In a modest facility just outside Chicago, the future of American manufacturing is taking shape at Madon Sheet Metal. The company’s decision to specialize in welded products, particularly curb adapters and roof accessories, was born of both practical wisdom and market insight. “Welded stuff, we usually get a little bit more lead time with so it’s easier to schedule out,” noted John Madon, explaining one of the key advantages that drove their specialization.
Their specialized focus serves a critical need in the mechanical contracting market, though they face stiff competition in the rooftop accessory sector. While union contractors routinely seek out union-made ductwork, the same scrutiny often doesn’t extend to accessories like curb adapters and rails. This is particularly evident in the restaurant sector, where thin profit margins often drive purchasing decisions toward the lowest-cost options. With many restaurant chains following cookie-cutter designs and working with non-union manufacturers, competing on price alone becomes challenging for a union shop committed to quality craftsmanship.
The path to finding their niche hasn’t been straight or simple. In just five years of operation, Madon Sheet Metal has relocated three times. Their previous facility fell to the growing demand for data center space, as developers purchased and demolished entire industrial parks. This September, they finally settled into a custom-built facility secured under a five-year lease. “I’m very excited to be kind of set,” John said, reflecting on the stability this new location provides.
CURBED: Madon Sheet Metal’s “bread and butter” is fabricating curb adapters for rooftop air handlers. (Staff photo)
These moves profoundly influenced their business strategy and equipment choices. Rather than maintaining the full complement of traditional sheet metal machinery, they opted to specialize and streamline. By eliminating roll formers and related equipment, they dramatically reduced their inventory needs. “We’re able to keep our stock down to a few specific gauges, versus running the gamut of having to keep every gauge in stock,” explained John. “We don’t have to stack crazy amounts of different types of liner, or any of the other little ancillaries, TDC corners and sealants and everything. It’s a big cash flow saver.”
The centerpiece of their modernized operation is a new laser cutter – a strategic investment that transformed their production capabilities. “The day before it was delivered, Dan came in and said, ‘I was up all night reading all the science behind how lasers cut,'” recalled John with pride. The precision of laser cutting eliminates the need for deburring, producing clean, exact cuts that streamline production. The machine’s operator interface also allows for greater flexibility, enabling workers to reconfigure cutting patterns and maximize material usage by utilizing scrap pieces.
Even their approach to shop infrastructure reflects lessons learned from multiple relocations. Rather than installing complex central exhaust systems that would need to be relocated with each move, they’ve opted for portable smoke eaters. “We’ve moved so many times, I think I have PTSD,” joked John. “I didn’t want to set up another exhaust system again.”
SAILING: Husband and wife, as well as business partners, John and Devon Madon started Madon Sheet Metal in 2019. (Staff photo)
Deep roots in Chicago’s mechanical contracting community have helped shape the company’s trajectory. John’s experience at Sheet Metal Werks, where he started in shipping before completing his apprenticeship and moving into project management, provided invaluable insights into the industry’s needs. Thereafter, his work handling sophisticated ductwork on significant projects like the Elmhurst Hospital would prove instrumental in developing the company’s expertise.
The seasonal nature of rooftop work presents another challenge. When Chicago’s winter weather keeps contractors off roofs, orders for curb adapters and similar products naturally slow down. Rather than accepting these seasonal doldrums, the Madons have gotten creative. Their shop has begun exploring various specialty welded products to net revenue during the off-season. This innovative approach was perfectly illustrated when Dan, their lead welder, decided to prototype a sheet metal boat during a slow period. “Dan’s making a float boat,” explained Devon Madon, co-owner of Madon Sheet Metal.
Beyond their core business, the shop demonstrates American manufacturing capability through unique custom fabrication. Their handcrafted fire pits, featuring precise laser-etched logos and crafted from domestic steel by union workers, showcase both their technical expertise and commitment to quality American manufacturing. “We give these away for golf outings and things,” John explained. “It’s better than a gift card.” These pieces serve as proof of what skilled American craftspeople can create – a stark contrast to mass-produced alternatives.
INNOVATION IN ACTION: The Madon Sheet Metal team showcases a custom-fabricated project, demonstrating the creativity and technical skill that set their shop apart. (Staff photo)
Recent market changes and tariff discussions, particularly regarding Canadian imports, have impacted material costs. “Aluminum has gone crazy,” John noted. “Stainless and steel are still pretty reasonable in this area, but aluminum used to be considered the less expensive option. Now that’s not necessarily true.”
Their work extends beyond standard HVAC components to include specialized projects like kitchen hood exhaust systems, which require particular attention to safety and maintenance.
“We’re trying to encourage more and more people, especially if they’re union contractors, to be intentional about buying union curbs and curb adapters and rails,” Devon said. She suggested that supply houses could help by being more upfront about union-made options, perhaps even adding checkboxes to their forms to identify union-made products. “Everybody wants it,” she noted.
As American manufacturing continues to evolve, shops like Madon demonstrate how traditional trades can adapt and thrive in the modern economy while maintaining high standards of craftsmanship and labor practices.