Bulletproof Glass Installation: 7 Tips for Getting It Right

Installing bulletproof glass is nothing like standard commercial glazing. 

Success requires more than just a steady hand and clean caulking lines. These are complex, high-stakes systems designed to stop bullets, resist forced entry, and maintain visibility and functionality without compromising aesthetics. 

At Total Security Solutions, we regularly get calls from experienced professionals who think they can handle a bullet-resistant window like any other bulletproof glass installation—until they're knee-deep in delays, adjustments, and unanticipated costs. 

This post will help you avoid common mistakes and get the job done right the first time.

Understanding the Differences: Ballistic Glass Isn’t Just Heavy Glass

Bulletproof glass (more accurately called bullet resistant glass) is engineered to stop bullets, absorb impact, and stay intact enough to preserve safety and visibility. Whether you're working with acrylic, laminated polycarbonate, or glass-clad polycarbonate, the weight and thickness alone can surprise even veteran installers. 

It’s not uncommon to work with panels over 1.25" thick and weighing more than 10 pounds per square foot.

Common ballistic glazing types include:

Acrylic

Acrylic bulletproof glass, also called bullet-resistant plexiglass, is ideal for interior transaction windows and settings where weight savings and clarity are critical, such as reception areas. It’s designed to stop bullets from common handguns.

Laminated Polycarbonate

Laminated polycarbonate also excels in interior applications and can be tested to up to UL 752 Level 3 to meet higher threat levels. 

Glass-Clad Polycarbonate

Glass-clad polycarbonate (GCP) can be designed to meet the highest threat levels, up to UL 752 Level 8, making it ideal for interior and exterior applications. It can be heat-strengthened, insulated or customized with a variety of tints, frosting or one-way mirrors. Due to its weight, GCP often requires structural framing reinforcement and careful coordination with door and window systems.

Laminated Glass

Laminated glass consists of several sheets of glass bound together with resin. It can be engineered to stop bullets, prevent break-ins, and improve energy efficiency. There are many advantages to all-glass installations, including transparency, weatherability and durability. 

Insulated Glass

Insulated ballistic glass is made of two or more laminated glass panes separated by an airgap. It’s ideal for exterior windows that need to offer protection from bullets while also protecting the building from the elements. 

Each of these materials responds differently to environmental conditions, mounting techniques, and handling during installation.

Top 7 Tips for Installing Bulletproof Glass Systems

1. Start with the Specs: Ensure Glass Meets Physical Security Standards

UL 752 standards define levels of bullet resistance, specifying the type of bullets and velocity specific types of glass have been tested to withstand. 

There are also other relevant physical security standards you may need to consider, including common ASTM standards for forced entry, such as ASTM F3038 and ASTM F1233.

To offer the expected level of protection, every component of a system must match the required rating, including the glazing, frames, doors, and accessories. 

2. Measure to 1/32” of an Inch

Precision matters. We can’t stress this enough. Ballistic materials are rigid, and they cannot be trimmed or adjusted on-site like standard glass. 

Even slight measurement errors can lead to days of rework or costly remakes. That’s why our field engineers use professional measuring tools and CAD modeling to ensure all panels and systems are cut precisely to spec. 

3. Verify Door Swings Early

Bullet-resistant doors often include reinforced framing and ballistic hardware, which are not easily modified after fabrication. Incorrect door swing specification is one of the most common reasons for project change orders. 

Be sure the “threat side” and door orientation are clearly marked. 

4. Account for the Weight

Bulletproof glass weighs significantly more than standard glass. Make sure the framing is designed to bear the additional weight. Most standard frames won’t support it. 

If you aren’t sure what framing system is right for you or you, talk with an expert about your options

5. Use the Right Tools and Hardware

Some bullet-resistant glazing materials require special drill bits during installation to avoid cracking or damage. 

Standard bits may overheat or cause edge blowout. Make sure you have the right installation tools and know how to use them before you get to the job site. 

6. Consider Environmental Exposure

Acrylics can craze, and polycarbonates can yellow if improperly sealed or cleaned. If your installation is near direct sunlight, moisture, or fluctuating temperatures, ensure your glazing and coatings are specified for those conditions. 

Failure to account for exposure will degrade system appearance and effectiveness over time.

7. Don’t Skip The Accessories

Speak-thrus, cash trays and other accessories are critical to the functionality of many bulletproof systems. These are common for buildings with many customer transactions, such as convenience stores, customer service centers, pharmacies, pawn, and money-lending stores.. Pre-plan for wiring, cutouts, and mechanical clearances. 

Common Contractor Pitfalls (and How to Avoid Them)

Assuming it works like standard glazing

Ballistic glass is part of a system that includes frames, hardware and more. Installing bulletproof windows or other barriers after other trades have already closed up the area may mean cutting out finished work or reinstalling components that weren’t properly reinforced. Work with your GC and design team early to get the sequence right.

Modifying on-site

Even minor changes to glazing or framing can change the protection it offers. 

You can’t easily trim an edge to make it fit, drill an extra hole for a latch, or rework a misaligned door after delivery. This is why obtaining precise measurements and ensuring other components are ordered ahead of time is so crucial.  

Underestimating the budget and timeline

Supply chain disruptions can cause significant increases to your budget or lead to delays. For instance, many contractors don’t realize door hardware has longer lead times, often up to four months. 

Working with a manufacturer that uses primarily US-based building materials can reduce these delays. Our team prioritizes domestic sources. A large majority of what we deliver and install is produced in the United States, reducing delays. 

Overlooking integration with surrounding elements

Mismatched finishes, unsealed gaps around counters, or conflicting dimensions with millwork can detract from the professional finish your clients expect. 

Our team has extensive experience ensuring bulletproof systems integrate with custom millwork and retrofitting ballistic glass into existing buildings, including those with historical features.  

Assuming your crew is equipped for the job

Installing bullet-resistant materials may require different equipment, lifting strategies, PPE, and fasteners than your typical commercial glazing job. Be realistic about what your team is trained to do, and know when to contact someone for professional installation services. 

Working with TSS: Installation Support That Makes You Look Good

Total Security Solutions has decades of experience in ballistic systems and can support you through every stage of your project, whether you need help specifying materials, designing systems, manufacturing or installing them. 

We regularly work with contractors, glaziers, and millwork teams to support on-site installs. Our field support team and expert project managers help you get field measurements right the first time, provide detailed CAD drawings and specifications matched to your jobsite, and offer guidance on-site or over the phone. 

Our professional installation crews are available to work nights and weekends, minimizing disruption and getting your space secured faster. Because we’ve already taken detailed site measurements and coordinated closely with your plans, we can help you reduce the risk of costly changes and delays. 

If your upcoming project involves bulletproof glass, ballistic doors, or bullet-resistant windows, feel free to contact us with questions or installation support.