The entire roof, 60,000 sf over the main dome and several smaller domes, will be replaced.
Having recently done a similar copper roof restoration on the Basilica of St. Mary in Minneapolis, McGough Construction of St. Paul was hired as the general contractor for the project. The St. Paul roof is about three times larger than the Basilica's.
"The biggest challenge for us is access -- how do you get up there on that building?" says Tom Nonnemacher, vice president for McGough. "We're using cranes and scaffolding, ladders and lifts, baskets, a whole range of methods."
McGough has installed two 350-foot freestanding cranes that are located 180 degrees apart from each other -- one on the Selby Avenue side and the other on the Dayton Avenue side. Each crane stands higher than the cross, which is mounted at the top of the 306-foot-high cathedral dome and required clearance by the FAA before they could be installed.
The roof is original to the cathedral, completed in 1915. Although no leaking has been visible inside, cracks in the plaster, mortar and stone show evidence of water damage. The copper roof now provides most ofthe protection against the elements because the tile and felt sub-roof is old and worn. It will be replaced with a nine-layer roof and new copper. The renovation also involves tuckpointing, or replacing deteriorated mortar. Although the building's exterior has top priority, plans call for some patching of the cathedral's ceiling.
As the project progresses, more than 100,000 pounds of scaffolding will be used, 80,000 pounds of planking, 170,000 pounds of temporary structural steel, more than 70 tons of copper, and 167,000 sf of stone will be cleaned, according to church officials.
The roof will lose its green patina, at least until the natural aging process turns it that color in a quarter-century or so. Pre-patina copper is more expensive and more difficult to use because it is less pliable, Nonnemacher says.
Another big challenge is raising the money to pay for the work. The estimated project cost of $35 million is well beyond the ability of the cathedral parish to pay for it. Because the cathedral is considered the mother church for Roman Catholics in the Twin Cities, the Archdiocese of St. Paul and Minneapolis is seeking to raise money from the community at large.
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