Jim Richards | |
Just because ballistic glass is designed to take a bullet doesn’t mean it won’t crack if it’s mishandled.
If you’re a contractor planning to install ballistic glazing, don’t assume your team can take the same approach as installing standard commercial glass.
Ballistic glass is thicker, heavier, and less forgiving. Whether you’re working with glass, acrylic, or laminated polycarbonate, bullet-resistant barriers are designed as a system of integrated components rather than a set of panels.
Small mistakes like over-tightening fasteners or using the wrong sealant can damage the glazing and in some cases, compromise the rating.
At Total Security Solutions (TSS), we’ve designed, fabricated, delivered, and installed over 30,000 custom ballistic systems. Our in-house team has expertise in planning, engineering, and working shoulder-to-shoulder with contractors.
Here are some of our top tips for preserving the integrity of the glass and protecting your crews while staying on schedule.
For more tips on planning, measuring and installing glass barriers, download this helpful checklist.
12 Safety Tips for Handling Bullet-Resistant Glass
1. Inspect the glass on arrival
Note any crushed corners, torn wrap, or cracking. If the glass has been tested to UL 752 standards, be sure it’s clearly labeled. If you are not the manufacturer, be sure you understand any applicable warranties and what they cover.
2. Handle like precision equipment
Ballistic glass is designed to withstand a variety of weapons and attacks according to the physical security standards it meets, but it’s not immune from scratches or damage.
Wear clean, dry gloves and remove anything that can scratch: rings, watches, or belts, for example.
3. Plan your route and avoid any obstacles
Our team regularly works on projects where we need to install executive protection on the 25th floor of a high-rise building or a penthouse suite.
We’ve had to navigate narrow hallways, elevators, and tight turns. That’s why when we initially visit a site, we plan our path and measure openings to ensure there’s adequate clearance. The last thing you want is to arrive with your installation crew only to find your glass panels won’t fit through the door.
4. Understand size and weight limits
Larger ballistic glass panels increase weight and handling risk. As a general rule, glass-clad polycarbonate typically has maximum sizes of 60″×120″, while acrylic/laminated polycarbonate may be slightly larger. Larger pieces require careful rigging and more labor. Any ballistic glazing tested to UL 752 must also be supported by frames tested to the same standards. Plan for this in advance and don’t assume you’ll be able to retrofit your glass into standard frames.
If your goal is to make doors and windows more resistant to forced entry and you don’t require ballistic glazing, there are options that will fit your frames.
Our SchoolDefender®glass is a good, cost-effective option for retrofitting stronger glass into existing frames as it has been independently tested to withstand forced entry, making it a better alternative to window film.
5. Use the right tools and enough manpower to carry it
The heaviest bullet-resistant glass can weigh as much as 20-25 pounds per square foot.
Always use at least two people to carry glass panels, and avoid lifting them above your head. If possible, use heavy-duty suction cups, carts, or mobile glass lifters to reduce strains.
6. Watch the weather
Although exterior glass is designed to withstand harsh outdoor elements, high winds can pose a hazard when moving glass outdoors, especially if you’re using mechanical glass lifters. Keep an eye on wind speeds or impending storms and pause work if necessary.
7. Respect the “threat-side” labeling
Keep protective films or labels on until the installation is complete. If you can read the UL 752 sticker from the attack side after install, you’ve oriented it correctly.
Before inserting the glass into the framing, peel the edge of the protective paper so it’s easier to remove after the glass is in place.
8. Store upright, dry and cushioned
If the glass arrives before you’re planning to install it, be sure you’re storing it according to the manufacturer’s guidelines. Store them upright and use soft blocks at the base and between contact points. Keep them clean and dry.
9. Be careful with any on-site modifications
Ballistic glass or glazing is tested to meet specific criteria, and some materials, such as glass-clad polycarbonate, cannot be altered at all. Making modifications on-site may potentially void warranties. Other types of glazing, such as acrylic or laminated polycarbonate, can be modified in the field if you’re using proper tools, such as a circular saw. Check with the manufacturer before making any adjustments.
10. Don’t over-tighten fasteners
Excess torque transfers stress into laminates and can create stress fractures that may not be obvious upon installation. Use the hardware schedule’s torque values and check your work before tightening again.
11. Use compatible, neutral-curing sealants
Certain solvents attack interlayers and can cause crazing, or tiny cracks that make the glass appear foggy. Stick to approved, non-reactive, neutral-curing sealants specified in submittals.
12. Clean with the right products
Caring for and cleaning bulletproof class barriers protects your investment and helps you avoid damage. For acrylic or laminated polycarbonate, use a mixture of warm water with mild soap or detergent and a soft microfiber. To remove grease, use hexane, kerosene, or naphtha. Never use commercial cleaning products containing ammonia, lacquer thinner, acetone or abrasive chemicals. Polish acrylic or polycarbonate with commercial wax, which will fill in minor scratches and smooth the surface.
It’s also a good idea to leave instructions for third-party cleaning crews to ensure they know how to properly care for the system.
Protect Your Crew and Your Investment With TSS
On a typical bulletproofing project, you’re likely working with an architect, security consultant, manufacturer and potentially a separate crew handling installation. Good communication between all parties is essential to any successful project.
Over more than two decades of protecting people across the country, Total Security Solutions has developed a proven process to ensure every project is performed safely, correctly, and on time.
We’re involved in every stage of the project, from assessing security risks and planning custom barrier systems to engineering, fabricating, and installing them.
We can also consult with your crew at any point, answering questions about material, recommended tools, solvents, and more.
Download this helpful field guide for your crew and contact us for a quote when you’re ready.
