Zehao supplied custom double-decker prison beds for a Malaysian government correctional facility upgrade, engineered to local durability standards and tropical climate conditions.
Project Overview
In collaboration with Naga Steel, a Malaysian steel contractor serving public infrastructure projects, Zehao designed and manufactured heavy-duty double-decker prison beds for a Malaysian government prison infrastructure project. The delivery supported the Prison Department’s cell-block modernization program, increasing inmate housing capacity within existing footprints. Every bed was engineered for tamper-proof security, tropical humidity resistance, and rapid bulk production.
Product Specifications
| Feature | Specification |
|---|---|
| Product Name | Double Decker Prison Bed with Additional Leg |
| Overall Dimensions (L × W × H) | 2,030 mm × 816 mm × 1,360 mm |
| Main Frame Support | Square hollow tube 19 mm × 19 mm × 1.0 mm |
| Safety Barrier | Round tube Ø19 mm (top) / Ø16 mm (horizontal & vertical) × 1.0 mm |
| Mattress / Sleeping Surface | Steel plate sheet 1,880 mm × 740 mm × 1.2 mm |
| Main Legs | Round tube Ø50 mm × 1.2 mm |
| Middle Support Leg | Round tube Ø19 mm × 1.0 mm, fully welded |
| Ladder | Round tube Ø19 mm (vertical) / Ø16 mm (horizontal) × 1.2 mm |
| Rectangular Hollow Rail | 25 mm × 50 mm × 1.2 mm |
| Surface Finish | Epoxy powder coated |
| Floor Fixing Plate | Ø75 mm × 3 mm (bolt-down to concrete) |
| Design Standard | Engineered for Malaysian correctional facility durability requirements |
Engineering & Compliance Highlights
- Welding Integrity: Minimum weld length of 38 mm on all safety-barrier and leg joints; critical connections are fully welded.
- Deep Insert Construction: Safety-barrier and ladder end-bars are inserted 50 mm deep into the main floor frame, then fully welded for maximum rigidity.
- Gap Reduction: Barrier spacing and geometry were engineered to reduce hazardous gaps, meeting correctional-facility safety benchmarks.
- Tropical Climate Resistance: Epoxy powder coating selected for long-term anti-corrosion performance in Malaysia’s high-humidity environment.
- Tamper-Proof Design: Fully welded steel frame with no removable bolts or fasteners, eliminating unauthorized disassembly and contraband concealment.
- Secure Floor Anchoring: Integrated Ø75 mm × 3 mm fixing plates at each leg allow bolt-down to concrete floors, preventing movement or lifting.
- Steel Plate Sleeping Surface: Solid 1.2 mm steel plate replaces traditional slats, removing hiding points and simplifying disinfection protocols.
Production & Quality Control
Production was carried out in Zehao’s ISO 9001–certified partner facility. Factory photos show the beds during welding, assembly, and pre-shipment staging.
Technical Drawings
Zehao provided full manufacturing drawings approved by the Malaysian contractor, covering front-view dimensions, tube specifications, weld details, and floor-fixing layout.
Packaging & Logistics
Beds were partially knocked down for efficient container loading. Corner protectors and PE film wrapping prevented coating damage during sea transit from Tianjin Port to Malaysia.
Why This Configuration Fits Malaysian Government Prisons
Malaysia’s tropical climate accelerates rust on untreated metal furniture. The epoxy powder coating provides a hard, non-porous surface that withstands frequent washing and resists salt-air corrosion. The solid steel plate sleeping surface eliminates contraband concealment points and simplifies hygiene protocols, while the additional middle support leg and bolt-down floor-anchor system ensure long-term rigidity under continuous use.
FAQ
Why was epoxy powder coating chosen for this Malaysian prison project?
Epoxy powder coating delivers a smooth, uniform finish that is easy to clean and resists abrasion in high-use detention environments. When applied over pre-treated steel, it performs reliably in tropical humidity and reduces long-term maintenance.
What is the purpose of the additional middle support leg?
The additional leg provides extra vertical support to prevent frame sag under continuous load. It is fully welded and integrates with the floor-fixing plate, distributing weight more evenly across the concrete slab.
How does the floor-fixing system work?
Each main leg terminates in a Ø75 mm × 3 mm steel plate with a central hole. The bed is anchored with expansion bolts into the concrete floor, preventing tipping, lifting, or unauthorized relocation.
Why use a solid steel plate instead of slats for the sleeping surface?
Solid steel plates remove gaps where contraband or pests can hide and allow rapid disinfection. This design simplifies hygiene inspections and reduces the risk of inmates removing or weaponizing individual slats.
Can the dimensions or finish be customized for other Malaysian government tenders?
Yes. Zehao reviews tender drawings or cell dimensions, adjusts tube gauges, sleeping-surface materials, and coatings to match local specifications (including JKR or Prisons Department clauses), and produces pre-production samples for approval before bulk manufacturing.
What welding standards are applied to ensure safety-barrier strength?
All safety-barrier joints meet a minimum weld length of 38 mm, with full circumferential welding at leg-to-frame connections. Barrier and ladder end-bars are inserted 50 mm deep into the main frame before welding, creating a load path that resists lateral forces and climbing-induced stress.
Get Drawings or a Quotation for Your Prison Furniture Tender
If you are preparing a tender for the Malaysian Prisons Department, JKR, or another Southeast Asian correctional infrastructure program, Zehao can supply detailed engineering drawings, material certifications, and competitive bulk pricing.
Contact: zehao@cntjzh.com | WhatsApp: +86 155 1090 8182 | www.zehao-world.com
About the Manufacturer
Zehao is a steel bed manufacturer based in Tianjin, China, supplying correctional facilities and government institutional projects across Malaysia, Singapore, the Middle East and Africa. See our prison bed factory and government project capability for certifications, tender support and reference projects.
