Best practices in lightweight construction: Modular ballistic safety wall

Modular safety system after shelling

Modular safety system after shelling

Source: Blomberger Holzindustrie GmbH

Modular ballistic safety wall

Markets

Savings*

Weight*

Energy*

* In this example, lightweighting allowed for the following reductions compared to a conventional design based on steel and concrete.

The challenge
The aim was to produce a modular safety system made of sustainable materials that allows for a flexible design of ceilings and walls that can be assembled and dismantled without technical tools. The energy-intensive materials used during production were to be substituted by carbon-neutral materials.

The application
A modular ballistic wall is to be used to protect persons and property against firearms, explosives and attempted break-ins.

The solution
The solution was to design a system of armoured-wood panels and profiles that could be used to provide shelters and safe ceilings in crisis regions as needed. Other features such as sound insulation and fire protection can be included. The individual elements can be reused and adapted at any time.

Safety wall with electrical socket

Safety wall with electrical socket

Source: Blomberger Holzindustrie GmbH

Back with steel plate reinforcement for through-holes, e.g. for electrical installations

Back with steel plate reinforcement for through-holes, e.g. for electrical installations

Source: Reinhold Bentler

Further information

Other feasible applications

This solution allows for major energy savings compared to the conventional steel design. During the production of 1 kg of steel, an average of 1.46 kg of CO2 is released. To achieve ballistic class VPAM 4 (VPAM scale – European armour standard), a 5 mm thick steel plate is required, weighing 39 kg/ m². The armoured wood used is carbon neutral in its production, i.e. the CO2 savings potential can be calculated as follows: 39 kg x 1.46 = 56.9 kg CO2 per m².

The multi-layer structure and the reduced weight of the individual elements are devised to allow a rapid and simple assembly without any tools. The potential for energy savings amounts to 230 kWh per m² (ballistic class VPAM 4, steel vs. armoured wood). This corresponds to the amount of energy needed by a private household in a month.

All domain-specific regulations were considered. Work safety, environment protection and recycling are developed and improved within research activities.

Lightweighting classification

	Realization
Offer
Products Parts and components, Semi-finished parts, Materials
Services & consulting Testing and trials
Field of technology
Design & layout Lightweight manufacturing, Hybrid structures, Lightweight construction concepts, Lightweight material construction
Functional integration Material functionalisation
Measuring and testing technology
Modelling and simulation
Plant construction & automation
Recycling technologies
Manufacturing process
Additive manufacturing
Coating (surface engineering)
Fibre composite technology Pre-preg processing
Forming
Joining Adhesive bonding, Screwing
Material property alteration Thermomechanical treatment
Primary forming
Processing and separating Drilling, Milling, Sawing, Grinding
Textile technology
Material
Biogenic materials
Cellular materials (foam materials)
Composites
Fibres
Functional materials
Metals
Plastics
Structural ceramics
(Technical) textiles

Access best practices on various technologies and processes in lightweight construction from industry and research.

Contact