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Keeping the BAD GUYS In
A structural
integrity evaluation of corroded prisoner cell doors
was requested. It was reported that during very
heavy spring rains, the lower edges of vertical
stacked doors were submerged in water and mud. An overall view of the prison doors
installed in modular cell units prior to permanent
placements are shown in Photograph A .
Photograph A: Overall view of prison
doors for which an integrity evaluation was
requested.
Questions about the
prison cell door integrity were raised when the
bottoms, sides and hinge areas of numerous cell
doors were visually observed to exhibit external
corrosion.
An overall view of
stacks of the questionable cell doors is shown in
Photograph B.
Photograph B: Overall view of stacks of
prison cell doors with questionable integrity.
A
close-up view of the bottoms of stacks of questioned
cell doors is shown in Photograph C.
Photograph C: Close-up views of the bottoms
of questionable prison cell doors.
A close-up view of the lower corner on one cell door
and lower door hinge is shown in Photograph D.
Photograph D: Close-up view of bottom
(foot) of lower door panel.
A close-up view of the bottom (foot) of the lower
cell door panel is shown in Photograph E.
Photograph E: Close-up view of corroded
bottom edge of door.
A close-up view of a corroded hinge and hinge pocket
is shown in Photograph F.
Photograph F: Close-up view of corroded
hinge and hinge pocket.
The internal
structure of the subject doors was quite
remarkable. The door panels were reinforced with an
internal truss structure. Columns of fiberglass
insulation (for sound, not thermal insulation) were
inserted into the truss interstitices (inside the
door).
A close-up view of
this internal structure is shown in Photograph G.
Photograph G: Close-up view of internal
truss structure.
Corrosion of the
door’s internal truss structure is clearly evident.
The lower sections of selected cell doors were cut
for internal visual examination.
A typical corroded
condition of the lower cell door is shown after
sectioning in Photograph H.
Photograph H: Close-up view of section cut
from lower corner of one cell door.
Some cut sections
had a consolidated dirt/mud residue as shown in
Photograph I.
Photograph I: Close-up view of
section cut from cell door. Loose consolidated
dirt/mud residue was found.
To view
and examine the entire internal structure, including
the truss structure, extent of corrosion and
moisture migration, the spot welds attaching the
truss structure to the front and rear panels were
marked and drilled. Drilling was conducted in
an attempt to remove wall to truss spot welds,
thereby enabling viewing of the door truss internal
structure.
An overall
view of the drilled lower section of one of the test
doors is shown in Photograph J.
Photograph J: Overall view of test door after
drilling to remove spot welds.
The subject door was then opened (drilled panel
removed) and the opened door is shown in Photograph
K.
Photograph K: The subject “opened” cell door
revealing internal structure/corrosion.
As can be
seen from Photograph K the fiberglass insulation has
acted as a “wick” and moisture and mud in the
bottom of the doors has wicked up 12 to 18 inches
from the bottom of the door. In some cases (light
brown areas in Photograph K) the fiberglass did not
get as wet at the bottom of the door and thus much
less wicking and moisture migration occurred.
The final
result of this investigation was an opinion that the
internal structure had been completely compromised
and that nothing could be done to mitigate and/or
reduce future corrosion. Thus, in order to keep the
“bad guys” in their cells it was recommended that
the subject corroded cell doors not be salvaged and
that they be replaced.
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