Thursday, May 28, 2009

Copper Dome Building

Today's blog will take a simplified look at custom copper dome construction. Copper domes are typically constructed with the surface consisting of some variety of either copper tile or copper panels. For this example we will be using copper tile for our custom copper dome roof. Copper roof tile can be purchased from a manufacturer and in this particular case we will be using hand-made copper tile, hand-cut from copper sheets. Diamond shaped hand made, hand cut, interlocking copper tile are shown below - there are approximately 136 copper tile per square (100 sq ft).

copper tile hand cut diamond shape
For the framework we will be using aluminum tubing, plywood sheathing and waterproof membrane. We begin by precisely cutting square aluminum tubing to size and bending the tubes using a roll forming machine to form the base and the many vertical support cross members. Partially completed aluminum frame shown below.
copper dome frame is made from square aluminum tubing
After all the aluminum framing tubes have been fully welded together, we then cut plywood sheathing panels to size, to fit precisely between the aluminum cross members and stretch from base to top. We affix them to the aluminum vertical support framework. See the partially completed plywood sheathing work shown below.

copper dome gets plywood sheathing attached to framework

After all the plywood sheathing panels have been securely fastened in place with self-tapping screws, we then apply to the partially completed dome a self-sealing waterproof membrane, taking care to completely seal the dome. After the membrane is in place, we draw guidelines and begin carefully attaching the hand-cut copper tile to the dome and to each other. The copper tile have been designed to interlock securely with each other and we use copper ring shank nails to fasten them to the plywood.
copper tile placement is meticulous


copper dome project moving right along

Copper dome nearly completed
Now this copper dome project is nearly completed as we attach the last of the copper tile to the very top of the copper dome roof. When all the copper tile have finally been attached, we are ready to crown the top of the copper dome with a copper finial. Copper finials come in a multitude of shapes, sizes and designs. They can be simple like the first photo below or more elaborate as in the 2nd picture below.

Copper tile roof with copper finial ball
Copper Tile Dome with Copper Ball Finial

Copper Dome with copper finial pineapple
Standing Seam Copper Panels With Copper Finial Pineapple

Although this project may have been over simplified here, it was actually extremely labor intensive, benefiting from knowledgeable construction and metal fabrication expertise. Copper dome construction is very precise work and it can be very exacting just keeping each copper tile perfectly lined up straight and in perfect alignment with each other. All pictures which are provided herein and this copper dome project very beautifully accomplished by the skilled team at Rutland Copper Gutter Supply. Rutland's skilled artisans and coppersmiths craft virtually every type of Architectural Copper Work for a eco-friendly green copper building.

Friday, May 22, 2009

Leader Head - Church Restoration Project

This custom copper leader head (leader heads are also known as conductor heads, hopper heads, rain collector boxes) shown in video below is an exact recreation of cast iron leader heads that adorned a church in England for centuries. Rutland Gutter Supply specializes in high quality custom architectural copper work and copper gutter systems. There are over sixty-five different leader head designs now in Rutland's growing collection. View some of these custom copper leader heads and other custom copperwork, such as copper domes, copper cupolas, copper finials, copper chimney caps, copper spires, copper gutters, etc at Rutland Gutter Supply & Architectural Copper Work. Leader heads are mounted inline on the downspouts being fed from a building's gutters. Leader heads mix air in with the water flowing down through the downspouts, eliminating the back pressure or vacuum. See picture below of an installed copper leader head and copper guttering.


copper guttering

Custom leader heads are typically manufactured from pure copper, zinc, mill finish aluminum or lead coated copper on the finest commercial and residential gutter systems. Copper guttering and copper leader heads particularly, can last 80-100 years, require little to no maintenance, are aesthetically pleasing, they can be recycled nearly 100% and contribute to green building objectives. Leader heads add both a decorative (as seen in picture) and functional touch. Watch video below of a custom leader head that has been recreated from a centuries old one.



 



Sunday, May 3, 2009

Copper Effective At Stopping Spread of Germs, Microbes, Pathogens

The need to prevent the spread of germs has always been a major concern. Research indicates that a copper surface is more effective at preventing the spread of germs than stainless steel. Copper has a 2000 year history of antimicrobial applications in a multitude of cultures. More recent research has sought to determine uncoated copper's effectiveness in stemming the proliferation of infectious disease. At the University of Southampton in the U.K. research studies have shown that many common disease causing microbes such as  E. coli, Aspergillus niger (black mold) and Influenza A, die within hours on copper surfaces. The Influenza A family of viruses includes the problematic Avian flu and swine flu strains and copper can help contain outbreak of these flus. Even deadly antibiotic resistant bacteria associated with infections such as MRSA (Methicillin Resistant Staphylococcus Aureus) die within 1.5 hours on pure copper surfaces. On stainless steel and plastics, typically used for food-processing hardware, pathogens survived unabated for days, sometimes for more than 30 days.

There is enough solid evidence to put man’s oldest metal, copper, to work throughout the world to help protect us from infectious disease, including all strains of Influenza A, the "flu". Tested copper alloys, such as brass or bronze also offer increased protection over non-copper containing materials such as stainless steel, painted surfaces, wood and plastics, although not nearly as effective as pure copper surfaces.

Some fairly common and obvious uses in the home for copper products include copper kitchen sinks, bathroom copper sinks, copper bar sinks, food prep sinks, copper basin, copper vanity sinks, copper door knobs, copper handles, copper range hoods, copper planters, copper pot racks, copper bowls, copper sheeting or tiles for countertops & sink backsplashes, copper wall plates & switches, copper light canopies, copper ceiling fans, copper cookware, etc. There are germ killing copper facades available for refrigerators, dishwashers, freezers, ice-makers, ovens and ranges. There are copper-plated kitchen appliances, copper vases, copper sculptures, copper accent pieces, even copper flowers, etc.

For more detailed health information regarding the necessity of copper in the human diet and medicinal purposes, I will heartily recommend starting out with these two excellent articles: Copper and Human Health and Copper in Human Health.

Gutter Hangers - Focus on Gutter Brackets

Rutland Gutter Supply is family owned and operated. Their manufacturing facility is located in beautiful Orlando, Florida. They have over 40 years of experience in the construction and sheet metal fabrication business. Rutland operates some of the most modern CNC machinery available, from computerized roll forming machines to a fully automated 4" round seamless, welded pipe machine. They have many customers globally and have installed copper gutters and architectural copperwork spanning Florida and the Caribbean. Rutland Gutter Supply’s products are marketed and sold throughout the United States, Canada and Internationally.

Rutland’s products can be fabricated in Mill Finish Aluminum, Zinc, Lead Coated Copper, Stainless Steel, Copper, Galvanized Steel and Galvalume. They stock the largest selection of custom gutter supply components including decorative hangers, decorative brackets and pipe straps, flat and radius end caps, box mitres, elbows, rain chains, copper pipe and custom leader heads with copper castings.

Rutland’s latest line of products include fully welded, hand made 48 oz copper custom kitchen hoods, island range hoods, fireplace hoods and copper billiard hoods, most incorporating hand finished designs. Rutland is able to hand craft any view or scene of your choice into them as these are truly custom design hoods. Additional items available for your copper kitchen are copper pot racks, copper bowl, copper sink, copper basin, hammered copper range hoods and copper fireplace hoods. All Rutland's copper hoods and sinks are available as custom copper hammered designs created by artisans who can create the truly personal design touch for your "copper kitchen".

Rutland also fabricates both stock and custom copper chimney caps, copper cupolas, copper stove pipe and roof vents, copper gable vents, copper dormers, copper roof tiles, copper seam roofs, copper dome roofs, copper chimney turbines, copper roof scuppers or rain spouts, copper finials, copper spires, copper steeples, copper balustrades, copper pineapples, copper balls, copper spheres, copper dock lights, copper fish elbow downspouts and copper dragons, etc. Virtually every architectural copper work and metal fabrication has been or can be accomplished by Rutland.


Gutter Hangers, Gutter Hangers, Gutter Hangers . .

Rutland stocks the largest selection of gutter hangers in the country. Rutland offers decorative gutter hangers such as their seahorse, rope, scroll, combo and acanthus gutter hangers available in cast copper and also in powder coated finished or mill finish cast aluminum. They are designed to fit Rutland’s seamless gutters ranging in half round gutter sizes from 5” to 10”. Various size wedges from 1” to 2.5” are available in both cast copper and aluminum to properly align the gutter system to various fascia angles.

Rutland also stocks many different types of stamped and hidden gutter hangers, all available in a wide selection of materials and sizes. Hidden hangers are available for half round, K-style, quarter round and box gutters in a wide variety of sizes and materials including copper, aluminum and stainless steel. Rutland also stocks many roof mounted, rafter tail mounted and fascia mounted gutter hangers for both half round and K-style gutters including copper, aluminum and stainless steel. Many different sizes of these are stocked by Rutland Gutter Supply and scroll design hangers are available for fascia, roof and rafter mounting.

Rutland Gutter Supply’s superior selection of in stock gutter system parts, components or accessories is immense and unmatched in the U.S. Rutland offers next day shipping on most of Rutland’s gutter supplies as virtually all gutter system components are in stock. In addition to having the largest selection of gutter hangers, Rutland has the largest selection of decorative downspout pipe straps, available in cast copper and aluminum, as well as custom and standard pipe straps. Rutland’s selection of leader heads (else known as conductor heads-collector heads-hopper heads) is again the largest in the U.S.A and most of them are in stock and available with or without one of Rutland’s custom decorative castings incorporated. Rutland strives to have the largest selection on hand for same day shipping. Rutland also encourages it’s customers to submit custom requests as Rutland has extensive custom fabrication experience and Rutland’s facilities and operations are conducive to custom metal work.