PVG millwork meets the challenges of historic renovations

DVC rRIM AND millwork can provide a long-lasting I solution to a common challenge of historic-renovation projects: recreating intricate trim and millwork patterns that must be replaced.

"PVC trim can be milled to replicate historic profiles accurately, but without the time, labor or costs associated with maintenance," says Ergun Merdin, owner of D&E

Construction, Boston, Ma., who uses cellular PVC trim from Azek Building Products, Scranton, Pa. "We've been able to make the transition to PVC very successfully."

Bill Sandrock, owner of Stratton Creek Wood Work, Kinsman, Oh., agrees. He's been working with PVC products from Versatex Trimboard, Aliquippa, Pa., for the past eight years.

"We do a great deal of intricate restoration work, so we started using cellular PVC for exterior applications because it can be cut and shaped like wood. We laminate Versatex's PVC sheet to give us the needed thickness, and then mill it to our specifications."

His latest historic project involved renovation of a cupola at Baldwin Wallace University, Berea, Oh., which dated to 1897 and had been irreparably damaged by the elements. He started by taking samples of all the original crown moulding, corbels, handrails, and turnings.

"With PVC, fabrication wasn't so much of a challenge," he notes. "We measured the original piece, drew it in AutoCad, and then figured out how to manufacture it. We custom-ground knives to match and ran the profiles through the moulder."

According to Sandrock, it took about 1,100 man-hours over the course of five months to construct all the millwork needed for the six-sided cupola.

"This was probably the most detailed project we've ever done," he says. "By doing this in PVC, the paint will stick and it will last. It's never going to rot and it's not going to peel. The new paints expand and contract with the material. "

Although PVC trim components are designed to repliBuilding-Products.com cate the look of wood, they aren't affected by moisture and are highly resistant to mold. In addition, PVC trim is consistent in size and finish, immune to rot and insect infestations, and lightweight and easy to install over solid substrates.

"PVC delivers the authentic, rich appearance of wood, coupled with the durability and very low maintenance homeowners want," says Jack Delaney, national sales manager of The Tapco Group's Kleer Lumber division. "Whether it's a coastal mansion or modest neighborhood home, PVC is appropriate on virtually every house."

Perhaps best of all, PVC trim requires little maintenance-unlike wood trim, which must be re-painted on a regular basis.

"I've never met a homeowner who likes maintenance." says Joe Cracco, c.e.o. of Modern Yankee Builders, Cumberland, R.I., who also uses Versatex products. The company works on historic homes and landmarks, plus traditionally styled new homes, that must withstand the harsh elements of the New England coast.

"In areas where wood trim is exposed to a lot of water and then deteriorating, we come in, remove the rotten trim, and install accurate new profiles made from PVC," he notes. "It's a sad fact, but wood rots. They see that we can get a historic effect with materials like PVC trim-and bring the level of maintenance a lot closer to zero."

Carter Lumber, Fairview, Pa., supplied and custommilled Azek PVC for the renovation of an 1873 farmhouse with a new barn/garage.

"On both the house and barn, we were able to match the period look beautifully," says Kevin Raines, one of Carter's outside sales reps. "We used a CAD program to recreate the historic brackets we were able to save on the house, designed and built windows, and milled a crossbuck pattern for the barn doors."

Recreating historic trim in PVC also means that the structure will be around for future generations to appreciate. "Some people shy away from PVC in the restoration business, and I don't understand why," comments Sandrock. "It doesn't rot-and we recycle all the dust and scraps when we mill it, to make more product-so it's as green as can be."

By Tom Patterson, Intertek