How Much Does Sheet Metal Fabrication Cost in 2022?

Sheet Metal Fabrication Prices

In the most general of terms, a ton of raw steel typically costs about $400. A good rule of thumb when it comes to fabrication costs is you’ll pay roughly three times the cost of the material to have it cut, pressed, and finished. This means you can usually add $1,200 in fabrication costs, for a total cost of $1,600 for a ton of fabricated sheet metal.

The cost of prefab sheet metal varies based on its intended use. Metal siding panels can cost as little as $1 per square foot for tin and as much as $35 per square foot for copper. Aluminum screening for windows and doors starts at $0.35 per square foot, while brass for the same purpose can cost up to $2.50 per square foot.

Sheet metal fabrication costs vary greatly depending on the material and the amount of customization you need. When deciding how you’ll go about your construction or repair project, weigh the costs and benefits of having a professional fabricate metal for you versus heading to the hardware store for prefabricated pieces. While the trade-off is you won’t have the prefabricated metal worked to your exact specifications, you’ll find there are often many design choices available.

Sheet Metal Fabrication Installation Cost

Depending on the professional you hire and the scope of the work, they'll generally quote per project or hour for installation pricing.

Per Project

Siding installers may charge $3,300 to $7,900 to install 1,500 square feet of metal siding. Roofers generally charge around $7,000 to $10,000 to work with higher-end or customized materials like metal.

When installers have a good idea of how much time and effort a project will take to complete, they generally price their services per project. The cost of these services will vary depending on what you have done.

Per Hour

If a handyperson can tackle your project, you'll pay $65 to $125 per hour for their services. Roofers charge approximately $45 to $75 per hour to repair a metal roof, with average metal roof repair costs at around $1,600. A professional may quote a per-hour rate for smaller jobs.

Sheet Metal Fabrication Cost by Type

Sheet metal is an extremely versatile material, so you can use it for all sorts of home improvement and repair projects. The following are just a few examples of how you can use sheet metal around your home and what you can expect to pay per project type.

Siding

A basic project or minor repair can cost as little as $850, while replacing existing panels or installing new siding can cost as much as $35,000. Metal siding costs vary dramatically based on several factors, such as the material, style, size, and scope of your project.

Metal siding is a popular construction material because it provides superior strength while offering an attractive look. Unlike some other materials often used in siding, such as wood and vinyl, metal does a better job withstanding harsh weather, corrosion, and other types of damage.

Roofing

A basic steel roof can cost as little as $8,000, while a more elaborate copper roof or one requiring custom stamping can cost as much as $29,000. When determining metal roof costs, account for materials, labor, and overhead, with each representing about one-third of the total cost of your project. The price for materials goes up based on material type, material gauge, and any custom fabrication needs.

Metal roofs are a top choice among homeowners for all the same reasons as metal siding. While a new metal roof can be a considerable expense, it comes with many benefits, including lower maintenance costs, increased energy efficiency, cheaper insurance rates, and a longer roof lifespan. You can typically recoup up to 95% of the cost of your metal roof when you sell your home.

Screening

Stainless steel, copper, and brass are popular metals for screening, ranging from $1 to $2.50 per square foot. Security screening, made from even thicker metals and sometimes utilizing bars or grates, can cost up to $25 per square foot. Depending on the size and scope of your project, you can expect to pay $50 to $1,000 for new screening.

While fiberglass is a common material for window or door screening, it isn’t a durable option. If you’re looking for something that’ll last longer and look better, consider metal screening. It costs more upfront but can pay for itself with reduced repair costs.

Structure

On average, the cost to create a basic metal structure or outbuilding is around $3,000. For larger buildings or customized projects, the price can easily reach $20,000 and even surpass it.

If you’ve been thinking about building a carport, shed, barn, or other outdoor structure, consider using metal over wood to enjoy a building that’ll last longer and better withstand the weather. The costs for these building types vary immensely. If you’re only building a small shed to store garden equipment, you’re better off purchasing sheet metal from a local home improvement store.

However, if you have plans for custom construction, you may need to hire a nearby metal fabrication service to transform raw materials to your exact specifications. This is a more expensive endeavor as you have to pay for both material and production costs. But it’s also the only way to achieve the exact look you want.

Sheet Metal Fabrication Cost Factors

When planning a project that involves sheet metal, you can determine how much you'll pay by considering material costs, custom fabrication, and installation.

Material

Metal siding made from steel generally runs $4 to $8 per square foot, while aluminum ornamental fencing costs $15 to $40 per square foot on average. The cost of raw materials plays a big part in what you’ll pay for the project completion. Determining how much materials cost depends largely on the type of material and at what stage of the manufacturing process you purchase it.

For example, 1 ton of raw steel generally costs about $400. This may seem quite reasonable, but remember, this is the cost for just the raw material—you still have to pay to have it fabricated into something useful, like siding, roofing, or fence panels. Other material choices include aluminum, copper, tin, titanium, and zinc.

If you have a smaller project or don’t require custom fabrication, you’ll pay a lot less if you purchase materials that have already been fabricated. You can buy them online or at a local home improvement store. As far as pricing, it depends on what you want to do.

Design

Design costs range widely. You can pay anywhere between $50 and $200 per hour for a sheet metal designer’s services.

Production

It’s very hard to estimate production costs because there are many variables. However, one rule of thumb is the cost of metal fabrication is generally three times the cost of the raw material. This means if you purchase 1 ton of raw material for $500, you might pay about $1,500 to take it from metal block to customized fence panel, roofing shingle, or screen. There are many different manufacturing processes it may involve, from slicing and shaping to bending and finishing.

Installation

Depending on your location and the project scope, expect to pay a nearby handyperson $65 to $125 per hour to repair metal screening if you supply all the necessary materials. Your particular project depends on the professional you'll contact and how much you'll pay for their services.

Sheet metal is generally heavy and unwieldy, making it difficult and outright dangerous to work with sometimes. For this reason, it's highly recommended you hire a professional to provide installation services. Depending on the project, you may need additional help to customize your sheet metal, such as a local welder.

For larger projects, you may need to contact roofers, siding professionals, or general contractors.

How to Get an Accurate Sheet Metal Fabrication Quote

Receiving an accurate quote relies on you submitting all relevant details to your pro well in advance. Be sure to include:

• Your part’s shape, specific angles, and intended use

• Up-to-date drawing/models—the more detail, the better

• Any specific concerns or considerations your metal fabrication company should know

No matter your needs, it’s always best to reach out to at least three professionals before choosing whom to go with. 

Cost to Fabricate Sheet Metal Yourself

Taking metal from its raw state to something you can use to build or make repairs with isn’t a simple process. It requires serious planning and heavy machinery to cut and shape metal into pieces, strips, or panels you can use to build a fence, install a roof, or construct a building.

There’s no way for the average consumer to do this on their own, so your choices are to purchase prefabricated metal from a hardware store or pay an experienced metal fabricator to shape metal to your exact specifications.

DIY vs. Hire a Sheet Metal Fabrication Pro

Once you’ve got the sheet metal in hand, you might consider completing the rest of the project yourself to save some money. This might be a viable strategy for small jobs, like installing a door or replacing a shed panel. But it’s not a good idea for larger projects, mostly because metal is heavy and hard to lift or move, with sharp edges that can cause serious injury if mishandled.

For most projects involving fabricated metal, it’s a safer decision to hire a professional to handle the installation.