As physical threats continue to rise across industries—from commercial buildings and schools to government and financial services—ballistic and bulletproof construction has become an essential part of modern building design.
For project managers, understanding the nuances of ballistic-resistant materials, threat levels, and how much protection they need based on bulletproofing standards is critical to delivering safe and cost-effective solutions.
Here, we break down best practices and key considerations to keep in mind for your next bulletproof and ballistic construction project.
Whether you're designing a new facility or retrofitting an existing one to support added security, these guidelines will help you make informed decisions that protect both people and property.
1. Understand Ballistic Threats and Protection Levels
Ballistic threats vary significantly depending on the setting, and the systems you implement to protect personnel will be unique to each building. The idea that you can simply install ballistic panels in a few areas is a misguided approach to security.
Bulletproof panels are just one of many elements of a systems approach to security.
First, the security director or building manager should work together to assess the risks they face and evaluate any existing security features. They should consider the surrounding environment and what types of incidents have taken place previously in the nearby area, if any. Have there been break-ins at nearby buildings? Reports of gun violence?
They'll need to consider how daily operations at the building impact potential threats as well. In buildings where hundreds of people enter each day, such as schools or government agencies, you'll need to secure the main entrance without inhibiting the flow of traffic.
Once you've identified your needs, consider what materials are best for protecting people within that environment.
To find the right bulletproof protection levels, consult national standards including UL 752, the industry’s most recognized standard for bullet-resistant materials. The revised 12th edition still includes 10 levels of bulletproofing but groups them into three tables based on the type of firearm for which they are tested, including handguns, rifles, and shotguns.
Other bulletproofing standards include those established by the National Institute of Justice, specifically NIJ 0108.01, which focuses on body armor, and ASTM F3561-22, which focuses on forced-entry resistance after a ballistic assault.
2. Use Tested Ballistic-Resistant Materials
Selecting the appropriate materials is one of the most critical aspects of ballistic construction. Materials such as ballistic glass, ballistic fiberglass panels, and reinforced framing for doors and windows work together to form a comprehensive security system.
Here's a closer look at some options to consider.
Ballistic glazing
Bullet-resistant glass, including laminated glass and glass-clad polycarbonate (GCP), is ideal for windows and doors, especially in high-traffic or externally-facing areas. Acrylic and polycarbonate glazing options provide lighter-weight solutions suitable for interior barriers where aesthetics and clarity are priorities.
Ballistic glass is available in a variety of materials depending on the level of protection your project needs and the aesthetic look. The most common types are:
- Acrylic glazing, which is ideal for interior doors and windows and typically offers a UL 752 protection level of 1-2
- Polycarbonate and laminated polycarbonate glazing, which ranges from Levels 1-3
- Glass-clad polycarbonate glazing, which is ideal for both interior or exterior doors and windows and offers protections levels up to 8, as well as forced entry protection
- Insulated glass, which is ideal for exterior doors and windows and and also offers protection levels up to 8
As you choose the type of glass or glazing that is best for your project, consider the protection level you need, as well as weight, thickness, size, and light transmission. You may also want to consider whether you want glazing that is compatible with LEED building certification or if you need a certain bevel, polish, or tint to match the look of the building.
Though sometimes marketed as a ballistic solution, window film is not bullet-resistant. However, it can serve a valuable role in delaying entry or preventing glass from shattering outward after an impact, especially in areas that are not directly exposed to occupants. For comprehensive protection, combining multiple layers—such as reinforced glass backed by fiberglass panels—can significantly improve performance against ballistic impacts.
Ballistic fiberglass panels
Ballistic fiberglass panels are a popular option for bullet-resistant wall reinforcements, countertops, dividers, and event reception desks or guard booths. They offer cost-effective, flexible protection that can be installed behind drywall or by attaching ballistic panels directly over existing structures.
Ballistic fiberglass panels can be tested to UL Levels 1-8, depending on their weight and thickness. They can also be tested to NIJ0108.01 standards or ASTM F123-98 standards for forced entry protection.
Ballistic doors
As the first line of defense for most buildings, doors are an important investment in building security. Aluminum or steel is the most common material used for exterior doors, while wood, glass, or acrylic are used more frequently inside. Wood tends to be a more cost-effective material for offering ballistic protection, while glass doors typically have higher costs. The level of protection you need will also impact the cost. This is why it's important to think strategically about where you need to have the most protection—for instance, in high-traffic areas—and where lower levels may be more appropriate.
Keep in mind that ballistic-resistant doors also require specialized hardware, including strikes, hinges and handles.
Framing
Ballistic-resistant materials often have multiple layers, so framing is essential. Consider the protection levels you need, the wall thickness, whether the barrier is indoor or outdoor, how it will be used, and its appearance.
This is not an area to cut corners by reusing existing frames. Most ballistic-resistant barriers are too thick or heavy to be supported by a frame that isn't designed for it.
3. Design With Application and Layout in Mind
No two facilities are the same, and ballistic protection must be thoughtfully applied to the unique layout and use case of each site. For example, a financial institution may focus protection on teller stations and cash-handling areas, where bulletproof glass and ballistic counters can safeguard staff during high-risk interactions. Corporate facilities often prioritize executive offices, lobbies, and conference rooms with reinforced doors and glazing that align with their security posture and brand image.
In healthcare, emergency departments, reception desks, and pharmacies are the most common targets, requiring solutions that blend protection with patient-facing functionality. Retail environments tend to center their ballistic defenses around point-of-sale counters, display areas, and entrance vestibules, often using transaction windows, package passers, and secure mantraps to prevent rapid intrusion.
It’s not just about stopping bullets—it’s about maintaining operational flow.
That’s why early-stage collaboration with ballistic experts is essential to ensure everything integrates seamlessly into the architectural layout while still offering critical protection.
4. Prioritize Professional Installation
Proper installation is just as important as material selection. Bullet-resistant products only offer ballistic protection when installed correctly, with precise alignment, adequate structural support, and complete sealing. These materials are substantially heavier than traditional building components, and incorrect handling can lead to sagging, gaps, or compromised protection. Even minor oversights—like failing to anchor a wall or incorrectly framing a window—can render a ballistic system ineffective.
We recommend scheduling installation near the end of the project timeline to minimize the risk of damage. It’s also essential to use specialized tools and follow best practices for drilling and mounting ballistic-grade acrylics and polycarbonates. Cleaners and maintenance products must be vetted as well; conventional cleaning chemicals can cause crazing or long-term surface damage to ballistic materials.
If you’re using a third-party installer, make sure they’re briefed on the materials’ unique handling requirements. Better yet, choose a partner who offers complete design-to-installation service with factory-trained crews.
5. Consider Industry-Specific Threat Profiles
The type and level of ballistic protection needed will differ by industry. In retail, businesses typically worry about smash-and-grab thefts, robberies, and random street violence. Here, ballistic panels at counters, transaction windows, and secure vestibules provide deterrence and delay entry. Bulletproof storefront systems can also help protect valuable merchandise and staff.
In the financial sector, teller windows, vault entrances, and cash-handling areas are the most common targets. Bandit barriers made of bullet-resistant glass and fiberglass-backed counters create a protective envelope around staff, while transaction drawers and voice ports facilitate daily operations.
Healthcare facilities face unique challenges. Emergency rooms, behavioral health units, and pharmacy windows are common areas for ballistic upgrades. These spaces often require anti-ligature features and custom-engineered components that support both patient care and protection.
Corporate buildings tend to protect high-level executives and reception staff. Entry lobbies, conference rooms, and C-suite offices are frequently upgraded with UL-rated windows, ballistic-resistant doors, and fiberglass wall panels. Government facilities, military installations and critical infrastructure often require protection against higher-level threats like high-powered rifles, requiring a more layered approach with UL Level 4 materials and above.
6. Factor in Ballistic Barrier Costs
Cost is always a consideration, and ballistic construction is no exception. Materials like bullet-resistant glass start at around $50 per square foot for Level 1 protection but can rise substantially based on level, glazing type, and custom requirements. This price does not include framing, labor, or structural reinforcements, which can add significantly to the total investment.
Ballistic-resistant panels, by comparison, offer a more affordable way to reinforce walls and counters. They start at around $30 per square foot and are often used in conjunction with glass to build a layered defense system. A full ballistic barrier installation can range from $7,000 to $30,000 or more, depending on the scope and complexity of the project.
This is why we often recommend phased implementation plans that prioritize high-risk areas first. You may also be able to fortify existing windows with bulletproof backglazing instead of replacing them.
7. Avoid Common Mistakes
There are several avoidable missteps that can compromise your project. One of the most common is focusing exclusively on ballistic-resistant glass while overlooking the need for ballistic panels in walls and millwork. Without complete envelope protection, attackers may simply bypass the most obvious defenses. Another frequent error is using uncertified or inadequate materials that fail to meet UL or ASTM standards. These products may look the part but offer little real protection.
Improper installation, especially failing to fully seal frames or align panels correctly, is another serious issue. Barriers must be airtight and flush to prevent bullets or break-in tools from breaching through gaps. Additionally, failing to account for ventilation, weight support, or line-of-sight can negatively impact both safety and usability.
Our engineers routinely collaborate with contractors to identify and correct these issues during pre-installation planning.
8. Partner With a True Ballistic Expert
Working with a seasoned ballistic partner like Total Security Solutions ensures your project is not only compliant and secure, but also cost-efficient and seamlessly integrated with your architectural goals. We offer end-to-end services, from site assessments and threat analysis to fabrication and nationwide installation. With over 30,000 successful projects completed, we bring unmatched expertise and peace of mind to every job.
Our approach prioritizes collaboration, education, and customization. We understand your team needs more than the right ballistic panels or glass—they need a trusted advisor to navigate timelines, regulations, and threats.
Build Smart to Protect What Matters Most
As the need for physical security grows, so does the responsibility of project managers to build safe, resilient environments. Ballistic and bulletproof construction isn’t just about materials—it’s about making smart, strategic choices that protect lives, reputations, and operations.
By aligning your project with certified materials, proper design strategies, and expert installation, you create spaces that withstand violent threats while supporting everyday functionality and aesthetics. If you’re planning a security upgrade or a new build, now is the time to integrate ballistic protection into your scope.
To learn more about selecting materials for your next project, download our ultimate guide to ballistic security.
