Copper in Architecture Awards

Waipolu Gallery and Studio
Oahu, HI

New Construction

The fluid presence and beauty afforded by the copper wall and roof cladding of this studio are a perfect compliment to the modern art it reveals.

Located on the island of Oahu in Hawaii, this private gallery and studio offers spectacular views of the Pacific to the south and nearby Diamond Head to the northeast.

Rather than replicate the traditional Hawaiian character of the existing residence, the new building is a sculptural presence whose varied spaces house a modern art collection. A copper clad structure encloses the primary gallery space, its apertures framing views of Diamond Head and the ocean. Orientation on the site and precisely positioned overhangs mitigate the tropical sun. Along the other edge of the steeply sloped site, a bar of concrete, glass and stainless steel defines the linear studio space. Three horizontal trays separate guest quarters, home office and art display and storage.

The building’s two elements are joined by a glass bridge that floats above a limestone staircase linking all three levels. The land’s natural terracing offers each level its own private entry sequence. Following the topography, lava steps accommodates small gatherings and connects the new building to the existing house and garage.

Copper fit into the project when they were looking for a material that would perform well over a long period of time in a corrosive oceanfront environment with little or no maintenance. The unusual shape and slightly bowed walls of the gallery volume needed a cladding material that could express a softer form in contrast to the other, more linear materials in the project.

“Actual malleability of the material was important due to the fact that the installation was occurring at a great distance from the fabrication shop and some shaping in the field was necessary,” said the project architect, Campie Ellis. “We also liked the idea that the building’s coloring would change over time, creating an evolving work or sculpture.”

Additional Key Partners:

• Helber Hastert & Fee (Landscape Architect), Honolulu, HI hhf.com/
• Dewhurst Macfarlane and Partners (Glass Engineering), New York, NY dewmac.com
• WSP Lincolne Scott Inc. (Mechanical Engineering), Honolulu, Hawaii wspgroup.com
• Renfro Design Group, Inc. (Lighting Design), New York, NY renfrodesign.com
• Lighting & Engineering Integrated (Electrical Engineering), Honolulu, HI
• Pacific AquaGroup (Pool Consultants), Kapolei, Hawaii pacificaquagroup.com
• Ryan Associates (General Contractor), San Francisco, CA ryanassociates.com

Architect

Bohlin Cywinski Jackson
Seattle, WA

Associate Architect

Garduque Architects
Honolulu, HI

Structural Engineer

PCS Structural Solutions
Seattle, WA

Civil Engineering

SSFM International, Inc.
Hilo, HI

Geotechnical Engineering

Masa Fujioka & Associates
Aiea, HI

Copper Manufacturer and Installer

A. Zahner Co.
Kansas City, MO
A. Zahner Co.

Mark Olsen Project
Holladay, UT

New Construction

Exquisite craftsmanship in copper roofing and architectural elements brings European charm and quiet elegance to this stately home.

This 10,000 sq. foot home located in a prestigious suburb of Salt Lake City, Utah, features diamond-shaped copper shingle roofing, along with a variety of other hand-crafted copper products from Copper Exclusive and its founder Erno Ovari. Outstanding craftsmanship and exquisite detailing combined with the naturally weathered look of the copper elements exude quiet elegance and reflect quality construction.

Among the impressive array of custom copper products designed, hand-made and installed by Copper Exclusive were:

• 6,000 diamond-shaped, interlocking copper shingles in 16 oz. copper installed on a 24:12 pitched roof.
• Crown molding, soffit and fascia.
• A gutter solution for very high difficulty roof-eave applications, including ornamental downspouts.
• Double-locked standing seam roofing at the eave as a subsurface for the snow guard system.
• 700 snow hooks for the copper shingle roof.
• A German double-pipe snow guard system.
• Over 1,000’ of inside and outside parapet molding with welded corners, hidden hold-downs and hidden fasteners.
• Over 900’ of 48” width parapet roofs with hidden fasteners and hidden expansion joints.
• Specially-designed copper finials for the parapets.
• A 3:12 pitched upper roof, with 6 skylights, using a double-locked standing seam system.
• 240’ of designed ridge ventilation.
• Chimney crown with stainless steel square-tube subsurface.

In total, 16,000 lbs. of hand-crafted copper products were used on the home. By employing time-tested craftsmanship and installation techniques, Copper Exclusive did not use any sealants or any soldering on the roof — aside from soldering the rain gutter.

Sheet Metal Contractor

Copper Exclusive
Midvale, UT

Architect

Mark Christian Design
Holladay, UT

4143 Buena Vista Project
Dallas, TX

New Construction

The natural aging of corrugated copper wall cladding assures these townhomes look at home on the Katy Trail.

The Buena Vista Townhomes are located on a 90' x 140' lot near downtown Dallas Texas adjacent to the Katy Trail, a converted railroad track that is now a popular urban hike and bike trail connecting downtown to Southern Methodist University.

The project consists of five units, three levels each. Three of the units face the trail to maximize their exposure; the other two are free-standing units with roof decks and views of downtown. The materials were all direct responses to the environment of the trail, vertical corrugated copper, milsap stone (used in earlier WPA projects along the trail) and IPE wood screens to lend privacy.  The idea was to let the project try to enmesh itself into the world of the trail, and the materials to naturally change over time.

With copper’s ability to patina over time, it lends itself perfectly to help with the natural look with the trails.

Architect

Ron Wommack Architect
Dallas, TX

Sheet Metal Contractor

Beach Street Metal
Dallas, TX

General Contractor

Steve McCombs
Dallas, TX

Cathedral of St. John the Baptist
Charleston, SC

Restoration

A neo-gothic copper spire adds stunning beauty and completes the design intent of this restored cathedral nearly 150 years in the waiting.

In 1861, the entire Cathedral of St. John the Baptist was destroyed in a fire that devastated much of Charleston, South Carolina.  Since that time, parishioners saved and worked to restore their beloved cathedral.  Though a Neo-Gothic style spire was always planned, it wasn’t until March 8, 2010 that that dream became realized.

The parishioners could have chosen to put up something quick and inexpensive that looked passable from the ground, but instead they waited spire-less for well over a century for a permanent art piece. They selected their general contractor and architects with great care. Glenn Keyes Architects has long been known for their prowess in historic restoration designs. Jimmy Hightower, president of 50-year-old Hightower Construction, faced with numerous engineering obstacles such as the old construction of the existing building coupled with seismically active and hurricane-prone Charleston, developed a radically new and ingenious solution for the tower.

The towers would not be made of brownstone, they would be covered in a stone veneer. And the copper for the ornate spire would clad a cold mold; a process Jimmy used in his fine boat crafting company, Hightower Boatworks.  When asked what his Plan B was, he replied, “I have no plan B.” Through his efforts, Jimmy found German master and brand-new American immigrant, Erno Ovari, of Copper Exclusive.  Ovari was easily among the most skilled, experienced and knowledgeable in his field throughout Europe and was able to effectively aid the team to the solutions they sought.   Such began a historic collaboration of artists and innovators who crafted, designed and engineered a true work of art that forever enhanced the historic Charleston skyline.

Copper Exclusive created the ornate cold-mold clad copper archways, torch finials, and gilded copper cross.  The copper sheet covers a stainless steel substructure which acts as a stabilizer, a lifting tool (the loop at the top was used to lift the cross and the spire), and it also serves as a lightning rod. Twenty ounce copper was primarily used throughout the project.  Two hundred square feet of gold leaf was used to cover the copper cross.

The cathedral’s gleaming spire is easily recognized all the way from Sullivan’s Island.  The gold will last for at minimum 40 years without touch-ups, and the copper work will remain beautiful for generations.

Sheet Metal Contractor

Copper Exclusive
Midvale, UT

Architect

Glenn Keyes Architects
Charleston, SC

General Contractor

Hightower Construction
Charleston, SC
Hightower Construction

Marcus Nanotechnology Research Center Building, Georgia Institute of Technology
Atlanta, GA

New Construction

A perforated copper panel screen around three sides of this hall of technological learning and development bring thermal control, aesthetic beauty, and sustainability into a unified context with the campus and surrounding landscape.

The Marcus Nanotechnology Research Center Building is among the nation's leading nanotechnology research centers and one of the largest cleanroom facilities in the southeast.  Located in Atlanta, GA, it is the first such facility designed to provide significant space for the application of nanoscience to biotechnology research, particularly in the fields of health care, green energy development and personal technology. The client, a large technological university, envisioned the building as an important campus landmark.

The $70 million project accommodates a program of 190,000 gross square feet, including 30,000 square feet of cleanroom floor space for organic and inorganic research, and about three times that amount in support space, such as flexible lab space, office and conference facilities, and central public area for circulation and social activities. The architects transcended rigorous technical requirements to achieve a humanistic, campus-oriented building reflecting the excitement of cutting-edge research.

A 22,000-square-foot, perforated copper panel screen wall encloses the cleanroom block's central mass and peripheral support areas. The copper screen wall is the primary visual expression of the cleanroom block, making it a unified architectural whole that befits the building's central campus location. Copper was selected for its sustainable, naturally weathering, low-maintenance and aesthetically pleasing qualities.

The copper panel screen wall harmonizes with the building's architectural elements, as well as the adjacent landscape and campus context. Perforated to varying degrees around the building, the copper screen wall permits varied daylight penetration and airflow, depending on localized visual and ventilation requirements. The copper screen wall provides a shading element to improve thermal performance, while acting as an additional sun reflector on the south elevation. At night, the copper screen wall is backlit, accentuating this remarkable architectural feature.

Despite the center's energy-intensive research activities, the architects designed the building to meet LEED certification requirements. Extensive passive solar control, sophisticated mechanical systems, rainwater harvesting and other cutting edge building elements all lower the buildings environmental footprint while external plug-in charging for the University’s fleet of zero-emission vehicles extends the buildings environmental benefit beyond the building space.

Additional Key Partners

• Georgia Institute of Technology Owner/Developer, Atlanta, GA gatech.edu
• Clough Harbour & Associates LLP (Structural/Civil Engineer), Atlanta, GA chacompanies.com
• M+W Group (Mechanical/Electrical Engineer), Chicago, IL 60661 usa.mwgroup.net
• Research Facilities Design (RFD) (Laboratory Planner), San Diego, CA rfd.com
• EDAW, Inc. (AECOM) (Landscape Architect), Atlanta, GA aecom.com
• Fisher Marantz Stone (Lighting Design), New York, NY fmsp.com

Design Architect

Bohlin Cywinski Jackson
Philadelphia, PA

Architect of Record

M+W Group
Chicago, IL

General Contractor

Whiting-Turner Company
Atlanta, GA

Copper Manufacturer

Luvata Buffalo, Inc.
Buffalo, NY

Sheet Metal Contractor

LinEl Signature
Mooresville, IN

Benning Library
Washington, DC

New Construction

Copper’s warm glow helps ignite the spark of learning in this flexible community library.

The Benning Library is the first in a series of new libraries in Washington D.C. that are designed to be flexible and open, to meet the needs of the community now and in the future. Benning Library is terraced into a sloped site along Benning Road, N.E.

The two floors of the 22,000 square foot, $12 million facility are connected by a public stair inside the building, creating a space which encourages pedestrian circulation through the library in order to connect one street elevation to another. Benning Library utilizes a warm color palette of earth tones and a copper panel facade to complement its residential setting. The completed facility includes community spaces on the lower level including a 100-person multipurpose room, two 12-person conference rooms and a public gathering and exhibition space. The upper level of the library houses the library’s collection, which on opening day will include 40,000 books, DVDs, CDs and other library materials. The library has space to allow the collection to expand to up to 80,000 items. Additionally, the upper level features separate reading areas for adults, teens and children, as well as the children’s program area.

The library is situated in a bowl-like condition with ample southern exposure. Approximately 315 copper panels chosen for the exterior reflect the sun and provide a warm glow in the late afternoon. The copper is 16 oz. copper arranged in 18” panel widths with 1” standing seams over ¾” plywood sheathing on structural metal studs. The copper clad volumes house the library reading rooms and administrative spaces on the building’s upper level.

Copper was chosen in large part because it is a “green” material, comprised almost entirely of recycled content and will require minimal maintenance.

Architect

Davis Brody Bond Aedas
New York, NY
davisbrody.com

Owner

DC Public Library
Washington, DC

General Contractor

Forrester Construction Company
Rockville, MD

Sheet Metal Contractor

CHU Contracting, Inc.
Chantilly, VA

Private Residence
Edwards, CO

New Construction

Specially patinated copper wall cladding in the form of interlocking copper shingles, and copper roof elements bring lasting protection to this home with a custom hue that ties it to the natural landscape.

Located in Edwards, Colorado in the White River National Forest Mountain Range at an elevation of 8,200 feet, the house is positioned to face a manmade pond with spectacular views of the surrounding Gore Range and New York Mountains. As an interpretation of the prevalent mountain lodge vocabulary, the project is a modernist response to the oversized log cabins that characterize many Colorado resorts.

Two major principles drove the overall design concept: the interpenetration of indoor and outdoor space, and the organization of the building around a central courtyard as an antidote to the overwhelming views. At 12,000 square feet, the house is substantial but feels more modest in scale because the building is arranged around the courtyard as a series of one-story pavilions dedicated to specific functions, with the exception of the three-story tower. Internal circulation is thus organized along the perimeter of the courtyard, the spaces opening directly from the corridor. Interior walls are solid, while exterior walls of floor-to-ceiling glass, shaded by horizontal brises-soleils to protect from excessive solar gain, provide ample natural light and constant views of the landscape. An exterior porch along the north side of the courtyard provides layered views south through the building.

The house is anchored on a stone plinth. A floating stepped wooden dock allows access to the water’s edge from the south-facing terrace. The entrance façade of log-pole siding preserves the privacy of the complex, while the south façade opens to a long terrace, the water steps, and the pond. The main floor houses the guest rooms, kitchen, dining room, living room, library and playroom, while the family’s bedrooms are organized vertically in the tower portion of the house. An outdoor living space between the living room and the library is shaded by a pergola of cedar beams connecting the two, and features a two-sided fireplace. Use of materials includes different types of siding, (i.e., log-pole siding and stacked beetle kill pine wood), and oxidized interlocking copper shingles. The shingles required custom field fabrication of the corner pieces to achieve the “stitching” of the outside corners. Field rock walls reinforce the building’s relationship to the high mountain landscape.

The sloped roofs are sheathed with site-assembled 12-inch-wide standing seam, full-length copper panels installed to align with the centers of the cedar rafters. The roof panels were fabricated from copper coils and upon installation, were hand-sanded and treated with potash to achieve the rich dark patina. Years of experience brought to the project by the copper subcontractor, Plath Construction, provided seamlessly executed installation.

The door jamb and head were similarly sheathed with copper patinated with the same process as was used for the roof. The property’s landscaping is discreet and based entirely on indigenous chaparral vegetation, so as to ground the house in its natural surrounding. A narrow path from the southwest corner of the plinth leads to a slant-roofed gazebo in the pond. A great deal of care was taken to build it with a minimum of disturbance to the site’s natural vegetation and to provide an orientation favorable to passive solar heating. In addition, remotely located solar panels offset the building’s energy consumption. Wall sections are highly insulated and all spaces are cross-ventilated.

Architect

Selldorf Architects
New York, NY

General Contractor

George Shaeffer Construction
Vail, CO

Sheet Metal Contractor

Plath Construction
Eagle, CO

Rose Theatre
Brampton, ON

New Construction

A combination of copper roofing and wall cladding help this performing arts center deliver a stunning visual performance.

Located in the historic downtown centre of Brampton, Ontario, the new Rose Theatre is a welcome addition to that cities arts scene. Designed by architecture firm Page+Steele, the 65,000-square-foot performing arts facility includes an 890-seat theatre and a 2,000-square-foot secondary hall.

The hall was designed in collaboration with acoustical and theatre consultants in order to create a space with superior sound and sight lines. As well, an innovative structural solution was devised to overcome the issues of ground and airborne vibrations compounded by the close proximity of a railway line on its site.

One of the key materials used on the exterior of the structure was a great amount of copper roofing and cladding. The project called for approximately 34,000 lbs. of 16 oz. copper to complete the covering of three roof areas (rotunda, fly tower and the auditorium roofs) plus the walls for the tower and parapet cap flashings in certain locations. The roof system assembly basically consisted of a 16 oz. copper standing seam roof panel on top of a roof shield membrane all fastened to a plywood sheathing backup. All roofs were designed with a hidden copper in laid gutter system as not to be noticeable from the ground level.

The architect had designed the Fly Tower copper wall panel system using a combination standing seam and batten cap profile followed by a boulder accent profile containing 275 mm. x 121mm. copper clad buttress design.

Sheet Metal Contractor

Semple Gooder Roofing Corp.
Toronto, ON

Architect

Page + Steele / IBI Group Architects
Toronto, ON

The Coweta County Courthouse
Newnan, GA

Restoration

Extensive copper work returns J.W. Golucke’s “most ambitious” courthouse project to its former glory.

The Coweta County Courthouse located in Newnan, GA, was built in 1904. The Neoclassical styled courthouse was designed by J. W. Golucke, an architect who specialized in designing county courthouses at the time. Because of the strong vertical projection of the portico and clock dome, the Coweta County Courthouse is considered his “most ambitious” of the 27 Golucke constructed. Lord, Aeck, & Sargent Architecture headed the recent restoration, which began in 2008. Steinrock Roofing & Sheet Metal, Inc. was contracted by Headley Construction Corporation out of Newnan, GA, to restore the exterior walls and ceiling, dome roof, and cupola of the courthouse.

The scope of work on the Coweta County Courthouse began with the removal of the copper skin of the walls, ceiling and roofing. All decorative and structural pieces were replicated and reinstalled using 20 oz. copper.
 
Each piece of roofing and decorative detail was carefully removed, lowered to the main roof initially, and subsequently lowered to the ground for shipping to Steinrock’s sheet metal shop in Louisville, KY. Here, wooden forms were built, and each copper piece was fabricated, assembled, disassembled, and transported back to the jobsite to be reassembled and installed.
 
Significant challenges included the thousands of individual hand-cut pieces that were assembled and installed to replicate the original details. Additionally, we faced the painstaking task of devising an effective cleaning solution to restore the 1,580 feet of copper guttering to an acceptable level of luster. The process involved restoring and repairing the original copper of the main lower perimeter of the building to address the 100+ year accumulation of oxidation, minerals, tar and caulking. These elements were removed with high speed nylon grinders and hand sanding. Loose or missing fasteners were replaced along with any missing pieces. And drip edging was incorporated to correct the staining problems. Lastly a three-step chemical process was employed to return the bright copper to an aged appearance.

Though challenging, the project was an excellent opportunity to further the restoration and preservation of America’s architectural history.

Sheet Metal Contractor

Steinrock Roofing & Sheet Metal
Louisville, KY

Architect

Lord, Aeck & Sargent Architecture
Atlanta, GA

Old City Hall
Toronto, ON

Restoration

Replica bronze gargoyles stand watch over this completely restored Toronto landmark.  Copper roofing and details assure that it will function long into the future.

A restoration phase of Old City Hall in Toronto was completed recently, restoring part of the gem by Architect E. J. Lennox to contemporary standards. Part of the project included the replacement of the copper roof and many of the details that were part of Lennox’s original vision.

Originally the roof was tiled, which was later replaced with copper, because of the lack of maintenance required. The Old City Hall was built in the years just prior to the turn of the century, and it was the result of a competition held in 1884. At first intended as a courthouse, the functions of a city hall were added as the budget ballooned to $2.5 million. For a city of only 150,000 inhabitants, it was a grand statement. Today the building serves as a courthouse, fulfilling its original purpose.

Over the years there have been numerous small programs to repair certain sections of the structure as necessary. They included segments of the steeply sloped copper roof as late as the mid-1980s. In the latest program, an enduring commitment, a decision was made to replace the entire roof area, on the exterior, in the courtyard, and on the clock tower, and to repair the stonework to bring the structure to a uniform state. The task fell to The Ventin Group Architects, a firm well experienced with projects of this nature, having completed the restoration of the Legislature at Queen’s Park, the County of Lennox civic building, and Castle Kilbride in Baden, Ontario. The budget for the project was $35 million. The roof is 20-oz. copper sheet, laid in a batten seam pattern. The roof itself is made up of ½” plywood laid over the existing deck. This is followed by a peel and stick membrane and insulation spaced with wood sleepers. Finally ¾” tongue-and-groove plywood was used and covered with Roofshield, an underlayment system relatively new to North America, but used extensively in Europe with copper and other metal roof systems.

Because of the numerous dormers, snow guards, and other details, including the installation of bronze replicas of four stone gargoyles that had been removed in 1938, the work was time consuming and required special attention and care. It was undertaken by Heather & Little Limited, of Markham, a roofing contractor with extensive experience with copper. Incredibly, Old City Hall was threatened with demolition during the planning for the Eaton Centre. Thanks to groups of concerned citizens, it was saved and today enjoys the designation as a Canadian National Historic Site.

The newly completed restoration will ensure that it continues to function efficiently for many more decades, while fulfilling the role of a Toronto landmark.

Sheet Metal Contractor

Heather & Little Ltd.
Markham, ON

Architect

+VG Architects
Toronto, ON

Rideau Hall
Ottawa, ON

Restoration

A 16,000 square foot, copper batten seam copper roof crowns this historic residence of Canada’s Head of State, as the representative of the Crown in Canada.

Rideau Hall is the official residence and workplace of every governor general since 1867. This heritage site is a national gathering place, where the governor general lives, honors Canadians for their excellence, hosts foreign dignitaries and performs the functions of Canada’s Head of State, as the representative of the Crown in Canada.
 
Rideau Hall is the largest official residence in Canada’s Capital Region and the only one open to the public. The residence houses rooms for state functions, offices and other work spaces, including kitchens, and a greenhouse run by the National Capital Commission (NCC) where plants and flowers are grown for use in all six official residences.
 
Heads of State and royalty stay at Rideau Hall during visits to Ottawa. Most recently, in 2002, Her Majesty Queen Elizabeth II stayed at Rideau Hall, during the Golden Jubilee, commemorating the 50th anniversary of her Accession to the Throne.
 
Demolition consisted of removing existing copper panels, gutters and downspout to existing structure and installing new plywood sheeting, waterproof membrane, insulation and 16,000 square feet of 16 oz. copper batten seam roofing panels, 2,100 square feet of custom copper gutter system and a brass snow fence.
   
Copper was chosen for the project for its durable properties, long-term quality and detailing and to achieve a patina look that cannot be duplicated with other metals. For a location of high significance that required an intervention such as a restoration, material selection had to be first rate.

Sheet Metal Contractor

Flynn Canada Ltd.
Mississauga, ON

Architect

Robertson Martin Architects Inc.
Ottawa, ON

Milwaukee City Hall
Milwaukee, WI

Restoration

Restoration, reproduction and replacement of original copper decorative elements usher this hallmark of German inspiration into its second century of service.

Constructed in 1895, Milwaukee's City Hall, is classified as a late Victorian/German Renaissance Revival.

It is one of the largest city halls in the country with a Common Council Chamber that likewise eclipses in size that of larger cities.
 
Milwaukee City Hall is unique in its architecture. The product of a fierce design competition, City Hall was designed by the German-born “court architect” of Milwaukee, Henry Koch, to reflect the overwhelming influence of German culture on a city that became known as the “Deutsch-Athen” of America. The architect used as his model both German buildings, most notably the Hamburg Rathaus (city hall), and locally significant structures like the nearby Pabst Building (razed in 1980).

To preserve its historical architecture and preserve it for future generations, the city recently completed the restoration of this grand building which began in August 2005. Working with F.J.A. Christiansen Roofing Company of Milwaukee, Heather & Little performed the shop fabrication and reproduction of missing original decorative copper elements all in 24-oz. copper, solid riveted, and fully soldered. The decorative components alone consumed over 6-tons of copper.

Sheet Metal Contractor

Heather & Little Ltd.
Markham, ON

Architect

Engberg Anderson
Milwaukee, WI

Roofing Contractor

F.J.A. Christiansen Roofing Co., Inc.
Milwaukee, WI