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Copper Roofing: the Original Green Roof

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Copper Roofing: the Original Green Roof I S S U E 2/2013 VOLUME 30 NUMBER 2 Journal of architectural technology published by Hoffmann Architects, Inc., specialists in the rehabilitation of building exteriors. Copper Roofing: The Original Green Roof Juan Kuriyama, AIA and William Hayes, Assoc. AIA Copper is a remarkable metal. It is treated to mimic the color, if not quite resistant to corrosion, malleable yet the appearance, of copper, owners not strong and ductile, and ranges in color subject to the dictates of a landmark from bright salmon pink to soft grey- authority may choose to forgo au- green. Highly durable, copper roofs thenticity in favor of expediency. can last 100 years or more with little True, the high initial cost of a new maintenance. No small wonder, then, copper roof may make it impractical, that copper has even undesirable, for many build- been used for ings. Not all structures are intended centuries on some of our to survive through the ages, and it most notewor- makes little sense to cover a building thy civic and designed to last twenty or thirty years institutional with a roof that might last five times buildings as a as long. Where sustainability, durability, distinctive roof- and longevity are priorities, however, ing material. copper emerges as a top contender. In But are copper the modern climate of evolving prod- roofs solely rel- uct types and green design, it can be ics of the past? easy to forget that one of our most environmentally sound options is also Historically, one of our oldest. copper was used widely for Copper in Architecture: A History institutional and public build- Examples of sheet copper roofing in Known for its striking appearance, copper is also a strong environmen- ings. Until the Europe date to medieval times, and tal choice, given its longevity, recyclability, and low embodied energy. development the first discovery of naturally pure of efficient copper can be traced to Neolithic aluminum ore peoples around 8000 B.C. Saint Mary’s extraction in the late 1880s, copper Cathedral at Hildesheim has a cop- had few rivals in building construction. per roof said to date from the 1300s. Today, prefabrication makes alumi- In America, copper mining began num products relatively inexpensive, in earnest in the mid-1700s, with whereas copper roofing, which must copper derived from Maryland and be handcrafted, costs substantially New Jersey and, a century later, from more. Given that aluminum can be Michigan and points west. Juan Kuriyama, AIA, Senior Architect with Hoffmann Architects, has extensive experience designing and overseeing the rehabilitation of copper roofs, cupolas, and decorative elements. Project Manager William Hayes, Assoc. AIA develops copper restoration solutions that balance cost-effectiveness with durability. JOURNAL Decorative Use Embodied Energy and rating systems, including Leadership in Energy and Environmental Design Copper’s malleability permitted its Environmental Impact (LEED), now incorporate life cycle ready adaptation to architectural The “embodied energy” of a material assessment (LCA) data into their ornamentation. Copper finials and refers to the total amount of energy certification scores—and with good weathervanes were popular during consumed during that material’s lifes- reason. LCA is a method of evaluat- the late 1800s, and copper was com- pan, including extraction, processing, monly hammered or stamped into ing a product’s environmental impact manufacture, transport, installation, across its lifespan. decorative details, moldings, friezes, maintenance, and disposal. Compared and embellishments. Perhaps the most with other metals, copper requires a Embodied energy is part of an LCA famous American example of monu- relatively small expenditure of energy calculation, but the assessment also mental copper use dates from 1886: to extract and process. considers reuse and recyclability. Here, the Statue of Liberty Enlightening the too, copper has an advantage over World in New York City. Embodied energy comparisons should other roofing materials: it is recyclable consider the life span of the material. Today, the high cost of copper tends in all forms. Salvaged copper, archi- A single-ply or built-up low-slope roof tectural copper, and the cuttings and to preclude its ornamental use, but might claim to have a lower embod- decorative copper is still used in his- filings produced during finishing can all ied energy than a copper one—that be re-incorporated into new copper toric preservation and conservation is, until material lifecycle is taken into applications. products. Such recycled copper isn’t consideration. With an expected restricted to low-grade materials; in Roofing service life of 100 years or more, a the U.S., architectural copper is made copper roof has four times the lifes- In the years leading up to the primarily from recycled content, with pan of a standard 25-year assembly. American Revolution, sheet copper some products made from as much as Therefore, the embodied energy of a came into general use as a covering 90% recycled material. copper roof should more accurately for ship hulls, which in turn led to its Copper’s impressive lifespan and be compared with that of four 25-year ready availability for roofing appli- nearly infinite recyclability derive from roof assemblies. In these terms, copper cations. Early examples of copper its unique material properties, which emerges as the clear energy champion. roofs include the New York City Hall allow the metal to retain its appear- (1763-1789), Maryland State House in Durability isn’t the only factor that ance, strength, malleability, and corro- Annapolis (1772-1793), Massachusetts makes copper a strong choice, envi- sion resistance for multiple uses across State House in Boston (1795- ronmentally speaking. Green building the centuries. 1798), and the Old Christ Church in Philadelphia, the copper roof of which lasted from its initial construc- tion in the 1830s until 1967, when it was finally replaced. The copper roof over the pediment of the First Bank of the United States in Philadelphia, built between 1795 and 1797, is still intact today, over two centuries later. Given the astounding endurance of historical copper roofs, it’s reasonable to conclude that a well-designed and skillfully installed copper roof is worth the up-front investment. Compare the lifespan of a copper roof with that of a pre-fabricated metal roofing system warrantied for 35 years, or with the even shorter lifespans—and high maintenance demands—of bituminous Beyond roofing, copper is also used for ornamentation. Restoration of this copper eagle atop and synthetic materials. a 1929 high-rise involved off-site and on-site repair, cleaning, and reconstruction. 2 VOLUME 30 NUMBER 2 The Roof Runoff Scare In 2000, the City of Palo Alto, California commissioned a study on the environmental impact of stormwater runoff from copper roofing, which precipitated a city ordinance prohibiting the installation of copper roofs and gutters on both new and existing buildings. A num- ber of other jurisdictions across the country followed suit. copper, now basing its standards on bioavailability, not The study raised a number of questions. How much just concentration. Reducing bioavailable copper – that copper was getting into the environment, and what is, copper that can be absorbed by organisms – has were its effects? Could copper runoff be harmful to since become the aim of environmental watchdog humans? Were copper roofs dangerous? groups and copper industry associations alike. These and similar concerns plagued the copper indus- Research is also currently underway to determine the try. However, research has since emerged that calls into effectiveness of on-site stormwater treatment systems, question the Palo Alto study’s conclusions. One such such as rain gardens, that filter runoff naturally. As run- study appeared in 2008 in the New Zealand Journal of off flows through these systems, free copper ions bind Marine and Freshwater Research, which suggested “an to conduits and organic debris, reducing the bioavail- overestimation of bioavailable copper” in previous re- able copper concentration. Runoff that might have toxic ports, including the Palo Alto study. The authors found levels of copper at the roof downspout may not be that the effective copper concentration in waterways is hazardous once it reaches the watershed. actually less than had been assumed, due to the binding As the results of further research emerge, the copper of free copper ions into nontoxic hydroxide and car- industry, the EPA, and local governments will continue bonate complexes. to revise recommendations for stormwater treatment Recognizing that not all forms of copper in the environ- and copper roofing. For the time being, architects and ment are harmful, the U.S. Environmental Protection engineers will have to stay current with regulations and Agency (EPA) revised its water quality criteria for design accordingly. Uses in Roofing Standing Seam Panels are separated by wood battens, which are covered with copper batten Traditionally, there are three types of Pre-formed or field-formed pans are caps that are loose-locked to adjacent copper roofing, each with its own dis- used to create standing seam cop- pans to accommodate expansion and tinct aesthetic qualities and applicabil- per roofing. One side of each pan is contraction. ity for a given roof condition. formed longer and folded twice over In addition to its use as a roof cladding, Flat Seam the adjacent pan, joining the panels together. These double-locked standing copper is also widely used for roof Unique to copper roofs, flat seam seams run parallel to the roof slope, flashings, gutters, downspouts, and cor- construction is generally reserved for with fixed copper cleats securing the nices, in conjunction with other roof- low-slope roofs or curved surfaces, roofing to the structural deck. ing types and materials. Its resistance such as domes or vaults. Cold-rolled to corrosion and its malleability allow copper sheets are folded over at adja- Batten Seam copper to be readily shaped to ac- cent sides, with copper cleats installed With its characteristic box-shaped commodate intersections, bends, and in the seams.
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