Roofing behind bars

Westville Correctional Facility, Westville, Ind., is a medium- to maximum-security prison for adult male offenders. Originally built as Beatty Memorial Hospital in 1951, it was converted to a correctional facility in 1979.

The facility currently is undergoing a $1.2 billion renovation project called Build Westville that includes the construction of a new state-of-the-art prison on the same grounds as the existing, outdated facility. The joint venture project for general contractors F.A. Wilhelm Construction, Indianapolis, Garmong Construction, Terre Haute, Ind., and Granger Construction Co., Lansing, Mich., is expected to be completed in 2027. The new 4,200-bed prison will include 700 more beds, enhance capacity and modernize infrastructure.

Korellis, Hammond, Ind., was selected as the roofing contractor for the project.

“We had recently done a project on the old Westville prison, so we were the preferred contractor for the Indiana Department of Corrections,” says Cody Junge, project manager at Korellis.

Logistics and safety

In July 2024, the Korellis team began work on Westville Correctional Facility. For this new construction project, there were as many as 50 contractors from other trades working at the same time, making logistical coordination essential. Material procurement was another hurdle.

“Material shortages, delivery delays and tariffs were a key focus point to control, requiring Korellis to secure materials at least a month in advance,” Junge says. “This proactive approach ensured timely installation and kept the project on schedule despite market constraints.”

Twelve Korellis crews contributed to the project. To ensure safety for all workers, a guardrail system was maintained throughout the project’s duration.

“Korellis’ culture of safety is deeply ingrained in everything they do,” says Carson Thomas, regional business manager—midwest division at Elevate,™ Nashville, Tenn. “In addition to monthly safety meetings for all employees, they host an annual Safety Fest that covers a wide range of topics from fall protection and firefighting to material handling and hazard awareness.”

Installation

Korellis’ work was divided into four roof areas.

The largest roof area was 191,000 square feet. For this section, the team placed Elevate ISOGARD^™ GL flat and tapered polyisocyanurate insulation and Georgia-Pacific DensDeck® Prime Roof Boards in low-rise polyurethane foam adhesive over precast concrete.

“The precast concrete deck was an uncommon feature with limited industry data available,” Junge says. “We engaged directly with NRCA to confirm best practices and ensure the highest level of quality.”

Next, team members adhered Elevate UltraPly^™ 60-mil TPO membrane in grey.

On the second-largest roof area covering 189,478 square feet, team members placed Elevate ISOGARD GL flat and tapered polyisocyanurate insulation, Georgia-Pacific DensDeck Prime Roof Boards in low-rise polyurethane foam adhesive over precast concrete and UltraPly 60-mil TPO membrane in grey.

“The tapered roof system reached 26 inches at its highest point, requiring precise layout and skilled installation,” Gellert says.

On a third area covering 107,295 square feet, team members placed Elevate ISOGARD GL flat and tapered polyisocyanurate insulation and Georgia-Pacific DensDeck Prime Roof Boards in low-rise polyurethane foam adhesive over precast concrete followed by UltraPly 60-mil TPO membrane in grey.

“Korellis has been an Elevate Master Contractor and a member of our prestigious Hall of Fame, which is given out to our top contractors around the country,” Thomas says. “They bring a deep level of expertise to every job site.”

A fourth 26,990-square-foot roof area had a metal deck. For this section, team members mechanically fastened Carlisle® Syntec Systems InsulBase^® Polyiso insulation followed by adhering Carlisle Sure-Weld^® 60-mil TPO reinforced membrane in grey.

In addition, the Korellis team installed 8,000 linear feet of fabricated sheet metal flashings, 261 skylights and high-security roof hatches across all roof areas.

“Every element demanded meticulous planning and execution to meet performance, security and Korellis quality standards,” Junge says.

The project encompassed about 27,000 man-hours and involved all Korellis tradespeople. In addition to roofing and sheet metal, the masonry team cut reglets into the precast concrete walls for counterflashing.

“The Westville Correctional Facility was a monumental roofing project defined by its massive scale, precision requirements and unwavering emphasis on safety and craftsmanship,” Junge says.

Ready to serve

In April 2026, the Korellis team completed work on the Westville Correctional Facility on time.

“The scale and complexity of the roofing work on this project was extraordinary,” Junge says. “From installing a fully tapered Elevate TPO roof system and a Carlisle roof with metal decking to integrating hundreds of skylights with precision safety measures, Korellis showcased unmatched roofing expertise and precision. Every seam, slope and penetration was executed with accuracy and care, resulting in watertight, high-performance roof systems that meet the toughest performance and security requirements.”

For its work on Westville Correctional Facility, Korellis was selected as a 2026 NRCA Gold Circle Awards finalist in the Outstanding Workmanship: Low-slope category.

“This project is a lasting example of the team’s skill, coordination and dedication,” says Tony Sagrati, commercial estimator at Korellis. “It is built to the highest standards and ready to serve its critical role for decades to come.”

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