Why In-House Fabrication Matters
Sheet metal is a critical component of every commercial roofing system. Flashings, copings, edge metal, gutters, and downspouts are the details that seal the transitions, direct water away from the building, and protect the most vulnerable points of the roof assembly. When these components are poorly fabricated, improperly sized, or made from inferior materials, they become the first point of failure in an otherwise sound roofing system, often leading to costly roof repairs.
Windward Roofing & Construction operates a fully equipped in-house sheet metal fabrication shop at our Chicago facility. This capability sets us apart from roofing contractors who outsource their sheet metal work to third-party fabricators. By controlling the fabrication process from start to finish, we deliver sheet metal components that are built to exact specifications, inspected for quality before they leave the shop, and available on the timeline our projects demand. Over 40 years of commercial roofing experience has taught us that the quality of the sheet metal work is often what separates a roof that lasts from one that fails prematurely.
Custom Flashings
Flashings are the most important sheet metal components on any commercial roof. They seal the transitions between the roof membrane and vertical surfaces, penetrations, edges, and other interruptions in the roof plane. Every wall-to-roof junction, equipment curb, pipe penetration, skylight, and parapet requires properly designed and fabricated flashing to prevent water intrusion.
Windward's fabrication shop produces custom flashings for every application encountered in commercial roofing. Our flashing products include base flashings that transition from the membrane to walls, curbs, and other vertical surfaces. Counterflashings that cover and protect the top edge of base flashings at masonry walls and concrete parapets. Through-wall flashings that intercept moisture within masonry walls and redirect it to the exterior. Pipe and conduit flashings custom-fitted to the exact diameter of each penetration. Equipment curb flashings designed to match the specific dimensions and configuration of rooftop HVAC units, exhaust fans, and other mechanical equipment. Every flashing we fabricate is made from the appropriate material and gauge for its application, with properly formed hems, drip edges, and laps that ensure watertight performance.
Copings and Edge Metal
Copings cap the top of parapet walls, providing both weather protection and an attractive finished appearance. Edge metal defines the perimeter of the roof, securing the membrane termination and directing water into the gutter system. Both components must be fabricated with precision to perform correctly and maintain their appearance over time.
Windward fabricates copings in a wide range of profiles, widths, and materials to match any building design. Our standard copings feature continuous cleat attachment systems that allow for thermal expansion and contraction without buckling or loosening. We also produce custom profiles for buildings with specific architectural requirements. Our edge metal products include standard drip edges and gravel stops as well as engineered edge systems designed to meet Factory Mutual wind uplift requirements. For buildings in high-wind zones or with specific insurance requirements, we fabricate and install tested edge metal systems that provide documented resistance to wind forces.
Gutters and Downspouts
Effective water management starts at the roof edge. Gutters collect water as it leaves the roof surface and channel it to downspouts that deliver it safely to grade-level drainage systems. When gutters and downspouts are undersized, poorly pitched, or fabricated from lightweight materials, they fail under the load of heavy rainfall, causing water to overflow and damage the building facade, foundation, and surrounding landscape.
Windward Roofing fabricates commercial-grade gutters and downspouts sized to handle the water volume produced by each specific roof area. Our gutter systems are formed from heavier-gauge materials than standard residential products, with soldered or sealed joints that eliminate leak points. We calculate the required gutter capacity based on the roof area served, the local rainfall intensity, and the number and spacing of downspouts. Downspouts are fabricated in round or rectangular profiles to match architectural preferences and are sized to deliver the full capacity of the gutter system without backing up. Our installations include proper hangers, brackets, and support systems designed for commercial service life.
Architectural Sheet Metal
Beyond the functional components that every commercial roof requires, Windward Roofing's fabrication capabilities extend to architectural sheet metal elements that contribute to the building's visual design. Our shop produces fascia panels and soffit materials in custom profiles and finishes, column covers and beam wraps that conceal structural elements, decorative cornices and trim that replicate historical details or create modern design features, wall panel systems and accent elements, custom conductor heads and decorative downspout components, and specialty items fabricated from copper, zinc, stainless steel, and other premium materials.
Our fabrication team works from architectural drawings and shop drawings to produce components that meet the designer's intent while incorporating the practical details needed for weathertight installation and long-term durability. For restoration projects involving historical buildings, we can replicate original sheet metal profiles and details using traditional techniques and period-appropriate materials.
Quality Control Advantages of In-House Fabrication
Operating our own fabrication shop provides quality control advantages that are simply not available when sheet metal is outsourced. Every piece that leaves our shop has been fabricated by our own trained metalworkers using our own equipment and quality standards. We inspect materials before fabrication to verify gauge, finish, and condition. Our equipment is calibrated and maintained to produce consistent, accurate bends and cuts. Finished pieces are inspected for dimensional accuracy, hem quality, and finish integrity before they are loaded for delivery to the job site.
When field conditions require modifications, our fabrication shop can produce revised components quickly, often within the same day. This eliminates the delays that occur when field-discovered discrepancies require new orders from outside suppliers. Our project managers and field supervisors communicate directly with our shop foreman, ensuring that any changes are understood and executed accurately.
Materials We Work With
Windward Roofing's fabrication shop is equipped to work with a full range of commercial sheet metal materials. These include galvanized steel in various gauges for standard roofing applications, stainless steel for corrosive environments and high-end architectural applications, aluminum for lightweight applications and coastal environments where corrosion resistance is essential, copper for premium architectural work and historical restoration, zinc for long-life architectural applications with natural patina development, and pre-finished metals with Kynar and other fluoropolymer coatings in a wide range of standard and custom colors. Material selection is guided by the application requirements, exposure conditions, architectural specifications, and project budget. Our team advises clients on the most appropriate material choice for each situation.
From Shop Drawings to Installation
Windward Roofing manages the complete sheet metal process for commercial projects. We review construction documents and develop detailed shop drawings for architect and owner approval. We take precise field measurements to ensure accurate fabrication. All components are fabricated in our shop under controlled conditions. Materials are delivered to the job site on the schedule that our installation crews need. Our trained sheet metal installers handle the final installation using proper fastening, sealing, and flashing techniques. This end-to-end control means that the people who fabricate the metal understand how it will be installed, and the people who install it know exactly how it was built. The result is sheet metal work that fits correctly, performs reliably, and looks professional.
Get a Quote for Custom Sheet Metal
Whether you need standard flashings and copings for a re-roofing project, custom gutters for a new construction build, or architectural sheet metal for a specialty application, Windward Roofing & Construction has the equipment, experience, and craftsmanship to deliver. Contact us at (844) 880-8844 to discuss your project requirements and request a fabrication quote.
Frequently Asked Questions
In-house fabrication gives Windward Roofing complete control over quality, dimensions, and turnaround time. We can produce custom pieces to exact specifications without relying on third-party suppliers, ensuring perfect fit, consistent quality, faster delivery, and the ability to make immediate adjustments on the job site.
Our fabrication shop produces a full range of commercial roofing sheet metal including custom flashings, copings, gravel stops, gutters, downspouts, conductor heads, edge metal, drip edges, counterflashings, equipment curbs, expansion joint covers, and architectural sheet metal elements such as fascia panels, column covers, and decorative trim.
Windward Roofing fabricates sheet metal from a variety of commercial-grade materials including galvanized steel, stainless steel, aluminum, copper, zinc, and pre-finished Kynar-coated metals. Material selection depends on the application, exposure conditions, aesthetic requirements, and project budget.
Yes. Our fabrication team can replicate existing profiles and match colors and finishes for repair and replacement projects. We take precise field measurements and create custom pieces that integrate seamlessly with existing sheet metal work, maintaining the building's appearance and weather integrity.
Absolutely. Windward Roofing works with architects, general contractors, and building owners on new construction projects of all sizes. We review construction documents, provide detailed shop drawings for approval, fabricate all required sheet metal components, and install them as part of the complete roofing package.