Blast Wall Design and Testing in North America

A blast wall is engineered to protect people, equipment, and infrastructure from the force of explosions in industrial, utility, manufacturing, and defence environments. In North America, while test standards exist for glazing and door assemblies intended for installation in blast resistant walls, a standard does not exist for the testing and certification of blast resistant walls. Understanding the applicable standards helps engineers, life safety professionals, and project managers identify and validate blast-resistant walls for each application.

ASTM Testing Methods

Industry-wide recognition of ASTM standards forms the foundation for evaluating blast-proof assemblies.

• ASTM F1642, Standard Test Method for Glazing and Glazing Systems Subject to Airblast Loadings, outline test methods for evaluating glazing systems under blast loading. Test setups simulate specific overpressure levels to assess structural performance and post-event integrity.
• ASTM F2247, Standard Test Method for Metal Doors Used in Blast Resistant Applications (Equivalent Static Load Method), and F2927, Standard Test Method for Door Systems Subject to Airblast Loadings, outline test methods for evaluating door assemblies under static and dynamic blast loading scenarios.
• ASTM F3664, Standard Practice for Blast Testing, which aimed toward maximizing the consistency and repeatability between individual blast tests, and test performed at different facilities.

Blast Design Methods

While a test standard for qualifying and certifying a blast wall design is not currently in place, various organizations have standards and publications related to the design of blast resistant buildings and structures.  Examples of these publications are:

• ASTM/SEI 59, Blast Protection of Buildings.
• ASCE, Design of Blast-Resistant Buildings in Petrochemical Facilities.
• CSA S850, Design and Assessment of Buildings Subjected to Blast Loads
• UFC 3-340-02, Structures to Resist the Effects of Accidental Explosions
• UFC 4-010-01, DoD Minimum Antiterrorism Standards for Buildings

Overpressure Resistance Testing Procedures

Overpressure resistance testing verifies that a blast-proof wall  design can withstand the specific force levels outlined in project risk assessments. Procedures generally involve:

• Calibrating sensors and gauges to measure deflection, strain, and pressure at impact.
• Using shock tubes, explosives, or pneumatic systems to generate the required blast wave.
• Recording results to evaluate post-blast deformation, anchoring integrity, and surface condition.

Test data from overpressure resistance evaluations provides measurable confirmation that the barrier can contain or deflect energy as intended.

Common Documentation and Reporting Formats

Certification and compliance require comprehensive documentation. Standard reporting includes:

• Detailed descriptions of the blast wall design, materials, and fastening systems.
• Test setup diagrams and environmental conditions during testing.
• Measured results compared to pass/fail criteria.
• Photographic or video evidence of the test process and outcomes.
• Consistent reporting formats make it easier for regulatory agencies, insurers, and project engineers to verify that blast-resistant walls meet the contractual and legal requirements.

Re-Certification and Reinspection Timelines

In industrial settings, re-certification may be an ongoing process. Environmental factors, mechanical damage, or modifications can affect performance over time.

• Periodic Re-Certification: Many facilities schedule re-certification every three to five years, depending on regulatory guidelines and site-specific hazards.
• Post-Event Inspection: Any blast incident or significant impact requires immediate reinspection to confirm continued structural capability.
• Maintenance Records: Keeping detailed inspection logs helps maintain compliance and identify any need for replacement or reinforcement of blast-proof wall

Integration of Testing with Project Planning

Incorporating certification testing early in the project schedule minimizes costly delays. Coordination with testing laboratories, certification bodies, and installation teams ensures that each blast wall is evaluated before operational use. This integration also helps align barrier performance with other safety systems, such as fire-rated enclosures or emergency egress pathways.

Final Recommendations for Blast Wall Compliance

Rigorous testing and certification provide measurable confidence in the protective capability of each blast-proof wall.

• Select testing standards that align with site-specific risks and regional regulations.
• Maintain clear documentation from initial certification through re-certification.
• Include overpressure resistance evaluations as part of preventive maintenance.

When specified, installed, and maintained in line with recognized design methods and standards, these structures form a key component of hazard mitigation in North American industrial facilities. For compliant blast wall solutions, contact DuraSystems today.