Introduction

Foothills Correctional Institute in Morganton, NC needed a dependable, long-term roofing solution for a large, low-slope roof in a high-security environment. The existing EPDM roof was more than 31 years old and had moved beyond “repairable” condition.

The objective was clear: eliminate recurring leak risk, rebuild critical roof details the right way, and deliver a system that supports predictable budgeting through strong warranty options.

The Challenges

Several factors made this project more complex than a typical roof replacement.

An EPDM roof beyond its service life
The RFQ documentation identified broad issues at seams/splices, curbs, and penetrations—classic indicators that the roof system had exceeded its useful service life and that ongoing patching would not provide lasting reliability.

A large roof footprint with numerous vulnerable details
With a roof footprint in the ~65,000 SF range and multiple penetrations, drains, scuppers, and expansion joints, the project required disciplined detailing. On roofs like this, the field membrane matters—but the details determine whether leaks return.

Coordination inside a high-security facility
Roof work at a correctional facility adds complexity: controlled access, tighter scheduling, strict jobsite expectations, and a need for consistent end-of-day conditions that do not disrupt operations.

Ballasted system considerations
Ballasted systems rely on stone placement over the membrane. Without the right protection strategy, rough or aged ballast conditions can increase abrasion risk over time, especially in high-traffic areas or where stone distribution becomes uneven.

The Process

WNC Roofing’s approach focused on full membrane replacement and “detail-first” execution to remove systemic failure points and create a maintainable system moving forward.

Step 1: Plan, stage, and prepare for a secure facility workflow
Work was organized to support access control, safety, and day-to-day operational continuity typical for institutional environments.

Step 2: Manage existing ballast and salvage re-usable components

• Existing gravel ballast was shifted and saved for reuse.
• Existing edge metal was removed and saved for reuse where applicable.

Step 3: Rebuild the system with a new EPDM membrane

• Install new Carlisle 60 mil black EPDM membrane in a ballasted configuration per manufacturer specifications.
• Upgrade seam durability by using 6-inch seam tape (instead of narrower tape), strengthening the most common long-term vulnerability on EPDM roofs—seams and splices.

Step 4: Overbuild the leak-prone details

• Penetrations: remove old flashings, clean substrates, and install new EPDM flashings and sealants per manufacturer requirements.
• Expansion joints: install new flexible backer rod and complete seal per manufacturer specifications.
• Drains: recondition by cleaning, applying new sealant, and using stainless-steel bolts.
• Scuppers: clean and install new EPDM flashings and sealants.

Step 5: Add protection fabric to reduce ballast abrasion risk

• Install Carlisle 200V protection fabric over the new EPDM to help protect against abrasion from rough stone ballast conditions.
• Respread existing gravel evenly across the roof.

Step 6: Perimeter completion and closeout

• Reinstall coping with new fasteners and sealants.
• Final walkthrough with a building representative and manufacturer inspector with the seam exposed for a full visual inspection.

The Results

Because this was a full roof replacement (not a coating or small repair), the results are best measured in risk reduction, system durability, and long-term maintainability.

Eliminated systemic seam-failure risk
Replacing the end-of-life EPDM membrane removed the root cause of widespread seam/splice problems that had become a recurring source of leaks.

Reinforced the areas where leaks usually start
Penetrations, curbs, drains, scuppers, and expansion joints were rebuilt with new EPDM flashings and sealants—targeting the failure zones that typically drive repeat service calls.

Increased durability in a ballasted environment
The addition of protection fabric created a buffer layer between the new membrane and stone ballast, supporting longer-term durability and helping reduce abrasion-related wear points.

Improved asset planning through warranty pathways
The project included a 20-year manufacturer material warranty and 2 year workmanship coverage, with an optional upgrade to a manufacturer labor-and-material NDL warranty (with inspection and maintenance requirements). This provides clearer long-term forecasting for institutional facility budgets.

Conclusion

Foothills Correctional Institute’s reroof demonstrates what the right plan looks like when an EPDM roof reaches true end-of-life: stop spending on recurring patches, replace the membrane, and overbuild the details that cause most leaks.

By combining a new 60 mil EPDM system, reinforced seams, disciplined flashing work, and protection fabric for ballast durability, the facility moved from reactive leak risk to a long-term, maintainable roofing system—backed by strong warranty options and a clearer path for future budgeting.