\nGENERAL CONTRACTOR:<\/b> Consigli Construction Co. Inc.<\/a>, Portland, Maine
\nARCHITECT:<\/b> LEO A DALY<\/a>, Minneapolis
\nENGINEER:<\/b> Becker Structural Engineers<\/a>, Portland<\/p>\n
![\"To](\"\/wp-content\/uploads\/2015\/11\/nov-dec-maine-dome-1-photo-200x300.png\")
<\/a>To remain proportional with the larger building, a new, higher copper-covered dome was built to replace the original cupola.<\/p><\/div>\n
Roof Materials<\/h4>\n
Working 200 feet in the air on elaborate staging, carpenters, coppersmiths, engineers and other construction workers replaced more than 7,000 square feet of copper on the dome. The existing unique, curved copper components were carefully removed and saved to serve as models for the new components.<\/p>\n
A full sheet-metal shop, consisting of an 8-foot brake, 52-inch jump shear and benches, was set up onsite at the 63-foot elevation mark, along with five cases of 20-ounce copper (about 12,880 pounds). Each copper component was carefully measured, cut and bent onsite, and then installed.<\/p>\n
The compound curving components were made in The Heritage Co.\u2019s \u201chome\u201d shop, using a shrinker\/stretcher machine and an English wheel. Then, the copper was handformed over custom-made wood forms. Care was taken to exactly match the size and configuration of the existing components, as well as the seam layouts that were prevalent in the original copper work<\/p>\n
Approximately 15 to 18 percent of the copper was waste because of the curved nature of many of the components. The waste was made into copper clip stock for the roof installation or recycled.<\/p>\n
COPPER MANUFACTURER:<\/b> Revere Copper Products Inc.<\/a> The Maine State House was originally designed by renowned architect Charles Bulfinch in 1832. The dome was added in 1910 as part of a major remodeling and expansion project that ultimately created the building\u2019s current appearance based on designs by G. Henri Desmond.<\/p>\n The original fa\u00e7ade was preserved during remodeling, though the length of the building was doubled to 300 feet by extending the north and south wings. To remain proportional with the larger building, a new, higher copper-covered dome was built to replace the original cupola. The new dome rises to a height of 185 feet and is topped by a gold-clad copper statue, called \u201cLady Wisdom\u201d, designed by W. Clark Noble.<\/p>\n Over time, weather damage and holes caused by hail strikes on the top of the dome caused leaks in the building. The seams between the copper sheets also caused problems for the underlying steel and concrete structure of the dome. The work included the installation of expansion joints, repairs to prevent water infiltration and restoration of the cupola (located between the top of the dome and Lady Wisdom), using a highly durable paint system. Lighting upgrades, copper repairs and the restoration of the gilded Lady Wisdom statue located atop the dome were also part of the project.<\/p>\n The dome\u2019s structural system and framing were analyzed by Becker Structural Engineering one year in advance of dome construction, so Consigli Construction could create a 3-D model for staging to eliminate interior shoring.<\/p>\n Overall, this project restored one of Maine\u2019s most significant historic landmark buildings, returning its signature copper dome and gilded Lady Wisdom sculpture to their original intended conditions.<\/p>\n PHOTO:<\/b> Consigli Construction Co. Inc.<\/p>\n <\/p>\n SHEET-METAL CONTRACTOR:<\/b> Gilbert & Becker Co. Inc.<\/a>, Dorchester, Mass. The museum roofing project was a massive undertaking, requiring the duplication of the existing copper roof\u2014the bulk of which consisted of copper panels with vertical batten seams and horizontal flat seams.<\/p><\/div>\n The thickness of the copper panels, fasteners for the copper and wood battens, and the clip thickness and spacing were all factors that had to be engineered. Most of the new roofing material is 20-ounce copper. There are nearly 10,000 panels with an exposure of approximately 12 by 42 inches, matching the existing historical layout.<\/p>\n Because of the roof\u2019s low slope, horizontal hook strips needed to be fully soldered to each panel with significant headlap. Altogether, Consigli Construction soldered nearly 6.6 miles of hook strip. Counting the hidden hook strips, headlap, locked seams and batten caps, more than 70,000 square feet of copper was used to cover the 34,000-square-foot roof area.<\/p>\n Not only was the installation demanding in the field, but fabrication of the 10,000 panels in the shop was also a challenge. Consigli Construction took standard sheet-metal brakes, notchers and shears and customized them for this job. Each machine performed one function, and the company created an assembly line of cutting, notching, folding, bending and soldering that moved at a quick enough pace to keep up with the crew of 18 installers at the job site.<\/p>\n In addition to the panels, the contractor installed all-new replicated gutters, downspouts, parapets, chimneys and ventilators for a complete roof system.<\/p>\n COPPER MANUFACTURER:<\/b> Revere Copper Products Inc.<\/a><\/p>\n The museum roofing project was a massive undertaking, requiring the duplication of the existing copper roof\u2014the bulk of which consisted of copper panels with vertical batten seams and horizontal flat seams. The new roof system had to also meet requirements set by FM Approvals, Norwood, Mass.<\/p>\n PHOTO:<\/b> Alex Alpert<\/p>\n <\/p>\n SHEET-METAL CONTRACTOR:<\/b> Gotham Metalworks<\/a>, Long Island City, N.Y. During the design phase, it was decided the most cost-effective and durable replacement would be ornamental-formed copper, specifically because of its malleability, which would allow the existing wood millwork to be easily replicated.<\/p><\/div>\n Unable to add any weight to the masonry walls, the new cornice and gutter system was designed to be supported by the building\u2019s heavy-timber roof trusses, thus avoiding any tension or compression stresses in the brick masonry. The old cantilevered wood joists were replaced with 7- by 3-inch rectangular steel tubes spaced 3 feet, 8 inches; projecting 2 feet from the outside face of the walls; and placed at the underside of the continuous cornice gutter.<\/p>\n Once the new steel cantilever support structure was designed and installed, fabrication of the new copper gutters and cornice began. This process involved careful documentation, detailed preparation and extensive shop drawings to replicate the original cornice, including its dentils, brackets and fascia elements. Approximately 1,000 sheets of Revere Red Copper were utilized to manufacture the 44 decorative replica brackets, 308 large modillions and extensive cornices with hundreds of dentils. Twenty ounce hard-rolled sheets were used for the cornice panels, fascias and formed trim; 16-ounce hard-rolled sheets were used for the fabrication of smaller items where more malleability was required; and 16-ounce soft copper was used for the stamped fluted faces of the decorative brackets.<\/p>\n Castings and dies were made from the original wood decorative brackets, and fluted bracket faces were stamped in copper to match. The decorative fleur de lis detail, which was cut into the face of the brackets, was utilized to create matching snow guards on sloping copper roof areas where needed. Every attempt was made to eliminate or reduce exposed fasteners to ensure an attractive installation. In addition to aesthetics, extensive attention was given to the proper handling of expansion and contraction of the copper. Overlapping copper components were designed with slots and notches to allow normal movement. New gutters were designed with joints for expansion; a raised copper baffle was installed to keep them from overflowing; and new copper leaders were fitted to prevent electrolytic reactions.<\/p>\n A unique challenge was presented at the west stair tower, where the original crowning mansard roof\u2014rising approximately 12 feet above the cornice\u2014had been removed in the 1940s; the cornice was replaced by a reinforced stucco fascia. The team decided to fully reconstruct this cornice in copper to closely match its original features. Photos of the original school were carefully studied, and a replica of the original wood cornice was recreated in copper, including matching frieze panel, moulding and 36 copper modillions.<\/p>\n The project also included removal and reroofing of the slate mansard roofs and restoration of damaged brick and stonemasonry. For the roofs, all slates were replaced with new and reinstalled slate tiles, replicating the original pattern. The adjoining copper step flashing, trim boards and copper ridge were also replaced. Old photos showed there were copper roofs above the mansards, which had been previously replaced with flat roofs. This project reconstructed the original copper pyramidal roofs at the corners. Flat-seam and standing-seam copper roof panels were utilized to achieve this, along with copper fascia trim to recreate the original wood-trim panels.<\/p>\n COPPER MANUFACTURER:<\/b> Revere Copper Products Inc.<\/a><\/p>\n NYC Public School 39, founded in 1877, is one of the nation\u2019s oldest schools in continuous use. Because of the careful and effective exterior rehabilitation of this building, highlighted by the replacement of the historic cornice in new copper, it will continue to serve future generations of students.<\/p>\n The NYC School Construction Authority assigned this project to Ivan Brice Architecture, which completed all phases of design and construction. Initially approached as a simple remediation project to address water infiltration, survey work indicated the long-term effects of weathering, along with previous piece-meal repair projects, led to severe deterioration of the original wood cornice and a compromised building envelope.<\/p>\n During the design phase, it was decided the most cost-effective and durable replacement would be ornamental-formed copper, specifically because of its malleability, which would allow the existing wood millwork to be easily replicated. As a landmark building, all design and fabrication decisions were subject to approval by New York\u2019s State Historic Preservation Office. The character of this landmark school has been preserved and, with its new copper crown, has renewed its place as a continued source of pride in the Brooklyn community.<\/p>\n PHOTO:<\/b> Ivan Brice<\/p>\n <\/p>\n GENERAL CONTRACTOR:<\/b> Gibson\/Magerfield Corp.<\/a>, Charlottesville, Va.<\/p>\n Gibson\/Magerfield removed the existing roof system and then replaced damaged sheathing and mouldings, as well as re-framed damaged built-in gutter areas.<\/p><\/div>\n Gibson\/Magerfield removed the existing roof system and then replaced damaged sheathing and mouldings, as well as re-framed damaged built-in gutter areas. The team fabricated and installed 20-ounce Freedom Gray built-in gutter, as well as 16-ounce Freedom Gray standing-seam roof panels. The panels were fabricated from a 20-inch coil. Freedom Gray was selected because it closely matched the color of the existing painted tin (terne) roof but does not need to be painted.<\/p>\n The flat roofs were covered with 90-mil EPDM.<\/p>\n GUTTER AND STANDING-SEAM ROOF MANUFACTURER:<\/b> N.B. Handy<\/a> This small plantation house was designed by Thomas Jefferson and built in 1793 for James Madison\u2019s brother William Madison. William was a member of the Virginia House of Delegates for seven consecutive terms. In 1870, the property was purchased by Robert String fellow Walker who founded Woodberry Forest School in 1889. The house was renamed The Residence and became the headmaster\u2019s house.<\/p>\n PHOTO:<\/b> N. B. Handy<\/p>\n <\/p>\n RESTORATION CONTRACTOR:<\/b> Jim Filipowicz & Associates<\/a>, San Antonio<\/p>\n
\nCOPPER SUPPLIER:<\/b> Beacon Sales Co.<\/a><\/p>\nRoof Report<\/h4>\n
Museum of Comparative Zoology, Harvard University, Cambridge, Mass.<\/h3>\n
Team<\/h4>\n
\nARCHITECT:<\/b> Perry and Radford Architects<\/a>, Cambridge
\nGENERAL CONTRACTOR:<\/b> Consigli Construction Co. Inc.<\/a>, Milford, Mass.<\/p>\n![\"The](\"\/wp-content\/uploads\/2015\/11\/nov-dec-museum-zoology-2-photo-300x62.png\")
<\/a>Roof Materials<\/h4>\n
Roof Report<\/h4>\n
NYC Public School 39, Brooklyn<\/h3>\n
Team<\/h4>\n
\nARCHITECT:<\/b> Ivan Brice Architecture, New York<\/p>\n![\"During](\"\/wp-content\/uploads\/2015\/11\/nov-dec-public-school-3-photo-300x221.png\")
<\/a>Roof Materials<\/h4>\n
Roof Report<\/h4>\n
The Residence, Woodberry Forest School, Woodberry Forest, Va.<\/h3>\n
Team<\/h4>\n
![\"Gibson\/Magerfield](\"\/wp-content\/uploads\/2015\/11\/nov-dec-residence-4-photo-300x200.png\")
<\/a>Roof Materials<\/h4>\n
\nEPDM MANUFACTURER:<\/b> Carlisle Syntec<\/a><\/p>\nRoof Report<\/h4>\n
Emmanuel Episcopal Church, San Angelo, Texas<\/h3>\n
Team<\/h4>\n
![\"The](\"\/wp-content\/uploads\/2015\/11\/nov-dec-church-5-photo-300x225.png\")
<\/a>