More than a century after copper panels were installed on the iconic dome of the Customs House building in Brisbane, work began on the heritage structure in August 2024 to repair and restore the dome as well as redesign the roof, which was last replaced in 1994.

Built more than 136 years ago, Brisbane’s Customs House is a historic landmark and an enduring symbol of the city’s rich architectural heritage. The copper-sheathed dome, which can be viewed from every elevation, is the most visually distinctive feature of the building. While the building’s interiors have gone through extensive restoration over the years, the dome and façade were left untouched. Recent weather events combined with natural wear and tear necessitated a full-scale roof restoration, involving the repair and partial replacement of the copper sheets in addition to replacing the existing damaged Colorbond roof with a new roof.

With a view to protect the structural integrity of the building, return it to its former glory, and extend its life further by a couple of centuries, The University of Queensland sought a partner with a deep understanding of traditional craftsmanship, who could deliver heritage-aligned outcomes while navigating multiple challenges including logistical problems, regulatory approvals, Queensland’s volatile weather, and a building that would remain fully operational during the restoration.

Commercial builder FARA entered the monumental restoration project through an Early Contractor Involvement (ECI) engagement that evolved into a value-engineered Design and Construction (D&C) contract. Working closely with The University of Queensland, the Queensland Heritage Council and specialist heritage architects from Architectus Conrad Gargett as well as engineers and subcontractors, FARA collaborated with the whole project team to ensure the highest standards of heritage preservation and facilitate problem-solving in real-time.

The primary project brief sought to maintain the original aesthetic of the copper dome as much as possible and maximise reuse of existing materials while bringing the restored building up to modern Australian standards.

FARA Director Warrin Orman, who has considerable experience in heritage restorations, led the project with a sharp focus on ensuring historical authenticity through traditional craftsmanship while using modern engineering techniques and materials to deliver the required long-term resilience.

“Customs House is a Brisbane icon and this restoration required a balance between respecting the past and ensuring a resilient future,” Orman says. “We approached this project with an immense sense of responsibility.”

Commenting on the complex dome restoration, he says, “The Customs House project wasn’t just about replacing old materials with new ones. It was about understanding how the building was originally designed, what had changed over time and how modern construction methods could improve its longevity without compromising heritage values.”

As the lead contractor, the FARA team began their work by carefully removing three original copper sections of the dome, meticulously cataloguing and assessing every copper piece, cleaning and retaining some components including the crown ornament, and discarding those that couldn’t be salvaged. For the parts that needed replacing, the team worked with specialist fabricators to hand-form and hand-finish copper components using traditional blacksmithing techniques to match the original detailing.

Sustainable Cladding and Roofing was entrusted with the responsibility to install the restored as well as newly fabricated copper elements after final approval from Architectus’ heritage architects, who oversaw the restoration.

There were several challenges during the course of the project. Modern copper, manufactured to Australian standards, for instance, was harder than the original copper used on the roof, which was easier to manipulate. With modern copper more difficult to bend and stretch to match the dome’s curvature, machines were employed to shape the copper sheets while traditional blacksmithing techniques were used for intricate detailing, meeting the requirements of both the heritage architects as well as the structural engineers.

“Mark Traucnieks Consulting Engineers played a crucial role, conducting load testing to ensure that the copper thickness, connection methods, and folding techniques could withstand Queensland’s harshest environmental conditions,” says Orman.

Another challenge discovered during the removal of the original copper panels was that the sheets weren’t completely fixed to the dome structure, allowing them to form a natural curve. Since modern regulations required the new copper sheets to be fixed together with clips, a new problem arose when the edges of the sheets began to wrinkle around the fasteners. A packing system was then developed to correctly guide the sheets to curve as they were clipped together to meet today’s structural requirements.

A waterproof membrane installed beneath the copper panels protects the internal structure from water damage. Designed with longevity in mind, the dome’s new copper sheets can stand up to hail and extreme weather, setting it up for another 200 years.

To maintain historical integrity while adhering to modern construction standards brought the entire team together to ideate and deliver the best original solution that honoured the history of Customs House, says Orman.

The roof restoration was a major challenge – the original roof designed and built in 1886 as well as the replaced roof in 1994 didn’t factor in Queensland’s heavy rains. Consequently, a heavy downpour would flood the roof because the downpipes couldn’t handle the flow. To mitigate this problem, the team redesigned and replaced the roof, with the new design incorporating additional features to manage water runoff smoothly without flow or leak issues.

Extreme weather conditions from Brisbane’s hot summer to rains not only increased discomfort for the workers but also slowed down the progress of work over the 16-week period. As one of Brisbane’s premier dining and events destinations, Customs House continued to operate throughout the restoration, with the project team taking great care to ensure the building’s visual appeal was not impacted.

Over four tonnes of copper sheets featuring a flat lock profile, custom ridges and ornaments were installed during the restoration. Completed in November 2024, the restored dome stands out in all its gleaming glory. The original green patina of the copper dome will return over time through a natural aging process with exposure to the elements.

Customs House, featuring a restored dome and new roof, is now ready to weather another century or two of Queensland’s harsh weather.

“This wasn’t just about replacing a roof,” Orman reflects. “It was about protecting history, enhancing resilience and ensuring that Customs House continues to inspire and serve the community well into the future.”

Images: FARA

Architecture News & Editorial Desk

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