What is Bulletproof and Ballistic Drywall?
Bulletproof and ballistic drywall is a specialized building material designed to provide enhanced protection against ballistic threats. It is constructed using multiple layers of ballistic-resistant materials and is commonly used in high-security environments to mitigate the risk of penetration by bullets and other projectiles.
Bulletproof and ballistic drywall can appear complex until you grasp some fundamental principles. Homeowners construct safe rooms, while businesses, retail stores, government agencies, and schools install ballistic wall panels to ensure protection and peace of mind.
The World of Bulletproof and Ballistic Drywall Unveiled
Before you embark on your drywall construction project, it’s crucial to familiarize yourself with various aspects of ballistic drywall. We’ll delve into topics such as the rating of bullet-resistant drywall, its manufacturing process, installation procedures, sources to procure it, and its significance in diverse building types globally.
Defining Ballistic Drywall
To begin, let’s establish the basic definition of “ballistic.” According to Merriam-Webster, it relates to the science of projectile motion in flight. Ballistic drywall, also known as bulletproof sheetrock, serves as a shield safeguarding building occupants from deflected bullets and other projectiles in active shooter scenarios.
However, it’s essential to note that “bulletproof” is a misnomer, as no material is completely impenetrable. A more accurate term for “bulletproof sheetrock” would be “bullet-resistant sheetrock.” Real-life attacks vary based on the weapon and ammunition used, but standardized requirements exist for bullet-resistant environments.
Exploring the Cost of Bulletproof Drywall
The cost of ballistic and bulletproof wall panels depends on the level of protection you require. Generally, a 4′ x 8′ sheet of bullet-resistant panel can range from as low as $350 to as high as $1,800. This translates to a cost ranging from $10 to $60 per square foot for the material.
Diverse Levels of Drywall Protection
Irrespective of the terminology used, “ballistic drywall” resists firearm projectiles but cannot prevent all bullets from penetrating. It is categorized based on the type and quantity of bullets it can resist from various calibers of firearms, providing multiple levels of protection against different threats.
The Mechanics of Ballistic Panels
Ballistic panels employ a multi-layer construction that absorbs the energy of bullets, preventing blast fragmentation and ricochets. These panels not only reduce the risk of injuries but also offer a secure haven for individuals seeking shelter during an armed attack. They are installed in flat, rigid sheets, similar to standard drywall, using regular hand tools.
Applications of Ballistic Drywall
Residential properties, commercial establishments, government buildings, and educational institutions all face potential security threats. Therefore, architects specify the use of ballistic and bulletproof drywall to meet demands or adhere to building codes and regulations. The following types of buildings are prime candidates for ballistic drywall:
- Access points of military bases
- Airports
- Banks and credit unions
- Border posts
- Check cashing companies
- Commercial businesses
- Correctional facilities
- Courtrooms
- Embassies
- Government facilities
- Guard houses
- Gun ranges
- Gun rooms in residences
- Home vaults
- Military installations
- Panic (or safe) rooms in residences
- Pawn shops
- Pharmacies
- Police stations and police departments
- Religious centers
- Retail stores
- Schools, including grade schools, high schools, colleges, and universities
- Stadiums
- Nightclubs
- Storm shelters
Assessing Different Ratings of Ballistic Drywall
The National Institute of Justice (NIJ) standard is the accepted benchmark for body armor worn by law enforcement and corrections officers. For ballistic materials, Underwriters’ Laboratories (UL) offers ratings, and “UL-listed” signifies product safety. UL’s certifications are recognized by various safety agencies, including the Occupational Safety and Health Administration (OSHA).
The Significance of UL752 Certification
Manufacturers benefit from obtaining a UL752 level certification as it provides third-party validation of their product’s performance characteristics. Additionally, some ballistic products comply with ASTM testing standards for flame spread and smoke ratings. The H.P. White Laboratory conducted ballistic testing for over 80 years until its recent closure. There are also specific ratings for bulletproof drywall to protect against forced entry.
Understanding Ballistic Protection Level Ratings
Ballistic protection level ratings consider the number of rounds and the weapon size tested, ranging from small-caliber handguns to high-caliber rifles. These ratings ensure that bullet-resistant material forms effective barriers against robberies, holdups, and other armed attacks.
Different Ratings of Bullet Resistant Materials Identified by UL 752
| Rating | Ammunition | Weight (grains) | Weight (grams) | Minimum fps | Maximum fps | Number of shots | ||||||
|---|---|---|---|---|---|---|---|---|---|---|---|---|
| Level 1 | 9mm with Lead Core | 124 | 8.1 | 1175 | 1293 | 3 | ||||||
| Level 2 | .357 Magnum | 158 | 10.2 | 1250 | 1375 | 3 | ||||||
| Level 3 | .44 Magnum | 15.6 | 1350 | 1485 | 240 | |||||||
| Level 4 | .30 Caliber Rifle | 180 | 11.7 | 2540 | 2794 | 1 | ||||||
| Level 5 | 7.62mm Rifle Lead Core | 150 | 9.7 | 2750 | 3025 | 1 | ||||||
| Level 6 | 9mm Full Metal Jacket | 124 | 8.1 | 400 | 1540 | 5 | ||||||
| Level 7 | 5.56mm Rifle | 55 | 3.5 | 3080 | 3383 | 5 | ||||||
| Level 8 | 7.62mm Rifle Lead Core | 150 | 9.7 | 2750 | 3025 | 5 | ||||||
| Shotgun | 12-Gauge Rifled Lead Slug | 12-Gauge Buckshot | 1oz | 1.5oz | 28.3 | 42.1 |
The Manufacturing Process of Ballistic Drywall
Bullet-resistant drywall is produced by injecting polyester resin into woven ballistic-grade fiberglass cloth through a series of small holes. The impregnated cloth is subjected to heat and pressure in a hydraulic hot press, resulting in flat rigid sheets. After pressing, the boards are cut to size using a water jet or semi-automatic beam saw.
Where to Purchase Ballistic Drywall
Finding manufacturers of ballistic fiberglass panels is as simple as conducting an internet search or using industrial sourcing platforms like Thomas. This directory offers a wide range of bullet-resistant panels, featuring top brands such as Armorcore, Bullet Guard, and Armortex.
Determining Ballistic Drywall Costs per Square Foot
The cost of ballistic drywall panels varies significantly. A 4′ x 8′ sheet of bullet-resistant fiberglass or drywall panel ranges from $300 to $1,800, equating to approximately $10 to $60 per square foot. Material price fluctuations underscore the importance of obtaining project-specific quotes.
Availability is another crucial factor. Lead times for these products can be extensive, so it is advisable to confirm delivery timelines with manufacturers or distributors before placing orders.
Exploring Alternatives to Ballistic Drywall
Numerous alternative products have been developed to counter ballistic threats, with many more in the developmental pipeline. These alternatives include:
- BallistiCrete: An interior plaster coating providing NIJ Level III and Level IV ratings, which can be mixed and applied on-site. It is utilized in the construction of bullet-resistant safe rooms and panic rooms and possesses non-combustible properties with minimal flame spread and resistance to mold and mildew growth.
- Armorcore Level 3 Bullet Proof Panels: These ballistic panels employ woven fiberglass and composite laminate to absorb energy and halt bullets. Armorcore panels are tested and approved for UL 752 standards, offering a range of products from Level 2 to Level 7, each with varying price points.
Installing Ballistic Drywall
While the installation of ballistic drywall may not be a typical DIY project, it is feasible. Here are the essential steps:
- Panels are secured along the edges and reinforced with ballistic fiberglass batten strips.
- A final layer of bullet-resistant gypsum board or veneer is applied on top of the shielding.
- Ballistic drywall panels maintain a similar appearance to untreated wall panels.
Panel Sizes
Ballistic panels are typically available in combinations of 3’, 4’, and 5’ widths and 8’, 9’, and 10’ lengths. They can be cut in the field using standard carpentry tools, including a circular saw, table saw, panel saw, or saber saw. A diamond grit blade is recommended for larger cuts and cutting around electrical boxes and openings.
Fastening and Drilling
You can drill through bullet-resistant drywall using high-speed steel twist drills at a slow speed. The panels can be attached to wall studs or substrates with self-tapping drywall screws. Panels with a nominal thickness of 1 1/8” and thicker can be pre-drilled with fastener holes to facilitate installation, using a carbide or cobalt tip drill under medium speed and pressure.
Adhesives
Another method for affixing ballistic drywall is through adhesives. For non-porous substrates such as aluminum or steel, stronger adhesives like Plexus MA 320 are recommended. Laminates can be applied using standard contact adhesives.
Wall Assembly
While it’s most straightforward to install bulletproof drywall in new construction, retrofit renovations are also possible. To maintain the ballistic properties of the panels, it’s advised to attach a 4” overlap batten strip at joints, ensuring a 2” overlap on each side of the seam. Batten strips can be added wherever there are vertical or horizontal joints.
Finishing
Various finishes can be applied to bullet-resistant panels, including wood, plastic veneer, additional layers of drywall, or stainless steel sheets, using contact cement. Panels can also be upholstered or painted. It’s essential to note that while the material in the panel poses no hazards during storage or use, irritant particles may be produced when the panels are cut or machined. Therefore, protective gear such as gloves, eye protection, face masks, and appropriate clothing should be worn when installing ballistic drywall.
The Evolving Landscape of Bulletproof and Ballistic Drywall
In today’s world, personal protection and security are paramount concerns. Homeowners and business owners turn to ballistic wall panels to enhance security in buildings exposed to potential threats or hostile environments. While no drywall is entirely “bulletproof,” bullet-resistant materials are readily available, easy to install, and provide an added layer of security across a broad spectrum of industries and businesses.
tag: # Bulletproof and Ballistic Drywall
