Detention Design and Construction with Truss-reinforced Steel Panels

550 Oak Grove Parkway Vadnais Heights, MN 55127 651-633-6100 Detention Design and Construction with Truss-reinforced Steel Panels Credit for this course is 1 AIA HSW CE Hour Course number: tru11a Ron Blank & Associates, Inc. 2013

An American Institute of Architects (AIA) Continuing Education Program Approved Promotional Statement: Ron Blank & Associates, Inc. is a registered provider with The American Institute of Architects Continuing Education System. Credit earned upon completion of this program will be reported to CES Records for AIA members. Certificates of Completion are available for all course participants upon completion of the course conclusion quiz with +80%. Please view the following slide for more information on Certificates of Completion through RBA. This program is registered with the AIA/CES for continuing professional education. As such, it does not include content that may be deemed or construed to be an approval or endorsement by the AIA or Ron Blank & Associates, Inc. of any material of construction or any method or manner of handling, using, distributing, or dealing in any material or product.

An American Institute of Architects (AIA) Continuing Education Program Course Format: This is a structured, web-based course with a final exam Course Credit: 1 AIA Health Safety & Welfare (HSW) CE Hour Completion Certificate: A confirmation is sent to you by email and you can print one upon successful completion of a course or from your RonBlank.com transcript. If you have any difficulties printing or receiving your Certificate please send requests to: certificate@ronblank.com Design professionals, please remember to print or save your certificate of completion after successfully completing a course conclusion quiz. Email confirmations will be sent to the email address you have provided in your RonBlank.com account.

Course Description In this one hour course, the design professional will learn about several approaches to constructing cells and other secure areas in detention facilities. The course will discuss the advantages and disadvantages of each of these approaches which will help the professional achieve the optimal design for the owner s requirements for a safe and secure prison while also meeting cost and scheduling goals.

Learning Objectives By completing this course, the design professional will be able to: Describe the evolution of detention construction Describe advanced detention construction solutions using truss-reinforced steel panels with hollow metal doors, frames and windows Describe contemporary detention design requirements and the advantages of using truss-reinforced steel panels for both new construction and retrofit of existing facilities for detention uses Describe contemporary detention construction requirements and the advantages of using truss-reinforced steel panels

The Evolution of Detention Construction

Prisons of the Past In the 1800 s, prison cells were made out of steel, like this one in Texas, and were frequently pulled around on wagons. When cells were moved inside, concrete block was the easiest construction method. Bar grille cell fronts were the norm and are still seen today in aging prisons.

More Modern Approaches As interest in more humane and protective approaches grew, new cell construction techniques emerged. Site-built concrete walls CMU (concrete masonry units) and pourin-place walls using forms Modular units Truss-reinforced steel wall panels

Concrete Masonry Units (CMU) Oldest approach of modern construction methods. Lay terminology is cinder block or concrete block. Concrete blocks are reinforced with rebar, then grout-filled. Hollow metal frames are built into walls on-site.

CMU -- Advantages Relatively flexible design Abundance of suppliers of CMU blocks CMU blocks are inexpensive

CMU -- Disadvantages Cells are on the critical path (the sequence of tasks which define the shortest completion period for the project). Many other trades are dependent on completion of CMU cell construction. Cells must be built before the structure is enclosed, potentially causing weather delays for the construction schedule.

CMU -- Disadvantages The logistics of laying block are hard to manage and require wet work, rebar, scaffolding and shoring. Windows and frames must be onsite before cell construction can proceed. MEP preparations and furniture & equipment embed placements must be done on-site. Heavy weight on multi-story units greatly impacts structural steel requirements. CMU blocks may crack as the building settles.

Pour-in-Place Concrete Walls This niche solution emerged in the earlier days of concrete cell construction and is now rarely used. All walls are formed on the job site by filling wood planking with concrete. Walls and ceilings serve as major structural components of the building. Pour-in-place walls are currently used only as load bearing walls.

Pour-in-Place -- Advantages Structurally strong Resistant to natural disasters Construction approach familiar to most GCs

Pour-in-Place -- Disadvantages Cells are on the critical path with the construction schedule dependent on their completion. The building must be either roofless or not completely enclosed to allow access, and only one floor at a time can be built. Several days are needed after the pour before forms can be fully removed, and in many instances nearly 30 to 45 days are necessary before primary or re-shoring can be removed. The cast-in-place contractor/installer must also frame out MEP penetrations and incorporate embeds in the walls before concrete is poured. This is a difficult, time-consuming and expensive effort, and quality is difficult to control. Aesthetics are poor.

Modular Construction Concrete Precast Modules These cell modules were the first approach to compete successfully against CMU block. Cells are made from molds designed by the precast cell manufacturer. Cells can be cast either at the plant (plant-cast precast modules) or at the construction site (site-cast precast modules). If site-cast, a large space at the construction site must be made available. Modules are lifted and stacked into an unenclosed structure by crane. Steel Modules Metal boxes Modules are manufactured offsite and trucked as single cells to the jobsite. They are generally fixed in size and shape.

Modular Construction -- Advantages Cells are designed early, which speeds the construction design phase. A complete unit is delivered to the jobsite, reducing field labor. Delivery is faster than CMU and cast-in-place approaches. Modules are less expensive than cast-in-place.

Modular Construction -- Disadvantages An additional bid pack is required (cells are not in the DEC package), leading to higher cost and more coordination. Cells are on the critical path, with other trades dependent on their installation. The building cannot be fully enclosed until cells are in place. Heavy weight means only one or two cells will fit on a flatbed truck, leading to huge transportation costs. Weight is also a limiting factor in high-rise designs. Design flexibility is minimal module manufacturers want architects to design all cells the same to fit existing molds. New molds are expensive. Maintenance is an issue since concrete is subject to chipping and gouging.

Truss-Reinforced Steel Panels The latest development in detention construction technology. Combines the strength of steel for the highest security possible with a thin-panel approach that delivers significant space savings as compared to concrete. Appropriate for both new construction and retrofit of existing buildings for detention purposes.

Truss-Reinforced Steel Panels The system uses a truncated, triangular-shaped, roll-formed steel truss that spans the panel s full length and width.

Truss-Reinforced Steel Panels -- Advantages A space-saving and lightweight approach. Maximum design flexibility. Installation is not on the critical path of the construction schedule. Maximum construction scheduling flexibility as panels can be installed on slab before the building is erected, after the superstructure is in place, or after the building is enclosed. Erection within enclosed building allows work in inclement weather.

Truss-Reinforced Steel Panels -- Disadvantages Panels do not support the superstructure, so building must be self-supporting. Initial material cost is higher than CMU material. Requires more onsite labor than precast modules.

Advanced Solution: Truss-reinforced Steel Panels

Description Double-skinned, 2 thick hollow metal panels are manufactured with interlocking rabbeted edges. Panels are used with hollow metal doors and frames. Heavy gauge galvanized steel or stainless steel are available for high moisture areas such as showers and laundries. Panels are generally grout-filled in the field for improved acoustics, although this is not required for security. Rock wool can be used as a lower cost solution. Panels are mounted in floor and wall channels, then welded to channels and to adjoining panels. After installation in the field they are finish painted.

Installation Floor and wall channels are laid out and secured to slab. Panels are slid into place and welded. Panels are easily installed by general laborers. Panels can be preassembled in the factory to achieve near-assembly line efficiency at installation.

Filling Grouting is done after the panels are installed and welded. Grout decreases sound transmission but is not necessary for security. Factory-installed mineral wool may also be used as an inexpensive filling

Contemporary Detention Design Requirements

Contemporary Design Requirements Trends in detention facility design require a new approach that is more flexible than traditional construction methods. These trends include: Modular designs of multiple cell pods supervised from a central control room Multiple security requirements within a single facility general population, isolation, holding areas, dayrooms, visitation areas, medical facilities, and 4 or 8-man cells. Limited funds for additional space, especially at the county level. Many architects have only one detention project during their careers and so they need to get up-tospeed quickly with new technologies that can effectively meet these challenges.

Contemporary Design Requirements The architect s primary responsibility is to ensure all parts of the facility meet the level/s of security required. Architects need complete design flexibility, using products that accommodate multiple usages within one facility isolation cells, dayrooms, visitation areas, etc. They also are increasingly called on to design a level of protection against spread of infectious disease. The architect shares the project responsibility of controlling costs and enabling timely completion.

Contemporary Design Requirements Need to be able to use any good potential site, even those with poor soil that cannot support heavy loads. With increasing emphasis on LEED in new construction, the architect s choice of the cell construction system can help secure needed LEED points. Local jurisdictions may seek to retrofit existing facilities for detention use, which the right cell system can make possible. Buildings need to be adaptable to changing requirements in the future.

Design Advantages of Truss-Reinforced Steel Panels

New Construction Superior Security When compared to the impact resistance of concrete solutions, truss-reinforced steel wall panels made of 14 gauge steel are considerably more secure. 14 gauge truss-reinforced steel wall panels test to failure at 4800 impacts, more than 4 times the impacts of CMU. 12 gauge ungrouted panels test to failure at 5800 impacts. (Impact testing conducted according to requirements of the ASTM F2322 standard using a pendulum battering ram style attack. The testing ram has 2 heads, one blunt and one sharp. Blows are applied in sequences of 50 blows from each head. ASTM requires 600 impacts to pass the test.)

New Construction Design Flexibility Any design can be accommodated with truss-reinforced steel wall panels, unlike modular solutions. Floor and wall channels are laid first, based on the design, and panels are then dropped in. 2-man, 4- man and 8-man holding cells can easily be accommodated. Main/mezzanine designs with a cantilevered ceiling/upper walkway are easily accommodated. Owners have the option of using a pre-engineered metal building to lower costs. The steel panels (walls, floors, ceilings, cell fronts and hollow metal doors, frames and windows) provide an interior secure perimeter. Steel panels can be removed when the building is no longer needed for inmate cells, allowing reuse of the building shell for warehousing, manufacturing, offices, etc.

New Construction Chase designs Owners and architects have the flexibility to design the MEP chase approach that best fits their needs. A front chase with a Y configuration, where the chase is accessed from the corridor between cells. A rear chase, where the chase is accessed in a back area not exposed to the inmate population.

New Construction Front chase design In this approach, steel panels form the partition walls and cell fronts, and the back of the cell is a load bearing building exterior wall. The plumbing chase is a Y-configuration at the front of the cell.

New Construction Rear chase design In this approach, steel panels are used for all cell walls with a rear chase. This means an inexpensive outer shell is possible, e.g., a metal building. Rear chase design also allows maintenance access without exposing staff to the prison population.

New Construction Material and Panel Size Options Unlike CMU and modular construction, truss-reinforced steel panels have a variety of material options to meet the varying needs within a facility. 12 ga and 14 ga A60-galv, 304 stainless steel, and 409 stainless steel are all available in standard and custom sizes up to 56 W x 12 H. Panels can be spliced for more height as necessary. 2 different materials can be used on one panel, e.g., 14 ga A60- galv on one side and 304 stainless steel on the other side for cell walls that abut high-moisture areas such as showers or kitchens.

New Construction Finish Paint Options Panels are shipped prime coated with a 2- part epoxy baked-on finish, then finished in the field with a variety of options: 2-part epoxy air-dry finish Security caulking to fill in joints between panels for a seamless appearance Flecked finish for anti-glare protection Anti-microbial and anti-mrsa finish to protect against the spread of infection Wood grain finish when aesthetics are important

New Construction Lightweight Truss-reinforced steel wall panels filled with concrete grout weigh from 1/4 to 1/3 the weight of grouted CMU block. As a result: Foundation and footing requirements are substantially reduced Soils that cannot support concrete solutions may be suitable for a steel panel approach Structural beams can be minimized because the system is self-supporting Provides a lighter building footprint, minimizing seismic impact on the building

New Construction Square footage requirements and space savings Designed to the ACA standard requirement of 80 sq ft per cell, eight 8 x 10 cells with 8 CMU/concrete walls require 795 sq ft of building space.

New Construction In contrast, eight 8 x 10 cells with 2 thick steel wall panels require 678 sq ft. This is a savings of 117 sq ft, more than enough for one additional cell.

New Construction LEED 90% of panel material is recycled steel Panels can be demounted and recycled or reused. Labor for grouting, mechanical, electrical and plumbing trades fulfill local labor requirements.

Retrofits/Renovations Truss-reinforced wall panels have clear benefits both for counties looking to retrofit existing buildings for detention use and for states that need to modernize aging prisons. Panels can be carried in the front door in enclosed buildings. Existing building loads can generally accommodate panels but not concrete solutions. Maximum design flexibility allows for varied detention spaces. Old style bar grille cell fronts in aging prisons can be replaced with steel panel cell fronts at a relatively low cost.

Retrofits/Renovations This project converted an existing facility into a juvenile justice center. Panels were carried in the front door and then installed. A courthouse basement was renovated into a detention facility

Contemporary Detention Construction Requirements

Contemporary Detention Construction Requirements The general contractor s overall responsibility is to bring in the project on time and on budget. In the process, the GC must: Stay in control of the project schedule Coordinate the work of multiple trades, often working simultaneously Mitigate the risk of weather delays Manage the project s general requirements

Detention Construction Advantages of Truss-reinforced Steel Panels

Scheduling Flexibility GC s can choose when to erect the cells on a slab, when the superstructure is in place, or when the building is fully enclosed. This means the cells are off the critical path, unlike CMU or modular solutions. These options minimize lost work days due to bad weather and allow work to proceed throughout the winter in colder climates. All other options require the building to be unenclosed until installation is complete. Panels can be preassembled for even faster installation.

Panel Installation on Open Slab For this project in a southern location where weather was not a concern, the panels were installed immediately after the slab was poured. The building was then erected around the cells.

Panel Installation with Superstructure in Place Here, panels are staged at each level and then installed.

Coordination with Other Trades All MEP coordination is done at the plant rather than on-site panels come with all necessary cutouts. CMU masons must box out these openings as they build. Multiple trades can work at the same time. The wall installation process allows MEP trades to work in an open environment, compared to modules, where MEP trades must wait until the roof is on and all modules are installed. Embeds are not required since cell furniture is welded directly to the walls. Precast concrete manufacturers need information on every item before casting, which happens much earlier in the construction process. With CMU, embeds must be on site before work is begun.

Detention Construction Advantages of Truss-reinforced Steel Panels Reduced general requirements Requirements for framing, scaffolding and shoring are greatly reduced from what is required with CMU. General laborers can easily install the panels. Availability of masons is not a limiting factor, as is the case with CMU. Modules require several crane operators, special heavy load access roads and a very large staging area. Panels are compact and easy to store. They are delivered in weeks, not months. Site cast concrete modules require a large dedicated area onsite.

Course Summary Now the design professional will be able to: Describe the evolution of detention construction Describe advanced detention construction solutions using truss-reinforced steel panels with hollow metal doors, frames and windows Describe contemporary detention design requirements and the advantages of using truss-reinforced steel panels, as well as understand the unique requirements of retrofitting an existing facility and the advantages of trussreinforced steel panels for retrofits. Describe contemporary detention construction requirements and the advantages of using of truss-reinforced steel panel solutions