How To Build A Prison Cell Module

Many of you have expresed an interest in the modular prison cells we will be producing in Fuquay Varina. During the past few weeks, we have made several trips to our sister plants who are currently producing the modules. The following photos were take in Lebanon,TN and Telford,PA and show the dual cell modules, each containing two complete cells. Our modules will be quads, with four cells each. For a size comparison, the modules shown here are about 12' x 15' in size. The quad modules will be 12' x 30' and will weigh in at a hefty 40 tons each. I have arranged the photos in sequence to simulate the production process. Enjoy your tour.

Tape The Doors

All door and window frames, junction boxes, and other inserts must be taped and caulked to prevent entry of the concrete.

Oil The Form

The forms are sprayed with release agent to prevent sticking of the concrete. The excess is then wiped off.

Install The Wiring

All the junction boxes and conduit are cast in place.

Build A Cage

The reinforcing cage is built on a steel and plywood jig to ensure proper alignment of all the components.

Set The Cage

The cage is lifted off the jig and placed on the form with the crane.

Put In The Doors

The door frames are located on the form and secured.

Place The Windows

The window frames and all other inserts, such as chase doors, A/C grids, and numerous threaded bolt inserts are attached to the form.

Caulk

Most of the inserts are also caulked to insure a good seal against the concrete.

Caulk Some More

Many of the form seams are caulked where possible to prevent bleed out of the cement paste in the concrete. The forms also have rubber gaskets to help prevent leakage.

More Things To Put In

More conduit, the lifting cables, and two inches of styrofoam insulation for the outside wall are all added.

Close The Form

The form is closed up, ready to pour the concrete

Pour The Concrete

Very high slump, self-compacting, concrete is poured into the form. Great care must be taken to prevent damage to the styrofoam in the back wall. If the concrete gets too high on one side or the other, a "blow out" of the styrofoam will result.

Spread and Screed

The concrete is spread evenly and then leveled with an aluminum screed.

Float It

The concrete is given a once-over with the bull float

Trowel It

The tops are given a magnesium trowel finish. Those modules where the top will be the floor of the cells above it are then given a steel trowel finish surface.

Strip The Chase Core

The chase forms a "homeplate" shaped opening through the module and is used as a conduit for plumbing and wiring services. The chases connect to plenum risers which are placed between every two layers of cell modules and allow for easy access to utilities and HVAC equipment throuhout the finished building. We will also be producing the plenum risers in Fuquay Varina.

Hook Up The Crane

The cranes are hooked to the lifting cables cast into the module. These cables are cut off after the modules are placed at the building site.

Strip The Module

The module is lifted out of the form by the crane.

Carry It To The Door

The module is carried to the door and set on a truck to be carried outside. In Fuquay, our crane rails will extend outside the building, eliminating this step.

A Peek Inside

This is a view of the inside of the module from underneath. The unique shape of the chase is plainly visible.