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Fireproof Solutions

Blast mitigation

Dramatically reduce blast impulse and heat release

FPS containers and panels dramatically reduce blast impulse and heat release. This is new-to-the-world FPS blast mitigation technology: lightweight containers and panels filled with mitigating media that dissipate blast energy and suppress the fireball. Test data from Southwest Research Institute is in our presentation.

Split-screen high-speed frame from a 600 gram C-4 test. The unmitigated left side shows a large bright fireball and smoke; the mitigated right side shows dark smoke and debris with no large fireball.
600 gram C-4 detonation inside corrugated paper boxes. FPS-protected boxes on the right side of the comparison.

The objective

The objective of blast protection

Reduce blast impulse pressure, which includes reverberation and shrapnel. Suppress the fireball flame. Reduce heat release.

These are not new objectives for blast mitigation technology. What is new is the new-to-the-world FPS blast mitigation technology.

Why it is different

What makes this technology different

  • Works in enclosed spaces such as buildings, vehicles and ships.
  • Takes up little space.
  • Made from readily available materials.
  • No sophisticated manufacturing processes required.
  • Easy to install with just hand tools.
  • Low cost.
  • Proven effective by multiple tests at an independent research institute.

The idea

Blast effect mitigation is not the same as blast resistance

Only by mitigation
You can only reduce blast pressure and impulse inside buildings, under vehicles and inside ships by mitigation.
Reflection
Blast wave pressure and impulse reflecting off non-mitigating surfaces are always higher. Gas temperature always goes way up. Shock waves reflect and travel long distances.
Load transfer
Non-mitigating walls and barriers transfer all of the blast load into structural supports and vehicle floors.
People and debris
Exposed people, vehicles and structure debris are slammed and hurled because they cannot resist blast loads.
Barrier materials
Barrier and wall materials do not make a difference to a blast. Steel, concrete, aluminum, composites and sandbags all make impulse and peak pressure jump, form high-energy projectiles, and do not significantly reduce safe separation distances based upon Q/D requirements.

Definitions

Blast impulse and blast effect mitigation

Blast impulse is:

  • momentum transfer per unit area from blast waves into targets (bar-ms, Pa-s, psi-sec and so on);
  • the area under the pressure-time curve of a blast wave;
  • the mechanism that knocks down barriers, destroys vehicles and hurls people against walls.

Blast effect mitigation means:

  • reducing impulse and peak pressure;
  • reducing and suppressing heat release from detonations and deflagrations, which can prevent post-blast fires (“keep cool and carry on”).
Split-screen high-speed frame from a 600 gram C-4 test. The unmitigated left side shows a large bright fireball and smoke; the mitigated right side shows dark smoke and debris with no large fireball.
600 gram C-4 detonation inside corrugated paper boxes. FPS-protected boxes on the right side of the comparison.

What it does

What FPS containers and panels do

Pressure
Dramatically reduce peak overpressure.
Heat and fire
Quench hot blast gas, suppress fireballs and prevent most post-blast fires.
Fragments
Dissipate blast energy so fast that fragments cannot travel far or penetrate.
Containment
Make blast containment possible.
Structures
Reduce blast loads so that lighter structures can survive.
Separation distances
Dramatically reduce safe separation distances (Q/D) between explosives and public spaces such as roads, outdoor work and buildings.
Indoors
Mitigate blast effects indoors, vented or not.
Mounting
Panels can be mounted on walls and ceilings or be integral structural components.
Weight
Panels and containers are lightweight and man-portable.
Space
Panels need less than 2% of the interior volume to protect.
Fillers
FPS fireproof fillers inside containers also serve as impact and vibration protection.

Why mitigate

Separation distances (Q/D)

In the US, regulations set separation distances (D) from explosive hazards (Q for quantity). Q is often called net TNT-equivalent charge weight (NEW) or NEQ.

D is based upon allowable pressures suitable for the situation: separation from public highways and communities, between explosives manufacturing facilities, between facilities on military bases and so on.

Q/D constraints limit where magazines, aircraft “bombing up” operations and even military units disembarking in ports (in peacetime) can be near urban areas.

Impulse is the proper criterion, but these regulations assume a linkage between peak pressure and impulse. It is crude, but pressure is easier to measure.

Bottom line: blast mitigation reduces the net effective Q (NEQ, NEW), which under Q/D regulations would greatly expand usable military base areas and allow safe operation of energetic material-handling operations near highways, ports and resources.

Bonus: blast-mitigating containers may allow Hazard Class 1.1 (“detonating”) materials to be reclassified as 1.4 (“insensitive”), substantially reducing limits on public roadway and railway transportation use.

Why mitigate

Confined spaces

Confining blasts inside structures (buildings, ships, magazines) is limited to small charge weights (Q, NEQ, NEW) because pressure and impulse cause structural failure.

Venting helps, which allows confinement of somewhat larger NEQ. But blast pressure and impulse build up faster than vents can relieve them, because of the distance from vents, the time delay before they open and choked flow in ducts that limits vent effectiveness.

Venting is not possible inside ships and submarines, inside large buildings or inside mines.

Blast mitigation inside ships, submarines, structures and mines is possible without venting, through exploitation of irreversible processes. Venting does help when it can be used.

How it works

Dissipating blast energy and momentum

Reducing peak pressure is often easy. Reducing blast impulse is difficult.

Sir Isaac Newton was right: total energy and total momentum are conserved (reversible processes) when two masses collide. Pressure is reduced and velocity increases as fluids pass through nozzles and screens. Pressure recovers and velocity drops as the fluid passes into the surroundings (ambient conditions).

But friction, viscous drag and heat transfer (irreversible energy and momentum processes) extract energy and momentum from the fluid. Blast impulse reduction is possible through the artful use of every possible combination of irreversible processes and mechanisms.

Mechanisms for rapidly dissipating blast energy and momentum in granular media:

  • Multitudinous collisions between granules disperse momentum.
  • Phase change materials (PCMs) absorb energy (kJ) through the enthalpy of fusion or decomposition (ΔHm, kJ/kg).
  • Aerodynamic drag [proportional to (velocity)²] due to huge specific surface area.
  • Heat transfer from hot gas to granular media due to huge specific surface area.
  • Interference heating (in gas flow velocity above Mach 8).*

*Interference heating is the breakdown of the boundary layer due to turbulent flow and shock wave interactions. Heat transfer across the boundary layer increases about tenfold.

Test evidence

UK MoD DERA (now dstl) 1996 tests

200 g C-4 spherical charges detonating in 51 cm × 51 cm × 51 cm boxes.

*DERA predictive software. CONWEP predicted impulse at 200 g C-4 to be 71.0 Pa·s. **The trigger for the data acquisition system was set at 35.2 kPa, so no pressures were recorded. ***Panels on 4 vertical sides. Perlite-filled panels 1.7 cm thick, foam bead-filled panels 1.5 cm thick. Reductions are against the DERA prediction.
Shot and filler or panelFormIncident pressure average (kPa)Impulse average (Pa·s)Pressure reduction (P / CONWEP P)Impulse reduction (I / CONWEP I)
DERA predicted*Free air326.473.0––
2: Perlite-filledBox< 35.2**No resultNo resultNo result
3: Perlite-filledPanels***39.730.087.8%58.1%
4: Foam bead-filledBox81.533.175.0%54.7%
5: Foam bead-filledPanels***133.846.459.0%36.4%
Close-up of a hexagonal honeycomb core panel filled with granular material, from the 1996 DERA tests.
DERA 1996 test panel: honeycomb core filled with mitigating media.
Close-up of a hexagonal honeycomb core panel filled with white granular beads, from the 1996 DERA tests.
DERA 1996 test panel: foam bead filled, 3.8 cm thick honeycomb core, and perlite filled (volcanic foam glass), 3.7 cm thick honeycomb core.

Test evidence

Recent research, 2024 to 2026

Adapting the DERA/dstl test setup and protocol, Southwest Research Institute (SwRI) conducted three test series using mitigating media in (a) panels and (b) granular media-filled cylinders surrounding the charges.

  • Bare cylindrical C-4 charges were used in all tests, from 200 g to 600 g, mounted in the geometric center of each box.
  • Single-wall corrugated kraft boxes, all 51 cm × 51 cm × 51 cm, were mounted atop a 150 cm cardboard tube, to record pressure data without reflected shock influence.
  • Pressure transducers were placed at 1 m and 2 m from the charge surfaces.
  • High-speed video with still photo captures.
Black-and-white photograph of the test field with pressure transducer stands and a box mounted on a tube.
Test arrangement: pressure transducers and a box mounted atop a cardboard tube.
Inside of a corrugated box lined with panels along the walls, with a tape measure across it.
Panels along the walls of the box. No panels on the bottom of the box.
Looking down into a box lined with panels, with a cylindrical charge mounted on foamboard in the center.
The charge mounted on foamboard.
Looking down into a box with concentric empty kraft cylinders around a charge.
Concentric kraft cylinders, baseline: no media filling, with the charge.
Looking down into a box with concentric kraft cylinders filled with media and sealed with a thin plaster layer.
Concentric kraft cylinders with granular two-phase media fillers: vermiculite-filled inner annulus, aerogel-filled outer annulus sealed with thin plaster.

2026 test results

600 g C-4 cylindrical charges. SwRI-computed mitigation for different configurations. Shot 8 was the baseline.

*V is vermiculite filler, MT is empty. **Impulse in Pa·s. ***DERA prediction for 200 g C-4. No readings or predictions for 2 m. Note: the aerogel product is a saturated felt, not a granular or flowable medium.
Configuration*Tubes / panelsFiller mass (g)Impulse** at 1 m (Pa·s)Impulse** at 2 m (Pa·s)
V (front) / MT (back)Tubes723111.769.0
V (front) / MT (back)Panels1,393140.760.0
V (front) / lactate (back)Tubes2,02953.157.2
V (front) / PCM (back)Tubes1,78172.457.2
V (front) / aerogel (back)Tubes856111.773.1
Vermiculite (17.5 cm)Tubes1,57175.263.5
Foam beads (17.5 cm)Tubes547131.770.3
CONWEP (600 g C-4)Free air0149.077.9
Perlite 4.3 cm (200 g C-4)Panels3,25033.6N/A
Foam beads 3.8 cmPanels2178.0N/A
DERA predicted***Free air073.0N/A
Bar chart titled Percentage Reduction in Peak Pressure and Impulse, showing the percent reduction versus baseline test 8 in average peak pressure and average peak impulse for tests 1 to 12.
Percentage reduction in peak pressure and impulse versus baseline test 8, for tests 1 to 12 (average Pmax and average Imax).

Test photographs

Blast mitigation without and with phase change materials

600 g C-4 charges. Split-screen high-speed frames: unmitigated on the left, FPS-protected boxes on the right.

Split-screen high-speed frame 5 milliseconds after a 600 gram C-4 detonation, unmitigated on the left and mitigated without phase change materials on the right.
Without PCMs. 5 milliseconds after detonation (unmitigated on the left of the split screen).
Split-screen high-speed frame 75 milliseconds after a 600 gram C-4 detonation, with glowing gas visible in the upper right of the mitigated side.
Without PCMs. 75 milliseconds after detonation. Vermiculite in the inner annulus, unfilled outer annulus (note the glowing gas in the upper right).
Split-screen high-speed frame 5 milliseconds after a 600 gram C-4 detonation. The unmitigated left side shows a large bright fireball; the mitigated right side shows dark smoke with much less visible flame.
With PCMs. Inner annulus vermiculite-filled, outer annulus PCM-filled. 5 milliseconds after detonation.
Split-screen high-speed frame 75 milliseconds after a 600 gram C-4 detonation. The unmitigated left side is filled with a bright fireball and smoke; the mitigated right side shows a pale smoke cloud with no large fireball.
With PCMs. 75 milliseconds after detonation. A small amount of flame at the base because no media is present on the bottom of the box (same for all tests).

Applications

Where to use it

Use FPS packaging products and containers for munitions transport and storage.

Use FPS panels and barriers for:

  • Building interiors and tunnels
  • Ship interiors
  • Demilitarization and mine clearing
  • Protection for tactical breaching operations
  • VIP protection
  • Protecting in-theater bases and checkpoints

What comes next

Future research and development

Modeling blast mitigation requires a much greater experimental database. Parametric relationships of particle and shock wave velocities, impulse and temperature reductions, as functions of blast intensity, media density and thickness, total media mass, specific surface and granular media characteristic dimensions (and dimension range), cannot be established without more experimental data.

The optimum thickness or placement of PCMs requires much more experimentation, since packed beds of any kind (sand, powdered PCMs, granular two-phase media) increase impulse and reflected shock parameters.

Experiments by Halsey and Berry* showed substantial reductions of fragment kinetic energy when cased munitions (bombs and projectiles) packed in granular pumice (another volcanic foamed glass) detonate. Experiments must be performed to quantify kinetic energy reductions and obtain quantified parametric data to model and design protection means.

*Halsey, C. C. and Berry, S. L., Expanding Pumice Technology to the Protection of Missile Warheads from Sympathetic Detonation. Paper presented at the DOD Explosives Safety Board Explosives Safety Seminar, Las Vegas, NV, 20 to 22 August 1996.

Presentation

Download the presentation

Blast effect reduction using mitigating media. Guy L. Gettle, Fireproof Solutions, Inc. Prepared for the International Ballistics Society symposium (ISB 2026).

The presentation covers the test setup, the 1996 UK Ministry of Defence DERA results and the 2024 to 2026 Southwest Research Institute results, with the supporting photographs.

Discuss a blast mitigation application

Tell us what you want to protect and the kind of space it is in. We reply by email within one business day.