08/13/2023
Good morning Sauer Castle friends! As you have seen by several posts over the last few days, the scaffolding is being erected to allow the tower restoration to begin. You Sauer Castle followers are an enthusiastic bunch! It's hard to stay ahead of the reporting! We apologize for the length of time since the last post...we have been jumping through numerous hoops to allow construction to begin.
There are two primary work activities taking place over the next few months - rebuilding of the outer brick wythe at the tower (described in our last post) and reconstruction of the roof.
The roof replacement is complex, and we are happy to have Kaw Roofing & Sheet Metal performing this scope. The roof has an integrated gutter and downspout system that is entirely copper. The copper is flat-seamed with 100% soldered connections. The gutter system is supported by 'outlookers', which are small wood pieces embedded in the masonry. The existing outlookers are deteriorated and will be completely rebuilt. The replacement of the outlookers will be performed simultaneously with the masonry work since they are slotted directly into the brick.
The sloped portion of the roof will be covered with slate shingles. The slate shingles are being procured from Vermont and they are real-deal slate shingles. The structural engineer, Steve Huey, had to inspect the existing roof framing to ensure it could support the weight of the slate. Fortunately, the underlaying roof structure looks good and is plenty sturdy to provide the necessary support. Steve said that the 150 year old 2x6's in the castle provide almost twice the support of a modern 2x6. This tells you how much stronger the old growth lumber is.
All of the existing window/door headers and sills were carved out of sandstone. This is how they built them 150 years ago. You can see in the attached picture that they are deteriorating and falling apart. All of these will be replaced with new cast stone material. I'll explain this further in our next post.
In other news, our security cameras in the castle often spot a raccoon wandering around in the middle of the night. We aren't sure how he gets in, but he acts like the owns the place. I need to find a small hard hat and put him to work.
We are beyond excited to get everything rolling. The support from all of you and the surrounding community has been tremendous and we are very grateful. Now that construction is starting, we will try to post more frequently. Enjoy your day!