Stratus has historically seen its greatest adoption in the plumbing and piping segments of the MEP specialized trades. But this new feature – developed by a sheet metal manufacturer working closely with sheet metal contractor Hermanson Company – marks a clear expansion for the fabrication software and opens new possibilities for automation for sheet metal contractors.

“We used to spend hours creating cut lists by hand, shuffling paper, and trying to nest parts for efficiency,” said Matt Cordova, a project lead at Hermanson who worked closely with Mestek and Stratus to develop the integration. “Now, Stratus handles it all – grouping by diameter, gauge, even color-coding for our material handlers. The operator just hits a button on a Surface tablet, and the machine takes care of the rest.”

A Dashboard for Every Role

The new system is designed with flexibility in mind, offering customizable dashboards that cater to different users – whether they’re on the shop floor or managing logistics. A spiral-machine operator, for example, sees only the essentials: what size duct to run, how many pieces, and which gauge. For project managers, the system displays fabrication status, shipping details, and field installation progress, all linked to project delivery dates that drive the entire workflow.

“When it comes to scheduling, our whole shop runs off those dates,” Cordova explained. “Stratus keeps everyone in sync – from the fabrication line to the folks out in the field.”

Efficiency Gains and Real-Time Traceability

One of the most lauded features is the ability to nest multiple projects and packages automatically, reducing material waste and head changes for the operator. The integration also supports QR-coded labels, which allow anyone – shop worker or field installer – to scan a part and instantly access its specifications, installation location, and status.

“I underestimated how powerful the QR code would be,” Cordova admitted, recalling how a veteran tradesman quickly adopted the scanning feature to find assemblies without relying on paper prints or PC navigation. “It’s a game changer for both the shop and the field – total traceability and zero paperwork.”

A Platform Built for Contractors' Needs

The Stratus integration isn’t just about automation; it’s also about customization. Mestek representatives emphasized that their control and automation teams welcome user feedback, routinely adding new features based on contractor requests. “Every contractor has a different way of sorting, packaging, and running jobs,” said Mike Bailey, Hermanson’s automation manager. “If you need a feature, just ask. We’re building this to be as flexible and future-proof as possible.”

While the Stratus integration is now fully operational for spiral duct machines, extending similar functionality to coil lines – which fabricate rectangular ductwork – remains a significant challenge. Automating data transfer to coil lines is far more complex, and Cordova was candid about the uncertainty: “There’s a lot going on there,” he admitted. For now, the focus remains on spiral machines, and bringing aftermarket integration to Mestek spiral equipment sitting in shops across the country is a top priority for Bailey and his team.

The new system runs wirelessly on basic Wi-Fi, with only one key requirement: assigning a static IP address to the spiral machine. This ensures reliable, one-way communication between Stratus and the equipment, even after a restart. Cordova described the site manager setup as “super simple,” making it accessible for both IT staff and shop personnel.

For an industry long reliant on legacy equipment and labor-intensive processes, the Stratus-Mestek partnership represents a major step toward fully digital, data-driven fabrication – from the BIM model in the office to the duct run in the field.

With the first machines already running in the field and positive feedback rolling in, Mestek’s bet on digital integration looks poised to deliver efficiency, accuracy, and adaptability for contractors nationwide.