Leading Innovator of Security Products for Over 80 Years

Steel Security Wall System

TrussWall

TrussWall, Trussbilt’s steel security wallsystem, sets the standard for meetingthe highest security requirements in themost cost-effective manner. TrussWall’sinnovative approach builds on Trussbilt’sunique core design to provide a light-weight, highly secure wall system thateasily integrates with other Trussbiltproducts for a total security solution.

TrussWall’s double-skinned, hollowmetal wall panels with interlockingrabbeted edges are manufacturedfrom heavy gauge galvanized steel.Built with Trussbilt’s unique TrussCoretechnology, TrussWall’s 2" thick panels,compared to 6" or 8" thick concretewall systems, result in sizable weightreduction for the facility, greatly reducingfooting and foundation requirements.

This smaller footprint means overallspace requirements can be reducedor existing space can be optimized.In Maricopa County, AZ, an entirefloor in the new 4th Avenue jail waseliminated by using TrussWall, asavings of 30,000 square feet offloor space and 300,000 cubic feetof building volume. The county alsorealizes ongoing benefits from reducedstaffing and energy requirements.

General laborers can easily erectlightweight TrussWall panels withoutscaffolding, forms or an army of masons.The facility’s superstructure and roofingsystem can be completed beforeTrussWall is installed, giving moreflexibility during construction whencompared to both CMU block andprecast concrete modular installations.This flexibility allows General Contractors

to minimize lost work days by preventingdelays during cold and rainy seasons.

A special concrete grout is pressure-pumped into TrussWall panels after theyare installed, minimizing the "wet work"found with block and pour-in-placeconcrete installations. With the super-structure and roof in place, all othertrades can realize early starts --something that is virtually unheard of

with pre-engineered modular systems.The TrussWall panel system achievesthe same Sound Transmission Class(STC) rating as an 8" block wall andmeets all ASTM requirements. Whenused with the Trussbilt TrussDekceiling system and Trussbilt’s securityhollow metal, the result is an integrated,secure solution that is the most cost-effective in the industry.

Trussbilt sets the standard for productsthat cost-effectively meet today’s highsecurity requirements.

Steel Security Wall System

Maricopa County 4th Avenue Jail, Phoenix, AZ – DEC: Norment Security Group

(right page) Northwest Detention Center, Tacoma, WA – DEC: CML Specialties

TrussWall’s 2" thick steel panelsuse Trussbilt’s unique TrussCoreconstruction. TrussCore is a truncated,triangular-shaped, roll-formed steel trussthat spans the full width and height ofthe panel; it is internally welded to bothface sheets every 3" vertically and2-3/4" horizontally.

Trussbilt has used this unique corewelding process for nearly 80 yearsand has the capacity to produce over100,000 panels annually.

This panel-stiffening approach preventsthe de-lamination that may occur withhat sections or other core materials,and TrussCoreprevents bowing andbulging when the panels are pressure-filled with grout.

Trussbilt uses a state-of-the-art, German-designed, high pressure, high volumepump to grout the panels after they areerected at the job site. This speciallydesigned machine can pump grout ashigh as 11 stories. Trussbilt’s proprietaryconcrete grout mixture decreases soundtransmission, increases bullet and blastresistance, and enhances overall security.The mixture is specifically formulated toresist internal corrosion and givesTrussWall its premier status of being thelightest security Level 1 wall systemmanufactured today.

TrussWall panels are de-mountable andreusable. Available custom sizes meanyou can design the layout to fit yourneeds.

Steel Security Wall System

The TrussWallSystem

TrussWall panels are self-supporting, easily accommodating one or twomezzanine levels.

59' – 8-9/16"

2" THICK WALLS

7' – 3-1/4"TYPICAL

80SQ. FT.11

'–0"

11'–

4-1/

8"

70' – 0-9/16"

8" THICK WALLS

8' – 0"TYPICAL

80SQ. FT.10

'–0"

11'–

4-1/

8"

(8) 8' x 10' cells with 8" CMU/concrete wallsrequire 795 sq. ft.

Designing with TrussWall vs. CMU/Concrete

Using 8” CMU in a typical cell pod of 64 cells (16 cells, 2 levels, both sides of the dayroom) requires6,360 sq. ft., compared to only 5,424 sq. ft. when using TrussWall. This is a savings of 936 sq. ft.At a construction cost of $250 per sq. ft., using TrussWall saves $234,000.

Alternatively, for a 64-cell pod, 8 additional cells could be placed in the same space required by theCMU block system. For those facilities which rent cell space, the 8 additional cells will pay for theentire 74 cells in less than 3 years.

(8) 8' x 10' cells with 2" TrussWallrequire 678 sq. ft.

This is a savings of 117 sq. ft. – morethan enough for (1) additional cell.

TrussWall installations are substantiallylighter, more durable, and more space-efficient than concrete wall systems.TrussWall vs.Its CompetitorsWhile filled block and poured or precastconcrete have been used for many years,TrussWall has substantial advantagesover concrete construction approaches.TrussWall has proven to be more flexibleunder challenges such as poor soil,lack of skilled masons, retro-fit weightrestrictions, lack of funding, spacerestrictions, or the desire to use theskills of locally available labor.

� TrussWall’s reduced weight andsmaller footprint can mean substantialsavings at the time of construction(see upcoming Cost Savings section)and more flexibility for retrofits.

� TrussWall does not depend on theavailability of masons.

� TrussWall is manufactured underrigid ISO 9001:2000 standards,resulting in consistent quality vs.the varying results that multipleconcrete laborers can produce.

� TrussWall minimizes the amountof wet work.

� TrussWall greatly minimizes oreliminates scaffolding and shoring.

� Steel TrussWall panels will notcrack as the building settles.

� TrussWall panels are deliveredprime painted, requiring only afinish coat of paint.

� Steel TrussWall panels are longerlasting and will not degeneratewith age.

� There is no need for re-bar withthe TrussWall steel panel system,assuring owners of the strengthof steel in every cell.

� TrussWall cell fronts are trueand straight, eliminating theshimming required with concreteunits for sliding door deviceapplications.

TrussWall vs. ConcreteBlock and Pour-in-PlaceConcrete Walls

TrussWall construction site - walls erected after building is enclosed

CMU block construction site - exposed to weather and subject to delays

Steel Security Wall System

Maricopa County Jail, Phoenix, AZ – DEC: Norment Security Group

TrussWall vs.Pre-cast ConcreteCell ModulesTrussWall has these additionaladvantages over pre-cast concretemodules:

� Delays due to inclement weatherare reduced because TrussWallpanels can be installed after thesuperstructure is complete.

� The General Contractor is back incontrol of the construction schedule,no longer dependent on theprecaster’s delivery schedule.

Cost Savingswith TrussWallTrussWall’s lightweight, thin walltechnology yields substantial savingsboth at the time of construction and overthe life of the facility. Given current issueswith concrete costs and availability,steel wall panels provide significantadvantages. TrussWall panels weighfrom 1/4 to 1/3 of the weight of CMUblock, substantially reducing footing andfoundation requirements and providingmore flexibility in site selection. Becausethe system is self-supporting and caneasily be stacked, structural beamscan be minimized.

In most cases, existing building loadratings can easily accommodate remodels.Retrofit applications with TrussWall haveproven successful across the country.Just as importantly, TrussWall’s smallerfootprint reduces overall space require-ments while providing superior security.TrussWall saves 10 sq. ft. per cellcompared with CMU block construction.And, reduced space means dollarssaved, both at time of constructionand over the life of the facility.

Construction savings includereduced requirements for:

� Footings and foundations� Building structural components� Electrical conduit and wiring

� HVAC equipment� Plumbing� Finish painting� Other components such as framing,

scaffolding, shoring� Overall time to completion

(general conditions)

Resulting operationalsavings includereduced costs for:

� Staffing (when floors or cell podsare eliminated)

� Cooling and heating� Maintenance

"DLR’s design experience using the TrussWall steel panel system has demonstrated many advantages over precast

concrete cell systems. One example of these advantages is scheduling. Typically, precast cell units must be installed before

the roofing system. This means that the cell erection schedule impacts the overall project schedule for the housing units.

In contrast, since TrussWall panels can be installed after the building shell is complete, contractors can schedule

early completion of the building shell to allow the steel panel cell construction to proceed during inclement weath-

er. On one large DLR correctional project the contractor is considering the pre-assembly of common plumbing chases and

adjacent walls into singular units that can be installed as sub-assemblies, potentially creating “assembly line” efficiency.

Another advantage of the steel wall system is its flexibility for change. Detention furniture such as steel beds, shelves and

desks can easily be attached to the walls to accommodate future changes.”

Joseph F. Haines, AIA, Senior Principal, DLR Group, Inc.

Ease of installation makesTrussWall ideal for retrofits,enhancing design options formaximizing available square footage.Coordination and IntegrationTrussWall easily integrates with Trussbilt-manufactured frames, doors,windows, ceilings, and cell furnishings, greatly reducing coordination issues.Also, Trussbilt coordinates all hardware preparations, HVAC, plumbing andelectrical access and/ or penetrations, and glazing preparations, through ourlong term relationships with the most experienced Detention EquipmentContractors (DEC) in the country. Trussbilt and the DEC are able to greatlyreduce the probability of errors and delays caused by scheduling conflicts,integration incompatibility issues, and communication breakdowns by limitingthe number of subcontractors and suppliers needed to deliver the facility’ssecurity package.

Unmatched VersatilityTrussWall is available in both standard and custom sizes, giving you totalflexibility in designing your facility. Its light weight and ease of installationmake it ideal for retrofit projects, saving on labor costs, enhancing designoptions, and maximizing current space. Using TrussWall as an internal

security perimeter allows thedesigner to use a more affordablesuperstructure, such as a pre-engineered metal building.And, with the dollars saved byusing the TrussWall system,you can afford to use moreaesthetically appropriate facadesto accommodate surroundingstructures.

Steel Security Wall System

‘‘The beauty of the TrussWall system

is that it can go up before, during or

after the construction of the shell,

giving enormous flexibility in the

scheduling process. Trussbilt’s concise

engineering and on-time deliveries make

TrussWall a viable alternative to

conventional construction. ”

Mike Langersmith

Owner, CML Specialties, Inc.

Panel distribution and floor channel layout,retrofit in existing building(Harris County Juvenile Facility, Houston, TX)DEC: CCC Group, Inc.

TrussWall panel erection,(Maricopa County Jail, Phoenix, AZ)DEC: Norment Secuity Group

Construction of Building G(LImestone County, TX Detention Center)DEC: CCC Group, Inc.

Typical cell(Northwest Detention Center, Tacoma, WA)DEC: CML Specialties

Visitation area using TrussWall(Northwest Detention Center, Tacoma, WA)DEC: CML Specialties

TrussWall dorm room application(Northwest Detention Center, Tacoma, WA)DEC: CML Specialties

1

2

3

4

5

6

1 4

2 5

3 6

Steel Security Wall System

Fire WallComplianceFire-rated TrussWall is marketedunder the name ThermaWalland is fire code compliant with allbuilding code entities including:International Building Code (IBC),United Building Code (UBC), andSouthern Building Code (SBC).ThermaWall complies with thefollowing firewall standards:

� ASTM-E119, Standard Methodsof Fire Tests of BuildingConstruction and Materials

� CAN/ULC-S101, StandardMethods of Fire EnduranceTests of Building Constructionand Materials

� NFPA-251, Fire Tests of BuildingConstruction and Materials

� UBC-7-1-94, Uniform BuildingCode Standard

� UL-263, Fire Tests of BuildingConstruction and Materials

ACA Compliance

TrussWall meets and exceeds theAmerican Correctional Association’ssuggested requirements for SoundTransmission Class (STC) ratingof 45 – 49.

Seismic ZoneComplianceThe TrussWall system has beenengineered to meet the requirementsof the nation’s most fierce seismicenvironments, like those of Alamedaand San Mateo Counties inCalifornia. TrussWall’s light weightmeans there are smaller seismicloads to consider, potentially reduc-ing the overall size of the foundationneeded to resist seismic loads.When TrussWall is attached to thebuilding’s floor and into the primarybuilding structure the system pro-vides lateral support, which helpsother building components resistseismic loading. And, TrussWall’slight weight means cell walls willinduce a smaller seismic reactionon the building structure thanwould concrete, further reducingrequirements for reinforcementand footings. TrussWall designs canbe certified by licensed structuralengineers in all 50 states.

SecurityComplianceThe TrussWall system complies with:

� ASTM F 2322 Physical Assaulton Fixed Horizontal Barriers forDetention and CorrectionalFacilities (passes SecurityLevel 1);

� ASTM F 1450-97 (2004),Standard Test Methods forHollow Metal Swinging DoorAssemblies for Detention andCorrectional Facilities (passessecurity Level 1);

� ASTM F 1592-01, Standard TestMethods for Detention HollowMetal Vision Systems (passessecurity Level 1);

� Wall De-lamination Test (passes3,000 pound pull apart test);

� Cell Furnishing Static Load Test(passes static loads of 1,500pounds for items welded directlyto the TrussWall face sheets);

� UL 752 -00 10th Edition BulletResisting Equipment (Level 8);and

� Standard Test Methods forPhysical Assault on OverheadFixed Barriers for Detention andCorrectional Facilities (passes3,000 pound static load upliftand 400 blow impact test).

Code and Specification Compliance

TrussWall Benefits� TrussCore technology provides

high security with superior quality.

� Lightweight, thin panels meansubstantial weight reduction inthe facility.

� Small footprint means space canbe reduced or optimized.

� Panels can be erected by generallaborers.

� Installation process allows moreflexibility during construction,minimizing lost work days andfacilitating early starts by other trades.

� Concrete grouting decreases soundtransmission and enhances security.

� Panels are load-bearing andself-supporting.

� Light weight and custom designpossibilities make TrussWall idealfor retrofits.

� Trussbilt coordinates all accessesand penetrations, minimizingchances for errors.

� Sliding door devices can be installedin TrussWall in half the time requiredfor installation in concrete cells.

� TrussWall can easily be integratedwith other Trussbilt products for atotal security solution.

� Substantial savings at time ofconstruction and over the life ofthe facility can be achieved.

See why TrussWall can provide thesecurity you require while reducing thecost of your project, both at time ofconstruction and over the life of yourfacility. And, Trussbilt’s ceilings, hollowmetal, and detention furnishings offerintegrated additions to your design,all with Trussbilt’s industry-leadingquality and backed with our outstandingcustomer service. For nearly 80 years,Trussbilt has responded to your needswith innovative security solutions, andwe believe TrussWall is in a class of itsown in the security market.

Thinner is better.

TrussWall vs. Competitors

Excellent

FairTrussWall Precast Cast-in-Place Grout-Filled Plate Steel

Poor Modules CMU Modules

Installed Cost $$ $$ $$$ $* $$

Operating Life-Cycle Cost $ $$$ $$$ $$$ $$

Speed of Construction

Project Scheduling Flexibility

Light Weight

Space Usage

Impact Resistance

Product Quality and Consistency

Ability to be Customized

Appropriate for Retrofits

Ability to use Local Labor

Facilitates Coordinationwith Other Trades

* This metric is relative to the availability of journeymen masons.

Leading Innovatorof Security Productsfor Over 80 Years

Trussbilt has designed and manufacturedhigh quality security products since 1926.Trussbilt’s products are used in over 2,000prisons throughout the world.

• TrussWall Security Walls• Security Ceilings• Detention Doors and Frames• ViewAll Wire Mesh /Screening• Detention Furnishings• Safe-T-Feed Food Pass System

We have developed and pioneeredperformance tests that demonstrate thesuperiority of hollow metal fabricationfor security. Trussbilt’s racking load test,static load test, impact test and edgecrush load test have become industrystandards.

Our expertise and experience position usas the detention industry’s market leader.

ISO 9001:2000 Certified

The product detail and specification informationprovided herein reflects past experience and is forreference purposes. Trussbilt reserves the right tomodify designs and specification requirements.Details will be provided to meet project specificationrequirements or upon request for specific applications.

MANUFACTURING FACILITIESMain Plant555 Lincoln Avenue NWHuron, SD 57350TEL: 605.352.5283FAX: 605.352.7141

North Plant /Ceiling Products801 Lincoln Avenue NWHuron, SD 57350TEL: 605.352.7096FAX: 605.352.7153

GENERAL OFFICES

550 Oak Grove ParkwayVadnais Heights, MN 55127-8509TEL: 651.633.6100FAX: 651.633.7100

www.trussbilt.com