Restoring an Icon: Behind the Customs House Restoration with Warrin Orman

Upon completing the intricate restoration of Customs House’s iconic dome and roof, we sat down with the project lead – FARA Director Warrin Orman – to uncover the challenges, craftsmanship and dedication behind this once-in-a-lifetime project.

Written by: Julia Pegg

For 136 years, Brisbane’s Customs House has stood as an enduring symbol of the city’s architectural heritage. While its interiors have seen careful restoration, most notably in 1994, the iconic copper dome and facade remained largely untouched – until now.

Recent severe weather events made it clear that the time had come for a full-scale roof restoration. The dome itself, perhaps the most recognisable feature of Customs House, was in desperate need of attention. The copper panels, installed over a century ago, had thinned and lifted in several places. ‘Old copper has a higher lead content, which made it softer and less consistent,’ Warrin explains. ‘Over time, the sun and weather took their toll and maintenance fixes – like nailing down lifted sections – only made things worse.’

Warrin was at the helm of this ambitious project. With extensive experience in heritage restorations and complex construction projects, Warrin led the team with a clear vision – blending traditional craftsmanship with modern engineering to ensure both historical accuracy and long-term durability. ‘Customs House is a Brisbane icon and this restoration required a balance between respecting the past and ensuring a resilient future,’ Warrin says. “We approached this project with an immense sense of responsibility.”

Starting off as an Early Contractor Involvement (ECI) engagement that evolved into a value-engineered Design and Construction (D&C) contract, the project required collaboration and problem-solving in real-time with the whole project team – essential when working with a structure that had weathered more than a century of Queensland’s harsh climate.

FARA was entrusted with this monumental task, working closely with The University of Queensland, leading consultants, subcontractors and the Queensland Heritage Council, to ensure the highest standards of heritage preservation. The project’s key objectives were clear: maintain the original aesthetic as closely as possible, reuse as much of the original material as feasible, and ensure that all replacement materials and installation techniques meet modern Australian standards.

Replacing the dome wasn’t a simple matter of swapping out old for new. Ensuring historical accuracy while incorporating modern construction methods was a meticulous process. To start, the team carefully removed three original segments of the dome. ‘Every piece of copper removed was catalogued and evaluated. Some were cleaned and reinstalled – like the crown ornament piece – and others were beyond saving. We wanted it to be as close to the original as possible,’ says Warrin. ‘That meant custom fabrication, hand-finishing and using traditional blacksmithing techniques to replicate the original detailing.’

The team from Sustainable Cladding and Roofing installed the restored or newly fabricated pieces alongside the existing sections for benchmarking and final approval from the heritage architects at Architectus. The restoration required extensive craftsmanship, with blacksmiths shaping and heating the copper by hand to match the original details. This process gave the team a deep appreciation for the skill of the original tradespeople.

Modern copper, manufactured to Australian standards, presented its own challenges. Unlike the original material, which contained more lead and was softer – making it easier to manipulate – the new copper was harder and more consistent but significantly more difficult to bend and stretch to match the dome’s curvature. The ridge sections, in particular, required extensive work. While machines assisted in shaping the sheets, certain intricate details had to be formed using traditional blacksmithing techniques, ensuring the final result met both heritage architect and structural engineer requirements. ‘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 Warrin.

One of the most unexpected discoveries came when removing the old dome. Unlike modern construction methods, which secure sheets of metal firmly to the structure, the original copper sheets weren’t fully fixed across their length. Instead, they floated slightly above the structure, allowing them to form a natural curve. Modern regulations required the new copper sheets to be fixed together with clips, but this created a problem: the edges of the sheets began to wrinkle around the fasteners. ‘So, we had to develop a packing system that correctly guided the sheets to curve as they were clipped together to meet today’s structural requirements,’ Warrin explains.

Achieving this level of precision took multiple attempts, blending traditional craftsmanship with contemporary technology to maintain historical integrity while adhering to modern construction standards.

Beyond aesthetics, the new dome was designed with longevity in mind. A waterproof membrane was installed beneath the copper to protect the internal structure from water damage. The new copper is heavier and stronger, capable of withstanding hail and extreme weather. With proper maintenance, this restoration sets the dome up for another 200 years.

But restoring the dome was only part of the challenge. The roof, last replaced in 1994, was fundamentally flawed for Queensland’s climate. ‘When the building was originally designed in 1886, there was little understanding of how much rain Queensland could get,’ Warrin explains. ‘Heavy downpours turned the roof into a swimming pool because there weren’t enough downpipes to handle the water.’ The team addressed this by entirely redesigning and replacing the roof. The new design features 18 additional spitter drains to assist the box gutters in managing water runoff, an access walkway and ladders to the dome. The team also relined all internal downpipes with fibreglass, ensuring maximum flow and eliminating leaks – an ongoing issue that had plagued the building for decades.

The team experienced the full spectrum of Brisbane’s challenging summer weather during the project. The dome, exposed to the full brunt of the sun, became incredibly hot, making work conditions extremely difficult – hot enough to fry an egg, as one team member put it. At the other extreme, wet weather slowed progress, making waterproofing critical to protect exposed roof sections.

The safety and logistical challenges were equally complex. Scaffolding provided by Premier Scaffolds was suspended off the building using a steel frame designed specifically for this job, allowing Customs House to remain fully operational as one of Brisbane’s premier dining and events destinations. With weddings and events continuing throughout the restoration, the team took great care to ensure that the building’s visual appeal was maintained for those special occasions. Road closures on Queen Street were necessary for crane lifts and material transport, requiring extensive traffic management and coordination with the council to minimise public disruption.

The visual transformation of the dome alone is striking. The new copper gleams brightly, but over time, it will undergo a natural aging process – first turning brown, then dark chocolate, before developing the iconic green patina that has defined the dome for generations. As Warrin put it, ‘Every old girl loves a new haircut’.

Reflecting on the project, Warrin is proud of how the team came together and rose to the occasion. ‘This was something that hadn’t been touched in nearly 140 years, and we went into it without detailed knowledge of what was waiting for us beneath the surface. Every discovery required creative problem-solving. Every member of the team – UQ, the consultants, the subcontractors – brought their best ideas forward. It wasn’t just about delivering a great outcome but delivering the best original solution that honoured the history of Customs House.’

With its new dome and roof, Customs House is now prepared to face another century or two of Brisbane’s weather – already put to the test with Cyclone Alfred. ‘This wasn’t just about replacing a roof,’ Warrin reflects. ‘It was about protecting history, enhancing resilience and ensuring that Customs House continues to inspire and serve the community well into the future.’

As the builders behind this transformation, FARA takes immense pride in delivering a project that seamlessly blends craftsmanship, heritage preservation and modern innovation. Customs House stands renewed, ready to witness the next chapter of Brisbane’s history under its new roof and freshly restored copper dome.

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