We are working on a very exciting project that involves design, fabrication and installation of an intricate wood moulding on a barrel ceiling. The ceiling is located in the master bedroom of a 5,500 square foot house on the coast of Maine. The architect is Rick Nelson and the construction manager is Marcus Golding, both with Knickerbocker Group. The millwork was handled by Alex Hamilton of Tidewater Millwork in Woolwich Maine.
This has been a very challenging process… from schematics through install. The following is a quick outline of how the team pulled this together, along with some construction photos to demonstrate each step:
1. KGroup architectural team first created a schematic design, and then followed up with a rough 3-D Sketchup computer model to demonstrate the design concept.

2. KGroup construction team then hand-drew the design on the barrel ceiling.
3. Tidewater Millwork created a full-scale computer model of the ceiling and proposed wood work.

4. Tidewater then ‘flattened’ the computer model to create MDF templates for the ceiling.
5. KGroup then assembled the templates on the ceiling for a final round of architect/owner design review and ‘tweaking’.
6. Tidewater created an 8’x8’ mold of the ceiling in order to bring the ‘real’ built curve of the ceiling back to their shop. They then made templates of mouldings and located them on the mold to test the fit.
7. Poplar strips were laminated directly on the mold, then run through a shaper to create the profiles and finally delivered to the job site.


8. KGroup construction crews then installed the ribs over the hand-drawn sketch on the ceiling, using specialty tools to finalize the intricate curved connections.


9. And finally, Herb Clarke with Chameleon Coatings adds a finishing touch of gold leaf to an intricate moulding in the gallery, with the finished barrel ceiling visible in the background.
