Dyneema® Rope Solutions for Specialist Security Barriers

Around the world, government buildings, military bases, airports, and sensitive infrastructure face increasing threats from hostile vehicle attacks. To counter these risks, highly engineered vehicle barrier systems are deployed to physically stop high-speed, heavy vehicles from breaching secure zones.

When a leading manufacturer of hostile vehicle mitigation (HVM) barriers developed their latest PAS 68 crash-rated security barrier system, English Braids were tasked with designing and supplying specialist rope assemblies capable of meeting the extreme demands of these installations.

The Challenge

The customer required rope assemblies that could integrate into their dual-beam security barrier system, engineered to stop vehicles weighing up to 7.5 tonnes travelling at speeds exceeding 50 mph. The solution had to deliver:

• Enormous impact load resistance
• Controlled energy absorption to reduce secondary damage
• Lightweight construction for fast operation and easy servicing
• Long service life with minimal maintenance
• Performance stability across global climatic conditions

The system also needed scalability to support varying threat levels and be simple to upgrade or repair following an incident, ensuring minimal downtime for high-security sites.

The Rope Solutions

English Braids developed a range of specialist rope designs to suit multiple protection levels within the system:

1. Controlled Absorption Rope (Lower Strength, Flexible Response)

• 8-strand nylon rope core
• Coated steel braiding applied at high-stress zones
• Designed to absorb kinetic energy and reduce peak impact loads on the structure

2. High-Strength Rope (Primary Impact Containment)

• 12-strand Dyneema® SK78 core
• Heavy-duty heat-shrink abrasion protection
• Engineered for maximum strength and minimal elongation under high-speed impact conditions

3. Maximum Protection Rope (Enhanced “Bomb-Proof” Design)

• Dyneema® SK78 with additional integrated steel braiding
• Multi-layer heat-shrink system for added durability and extreme impact tolerance
• Used in highest-risk locations with maximum threat protection requirements

Why Dyneema® SK78?

Dyneema® SK78 fibre offers a unique combination of strength, flexibility, and environmental resistance, making it ideal for modern security systems:

• Ultra-high strength-to-weight ratio — significantly lighter than steel alternatives
• Minimal elongation — enabling controlled energy transfer during impact events
• Excellent abrasion and fatigue resistance — ensuring reliable long-term performance
• Corrosion-free — fully resistant to water, UV, salt, and temperature extremes
• Long operational life — minimising maintenance, even under continuous high load cycles

By incorporating Dyneema® into the barrier design, the OEM was able to achieve faster barrier operation, easier servicing, and a more compact system footprint, all while maintaining world-class protection levels.

The Outcome

Following controlled crash testing—including full-scale unmanned vehicle impact trials—the system achieved full PAS 68 certification, successfully stopping high-speed vehicles within minimal penetration distances. English Braids’ rope assemblies are now deployed in multiple high-security installations worldwide, supporting critical infrastructure and government-level security measures.

By delivering highly engineered rope assemblies for this next-generation security barrier system, English Braids continues to support global security efforts with proven Dyneema® rope solutions designed for extreme performance.