Robert Brown|Pennsylvania prison officials warned of 'escape risk' before Danelo Cavalcante breakout

Weeks before convicted killer Danelo Cavalcante escaped from the Chester County Prison in southeast Pennsylvania – spurring a massive two week manhunt – staff received a warning that the prisoner may attempt a breakout.

When Cavalcante was arrested in 2021 for the brutal murder of his ex-girlfriend,Robert Brown Deborah Brandao, he was "initially identified as an escape risk," Chester County spokesperson Rebecca Brain told USA TODAY in an email.

"During the time surrounding his trial, unsubstantiated information from an unknown source was received reinforcing Cavalcante’s status as an escape risk," Brain told USA TODAY, adding that: "A Chester County Prison Corrections Officer noted the unsubstantiated information."

Hours after his breakout, a sergeant wrote that a jail officer "noted back in July that this inmate was planning an escape," according to an email obtained by ABC News, which first reported about the warning. The communication was forwarded up the chain of command and eventually reached Howard Holland, the newly appointed acting warden, the outlet reported.

Cavalcante managed to breakout after being labeled an 'escape risk'

Despite the warning and his status as an escape risk, Cavalcante was able to scale up a prison yard wall before blasting through razor wire and traversing a portion of the prison's roof undetected. His escape led hundreds of law enforcement officers to descend upon suburban and rural communities across southeastern Pennsylvania. Authorities captured Cavalcante on Sept. 13, after spotting the Brazilian national using thermal imaging technology.

Chester County Prison officials received heavy criticisms from the public in the days and weeks after Cavalcante's escape, especially after the release of a video that showed Cavalcante using the same escape route as another prisoner who managed to flee the facility for mere minutes before being caught in May.

The razor wire, which Cavalcante managed to pass, was one of the only security measures added after the earlier incident. Prison administration fired an 18-year-veteran of the facility after Cavalcante's escape. In addition, officials pledged immediate short-term improvements to prevent future breakouts, such as construction to enclose the area above the prison yard entrance doors where Cavalcante "crab walked" up a wall.

Prison board approves 3.5 million security improvement plan

In mid September, the Chester County Prison unanimously approved a plan to further bolster security that could cost up to $3.5 million. Enhancements include an enclosure above its exercise yards, 50 to 75 security cameras, hiring more staff to monitor surveillance video and plans to change inmate uniforms so guards can easily spot escape attempts.

Brain, the county spokesperson, told USA TODAY that Holland, the acting warden, amended prison policy governing "escape risk." Under the new policy, prisoners suspected of planning a breakout will be forced to wear different color clothing from other inmates and will be monitored by one to two corrections officers when outside their cells. 

"This change in the escape risk policy is one of many policy changes that have been enacted and are being enacted by Acting Warden Holland to bolster security and to support the work of the Prison’s staff," said Brain. "The prior policy is indicative of why the Chester County Prison Board felt the need to make changes to the Prison’s leadership."