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Understanding Low-Spall Bulletproof Glass
February 6, 2026
Bullet-resistant glass is often expected to provide complete protection once a projectile is stopped. However, real-world ballistic events demonstrate that stopping penetration alone does not guarantee occupant safety. In many cases, the interior surface of conventional ballistic glass fractures on impact, releasing sharp fragments into the protected space. Low-spall bulletproof glass addresses this critical safety gap by controlling how the glass behaves after impact, significantly reducing the release of hazardous debris.
What Causes Spall in Ballistic Glass
Spall occurs due to the way glass reacts under extreme ballistic stress. When a high-velocity round strikes a glass assembly, the exterior layers absorb and slow the projectile while a shockwave travels through the laminate. As this energy reaches the protected side, the interior surface experiences intense tensile stress. Standard glass materials lack the flexibility to absorb this stress, causing the rear surface to fracture outward.
Even when the bullet is fully stopped within the glazing, glass shards may be expelled into the occupied area. These fragments, known as spall, can act as secondary projectiles capable of causing serious injuries, including lacerations, facial trauma, and eye damage.
Defining Low-Spall Bulletproof Glass Performance
Low-spall bulletproof glass is engineered not only to stop ballistic threats but also to limit or prevent interior glass fragmentation. Its primary function is to protect occupants from secondary hazards created by glass debris following impact.
Bullet-resistant glazing systems are commonly categorized based on their post-impact behavior:
- Standard ballistic glass: Stops the projectile but allows significant interior fragmentation, potentially ejecting glass shards into the protected space.
- Low-spall ballistic glass: Controls rear-surface debris to levels unlikely to cause injury, reducing the risk of secondary harm.
- No-spall ballistic glass: Prevents interior fragmentation entirely, keeping the protected side free of hazardous debris.
While all three categories may meet ballistic penetration requirements, only low-spall and no-spall systems actively address occupant safety after impact. This distinction is particularly important in environments where people are positioned close to the glazing.
How Low-Spall Bulletproof Glass Is Constructed
Early ballistic glass relied on thick, all-glass laminates that used mass to capture projectiles. Although effective against penetration, these assemblies were heavy and often produced significant interior fragmentation.
Modern low-spall systems use advanced composite construction. These assemblies typically combine glass with polycarbonate or similar materials and incorporate a dedicated spall-control layer bonded to the interior surface. This flexible layer absorbs impact energy and contains glass fragments as the glazing fractures.
By allowing controlled deformation rather than brittle failure, low-spall bulletproof glass delivers reliable occupant protection while reducing weight and structural demands.
Key Advantages of Low-Spall Bulletproof Glass
- Enhanced occupant safety: Interior glass fragments are contained, lowering the risk of lacerations and eye injuries.
- Reduced secondary hazards: Effective fragment control minimizes the danger posed by glass acting as secondary projectiles.
- Preserved visibility: An intact interior surface supports situational awareness for security personnel during critical incidents.
- Lower structural impact: Advanced materials achieve high protection levels without excessive thickness or weight.
- Long-term performance: Spall-control layers are engineered to maintain clarity and adhesion over time.
Applications Where Low-Spall Performance Is Essential
Low-spall bulletproof glass is particularly important in installations where occupants are in close proximity to the glazing. Typical applications include teller windows, reception counters, guard booths, and security checkpoints.
In high-occupancy environments such as schools, hospitals, and government facilities, controlling interior fragmentation is critical to reducing injury risk during a ballistic event. Similarly, guard stations, control rooms, and critical infrastructure sites rely on low-spall performance to ensure personnel remain protected and operational.
Armortex Low-Spall Bulletproof Glass Solutions
Effective ballistic protection extends beyond stopping a projectile. It must also safeguard the people behind the barrier during and after impact. Armortex designs low-spall and no-spall bulletproof glass systems with this principle in mind, integrating advanced materials, precision manufacturing, and rigorous testing.
By focusing on both ballistic resistance and post-impact safety, Armortex delivers glazing solutions that support true life-safety performance in high-risk environments.
Original article: What Is Low-Spall Bulletproof Glass?
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Armortex
Product: Bullet resistant windows and glazing
Source: https://www.armortex.com/what-is-low-spall-bulletproof-glass/
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