Modular jail system and method of preparing same

The present invention is directed to a modular jail structure comprising a plurality of removable cells in adjacent relation arranged in a configuration to form an open area, a plurality of support columns removably coupled to the plurality of cells, and a roof supported by the plurality of support columns, covering at least the open area, such that the roof remains in place, supported by the support columns, when the plurality of cells are removed. It is also directed to a method of preparing and dismantling a jail facility comprising the steps of pre-fabricating a plurality of jail cells at a first site, preparing a foundation comprising at least one slab at a second site, transporting the plurality of jail cells to the second site, arranging the plurality of jail cells in at least one level in a configuration on at least one slab to create a central open area, coupling a plurality of support columns to the cells, erecting a roof supported substantially only by the support columns, and removing the arranged cells, when use of the jail facility is complete, leaving intact the roof supported by the support columns.

FIELD OF THE INVENTION 
The present invention relates generally to jail facilities and more 
particularly to modular jail facilities which can be quickly constructed 
and/or dismantled. 
BACKGROUND OF THE INVENTION 
The establishment of a jail facility in a given location is an inherently 
controversial undertaking. Few communities want to have a prison near 
their environs. Thus, when a site has been chosen, one method of allaying 
a community's fears is to emphasize the ability of the jail facility to be 
easily dismantled or relocated when the need for its services no longer 
exists. 
Many prisons have been judicially determined to be overcrowded. In order to 
comply with court imposed conditions, governmental bodies have been forced 
to find relatively quick means by which such overcrowding can be 
alleviated. Thus, it has become crucial for the construction industry to 
provide for the accelerated creation of additional jail space on new or 
existing prison sites. 
Finally, as older prisons deteriorate to the point of uninhabitability, 
their replacement and/or repair becomes necessary. This results in a need 
for jail facilities which can be put into use expeditiously. Thus, the 
inexpensive establishment of facilities which are capable of serving as 
either temporary or permanent facilities is extremely desirable. 
Efforts have been made to address the above problems by the development of 
"modular" jail systems. Such systems generally rely on pre-fabricated 
cells or cell components which can be combined at a selected site to 
create or augment an operational prison facility. At least three types of 
modular jail systems are generally available: pre-cast concrete, trailers 
and steel cellular. 
Pre-cast concrete systems use pre-formed, finished or unfinished concrete 
cells which are arranged on-site. The cells may be finished at the site 
and appropriate fixtures added. Finally, a roof and other elements are 
added to complete the jail facility. Alternatively, they may be installed 
in an existing or new building. 
Pre-cast concrete systems have several drawbacks: they take a relatively 
long time to construct; they require a significant amount of on-site 
fabrication; they are extremely heavy, thereby requiring substantial 
support structure; and they are subject to deterioration caused by human 
and natural elements. 
Trailer systems employ cell units (one or multiple cells) which are 
completely pre-assembled. These units are typically deployed outdoors 
within a secure perimeter. If the jail facility is to be an indoor 
facility, the trailers must be brought into a building built to the 
appropriate security standards and anchored in place. 
Trailer systems are, by their nature, temporary installations. While they 
can quickly be placed into service, they cannot be satisfactorily used in 
high inmate population situations (in part because they cannot be readily 
deployed in multiple levels) and because of the difficulty in integrating 
them to the ancillary areas required for a full detention facility. 
Finally, trailers require substantial maintenance to remain habitable and 
secure over time, primarily due to their typically flimsy construction. 
Steel cellular systems, such as the Mark Cellular System, provide a cost 
effective, quickly established, low maintenance alternative to other 
modular systems. The cells of these systems are totally pre-fabricated. 
On-site, they are simply secured in position. Either a building is built 
to surround the cells or a roof is mounted directly on them. The low 
weight, resistance to corrosion and the flexibility provided by a steel 
cellular system overcome many of the problems associated with the pre-cast 
concrete and trailer options. 
While steel cellular systems are generally superior to other modular 
systems, they are not without their own drawbacks. For example, as noted 
above, these systems require that either a complete building be 
constructed to house the cells or a roof be erected directly on the 
modules. In the latter case, no structure remains when the cell modules 
are removed. In the former case, the building must be substantially 
dismantled when the cell modules are removed or made overly large to 
accommodate a temporary entryway/exitway. Still further, when cells are 
used within a secondary building, dead space is created between the walls 
of the cells and the walls of the building. This is a potential security 
problem since prisoners may be able to secrete themselves or other things 
in that dead space. 
OBJECTS OF THE INVENTION 
Accordingly, it is an object of the present invention to provide a cost 
effective modular jail system which can be easily dismantled with the 
option of leaving behind a usable structure. 
It is another object of the present invention to provide a modular jail 
system which does not require a separate building for containment of 
modular cells. 
It is a further object of the present invention to provide an efficient 
arrangement of modular cells within a complete modular prison system, 
enclosing a central day room area. 
It is yet another object of the present invention to provide an efficient 
layout of a complete prison system incorporating modular jail cells 
arranged in manageable groups that can be combined into a prison facility 
with the most efficient utilization of supervisory personnel. 
SUMMARY OF THE INVENTION 
The present invention is directed to a modular jail system, preferably of 
the cellular steel type, which associates a plurality of columns with a 
number of modular jail cells such that the columns support an otherwise 
freestanding roof. This construction permits the cells to be removed while 
leaving behind a structure immediately capable of serving as a gym, 
recreational pavilion, or the like. With the simple replacement of side 
walls, the structure can be used as a warehouse, a edifice for civic 
functions or the like. This configuration thus substantially enhances the 
overall value and utility of the system to the municipality. 
The modular jail cells of the present invention are preferably deployed in 
rectangular wings with the cells arranged in a quadrangle or `U`-shape 
which may be subdivided by fire walls to limit the number of inmates for 
which a guard or guards are responsible. These wings may then be arranged 
in any configuration around or adjacent to an administration building, 
joined by secure corridors. This arrangement provides maximum security 
while making efficient use of space. 
A complete jail facility made in accordance with the present invention may 
be built and dismantled by pre-fabricating a plurality of jail cells, 
columns, and roof panels at a first site, preparing a foundation 
comprising at least one slab at a second site, transporting the plurality 
of jail cells to the second site, arranging the plurality of jail cells in 
at least one level in a configuration on the slab to create a central open 
area, coupling a plurality of semi-dependent support columns to the cells, 
and erecting the roof panels supported substantially only by the support 
columns. When use of the jail facility is no longer required, the knockout 
panels are unbolted, permitting the cells to be removed leaving the roof 
intact supported by the columns.

DETAILED DESCRIPTION OF A PREFERRED EMBODIMENT 
As shown in FIG. 1, modular jail cells, made in accordance with the present 
invention are generally identified with the reference numeral 1. The cells 
1 are preferably prefabricated at an external facility and transported to 
the appropriate prison site. The cells 1 are then joined together with 
other components at the site to form a complete structure 100 (see FIG. 2 
described below). 
As shown in FIG. 3, when a cell 1 is fabricated, a plurality of panels 2 
are bolted or riveted together to form the sides 4, 6, front 8, chase 10, 
and back walls 12 of the cell 1. The panels 2 are bent 90 degrees at their 
edges to form abutting flanges 14 which are fastened together with rivets, 
bolts or the like 13, as shown in FIG. 4. The panels may also be welded 
together. Secondary flanges 15, which are bent an additional 90 degrees 
from the flanges 14, render the overall shape of the panel edges in the 
form of a `C`, and provide strength and stiffness as well as a surface for 
attaching external facings such as aluminum siding or the like if desired, 
and to entrap fireproofing and sound deadening material 15a. The bent 
flange configuration 14 makes the fasteners 13 inaccessible to inmates. 
The floor 16 of each cell 1 is preferably constructed primarily of 
concrete. The use of concrete, as opposed to steel in prior art systems, 
significantly reduces the ability of inhabitants of a cell 1 to generate 
noise. As shown in FIG. 5, the floor 16 comprises a reinforced concrete 
base 17 surrounded, on all sides, by a metal frame 18. The steel 
reinforcements are spaced to prevent escape if the concrete is broken 
through. The base 17 is supported on the bottom by flanges 20 which are 
integral with the frame 18. When the base 17 is fabricated, a groove 22 is 
left around its top edge to provide room for the use of fasteners to 
attach the frame to the walls 4, 6, 8, 10 and 12 of the cell 1. Once these 
walls are attached, by rivets or other fasteners, the groove 22 is then 
filled, as shown in FIG. 6, with epoxy cement or the like to prevent 
access to the fasteners. Preferably, the floor 16 is sloped away from the 
walls 4, 6, 8 and 12 toward a drain (not shown) adjacent the chase wall 
10. This permits the cell floor 16 to be hosed down when a quick and/or 
thorough cleaning is desired. 
The ceiling 24 of the cell 1 is constructed in the same manner as the walls 
4, 6, 8, 10 and 12 and is comprised of the same or similar panels 2 joined 
with fasteners 13 along flanges 14. The ceiling 24 is attached to the 
walls 4, 6, 8, 10 and 12 at its edges with fasteners 19 which fit into 
pre-cut holes in secondary flanges 26 of panels. These secondary flanges 
26 extend outwardly at 90 degrees from the top inner face 21 of the walls 
4, 6, 8, 10 and 12 as shown in FIG. 7. A corner angle member 28 is then 
welded or fastened over the ceiling-to-wall joint to square off the cell 
1. 
Each cell 1 is typically fitted with specialized fixtures including one or 
two bunks 30, a table and stool combination 36, a sink and toilet 38, a 
mirror 40 and a light 42 (see FIG. 8). These fixtures are commercially 
available from various suppliers and are specifically designed for use in 
prisons. 
The chase wall 10 of the cell 1 cuts off what would otherwise be a front 
corner of the cell 1. Located directly behind the chase wall 10 are the 
plumbing, heating and cooling ("HVAC") systems for the cell 1. As shown in 
the layout in FIG. 9, by arranging two chase walls 10 in a back-to-back 
configuration, a triangular utility area (chase) 43 is created between 
each pair of cells 1. The utility area (chase) 43 is accessible via a door 
45, preferably fitted with a lock, which provides a secure means by which 
repairs can be effected to the cells' plumbing and HVAC systems. 
As shown in FIGS. 2 and 9, the cells 1 are preferably arranged in a bilevel 
configuration, in a rectangular grouping around an open area, into a wing 
120. Single tier, as well as multiple tier arrangements are possible. By 
dividing a group of rectangularly organized cells with a secure fire wall 
126, a manageable number of prisoners may be housed (e.g. in accordance 
with governmental regulations) such that one guard may be placed on duty 
in each wing at a time. However, the modular cells 1 of the present 
invention provide enormous flexibility, and can thus be arranged in 
virtually any desired pattern providing any guard-to-prisoner ratio 
desired. 
The open area or common area 46 of the wing 120 is formed as part of the 
interior space of the jail facility. Solid walls separate these spaces 
into areas in the quad allocated to each wing. Specialized fixtures such 
as tables 47 and seats 49 are preferably located in the common area 46 to 
provide eating facilities for the inmates. An elevated guard post is also 
preferably provided to house a guard to enhance the security of the 
circulating guard(s) on duty, to permit a clear view of each wing and its 
entire common area 46 at all times, as well as a separated exercise yard 
133, and to facilitate control of all cell doors and surveillance cameras. 
Before the cells 1 are put in place, a foundation 51 is prepared at the 
site. As shown in FIG. 12, the foundation 51 comprises two slab portions. 
A first, raised slab portion 44, forms the main floor for the common area 
46 of a grouping of cells. A second, lowered slab portion 48, supports the 
cells 1 as they are deployed around the periphery of the common area 46. 
This brings the cell floor 16 (constructed as shown in FIG. 6) to a level 
even with the main floor of the common area 46. The slab portions 44 and 
48 are typically supported by footings 50 prepared in accordance with 
standard building practices. 
As shown in FIG. 10, the bilevel arrangement of cells 1 are joined 
together, one on top of the other, and in side-by-side relation by bolts 
54 fitted through two holes 56 in corner members 52. The corner members 52 
are joined to the cells via corner posts 80 and are preferably in the 
shape of a cube with at least one side omitted to provide bolt 54 access 
to the holes 56 and tool access to the bolts 54. The two holes 56 of each 
corner member 52 are located in the downward or (upward) and outside faces 
of the sides of each corner member. At least eight corner members 52 are 
attached to each cell 1 providing the ability to establish four points of 
connection between each adjacent cell (i.e. those cells next to and/or 
below a given cell). 
Each lower level cell is preferably connected to the lower slab portion 48 
of foundation 51 by fitting bolts 54 through the downward facing holes 56 
in the four corner members 52 on the bottom of the cell 1. The bolts 54 
are then threaded into floating nuts 58 set in anchor angles 60 (see FIGS. 
11 and 12) cast into the lower slab portion 48 at appropriate locations. 
A plurality of columns 62 are affixed to the foundation 51 where the lower 
slab portion 44 joins raised the slab portion 48, as illustrated in FIG. 
12. These columns 62 are preferably spaced about 17 feet apart and are 
connected to or at least associated with a portion of the cells 1. 
However, the columns form no part of the structural support of the cells. 
In one embodiment of the present invention the columns 62 are formed as `I` 
beams (see FIGS. 13a and 13b). In another embodiment the columns are 
hollow, comprising a U-shaped column body welded to a backing plate (see 
FIGS. 14a and 14b). In yet another embodiment the columns are beams in the 
form of `T`s, the stems of which increase in width towards their top ends 
(see FIGS. 15a and 15b). In this embodiment, holes are precut in the 
outboard edge of the stem of the `T` to accept bolts and angles or T's to 
be fastened to the `T` for stiffness after the cells are removed. 
As shown in FIGS. 12, 13a and b, 14a and b and 15a and b, to initially 
secure the columns 62 in place, each I-beam, T-shaped or U-shaped column 
has a plate 66 welded to its bottom which has holes for accepting a 
plurality of anchor bolts 70. In the I-beam and U-shaped column 
embodiments a channel 68 is left between the lower slab portion 48 and the 
raised slab portion 44. In these embodiments, anchor bolts 70 or floating 
nuts (FIG. 11) are cast in the concrete below the channel 68 in such a 
manner as to mate with the holes in each column's plate 66, thereby 
providing a means to anchor the columns 62 to the foundation. The channel 
68 is then filled with concrete to the level of the raised slab portion 
44. 
In the T-shaped column embodiment a wide channel 68 is not necessary. The 
plate 66, welded to the bottom of the column 62, is fastened to the slab 
portion 48 and/or the grade beam 50 by floating nut (FIG. 11), as 
previously described. 
The columns 62 are preferably deployed at the joint 72 between every other 
cell 1 (about 17 feet) along each of two opposing sides (FIG. 2). In the 
I-beam and hollow column embodiments, the columns 62 abut the outside 
faces 74 of the front walls 8 of the two cells 1 whose joint 72 they span 
and are fastened to the cells' front-most corner post 80 and the girder 
panels 76 above the cells 1 (see FIG. 16). In the T-beam column 
embodiment, the stem 78 of the beam fits into the joint between the two 
cells and the flange 79 is fastened to the corner post 80 of each of the 
cells 1 as well as the end of girder panels 76 (see FIG. 17). 
The girder panels 76 form the web of the girder 82 with the angle sections 
82a and 82b, spanning the gap between the columns. This forms a closure 
between the uppermost cell and the supporting members (roof rafters) 84 of 
the roof panel 108 of the complete structure 100. The girders 82 are, as 
noted previously, affixed to the columns 62 by their endmost girder panels 
76. Each column 62 is also affixed to the rafters 84 by a haunch 85 welded 
to each column at its upper end (see FIG. 18). The wall sections (girders) 
82 provide lateral support to the structure 100 by acting as a web between 
the columns 62 and act as a support for the stub post 77. They also 
provide security by preventing prisoners from getting into the area above 
the cells. Insulation 83 is preferably placed directly above the 
upper-most cells 1 behind the girder wall 82 (see FIG. 24, described 
below). If desired, the secure area behind the girder wall 82 can be used 
for piping, wiring, and ventilation ducts. The gable end walls can house 
mechanical equipment or may be used as storage by providing locking doors 
(not shown) in place of one or more of the girder panels 76. 
Affixed to the top of each haunch 85 is a plate 104 which, in turn, is 
bolted or otherwise fastened to a roof rafter 84, as illustrated in FIG. 
19. The haunches 85 provide rigidity at the column to rafter connection 
and distribute the weight from the roof rafters 84 more evenly to the 
columns 62 to avoid placing the entire load on a relatively few points. 
As shown in FIGS. 19-21, the roof structure is composed of roof panels 108, 
splice caps 110, ridge caps 111, and ridge cruciform caps 113. The roof 
panels 108 are composed of rafters 84 connected by transversely spaced 
purlins 112, soffit/fascia 119, ridge members 136 and ridge angles 138. 
The outer roofing 140 is weather tight membrane which covers a vapor 
barrier and thermal break (not shown) and insulation 116 which in turn is 
enclosed by an inner perforated lining panel 142 for acoustical and 
security enhancement. The inner panel 142 is secured to ridge support 
angles 144, inner roof angles 146, and purlins 112. 
The roof panels 108 are joined to one another by removable fasteners and in 
turn are joined to the columns 62 in a like manner. Weather tight seals 
between the roof panels are accomplished with ridge caps 111, splice caps 
110 and ridge cruciform caps 113. 
The roof structure, comprises roof panels 108, supported by columns 62 and 
stub posts 77 to provide protection from the elements. Panels 108 are 
bolted together and splice caps 110 join the roofing 140 together creating 
water tight seals. At the peaked center of the roof a ridge cap 111 is 
preferably used together with a ridge cruciform 113. The purlin channel 
112 supports an inner roof liner 142 and insulation 116 which is placed 
above it. The insulation 116 thus is located within the area defined by 
the purlin 112 and the rafters. 
When the cells 1 are stacked to achieve multiple levels, as shown in FIG. 
2, a walkway 88 preferably is provided to permit access to the upper level 
cells 1. As shown in FIGS. 22 and 23 the walkway 88 comprises a bed 90, 
preferably in the form of a steel grating (although solid decking with 
steel or concrete is also acceptable), a railing 92 and support hangers 94 
on the outboard side. The bed 90 is supported by inboard and outboard 
runners 96 and 98. The inboard runner 96 is fastened to the front face of 
the front wall of the upper and lower cells 1. It may also be fastened, on 
either end, to columns 62, between which it extends in sections. The 
outboard runner 98 is attached to the lower end 102 of the support hangers 
94. The support hangers 94, in turn, are hung from the roof rafters 84 
which provide the majority of support for the walkway 88. The railing 92 
is in sections which extend between each support column 94. Alternatively, 
the walkway may be cantilevered out from the cells or supported by columns 
below. 
As shown in FIG. 24 a connector channel or knockout member 118 spans the 
small gap between the top of the upper cells 1 and the rafters 84. It is 
attached to the rafters 84 and the corner posts 80 of the cells 1. The 
member 118 provides little or no support to the roof 108, but acts to tie 
the cells to that portion of the roof structure 108. If the cells are to 
be removed at a later time, the member 118 insures that sufficient space 
exists after it is removed to permit the cells 1 to slide out and thus be 
removed from the roof structure 108 and columns 62 without damage to the 
rest of the structure 100. 
In use, the cells 1 are pre-fabricated at a first remote site, transported 
to the site of the jail facility and where they are preferably deployed in 
a rectangular manner, stacked two high, as shown in FIGS. 2, 9, and 25, to 
form a wing 120. The cells are mounted on a foundation which is prepared 
at the site and is comprised of the lowered and raised slabs 44 and lower 
slab 48. The columns 62 are attached to the floor and coupled to the cells 
and/or girder walls 82, as appropriate, and the roof 108 is erected 
thereon. 
The wing 120, if rectangular in shape, may be divided into two sections 122 
and 124 with a secure firewall 126 to keep the number of inmates down to 
an acceptable number. If, however, a larger number of cells/inmates are 
desired in a given location, the cells can be stacked three or more high 
and additional firewalls can be added or the single firewall omitted 
completely. 
If the cells 1 of the present invention are used as part of a large 
installation, multiple `U` shaped wings 120 may be employed. The 
additional wings 120 are preferably arranged in configurations as shown in 
FIGS. 26 and 27 around a common core forming a quad 134. Secure corridors 
132 link the administration facility to each quad 134. In one embodiment 
(shown in FIG. 25) the administration building 128 forms the core around 
which all the wings 120 are arrayed. In a second embodiment (shown in 
FIGS. 26 and 27), a plurality of quads 134 and a half quad are either 
directly attached to the administration building 130 or linked by secure 
corridors 132. 
When it is desired to remove the cells 1, the knockout member 118 is 
removed, as are any bolts connecting the cells 1 to the slabs. The bolts 
54 connecting the cells 1 to each other preferably are also removed. If 
sufficient equipment exists to move very large loads, cells stacked one on 
top of another may remain bolted together (as could some of the cells in 
side-by-side relation). 
After all of the cells 1 are removed from the structure 100, an open sided 
structure with a roof 86 supported by columns 62 remains. This structure 
can be dismantled for future use elsewhere or can be left at the site to 
be utilized for other functions. When the `T` beam columns are employed, 
angles (not shown) are attached to the stem of the `T` to form an `I` 
beam. This compensates for the loss of the cells as supporting webs and 
allows the columns 62 to completely support the roof under all normal load 
conditions. Similarly, when the hollow beam columns are employed a backing 
piece (not shown) is connected to strengthen each column 62 to provide 
sufficient support for the roof panels 108. Finally, the lower slab 48 may 
be brought up to the height of the raised slab 44 with additional concrete 
and simple walls may be erected around the peripheral edge of the lower 
slab to quickly and inexpensively create a warehouse or the like. Thus, 
when the jail facility is no longer necessary, or it is desired to move it 
to another site, a useful structure may remain, and the cells and 
structure can be re-used at alternate locations. 
As can be readily seen, the present invention provides significant 
advantages over the prior art. It provides a system and method which 
allows for continued use of a portion of the jail facility even after the 
cells have been removed. It also provides an efficient system and method 
for deploying modular cells in a prison facility. 
While reference has been made to specific embodiments, one of skill in the 
art could modify these embodiments without departing from the spirit or 
intent of the present invention. Thus, neither the particular structural 
components nor the described dimensions should be construed as limited to 
those details disclosed herein as the disclosed embodiments are merely 
illustrative of the invention.