Our team recently had the distinct honor of completing a comprehensive roof restoration for one of the city’s true architectural gems: Zealandia Castle, located at 1 Vance Gap Road in Asheville, NC.
When you are dealing with a property of historical significance like this, the standard roofing practices simply won’t cut it. This project required a perfect blend of old-world craftsmanship and premium materials. Here’s a look at how we protected and preserved the majestic Zealandia Castle for generations to come.
Setting the Stage for Success
A successful project on a grand estate starts long before the first piece of slate is removed. Before any work began, we conducted a thorough pre-construction meeting with the building representatives to map out everything, from equipment staging areas to strict safety protocols and production timelines.
Once the plans were locked in, we began the careful process of tearing off and disposing of the existing slate, ensuring the beautiful grounds remained protected and clean throughout the process.
Modern Protection Beneath the Surface
One of the most critical upgrades we brought to the Castle is what happens underneath the slate.
Typically, a self-adhered rubberized Ice & Water shield is only installed at high-risk areas like eaves, valleys, and around chimneys. However, to guarantee a longer life for the roof of a building like this, our team applied a self-sealing underlayment to 100% of the roof deck. This provides an impenetrable moisture barrier against rain and winter ice!
The Crown Jewel: Vermont Unfading Green Slate
For the primary roof system, we installed Vermont Unfading Green Slate. Renowned worldwide for its durability, unique texture, and enduring color, this slate complements the natural beauty of the Asheville skyline and surrounding mountains.
To help ensure this roof lasts for a century or more, every tile was installed according to strict manufacturer specifications using high-grade stainless steel fasteners, minimizing the risk of rusting and degradation.
Exquisite Copper Detailing
A slate roof is only as good as its flashings, and for a castle, we outfitted the roof with a comprehensive premium copper trim metal package that will develop a beautiful, natural patina over time. This included:
- Custom copper drip edges
- Copper hip and ridge flashings
- Copper step and head flashings
- Custom copper valley pans
At the eaves and rakes, we used oversized drip edges. The large face and “drip kick” dramatically increased the longevity of the trim and fascia boards.
Furthermore, we paid special attention to the chimney masonry. Our crew installed new ice & water shield, copper step-flashing, and reglet flashing that was precision-cut directly into the masonry for a complete watertight seal.
Managing the Low-Slope Areas
This castle features specific low-slope sections. For these areas, our team executed:
- Complete Tear-Off: We removed the old roof systems completely down to the original wood decking.
- Thermal Upgrade: We installed new perimeter wood blocking to accommodate two staggered layers of 1.5” Polyiso insulation, achieving an R-17.4 thermal value to improve energy efficiency.
- Premium EPDM: We topped this off with a fully adhered Carlisle 60-mil EPDM rubber membrane.
- Finishing Touches: We finished the roof eaves with a new drip edge featuring a 4” face perfectly positioned above the existing gutters to seamlessly manage water runoff.
The Final Seal of Approval
We don’t consider a job complete until it has been thoroughly vetted. Upon completion of the project at Zealandia Castle, our project managers conducted a rigorous final walkthrough alongside the Building Representative to ensure every detail met our elite standards.
By combining the beauty of Vermont slate, fine copper, and the invisible strength of modern underlayments and insulation, we ensured this Asheville landmark remains protected and beautiful for a lifetime.
Ready to See More?
Whether you own a historic Asheville landmark or want to elevate your home with premium craftsmanship, our team is here to help.
- Explore Our Work: Browse our portfolio to see more of our recent roofing projects and transformations.
- Have Questions? We’d love to hear from you. Contact us today to speak with one of our experts about your upcoming project or to get answers to any questions you may have!
