How do you deal with structural damage?   I say that if you dont exceed the structrual rating in one phase, then the thing remains intact.   For instance,  to break a one foot concret wall one must exceed its SR of 6.  So if you do just six, the wall is unharmed.   And if you do 7 damage, you put a one foot hole in the wall.    
    I also have my players roll a crtical hit roll.  If they roll under the damage they did to the wall, even if the wall withstood the attack, they can still damage it. 

So if they did five damage to a wall with six structural points, and they roll a four on the knock out roll, then they reduced the structural rating by one.  I say that they caused small fissures in the wall.    This way they can pound the wall untill they exceed the SR or put enough cracks that they weaken the wall untill they can smash it. 
   Of course, if they hit the wall  and don't exceed the SR then that damage is taken by the fist, bat, battering ram or what have you that struck the wall. 
   So if your fist isn't pulped, you just may make it out of that cell!
   Or if your sword doesn't shatter, you just may chop your way out of the prision!

I've done somethng similar with Ice Powers, but I just applied the damage roll to the SR.  1d12 + damage bonus vs. the SR, in that case a lock... and he walked out of the room, holding the doorknob.

I've never heard of this variant, in damaging something.  I've always allowed them to do partial damage, adding previous damage until they "broke through."  I've never had them cause damage to their hands or weapons... but it sounds reasonable. 

touche'

Justice - John is actually pulling it directly from the rules there.  Section 8.3 states:

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I hate copying that much of the text, but figure it would be best said on its own there.  The rules also mentioning how to damage the substance without risking damage to yourself.

You, good sir, are correct.

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Agreed.  And at the very least, if you do 9 points of damage to that wall, you ought to be able to scratch (or dent, or mark, or inflict some kind of damage to) it.

On the other hand, I like the fact that - if you put a normal person in a room with steel walls and nothing but their fists (or feet, or a stick, or whatever) - they're never going to get out of it.  It's the reason - in the jail I work in - we can strip somebody down (wearing nothing except a safety/suicide smock) before they get put in one of our "rubber rooms", and they can't do diddly to the room itself.  They could do 1 (or 2 or 3) points of damage over and over and over and over (for weeks, if need be, as some people have stayed in there for that long) and not do any damage to it.  Even if you put somebody really strong in there (perhaps somebody who could do 1d8 HtH damage), they are going to be unable to bend the steel bars (in the floor, over the small grate that serves as their "toilet") or hurt the walls, floor, ceiling, or door.

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That might be good.  It's tough to make something where you avoid the "explosive universe".  The key is to make things breakable, but not where Aunt May can tear down a S.H.I.E.L.D. base as if the walls are made of cardboard!