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Description of Work:

The scope of work for this project was to remove the old existing copper covered wooden steeple structure down to the masonry base and to replace it with new, along with a major masonry restoration to the building facade. The new steeple was to be a replica of the old except for the utilization of modern structural steel design. Merrick's responsibility was to copper cover all exposed surfaces of the structure from the masonry upward. This included the cross, finial under the cross, surfaces of the spire, the four louvered dormers with ornamentation, the eight pinnacles with finials, and the four pinnacles with crosses. Merrick was also responsible for design and fabrication of the structural requirements for certain components such as the cross, large finial, and the twelve pinnacles.

Materials used:

In the steeple portion of the project, modern materials replaced the normal items used one hundred and fifty years ago. However, Merrick did use 20-ounce cold rolled sheet copper that was probably the same or similar to that used originally whenever the copper was installed. In addition to copper, there were items of treated lumber and plywood, structural steel, roofing felt, rosin paper, stainless steel sheet – shapes – and tubing, along with non-corrosive fasteners throughout.

What types of metal (alloyed or grade) were used on the job?

All copper used was 20 ounce cold rolled copper sheets, produced in America by Hussey. Care was given to insure that all copper used was from the same production lot or heat. This is an attempt to insure that the coloring of the copper will be fairly uniform during its twenty year plus journey toward having a full green patina.

Fabrication:

Design work was accomplished within the Merrick organization. While replication was critical for appearance purposes, a whole new modern method of construction needed to be designed to fulfill the scope of the of the project. The following listing is a representation of the various components required to be fabricated in the Merrick shops on Ralph Avenue in Louisville.

Copper ornamentation for scroll ornaments, small finials, and crockets was furnished to Merrick by the W. F. Norman Corporation of Nevada, Missouri.

Installation:

The steeple base was fully scaffolded on four sides, to a point approximately 150 feet above ground level. This scaffolding accommodated both the steeple replacement and the masonry restoration. Various cranes were used during the course of construction. The largest crane involved had a boom of 330 feet. The spire was built at ground level and hoisted in three sections. The bottom two sections were clad downtown on the job site. The top section measuring 64 feet tall, including the cross and finial, was clad and assembled in the Merrick shop and transported to the job site in one piece. The copper clad tie-ins between sections were accomplished from a man basket from the 330 foot crane.

What makes this job different, challenging, interesting, or special?

When this cathedral structure was built, sometime about 1850, it was the tallest church building on the North American continent. It has been exciting and challenging to play a major role on the team charged with this phase of reconstruction and replication of this historic structure. The top of the cross stands approximately 275 feet above ground level. The combination of the cross and finial stands 25 feet tall and weighs 2.15 tons. The spire portion of the steeple stands 100 feet tall above the masonry base which itself stands 150 feet above ground level. In the ninety six years Merrick has been in business, this is possibly the most prestigious true architectural sheet metal project completed. Merrick, in its fourth generation, specializes in both architectural and industrial sheet metal.

For comments, questions, or more information send electronic mail to: info@merrickind.com

This page was last updated: December 08, 2001