Prefabricados Delta has extensive expertise in the building of fully-integrated pre-fabricated prison cell modules. This pre-fab method respects the design, quality and specifications of the project but also adds the experience we acquired during the manufacturing and assembly of seven prisons. This has enabled us to find suitable solutions to overcome the disadvantages of prefabrication of reinforced concrete parts.
To date, Prefabricados Delta has manufactured a total of 6,300 cells, distributed among the following Spanish prisons:
- Dueñas (Palencia) Prison: 1,116 cells.
- Albolote (Granada) Prison: 1,130 cells.
- Aranjuez (Madrid) Prison: 1,118 cells.
- Mansilla de las Mulas (León) prison: 626 cells
- Segovia Prison: 379 cells.
- Algeciras (Cádiz) Prison: 1,116 cells.
- Villena Prison: 815 cells.
Manufacture of prison cells
The company has a purpose-built facility for manufacturing prison cells. It consists of three frames with a floor length of 100 metres and eight sets of moulds to design the cell and the relevant furnishings, as well as the necessary arrangement of compressed air and steam ducts.
The manufacturing process begins by fitting the floor steel reinforcement, which has previously been produced in the iron workshop. Then the inner mould is fitted. In order to position the inner mould properly, it is supported on spindles that have a pre-set position in the floor mould. Then concrete is poured into the floor and the spindles used to position the inner mould removed once the concrete has reached sufficient strength.
After that, the reinforcement of the side walls and door frames, window and light recesses is fitted. Once the reinforcement has been verified, the outer mould is fitted and concrete poured into the walls. The entire unit is then covered with tarpaulins for the steam curing process.
Once cured, the inner mould and the outer mould are removed and the cell is transferred to the storage area, where its size is checked and the cell is marked. The furnishings are then fitted and the cell is ready for loading and shipment, which is usually done by rail. See attached photos.
Fitting the cell on site
To assemble the cells, the land stakeout grid previously made to plan the cell support structures is used. This means that assembly only requires the use of lifting gear to place the cells directly on the lines drawn on the grid.
As mentioned above, cells are usually transported by rail to the nearest station to the site. From the station, cells are transported by road haulage to the site and erected directly from the truck onto the structure using a 100 ton capacity telescopic crane.
To provide the maximum flexibility in transport and assembly it is also possible is to stock cells on-site. This takes advantage of the large amount of open space that often exists where prisons are being erected. To avoid moving cells onsite modules can be stored around buildings, placing each one opposite its final position.