custom arc and round Top doors, gates & Windows

by Matthew Wiley | Oct 17, 2023 | Historic Restoration, Wooden Windows

In the world of construction and preservation, few elements evoke the same sense of wonder and complexity as round windows in historic buildings. These architectural marvels have graced our cities for centuries, captivating the imagination with their intricate designs and timeless beauty. As a construction manager deeply involved in the restoration of historic structures, I have come to appreciate the unique challenges and rewards that come with the territory. In this narrative, I will explore the intricate world of round windows in historic buildings, shedding light on their complexity and the indispensable need for experienced millwork craftsmen, such as Gepetto Millwork, to handcraft these exquisite features rather than opting for on-site construction or less experienced manufacturers.

The Fascination with Historic Round Windows

Before diving into the specifics of round windows, it is essential to understand why these architectural elements hold such a special place in the hearts of preservationists, architects, and construction managers alike. Round windows, often referred to as oculi or rose windows, are not just functional openings to let light into a building; they are intricate works of art, often featuring intricate tracery, stained glass, and decorative detailing. They serve as both practical and aesthetic elements, offering glimpses of the world outside while simultaneously enhancing the building’s visual appeal.

The Complexity of Round Windows

a. Architectural Challenges

Historic round windows, unlike their rectangular counterparts, present a myriad of architectural challenges. Their curved shape defies the straightforward geometry that most modern construction methods are built upon. This complexity necessitates precise calculations, measurements, and a deep understanding of materials so as not to create weakness and structural failure.

b. Structural Integrity

One of the foremost concerns when dealing with round windows is ensuring structural integrity. These windows often occupy large portions of the building’s façade, which means they must withstand considerable loads and environmental stressors. Failing to address structural concerns could lead to costly and dangerous consequences, compromising the safety of the building and its occupants.

c. Historical Authenticity

Preserving the historical authenticity of a building is paramount in restoration projects. Round windows are often integral to a building’s historical identity, and any attempt to replace or modify them must be done with the utmost care and attention to detail. Using the wrong materials or techniques can irreparably damage the building’s historical integrity.

The Artistry of Round Window Design

a. Intricate Tracery

One of the most captivating aspects of round windows is their intricate tracery, which refers to the ornamental stonework or woodwork that forms the window’s framework. The design of tracery can range from simple geometric patterns to elaborate, flowing motifs that tell a story or convey religious symbolism. Crafting tracery requires not only technical skill but also a deep appreciation for the artistic and historical context in which the window exists.

b. Stained Glass

Stained glass is a hallmark of many historic round windows, adding a mesmerizing play of colors and light to the interior of the building. The creation of stained glass windows is a highly specialized craft that demands a deep understanding of glasswork and painting techniques. Each piece of glass must be meticulously chosen for its color and translucency, and the final composition must be both beautiful and structurally sound. The Role of Experienced Millwork Craftsmen

a. Artful Construction

Millwork refers to the crafting of wood elements for architectural purposes, and it is a crucial aspect of round window construction. The skills required for millwork are highly specialized, involving precision cutting, carving, and shaping of wood to create intricate designs. Experienced millwork craftsmen possess the knowledge and expertise necessary to execute the most intricate and historically accurate round window designs.

b. Gepetto Millwork: A Trusted Name

When it comes to entrusting the creation of round windows in historic buildings, Gepetto Millwork is a name that resonates throughout the industry. With a 20 year legacy of craftsmanship Matthew Wiley has earned a reputation for excellence and delivered on big projects. His dedication to preserving historical accuracy and attention to detail make them a preferred choice for construction managers and preservationists alike.

The Perils of On-Site Construction

a. Compromised Quality

Attempting to construct round windows on-site presents a host of challenges that can compromise the quality and authenticity of the final product. On-site construction lacks the controlled environment and specialized equipment necessary for crafting intricate designs and achieving precise measurements.

b. Delays and Cost Overruns

On-site construction of round windows often leads to delays and cost overruns. Any miscalculations or mistakes can result in significant setbacks, including the need for costly revisions and repairs. These delays can be especially problematic when working on historic restoration projects with tight timelines and budgets.

The Pitfalls of Less Experienced Manufacturers

a. Cookie-Cutter Approaches

Less experienced manufacturers may take a one-size-fits-all approach to round window production, neglecting the unique historical and architectural context of each project. This can result in generic, uninspired designs that fail to capture the essence of the building or the period in which it was constructed.

b. Lack of Expertise

Experienced millwork craftsmen, like those at Gepetto Millwork, possess a level of expertise that is simply unmatched by less experienced manufacturers. The intricate detailing, historical accuracy, and structural integrity of round windows require a depth of knowledge and skill that cannot be easily replicated. In the world of historic preservation and construction, round windows stand as testaments to the intersection of art and architecture. Their complexity and beauty captivate the imagination and inspire awe. Yet, these architectural marvels are not easily replicated or replaced, and their preservation demands the utmost care and expertise. As a frustrated construction manager, I have witnessed firsthand the challenges that come with attempting to construct or restore round windows without the involvement of experienced millwork craftsmen like Gepetto Millwork. The complexities of structural integrity, historical authenticity, and artistic design cannot be taken lightly. To do justice to these remarkable features of historic buildings, we must recognize the indispensable role of craftsmanship in their creation and restoration. The next time you gaze upon a historic round window, take a moment to appreciate the intricate tracery, the stained glass, and the centuries of artistry and craftsmanship that have gone into its creation. These windows are not just openings to the past; they are portals to a world where beauty and complexity converge, reminding us of the timeless allure of historic architecture.

Unique wooden and Historic Window Makers in the South East US

by Matthew Wiley | Jul 13, 2023 | Historic Restoration, Wooden Windows

Windows are not only functional elements in a building but also serve as aesthetic highlights, especially in historic structures. The South East United States boasts a rich architectural heritage, and preserving the authenticity of historic buildings is of paramount importance. In this article, we will explore the world of unique wooden window makers in the South East US, with a special focus on Gepetto Millworks completed construction project portfolio. Our job history and qualifications highlight our unique and notable contributions to the restoration of the Montgomery Building in Spartanburg, SC and the Bull Street District Mental Hospital renovation in Columbia, SC.

Window Maker in the South East United States

Gepetto Millworks owned and operated by Matthew Wiley with his wife Pamela became a renowned window maker based in the South East US, by starting in one of the oldest standing neighborhoods on the continent : Church Hill Richmond. The word spread fast as Matthew built to order and matched historic trims, embellishments and other unique elements that make history come alive in historic homes, churches, theaters and restaruants. Specializing in crafting historically accurate unique wooden windows for historic structures soon caught the attention of restoration specialists from Williamsburg VA’s historic district. With decades of experience, Gepetto is now an approved vendor to the National Parks Services & Pentagon specialist provider for historic military buildings. Our unwavering commitment to quality, craftsmanship, and attention to hand built detail from the blue ridge near Charlottesville VA established us as a leader in the field.

The Montgomery Building, Spartanburg, SC brought the largest order for historic windows ever seen by the Gepetto shop. Renovating an iconic landmark with a rich history in the center of Spartansburg made for an order of 940 windows on this 24 story building. Built in 1924, it was the first high-rise building in Spartanburg and South Carolina. Gepetto Millworks was entrusted with the task of restoring and replicating the building’s historic windows, ensuring the preservation of its original character as it evolved into a mixed use modern development with shops, condos and a full set of amenities. Gepetto’s extensive knowledge of period-specific window design and construction techniques Matthew successfully recreated the historic windows but added energy efficient weather beating parts seamlessly blending old-world charm with modern functionality. The windows underwent full durability testing before being ordered, as due dilligence would suggest. This video shows the windows under hurricane strength wind forces to test their breaking point<<

South East Washington DC historic window maker

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Our windows have withsstood tornadoes and pressure tests before installation - they passed, and they last!
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Southeast window maker for historic restorations

The Bull Street District renovation centers around the Historic Mental Hospital in downtownColumbia, SC. One of the first facilities to provide mental health services in the country it holds significant historical importance! As part of a major renovation project aimed at transforming the hospital into a vibrant mixed-use development with baseball dimond, urban shopping like REI now anchors a full set of modern amenities to this historic campus where they raised their own food. Gepetto Millworks played a crucial role supplying the windows and millwork elements that qualify as Historic Tax Credit building materials. Our expertise in crafting windows that adhere to the strict guidelines of historical preservation helped breathe new life into the building while maintaining its architectural integrity. Now residents walk their dogs under the beautiful living history of the mature trees on the campus.

Unique Qualifications – Customization and Replication

Gepetto Millworks specializes in the customization and replication of historic windows down to the panes of glass. Our skilled artisans meticulously note original window designs, materials, and construction techniques to ensure the accurate reproduction of frames, sashes and trims that add up to be indistinguishable from the originals when fully installed. Attention to detail while meeting all construction timelines is why large general contractors rely on Gepetto exclusively for projects at this scale.

Material Selection and Craftsmanship

The choice of materials is vital when recreating historic windows. Gepetto Millworks sources high-quality, sustainable wood that matches the original species used in the historic windows. Through their exceptional craftsmanship, they transform raw materials into intricate, durable, and beautiful window components that stand the test of time.

Preservation Expertise:

Preservation projects demand a deep understanding of how species of wood interact, how it will be machined into shape, and the order of installation to match historical preservation. Gepetto Millworks generously shares their expertise with contractors installing their products as woodworking is becoming a lost art with most commercial windows choosing aluminum for their material Gepetto ensures adherance to the authentic style and proportions of the era in which the building was constructed even if example windows are destroyed beyond recovery.

Impact and Legacy:

The work of Gepetto Millworks restoring historic windows extends beyond the mere physical preservation of structures. By meticulously replicating windows, trim, glass panes and sashes, they contribute to the overall cultural and historical heritage of the South East United States. Dedication to craftsmanship and historical accuracy ensures that future generations can appreciate and understand the architectural achievements of the past. If the windows in your home or building have lasted 200 years already, you do have a safe and reliable alternative to the plastics, vinyls, and metals that cloud the current marketplace. Ask your accountant to amortize the cost of the windows over 200 years as you get a quote – it puts the whole process into perspective.

Preserving historic structures requires a delicate balance between maintaining authenticity and meeting modern functionality standards. Gepetto Millworks can apply UV Coatings, Weather Stripping and other small nuances that bring the historic window up to all energy efficiency expectations. Through exceptional skills and creative problem solvoing we have made significant contributions to the restoration and replication of historic windows across the eastern seaboard. With notable projects like the Montgomery Building in Spartanburg, SC, and the Bull Street District Mental Hospital in Columbia, SC, Gepetto Millworks continues to leave an indelible mark on the South East US’s regional architectural heritage.

Arch & Round Top Radius Wooden Windows Custom Built to Order or Restored in Virginia

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South Carolina Wooden Window Supplier

by Matthew Wiley | Jun 17, 2023 | Historic Restoration, Wooden Windows

In the realm of architectural preservation and restoration, historic buildings hold a special place, preserving the essence of South Carolina’s rich heritage. When undertaking historic building projects, architects and construction managers can greatly benefit from the historic tax credit certification program. In this article, we will explore the significance of historic wooden windows in these projects, highlight the expertise of Gepetto Millworks as a supplier, and shed light on the advantages of leveraging the historic tax credit certification from a professional perspective.

Historic Wooden Windows and the Importance of Preservation

Architectural Integrity: Historic wooden windows are an essential component of a building’s architectural integrity. These windows showcase the craftsmanship, detailing, and design principles of a specific era, adding to the overall character and historical significance of a structure. Preserving and restoring these windows is crucial to maintaining the authenticity and charm of historic buildings.

Preservation Guidelines: When working on historic building projects, adherence to preservation guidelines is of utmost importance. These guidelines often dictate the retention or replication of original features, including windows. Gepetto Millworks specializes in producing historically accurate wooden windows that comply with preservation standards and bring the building back to its former glory.

Energy Efficiency and Sustainable Solutions: Contrary to misconceptions, historic wooden windows can be energy-efficient when properly restored and upgraded. Gepetto Millworks utilizes modern weatherstripping techniques and energy-efficient glass options to enhance the performance of historic windows while preserving their original aesthetics. This approach aligns with sustainable design practices and promotes energy conservation in historic building projects.

Expertise in Historic Wooden Windows

Craftsmanship and Attention to Detail: Gepetto Millworks has a well-established reputation for its commitment to exceptional craftsmanship and attention to detail. Their team of skilled artisans combines traditional woodworking techniques with modern innovations, ensuring the production of historically accurate and superior-quality wooden windows. Each window is meticulously crafted to meet the highest standards of excellence.

Customization and Replication: Gepetto Millworks understands the importance of customization and replication when it comes to historic building projects. They possess in-depth knowledge of various architectural styles prevalent in South Carolina, enabling them to replicate windows with utmost precision, even in cases of unique or intricate designs. Their ability to provide customization options allows architects and construction managers to tailor the windows to the specific requirements of the project.

Material Selection and Durability: Gepetto Millworks takes pride in sourcing only the finest materials for their historic wooden windows. Premium-grade hardwoods are carefully selected to match the original species used in historic structures. This meticulous attention to material selection ensures that the windows not only maintain an authentic appearance but also exhibit exceptional durability and longevity, supporting the long-term preservation goals of the building project.

Benefits of Historic Tax Credit Certification

Financial Incentives: The historic tax credit certification program offers significant financial incentives for owners and developers of historic buildings. By adhering to specific preservation standards, projects can become eligible for tax credits that can offset a portion of the rehabilitation costs. These credits can be used to reduce tax liabilities, attract investors, and lower overall project costs, making historic building projects more economically viable.

Preservation Advocacy: The historic tax credit certification program promotes the preservation and restoration of historic structures. By participating in the program, architects and construction managers contribute to the preservation of South Carolina’s architectural heritage. This involvement not only enhances the cultural value of the community but also positions them as stewards of historic preservation.

Marketing and Recognition: Buildings with historic tax credit certification gain recognition and prestige within the industry. They become eligible for various marketing

Historic Wooden WIndows Pressure TEsted Performance

by Matthew Wiley | Apr 18, 2023 | Historic Restoration, Wooden Windows

In order to pass installation and certification in some of the larger commercial restorations our windows have been placed in testing chambers to prove their durability against other industry products. So far, we have passed with flying colors. With the insight from these tests we did add a special weather beating feature to the windows that assists in bridging the gap between historic building methods and modern materials. If you’re buying a thousand windows, we’ll show you what it is! We can produce any type of complex multi-pane wooden historic window.

Wooden Window Restoration for Historic Churches

Historic Window Builder VA

Gepetto Millwork shop is tooled up to support your large historic restoration project and can meet your demands for up to 100 window frames and 200 sashes per month. Several of our large restoration projects across the south like the Montgomery Building in Spartansburg SC and the Bull Street District renovation of the State Hospital Building in Columbia SC. Both of these multi year renovations of existing structures were driven by Historic Tax credit incentives that hinged on finding a supplier for historically accurate windows.

Montgomery Building Spartansburg SC

by Matthew Wiley | Apr 18, 2023 | Historic Restoration, Wooden Windows

Montgomery Building

Spartansburg SC

Unique wooden and Historic Window Makers in the South East US

Montgomery Building Spartansburg SC Project Details

Project Awards:

Preservation South Carolina, Honor Award, 2021
Spartanburg County Historical Association, Peggy T. Gignilliat Preservation Award, 2021
Traditional Building Magazine, Palladio Award for Adaptive Reuse, 2021
CREW Upstate, Development Impact Award, 2019
ENR Southeast, Best Projects Award of Merit for Renovation / Restoration, 2019

In 1924 the Montgomery family, a very prominent family in Spartanburg’s textile manufacturing industry, commissioned Lockwood Greene to design and build the building. Completed in 1925, the 10-story Montgomery Building is one of the first Chicago-style construction projects ever built outside of Chicago.

In 2016, local developer BF Spartanburg came forward with a plan that city officials praised as a “next-level” catalyst for downtown Spartanburg. After engaging McMillan Pazdan Smith on a feasibility study, the development team created plans to restore the 92-year-old, iconic high-rise into a mixed-use retail, commercial, and residential project in the heart of the city’s central business district.

Our design team worked carefully with the National Park Service to meet their criteria for preserving and updating the building appropriately. The building façade’s pre-cast concrete panels were very innovative for their time, making it possibly the only remaining historic pre-cast Chicago-style building in the region. McMillan Pazdan Smith was able to source new concrete panels that replicate the old panels closely enough to receive approval in accordance with the building’s protected status on the National Historic Register of Places. Many of the building’s original Renaissance Revival style architectural details on the interior were also be preserved, including the decorative plaster ceilings and marble floors and walls. The renovated and restored Montgomery Building features 9,000 SF of select boutique retail stores and intimate restaurants on the ground floor. The second floor is dedicated office space, and the eight floors above are residential units, with approximately 92 one- and two-bedroom apartments ranging in size from 422 – 1,374 SF. The CM-At-Risk project was completed in 2019.

^From : McMillan Pazdan Smith Architectdure

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Featured in Traditional Building Magazine

McMillan Pazdan Smith revives the Montgomery Building, one of the only remaining pre-cast buildings in the Chicago School of Style in the country.

Gepetto Built Historic Replica Wooden Windows Installed in the apartments of the Montgomery Building

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“Work was underway on the Montgomery Building in Spartanburg, South Carolina, when a consultant with the South Carolina State Historic Preservation Office noticed a slight discrepancy between the original column capitals and a new capitol mold awaiting approval.” ~Restoration of the Montgomery Building – Traditional Building Magazine

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Montgomery Building reconstruction to be honored by governor

For two decades, the 127,000-square-foot Montgomery Building, located along downtown Spartanburg’s North Church Street, remained vacant.

After years of neglect, the 10-story building’s precast concrete façade had deteriorated to the point that it was necessary to erect scaffolding along the buildings’ perimeter to protect pedestrians on the street from falling debris.

With the restorative hand of Harper General Contractors and design of McMillan Pazdan Smith, however, the Montgomery Building has reached new heights since its 2018 reconstruction.

On July 23, the team will be recognized by Gov. Henry McMaster in a ceremony at the Statehouse with Preservation South Carolina’s 2021 Honor Award.

“This is one of the most extraordinary projects that has ever been submitted,” Mike Bedenbaugh, president and CEO of Preservation South Carolina, said in a news release. “The challenges that had to be overcome with this building, most of the time, would have led to the demolition of other buildings. That’s why it deserves this award.”

Preservation South Carolina, the S.C. Department of Archives and History, and the governor’s office have recognized accomplishments in the preservation, rehabilitation and interpretation of the state’s architectural and cultural heritage with a series of awards since 1995.

In order to be considered, projects must have been completed, including all phases, within the last three years, made a positive impact on the community and the state, and achieve a degree of project difficulty while serving as an example of outstanding commitment to historic preservation and exemplary preservation techniques, according to the release.

Projects like this are why people like me become architects,” McMillan Pazdan Smith’s K.J. Jacobs, principal in charge and lead architect on the project, said in the release.

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Arch, Round Top, and Radius Window Builder

by Matthew Wiley | Mar 20, 2023 | Church Restoration, Reclaimed Wood Builder, Wooden Windows

Round & Arc Top Windows

Arch & Round Top Radius Wooden Windows Custom Built to Order or Restored in Virginia by local craftsmen with historically accurate methods

Gepetto craftsmen have been restoring windows with half-round lights above the window or full arc keystone panes (pictured in next photo) for over 15 years. Restoration of water rot or damaged sashes, or completely new solid wood replication to fit your historic Virginia home or church. Gepetto uses a mixture of modern shop tools and hand assembly to speed the building process. Historic homes of the 18th and 19th century relied heavily on the natural light from windows as remember it was either candles or oil lamps for light after the sun had hit the horizon.

Made with Love in the Blue Ridge Gepetto Craftsmen supply plantation house, row house, and all manner of 18th and 19th centrury historic replica windows. Specifically hard to find are craftsmen skilled and trained to replicate or repair uniquely shaped round windows or upper window panes of various arc lengths.

Rounded Top Replica Historic Windows

Arch & Round Top Radius Wooden Windows Custom Built

If you are a homeowner who needs window service, it’s best to bring in a local contractor because Gepetto acually supplies local contractors. If your local contrator or handyman seems shy to work with your historic wooden windows, have them give Matthew a call and we’ll be glad to assure them of the skills or techniques they would need to have the hardware fabricated at our millwork shop, and installed by them locally. Our craftsmen are generally millwrights and while they can install windows, it’s simply not time efficient for us as most general contractors can do a good job.

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Historically Accurate Round Windows

Arc top classic southern historic window builder supplying replacement windows from our Virginia shop. Built by hand to historic standards and matching solid wood mortise and tennon construction of the original windows. Whether it’s a specific wood rot, that just needs some restoration we can replace anthing from a section to the whole window. Bring in a single sash to our shop in the blue ridge and we’ll gladly restore it by hand. We have also handled large scale commercial restorations supplying as many as 900 sashes (450 windows and frames) to a single building historic restoration.

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