Blast and Ballistic Partitioning System

Client: Explosives and pyrotechnics manufacturer.

Aigis design and produce internal blast and ballistic partitioning systems. These systems are based on floor mounted modular constructions that can be easily tailored to suit client’s requirements. These requirements are often threat specific, but the design of the system allows for flexibility in the multi-layered components to suit a vast variety of threats. Practicality and functionality of these partitioning modules can be suited to the client’s needs, incorporating hatches, windows, opening and closing transfer hatches etc.

The modular approach to the design allows for greater flexibility whilst maintaining the use of more standardised components to keep costs down. Pre-fabricated modules can be quickly and easily installed with minimal disruption and down time for the client. The structures can be used for permanent installations or more temporary solutions which allows for expansion or new layouts within the production facility.

The final customisable solution enables the client to provide safer working environments for its employees, improved protection of capital equipment and existing structures, all by containing and reducing the threats effects.

Basic Overview:

• Blast and fragment protective factory partitioning system
• A modular blast walling system that can be used to separate a factory floor into several protected work cells, and hence improve productivity with more usable safe space for the workforce
• Quick installation, with a limited footprint
• Fully tested and certified solution to Health and Safety recommendations
• Blast and fragment protection both back and front if required
• Reduce blast overpressure to a maximum 14kPa from one work cell to the adjacent work cell
• Completely customisable with hatches, apertures, windows and transfer hatches
• The system can be added to in the future to allow for factory expansion or a new layout
• Tailored specifically to suit the client’s needs, from brief and specification to final install and commissioning
• Low maintenance, with a variety of durable and aesthetic finishes
• Options for attaching cable tracking, machinery components and other utilities
• Fully tested solutions with the flexibility of in house testing for more specific and complex threats, all from one supplier

Method:

• A detailed specification was established with the client, to ensure that all of the required bespoke features were considered in the design
• Concept designs were created and presented to the client for discussion
• Development of specific materials to suit weight, thickness and protection levels
• Trials protocols were constructed and agreed with the client. These included multilayer material trials, full scale prototypes and a multi-shot pre-production proofing trial
• Comprehensive testing results package to enable IPE approvals
• Construction of manufacturing drawing set to client specific dimensions and layout
• Production and manufacturing planning to ensure on time supply and install
• Supply and installation of final system
• System commissioning and client sign off

Client: Explosives and pyrotechnics manufacturer.

Basic Requirement:

• Many munitions manufacturers need to improve health and safety aspects of their production process that will include limiting propagation of munitions and components during production. Reducing sensitivity of munitions and their components both during and following assembly assists with transportation limitations and general factory safety.
• Bespoke transit containers and factory partitioning to reduce the effects of an accidental detonation within a factory.
• Reduction in component and munitions separation distances helping to utilise more factory space for production.
• Blast absorbing materials that can be moulded to suit a variety of shapes, sizes and apertures.
• The design must be proven in explosive trials.

Method:

• A detailed specification was established with the client, to ensure that all of the required bespoke features were considered in the design.
• Concept designs were created and presented to the client for discussion.
• Development of first stage prototypes that would be used in explosive trials.
• Trials protocols were constructed and agreed with the client. These included propagation detonations, and extensive use of data capture equipment to gain pressure readings and high speed imagery.
• Results and development considerations were obtained from the trials which lead to modifications of the design. The modifications were quickly implemented into the revised design and a second batch of prototypes were constructed for further explosive trials.
• The final design was put into production. The flexibility of the design allows for alteration to the internals to cater for various quantities and sizes of explosive containers. This makes this product ideal for a wide variety of explosive transit conditions that can be tailored to suit the client’s needs.

Client: Aigis generated brief to provide a new blast containment unit that would be suitable for suspect packages that are found during screening of international cargo.

Basic Requirement:

• A blast protection unit that would be capable of containing the harmful blast effects from a detonation of an explosive device that may be found during screening of international cargo.
• The unit must accommodate packages with the dimensions 550mm x 430mm x 340mm.
• The unit must be operable by a single user, and must be easily manoeuvred by that single user.
• The unit should be designed in such a way as to reduce the maintenance required for the life of the unit.
• All opening and closing of the unit should be mechanical, without the need for hydraulic or electronic devices, to ensure a trouble free guaranteed operation.
• The design must be proven in explosive trials.

Method:

• The IU1700 unit was designed around the Aigis TABRE attenuation system. This ensured that the unit would perform during live blast testing.
• The internal capacity of the unit was kept to a maximum whilst still providing a small external footprint and single user operability. This ensured the unit would easily accommodate the maximum package size, and provide increased capacity for larger items. Maximum internal capacity achieved was 595mm (23.4")width x 825mm (32.4")depth x 700mm (27.6")height. This provided the IU1700 with an internal volume of 343litres (12ft³).
• The opening and closing of the unit was based on a simple sliding door mechanism. This mechanism not only provided a trouble free and simple user interface, but also a very sturdy framework to retain the door closure during an internal detonation.
• A spring loaded locking bolt meant the unit had a simple and single stage locking that could be achieved using only one hand. The mechanism has a very positive lock that operates automatically upon the door closing ensuring safety and eliminating operator error.
• The unit can be operated by a user with almost no training requirement.
• The design has been blast tested to ensure its performance. The vigorous testing incorporated a 20% safety margin on explosive qty and also various fragmentation hazards. All of the fragments were safely contained within the unit and all of the damaging blast effects were reduced to such a level as to effectively protect the operator of the unit even in very close proximity.
• The IU1700 unit will now be subjected to live client user trials to confirm and hone the user interface. This ensures that the unit will provide the most trouble free, and simple operation within any business to provide operational continuity in the event of discovering a suspect package.

Insensitive Munitions and Non-Propagating Packaging specifically for 500g plastic explosive blocks.

Basic Requirement:

• To provide disposable transport packaging that will eliminate propagation of explosive effects between packing cases.
• Aigis to provide a solution to either stop propagation from one 500g block to another 500g block, or one 20Kg fully packed case to another 20Kg fully packed case, positioned adjacently.
• The design must be proven in explosive trials.

Method:

• A detailed specification was established with the client, to ensure that all of the required features were considered in the design: Packing densities, pallet distribution, ergonomics, logistic considerations etc.
• Concept designs were created and presented to the client for discussion.
• Development of first stage prototypes that would be used in explosive trials.
• Trials protocols and experiments were created and agreed with the client. These included propagation detonations, and extensive use of data capture equipment to gain pressure readings. The design of the experiments were orientated around maximising valuable range time with a quick turnaround of trials. This meant that Aigis could carry out dozens of detonations in a single day, to obtain multiple shot results and further details for honing the design boundaries. The trials design meant that propagation results could be ascertained by a post test visual examination and also backed up with accurate pressure readings, calibrated against base line detonations.
• Results and development considerations were obtained from the trials which lead to modifications of the design. The modifications were quickly implemented into the revised design and a second batch of prototypes were constructed for further explosive trials.
• A set of design boundaries were finalised following testing and results analysis which gave clear criteria for implementing packaging densities and qty`s. Aigis' technical team could then apply these criteria alongside ergonomic and logistic considerations to provide a complete packaging solution.
• The next stage of the project is to take the product through to hazard classification trials.