Frequently Asked Questions

Architectural metal fabrication is the process of creating custom metal elements specifically designed for buildings and structures. This specialized field combines traditional metalworking techniques with modern fabrication methods to produce functional and decorative elements that enhance both the aesthetic appeal and performance of architectural projects.

At Salvo Metal Works, we focus specifically on copper fabrication, which involves shaping, forming, joining, and finishing copper to create elements such as chimney shrouds, cupolas, dormers, finials, leader boxes, roof vents, and snow guards. Our fabrication process includes cutting, bending, welding, soldering, and patina application to achieve the desired appearance and functionality.

The architectural metal fabrication process requires a deep understanding of both the material properties of copper and the specific requirements of architectural applications. This includes considerations such as thermal expansion, weather resistance, structural loads, and aesthetic integration with existing building elements.

Architectural metal is used in a wide variety of applications throughout both residential and commercial buildings. Common applications include:

Roofing Systems: Metal roofing, flashing, gutters, downspouts, and related drainage components that protect buildings from weather while providing attractive finishing details.

Exterior Cladding: Decorative and protective metal panels, siding, and facade elements that enhance building appearance while providing weather protection.

Decorative Elements: Ornamental features such as cupolas, finials, weathervanes, and architectural details that add character and visual interest to buildings.

Functional Components: Ventilation systems, chimney caps and shrouds, roof vents, and other elements that serve important building functions while maintaining aesthetic appeal.

Structural Elements: Beams, columns, railings, and other load-bearing or safety components that combine structural performance with architectural design.

Copper, in particular, is prized for its durability, natural weather resistance, and beautiful patina that develops over time, making it ideal for exterior applications where both performance and appearance are important.

Custom architectural metal fabrication offers numerous benefits that make it an excellent choice for both residential and commercial projects:

Durability and Longevity: Properly fabricated copper elements can last for decades or even centuries with minimal maintenance. Copper naturally resists corrosion and develops a protective patina that actually enhances its weather resistance over time.

Design Flexibility: Custom fabrication allows for unlimited design possibilities. We can create elements that perfectly match your architectural vision, whether you're looking for traditional styles or contemporary designs.

Perfect Fit: Custom elements are made to exact specifications for your specific project, ensuring perfect fit and optimal performance. This eliminates the compromises often necessary with standard, off-the-shelf products.

Weather Resistance: Copper's natural properties make it highly resistant to weather, UV radiation, and environmental factors that can damage other materials.

Low Maintenance: Once installed, copper architectural elements require very little maintenance while continuing to perform and look beautiful for many years.

Sustainability: Copper is a naturally occurring material that is 100% recyclable, making it an environmentally responsible choice for architectural applications.

Value Addition: Quality copper architectural elements can significantly enhance the value and curb appeal of your property.

The difference between custom and standard metal fabrication lies in the approach, process, and end result:

Design Process: Custom fabrication begins with understanding your specific needs and vision. We work with you to develop designs that meet your exact requirements, while standard fabrication involves selecting from pre-existing designs and sizes.

Manufacturing Approach: Custom fabrication involves creating unique, made-to-order pieces designed specifically for your project. Each element is individually crafted to your specifications. Standard fabrication typically involves producing pre-designed, mass-produced items in common sizes and configurations.

Material Selection: With custom fabrication, we can select the specific grade and type of copper that best suits your project requirements and budget. Standard products are typically made from whatever materials the manufacturer has chosen.

Precision and Fit: Custom elements are made to exact measurements taken from your specific installation site, ensuring perfect fit and optimal performance. Standard products may require modifications or compromises to fit your application.

Quality Control: Custom fabrication allows for individual attention to each piece, with quality control measures tailored to your specific project requirements.

Timeline and Cost: While custom fabrication typically requires longer lead times and higher initial costs, the result is a product that perfectly meets your needs and often provides better long-term value.

Our design development process is collaborative and thorough, ensuring that the final product meets all your requirements:

Initial Consultation: We begin with a detailed discussion of your project goals, aesthetic preferences, functional requirements, and budget considerations. This helps us understand your vision and identify any potential challenges or opportunities.

Site Assessment: For most projects, we conduct a site visit to assess existing conditions, take precise measurements, and evaluate factors such as structural support, access for installation, and integration with existing building elements.

Concept Development: Based on our consultation and site assessment, we develop initial design concepts that address your requirements while considering practical factors such as manufacturing feasibility and installation requirements.

Design Refinement: We work with you to refine the design, making adjustments to ensure it meets your aesthetic and functional goals while staying within budget and timeline constraints.

Technical Drawings: Once the design is approved, we create detailed technical drawings and specifications that guide the fabrication process and ensure accuracy and quality.

Engineering Analysis: For structural elements or complex installations, we perform engineering analysis to ensure that the design meets all safety and performance requirements.

Final Approval: Before beginning fabrication, we review all design details with you to ensure everything meets your expectations and requirements.

The cost of custom architectural metal fabrication varies significantly based on several factors. While we can't provide specific pricing without understanding your project details, we can explain the factors that influence cost:

Project Complexity: Simple, straightforward designs typically cost less than complex, intricate pieces that require specialized techniques or multiple fabrication steps.

Size and Scope: Larger elements or projects with multiple components will generally cost more than smaller, single-piece projects.

Material Requirements: The grade and thickness of copper required, as well as any special finishes or treatments, will affect the overall cost.

Design Requirements: Custom designs that require special tooling, unique forming techniques, or extensive hand work will typically cost more than simpler designs.

Installation Complexity: Projects that require special equipment, difficult access, or coordination with other trades may have higher installation costs.

Timeline: Rush projects that require expedited fabrication or installation may incur additional costs.

Typical Price Ranges: Simple elements like basic finials or small roof vents might start around $500-$1,500, while complex cupolas or large chimney shrouds could range from $3,000-$15,000 or more. Large-scale projects involving multiple elements can range from $10,000 to $50,000 or higher.

We provide detailed, written quotes for all projects after our initial consultation, so you'll know exactly what to expect before any work begins.

Salvo Metal Works has been serving the Naperville area and Chicago metropolitan region for over a decade, building a reputation for exceptional quality and craftsmanship in custom copper architectural fabrication.

Since our founding, we have completed hundreds of projects ranging from small residential additions to major commercial developments. Our experience spans a wide variety of architectural styles and project types, giving us the expertise to handle virtually any custom copper fabrication challenge.

Our Growth and Evolution: Over the years, we have continuously expanded our capabilities and refined our processes to better serve our clients. We've invested in advanced equipment, developed new techniques, and built relationships with trusted suppliers to ensure we can deliver the highest quality results.

Industry Recognition: Our work has been recognized by architects, contractors, and property owners throughout the region. We've built long-term relationships with many clients who return to us for additional projects and refer us to others.

Continuous Improvement: Throughout our history, we've remained committed to continuous improvement, staying current with industry best practices and new technologies while maintaining our focus on traditional craftsmanship and attention to detail.

Looking Forward: As we continue to grow, we remain committed to the principles that have made us successful: quality craftsmanship, personalized service, and complete customer satisfaction.