Project Profiles: Education Facilities

Maury Hall, U.S. Naval Academy, Annapolis, Md.

TEAM

Roofing Contractor: Wagner Roofing, Hyattsville, Md.
General Contractor: C.E.R. Inc., Baltimore, (410) 247-9096

The project included 34 dormers that feature double-lock standing-seam copper and fascia metal.

The project included 34 dormers that feature double-lock standing-seam copper and fascia metal.

ROOF MATERIALS

Wagner Roofing was awarded the complete replacement of all roof systems. These included an upper double-lock standing-seam copper roof system, a bullnose copper cornice transition, slate mansard, 34 dormers with double-lock standing-seam copper and fascia metal, eight copper hip metal caps and a continuous built-in gutter with decorative copper fascia. Each of the dormers also had a copper window well.

The upper standing-seam roof was removed and replaced with 24-inch-wide, 20-ounce copper coil rollformed into 1-inch-high by 21-inch-wide continuous standing-seam panels that matched the original profile. The eave bullnose, which also served as the mansard flashing, was removed and returned to Wagner Roofing’s shop where it was replicated to match the exact size and profile.

The 34 dormer roofs were replaced with 20-inch-wide, 20-ounce copper coil formed into 1-inch-high by 17-inch- wide continuous standing-seam panels. The decorative ornate fascia of the dormers was carefully removed and Wagner’s skilled craftsmen used it as a template to develop the new two-piece copper cornice to which the roof panels locked. The cheeks and face of the dormers were also re-clad with custom-fabricated 20-ounce copper.

The oversized built-in-gutter at the base of the slate mansard was removed and replaced with a new 20-ounce copper liner custom-formed and soldered onsite. The replacement included a specialty “bull-nosed” drip edge at the base of the slate and an ornate, custom-formed fascia on the exterior of the built-in gutter. The decorative copper fascia included 85 “hubcaps”, 152 “half wheels” and 14 decorative pressed-copper miters. The original hubcap and half-wheel ornaments were broken down and patterns were replicated. Each ornamental piece was hand assembled from a pattern of 14 individual pieces of 20-ounce copper before being installed at their precise original location on the new fascia. The miters were made by six different molds, taken from the original worn pieces, to stamp the design into 20-ounce sheet copper.

In all, more than 43,000 pounds of 20-ounce copper was used on the project.

Copper Manufacturer: Revere Copper Products

ROOF REPORT

Maury Hall was built in 1907 and was designed by Ernest Flagg. Flagg designed many of the buildings at the U.S. Naval Academy, including the Chapel, Bancroft Hall, Mahan Hall, the superintendent’s residence and Sampson Hall. His career was largely influenced by his studies at École des Beaux-Arts, Paris. Examples of Flagg’s Beaux-Arts influence can be found in the decorative copper adorning the built-in gutter on building designs.

Maury Hall currently houses the departments of Weapons and Systems Engineering and Electrical Engineering. The building sits in a courtyard connected to Mahan Hall and across from its design twin, Sampson Hall.

PHOTO: Joe Guido

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A Metal Roof Crowns a Residential New-construction Project

When Charles Callaghan purchased the two vacant lots next to his home in Ponte Vedra Beach, Fla., he thought they would form the perfect location for his family’s dream home. A team comprised of architects, contractors and manufacturers worked together to bring his ideas to life in the form of a new 7,500-square-foot residence. The building’s crowning feature is a metal roof system that was designed to complement the aesthetics of the home and stand up to the harsh oceanfront environment for decades to come.

The roof of the Callaghan residence in Ponte Vedra Beach, Fla., features 12,000 square feet of Petersen Aluminum’s Snap-Clad in Slate Gray.

The roof of the Callaghan
residence in Ponte Vedra
Beach, Fla., features 12,000 square feet of Petersen Aluminum’s Snap-Clad in Slate Gray.

“With the larger lot, we thought we could do something unique to the neighborhood,” Callaghan says. “When we first met with the architect, there were a few keys we wanted to stress. First, we didn’t want a boxy-looking house. We also wanted shingle-style siding and a metal roof. We like the look of the metal roof, we like the durability, and we thought it would be a good way of complementing the shingles on the house.”

At every phase of the project, the team of construction professionals ensured the project was executed with precision, down to the last detail of the metal roof.

THE DESIGN

The house was designed by Jaycox Architects & Associates, Jacksonville, Fla. According to William R. Jaycox, principal, the plan made the backyard pool the home’s focal point. “They wanted to do a casual, shingle-style beach house that wasn’t like everyone else’s house,” Jaycox notes. “We designed the house so it was mostly single-story and spread it out around the pool, which made for an interesting roof design. It’s all in small modules.”

The L-shaped home features a master-bedroom suite on one side while the other side contains the living room, dining room, kitchen, family room and guest bedroom. “This one also has a four-car garage under the main roof, and, because the house wraps continuously around the pool, you get a fun little foyer in the front with a little cupola up above, you get the dormers for the bedrooms in the attic, and the master suite is a little pod unto itself,” Jaycox adds. “The back has a pool pavilion separate from the house. When you put all of those elements together, you get a very interesting structure, and the metal roof was perfect because it accentuates the lines.”

The roof system specified included 12,000 square feet of aluminum panels in the cool-color Slate Gray. “This house is only a few blocks from the ocean, and in those cases we typically use aluminum,” Jaycox says. “We’ve had great success with that system. It’s absolutely bombproof from a corrosion standpoint with stainless fasteners, heavy-gauge aluminum and the Kynar finish.”

Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified.

Thorne Metal Systems installed a high-temperature, self-adhered underlayment beneath the metal roof, as specified.

When applied by a certified installer, the system can qualify for a 20-year Oceanfront Finish Warranty from the manufacturer. In addition, the roof meets all Florida’s tough building-code requirements. The system, consisting of 0.040-gauge aluminum, 16-inch-wide panels with fastening clips spaced at 24-inches on-center, carries a Miami-Dade NOA with a -110 PSF uplift. (The UL 90 uplift is -52.5 PSF.)

THE INSTALLATION

The roofing contractor on the project was Thorne Metal Systems of Middleburg, Fla. Owner Bill Thorne has been installing metal roofs since 1989. He formed his own company 13 years ago, and it has become the go-to metal roof installer for Jaycox Architects
& Associates and the general contractor on the project, C.F. Knight Inc., Jacksonville.

Thorne has a lot of experience installing this particular aluminum roof system. “The system is a very easy system to install,” he says. “It’s very user- friendly. The panels have male and female joints that snap together and are held in place with stainless-steel clips.”

PHOTOS: Petersen Aluminum Corp.

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