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BURNT HILLS, NY — After nearly 170 years of upstate New York weather, time had taken its toll on the Calvary Episcopal Church. While proud of its designation on the National Register of Historic Places, the church board members were concerned about deterioration of the landmark bell tower. It was severely leaking into the building and there were concerns of collapse of both the tower and its 1000-pound bell. Jim Nally, owner of Nally Restoration, had a proposal for saving their bell tower. The board liked what they heard but paused on one point—Jim was proposing covering the exterior of the structure not in wood but in PVC polymer sheet and trim from AZEK.
Though initially skeptical, Jim changed their minds. He convinced them with samples showing the beauty of the material and demonstrating the strength of an AZEK adhesive joint. Once board members saw and felt the strength and beauty of the material, they agreed to its use. The clincher may have been when they understood that this renovation could easily last 50 years with minimal maintenance and no water damage. Considering the height of the steeple, that meant a huge labor and materials savings. Father Gabriel Morrow, the pastor of the church, also found photos showing the appearance of the tower from the early 20th century. The familiar square tower was topped with four magnificent spires and finials, one at each corner. No one living today had seen the tower in this configuration. The repair and renovation project had become a true restoration with AZEK materials front-and-center. The decorative elements were recreated with AZEK materials. The AZEK-to-Mill (ATM) product is designed for machining—routing and turning—to create panels and other details. To recreate the decorative finials, sheets of material were bonded together to create solid blocks of PVC, which could then be put on a lathe and formed as if they were a piece of wood. Smaller pieces of decorative work were individually cut, heat bent, and glued to the substrate.
Steady dimensions and the absence of knots, cupping, and splintering compared to wood.
Easily mill, shape, and apply AZEK Trim and Moulding using standard woodworking tools. Route and cut without chipping. Get creative with curves and other heat-formed applications.
Lightweight material reduces jobsite breakage and makes it easy to get the materials where they need to go.
AZEK materials are impervious to moisture and do not suffer from typical moisture-related issues that wood faces: rotting, swelling, & cracking.
The durability of AZEK Trim and Siding dramatically reduces the ongoing need for paint for protection. Ideal for a tower which would require scaffolding or lift for re-painting.
Extreme durability and low-maintenance meets a huge variety of moulding profiles and options, to fit every project.
AZEK-to-Mill’s thick profile makes it an ideal material for fabrication. Its consistent density offers a superior product for milling and routing operations while maintaining strength.
Leave the constant maintenance of wood behind with the same high-quality and lasting performance of AZEK Trim.
Nally’s carpenters use the same or slightly less labor with AZEK materials compared to wood. Jim and his team use biscuit joinery to make tight seams that won’t open up due to water absorption. For trim work, they use Kreg jigs to create fastener pockets. Because the polymer material is impervious to moisture, it does not suffer with typical moisture-related issues that wood faces: rotting, swelling, cracking, and the ongoing need for paint for protection. This is the key to the product’s—and the project’s—expected longevity. “It’s easier to work with than wood. It’s a bit more expensive, but when you factor in the lifespan of the material, it’s a no-brainer to choose AZEK.”
Jim Nally, Nally Restoration
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