ProtectiFlex masonry offers a bespoke blast and projectile force protection building product, which can be retrofit on to existing structures or integrated into new designs. Its innovative formula allows bullet and bomb blast overpressure to be absorbed and dissipated through the structure, preventing spalling.
It has undergone a rigorous testing regime and its performance consistently outstrips its competitors. It is the foremost one stop solution against blast and ballistic threat.
Masonry Block Blast Trial Spadeadam
ProtectiFlex masonry walls were put up against two explosive charges, each equivalent in size to a car bomb, at different standoff distances. The first trial set the benchmark performance; the second trial is where the walls were pushed to their limits.
The trials were designed in accordance to guidance provided in relevant test standards such as the ISO 16933 (used for blast testing of glazing systems) along with the “Home Office Test Standard, Explosive Resistant Walls and Doors” CAST Publication Number: 101/16, September 2016 and supplemented with existing blast data and test setup provided from the CPNI trials (Circa 2012-16) assessing the suitability of ordinary CMU partition walling for use in providing Protected Spaces (i.e. bomb shelter areas, data centers, occupied spaces) for direct comparison with the tested ProtectiFlex masonry wall specimens and their reported blast data and performance.
Over the two blast trials, 10 walls were tested (eight in culverted frames and two freestanding walls). The walls were arranged in a perimeter around the charge to receive the full impact of the blast. The walls were placed at different standoff distances from the charge.
Free standing Wall
Blast Test Results
A blast report summary was issued detailing the performance of ProtectiFlex walls against a charge the equivalent size of a car bomb. The data displayed shows the blast pressures and impulses the walls withstood and the subsequent hazard rating A-F the walls achieved. The hazard rating was based on the UK Home Office standards set out in their publication 101/16 shown in the image below. Figure 1, below, shows that ProtectiFlex walls achieved a hazard rating of C or better, which means that there was no spalling of the walls
Figure 1. Test Standard Explosion-Resistant Walls and Doors CAST Publication #: 101/16, September 2016.
Table 2 shows the blast pressure and phase impulse criteria needed to meet the UK Home Office protection category criteria for C25 and C15, which the ProtectiFlex walls in table 3, below, met. To meet Home Office standards then, a hazard rating of E or higher is required. To meet more stringent expectations for partition walling of protected spaces as set out by CPNI, it must be level B or higher.
Table 2. Protection Categories as Defined by the Home Office Test Standard
|Classification Code|| Mean Peak Air Blast Pressure
| Mean Positive Phase Impulse
*To achieve either C15 or C25 categories in accordance with the Protected Spaces guidance and trial data the samples must have a hazard rating of No Break (A) or No Hazard (B) only
Table 3. Summary Data Table of Results Taken from the Blast Report Conducted
|ProtectiFlex Wall Thickness||Blast Standoff Range
|Verified EXV Load Classification||Mean Air Blast Pressure
|Mean Positive Phase Impulse
|Protection Category||Hazard Rating||CPNI Requirement for Partition Walling Use Providing Protected Spaces||Home Office Standard for Explosive Resistant Walls and Doors|
|100mm||19||EXV19||170.4||663.7||C25||No Hazard B||Y||Y|
|215mm||12||EXV12||557.3||1363.1||C15||No Hazard B||Y||Y|
|280mm||12||EXV12||536.9||1377.2||C15||Minimal Hazard C||N||Y|
|280mm Horizontal Spanning||15||NA||239.1||561.2||NA||Minimal Hazard C||N||Y|
Table 4. Comments on the Blast Test Results
|ProtectiFlex Wall Thickness||Comments on Test Results|
|100mm||Tested to a higher load criteria than required to achieve the Protection Category C25. Existing data for ordinary CMU construction of 100mm thickness is for EXV25 loading compliance only.|
|215mm||Tested to a higher load criteria than required to achieve the Protection Category C15.|
|280mm||Tested to a higher load criteria than required to achieve the Protection Category C15.|
|The wall remained stabled following the test with only hairline cracking (<1mm) along the midspan. This performance proves adequate protection against the effects of a VBIED at 15m from a ProtectiFlex perimeter wall solution.
The residual Stability of the wall indicates that sufficient protection is remaining in the wll post-blast to prevent/limit intruder access, provide protection against fragment throw and other ballistic threats.
Figure 2. Deflection History of 100mm (4”) Thick Protectiflex Masonry Wall.
Figure 3. Deflection History of 215mm (8.5”) Thick Protectiflex Masonry Wall.
In summary the results were impressive, as shown in the tables above the ProtectiFlex walls exceeded the standard set for masonry concrete of equivalent thicknesses and densities.
The report summarized that "additional reserves of capacity available in well constructed ProtectiFlex walls beyond that shown by even the successful trials"and"ProtectiFlex is able to compete with heavier blocks whilst providing comparable levels of protection.
Masonry Block Ballistic Tests
ProtectiFlex masonry was ballistically tested at David Goode Associates (in the United Kingdom) in accordance with the ballistic resistance ratings, performance and testing methodology demands listed in BS EN 1063:2000 (used for security glazing) and BS EN 1522 (used for windows, doors, shutters and blinds).
The ballistic tests demonstrate ProtectiFlex superior performance against various caliber size and speeds. ProtectiFlex masonry not only stopped penetration of the projectile but also maintained an intact structural performance. This allows ProtectiFlex to continue to provide protection against multiple ballistic attacks, while maintaining the structural integrity for the mitigated walls or building façade systems.
Table 1. Ballistic Test Results Summary
|Tested in Accordance With:||Calibre||Block Depth||Bullet
|Shot Qty.||Penetration Prevented||Structural Integrity Maintained|
|BS EN 1063:2000|
|BR4||.44" Magnum||100mm||FMJ FN SC
15.6g ± 0.1
|422.95 - 463.30||9||Y||Y|
|BR6||7.62x51mm||140mm||FMJ PB SC
9.5g ± 0.1
|832.28 - 852.80||9||Y||Y|
|215mm||FMJ PB HC
9.8g ± 0.1
|819.37 - 833.15||3||Y||Y|
|FB3||.357 Magnum||100mm||FMJ CN SC
10.2g ± 0.1
|404.16 - 450.43||7||Y||Y|
|FB4||.44 Magnum||100mm||FMJ FN SC
15.6g ± 0.1
|427.82 - 452.27||5||Y||Y|
|140mm||FMJ PB SCP
4.0g ± 0.1
|930.00 - 971.88||14||Y||Y|
|FB6||7.62x51mm||140mm||FMJ PB SC
9.5g ± 0.1
|837.01 - 847.45||6||Y||Y|
|215mm||FMJ PB HC
9.5g ± 0.1
|815.70 - 834.98||7||Y||Y|
Performance Gallery of Royal Engineers Weapon Effects on ProtectiFlex and Other Force Defensive Products
Organised by the British Army, the Royal Engineers and held at COTEC (Cranfield University Ordnance Test and Evaluation Centre) Gore Cross, Wiltshire. The day was set out as weapons effect on structures, including ProteciFlex and other ballistic & blast solutions compared with conventional concrete and steel plates. Below is a gallery of how ProteciFlex performed against the best the military could fire at it.
Cannon Shell Protection
9 rounds of 30mm Rarden cannon shells fired at a ProtectiFlex masonry wall from a Warrior IFV F510 at 800m
British Army Warrior IFV F510
30mm Rarden cannon rounds
Masonry wall hit by cannon
122mm mortar detonated at 1.5m from ProtectiFlex wall, standard wall and other blast system.
ProtectiFlex is the only wall left standing with minor damage to the face of the wall but no spalling.
ProtectiFlex is the only wall left standing after the 5kg charge is detonated. Competitor wall system lying in the foreground Glazing system and concrete wall.
HMG repeat firing .50 calibre rounds on ProtectiFlex wall and Concrete wall.
ProtectiFlex is on the left and standard concrete wall is to the right after repeated 50 calibre fire.
Thermal Conductivity, Fire Safety and Durability Performance
A 2 hour flame test was conducted on a 100mm thick ProtectiFlex masonry block wall, accorrding to BS EN1364-1:2015.
ProtectiFlex wall at start of test
ProtectiFlex wall after 2 hours
ProtectiFlex Safety Data Sheets accord with EC-Regulations 1907/2006 (REACH) for all safety requirements.