Posted by RPM Developers on | Comments Off on How Bullet-Resistant Barriers Protect Electrical Grid Substations
Electrical substations are essential to grid reliability, yet they remain some of the most vulnerable points in the overall power system. As targeted attacks become more frequent and more sophisticated, utilities are reassessing how they protect critical equipment. A substation attack can disable transformers, disrupt regional power supply, and create days or even weeks of outages that impact homes, schools, businesses, and emergency services.
For many utilities, hardened ballistic barriers are critical to modern physical security strategies. UL 752 Level 7 and Level 8 composite panels, including those engineered by ArmorCore, help shield transformers, control houses, and perimeter points from gunfire and forced entry. Level 8 is the most commonly specified standard for substation protection because it can withstand repeated high-powered rifle rounds.
Growing Threats to Electrical Substations
The increase in physical attacks on substations has been documented for more than a decade, and each year brings new attempts to breach or disable grid infrastructure. Damage ranges from vandalism to coordinated firearm assaults aimed at taking down large sections of the electrical system.
Many utilities still reference the 2013 Metcalf incident as a turning point. That’s the year that gunmen targeted Pacific Gas & Electric’s Metcalf transmission substation in Coyote, California, firing on 17 transformers and causing more than $15 million in damage. Although the perpetrators were never identified, the attack exposed how quietly and quickly a small group could attempt to destabilize the grid. Federal regulators responded with new physical security standards, and states followed with their own requirements.
A Timeline of Notable Attacks and Regulations
Despite efforts to thwart would-be attackers, reports show a continuing rise in substation threats across the country:
April 2013 – Metcalf, California
Gunmen fire on 17 transformers, causing extensive damage and triggering national concern.
Becomes the catalyst for federal physical-security regulations.
March 2014 – FERC Directs NERC to Develop Standards
FERC orders NERC to submit a physical security reliability standard within 90 days, which is considered unusually rapid for regulatory development.
July 2014 – FERC Orders Further Improvements
NERC is directed to strengthen its proposed critical-infrastructure requirements.
November 2014 – CIP-014 Standard Approved
Requires transmission owners to assess risks, identify critical facilities, evaluate vulnerabilities, and implement security plans.
June 2015 – California Legislation (SB-699)
Adds state-level physical security requirements for substations.
September 2016 – Utah Transformer Shooting
An eco-terrorist attack that damages equipment and triggers a blackout.
The attacker admitted the intent was to strike multiple substations in one day.
Summer 2021 – “Lights Out” Plot, Foiled by FBI
A white supremacist group planned coordinated attacks on substations nationwide, but were stopped before the plan could be carried out.
2022 – A Growing Wave of Attacks
November: Thanksgiving vandalism at an Oregon substation.
December 3: Coordinated shooting attack in Moore County, North Carolina, leaves 45,000-plus without power for up to four days.
December 25: Two Washington state substations attacked on Christmas, causing millions in damages.
2023 – Record Incidents
185 reported physical attacks or credible threats, doubling 2021 levels.
The Benefits and Importance of Bullet-Resistant Barriers
Ballistic protection plays a crucial role in safeguarding equipment and maintaining grid reliability. Key benefits include:
Preventing firearm penetration through transformer radiators and control house walls.
Reducing the risk of catastrophic transformer failure caused by projectile damage.
Supporting faster restoration during emergency events.
Limiting access and line-of-sight exposure to critical components.
Strengthening compliance with physical security frameworks such as CIP-014.
Providing long-lasting, corrosion-resistant protection that holds up in remote or harsh environments.
Applications of ArmorCore’s Bullet-Resistant Panels
ArmorCore’s UL 752 Level 7 and Level 8 panels have been used in multiple utility hardening projects, including new builds, targeted retrofits, and full substation redesigns. Common applications include:
Transformer shielding walls that stop repeated shots from high-powered rifles.
Control house reinforcement to protect protective relays and SCADA systems.
Ballistic retrofits inside existing control structures without major reconstruction.
Perimeter upgrades that integrate with fencing and restrict clear lines of fire.
Modular ballistic partitions that can be installed quickly during outage windows.
Hybrid systems combining concrete, steel, and composites to meet advanced threat scenarios.
Utilities have installed ArmorCore panels around transformers in high-risk corridors and distribution hubs, as well as at remote rural sites where response times may be delayed. Panels have also been integrated into custom structures designed specifically for Level 8 performance and NERC reliability needs.
Top-Quality Ballistic Protection from ArmorCore
As grid hardening becomes a top priority nationwide, utilities rely on materials that balance strength, safety, ease of installation, and long-term durability. ArmorCore’s composite ballistic panels are engineered to meet UL 752 requirements, perform in extreme conditions, and integrate seamlessly into both new infrastructure and retrofit designs.
If you’re evaluating substation protection options or planning a security upgrade, the ArmorCore team can help you select the right solution for your site conditions and regulatory environment. Contact us or request a quote to get started.
Posted by ArmorCore on | Comments Off on What Bullet-Resistant Panels Really Mean
Fiberglass ballistic-resistant panels are commonly used for comprehensive ballistic and storm protection. While the term “bullet-resistant” is often used interchangeably in the industry, it’s important to understand what this actually means and why not all panels are created equal. In this guide, we’ll share what truly makes panels bullet-resistant and the features that can be incorporated to meet the security requirements of your application.
UL 752 Certification and Compliance
One of the most important factors to consider when evaluating bullet-resistant fiberglass panels is whether they meet recognized ballistic safety standards. UL 752, a set of rigorous ballistic standards developed by UL Solutions, is the most common standard used and is also the most up-to-date method of determining whether a panel is truly designed to be bullet-resistant.
What Bullet-Resistant Means
Bullet-resistant fiberglass panels are composed of multiple layers of woven fiberglass. Within these layers are small pockets that absorb and disperse the energy from a ballistic impact. When a bullet strikes, the panel’s controlled delamination process causes the layers to separate, absorbs impact, and prevents full penetration. Under UL 752, a material is considered “bullet-resisting” if it can prevent complete penetration by a bullet or bullet fragment and spalling on the protected side.
Explaining the Levels Scale
UL 752 defines multiple protection levels. Each one corresponds to specific firearm types, ammunition, and the number of rounds a material can withstand before failure.
Below is a general breakdown of UL 752 levels for fiberglass panels:
Level 1. Protection against 9mm full metal ammunition rounds. Often used in gas stations, retail stores, pharmacies, and transaction windows.
Level 2. Tested for .357 Magnum jacketed lead soft point rounds. Common in banks, credit unions, and check-cashing businesses.
Level 3. Effective against three shots from a .44 Magnum within a 4.6-meter range. Frequently installed in schools, courthouses, government facilities, and law enforcement buildings.
Levels 4–5. Designed for higher-caliber rifle threats. Typically used in embassies, high-risk facilities, and specific military applications.
Level 6. Effective against 9 mm rounds fired through submachine guns. Used in high-security environments where protection against ballistic threats is critical.
Level 7. Shields against 5.56mm rounds from military assault rifles like the M-16. Used in military and high-level government security.
Level 8. Protects against 7.62mm rifle rounds from weapons like the M-14. Primarily deployed for military defense.
Why ArmorCore® Panels Are Trusted for Real Protection
ArmorCore® bullet-resistant fiberglass panels have been used in diverse environments, from bank lobbies and courtrooms to military transport vehicles and police training facilities. These have a well-earned reputation for delivering reliable protection against bullets and blast fragments while maintaining versatility for different architectural and operational needs.
ArmorCore offers both standard and custom panels to fit virtually any installation. Every panel undergoes stringent testing against a range of ballistic threats, ensuring compliance with UL 752 standards. The company’s efficient manufacturing processes lead to cost-effective solutions and quick turnaround times without compromising quality.
By combining durability, tested performance, and adaptability, our panels have become the preferred choice for various applications, including:
Commercial buildings
Financial institutions
Government facilities and embassies
Grid and utility security infrastructure
Healthcare settings requiring controlled access
Law enforcement and corrections facilities
Military defense and transport systems
Safe rooms and schools
Bullet-Resistant Barriers from ArmorCore
In the world of security architecture, not all “bullet-resistant” claims are backed by the same level of testing and compliance. ArmorCore’s adherence to UL 752 ballistic standards ensures that every panel we produce meets verified safety criteria, providing both physical protection and peace of mind.
With nearly 30 years of experience and a singular focus on ballistic fiberglass panel manufacturing, ArmorCore continues to lead the industry in quality, performance, and customer support. Whether you’re securing a retail storefront, a financial institution, a government building, or a private safe room, ArmorCore’s solutions are designed to meet your needs without compromise.
Posted by Keller on | Comments Off on What are the Benefits of Using Fiberglass Panels for a Storm Shelter
When it comes to protecting your home and family from the devastating effects of severe weather, having reliable hurricane storm protection, tornado house protection, and tornado shelter panels is crucial. Whether you’re facing hurricanes or tornadoes, a well-built storm shelter can provide a safe haven. One of the key components that can significantly enhance the safety and durability of a storm shelter is the choice of building materials, such as fiberglass panels.
What is a Storm Shelter?
A storm shelter is a specially designed structure that provides protection against extreme weather events, such as hurricanes and tornadoes. It serves as a secure place where individuals can take refuge during a storm, shielding them from high winds, flying debris, and other dangers associated with severe weather.
Types of Storm Shelters
There are several types of storm shelters available, including above ground, below ground, and safe rooms. Each type offers unique advantages depending on your specific needs and circumstances.
Benefits of Using Fiberglass Panels for Storm Shelters
Hurricane Storm Protection
Fiberglass panels are highly durable and resistant to impact, making them ideal for hurricane storm protection. These panels can withstand high wind speeds and wind-borne debris, offering a reliable barrier against the elements.
Tornado House Protection
During tornadoes, homes are often at risk of severe damage from high winds and flying debris. Fiberglass panels provide robust protection, helping to reinforce the structural integrity of storm shelters and homes alike making it a good choice for tornado house protection.
Tornado Shelter Panels
ArmorCore by Waco Composites offers Bullet Resistant Fiberglass Panels specifically designed for storm shelters. These panels are engineered to provide superior protection against ballistic threats, which also translates to enhanced safety during tornadoes and hurricanes.
How to Protect Your Home from a Tornado
Protecting your home and family from tornadoes starts with a well-thought-out tornado safety plan. Identify a secure location in your home, such as a storm cellar, basement, or safe room, where you can take shelter during a tornado warning. Consider installing a storm shelter with durable materials like ArmorCore by Waco Composites’ Bullet Resistant Fiberglass Panels for added safety.
Keep your shelter stocked with essential emergency supplies, including water, food, a first aid kit, flashlight, and blankets, and maintain it regularly to ensure it remains in good condition. Stay informed about tornado warnings by signing up for emergency alerts and keeping a weather radio in your shelter.
Practice your tornado safety plan with your family, including pets and any elderly or disabled members, to ensure everyone knows what to do during an emergency. Educate your family and neighbors about tornado safety and encourage them to develop their own safety plans. These proactive steps can significantly reduce risks during severe weather events and protect your loved ones.
Shield Your Family with ArmorCore by Waco Composites
Our Bullet Resistant Fiberglass Panels are designed to withstand the most extreme conditions, providing peace of mind during severe weather events, making them good hurricane storm protection and tornado house protection. Protecting your home and loved ones from the unpredictable forces of nature begins with choosing the right storm shelter materials. For more information on how we can help you secure your storm shelter, visit our website or contact us today.
Posted by ArmorCore on | Comments Off on Waco Composites Recognized By OSHA
Waco Composites, manufacturer of fiberglass ballistic resistant materials, was recently recognized for the company’s safety program by the U.S. Occupational Safety & Health Administration.
With recognition through OSHA’s Safety and Health Achievement Recognition Program (SHARP), Waco Composites remains one of only two companies in Waco with this designation.
SHARP is an on-site consultation program recognizing small employers who operate an exemplary safety and health management system. Acceptance of a worksite into SHARP from OSHA is an achievement of status that recognizes a business as a model for worksite safety and health.
Upon receiving SHARP recognition, OSHA exempts worksites from OSHA programmed inspections during the period that the SHARP certification is valid.
“As manufacturers of ArmorCore®, a bullet-resistant panel, we are aware of the need for workplace safety and protection,” said Wayne Hampton, President of Waco Composites
”It’s at the heart of who we are.”
“We have been working with OSHCON, a consultative service through the State of Texas since 2004, and of the 58 different criteria that OSHCON considers, our company has consistently achieved high scores in all areas.”
The company is continually striving for improvement in safety and health programs, according to Hampton. “Kaizen,” the concept of continuous improvement, has been a major focus for Waco Composites since the company obtained ISO 9001-2015 certification three years ago.
“We invite our insurance underwriters, the fire marshal, outside vendors and other organizations in to look at our operation and provide suggestions for improvement, look for hazards, and perform testing for dust, noise and vapor hazards,” Hampton said. “We have been continually praised for the cleanliness of our operation.”
“The SHARP recognition validates our dedication to providing a safe and healthful workplace for our employees, and represents a great deal of hard work on the part of our management and staff to make safety within our facility a priority in all we do.”
Posted by ArmorCore on | Comments Off on ArmorCore® Panels Exhibited At Home Preparedness Show
ArmorCore® bullet resistance fiberglass, manufactured by Waco Composites, was among the products and services on display June 23 at the RAM Home Safety Prep Show in New Orleans.
The exhibition, sponsored by “Popular Mechanics,” featured local first responders, Popular Mechanics editors, weather professionals and survival experts offering families information on how to survive any disaster and thrive in the aftermath.
“Having a protected room for you and your family to go to is an important component of preparedness when a storm – figuratively and literally – approaches,” said Justin Clark, Waco Composites market development specialist. “ArmorCore® panels are an ideal solution for residential safe rooms, providing protection from flying debris in a storm in addition to the reliable ballistic protection and resistance against a wide range of assault tools that could be used in a home attack.”
“For many people, the addition of a safe room constructed with ArmorCore® panels adds the peace-of-mind that in the event of an intrusion or natural threat, they have a solid plan for their own security.”
The ArmorCore® ballistic resistant panels demonstrated at the New Orleans exhibition have been installed in a wide range of security-risk locations, including money rooms, courtrooms, cashier areas, and military personnel carriers.
ArmorCore® Level 3 panels carry a Class IV “Forced Entry Protection” rating per ASTM standard F1233-98, which means they have been tested against an assortment of attack tools, such as sledge hammer, chisel and cutting torch. The U.L. Level 3 designation indicates that the panel was shown to provide ballistic resistance against a .44 magnum handgun. The company offers panels in all eight of the U.L. ballistic-resistant levels.
“As rising numbers of people increase their awareness about personal protection, we are pleased that ArmorCore® panels are becoming recognized as a cost-effective solution for safe rooms in their homes and businesses,” Clark said.
Posted by ArmorCore on | Comments Off on Waco Composites Certified As ISO 9001:2015 Compliant
Waco Composites Certified As ISO 9001:2015
Waco Composites was again found to be compliant with high quality management standards following the company’s full ISO 9001:2015 certification audit this year.
Waco Composites, manufacturer of ArmorCore® fiberglass ballistic resistant materials, first became certified through the International Organization for Standardization in 2009 after a comprehensive registration and audit process. This most recent certification confirms the company has maintained its process for quality manufacturing.
“ISO was a real opportunity for us to set goals for quality management and achieve recognition for reaching those goals,” said Wayne Hampton, President of Waco Composites
“Each of our employees is responsible for knowing and adhering to our company policy statement and our company objectives.”
ISO 9001:2015 specifies requirements for a quality management system where an organization needs to demonstrate its ability to consistently provide product that meets customer and applicable statutory and regulatory requirements, and aims to enhance customer satisfaction through the effective application of the system, including processes for continual improvement of the system and the assurance of conformity to customer and applicable statutory and regulatory requirements.
“At Waco Composites, our faithfulness to standards of quality were formalized in our Quality Commitment, ‘Every ArmorCore® panel is made with our deliberate understanding that a life will depend upon the integrity of our product. High quality materials, skilled craftsmanship, and the best manufacturing processes will be utilized in the fabrication of every panel. Continual improvement and validation through product testing will ensure that our panels have the ballistic resistive integrity that we say they have,’” said Waco Composites Quality Assurance Manager Nina Whitworth.
Manufacturing ArmorCore® fiberglass panels that consistently meet or exceed the bullet resistive properties of the UL 752 Standard and achieving 100% on-time shipping are among Waco Composites’ company objectives, according to Hampton.
“Participation in the ISO program has made us a better and more efficient company,” Hampton said. “But it is also just as important as a benchmark that assures our customers that they are receiving the best bullet resistant building material available.”
Posted by ArmorCore on | Comments Off on Integrating With Designers’ Needs
As Building Information Modeling (BIM) has become embraced by an increasing number of building designers and construction professionals, providing accurate and complete models of engineered and specified products is critical to remaining current in the industry.
A recent report by McGraw-Hill Construction showed that 74 percent of contractors are now utilizing BIM technology, and that BIM usage among owners, architects, contractors and engineers is higher than 70 percent.
Through a cooperative program with ARCAT (www.arcat.com), Waco Composites has continued to be an innovator in bullet resistant material, with BIM models of ballistic resistant fiberglass panels achieving all eight levels of UL 752 standards.
The needs of architects and engineers have evolved, requiring new methods of product information which can help save time and expand the way construction and building operational information is presented and delivered. We remain committed to ensuring that ArmorCore® bullet resistant panels are not only the most reliable and efficient solution available, but are also presented with complete and accurate information that meets the needs of designers of risk-based security construction projects.
These are exciting times in the development of construction design, as powerful new tools and methods are making design-build projects more attractive and affordable, and the team at Waco Composites is determined to set the standard within the bullet resistance industry.
Posted by ArmorCore on | Comments Off on Customer “Proofs” Bulletproofing
A Customer Of Waco Composites Has Bypassed The Formal Laboratory Testing For A Trial By “Live Fire.”
Waco Composites, manufacturer of ArmorCore® fiberglass ballistic resistant materials, typically implements rigorous quality testing and regular audits in controlled laboratory environments in order to maintain its UL Listing and assure its performance. Set to air on National Geographic’s Doomsday Preppers, Tuesday, December 10th, Johnny Bulletproof, a consultant and installer of bullet resistant products, puts ArmorCore® to the ultimate test on national television.
“Years ago we used the motto, “We Stand Behind our Product” referring to our ArmorCore® product line. Never did we imagine that someone would take this literally for live fire ballistic testing,” said Sales Manager, David Breeland. Justin Clark in Market Development added, “Johnny presents the most extreme demonstration to prove a point and I imagine it will make for some interesting TV.”
ArmorCore® is used in wall systems to provide bullet-resistant protection. The product is primarily used in government buildings, banks, and military applications, but the company has seen a heightened interest in private safe rooms. “Interest in our product in homes and businesses has amplified for the ballistic protection as well as a safe barrier in violent storms and forced-entry protection. Unlike a pre-fabricated box it can be installed within any room and covered with drywall,” said Clark.
“Though we know the capabilities of what we manufacture, we are still anxious to see its performance on the small screen with such high stakes.”
For more information about ArmorCore® ballistic-resistant panels please call (254) 752-3622. Video footage of the episode, No One Will Ever Know, can also be viewed on the National Geographic’s Doomsday Preppers website.
Posted by ArmorCore on | Comments Off on Waco Composites Receives SHARP Recognition
Waco, Texas, June 15, 2013 – Waco Composites is proud to participate in and qualify for the Safety and Health Achievement Recognition Program (SHARP) implemented by OSHA under the U.S. Department of Labor. This certificate of recognition demonstrates the emphasis placed on a clean, healthy, and safe worksite environment. SHARP is one of the highest awards that OSHA can designate to small companies.
Quality product begins with a quality manufacturing facility. “We are pleased that this award expresses our attentiveness to safety and detail. The hard work of in-depth employee training and factory layout and practices will continue to pay off for us,” announces company president, Wayne Hampton. “We are continually improving our product and practices. Waco Composites’ success in this area can be attributed to its workers, supervisors and safety officer, Laura Simon.”
Waco Composites
Waco Composites manufactures and offices out of its 40,000 sq.ft. building in Waco, TX. The company’s primary focus is its line of ArmorCore, bullet resistant panels. These are UL Listed fiberglass sheets used for architectural armoring and ballistic protection. ArmorCore is shipped worldwide out of the Waco facility to be installed in home safe rooms, courthouses, police stations, banks, shooting range, and military vehicles.
Posted by ArmorCore on | Comments Off on Defense Against School Violence
Defensive Architecture One Answer To School Violence
The past couple of months have brought about stories of unbelievable horror, as children have been subjected to gun violence in what should be a safe haven: their schools.
The news media reports a wide range of often one-sided solutions, while most of us realize that any actual solutions will need to engage multiple facets, including mental health, our society’s culture of violence and providing adequate security within educational facilities.
For many, the thought of turning school buildings into fortresses is a concept far removed from our own experiences of worrying more about “lost” homework than physical security. But recent circumstances can not be ignored, and thoughtful “hardening” of educational buildings can offer one aspect of additional security for both students and educators.
ArmorCore® bullet resistant fiberglass panels has been proven effective against a wide range of threats, from bullets and blast fragments to storm debris and physical attack with hand-held implements. In the battlefields of the Middle East to bank counters and health care facilities in the U.S., strategically placed ArmorCore® ballistic resistant materials have saved lives.
These same materials can be used within doors, walls (such as within a closet, to create a “safe room”), counters and desks to offer protection from the previously unthinkable acts of an armed attacker, providing time for law enforcement to intervene.
Is this the only answer: Of course not. As a society, we have many decisions and solutions to explore. But as a parent of a school-aged child, I would feel just a little better knowing that some practical and affordable measures of protection have been integrated into the classrooms and building.
ArmorCore® was conceived and is manufactured as a protective measure against violence. And as a feasible and accessible aspect of potentially saving lives against an armed intruder, it’s one start to the larger questions we all face.
