nrca gold circle award winner
Our Zook Roof Replacement Project that won the Gold Circle Award for Outstanding Workmanship.
We are deeply honored to have received the prestigious Gold Circle Award for Outstanding Workmanship from the National Roofing Contractors Association (NRCA).
The Gold Circle Awards were presented at this year’s NRCA 2024 Industry Awards Ceremony during the International Roofing Expo® in Las Vegas.
This exclusive accolade is reserved for NRCA members who have made significant and lasting contributions to the roofing industry.
Our Zook Roof Replacement Project, which won the award, was a rewarding challenge that pushed our team to new heights of excellence.
From the unique design elements to the intricate craftsmanship required, this project tested our skills in the best possible way. It’s a project that demanded our expertise and allowed us to showcase the quality and innovation we strive for in every job, much like our other projects around the world, including ones for clients like Sir Richard Branson.
This month, we’re excited to take you behind the scenes of this project and share the details that made it such a proud achievement for our team.
The History of Zook Shingles
When our client entrusted us with the roof restoration of a truly unique, historic home built in 1929 in Silver Lake, Ohio, we were thrilled to take on this rare and challenging project.
European architecture was all the rage back in the 1920s, but the thatch roofing materials, the hallmark of the design, was not readily available in the U.S. A company called Creo-Dipt pioneered an innovative solution to this problem. They developed a method to mimic the appearance of thatch roofs using a specialized roofing system that included steam-bent cedar shingles and a complex framework with to produce a look similar to a thatched roof.
This technique allowed for the softening of eaves, gables, valleys, and hips, effectively capturing the essence of a thatch roof, as detailed in period catalogs like Sweets.
Renowned Chicago architect R. Harold Zook, designed a variation of this which used short stacked shingles instead of the rolled edged shingles around the eaves and gables. This style was name after him, and “Zook” Shingles can be found all over Illinois, Ohio and Indiana on the homes he designed.
The home’s architect, Roy Firestone, adopted the "Zook" short shingle concept for this home, incorporating the characteristic thatch wave coursing. Notably, while the front of the home prominently features the "Zook" short shingle style, the sides and back are constructed with steam-bent shingles—a rare and intriguing combination of both faux-roofing styles.
Creo-Dipt's instruction manual
Detail roofing plans from the original design
Reviving this specific technique for the Zook Roof Replacement Project required us to blend historical craftsmanship with modern day precision—an endeavor that made this project truly one-of-a-kind.
The roof we replaced is believed to have been installed after a fire in 1947, but it faithfully replicated the original design from 1929.
Check out the next section to see how we made critical updates while maintaining historic integrity.
2.The Restoration Process
Our team strategized on the best course of action as we dove into the restoration process.
Before the tear-off began, we took detailed photographs of each roof plane as invaluable references during the installation.
For the shingle replacement, we selected #1 Grade Western Red Cedar Perfections from Custom Shingles, known for their superior quality and durability. These shingles were CCA-treated to extend their lifespan. Flashings were custom fabricated in our shop with 16 oz. copper provided by ABC Supply.
The house before our work began.
A photo from before the restoration
Due to the small exposure of the shingles along the eaves and gables, over 10,000 short shingles were required. All of these specially cut shingles, along with the steam-bent, full-length 18” shingles for the back of the house, were fabricated in our shop.
The intricate details show the short shingles were tapered from full butt thickness down to a 1/8” over their 4” length with as many as 20 courses per foot, with each shingle layer glued before fastening with stainless steel fasteners.
With so many layers, the front of the house, where the short shingles were used, required an additional 44 squares of material—just for the edges alone—far exceeding the requirements of a traditional cedar roof installation. This intensive roofing process took about one month to complete.
Our work in progress
Our work in progress
Having re-roofed many historical homes, we've developed and patented our own steam-bending equipment, allowing us to replicate the designs of original roofs.
This innovation allows us to match old roof designs accurately, preserving the architectural integrity of these historic structures.
As with all older homes, we approached this project with a deep respect for the original aesthetic, taking meticulous care to maintain its timeless look. At the same time, we sought opportunities to subtly improve the roof's durability.
3. The Award-Winning Outcome
We are so proud to have completed this roof replacement project and hope to help keep the legacy of faux-thatch roofing alive.
Now, for the final result!
Our completed project!
The back of the house
Every roof we work on has its own unique beauty, and we hope to continue supporting different roofing styles for years.
At Huber + Associates, we offer roof services on thatch roofs and other materials, including wood, slate, clay, and copper. To learn more, check out our portfolio.
We believe in providing our customers with a quality roof that preserves old-world techniques while updating the materials to withstand modern elements. We delight in capturing the spirit of an original building while adding modern enhancements.
If you have a historical roofing project in mind, we'd love to hear about it! Preserving and restoring these architectural treasures is our passion, and there's nothing we enjoy more. Reach out to us today to discover how we can bring your vision to life!
