Rafter Stabilization Project

First Christian Church

This project took place from July to December 2010. Cost was $25,000. Expenditures up to $60,000 had been approved by the Congregation. This project was carried out by:

Contractor:                   Bouldin Construction

Project Engineer:       Bob Erner

Supervisor:                  Floyd Novotny

Structural Engineer:  Ron Beeby of Tulsa, OK

Background: When the main building was being inspected prior to the major renovation/addition of 2000, it was noted that the rafters and other roof supports over the 1920-era building seemed inadequate and in need of strengthening. This was deemed not immediately essential and was deferred. Some initial work was done by Floyd Novotny and others, but it became apparent that structural professionals should design, approve, and carry out this work.

Since very few church members have the inclination or ability to navigate the Church’s attic spaces, the following photographs and comments are an attempt to give the viewer an idea of the project. A notebook  describing this work is also available at the Church Office.

View of main church roof (North at top)

Most of the work was done under the sanctuary roof (the vertical red roof in the photo above). This roof has two pitches - a higher-pitched red roof and a lower pitched gray roof. This roof is a structural challenge because of its wide span — all the way from the West to the East side of the sanctuary space. It should be noted that the sanctuary ceiling itself is supported by a robust steel cage consisting of columns and beams.

 The east-west roof was also reinforced.

The next photos were taken before any work was started in the attic.

Looking North over balcony area.

Note that top ridge beam is about two inches less deep that the rafters resting against it — not a good design. The third rafter from front on left has completely split. Others are in the process of splitting.

Looking South above sanctuary.

Several rafters are in process of splitting.

The above two photos are above Choir and Baptistry areas. Some of the rafters are doubled up, showing previous attempts at repair. Note again that ridge beam is several inches less deep than rafters. The beam in this area is split and has allowed a few inches of sag in the roof over the Choir area. Some rafters show evidence of past repairs.

Photo at left is over Sanctuary, looking South. Split rafters are apparent. There is also a visible split in the ridge beam, at top right of photo. This has resulted in a few inches of roof sag over the choir area.

The red steel beam at bottom (barely visible) is part of the steel cage  around the Sanctuary.

The following photos were taken after most of the work was finished.

Looking north-south over the sanctuary. Note top of photo at left. The inadequate ridge beam was strengthened by adding a 2” x 6” laminated veneer wooden beam under it. This also gives full bearing support to the existing rafters.

Showing across bottom of this and the next photo, horizontal 2” x 16” laminated beams were laid on the existing main steel support beams (red).

Bracing was then added between the new horizontal beams and the reinforced ridge beam. Horizontal beams give added mid-length support along the rafters.

The following two photos show typical installations.

Horizontal 2”x6” laminated beams were added to give mid-length support to the existing rafters. The next two photos show installation down each side of the roof.

These photos do not show supports added in the lower pitched roof areas. These were installed from the steel cage out to the building’s exterior walls.

To reinforce the east-west pitched roof (above the Koinonia room to east exterior wall) the team erected a  studded vertical plywood wall reinforcing the ridge beam. The photos below show each side of this wall. Not shown is added reinforcement above the Koinonia and One Anothering rooms.

As a result of this work, we are assured that the roof of the main building is more structurally sound than when it was when constructed! All this was done at a very reasonable cost and a minimum of disruption.

Our special thanks go to: members Bob Erner and Floyd Novotny, who donated many hours to making this renovation so successful.