Today’s security requirements are no longer limited to simply “blocking the road.” Barrier systems used in critical facilities, government buildings, airports, and defense zones have become active defense elements against high-energy vehicle-borne attacks. In this article, we examine how anti-terror barriers (especially hydraulic road blocker systems) are designed, how impact analysis is performed, how field testing and measurements are carried out, and finally, what must be considered during production — all from an engineering perspective.
Security barriers are far more than ordinary traffic obstacles. They must:
• withstand high-speed and heavy vehicle impacts,
• absorb and redirect impact energy,
• remain functional even after a collision.
For example, the GateSet GSR-X Series hydraulic road blockers are crash-tested to stop a 7.2-ton vehicle at 80 km/h. In these tests, the dynamic and static “zero penetration” criterion is achieved — meaning the vehicle is completely stopped without breaching the barrier.
Designing a barrier at this level is not merely about placing a steel block on the ground; it requires calculating energy distribution, selecting the correct material strength, and ensuring continuous operational capability.
A barrier design cannot begin without answering the following engineering questions:
How much kinetic energy is transferred to the barrier when a 7.2-ton vehicle impacts at 80 km/h?
→ This energy defines the barrier’s required energy absorption capacity.
Heavy-core steel profiles, hinge strategies, and connection elements determine the barrier’s structural integrity.
Using standard Finite Element (FE) models, the barrier’s behavior during impact is simulated. Stainless steel plates, high-rigidity frames, and hinge mechanisms are modeled in these analyses.
Impact analysis does not only reveal the barrier’s static strength; it exposes its behavior under dynamic collision conditions. These analyses are typically performed using:
• high-accuracy Finite Element Analysis (FEA),
• realistic vehicle-barrier contact models,
• advanced material modeling (plastic deformation, impact flow behavior, etc.).
Modern simulation tools can visualize stress distribution and deformation during impact, allowing critical weak points to be optimized digitally during the design phase.
The reliability of simulation results must be proven through field tests. At this stage:
✅ High-speed cameras record the moment of impact.
✅ Accelerometers measure real-time forces acting on the barrier.
✅ Deformation sensors detect how and where the structure deforms.
In the GateSet example, full-scale crash tests demonstrated that the barrier not only stopped the vehicle but also remained fully operational — capable of opening and closing again. This represents not only durability, but sustainable security.
When analysis and test results are transferred to production, true success depends on:
• Material Quality: Heavy-duty steels such as 200 mm NPU body profiles and 40x100 mm plates significantly increase impact resistance.
• Welding and Assembly: Weld zones must provide strong integrity at high-stress points.
• Control Systems: PLC-based control units enable high-frequency operation and system reliability.
Production quality ensures that the barrier delivers not only physical resistance but also functional continuity when facing real threats in the field.
At FE-TECH, we execute all stages of this process under one roof:
📌 Design: Barrier architecture tailored to mission requirements
📌 Analysis: Performance validation through impact and dynamic simulations
📌 Field Testing: Real-world verification through measurement and data analysis
📌 Production: High-quality manufacturing and system integration
Anti-terror barriers are not just products; they form the backbone of critical infrastructure security. We approach this backbone with scientific precision, engineering discipline, and a balance of theory and practice.