Under construction

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After almost 40 years, Boca Raton Community High School, Boca Raton, Fla., no longer could accommodate students—more space was needed for classrooms and school functions. In addition, the school's buildings, which were prone to flooding because of their low-lying locations in Boca Raton, were in poor shape. Roof system leaks were common, and mold had plagued the school. The school district, therefore, created plans to build a new campus.

But the school district did not want to close the school during construction, so the project was completed in three phases to minimize disruption of the school. During phase one, some new buildings were built around the existing campus; the existing buildings were torn down during phase two; and the new buildings were finished during phase three. The area where the existing campus stood was replaced with an outdoor courtyard.

Because of the project's unique progression, Trans Coastal Construction Co., West Palm Beach, Fla., which was brought into the project by general contractor Centex-Rooney Construction, Plantation, Fla., had to pay particularly close attention to the schedule. The roofing contracting company's work began in June 2002—during phase one—and consisted of installing roof systems on six new buildings. The company returned to the job site in September 2003—during phase three—to finish roof system installations on other buildings.

"They had a tight schedule and were eager to make the new buildings watertight, which is one reason they wanted a roof system that could be installed quickly," says Duane Burgard, president of Trans Coastal Construction.

Architectural firm Schenkel Shultz, West Palm Beach, therefore, chose a Stevens EV white membrane roof system from Stevens Roofing Systems.

Roof system installation began when an eight- to 12-person crew from Trans Coastal Construction installed two layers of 2-inch- (51-mm-) thick polyisocyanurate insulation and massive crickets for drainage. Then, the 60-mil- (0.06-inch- [1.5-mm-]) thick Stevens EV, an Elvaloy®-based single-ply membrane, was installed. The membrane was mechanically fastened, and its seams were hot-air-welded. To meet the owner's 150-mph (241-km/h) wind-speed requirement, an enhanced fastening pattern was used.

"Instead of 12 inches (305 mm) on center, an engineered fastener spacing of 6 inches (152 mm) on center was required," Burgard explains.

During the project, Trans Coastal Construction faced several obstacles, such as getting materials to the job site. The company only could have materials delivered between 8:30 a.m. and noon to work around the student drop-off and pick-up times.

Another challenge was ensuring students' safety.

"As is typical when working at a school, we had to be safety-conscious for the well-being of the students," Burgard notes. "Fortunately, the area we were working in was blocked off from the rest of the school."

To keep workers safe, warning lines and safety monitors were used.

In August, when the $53 million project is expected to be completed, students will be able to fully enjoy their new campus. The campus features a larger auditorium and music building; additional classroom buildings; a new administration building; a locker-room building; more parking; and a rebuilt cafeteria, media center and gymnasium.

Trans Coastal Construction, which is celebrating 30 years in business this year, has repaired a number of schools in Florida. But working on Boca Raton Community High School stands out.

"It was rewarding to be part of the renovation of a 40-year-old high school," Burgard explains. "A project of this size and complexity always is a challenge. It was good to be involved and see our staff step up to the plate."

Kate Gawlik is associate editor of Professional Roofing magazine.

Project name: Boca Raton Community High School, Boca Raton, Fla.

Project duration: June 2002 to February 2003 and September 2003 to April 2004

Roofing contractor: Trans Coastal Construction Co., West Palm Beach, Fla.

Roof system type: Elvaloy®-based single-ply

Roofing manufacturer: Stevens Roofing Systems, Holyoke, Mass.

General contractor: Centex-Rooney Construction, Plantation, Fla.

Architect: Schenkel Shultz, West Palm Beach