Armortex® bullet-resistant fiberglass panels are rigid, UL 752-rated sheets that contractors fasten to wall framing, including metal stud assemblies, to create concealed ballistic protection behind drywall or other finishes. Armortex manufactures the panels in Schertz, Texas, and publishes the cutting, drilling, fastening, and seam instructions installers need to keep the wall’s rating intact.
Armortex supplies material only and does not install. Its products are designed to be installed by competent, experienced installers, often those with general construction experience. This guide organizes Armortex’s published instructions into a sequence for a metal stud wall.
Quick Answer
Contractors install Armortex ballistic panels in a metal stud wall by cutting sheets with RemGrit® Grit Edge blades, fastening them to the studs with self-tapping drywall screws, pre-drilling panels 1 3/16″ and thicker with high-speed steel bits at slow speed, backing every seam with a 4″ strip of the same material, and maintaining protection at perimeters and penetrations before finishes are applied.
What Is an Armortex Ballistic Fiberglass Panel?
An Armortex ballistic fiberglass panel is a fiberglass reinforced plastic (FRP) sheet made by mechanically injecting woven roving ballistic-grade fiberglass cloth with thermoset polyester resin and pressing it into flat, rigid sheets in a hydraulic hot press.
Armortex manufactures the panels as O.F. 100 through O.F. 800, covering UL 752 Levels 1 through 8. Every level is available in 3′ × 8′, 4′ × 8′, 3′ × 9′, 4′ × 9′, 3′ × 10′, and 4′ × 10′ sheets with a square edge.
How Does the Panel Work Once It Is in the Wall?
The panel captures bullets rather than deflecting them. Layers inside the laminate separate in a controlled delamination, and friction slows the bullet until it is retained in the panel.
That protection is continuous only where the panel is continuous. Armortex notes that any butt joint or seam creates a ballistic weakness, which is why seam backing is the most important step in the installation sequence below.
What Tools and Materials Do Installers Need?
| Item | Armortex guidance |
| Saws | Ordinary carpentry tools: circular saw, table saw, panel saw, or saber saw |
| Saw blades | RemGrit® Grit Edge blades: GC703 7″ circular, GC805 8″ circular, GC915 12″ circular, and GJ18 saber saw |
| Drill bits | High-speed steel twist drills, run at slow speed |
| Fasteners | Self-tapping drywall screws; screws or bolts may also be used |
| Adhesive | Industrial adhesive (mastic), alone or with screws or bolts |
| Seam material | 4″ overlap strips (battens) of the same bullet-resistant material |
| Protective equipment | Disposable respirator and Tyvek® disposable coveralls for continuous or prolonged cutting; always cut in a well-ventilated area |
Step-by-Step: Installing Armortex Panels on Metal Studs
- Confirm the product. Check the drawings for the specified UL 752 level and matching O.F. product, then review that product’s data sheet for thickness and weight.
- Verify the framing. Armortex’s Section 10 26 41 coordinates with Section 09 22 00, Metal Support Assemblies, for metal framing that receives the panels. Confirm that framing is complete before hanging panels.
- Lay out and cut. Cut panels to fit at the perimeter and around penetrations using the listed blades. Wear a respirator and coveralls for prolonged cutting and work in a ventilated area.
- Pre-drill thick panels. Armortex notes that panels 1 3/16″ and thicker may require pre-drilling. Use high-speed steel twist drills at slow speed.
- Fasten to the studs. Attach panels with self-tapping drywall screws. Industrial adhesive (mastic) may be used alone or together with mechanical fasteners.
- Back every seam. Install a 4″ batten of bullet-resistant sheet centered on each joint, giving 2″ of ballistic overlap on each side. The reinforced joint must be at least equal to the panel’s ballistic level.
- Protect perimeters and penetrations. Fasten or adhere panels so the rating is maintained at the perimeter, at junctures with other materials, and around penetrations.
- Apply the finish. Cover panels with drywall or another finish. Panels also accept wood or plastic veneer with contact cement, upholstery, or paint after the surface is roughed up with sandpaper.
How Much Does Each Panel Weigh for Handling?
Panel weight affects crew size, staging, and fastening. The sheet weights below are calculated by multiplying Armortex’s nominal weight per square foot by sheet area.
| Product | UL 752 level | Nominal weight (lb/ft²) | Calculated 4′ × 8′ sheet (lb) | Calculated 4′ × 10′ sheet (lb) |
| O.F. 100 | 1 | 2.9 | 92.8 | 116 |
| O.F. 200 | 2 | 4.1 | 131.2 | 164 |
| O.F. 300 | 3 | 5.25 | 168 | 210 |
| O.F. 400 | 4 | 13.7 | 438.4 | 548 |
| O.F. 500 | 5 | 15 | 480 | 600 |
| O.F. 600 | 6 | Confirm with Armortex data sheet | Confirm with Armortex data sheet | Confirm with Armortex data sheet |
| O.F. 700 | 7 | 12.2 | 390.4 | 488 |
| O.F. 800 | 8 | 16 | 512 | 640 |
Armortex notes that contractors tend to move fiberglass panels with standard forklifts or pallet jacks, and that lightweight panels allow smaller crews to install them safely.
What Should Architects and Specifiers Consider?
- Reference the framing section. Section 10 26 41 lists Section 09 22 00, Metal Support Assemblies, as the related section for metal framing.
- Draw the seams. Show 4″ battens at every joint so seam backing is a documented requirement rather than a field decision.
- Plan for curved conditions. Armortex’s fabrication instructions describe 12″ to 18″ vertical strips following the inside curve, with 4″ overlap strips at each joint.
- Coordinate wall depth. Account for the nominal thickness of the selected level plus battens at seams.
- Use CNC pre-cutting where it helps. Armortex offers fiber optic laser and waterjet cutting for complex shapes.
- Set installer expectations. Armortex states that its products do not require a special certification to install; competent installers with general construction experience are appropriate.
Why Choose Armortex for Metal Stud Wall Projects?
- Panels that cut with ordinary carpentry tools and fasten with self-tapping drywall screws
- Published fabrication instructions naming specific blades, drill bits, and seam details
- A CSI specification that links directly to metal support assemblies
- CNC laser and waterjet cutting to reduce field cutting
- Help locating a contractor in the project’s region
- One-hour fire rating to ASTM E119-00a and UL 752 Levels 1–8
Armortex Technical Resources
- Installation & Cutting Instructions
- Section 10 26 41 Specification
- Bullet-Resistant Fiberglass Panels product page
- Safety Data Sheet
- Advanced Cutting Capabilities
- Armortex FAQs
Frequently Asked Questions
Can Armortex ballistic panels be installed on metal studs?
Yes. Armortex’s Section 10 26 41 specification lists Section 09 22 00, Metal Support Assemblies, as the related section for metal framing that receives the bullet-resistant sheet. Armortex data sheets call for installation with self-tapping drywall screws, with pre-drilling for panels 1 3/16″ and thicker.
What screws are used to attach Armortex panels?
Armortex data sheets specify self-tapping drywall screws for installing its opaque fiberglass panels. The fabrication instructions also allow panels to be attached with screws or bolts, or with an industrial adhesive (mastic), either alone or combined with mechanical fasteners.
Do Armortex panels need to be pre-drilled?
Armortex states that pre-drilling may be required on panels 1 3/16″ and thicker. Drill with high-speed steel twist drills at a slow speed. Handgun-rated panels such as the ¼″ Level 1 O.F. 100 and the ½″ Level 3 O.F. 300 fall below that thickness threshold.
What saw blade cuts Armortex fiberglass panels?
Armortex recommends RemGrit® Grit Edge blades: the GC703 7″, GC805 8″, and GC915 12″ circular blades and the GJ18 saber saw blade. Armortex also notes that panels can be cut with standard construction tools fitted with carbide or diamond-grit blades.
How are seams handled between Armortex panels?
Armortex recommends 4″ overlap strips, or battens, at every seam, which provide 2″ of ballistic overlap on each side of the joint. Its specification requires the batten to be centered on the joint and the reinforced joint to be at least equal to the ballistic level of the panel.
Does an installer need a certification to install Armortex panels?
No certification is required by Armortex. The company states that its products are designed to be installed by anyone with skills and knowledge consistent with competent and experienced installers, often those with general construction experience. Armortex can also help buyers find a contractor in their region.
Can Armortex panels be painted or covered after installation?
Yes. Armortex panels can be covered with drywall or architectural finishes, and they accept a wood or plastic veneer applied with contact cement. They can also be upholstered or painted. Before painting, Armortex recommends roughing up the panel surface with sandpaper.
What safety precautions apply when cutting Armortex panels?
Armortex recommends a disposable respirator and Tyvek® disposable coveralls whenever continuous or prolonged cutting is anticipated, and advises always cutting in a well-ventilated area. The Armortex safety data sheet for its fiberglass is available on the fiberglass panel product page.
Conclusion
Installing Armortex® ballistic fiberglass panels in a metal stud wall follows a clear sequence: confirm the level, cut with RemGrit Grit Edge blades, pre-drill panels 1 3/16″ and thicker, fasten to the studs with self-tapping drywall screws, back every seam with a 4″ batten, and keep the rating continuous at perimeters and penetrations. Armortex supplies the material, instructions, and specification, and a competent contractor completes the protected wall.