First Congregational Church - Akron, Ohio

This project addressed the structural integrity, slate roof restoration, restoration of a monitor feature, and repairs to the exterior masonry of First Congregational Church in Akron, Ohio. The 2005 Cleveland Builders Exchange presented craftsmanship awards for the slate and metal restoration of the roof and monitor. The crew responsible for this lengthy restoration were Chris Bailey, Bill Koren, Rick Ladina, Ron Ladina, and John Meffley.

The historical slate roof of this turn of the century church had been replaced with asphalt in the 1970's, at which time much of the decorative copper on the monitor was removed along with the copper ridges and valleys. In addition to handling structural stabilization issues, Durable Restoration restored the original appearance of the roof and monitor to match historic photographs and plans.

Slate restoration

This enormous roof required 150 squares of variegated purple/green slates, measuring 12" by 18".

At the time when the original slate roof was removed, two skylights were closed. One of these skylights, located above a stained glass window at the end of the hip, was reopened and a new assembly was designed and executed, based upon the historic records.

The main portion of roof consists of a pyramid with a monitor intersected by a hip with a lower pitch. Several gables with parapets intersect both the pyramid and the hip roof sections along the perimeter. The slate roof was restored including all the copper valleys and ridges.

Copper restoration

The original crenellated parapet with decorative trim had been removed from the monitor. Durable Restoration's craftsmen reconstructed the crenellation, the copper cornice, architrave, and trim to match the original appearance. This was accomplished by reference to historic photographs.

The window openings of the monitor were restored including the stepped arch copper hoods. New copper clad arched windows were installed. A total of twenty stylized composite columns were fabricated for installation between the window openings. New copper box-gutter liners, valleys, ridges, vented ridges, and finials were fabricated and installed before the new slate was put in place.

Components for the monitor and ridges were handcrafted in the shop and transported to the job site. All other copper work was fabricated on site.

Masonry Restoration

The limestone exterior was in need of restoration as well. Masonry restoration requires that old mortar be removed to a depth which will allow new mortar to adhere securely (per the Secretary of the Interior's restoration standards, this means a depth of 2½ times the width of the joint). Precise formulation of historic lime mortar was done to match the original mortar. Durable Restoration did extensive repointing (i.e. replacement of failing mortar) on the upper portion of the walls. One of the chimneys had to be rebuilt and another repointed. Where stones had spalled, losing some of their exterior surface, undetectable stone patching was accomplished. Spot cleaning of the masonry concentrated on removing atmospheric pollution.

Challenges inherent in the project

The time schedule of this project was affected by the previously scheduled restoration of the church's pipe organ, which was shipped to Canada where the work was accomplished and later reinstalled in the church. The exterior building restoration had to be completed prior to the interior restoration scheduled for completion before the organ could be reinstalled.

As a result, it was necessary to begin working on the roof in September of 2004, and work continued on the roof throughout the northeastern Ohio winter weather. The crew spent some days shoveling snow off the roof for the first three or four hours before they could begin any actual work. Nevertheless, inspired by the historic significance of the project, the crew worked together to ensure that the restoration would go smoothly and everything would be done right.

Another challenge, especially with the tight time schedule, was presented by the sheer size of the building. The job was staged on the south side of the building, so materials had to be brought from that location to every point on the roof. Due to the layout of the structure, there was just one access point on the scaffolding. Just to get materials to where they were needed took additional time.

Unique nature of this project and quality of craftsmanship

The element most unique to this project was the restoration of the monitor and all the copper work that was done. From a state of complete disrepair the roof and its component structures were restored to resemble the historic appearance.

There were many layers of shingles (in some areas as many as eight) to be removed because shingles had been attempted as a solution to roof leaks when the problem was actually the roof flashings. Patchwork repairs done incorrectly over the years were corrected as historic accuracy was reestablished.

What sets this project apart as an example of outstanding craftsmanship is the time and care to make sure everything was done correctly and with respect to the historical accuracy. That sense of caring was shared by the entire crew.

This caring approach to the project can be seen in the metal work on the monitor, box gutters, and flat roofs where flatlock copper was installed. The craftsmen made sure everything was watertight.

On the slated roof surfaces it took a lot of time to lay out the slate in accordance with correct standards. All the slated portions were tied in to protrusions and adjacent materials in the proper, traditional fashion.

Benefit to the customer and community

This building is an historic landmark in the city of Akron. It is on the National Register of Historic Places. The architecture of the building is treasured, not only by its congregation, but also by the entire city of Akron and the county in which it is located. It was fitting that this ornate building, with its 17-inch thick limestone walls and exquisite century-old stained glass, have its slate roof and associated structures restored to their original design and condition.

Throughout the project, Durable Restoration endeavored to cause the least possible impact on the historic building and yet accomplish what needed to be done to restore its functional integrity and historic appearance. The overwhelming positive response of the congregation and the community indicates that this was accomplished.