benefit.”

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is North America’s premier zinc fabricator as well as a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, glazed-in panels, standing seam, ACM/MCM/plate panels and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Sheet Metal Supply introduces Batten & Board envelope option

Grayslake, Ill., August XX 2025 — Sheet Metal Supply has added a Board & Batten metal panel option to its growing envelope offering. The Board & Batten profile, fire and pest resistant, is for vertical applications. It’s available in all SMS color offerings, plus copper, zinc, exotics and woodgrain finishes. SMS also has a full line of supporting trim in matching or contrasting colors to meet architectural and client demands. LTL-specific crating and a vast network of shipping options ensures quick nationwide delivery. For more information, visit www.sheetmetalsupplyltd.com.

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is North America’s premier zinc fabricator as well as a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, glazed-in panels, standing seam, ACM/MCM/plate panels and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Sheet Metal Supply Brings in Weathered Steel for Residential Roof, Walls

Grayslake, Ill. July 17, 2025 — With a list of requirements that included energy efficiency, sustainability and traditional aesthetics, the design team of this Maine residence took a unique approach, selecting weathering steel for the walls and roofing.

“The homeowners wanted a very energy-efficient new home for aging in place with all the accessible features,” says Paul Bonacci, AIA, LEED AP at ARQ Architects of Kittery, Maine. “They wanted the home to fit into the existing natural features and take advantage of scenic vistas of the site. They asked that the house have a traditional New England form but perhaps use unconventional exterior materials that would be maintenance free.”

Sheet Metal Supply, a leading North American metal fabricator and supplier, delivered 11-gauge Corten prefabricated panels for the walls of the home and 22-gauge Corten A606 standing seam panels for the roofing.

“We looked at other options for the exterior cladding and roofing, but weathered steel turned out to be the best choice for both,” Bonacci says. “The weathering steel just fits so nicely in all seasons with the surrounding landscape of native woodland and exposed ledge.

“As architects, we are inspired by the simplicity of the Shakers. Using mostly all standard-width weathered steel panels, we were able to capture this design simplicity. The standard-sized panels worked well with the window and door openings to augment and enhance the simple gabled form. Using weathering steel for the standing seam roof enhanced the design approach. The weathering steel will have great longevity with basically no maintenance.”

Lou Rondeau, owner of Natural Metal Associates in Mont Vernon, N.H., was called on to install the Corten A606 roofing for this project and assist Brendan King Construction of Kittery, Maine, on the installation of the weathering steel wall panels. Rondeau is a fourth-generation roofer who has conducted more than 100 training sessions in the United States and Canada. As the name states, Natural Metal Associates specializes in working with unpainted specialty metals like zinc, copper, aluminum and weathered steel.

“This project was an awesome one to be involved with,” Rondeau says. “I’ve completed several weathered steel projects in the past and this one definitely felt solid when it was completed. The walls were 11-gauge prefabricated Corten panels, so they’re heavy and awkward, but worth the workout when you see the finished project.”

Rondeau says the 22-gauge Corten A606 roofing develops a natural patina quickly, sometimes overnight. He also installed a matching weathered steel snow retention system above the garage and front entrance, attaching the rail with clamps from S-5!.

“The material is a challenge to work with,” he says. “You have to be careful with the panels and have the proper tools. It takes a lot of preplanning and patience, but it was a fun challenge.”

The standing seam roofing panels were seamed with heavy-duty seamers from D.I. Seam Roofers of Corinth, Miss.

King, the owner of Brendan King Construction, says the crew of Ian Wilkey, Mitch Allen and Hayden Pate didn’t go through any installation training for this project with weathered steel, but there was a learning curve.

“The panels, though not super heavy at about 200 pounds, were quite awkward to work with because of their size, 4 feet by 10 feet and approximately 1/8-inch thick,” King says. “There was really no place to hold on to them. We initially tried to hoist them with large magnets, but because we were lifting vertically, the magnets wanted to slide. In the end we had the most success with suction cups. We also tried, with some success, using a ledger to set the bottom and edge location of the panels. We then screwed the panels to 1-inch by 4-inch strapping with about 32 screws. We chose a square drive stainless steel bugle-head screw that fit nicely into the countersunk holes made from SMS.”

Packaging of the panels helped keep the installation moving.

“SMS did a really nice job of packaging the material for delivery as well as labeling the location of all the panels. It saved us a lot of time moving all the panels right where we needed them around the building. The architects did a great job of measuring the panels so they needed almost no modifications, except for where we had to cut for vents. It was pretty slow going with a metal cutting jigsaw or a metal bandsaw. We had Lou make two nice flashing details out of a thinner gauge Corten, one for the windowsills and one at the bottom of the walls where the steel panels met the foundation. The windowsills were a little tricky because we had to notch the Corten wall panels around the windowsill flashing. And at the bottom of the walls, we needed more of a z-type flashing to kick the water out beyond the foundation.”

The home was constructed on an energy-efficient insulated slab.

“The home featured a 4-3/4-inch wood fiber continuous exterior wall insulation and a blown-in cellulose insulation in the wall framing,” Bonacci says. “The wide rafter I-joists were also filled with cellulose insulation. This allowed us to avoid using fossil fuel-based insulation materials where possible. The envelope uses an air-tight strategy but still allows the walls to breathe and avoid moisture condensation.

“On the interior, the owners desired an easy-to-clean palette. For raised ceilings, trim and interior doors, we used locally sourced ash to complement the painted walls. For the floor, natural linoleum was installed over the slab on grade in most all rooms.”

Bonacci says the new home meets everyone’s expectations and has drawn a lot of attention from the neighbors.

“We are extremely proud of the finished project and we’re happy to report the owners are thrilled with their house,” he says. “The owners were critical team players in this effort. This includes the natural siting and a floor layout that works perfectly for them. They love the feel of the weathering steel exterior and how seamlessly it fits into the natural environment. It was a great team effort to bring this to fruition.

“Everyone was excited about working with the weathering steel. The biggest surprise is how much all of the local community and passersby have expressed their great appreciation for the house design and the use of weathering steel.”

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is North America’s premier zinc fabricator as well as a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, glazed-in panels, standing seam, ACM/MCM/plate panels and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Architect: Paul Bonacci, AIA, LEED AP, ARQ Architects, Kittery, Maine.

Fabricator: Sheet Metal Supply LTD, Grayslake, Ill.

Roofing Installer: Lou Rondeau, Natural Metal Associates, Mont Vernon, N.H.,

Wall Installer: Brendan King Construction, Kittery, Maine

Completion Date: December 2024

Sheet Metal Supply Fabricates Ceiling Panels for Denver Office Space

Grayslake, Ill., March 20, 2025 — Unique applications often require some outside-the-box thinking. That certainly was the case when the owners of a business located in a downtown Denver office wanted metal ceiling panels as a part of their unique design.

As a business focused on helping customers create their own office space, Workplace Resource wanted to create a flexible showroom to work with its clients. That space included metal ceiling panels fabricated by Sheet Metal Supply.

“The front and core of our new space is meant to inspire and be a place of gathering for our team, the clients we serve and the community we support and connect with,” says Madeline Sapyta, Creative Studio Director at Workplace Resource. “The front of our showroom can be flipped from a series of lounge settings to a 100-seat lecture or panel discussion space and we wanted the finishes and the overall space to invoke emotion and inspiration.

“The goal of the ceiling, in particular, was to create an element that helped define the otherwise very open and flexible entertaining space we were wanting. The high reflectivity and texture of the material created movement and drama in the space, allowing light to play off it.”

Sapyta says the light and reflective material allows for a lower ceiling height to be successful in defining the space as well as the overall impact it has on those interacting in the space.

“Gensler Architecture and Workplace Resource came up with the concept to utilize stainless steel ‘pebbled’ rolled metal sheets from Rigidized Metals (Corporation of Buffalo, N.Y.),” says Dan Parker, project manager at SRB Acoustics of Denver. “When we were hired by (general contractor) i2 Construction, we contacted Rigidized Metals to find out what they had in mind for this ceiling and they referred us to Sheet Metal Supply to bend the stainless into ceiling panels.

“SMS produced a great design to make these flat panels into a ceiling tile. Their design added substantial integrity to a ‘floppy’ panel and the design allowed us to make an accessible attachment to the Armstrong Heavy Duty Grid above. As the metal is available in 48-inch widths, this ceiling was comprised of 45-inch panels to allow for the custom bends on all sides.”

Rigidized Metals textured the stainless steel, creating a product it calls its Pattern 1WND, a rolled pattern named to evoke the appearance of “Wind on the Water.” Rigidized Metals offers sheets up to 48 inches wide and 12 feet long.

“We worked together with Sheet Metal Supply to create mockup panels that were reviewed by Workplace Resource, Gensler and i2 Construction,” Parker says. “Once approved, we created CAD drawings of the space, based on field measurements, installed the uniform sized ‘field panels,’ then made measurements for the final ‘non-standard’ panels accurate to 1/16th of an inch. Those panels were created by Sheet Metal Supply and shipped to us.”

The decision to have Sheet Metal Supply fabricate the panels improved lead times by weeks, maybe months, Parker says.

“Had I been dealing with a manufacturer of ceiling panels with this type of material, this process would have taken much longer,” Parker says. “Field measurements are usually given to the manufacturer so they can create shop drawings, which takes six weeks; we have them reviewed, which takes another two weeks; and then place the product into production, which could take another 12 weeks. Add to that another six weeks to correct everything they screwed up and this is best-case scenario.

“SMS turned around our field measurements into shop drawings in a week and had panels produced in four weeks.”

Parker says this is the only time in 30 years he has experienced 100 percent accuracy with these types of panels and these lead times. He says SRB employees made some mistakes during installation and some adjacent surfaces moved between measurements and delivery of the panels. SMS was able to create replacement panels quickly.

“This was the first larger scope project using our new 1WND pattern,” says Steve Valdespoino, Director of Business Development Architectural Products at Rigidized Metals. “Lead time was a big challenge, but because we are a domestic manufacturer, we were able to meet all requests. We have a good relationship with SMS and have collaborated on various projects.”

Fabricating the stainless steel ‘pebbled’ rolled metal sheets was a unique assignment for Sheet Metal Supply, but proper planning and new equipment played a large role in the success of the project.

“The aerospace precision and capability of the laser allows it to cut this textured material perfectly, as it has proximity sensors to keep the head floating over the material at the proper height for a very precise and perfect cut,” says Ben Kweton, president at SMS. “Working with a mirror-polished stainless steel material, there is basically no margin for error in fabrication. That means the material must get through the laser without any surface damage and it must get through the press brake. Thankfully, our investment in state-of-the-art equipment didn’t stop at the laser. The Safan press brakes with their European precision ground tooling and non-marking accessory cloth assured perfect results.”

SMS project manager Zach Timmerman was responsible for heading up communication to help make the architect’s concept become an achievable reality. The fabrication process at SMS along with the SRB Acoustics installation team, led to successful completion of this unique project.

“We had to play with a few different designs to ensure the smoothest installation as well as an efficient usage of material,” Timmerman says. “We worked with Rigidized Metals to optimize sheet sizes based on our panel sizes, allowing us to eliminate as much waste as possible. Everyone is very happy with the end result on this project.”

 

Check out more photos from this project here.

 

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is North America’s premier zinc fabricator as well as a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, glazed-in panels, standing seam, ACM/MCM/plate panels and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Architect: Gensler Architecture, Denver

Installer: SRB Acoustics, Centennial, Colo

General Contractor: i2Construction, Denver

Stainless Steel Supplier: Rigidized Metals, Buffalo, N.Y.

Fabricator: Sheet Metal Supply LTD, Grayslake, Ill.

Owner: Workplace Resource, Denver

Photographer: ©Jason O’Rear

Completion Date: September 2024

Sheet Metal Supply Switches to Full Operation on Solar Power

Following the move into a new and energy efficient facility and investing in state-of-the-art equipment, Sheet Metal Supply (SMS) has recently flipped the switch to operating 100 percent on solar power.

Verde Solutions, a full-service energy company serving all of the United States, designed and installed a roof-mounted solar array for Sheet Metal Supply that has a power rating of 159.81 kW-DC. Throughout its 30-year lifespan, the system is estimated to produce 5,780,505 kWh, which is the equivalent to CO2 emissions from 459,865 gallons of gasoline consumed; greenhouse gases from 883 passenger vehicles driven for one year; or carbon sequestered from 68,113 tree seedings grown for 10 years.

“With our new facility and the recent purchase of new and more efficient equipment, the natural next step was to run our entire operation on solar power,” says Ben Kweton, President of Sheet Metal Supply. “The transition to lowering carbon emissions and minimizing our carbon footprint was a conscious decision dedicated to investing responsibly in our future as well as the future of our customers.”

The solar array was completed in February and up and running in March.

“At Verde Solutions, we are thrilled to congratulate Sheet Metal Supply and its visionary owners, the Kweton family, for their forward-thinking decision to incorporate solar power into their facility,” says Chris Gersch, Founder & CEO of Verde Solutions LLC. “By powering their operations 100 percent with green, onsite-sourced solar power, SMS is not only enhancing its commitment to providing top-quality roofing products in a cost-effective and greener way, but also setting a benchmark in sustainability.

“Additionally, we extend our gratitude to ComEd and the Illinois Power Agency for their invaluable education and incentives, which have been instrumental in making solar energy adoption a viable and attractive option for businesses in Illinois. Companies like Sheet Metal Supply are building a greener, more sustainable future.”

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, architectural zinc, glazed-in panels, standing seam and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Feature Image Courtesy of: Sheet Metal Supply

Sheet Metal Supply fabricates RHEINZINK panels for Texas municipal facility

Grayslake, Ill., Sept. 10, 2024 — In the 10 years between the 2010 and 2020 census, the City of Melissa, Texas, saw its population jump from 4,700 to almost 14,000. To accommodate the growing need of services for the community, the city constructed a new 40,000-square-foot public safety building to house its central fire station, fire administration, police headquarters and municipal court.

Zinc panels fabricated by Sheet Metal Supply were an integral part of the design goals and ultimate success of the new Melissa Public Safety Building.

“The building’s image was very important to us,” says Ron Hobbs, AIA, President of Ron Hobbs Architecture & Interior Design in Garland, Texas. “We wanted the building to be timeless in its appearance and convey a sense of permanence. To accomplish this, we chose a simple palette of materials – brick, metal panels and glass.

“Zinc was selected not only because of the way the material looks initially, but also the way it ages. Painted metal panels would not convey the sense of permanence that zinc provides.”

The Hobbs firm had also developed the Melissa City Hall interior design, the remodeling of City Hall and the remodeling of the fire station. This project included a 13,616 square foot three-bay fire station and a single-story 22,099 square foot police station and municipal courts building.

Sheet Metal Supply delivered 16,000 square feet of RHEINZINK’s 1.0mm GRANUM in Sky Grey. The 12-inch-wide reveal panels have a ½-inch reveal. Engineered Metals Co. (EMCO) of Gonzalez, Texas, met the challenge of installing the RHEINZINK panels.

“With zinc, we’re always careful with storage and handling,” says Dave Stone, EMCO project manager. “We tarp material to avoid white rust, use cotton gloves to avoid fingerprints and remove plastic protection from the panels. It’s important that any cutting is done with non-serrated snips as serrated snips cause microfractures in the material.”

EMCO has earned a reputation as a strong and capable installer through its zinc experiences. EMCO and SMS have collaborated on several high-profile zinc projects, always delivering successful results.

“Dave Stone and the EMCO team have invested valuable time and resources in proper training to establish themselves as a leader in zinc installation,” says Lisa England, Inside Sales at Sheet Metal Supply. “Our shared ethos for quality materials properly fabricated and installed by trained professionals makes for a great symbiosis. We are already looking forward to our next mutual opportunity.”

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, architectural zinc, glazed-in panels, standing seam and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Architect: Ron Hobbs Architecture & Interior Design, Garland, Texas

General Contractor: Crossland Construction Company, Prosper, Texas

Installer: The Engineered Metals Co., Gonzalez, Texas

Fabricator: Sheet Metal Supply LTD, Grayslake, Ill.

Sheet Metal Supply helps DIY couple install RHEINZINK walls on home

Grayslake, Ill., June 20, 2024 — Everyone is intrigued by a do-it-yourself project because you never know how it will turn out. The motivation behind DIY projects is usually, if not always, to save enough money to make the work worthwhile. In this case, the satisfaction of a puzzle solved and a job done well were equally at play.

 

This project case study is about a Michigan couple that set out to build their own home with as little help as possible. Admittedly, they paid contractors to take care of the tasks they thought better left to professionals, including the HVAC, electrical, plumbing and drywalling. When it came to installing zinc metal panels on the exterior of the home, Dirk and Ann VanZalen of Allegan, Mich., wanted to try it themselves. They loved the aesthetics and the environmentally friendly aspects of zinc and decided it would fit in their budget if Dirk could do the installation himself.

 

Sheet Metal Supply (SMS) fabricated and supplied the VanZalens with 3,000 square feet of 20-gauge RHEINZINK prePATINA trim and interlocking flat lock tiles, measuring 16 inches by 54 inches – approximately 500 tiles. Even those who have worked with expensive specialty metals like zinc may have found this undertaking a daunting task, particularly with all the angles of the house design.

 

Before we go any further, we should point out that this is a DIY project with an asterisk. Dirk VanZalen can handle more than his share of tools, having spent his career in the woodworking industry at Benchmark Wood Studio and Sligh Furniture, engineering and building custom cabinetry and office furniture. While searching for videos online featuring zinc fabrication and installation, VanZalen discovered Sheet Metal Supply, a leading national fabricator and supplier of a variety of metals used in construction. He watched several Sheet Metal Supply videos on YouTube about working with various metals, and then he and Ann made the trip around Lake Michigan to visit SMS.

 

“I know how to work with my hands and I enjoy figuring things out,” VanZalen says. “I really don’t think I could have done this at any other point in my life. It all came together at the right time, with my life experience and my access to equipment and know-how at my place of employment. Our kids are out of the house, so I was free to dedicate the time required to get this done.”

 

Those who install metal roofing or walls have their own set of specialty tools, large and small. After forming a couple of trim pieces by hand, VanZalen decided a brake would be a good investment.

 

“I went on Facebook Marketplace and found a used brake not too far from where we live,” he says. “I got there and the guy had it stored in a barn. It was big and heavy and old. He wanted $800 for it.”

 

VanZalen says after a little negotiating, he drove away with the bulky old brake. It served him well and when it had served its purpose, he sold it for $150 more than he paid for it and even had several other interested buyers.

 

VanZalen picked up some other necessary tools from Sheet Metal Supply and was ready to go. Getting started by installing trim around windows and doors turned out to be the most challenging part of the project. Once VanZalen started working with the actual tiles, he was comfortable using the brake and interlocking the tiles.

Time is a precious resource in any project. VanZalen says full panels installed quickly, but panels that required any cutting took extra attention. “You’d think with tiles that are 16 inches by 54 inches, it would install quickly,” VanZalen says, “but you’d be surprised how few tiles are actually installed without being cut to fit around a window or door or the soffits.”

 

The VanZalens also used some zinc indoors, up the 16-foot fireplace wall, and are very pleased with this interior connection to their unique exterior. They credit Sheet Metal Supply with a smart design and precise fabrication of zinc tiles for interior and exterior use that led to a simplified and cleaner installation.

 

“It’s a Covid project that got a little out of control,” VanZalen chuckles. “The floor plan was completely our own creation, but we absolutely could not have achieved the house’s overall design appeal without sharing an inspiration photo from One Kindesign with our architect friend, David Bareman RA, who provided roof pitch, window arrangement and massing expertise.

 

“There are some things left for us to do, but we’re getting there and the house is more than livable. Before we started, we cut down 15 oak trees on the build site, dried them and we’ve used the lumber from them for paneled ceiling, stairs and custom veneered interior doors.”

 

These bring just the right warmth to the interior with its cement floors and exposed steel structure. Dirk’s carpentry and Ann’s finishing skills show up in all trim, cabinetry and certain pieces of furniture.

 

“This has been a great team effort,” VanZalen says, “It can be challenging getting on the same page when a couple builds a home, but we’re still happily married! Even after tiling four bathrooms together! People are particularly surprised that we put in 150 feet of tongue and groove vinyl sea wall with just the two of us. Ann is a strong woman, a good worker and she has also kept us right on budget, even slightly under.”

 

Ann VanZalen agrees. “Sheet Metal Supply, specifically (president) Ben Kweton and Lisa England, certainly helped us feel comfortable throughout the process,” she says. “It was a little intimidating at first, but they were very encouraging. When we needed about 40 panels, all just 11 inches long for the window wall facing the lake, they fabricated them at that custom length, which saved Dirk many hours of cutting and refolding. They, like many other contractors we worked with, became great partners in our crazy adventure. We’re so very happy with the way everything turned out. We love our home and take great joy in all the things we were able to do ourselves. Definitely, a once-in-a-lifetime experience!”

 

The project is one that Sheet Metal Supply is proud of as well.

 

“It was nice working with the VanZalens, who appreciate the beauty and sustainability of RHEINZINK,” says England, Inside Sales at Sheet Metal Supply. “They were able to put together an outstanding example of a flatlock façade for a residential project. We appreciate the trust they put in Sheet Metal Supply. They were great partners.”

 

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, architectural zinc, glazed-in panels, standing seam and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

 

Fabricator: Sheet Metal Supply LTD, Grayslake, Ill.

 

Installer: Dirk VanZalen, homeowner

 

Completed: Spring 2024

Sheet Metal Supply Offering PVDF Black Metal for Sub-girts

Grayslake, Ill., March 28, 2024 — Sheet Metal Supply, a leading fabricator and supplier of a variety of metal construction products, is now stocking 16-gauge and 18-gauge galvanized steel for the fabrication of hat channels, Z-channels and U-channels in Polyvinylidene Fluoride (PVDF) Black.

“We’ve been getting more and more requests for pre-painted components for use as sub-structures under rainscreens and other façades,” says Phoebe McCorkindale, Director of Operations at Sheet Metal Supply. “Black sub-girts provide a shadowing aesthetic that is growing in popularity.

“To stay ahead of this trend, we’re stocking 48-inch-wide pre-painted coil in PVDF Black. With our new machinery, we can custom-fabricate those sub-structure components in custom widths and lengths up to 21 feet.”

Sheet Metal Supply has two in-house bidirectional folders that allow for the fabrication of longer and custom lengths of 16- and 18-gauge stock with shorter lead time to keep projects moving.

For more information, contact Sheet Metal Supply at (847) 478-8500 or visit www.sheetmetalsupplyltd.com.

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, architectural zinc, glazed-in panels, standing seam and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Copper Envelops Addition to 100-Year-Old Cambridge Home

Grayslake, Ill., July 11, 2023 — Copper has a way of standing out, especially when first installed. Natural Metal Associates of Mont Vernon, N.H., installed approximately 1,600 square feet of standing seam copper as the façade of an addition to a renovated home in Cambridge, Mass.

Lou Rondeau, owner of Natural Metal Associates (NMA), installed the copper purchased through Sheet Metal Supply (SMS), from Revere Copper of Rome, N.Y. Because of a demanding schedule, it took Rondeau a few months to get on the jobsite. By that time, the copper gutters and several standing seam copper eyebrows had been installed. So, the homeowners decided to install copper panels on the walls of the addition.

“The addition adds three rooms at the back of the house,” says homeowner Doug Brown, who along with his wife Dee Elms, purchased the home about 11 years ago. “It’s basically a set of stacked boxes.”

The couple first had the home lifted up to replace the original foundation built with concrete block and field stones in 1925. The new basement includes a 300 square foot addition at the back to serve as a workout room. The main floor of the addition is a new family room and the second floor above that is the new primary bedroom. The top floor addition is smaller than the main floor addition below it, allowing for a small balcony outside the primary bedroom.

“We wanted to keep the traditional Victorian look at the front of the house,” Brown says. “We discussed other metals for the addition but decided on copper because it is distinctive and it’s a living metal. Painted composite panels are very popular today, but they are the same color forever. Copper changes, it patinas, so the look of the home evolves with time.”

Rondeau, who specializes in working with natural metals, including copper, zinc and stainless steel, focused on lining up the vertical metal panel seams with window lines. He had jobsite assistance from Thiago DeSouza and all panels are mechanically double-locked.

“Every panel is a custom size,” Rondeau says. “The variety of widths gives it a contemporary look. Initially, we talked about installing flat-lock tiles on the walls, but decided it would look too busy. I’m happy with the way it turned out.

“The biggest challenge was getting materials into a tight urban neighborhood. Other houses are pretty close.”

Sheet Metal Supply custom-crated the panels for this job to accommodate the tight jobsite spaces. SMS and NMA both deal mostly in natural metals because they are sustainable: high recycled content, long life cycle and recycled at the end of that life cycle.

“If you ask Lou what he does, he’ll tell you he’s a roofer,” Brown says. “In truth, he’s an artist. He did a fantastic job.”

Rondeau is quick to offer up appreciation for Sheet Metal Supply. “Sheet Metal Supply is not just a supplier to me,” Rondeau says. “They treat me like family. They take an interest in every project, they’re invested in my success. They know how to get it done. My business would not be what it is today if it weren’t for SMS.”

About Sheet Metal Supply

Founded in 1991, Sheet Metal Supply Ltd. is a leading fabricator/supplier of custom-formed perimeter edge systems, wall facades, flat lock tiles, substructural components, ES-1 rated products, architectural zinc, glazed-in panels, standing seam and much more. The company ships internationally and is regarded for its high-quality products and quick turn-around. For more information, visit www.sheetmetalsupplyltd.com.

Fabricator: Sheet Metal Supply LTD, Grayslake, Ill.

Copper Supplier: Revere Copper, Rome, N.Y.

Installer: Lou Rondeau, Natural Metal Associates, Mont Vernon, N.H.

Architect: Richard Bernstein Architect, Gloucester, Mass.

Interior Design: Elms Interior Design LLC, Boston

Project Manager: Moughan Contracting, Newton, Mass.