EPDM Wall Flashing Repair — Oldcastle Infrastructure, Littleton
Project Overview
- Location: Littleton, CO
- Building Type: Commercial Industrial Manufacturing Plant (Oldcastle Infrastructure)
- Size: 600 sq ft of wall flashing across 160 linear feet
- Roofing System: Versico 60-mil EPDM flashing, fully adhered
- Duration: 4 days
- Completed: January 2026
- Manufacturer: Versico Roofing Systems
- Warranty: 5-year warranty on repaired areas
Roof Condition
Oldcastle Infrastructure’s precast concrete manufacturing plant in Littleton had a stone-ballasted EPDM roof with failed wall flashings on two sides of the building. On the north parapet, the EPDM flashing had torn loose and was hanging off the wall, leaving the wood behind it exposed to weather. Along the east side, where the flat roof meets a metal roof, the flashing had also failed.
- EPDM flashing on the north parapet torn loose and hanging off the wall
- Wood wall substrate exposed to weather behind the failed flashing
- East-side flashing at the flat-to-metal roof transition also failed
- Two additional repair areas identified during the project walk
Evaluation & Approach
The EPDM field membrane under the stone ballast was still serviceable. The failures were at the walls where the flashing had pulled loose, not in the field. Targeting the walls fixed where the roof was actually leaking without disturbing the working field membrane.
Why This Approach
- Mechanically securing the field sheet at the base of the wall stops the membrane from pulling on the flashing as it moves with temperature swings
- New wall substrate gives the fully adhered flashing a solid, clean surface to bond to
- Running the flashing under the metal roof panels on the east side makes the transition shed water the right way
- Fully adhered flashing over solid substrate provides a wind-resistant finish
- The plant stayed in full operation throughout the four-day project
- Ballast was pulled back for the work and replaced when finished
Scope of Work
- North Parapet — Substrate Replacement: Removed the failed EPDM and the old ¼” wall sheathing on about 60 linear feet of the north parapet. Installed new ½” wall substrate.
- North Parapet — Field Sheet Securement: Fastened the existing EPDM field membrane at the base of the wall with 2 3/8” membrane plates 9” on center to prevent the membrane from pulling on the new flashing.
- North Parapet — New Flashing: Fully adhered new 60-mil EPDM flashing up the north parapet wall over the new substrate.
- East Transition — Field Sheet Securement: Fastened the existing EPDM field sheet at the vertical wall with membrane plates 9” on center along about 100 linear feet of the east side.
- East Transition — New Flashing: Fully adhered new 60-mil EPDM flashing up the wall and 12” under the metal roofing, then refastened the metal panels.
- Additional Repairs and Ballast: Completed two additional repair areas identified on the project walk, then replaced the stone ballast in all work areas.
Result
Warranty: 5-year warranty on repaired areas
- 160 LF of Flashing Rebuilt: North parapet and east transition flashings replaced with fully adhered 60-mil EPDM over solid new substrate
- Exposed Wood Covered: Deteriorated wall sheathing replaced and sealed behind new flashing
- No Plant Disruption: Manufacturing operations continued throughout the four-day project
- Finished in 4 Days: All work completed in January with ballast replaced and a 5-year warranty on the repaired areas