PUBLISH DATE: CLASSIFICATION:

Laminated Glass Interlayers June 2019 OFFICIAL

Introduction to Laminated
Glass Interlayers
Guidance to raise awareness on which laminated
glass interlayer types to use

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 PUBLISH DATE: CLASSIFICATION:
Laminated Glass Interlayers June 2019 OFFICIAL

Introduction
Glass is widely used in buildings for its transparency and optical performance as well as resistance
to the environment, such as wind, rain and temperature variations etc. However, as a basic
material it is inherently brittle and has significant shortcomings for security applications. Using
laminated glass is generally the preferred way of overcoming these limitations.

A laminated glass comprises two or more layers of glass which are permanently bonded together
using an interlayer material. The layers in laminated glass are typically referred to as a ply or plies.
For certain applications, plies of glass will be replaced with alternative materials such as
polycarbonate to improve resistance. Laminated glass can be designed for a range of different
security requirements, including for example:

 bullet resistance – where primary requirement is a high degree of impact resistance

 forced entry resistance – where the requirement is to protect against cutting and impact,
although the impact requirements are much less than that required for bullet resistance
 blast resistance – where the requirement is primarily to absorb energy, which requires
‘ductility’
Laminated glass is a complex composite material, and its properties can be changed considerably
by:

 the type of glass plies used (e.g. annealed, heat strengthen, toughened etc)
 the number, thickness and order/orientation of plies used
 the type of interlayer used between the plies of glass – mechanical properties, thickness etc
 the process used to manufacture the laminate glass (this can be critical)
 substitution of glass plies with other materials, such as polycarbonate. Substitution may
also lead to other types of interlayer being used to ensure materials are compatible
 special coatings applied to individual plies or the laminate as a whole

Interlayers have developed over time to meet different requirements, and as such there are a
variety of products commercially available. Whilst they may all be referred to as interlayers, their
performance, especially against blast and other security threats, can vary significantly. Unless
specified, some glass processors may select an interlayer which may not be suitable for a security
product.

GLASS STRENGTH

Annealed Glass Heat Strengthened Glass Toughened Glass

1 2-3 x Annealed Glass 3-5 x Annealed Glass

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 PUBLISH DATE: CLASSIFICATION:
Laminated Glass Interlayers June 2019 OFFICIAL

The aim of the document

The aim of this document is to raise awareness and inform potential users, specifiers, designers and
engineers of the different types of interlayers available and the recommended interlayer types to
be used where there is a blast performance requirement. This guidance note should be read in
conjunction with the suite of glazing guidance notes relating to effective blast performance of glass.

How is laminated glass manufactured and how does it

perform if it breaks?
Interlayers are most commonly supplied as a roll of thin sheet material, normally 0.38mm or
0.76mm thick. The interlayer is laid between plies of glass of the required thickness, with multiple
sheets of interlayer being used to achieve the required thickness when required i.e. 2 x 0.76 =
1.52mm thick interlayer. Extreme heat and pressure are then applied to the assembled composite,
in a controlled manufacturing process which bonds the layers of interlayer and glass together.
Storage of the stock interlayer and the subsequent lamination process are undertaken in a
controlled environment as the final product performance is heavily dependent upon the care taken
during manufacture.

Should the glass break, the glass fragments should

be held in position by the adhesive bond between
interlayer and glass. The ductility and toughness
of the interlayer will also play a vital part in
delivering acceptable post-fracture performance
of the laminate. Interlayers can be classified
based upon their strength and adhesion level.
Variation in these parameters can have a
significant effect on the performance of the glass
Figure 1: Components of laminated glass if it breaks.

How does temperature impact the properties of the

interlayer?
Recent research has shown that strength and adhesion levels achieved by a specific interlayer can
also vary depending on the temperature of the product at breakage. Generally, higher
temperatures will increase the elongation properties of the interlayer i.e. its stretchiness, whilst
colder temperatures will make the material more ridged. In terms of adhesion level, higher
temperatures will typically reduce the strength of the adhesive bond. Such effects are known to
CPNI, and a research programme is underway to assess the influence of temperature on the blast
performance of PVB laminated glass.

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 PUBLISH DATE: CLASSIFICATION:
Laminated Glass Interlayers June 2019 OFFICIAL

Types of interlayer
A range of interlayers exist which are used by glass processors to produce laminated glass.
Selection of a particular interlayer is based upon a host of parameters including: availability,
durability, cost of material and manufacturing equipment, optical clarity and blast performance.
Where there is a blast requirement, the following two interlayers may be considered most
appropriate:

Polyvinyl Butryl (PVB)

PVB is one of the most popular and commonly used interlayers within the architectural, automotive
and transport sectors. Whilst laminated glass is manufactured by many different processors, the
PVB polymer itself is manufactured by a relatively small number of companies. Within Europe the
main manufacturers include Kuraray, Solutia and Everlam. PVB is popular due to its relative high
durability, predictable mechanical behaviour and ease of manufacture. Many different grades of
PVB exist, having been modified to achieve a range of structural properties, impact resistance and
acoustic performance.

For cost effective manufacture of a laminated glass incorporating PVB interlayers, in most situations
an ‘autoclave’ must be used which applies both heat and pressure as part of a controlled cycle. The
laminated panel is first assembled by placing PVB interlayers between two or more pieces of glass
within a clean room. This ’sandwich’ of different materials is initially de-aired and stuck together
using a vacuum or series of rollers before the laminate is placed within an autoclave and subject to
approximately 10 bars of pressure and heated to approximately 130ᵒC to produce the final
laminated product.

Ionomer (SentryGlas®)
This interlayer is commonly marketed under the trade name SentryGlas® (or SGP) and was
introduced into the architectural market in 1998. The ionomer material was originally developed to
improve the performance of glazing when subject to debris strikes resulting from hurricanes.
SentryGlas® is a much stiffer and tougher interlayer than PVB. The material also bonds well to some
metals which can be an advantage when designing bespoke glass structures. SentryGlas® is
intended for use in structural glass applications; for example, large unsupported sections of feature
glass and glass stairs, floors and beams.

SentryGlas® interlayers are typically processed in the same way as the PVB interlayer i.e. using an
autoclave. Due to the stiffness of SGP, this material may transfer more load to the supporting
structure when compared to PVB interlayer and this behaviour needs to be reviewed during the
design stage.

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 PUBLISH DATE: CLASSIFICATION:
Laminated Glass Interlayers June 2019 OFFICIAL

Other interlayers are commercially available and are used for commercial glazing. However, these
may not be suitable when a blast performance is required:

Ethylene-vinyl acetate (EVA)

EVA interlayers were most commonly used for the lamination of photovoltaic (PV) cells due to the
high adhesion levels achieved to silicon PV cells. The material is also highly malleable around
embedded components such as electrical connections. High adhesion levels can further increase
the edge stability of the interlayer which increases the resistance to delamination and therefore the
durability of the product.

Similar to PVB, EVA is supplied on a roll in varying thicknesses and can be layered to achieve the
required thickness/performance. The glass and interlayers are placed in a vacuum bag and heated
to approximately 120oC to create the laminated product. Due to the use of a vacuum bag, a hot box
chamber is sometimes used instead of an autoclave. For low volume manufacture, a hot box can be
a relatively low cost entry option making EVA laminated glass the preferred material for smaller and
lower cost fabricators. However, the processed cost is generally similar to PVB laminated glass.

EVA interlayers are known to rupture or tear and may not always be suitable for security
applications or where they are required to support fractured glass for long periods of time. Due to
the properties of this material, EVA interlayers may not be as suitable as PVB or SentryGlas®
interlayers for structural applications. EVA laminates have been shown to perform much worse
than PVB under blast loading.

Poured resin (cast in place)

Poured resin interlayers were commonly used for laminating architectural glass products in the
1990s and particularly for toughened and heat strengthened laminated products. This lamination
process involves the creation of a cavity between two or more panes of glass using a clear tape
around the perimeter of the glass. A liquid resin is subsequently poured into the cavity and is cured
using UV light, heat or catalytic reaction.

Poured resin interlayers are now used to laminate cast, patterned glass and curved glass which is
difficult to laminate using sheet interlayers like PVB. Poured resin interlayers are not as durable as
other interlayer products and, as such, are only used for specialist applications in non-safety critical
locations.

Polyurethane (TPU)
Polyurethane interlayers are typically used for specialist applications in which glass is laminated to
acrylic or polycarbonate sheets for ballistic resistance applications. Polyurethane is used to bond
such substrates because of its high adhesion and the ability to accommodate significant differential
expansion which can occur between plastics and glass as a result of variations in temperature. The
majority of ballistic rated laminates that utilise polycarbonate, acrylic or other plastics will
incorporate layers of polyurethane between the glass and the polycarbonate. This interlayer is
generally more susceptible to damage than other interlayers as it is not as durable, is thermally less
stable than other interlayers and is also more susceptible to moisture and chemical contact.
Cleaning fluids have been known to damage the polyurethane interlayer forming a white haze
which can be an indication of delamination.

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 PUBLISH DATE: CLASSIFICATION:
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Interlayer summary table

Common
Comparative Typical
Interlayer Common thicknesses manufacturers
1 cost when processing Typical application
type of the interlayer &
processed method
product name
Kuraray
Trosifol® &  Commercial façade glazing
Butacite®
 Glass balustrades
May be used for a blast requirement

Eastman
Multiples of 0.38mm,
Saflex®
Polyvinyl butryl common thicknesses are  Blast-resistant glazing
£ Autoclave
(PVB) 0.76mm and 1.52mm.
Everlam™
(supplied in a roll)
Lam 51H®

Sekisui
S-Lec™

 Windows subject to impact

0.76 mm, 0.89 mm, 1.52
mm, 2.28 mm
Ionomer Kuraray  Large unsupported glass panels
(supplied in either a roll £££ Autoclave
(SentryGlas®) SentryGlas®
or flat sheets for thicker
layers)  Overhead canopies

Bridgestone  Laminating photovoltaic cells

0.38mm, 0.76mm, ‘EVASAFE’, 2
Ethylene-vinyl 'Hot box ' or
acetate (EVA)
1.52mm £ plus variety of
autoclave  Locations with a high moisture
Not recommended for a blast requirement

(supplied in a roll) others, particularly content e.g. swimming pools

from Asia.

Circa 1 to 2mm  Laminating 2 or more uneven glass

(to match the thickness Ultra violet or surfaces e.g. cast or drawn glass
KÖMMERLING
Cast resin (CIP) of the void between the ££ 2 Part
‘Ködiguard’
glass) Supplied in liquid catalytic cure
form.

 Ballistic glazing

Polyurethane
1.25mm thick rolls ££££ Polymar Autoclave
(TPU)

Notes
1
Note that multiple layers of interlayer are typically used to create the desired interlayer thickness, e.g. 1.52mm PVB can be produced using 2 x 0.76 mm layers or
4 x 0.38 mm layers

2
A ‘hot box’ is a chamber used to laminate glass which subjects the unprocessed laminate to heat only, unlike an autoclave which applies both heat and pressure.
The laminates are individually sealed within purpose made plastic bags where a vacuum is applied which de-airs and ‘squashes’ the interlayer.

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Laminated glass – standards and branding

There are a range of standards which can be used to establish the performance and durability of
laminated glass. The following are some of the key standards to be aware of:

Production of laminated glass

BS EN ISO 12543: 2011 Glass in building. Laminated glass and laminated safety glass

BS EN 14449:2005 Glass in building. Laminated glass and laminated safety glass. Evaluation of
conformity/product standard (The Harmonised European Norm for CE Marking)

These standard covers factory production control during processing as well as the processes required
to evaluate the conformity for laminated safety glass for use in buildings. Companies who are
processing glass should be able to demonstrate that the laminated glass which they are supplying
complies with this standard. CE marking to BS EN 14449 is a legal requirement.

Performance specification
When laminated glass achieves a specific performance criteria, for example providing a
predetermined resistance to a person trying to break through the glass, a range of standards are
used to define the performance and ensure the appropriate combination of glass and interlayer are
selected. The two standards listed below are commonly used to define a performance classification:

BS EN 12600:2002 Glass in building. Pendulum test. Impact test method and classification for flat
glass.

This test standard is intended to classify flat glass products into three principal classes by
performance under impact and by the mode of breakage. The classification relates to increased
robustness and personal safety by the reduction of cutting and piercing injuries to persons and the
containment characteristics of the glass. The classification is recorded as number, letter, number, e.g.
1C1, to describe and categorise impact performance.

BS EN 356:2000 Glass in building. Security glazing. Testing and classification of resistance against
manual attack.

This test standard specifies requirements and test methods for security glazing designed to resist
actions of force by delaying access of objects and/or persons to a protected space for a short period
of time. The standard classifies security glazing products into categories by resistance to actions of
force.

CPNI are concerned about forced entry attacks from terrorist threats and have developed a separate
standard to address this threat. Products classified to BS EN 356:2000 do not necessarily meet the
requirement of this CPNI standard. If you have any concerns, please contact your CPNI POC.

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Compliance with the standards

It is possible to identify whether a glass product has been laminated (and/or heat treated) by
checking the branding with which it has been marked. It is not always a legal requirement to brand a
glass in a location which will be visible when glazed, however this is best practice and highly
recommended. If the glass processor is a member of the BSI Kitemark scheme they are permitted to
include a BSI Kitemark license within the branding. The branding, shown in Figure 2, may contain
multiple product standards, as well as the ones mentioned in this test standard. If used, the BSI
Kitemark should be visible and located in the corner of a pane of glass.

Glass Processor Name

COMPANY

BS EN 14449 BS EN 12150
(Laminated) (Toughened)

BS EN 12600 – Classification

Figure 2: Product brand intended to identify source, glass type and impact performance

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Laminated Glass Interlayers June 2019 OFFICIAL

Use of interlayers to achieve blast performance

A wide range of interlayers have been developed for different applications. If there is a blast
performance requirement, it is important that the appropriate interlayer is selected and information
provided to ensure that the required performance is achieved. The following points should be noted:

 PVB interlayer should be specified and used. When used within an insulated glass unit (IGU) the
laminated pane should be placed on the side of the IGU which is closest to the people or asset
requiring protection.

 PVB interlayers which are at least 1.52mm (or thicker) are recommended. Different varieties of
PVB interlayer are available and the performance of these are currently being reviewed by CPNI.

 EVA has been observed to perform poorly against a blast threat, and is not recommended for
use in laminated glass where a blast performance is required.

 It is extremely important that the type and thickness of interlayer is clearly defined to the supply
chain as there is a widespread lack of understanding concerning the different interlayer types
and associated levels of performance which can be achieved. If the wrong interlayer type has
been installed, it may be difficult to detect this and identify the associated risk of injury.

 It is important to check that the laminated glass supplier has the appropriate expertise and
quality control in place e.g. successful testing in accordance with the relevant product standards
which have been conducted by a notified body and continue to be monitored.

 Care must also be taken to ensure the durability of the interlayers after installation. Guidance
can be found on the CPNI website.

Other factors which may affect the blast performance

It is known that the properties of the interlayer i.e. the material properties and adhesion bond
between the interlayer and the glass, used in laminated glass are influenced by temperature, and
may affect the blast performance. CPNI are currently reviewing this effect.

Freedom of Information Act (FOIA)

This information is supplied in confidence to the named reader and may not be disclosed further without prior approval from CPNI. This
information is exempt from disclosure under the Freedom of Information Act 2000 (FOIA) and may be exempt under other UK information
legislation

Disclaimer
The information contained in this document is accurate as at the date it was created. It is intended as general guidance only and you should
not rely on it. This information should be adapted for use in the specific circumstances required and you should seek specialist independent
professional advice where appropriate before taking any action based on it. To the fullest extent permitted by law, CPNI accept no liability
whatsoever for any loss or damage incurred or arising as a result of any error or omission in the guidance or arising from any person acting,
relying upon or otherwise using the guidance. Full terms and conditions governing the use of this guidance are available on our website at
www.cpni.gov.uk. © Crown copyright