2008 Correctional Folder1

day t h ree

• module is removed from

mold

• interior of module is sand

blasted

• module is block filled by

hand to provide a uniform

surfaces

• block fill is cured

day one

• steel reinforcing cage is set

up

• reinforcing is tied together

on a jig, representing the cell

and chase interiors

• all electrical conduit runs are

pre-cut and tied into the cage

2

3

1

day t wo

• cage is placed on mold

• various embedded items are

installed onto the mold

(windows, doors, plumbing car-

riers, etc.)

• optional items are installed,

if applicable

• form is closed

• concrete is placed, consoli-

dated, and cured

Ma nufactur ing Process

c o r re c t i o n s

m a n u f a c t u r i n g p r o c e s s

day s i x

• pieces are inspected and

placed in the yard to await

shipping and erection

4

5

day four

• interior surfaces are painted

with high build, anti-graffiti,

epoxy paint

day f i v e

• plumbing fixtures installed

• electrical fixtures and devices

are installed and tested

• pull strings are placed in

empty conduits

• furniture is installed using

security fasteners

• doors installed

• security glass is installed

6

Miami County Correctional FacilityPeru, Indiana

United States PenitentiaryFederal Bureau of Prisons

Big SandyInez, Kentucky

Essex County Correctional Facility

Newark, New Jersey

Golden Grove Prison & Jail Addition

St. Croix, Virgin Islands

OPMG Nov 2002 Oldcastle Precast Modular Group

The State of NC stated that this method wouldsave about $5 million on just the design by

building three at one time.

North Carol ina 1 ,000-Cel l H igh-Security Prison ProjectsScott County, Alexander County & Anson County, NC

Old c as t l e P r ec a st M odu l ar Group

3 , 0 0 0 p r e c a s t c e l l s ,b a l c o n i e s a n d p l e n u m s

w e r e c o m p l e t e d i n

The State of North Carolinachooses “turn-key” precastconcrete construction to improvespeed, quality control, and safetyand cut costs.

The North Carolina Department ofCorrections (NC DOC) was able to culminatethe design and fast-track construction ofthree 1,000-cell high-security prisons built inAlexander, Anson and Scotland Countiesusing a first-of-its-kind project deliverymethodology. As stated by the NC Central EngineeringDepartment, “this methodology reducedproject costs by using the economy-of-scaleprinciple of a single contractor and employsprivate development and constructionfinancing to satisfy a build-to-suit, lease-purchase arrangement, availing these threeprisons in approximately half the timerequired under conventional buildingprocesses.” It took approximately 18 to 24 months tofinish the three new correctional facilities. Incontrast, using conventional construction itwould take an additional one to two years, ifnot longer. The North Carolina prison projects consistof the construction of three identical 1,000-cell high-security prisons based on aprototype design by the State of NorthCarolina. Each prison is approximately

500,000 SF and was constructed of precastconcrete modular cells, structural precastconcrete and concrete masonry units. Eachprison is composed of 992 inmate cells, 26-day rooms, 11 control rooms, administrativeoffices, a central energy plant, andrecreational faci lities. Each facility will be identical in design,layout and installed systems and equipment.

“Because we are building exactly the samestructure three times with a staggeredschedule of three months, we are able toaddress problems and issues at the Scotlandproject and convey that information to theAnson and Alexander projects before theycomplete that scope of work” stated AdamPearlman of Centex Rooney (GeneralContracting Firm).

The facilities will include seveninterconnecting buildings. Five of thesebuilding are for inmate housing. Three four-story housing bui lding will have a three-fingerdesign (general population) and two two-storyhousing buildings (segregation housing).Each of the three prisons is identical indesign and function with the exception oflocal site work.

The NC DOC selected, in their design andconstruction contract, structural precast quadcell modules that were required to be fullyoutfitted before erection. The four-cell precastmodules were outfitted with furniture, lighting,electrical components, plumbing, finishings,embeds, vertical & horizontal windows andopenings as specified in the prototype plansand specifications. The modules featured anexterior formliner finish with the intention ofproviding a finished aesthetically appealingexterior facade.

Precast Highlights:

Each quad cell module is 36 feet long, 12feet wide, weighs 85,000 pounds andcontains 23 cubic yards of concrete. Tosupport this project, Oldcastle built a newfactory in Varina, North Carolina, to build the3,000 precast cells and additional precastcomponents. The precast concrete modulesare load bearing monolithically cast five-sidedmodules, cast without a floor slab. Theexterior walls of the modules are cast with a10-inch back wall (5-inch structural wythe, 2inches of rigid insulation, and 3-inch exteriorwythe) cast with a form liner finish. Over 1,488 precast modular components ofwhich 744 were precast cell quad-modules,372 balcony slabs and 372 plenums wereproduced and erected in 12 months.

Ted Adams, who represented Centex-Rooney, said “bringing this facility on line in21 months was a major undertaking.” Hecommended the teamwork and commitmentby Centex-Rooney employees andcontractors to fulfill the contract with DOC.

3,000 precast cells, and numerous balconies and plenum unitswere produced and erected in 12 months at three different site locations

Case Study N

um

ber BM

C2002-03

PRECASTEROLDCASTLE PRECAST MODULAR GROUP

514 Township Line RoadTelford, Pennsylvania 18969

215.257.2255www.opmg.com

FILE UNDERCORRECTIONAL

CONSTRUCTION TEAM GENERAL DESCRIPTIONGENERAL CONTRACTOR: Centex Rooney Construction Co.8529 South Park Circle - Suite 200 Orlando, FL 32819Phone: 407.226.9819ARCHITECT:Little & Assoc.Charlotte, NC28217704.525.6350

CollaborativeHOKWashington, DC20007202.339.8700

Design EntityWRCSWinston-SalemNC 27120336.725.1371

TYPE OF HOUSING UNITS:

GENERAL HOUSING PER SITE- 864 CELLSNO. Buildings: 3 NO. Stories: 4 NO. Beds: 864

SEGREGATED HOUSING PER SITE - 128 CELLS

NO. Buildings: 2 NO. Stories: 2 NO. Beds: 128

FOUNDATION: Poured in Place ConcretePRECAST ENGINEER: H. Wilden & Associates7310 Tilghman Street – Suite 600 Allentown, PA 18106-9295Phone: 610.871.3935 EXTERIOR CELL WALLS: Precast Concrete with Form Liner FinishOWNER: North Carolina Department of CorrectionsP.O. Box 29540, 214 West Jones St. Raleigh, NC 27626-0540 CELL CEILING: Epoxy Painted Precast ConcretePhone: 919.733.4926

FLOORS: Smooth Troweled Precast Concrete Coated with Clear Sealer

INTERIOR WALLS: Epoxy Painted Precast Concrete

BUILDING COMPONENTS per site: 992 fully outfitted, single bunk cells(248 Quad Cell Precast Concrete Modules [30’ x 12’ modules]), 124Plenum Units- [30’], and 124 Balcony slabs- [30’] at Mezzanine levelsTOTAL PRECAST COMPONENTS= 2,976 fully outfitted, single bunk cells(744 Quad Cell Precast Concrete Modules [30’ x 12’ modules]), 372Plenum Units- [30’], and 372 Balcony slabs- [30’] at Mezzanine levels1,488 precast components Produced and Erected in only 12 months

DESCRIPTION: Three 1000 Cell High Security Prototype Correctional Facilities inNorth Carolina at Scotland, Alexander and Anson Counties. A total of 2,976 structuralprecast concrete correctional cells will be used to fast track the project.

DESIGN: All precast structure with exterior formliner finish Using an innovativedesign approach by the NC DOC, each facility will be identical in design, layout andinstalled systems and equipment. Because they built exactly the same structure threetimes with a staggered schedule of three months, there were able to addressproblems and issues at the Scotland project and convey information to the Ansonand Alexander projects before they completed that scope of work.

SECURITY LEVEL: High SecuritySITE: (3 Sites) Scotland County, Anson County, and Alexander Countyare each 500,000 square feet facilitiesBASIC CONSTRUCTION TYPE: Structural Precast Concrete usingprecast cell modules with valued added fully outfitted and pre-plumbedchase, precast plenums, balconies, hollowcore, wall panels, & double T’s.NUMBER OF BUILDINGS: (3 Sites) Each Site has: 7 InterconnectingBuildings, 5 of Which are Housing Units.

Production Began: January 2002Production Completed: November, 2002

Erection Began: March 2002Erection Completed: December 2002

DETAILS

BID DATE: April 10th, 2001 GROUND BREAKING FOR 1ST FACILITY: Nov 7 & 8th, 2001

CONSTRUCTION PERIOD: 18 to 24 months - Started in September 2001. Facility Turned over: August 2003– Scotland County; December 2003 –Anson County and Dec 2003– Alexander.

TOTAL SQUARE FEET and Layout: Each of the 3 prison facilities is identical in design and function. They are each 500,000 square feet and will house992 inmates and include 8 healthcare beds, 26 day rooms, 11 control rooms, administrative offices, a central energy plant, and recreational facilities.

TOTAL PROJECT VALUE for three (1000 cell) facilities = approx. $ 224 million

OPMG Nov 2002 Oldcastle Precast Modular Group

Lake City Correctional Faci l i ty Lake City, FL

O l d c a s t l e Pre c a s t Mo d ul a r G ro up

Case Study N

umber B

MC

2006-01

Adding Precast Prison Cells to Lake City

Correctional Facility.

Oldcastle Precast Modular Group was awarded the contract for the Lake City Correctional Facility expansion

located in Florida. The Lake City Correctional Facility is privately owned and operated by CCA, Corrections Corporation of America. Construction for the $21 million project began in May 2004 and was completed in April 2005.

Two 2-story housing pods were

added, approximately 38,000 sq ft and accommodating 286 beds each. The project also included the addition of 6,800 sq ft of administrative and classroom space and 6,000 sq ft of single bed cells in a remote location to the pods.

Centex Construction Company of

Orlando, FL is the General

Contractor and DLR Group is the

Architect of Record.

OPMG designed, manufactured and

erected the 286 fully outfitted precast

concrete prison cells that made up the

new three 2-story building expansion.

There are two buildings with 272

general housing cells each and one

building with 14 segregated housing

cells. The expansion was necessary

due to the increasing demand for cell

space.

The precast modules were produced

at Oldcastle’s sister facility in

Jacksonville, Florida. The 286 precast

concrete modules were load bearing

monolithically cast five sided modules

without a floor slab. The exterior walls

will be cast with 2” of rigid insulation

and 3” exterior wither with a standard

form liner finish. The interior is fully

outfitted with all security, electrical and

plumbing fixtures prior to erection. The

interior is finished with an anti graffiti

epoxy paint system.

PRECASTER OLDCASTLE PRECAST MODULAR GROUP

514 Township Line Road Telford, Pennsylvania 18969

215.257.2255 www.opmg.com

FILE UNDER CORRECTIONAL

CONSTRUCTION TEAM GENERAL DESCRIPTION GENERAL CONTRACTOR: Centex Construction Company7901 SW 6th Court Plantation, FL 33324 Phone: 954.585.4000

ARCHITECT: DLR Group 100 East Pine Street - Suite 404 Orlando, FL 32801 Phone: 407.648.1331

PRECAST ENGINEER: Consulting Engineers Group 1800 JFK Boulevard - Suite 300 Philadelphia, PA 19103 Phone: 267.238.3827

OWNER: Corrections Corporation of America 10 Burton Hill Boulevard Nashville, TN 37215 Phone: 615.263.3000

DESCRIPTION: Three 2-story buildings in Columbia County, Florida with a total of 286 precast concrete cells.DESIGN: The exterior of the buildings have a standard form liner finish. There are three pods total and all of the modules are double cells measuring 8’-8” in height. SECURITY LEVEL: Minimum/Medium Security SITE: Columbia County 7906 E Highway 90 Lake City, FL 32055 BASIC CONSTRUCTION TYPE: Structural Precast Concrete using precast cell modules with valued added fully outfitted, precast plenums, balconies, hollow core, wall panels, & double T’s. NUMBER OF BUILDINGS: 3 Buildings; two general housing buildings and one segregated housing building

TYPE OF HOUSING UNITS:

GENERAL HOUSING – 272 CELLS


SEGREGATED HOUSING – 14 CELLS


FOUNDATION: Poured in Place Concrete

EXTERIOR CELL WALLS: Precast Concrete with Form Liner Finish

CELL CEILING: Epoxy Painted Precast Concrete

FLOORS: Smooth Troweled Precast Concrete Coated with Clear Sealer

INTERIOR WALLS: Epoxy Painted Precast Concrete

BUILDING COMPONENTS: 286 fully outfitted cells; Pods H & J contain two levels of cells with plenum units on top and Pod K has one level of cells with plenum units on top.

Production Began: May 2004 Production Completed: September 2004

Erection Began: July 2004Erection Completed: October 2004

DETAILS

BID DATE: January 15, 2004

CONSTRUCTION PERIOD: 11 months; May 2004-April 2005

TOTAL SQUARE FEET: approximately 88,800 sq ft

TOTAL PROJECT VALUE: $21,000,000

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Facility of the Month -- Mar/Apr 2004

Three Prisons Deliver for North CarolinaAn innovative delivery method and financing system allowed for three identical 1,000-cellprisons to be built at a time when the North Carolina Department of Correction badly needed beds.

By Hava Leisner

An innovative delivery method and financing methodology allowed three identical 1,000-cell close-security prisons to be built for the North Carolina Department of Correction in 27 months with a very low change order rate. The unique financing combined with the project's size serves to make these three North Carolina prisons a model not only for the state but also for other correction departments across America.

North Carolina Needed Beds

When the Tar Heel State could not fund new prison construction using a traditional "pay-as-you-go" method they had to resort to a more innovative approach through new legislation, out of which came a hybrid financing and delivery system that allowed for

something North Carolina had never done before in corrections: have the private sector finance and build the facilities and then buy them using a lease-purchase financing strategy once they were inspected and complete.

The first of the three facilities was Scotland Correctional Institution in Laurinburg. It took 21 months to complete and accepted its first inmates in September 2003. The Lanesboro Correctional Institution in Anson County followed three months later. Then the third prison, Alexander Correctional Institution in Taylorsville, was completed January 12.

As the third 1,000-cell close-custody prison was completed, there was a backlog of hundreds of adjudicated

PROJECT DATA

Scotland Correctional Institution Lanesboro Correctional Institution Alexander Correctional Institution

Size: 409,600-square-feet per prison Total Project Cost: $223.8 million

Collaborative Design Entity: Little Diversified Architectural Consulting Inc. (Contract Architect); O'Brien Atkins Associates, PA; Walter Robbs Callahan & Pierce Architects, PA

Design Consultant: Hellmuth, Obata & Kassabaum, PC General Contractor: Centex Rooney Construction Corp.

Detention Equipment Contractor: ESI Electronic Security Design Consultant: Latta Technical Services

Food Service and Laundry Design: Food Design Associates Site and Civil Engineer: Hobbs, Uphurch & Associates, PA

Detention Equipment & Security Hardware: Erbschloe Consulting Services Inc.

Page 1 of 5CorrectionalNews.com

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inmates waiting in jails for a bed to open up within the state Department of Correction.

The trio of 1,000-cell prisons carries a $223 million price tag. Each prison has 864 general housing cells, divided among three buildings; 128 segregation-housing beds, across two buildings; and eight medical beds.

Each facility is 409,600 square feet, single-cell, close-custody. Everything is one level except the three general population buildings, which have two floors arranged in a star pattern. Within each of the prisons, which are identical in design, layout, and equipment and just site adapted at three different locations, are 26 dayrooms; 11 control rooms; a central energy plant; and recreation facilities.

"We didn't get into any of these [mirror reverse] type arrangements," said Architect Jim Metze with Little Diversified Architectural Consulting Inc. "The floor is the same in each of the facilities so that a person could be

transferred from one facility to the other and know exactly where things are and how they work."

The design itself did not dictate the use of precast, it could have been built with traditional construction methods, however, the only thing that was considered by all of the bidders was precast, according to the DOC.

"As it turned out there were a lot of advantages to precast in terms of time and cost," said Architect Metze.

Operations and Maintenance

Almost from the very beginning the North Carolina Department of Correction knew it wanted to use a prototypical design approach.

"We saw advantages operationally because it gave us consistent facilities, essentially you only had to write one set of standard operating procedures that could then be replicated very easily at each of the three facilities as they are built and brought on line," said William Stovall PE, director of engineering, who has been with the state DOC for 21 years.

"It facilitates your training of the staff because they are all training on a comparable facility. It makes sense in terms of maintenance and physical plant management because we have consistent equipment and uniform preventative maintenance protocols then can be implemented."

Each facility is designed to be expandable from its initial capacity of 1,000 inmates. "The core infrastructure was designed to expand to 1,500 inmates without any significant modification of food service or any of the support characteristics of the physical plant," said Stovall.

This is the North Carolina 1,000-cell close-security prototype. The segregation buildings are the two diamonds in the middle of the diagram. The dotted area (in the upper right) is perfectly sized to hold a future regional medical facility or another two general population buildings exactly like the two buildings on left of the circular road. There is also room for expansion out along the fields to the far left.

A view into one of the general population pods. Stacked above this is pod is another identical pod and control room. The elevated control room is built in a 90-degree frame such that an officer can view three, 48-cell pods. Each of the prisons utilizes indirect supervision, often called podular indirect, where an officer observes each of the three pods from a secure control room.



Plans for the Alexander facility, the last of the three to be complete, call for it to be a host site of one of North Carolina's future regional medical and mental health facilities. The state has several regional medical facilities in its long-term plan, which calls for at least three more close-custody, 1,000-cell prisons using the same design.

The notice to proceed on prisons four and five, to be sited in Greene County and Bertie County respectively, was issued December 31, 2003. Prison six is in the planning stages.

The state anticipates that even after completing prison six, it will still have deficits in its prison capacity based upon forecasted projections.

The Compact Star Design

The design improves upon an earlier close-custodyprototype known as the "foothills model."

James Kessler, AIA, senior principal at Hellmuth, Obata + Kassabaum, the design consultant, explained some of the geometrical improvements this design made upon the foothills model.

The former model was based on smaller modules, 32-cellmodules versus 48. "There is nothing wrong with the

foothills design, it is just that after operating that number of facilities for that number of years, they gained confidence in the size of the pods," said Kessler, who has 25 years of experience in correctional facility design. "And we still felt that we could observe three, 48s from a single control room, just as the foothills model was observing three 32s. So right there we gained a great advantage in terms of staffing ratio."

In the foothills model the layout was such that there was a staircase in the housing pods that could not be observed from the control room. Now, the stairs are within the sallyport and can be viewed from the control room.

Other improvements include moving the recreation, gymnasium, and dining areas away from the front of the prison where visitation and administration is sited, deeper within the facility near inmate housing areas.

Kessler said each component was looked at in terms of what is operationally most efficient without compromising safety and security. Medical, industry, and dining were among areas reviewed to see if they are related more to visiting and the public or are they more housing related. From there, organization was constructed around what functions are more suited toward the public and what needs to be further inside the prison, in close proximity to the housing pods.

The compact site gives each pod good access to outdoor areas. You can have all of the clusters exercising together without any connection to the other. In the two segregated housing buildings, inmates exercise alone in yards arranged in a radial fashion so that one officer can observe all inmates.

Build-to-Suit Buyback

In 2001, the state of North Carolina developed legislation to allow for the unique financing employed to build these three prisons. The North Carolina statute 148-37.2 allowed the state DOC to lease-purchase three correctional facilities over a 20-yearperiod.

Each prison has two segregation housing buildings with 64 cells in each building. Here inmates are confined to their cells 23 hours a day. Inmates are required to have one hour of exercise but they must eat in their cells. Here, one control room, with a 360-degree view, observes all 64 cells.

PRODUCT DATA

Bunks/Beds: Oldcastle, KLN Steel Products Co. Cabinet Steamers: Cleveland CCTV: Phillips; Pelco Chopper Pumps: In-Sink-Erator Concrete: Metromont Correctional Furniture: Trussbilt; KLN Steel Custom Stainless Equipment: Thompson & Little Detention Accessories: Trussbilt; American Specialties Exterior Finish: Metromont; Oldcastle Precast Modular Group Floor/Wall Tile: Dal Tile Food Services: Thompson & Little Gypsum Wallboard: Georgia Pacific-RCI; Bonitz HVAC: Environmental Systems; Yamas Controls-Marley; Cleaver Brooks; McQuay; Anemostat; Bell Gosset; Danfoss; Greenheck Intercom: Rauland-Borg Corp.; STI Ovens: Gemini PLC: Omron Plumbing: Eagerton Plumbing; Zurn; Metcraft; Charlotte Pipe Pneumatic Tube Systems: Gardner Denver; Hankison Precast Concrete Cells: Oldcastle Precast Modular Group Refrigeration: W. A. Brown Roofing: Johns Manville; Long Brothers Roofing; Anning Johnson Sallyport/Doors: Maxin; EPD Security Ceiling System: Drywall System-RCI; Bonitz Security Cell Doors: Southern Steel; Habersham Metal



During the construction period, Carolina Corrections LLC, of which Centex Rooney Construction Co. was a part, acted as the facility's interim owner. Once construction was complete, a public, non-profitagency, the North Carolina Infrastructure Finance Corp., purchased the facilities and entered into a lease-purchase agreement with the DOC to operate and maintain the prisons over a 20-year period.

Carolina Corrections LLC is a corporation that was created specifically for the development of these three prisons. Along with Centex the corporation is comprised of Lehman Brothers, Provident Financial Group, and Ambac.

The statute states that the facility's contractor is responsible for arranging and obtaining their own construction financing, which will consist solely of private funds. The three projects were sold to the non-profit North Carolina Infrastructure Finance Corp. using proceeds from certificates of participation.

When construction was complete and as each prison was inspected and accepted, Centex handed over the keys and the North Carolina Infrastructure Finance Corp. handed over a check.

Advantages

Building three facilities off the same design not only created uniform operations and maintenance, but construction was sped up and cost savings were actualized.

"The pricing we ultimately received showed that the lowest price and best value came with proposals that would build three facilities at one time," said Stovall.

"The three facilities were within approximately 100 miles of each other so they were within reasonable travel distance in terms of a single contractor being able to build all three."

"The real benefit [of the prototypical design] is continuity of operation and maintenance. We economize on our training, flexibility of staff movement, and minimize spare parts for equipment," said Jake Freeman, deputy director of engineering with the N.C. Department of Correction.

"It also gives us economies on the construction and design side, but it was driven by operational needs. We stressed as strongly as we could, in essence, to have the same equipment in all three of these facilities, and we are going to try to do the same thing for prisons four and five."

Others Notice

Other state correction departments are implementing similar hybrid-financing methods and developing new legislation to support construction of much needed capital projects. While other states are just watching to see how the officers and staff will receive these three new prisons.

Virginia, for example, has changed its legislation, creating the Public Private Educational Act of 2001, a very broad law enacted to save on time.

Ted Adams, senior vice president and criminal justice division manager at Centex Rooney, whose firm

Products Security Cell Lighting: Failsafe; Kenall Lighting Security Fencing: Safe Guards Technologies; Texas Fence Security Fire Equipment: Fairbanks Morse; Cuter Hammer Security Glazing: Lexgard-GE Security Locks: ASSA; Southern Steel Security Penal Plumbing: Willoughby Security Screens: Allien American Security Sprinkler Equipment: Reliable Security Systems: ESI Security Windows: CM Security Group; Baily Smoke Detection Systems: Stratos; Edwards Steam Kettles: Cleveland Touchscreen System: ESI; Phillips UPS: Powerware Ventilators: Captive Aire Walk-In Coolers/Freezers: W. A. Brown Weapons Detection System: CEIA USA LTD

The Quad

Oldcastle Precast Modular Group was responsible for the cells, plenum units, and balcony slabs in each of North Carolina's three identical prisons in Scotland, Anson, and Alexander counties.

The company manufactured all three 1,000-cell projects in less than 11 months. Oldcastle opted to go with a quad unit instead of a double to save on production and erection time.

"Our biggest thing with the quad is it sped up production because you could produce that many more," said Project Manager Sandra Marks with Oldcastle Precast Modular Group. "Our production time was cut down."

Oldcastle was responsible for buildings J, K, and L, the general population units, and buildings M and N, which are segregated housing units.

In the general population building, cells line the first floor, the first floor mezzanine, then a plenum unit, and then the second floor, and second floor mezzanine, and then a roof plenum.

In the segregated housing area there is only a first floor and a first floor mezzanine. Each of the two segregated housing buildings has 64 cells, 32 per level.

The balconies made the mezzanine walkways. The balconies were not monolithic with the cells; they were separate. "That was a unique bolted connection," explained Marks, "it worked very well."

Oldcastle was awarded the contract to produce the same components for prisons 4 and 5, to be built in Greene and Bertie counties, respectively.



submitted a proposal to the Virginia Department of Corrections, said Virginia, which had the same problem getting voter support for capital construction projects, saw how well things worked for North Carolina.

"It was a great solution for North Carolina," said Adams. "And other states are noticing and changing their laws and passing legislation to allow them the latitude to do things like this."

Stovall said a number of states have expressed interest in what North Carolina is doing. In addition to Virginia, Stovall talked to officials in Florida, Louisiana, and some folks in the juvenile system in New Jersey.

The bottom line: "It has allowed for critically needed prison space to be available when we needed it to address the public safety needs of this state," emphasized Stovall.

Compressed Geometry

The North Carolina Department of Correction used a similar star housing pod in the foothills model but it was not as compact.

In this design prototype, the same number of housing pods are compressed from 180 degrees to 90 degrees, and each pod holds 48 inmates instead of 32. This setup allowed for a significant advantage in the staff-to-inmate ratio.

As design consultant, Hellmuth, Obata + Kassabaum (HOK) examined how to maximize sightlines. The company used a diagram that identified the biometrics of an individual sitting at a desk. They concluded six pods or two buildings with two control rooms (see diagram below) could be sited in about the same space in which the foothills model held three pods and one control room in.

"That is a major way we make the site requirements of the facility more compressed," said James Kessler, AIA, senior principal and director of the Justice Focus Group at HOK in Washington DC. "Not only does it facilitate the sightlines from inside the control room but it also reduces the amount of site area that is needed to contain the 1,000 cells."

HOK was responsible for developing this compressed geometry in order to "minimize the building's area and circulation space inside the building's corridors."

In looking for a prototype, particularly in a state like North Carolina, which is quite mountainous in parts, explained Kessler, it is very important that it's done in the least amount of site area.

"It also reduces the cost and the one thing that will help on any site is to make it compact because it will mean less grading."

The vertex of the star, closest to the control room, is where the showers are located.

The orange sections show the corridors. The control rooms are red. The green areas are outdoor space that is observable from the control room.



Managing a Big Project on a Little IslandA crack team’s determination to bring a project in on time and under budgetdespite island isolation, limited resources, and nature’s fury. By Jay W. Schneider

W hen talking about the team’s workat the Golden Grove Prison on the

island of St. Croix in the U.S. VirginIslands, Brent Smith comes across as pro-fessional and resolute. You can still sensethe determination that helped the projectmanager from Perini ManagementServices see the completion of the $24.3million project in November 2000. Thatdetermination was needed to bring theproject—both an addition and new con-struction consisting of three prisons, twonew jail buildings, a control tower, anadministration building, and some infra-structure work—in on time and underbudget. “Virtually all government con-tracts on the Virgin Islands have schedul-ing and budget problems,” explainsSmith, who was absolute in his desire tobe the exception to that rule.

Additional persuasion came from aguaranteed maximum contract that stipu-lated if the project was brought in underbudget, they would get 40 percent of sav-ings; the owner—the U.S. Virgin IslandsDept. of Corrections—gets 60 percent.

However, working on the tropicalisland, even the largest of the three U.S.island territories, presented limitedresources and unique challenges that, ifnot understood or planned for, could havemeant certain failure in terms of cost andtime overruns. Smith, and Perini’s con-struction manager Robert Naylor, made ittheir mission, then, to see that the assem-bled team, including Telford, Pa.-basedOldcastle Precast Modular Group andarchitects Vitetta Group of Philadelphia,work seamlessly and that the companyclosely monitor and support the project’s

subcontractors. He wanted toensure the project ran assmoothly and as efficiently asany jail construction project inthe states—despite the obvi-ous differences, including thetransport of 164 precast cellsfrom Florida and the need toimport a 480-ton crane fromthe mainland to erect the mod-ular units. Of course, Smithhad little control over thethree tropical storms and onehurricane that battered theisland during the course of construction.

The Golden Grove ComplexThe Golden Grove prison complex

occupies approximately 10 acres and isthe only major detention area on theisland. The limited number of prison bedsforced the island government to spendlarge sums of money housing many of itsprisoners “off island.” They wanted toexpand the facility and bring back prison-ers housed in the United States while atthe same time add enough beds to accom-modate future inmate populations.

The joint venture of Hyde Park/Periniwon the construction contract in early1999 with Oldcastle Precast ModularGroup and Vitetta part of the design/buildbid. “The notice of award for thedesign/build was March 1999 and wewere mobilized to go in June 1999,” notesSmith. The team immediately startedworking on their respective pieces.

Hyde Park Enterprises is based in theU.S. Virgin Islands and was the liaison tothe St. Croix government, handling thebusiness development end and helpingsecure the contract.

F A C I L I T Y O F T H E M O N T H

You’re actually looking down at part of the Golden Grove Prison. Thisfreighter is stocked with about half of the 328 precast cells used to constructthe 75,000-square-foot project on the island of St. Croix in the U.S. VirginIslands. The freighter made its first 1,000-plus mile journey in October1999; the second shipment left the Jacksonville, Fla. dock in late December.

However, materials delivery is only one part of the story; the team handlingthe project—and determined to bring it in on time and under budget—alsohad to contend with island isolation, limited resources, and nature’s fury.

See “Facility of the Month,” page 20.

Keeping a watchful eye on the facility.

Seth Roy

“In the tropics you expect rain,

but we had buckets, and buckets,

and buckets of rain. We got into

hurricane mode.” —Brent Smith

The DesignAs soon as the contract was awarded,

Al Comly, Jr., program director of justicefacilities for Vitetta Group, was busyworking on final designs for the facility’sexpansion and new construction. Thedesign process was finished within four tosix weeks and called for a near doublingin size of the prison complex; the projectencompassed approximately 75,000-square-foot.

Comly says he “kept the design prettysimple, with a little island character;” itwas more important to keep the facilityfunctional and within budget than to tryto replicate tropical architecture. Thedesign also was kept simple to ease main-tenance, although Comly was surprisedto find that expertise existed on the islandthat allowed them to incorporate somesophisticated and state-of-the-art systems

in the building, includingsecurity electronics.

The layout of thefacility is, as Comlydescribes it, quasi-directsupervision. “It wasdesigned as much as pos-sible to operate and func-tion like a direct supervi-sion facility,” he says.

Although construc-tion was to take placeoutside of the UnitedStates, Comly designed a

“facility that could be every bit ofwhat you find in the states.” He saysthe facility was designed to U.S. stan-dards using Florida building codesas a basis for the buildings.

The Precast Modular CellsAlso mobilized was Doak Conn,

project manager for Oldcastle PrecastModular, who was working many longweeks, commuting from Pennsylvaniato Florida, overseeing an 80-day pro-duction process where 164 precastmodules—two cells per module for a totalof 328 cells—were cast. The cells had to befinished in time to be loaded on a freighterin Jacksonville, Fla., shipped more than1,000 miles to the island, and be at the sitewhen installation was to occur.

The precast, pre-finished modularunits produced by Oldcastle differed only

slightly from the units pro-duced for use in theUnited States. The unitsinclude increased structur-al reinforcing and all-weld-ed connections so they arebetter able to withstand asevere earthquake; St.Croix is located near amajor fault, putting it in a

seismic zone five—thehighest zone possible.Another changeinvolved casting non-insulated back wallsbecause the facility hasno heating or air condi-tioning. The chaseinside the cell acts as aventilation plenum andscreened window open-ings aid in the building’scirculation. OldcastlePrecast Modular

worked with Hope’s Windows to create along but slender window with heavy-gauge screen mesh instead of securityglass; the mesh maintains the level ofsecurity required for a medium- to maxi-mum-security facility. Operable louversblock against wind and rain.

The first shipment of modulesoccurred in October 1999 and consistedof 64 units. The second—and last—ship-ment set sail at the end of December 1999with 100 units; originally the contractcalled for 96 units, but two replacementcells and two “just in case” modules wereincluded with the second shipment.

Island ConstructionWith Vitetta handling the design and

Oldcastle handling the precast units,Perini’s Smith was making it his businessto understand—and accept—the capabili-ties of the subcontractors working the job.That knowledge and understanding isespecially important working on an islandwhere resources and labor are differentthan those available in the states. Smith, inan effort to stimulate the local economy,sought out island subcontractors to per-form as many of the jobs as possible. “Wepumped about $15 million into the localeconomy,” Smith points out.

In a very matter-of-fact way, Smith

Correctional Furniture: KLN Steel ProductsSecurity Windows: Hope’s Windows Inc.Security Cell Doors: HabershamSecurity Screens: Hope’s Windows Inc.Security Penal Plumbing: AcornSecurity Sprinkler System: Star Sprinkler Corp.Security Cell Lighting: FailsafeExterior Finish: Dayton stuccoSecurity Vents: AnemostatSecurity Bolts: J.P. Ruklic

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The building was designed to function like a directsupervision facility.

The Golden Grove complex has approximately 75,000 squarefeet and occupies about 10 acres.

Location: . . . . . . . . .St. Croix U.S. Virgin IslandsCompletion date: . . . . . . . . .November 7, 2000Construction budget: . . . . . . . . . .$24.3 millionProject delivery: . . . . . . . . . . . . . .Design/buildSecurity level(s): . . . . . . .medium and maximumTotal square feet: . . . . . .Approximately 75,000

GOLDEN GROVE

explains that Perini did self-perform someof the work after stepping in for subcon-tractors who were unable to fulfill theircontracts. “The secret to performing isunderstanding what local contractors arecapable of,” notes Smith. “The reason thejob was so successful is that we knew thesubs’ weaknesses and abilities and sup-ported them,” he says. “We didn’t beatthem up when they couldn’t perform. Wehelped them.” Smith, for example, discov-ered the subcontractor hired to performthe interior masonry portion of the proj-ect couldn’t perform the job so, Smithsimply imported a dozen masons fromFlorida who tackled the task.

And it was that sense of teamwork anddetermination that smoothed over thebiggest—or in this case the heaviest—challenges. There was no crane on theisland capable of erecting the precastcells—each weighing approximately56,000 pounds—so a 480-ton crane wasshipped over from Florida. An unexpect-ed challenge occurred when the moduleswere being delivered to the site from theport four miles away. The local contractortransporting the cells—with a policeescort—accidentally rolled one of theunits, damaging two cells. The damagedcells were part of the first shipment and

replacements were deftly handled byOldcastle who sent them over with thesecond shipment—along with two extraunits, “just in case.” Toward the end of theconstruction project, Smith found himselfchallenged by another large constructionproject on the island and was put in theposition of having to compete for alreadylimited labor and resources.

The Weather Forecast: StormsAs expert as the team was in working

the Golden Grove project, they wereforced to weather conditions they had nocontrol over—three tropical depressionsand one hurricane that pounded theisland during construction.

“In the tropics you expect rain,” Smithexplains, “but we had buckets, and buck-ets, and buckets of rain.” Although thestorms caused no damage to the build-ings, “we did get into hurricane mode,”says Smith, meaning that they lost timebattening down the hatches, waiting outthe storm, and then getting everythingand everyone back into constructionmode. The storms forced them to securea three-week force majeure—an exten-sion due to acts of God. This situation pro-vided Smith only with extra time, notextra money.

And while the unusual amount ofprecipitation affected the building dur-ing construction, a unusual design fea-ture—on this building as well as mostother buildings and houses on theisland—welcomed the heavy rain. A spe-cial membrane is sprayed on the roof tocollect and harvest rainwater that is thentreated and used as the facility’s mainwater supply.

A successful Completion In the end, the team completed the

project on time and under budget so sig-nificant savings was incurred by the own-ers, who are said to be very happy withthe project.

And when other members of the teamare asked about their final impressions ofthe project, they mention how excitedthey felt to be part of the project and howsurprised they were by how smoothly theprocess ran. Upon further reflection,however, team members Doak Conn, AlComy Jr., Brent Smith, the subcontrac-tors, and everyone else involved in theproject, have themselves to thank for theprofessional manner in which this facilityfound its many pieces put together on asometimes stormy, always tropical island.■

Owner: U.S. Virgin Islands Department of Corrections

Joint Venture Partners: Hyde Park Enterprises/PeriniConstruction Manager:

Perini Management Services Inc.Architect: Vitetta GroupModular Manufacturer:

Oldcastle Precast Modular GroupEngineers:

Tilden, Lobnitz, Cooper, and Antillean Engineer

P R O J E C T D A T A

The buildings are starting to take shape; the slab foun-dation is ready for the precast cells.

Seth Roy

The additions and the new buildings about doubled thesize of the complex.

Seth Roy

The crane capable of lifting each 56,000-pound pre-cast cell had to be brought to the island from Florida.

he State of Indiana needed todesign and build a new prison,and it needed to accomplish it

fast, due to continued overcrowding.The result, in only two years fromdesign to completion, is the MiamiCorrectional Facility in Peru, thelargest prison ever built in the state.Encompassing 17 buildings in all, the$97-million project provides housingfor 1,400 inmates, with allowances for400 future beds. To meet the fast-trackschedule, precast concrete was usedextensively, including for the modularcells, which were supplied nearlyfinished.

The 553,700-square-foot prison required alarge cast of players tocomplete construction inthe time frame pre-scribed by the IndianaState Office BuildingCommission (ISOBC).SchenkelShultz Inc. inFt. Wayne, Ind., servedas lead architect, withPhillips Swager Associatesin Peoria, Ill., acting asassociate architect. Con-struction manager Turner/Powers Inc. in Carmel,Ind., coordinated work on a total of 15bid packages, including that of the twogeneral contractors, Shook LLC andSherman R. Smoot Inc., both inIndianapolis.

Since 14 of the 17 new buildingswere built primarily with precastconcrete, four different precastersworked on different aspects of the

project: American Precast Concrete Inc.in Indianapolis; Rotondo Precast Inc.in Telford, Pa.; StresCore Inc. in SouthBend, Ind.; and Concrete TechnologyInc. in Springboro, Ohio.

Other Options Considered“We briefly considered alternatives

before selecting precast concrete as theprincipal building material,” saysCharles Goodman, a principal atSchenkelShultz. “Few manufacturerscould produce the needed quantity ofsteel cells within the tight time frame.”Additionally, these are “wet” cells, with

considerable moisture due to plumbingcomponents and shower rooms, henotes, and steel rusts. “Precast hasgreater durability and longevity.”Masonry was a possibility, he adds, butby using precast, the job could becompleted more quickly and meet thetime frame required by the Departmentof Correction.

“Precast concrete gave the Depart-ment of Correction peace of mind byproviding secure cells consisting of amonolithic pour, with no joints thatcan be picked,” he explains. Speed alsowas an important determinant. “Theprecasters could produce the neededquantity of components over arelatively short period of time.” Precastalso provided distinctive exteriorarticulation, he says. “We could create alook and feeling that is architecturallypleasing by using form liners. Thatrepresented an economical way toachieve a handsome exterior rather

simply.”State-of-the-art security

technology is a key tooperating a modern prison,Goodman points out,which added another rea-son to specify precast.“The installation of thesecurity system was expe-dited by the use ofprecast,” he says. “Systemcomponents were installedat the precasters’ plants

and connected on site,saving time.” Prisons andtheir electronic systemspresent a special challenge

to precasters, notes Eric Wolf, Schenkel-Shultz’s field representative. “Each doorhas alarms and electric locks, requiringmiles and miles of conduit through theprecast. The precasters have to coordi-nate their work with the electrical andmechanical engineers.”

Provided by Indiana AutomationSystems, the electronic security system

Precast ComponentsSpeed Fast-Track Prison Indiana’s requirements for speedy erection, high security, durability and low maintenanceall were met by four precasters working together at the Miami Correctional Facility

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Occupying a 200-acre site in Peru, Ind., the Miami Correctional Facilityhouses 1,400 offenders in its first phase of construction. Fourteen of the 17new buildings involved an extensive use of precast concrete. Six MediumHousing Buildings and the Recreation Building are grouped together on theleft. The Administration Building with the guard tower is at the top.

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at the Miami Correctional Facilityconsists of touch-screen control panelsand monitors in every control room

throughout the prison. The controlpanels allow the staff to open and closedoors, operate the lights, control thetemperature, and communicate by

intercom. The campus is tied togetherelectronically.

In fact, one of the project’s biggestchallenges came in casting all theelectrical conduits and boxes that hadto be imbedded in the precast com-ponents, adds Jim Kenbeek, projectcoordinator at Concrete Technology,which provided many of the wallpanels. Conduits and boxes also werecast into the columns in the MinimumHousing Unit.

Four bid packages covered construc-tion of the 14 precast concrete build-

‘Precast has greaterdurability and

longevity.’

American Precast Concrete had to coordinatewith Rotondo Precast to ensure that thebanding on their wall panels aligned withthe detailing on the exterior of the cell units.

Guard towers consist of precast concreteinsulated wall panels on a steel frame. Thisformat could be used since a secure envelopewas not required.

ings. Rotondo Precast produced all themodular cells, balconies, and plenumsfor the six Medium Housing Units andthe Special Housing Unit (maximumsecurity). StresCore supplied the precasthollow-core slabs. American Precastprovided insulated wall panels anddouble tees for Medium and SpecialHousing, additional wall panels for theRecreation Building, plus precastcolumns and beams, as well as insulatedwall panels, for the Minimum HousingUnit.

Structural steel was specified for theFood Service Building, AdministrationBuilding, Guard Tower, OffenderServices Building, and Receiving &Release Building because a secureenvelope was not a major requirementfor these structures. However, most ofthe thermomass-insulated wall panelssupplied by Concrete Technology forthese buildings were load-bearing.

To prevent confusion on the job sitewith 14 buildings simultaneously underconstruction, Sofco, an independenterector, scheduled the various compo-nents as they were needed while handlingmost of the precast erection. “The mainchallenge was coordinating the work ofall the contractors,” says Sam Campbell,

Turner/Powers’ project manager. “It wasdifficult to schedule everyone so theycould do their work fully withoutinterfering with the other trades.”

That also was true for coordinatingall the precasters and the erector, saysJohn Reihl, vice president at StresCore.

“It was critical to have everything fittogether at the right time and in theright sequence,” he says. Aestheticconcerns also meant close coordination,notes Tom Smart of American Precast.“We had to ensure that the pattern ofsmooth and ribbed banding on theexterior of our panels lined up with thepattern on Rotondo’s cell units,” hesays. “We had to coordinate with all theprecasters to ensure our interfacesworked smoothly, not just logistically,but also in appearance.”

Medium Housing Rotondo Precast produced 312 five-

sided cell modules measuring 14'11-1/2" by 12'4" for the six MediumHousing Units. Weighing 44,000pounds, each module contains two 7-by-11-foot cells separated by aplumbing chase, which also holds theelectrical boxes. The cells’ 10-inch-thick walls have thermomass insulation,while a five-inch-thick slab forms thecombined roof and floor for the celllevels.

The balconies were cast separatelyand attached in the field. Topped byplenums for the mechanical equipment,the housing units are two cells high,with a floor-to-ceiling height of 10 feet.Precast double tees rest on top of theload-bearing plenum walls. A rubbermembrane roofing system completesthe buildings. American Precast providedload-bearing insulated wall panels andsome miscellaneous walls for the housi-ng units.

The cell modules arrived at the jobsite with the steel furniture, plumbingfixtures and valves, light fixtures, andsteel door frames installed. Brackets forthe furniture and the door frames werecast into the concrete, as were electricalconduits. Cell doors at this prison usepneumatic sliding devices and locks,

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A crane lifts a 44,000-pound modular cell unit into place, forming the second level of one of the Medium Housing Buildings.

‘Everything fit togetherat the right time and in the right sequence.’

which are more efficient than electri-cally driven doors, according toSchenkelShultz’s Goodman.

Casting and finishing a cell moduletakes five days, according to SandraMarks, project manager at RotondoPrecast. It took her company eightmonths to produce the 312 cells forMedium Housing, plus 50 more for

Special Housing.

Minimum HousingSchenkelShultz developed the proto-

type for the Minimum Housing Unitfor Level One offenders in 1990. Anall-precast building, it is located outsidethe rows of security fencing at theMiami Correctional Facility. Inmates

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Precast Components For MiamiCorrectional FacilityMedium Housing Units:

246 pieces insulated walls192 pieces double tees300 pieces miscellaneous walls312 cell modules192 pieces plenums84 pieces balconies

Special Housing Unit:64 pieces insulated walls355 pieces hollow-core slabs50 cell modules50 pieces plenums

Minimum Housing Unit:357 pieces hollow-core slabs79 pieces insulated walls26 pieces precast columns57 pieces prestressed beams

Plus 744 pieces (101,339 squarefeet) of insulated walls for theRecreation, Food Service, Admini-stration, Offender Services, Receiv-ing & Release Buildings and theGuard Tower.

A piece of hollow-core slab, with one end angled to fit the building configuration, is hoisted intoplace on Special Housing. A few structural steel components were used in this building whereslender members were needed to maintain lines of sight.

Two converging wings of Special Housing under construction expose the precast components ofthe building: stacked modular cells, hollow-core slab corridors, plenums, and insulated wallpanels.

The cells arrived at the job site withfurnishings, light and plumbing fixtures,windows and door frames already installed.Cast-in plumbing valves were later connectedto plumbing in chases between each two cellsin a module.

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are housed in dormitories with lockersinstead of cells. Windows are widerthan the five-inch slits in the cell units,and they are equipped with securitybars. “The building has the potential ofbeing locked down,” Goodman says.

American Precast provided the insu-lated load-bearing wall panels, precastcolumns and prestressed beams for thebuilding. A typical wall panel, 8 feetwide by 27 feet tall by 12 inches thick,carries the second floor slab and roofdeck. Cast with 5,000-psi concrete, theprestressed beams have cast-in sleevesfor the plumbing, electrical conduitsand HVAC ducts.

The details on the wall panels’exterior faces match the ribbed bandingand reveals on the other buildings. Dueto budget concerns, the panels weren’tacid-etched or sandblasted; instead,standard gray concrete with a buff pig-ment was used. Some of the precastersexpressed disappointment that theywere not able to provide a more

finished exterior surface. “It’s difficultto control color consistency with un-finished gray cement and with a varietyof precasters from different areasinvolved,” Concrete Technology’sKenbeek says. “We would have pre-ferred to sandblast the panels.”

“The pre-manufactured cells and theload-bearing wall panels helped a greatdeal in enabling us to meet the con-struction schedule,” SchenkelShultz’sWolf says. Turner/Powers’ Campbellagrees. “The job ran fairly smoothly,with few delays, which were not causedby the precasters,” he says. “It’s almosta model project. The facility will openon time. In fact, 200 prisoners aregoing into Minimum Security ahead ofschedule.” ■

—Anne Patterson

Maximum Security HousingRequired Special Design

To handle the added needs forthe Special Housing Unit, whichcontains mentally ill and violentinmates, the architects developed alayout with five spokes radiatingfrom a central control room. “Linesof sight are critical in this type ofunit,” says SchenkelShultz’s CharlesGoodman. “The building geometryallows staff members to oversee fivehallways easily.”

The Special Housing cells weredesigned for one person instead oftwo. “The cell requirements in thatbuilding were more complicated,”explains Sandra Marks of RotondoPrecast. “We had to cast in specialconcrete bunks instead of using thestandard steel ones.” The precasteralso had to provide imbeddedstainless steel bars for restraints.

Casting the floor slabs waschallenging, too, notes StresCore’sJohn Reihl. The company had tocreate special angled end piecesbecause of the building layout andimbed up to 10 plates per panel forsecurity reasons. StresCore produced355 panels with more than 800imbeds for the facility.

AREA INDEX1. Cells2. Interview3. Indoor Exercise4. Administration5. Laundry6. Control7. Outdoor Recreation

To provide clear sight lines,the architects developed a planwith five wings radiating froma central control room for theSpecial Housing Unit (maxi-mum security).

2008 Correctional Folder1

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