Photo courtesy of James Myers Co. Inc., Beltsville, Md.
Photo courtesy of James Myers Co. Inc., Beltsville, Md.
Located on about 130 acres of national park land in Fairfax County, Va., is Wolf Trap National Park for the Performing Arts. The concept for a theater in the park began as a donation from Catherine Filene Shouse, who wanted to preserve a former farm from encroaching roads and suburbs.
In 1966, Congress accepted Shouse's gift and authorized Wolf Trap Farm Park, its original name, as the first national park for the performing arts. On Aug. 21, 2002, the park's name was changed to its current one, keeping the area's historical significance and reflecting its mission to create and present excellent, innovative performing arts programs.
Wolf Trap National Park for the Performing Arts organizes and operates several distinct venues and facilities, including the Filene Center. The Filene Center is a major indoor and outdoor performance venue with about 4,000 seats under a copper roof system that look out to tall trees and the park. The remainder of the seating is uncovered on a sloping lawn, where patrons can enjoy picnics while listening to performances nightly from May to September in a range of musical styles from opera to country.
Preparing to perform
The Filene Center's original copper roof system over the primary seating area was installed in 1984 during the entire facility's reconstruction following a devastating fire. The roof has a dramatic configuration of folded planes and structural elements to enhance the acoustical and visual experiences of hosted performances.
The design's complexity presented maintenance and functional difficulties, resulting in water leaks since installation. The leaking roof compromised operations, and after numerous repair attempts, the decision was made to replace the copper roof system. Because of its reputation for high-quality workmanship, James Myers Co. Inc., Beltsville, Md., was selected to replace the venue's copper roof system.
"We were fortunate to have contracted with James Myers to take on the reroofing efforts on such an important venue," says Christopher Eckert, senior director of operations for Wolf Trap Foundation for the Performing Arts. "The company first established strict safety protocols and then proceeded with great care for the installation of every detail and seam."
Opening act
James Myers began its work in December 2011 when the venue was closed for the season and remained on a tight schedule to complete its work on time for the venue's opening in the spring. Working from safety rails and field-fabricated handrails, bridges and walkways, crews of 20 to 27 metal mechanics, laborers and roofing workers began the tear-off process.
The original copper roof system contained large flat-seam soldered pans that had prematurely failed, as well as a mixture of batten-seam and standing-seam copper panels. In most locations, James Myers removed the existing copper panels and underlayment and re-covered the plywood deck with self-adhering Grace Ice & Water Shield.® The James Myers crew only removed the amount of existing roofing material it was certain it could re-cover the same day. In some areas, the plywood deck had deteriorated and required replacement. As part of the project's specifications, the removed copper was recycled.
Main performance
James Myers used Revere Copper Products Inc. coils and sheets consisting of 90 percent recycled copper, per another project specification, to fabricate new pans and flat-seam, standing-seam and batten-seam panels in its in-house shop.
"The most unique part about the job was the architecture of the roof itself," says Alex Zorich, project manager for James Myers. "It called for nearly every conceivable type of metal roofing and flashing."
A heavier copper gauge was used to conform to recommendations from sheet metal organizations and copper manufacturers. Once the materials were on-site, they were installed using traditional hand tools and torch rigs for soldered seams.
Small flat-seam soldered sections replaced the original large flat-seam soldered sections. In several areas, the slope was changed to better shed water. Pure batten-seam sections were used whenever possible, and numerous project-specific features such as new crickets to properly shed water, a new built-in gutter and new shop-fabricated copper vent hoods were incorporated. A new lightning protection system also was installed.
Wardell Hillard Jr., foreman for James Myers, coordinated all on-site activities and worked closely with the owner, design team and subcontractors to resolve scheduling issues and many unforeseen substrate conditions within the framework. As a result, James Myers installed 59,000 pounds of copper and 4,500 pounds of 50/50 solder without a safety violation or serious injury.
Standing ovation
Working seven days per week to ensure it remained on schedule for the venue's opening, in May 2012, James Myers completed its work on the Filene Center. After battling roof leaks for 28 years, performers, musicians and venue patrons no longer need to worry about roof leaks disrupting their evenings in the park.
"[People] may be aware of the infamous derecho that hit the Mid-Atlantic along with many eastern states in late June 2012," Eckert says. "Although it caused extensive damage in the immediate area, including damage to many roofs, there was not a single issue with our new roof."
For its exceptional work to enhance the integrity and aesthetic character of the Filene Center's roof, James Myers received a 2013 NRCA Gold Circle Award in the Outstanding Workmanship: Low-slope category and a 2013 North American Copper in Architecture Award in the Restoration/Renovation category from the Copper Development Association.
"It was a privilege to work on this high-profile venue that attracts thousands of people every year," Zorich says. "It is a shame that one cannot see all the beauty and architectural features of the roof from the ground."
Chrystine Elle Hanus is Professional Roofing's associate editor and NRCA's director of communications.
Project name: Filene Center for the Performing Arts
Project location: Vienna, Va.
Project duration: December 2011-May 2012
Roof system type: Copper
Roofing contractor: James Myers Co. Inc., Beltsville, Md.
Product manufacturers: Grace Construction Products, Cambridge, Mass.; Revere Copper
Products Inc., Rome, N.Y.
Gold Circle Awards category: Outstanding Workmanship: Low-slope
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