Church of Nativity, Episcopal

Huntsville, AL

Restoration

Sheet Metal Contractor/ Project Consultant & Specifier

Ornametals Manufacturing, LLC
Cullman, AL

Installer

CopperWorks Corp.
Decatur, AL

Photo Credits

Doug Brewster of Brewster Commercial Photography

Having lasted for more than a century and a half with copper, the Church of the Nativity Episcopal was recently refurbished with a new roof and steeple, using 41 tons of copper. Church of the Nativity, Episcopal Project Location: Huntsville, Alabama Dates of Construction: Two phases: (1) Bibb Hall & Ridley Parish Hall (February, 2010, to June, 2010); and (2) Sanctuary & Steeple (January, 2011, to September, 2011).

The Church of the Nativity was designed by Ecclesiological architect Frank Wills and completed in 1859. Designated a National Historic Landmark in 1992, the church consists of three main structures: the Sanctuary, Bibb Hall (added in 1884) and Ridley Parish Hall (added in 1953). Beginning in 2007, the congregation of the Church, together with Noblin Associates, an engineering firm headquartered in Bridgewater, MA, assessed the entire campus to determine recommendations for roof replacement, among other repairs.  After consultation with Ornametals Manufacturing (Guenther Huber), Noblin Associates recommended replacing the existing galvanized stamped shingles on all three structures with copper roofing. An affiliate of Ornametals Manufacturing (CopperWorks Corp.) was engaged as the roofing contractor responsible for the tear-off and prep-work, repair and restoration of the roofs, dormers, and walls on the three main structures, including the 154-foot steeple. Ornametals was responsible for the design and fabrication of the replacement ornaments and rainwater systems, including the fabrication of more than 22,500 custom, hand-fabricated Rauten (interlocking) copper shingles.

The Church of Nativity restoration objectives were: (1) to be faithful to the historic period (Gothic Revival); Architect (Frank Wills) and Twickenham Historic District, Huntsville, Alabama; and (2) obtain the best value considering longevity, maintenance and weather conditions. The Church of the Nativity received a “Save America’s Treasures” grant of $434,216 from the National Park Service and Department of Interior toward the restoration of the project. The total roofing cost exceeded $1,000,000.

Square Footage or Area: Bibb Hall – 4,064 square feet; Ridley Parish Hall – 9,950 square feet; Sanctuary & Steeple – 13,409 square feet Work Hours: 6,977 work hours Principal Features: Sanctuary: 12 custom radius copper window eyebrows (covers); decorative copper fascia covers; rolled copper ridge vent with lightening system; steep slope (16/12) in 16”x16” custom, hand-fabricated Rauten shingles (interlocking tile); flat-seamed copper wall panel system; and double-lock standing seam (short panels) in staggered widths Steeple: 154-foot steeple in 9”x15” “dragon-scale” hand-fabricated Rauten shingles (interlocking tile); double-lock batten seam (1.5”) on each hip; 8 decorative custom copper windows; 4-large (24 ft. high) decorative dormers; custom-made 24-karat gold-plated cross, with ball, topping steeple Ridley Hall: 16” x 16” custom hand-fabricated Rauten tiles; double-lock standing seam; and flat-seamed copper wall cladding system Bibb Hall: 16” x 16” custom hand-fabricated Rauten tiles; stone coping above copper roof fabricated in 0.8 mm VMZinc® KEY PRODUCTS, MATERIAL & SUPPLIERS.

The key material was approximately 82,000 lbs. of copper. The copper was fabricated into more than 22,500 custom hand-fabricated square Rauten shingles (interlocking tiles); 9,500 9”x 15” “dragon-scale” Rauten shingles; double-lock rolled ridge vent; double-lock standing seam panels; wall-cladding; flashings; coping; and decorative fascia, cornice and mouldings. Key Products (in copper unless noted): Rauten shingles (interlocking tile) Custom eyebrows and decorative windows and dormers 24-carat gold-plated cross with sphere EuroGutterUSA rainwater system (half-round gutter, seamless-weld downspout and all accessories) Stone coping fabricated from 0.8 mm VMZinc®.

The key supplier of the custom eyebrows, decorative windows, 24-carat gold-plated cross and the EuroGutterUSA rainwater system was: Ornametals Manufacturing, LLC Amir Massihzadeh, P.E., President 1411 County Road 1311 Cullman, Alabama 35058 (256) 255-0190. The raw material copper supplier was: Hussey Copper c/o Bill Locke 100 Washington Street Leetsdale, Pennsylvania.