•Satish Ramavat

•Devidas Thorat

•Prashant C.

Date – 25 July, 2016

Godrej Security Solution Division

Godrej & Boyce Mfg. Co. Ltd., Mumbai

‘ Blast Simulation of Vault Door As Per EN 1143-1'

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LINES OF BUSINESS

Physical Security Products

Record Protecting Equipment

Burglar & Fire Resistant Safes

Vault Equipment

Vault Accessories

Currency Handling Solutions

Premises Security Solutions

Crash Rated Barriers

Under Vehicle Surveillance Systems

Baggage Scanners

Hand Held Metal Detectors

Surveillance Solutions

Fire Alarm Systems

Burglar Alarm Systems

Monitoring Solutions

Scanning and Screening Solutions

Retail Solutions

Home Safes

Video Door Phones

CCTV Cameras

Burglar Alarm Systems

Marine Solutions

Steel and Aluminium Doors

Cargo Hatches

WT/GT/Weather Tight Steel Doors

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Product Introduction:

Frame

Door Leaf

Locking

Bolts

Hinge

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• Construction of Vault door:

• It consists of frame, door leaf and

mechanism for locking.

• Frame and door leaf are filled with concrete

barrier to provide the protection against any

attack.

• Frame is used to fix vault door with wall of

vault room.

• Intended function:

• Vault door is designed to protect against the

burglary attack and also provide the access

to vault room.

Introduction:

Door Leaf

Locking

Bolts

Frame

Hinge

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Locking Mechanism:

• It consists of locking bolts, handle, glass, and relockers.

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• Need for Simulation:

• The vault door was to be tested against explosion attack as per EN 1143-1, hence there

is a need to evaluate the performance of door against specified explosive attack before

actual test.

• To optimise the door design and thus eliminate the testing iterations which are very

expensive.

• Scope for Simulation:

• Analyse the effect of detonation of explosive placed in gap between frame and door.

• Visualization of blast wave propagation and its effect on different parts.

• Identify the forces and stresses at different locations.

• Effect of blast on mechanism parts like locking bolts, linkages and etc.

Blast Simulation of Vault door:

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FEM Details

• Hexahedral elements used for air and

explosive modelling.

• Shell elements used for door and frame.

• Concrete metal rebar’s are modelled as

beam elements.

• Type 18 contacts used between Air and

explosive.

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FE Modeling:

Detonation Point

Air Domain

Door Leaf

Frame

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Material details:

Yield Stress (y) (a) :250 MPa

Tensile Strength :410 MPa

Elongation at Fracture (EPS_max) :23 %

Modulus of Elasticity (E) :210 GPa

Mass Density () :7810 kg/m3

Poisson’s Ratio () :0.29

Material : IS 2062 E250 Gr.B0

Card image: M2_plas_johns_Zeril

Compressive strength (fc) :150 MPa

Density () :2900 Kg/m3

Flexure strength :12 Mpa

EPS (Max) : 0.5%

Material : Concrete

Card image: M24_Conc

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Boundary Condition:

• The frame (left picture) are fixed in all DOFs to replicate the test

conditions (right picture).

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PETN- 285 g

Explosive details:

Door Leaf

Frame

TNT Explosive :

Mass density (ρ) : 1500 Kg/m3

Detonation velocity (v) : 7000 m/s

Chapman-Jouget pressure : 16 GPa

Internal energy density (E0) : 10.1 GPa

Material constants of

JWL – EQS for TNT :

ω : 0.25

A : 617 GPa

B : 16.926 GPa

R1 : 4.4

R2 : 1.1

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Challenges faced:

• Concrete modelling– We modelled the steel bar reinforcement as beam

elements to get realistic result and study its behaviour.

• Modelling of explosive into the gaps – Since it is a small gap in Z shapes

couple of iterations were involved to get convergence

• Contacts and interface – Adjusting contact stiffness to model the interface

behaviour

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Results:

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Results:

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Results:

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Results & Discussion:

• Frame and door damaged only in area near to explosive, rest area was

considerably intact, same was also observed during actual test.

• Maximum force is observed in the locking bolt which falls into blast

wave path. In actual test two locking bolts (in centre) are dislocated.

• Due to induced force or vibration toughened glass has broken as

desired.

• Actual test results are very much similar to simulation results.

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Benefits Summary:

• Analysis helps to optimise the door design before actual test, this

reduces the cost by eliminating iterative testing's.

• Reduced development cycle time and cost and time to market

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Conclusion:

• This study has shown that the predictive capability for blast wave

propagation and its effect on door design is quite good with Radioss

non-linear explicit analysis. In addition, Altair provided the scope for

iteration with every design change to ensure the intended performance.

• With such good correlation between simulation and actual test results,

testing laboratory also exploring the option of evaluating the design on

the basis of simulation results only rather than going for actual test in

each case.

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Acknowledgments:

• We would like to acknowledge our company M/s. Godrej and Boyce Mfg.

Co. Ltd. Security Solutions Division and

Altair’s Technical support

• Mr. Swasthik Bangera

• Mr. Prashant Kulkarni

• Mr. Vasantha Kumar

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THANK YOU