Jim Richards | |
Ballistic polycarbonate is a resilient, durable, and aesthetically pleasing security solution.
Polycarbonate bulletproof windows, while not made of actual glass, are ideal for interior use. Its unique construction gives it the ability to “catch” a bullet without shattering. The laminated layers absorb the bullet’s momentum instead of forcing a bullet to dangerously ricochet off its surface. Polycarbonate also offers a high-resistance to forced entry; for example, a sheet of polycarbonate security glazing can withstand repeated strikes from a sledgehammer.Let’s explore the many stand-out features and benefits that make ballistic polycarbonate an excellent, versatile solution for securely protecting people and facilities.
How is Ballistic Polycarbonate Different from Acrylic Safety Glass?
The most modern ballistic glass includes at least one of the following thermoplastics:
- Acrylic (often sold as Plexiglass or Perspex)
- Polycarbonate (often sold as Lexan, Cyrolon, or Marlon)
Both these materials are stronger and lighter than glass, weighing roughly half as much at equivalent dimensions. Acrylic offers about 17 times greater impact resistance compared to glass. Polycarbonate is even better, measuring an astounding 250 times more resilient than glass.
In most cases, deciding between acrylic and polycarbonate options comes down to your situation and needs.
Polycarbonate is more resilient to impacts but is also softer and scratches more easily than acrylic. By flexing upon impact, polycarbonate can absorb tremendous pressure waves without cracking or spalling. When shot, polycarbonate usually “swallows up” bullets, rather than sending them ricocheting at high speed.
Acrylic is harder and less likely to scratch. Manufacturers can even buff acrylic out to a high-gloss finish, like glass. Its hardness also makes it more likely to crack or chip. If it repels a bullet, that bullet can ricochet unpredictably, and can injure bystanders on the “threat side” of a barrier. Acrylic is also more transparent than polycarbonate. But, because polycarbonate has a greater strength, a thinner piece may work just as well in a given application. That will at least somewhat reduce the impact of its poor light transfer characteristics.
As you shift your focus specifically to ballistically rated materials, the “Acrylic vs. Polycarbonate” debate becomes much more one-sided. You’ll generally find that bullet-resistant windows built around polycarbonate thermoplastic have broader applications in building safety and security.
Lamination Unlocks Ballistic Polycarbonate’s Customizable Qualities
Polycarbonate is more resilient than any other glazing material because it can flex. But that lack of rigidity makes it tricky to work with and maintain. To take full advantage of polycarbonate’s flexible resilience, manufacturers combine it with other materials, such as acrylic or tempered glass.
This combination of laminated materials is the key to creating ultra-resilient glass-clad polycarbonate windows that go beyond just stopping bullets.
Because they laminate bulletproof plexiglass windows in layers, manufacturers can include other materials to adjust and improve both its performance and aesthetics. For example, they can add window frosting or tints, or reinforce it with wire mesh.
Even a thin sheet of polycarbonate has built-in “forced entry” qualities. This can deter smash-and-grab burglars, deflect bomb blasts, and even protect against earthquake damage and tornado-tossed bricks. Specially formulated and layered polycarbonate ballistic windows can possess even more unique properties, like “one-way” ballistic characteristics and fire resistance. For more information about your specialty protective options, contact us.
Overall, ballistic polycarbonate is highly customizable and there are many options to choose from to meet your security needs.
Ballistic Polycarbonate Can Stop Large, Powerful Bullets
It’s important to consider the stopping power your bullet-resistant material needs. For example, the powerful, accurate .223 is a popular rifle cartridge in America, which also makes it a growing security concern. Unfortunately, the most common consumer-grade bulletproof windows simply cannot match the penetrating power of the .223.
Defending against the .223 calls for an entirely different approach. Not only must the ballistic glass be thicker, it also needs to be of an entirely different composition. The only common bullet-resistant glass that’s going to stop a .223 is glass-clad polycarbonate.
When a .223 strikes a window made of glass-clad polycarbonate, the outer surface of tempered glass forces the projectile to partially pancake, spoiling its aerodynamic design. That tempered glass then shatters, and the adhesive interlayers and polycarbonate flex like a backstop. Because this material is softer and denser than bullet-resistant glass or acrylic, their flexible characteristics deform and disperse the energy of the bullet strike. While an acrylic-based bullet-resistant window is unlikely to stop even a single .223, a UL Level 7 system using glass-clad polycarbonate ballistic glass will easily catch a burst of five of these bullets.
To learn more, read our blog about laminated polycarbonate bulletproof windows stopping the .223.
Three Options for Ballistic Polycarbonate (and How They Compare to Ballistic Insulated Glass Windows)
Polycarbonate sheets are used in three types of bulletproof windows at TSS:
All-Polycarbonate Windows (LP 750 AP, LP 1000 AP, LP 1250 AP)
All-polycarbonate bulletproof plexiglass windows are made of multiple sheets of polycarbonate laminated together. They usually have a pair of thicker standard polycarbonate sheets in the middle—to give the window strength—with thinner mar-proof layers of polycarbonate on the outermost surface to minimize scratching and scuffing.
This material is very easy for experienced bulletproofing companies like Total Security Solutions to work with. With all-polycarbonate windows, your design can be very intricate. Ballistic barrier system manufacturers can cut and fabricate these windows to blend in with any building aesthetic. You’ll have many options for talk-thrus, slots, fasteners, and more.
All-polycarbonate windows are thinner and lighter than a ballistic acrylic window with the same protection levels. Most suppliers can furnish polycarbonate windows in UL Levels 1 through 3, which provide protection from a wide range of easily concealed handguns. All-polycarbonate ballistic windows also carry a UL-tested forced-entry rating. In other words, third-party labs have tested the windows and confirmed that they will completely withstand breaching, even after an extended period of constant battering with sledgehammers and other tools.
There is a trade-off: an all-polycarbonate bulletproof window has relatively poor light transmission (around 70%, compared to acrylic’s +90%). The actual value is dependent upon themulti-layered ballistic makeup of the panel.
Acrylic and Polycarbonate Windows (LP 750 BR, LP 1000 BR, LP 1250 BR)
These bullet-resistant polycarbonate windows combine the aesthetic advantages of acrylic with the strength of polycarbonate. Usually, they have an acrylic core laminated to a set of 1/8th inch mar-resistant polycarbonate outer layers. Adding those polycarbonate caps doesn’t just strengthen the acrylic (bringing it up to Level 3 stopping power)—it also adds some measure of forced-entry and blast resistance to the material, although it has not been tested to an official UL forced entry standard at this time.
Glass-Clad Polycarbonate Windows (GCP)
Glass-clad polycarbonate ballistic windows are made of laminated layers of glass and polycarbonate. These windows are available in Levels 1 through 8 (with those higher levels able to stop multiple bursts from high-powered assault weapons and tactical rifles). There are many different options when layering glass and polycarbonate in a GCP window, depending on the application. They can tune the windows aesthetically, like adding tint, mirroring, frosting, or other features. They can also increase energy efficiency (with “low E” interlayers). GCP windows may have polycarbonate or glass outer layers, depending on the security and design needs.
Because of the many layers of glass, polycarbonate, and urethane, these are much more challenging to cut, form, and fabricate. They perform best as solid frame-mounted sheets, often for exterior windows.
Insulated Glass Windows
Insulated ballistic glass panels can be manufactured using all-glass constructions—without polycarbonate—for UL Levels 1 through 3, offering protection against a wide range of handgun threats. These panels combine multiple layers of glass with interlayers for energy absorption and are ideal for applications where thermal insulation, clarity, and traditional aesthetics are important.
At higher protection levels, such as UL Levels 4 through 8, insulated panels utilize glass-clad polycarbonate (GCP) to handle the increased energy of rifle rounds. GCP panels combine the clarity of glass with the flexibility of polycarbonate, providing superior stopping power while maintaining the insulating benefits of multi-pane glazing systems.
These insulated units can also be customized for added performance and comfort, with options such as low-E coatings for energy efficiency, tinted or reflective glass for privacy and glare control, and gases such as argon can be added between panes to further enhance thermal insulation.
Whichever type of material you end up choosing for your windows, the framing is just as important to ensure overall safety.
If you’re working on a ballistic security project and would like to learn more about your options, read our Ballistic Glazing Solutions Guide.
Total Security Solutions is Ready to Help You Improve Security with Ballistic Polycarbonate
For decades, TSS has provided all types of businesses, organizations, and companies with the bulletproof glazing they need to protect themselves, their customers, and their facilities. Consulting with a ballistic expert can take the guesswork out of the process and ensure that you choose the right material for the job.
If you’d like to get started with ballistic glass-clad polycarbonate or any of our other products, please don’t hesitate to contact us or request a quote.
