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Land Defence

Delivering lightweight passive composite protection solutions for military platforms

Delivering leading composite material solutions across Defence, Aerospace, Rail and Automotive markets since 1937

Appliqué Armour

Permali Gloucester develops, designs, tests, manufactures and supplies light weight passive ballistic and blast resistant lightweight armour panels to STANAG 4569, AEP-55 and other commonly used EU, US and NATO standards (EN, NIJ, DIN etc.)

Ballistic panels are manufactured using glass, aramid or UHMWPE materials and thermoset resin systems or advanced thermoplastic matrices. These can also incorporate ceramic tiles, for protection against armour piercing rounds, and aluminium or steel skins for greater rigidity or increased protection levels.

Panels can be supplied as appliqué upgrades or designed for integration into new build platforms, working closely with users and vehicle manufacturers to design optimise the armour solution for improved protection and reduced weight.

Permali appliqué armour panels can be painted or PU coated using our trademarked Tufshield polyurethane coating to provide greater environmental protection and wear resistance.

Permali appliqué armour solutions are in service on a range of military armoured vehicles, and have been proven on recent operations. These are fitted to the UK CVRT, Warthog and Viking tracked platforms, as well as the 4T DAF, Bedford truck and the Oshkosh Heavy Equipment Transporter (HET) and Wheeled Tanker.

All solutions were subjected to, and passed, rigorous environmental, ballistic and safety tests to required UK and NATO standards.

On each of these programmes Permali worked alongside the vehicle prime, the Authority, and the end user to deliver bespoke solutions that met challenging technical and project requirements.

See our Case Study section for further information about where Permali appliqué armour solutions have been integrated and proven on operational platforms.


Spall Liners

Permali Gloucester develops, designs, tests, manufactures and supplies internal spall liner panels for metal-hulled platforms to reduce the effect of an over match on vehicle occupants.

Spall liners are primarily used to reduce behind armour effects when a vehicle is hit by overmatched threats, caused by the 'spalling' of the metal hull and providing secondary fragmentation injuries to internal occupants. The addition of spall liners reduces internal damage by reducing the cone angle and amount of debris entering the vehicle (up to 95%), thus minimising casualties.

Permali spall liners (roof, floor and walls) can be supplied in a range of E and S2 glass, phenolic or rubberised aramid, or UHMWPE materials, and to a range of thicknesses. They can also include acoustic and thermal insulation materials, either bonded onto the panels or integrated using a sandwich structure.

Spall liners can be painted or coated using Permali's trademarked Tufshield polyurethane coating to provide greater environmental protection and wear resistance. Inserts can be fitted to the panels for through mounting to the hull, or the spall liner can be directly bonded to the platform using two part epoxy adhesive or velcro methods of attachment.

Permali spall liners can be supplied as flat panels, machined to customer shape requirements, or as moulded panel shapes to suit a particular vehicle internal geometry.

Through a number of competitive tenders, Permali have been selected as the preferred supply partner for the design and manufacture of a wide range of spall liner solutions for military armoured vehicles, from AFVs such as Viking, Warthog, Challenger 2, Bulldog, Trojan, Titan and Warrior platforms, through to medium and light protected vehicles such as VBCI and Aravis. Our spall liner solutions offer multi-functional capability, with the integration of EMC linings as well as thermal and acoustic insulation material; the UK MOD Foxhound vehicle has Permali roof insulation fitted to all variants delivered to date. All solutions are developed alongside the vehicle manufacturer, and end customer, to ensure 'right first time' integration by conducting extensive design, templating and validation activities, and conform to strict UK, EU and NATO standards for environmental, ballistic and safety requirements.

See our Case Study section for further information about where Permali spall liner solutions have been integrated and proven on operational platforms.

Composite Mouldings

Permali Gloucester develops, designs, tests, manufactures and supplies composite moulded structures for armoured vehicles.

Applications include roof, floor and side panels, wheel arches, belly plates and complete body structures.

Permali have developed composite moulding technology with excellent blast resistance for mine protection applications.

Permali composite mouldings can be painted or coated using Permali's trademarked Tufshield polyurethane coating to provide greater environmental protection and wear resistance.

Permali have undertaken a number of Urgent Operational Requirement (UOR), Core Equipment (EP) and Research and Development (R&D) programmes to design, manufacture, test and deliver complex composite moulded protection solutions for integration into both new build and upgrade land vehicle programmes. These include a single piece composite floor plate for a blast protection requirement on the UK MOD Land Rover WMIK platform, a complete composite cab for a light weight 4x4 vehicle, and a composite roof required to provide additional rigidity, for zero weight gain, on the UK MOD Panther platform. In addition to these programmes, Permali has, and continues to, run a number of internal R&D programmes developing the use of composite mouldings that can form part of, or complete, combined blast and ballistic protection and structural, mass efficient solutions for land platforms.

See our Case Study section for further information about where Permali composite mouldings have been integrated and proven on operational platforms.


Infrastructure Protection

Permali Gloucester develops, designs, tests, manufactures and supplies flat or moulded panels for integration into deployed infratructure to provide protection against ballistic, fragmentation and blast threats.

Applications include deployable box body and stand alone accommodation or working environment structures.

Fuel Tank Self Sealing System - BattleJacket®

 The BattleJacket® Fuel Cell Containment System (FCCS) is a revolutionary technology designed to minimise or prevent leakage from fuel tanks when subjected to small-arms fire. Fuel tanks and containers are prone to targeting as the 'weak point' of a vehicle system, which can cause hazardous conditions for both troops transporting bulk fuel, and operational risks to military vehicles caused through loss of fuel from the platform's on board tank(s).

The BattleJacket® system is an elastomeric 'spray on' coating, which can be applied to both metallic and plastic surfaces. It is based on a specially formulated fire resistant urethane modified for military applications. Special super absorbent polymer beads are used as the basis of the self sealing mechanism, which are sprayed into the middle layer during the application process. These beads swell into a solid when exposed to fuel, acting in conjunction with the top and bottom urethane layers to tightly seal the entrance and exit holes created by a projectile.

The BattleJacket® system is operationally proven, having been extensively used by the US military on both large scale fuel tankers and smaller 'saddle tanks' on trucks and other vehicles. One fuel tanker had over 600 rounds shot into it without any loss of fuel or function. The number of rounds is known as the operator retrieved them from the fuel filter after the attack!

BattleJacket® works like a mechanical skin, healing itself within seconds of attack and sealing any entrance holes. The thickness of coating can be varied to meet specific ballistic threat levels and, by allowing projectiles to harmlessly penetrate the tank without loss of fuel, it can also prevent lethal ricochets. For penetrations that exceed the engineered threat level, and therefore do not self seal, a field patch repair kit, able to be applied in seconds, can be simply screwed into the coating and underlying tank, sealing the damage using the same absorbent bead technology. Zero training or knowledge of the system is required.


Delivering leading composite material solutions across Defence, Aerospace, Rail and Automotive markets since 1937