Engineering Security Sustainably: Smarter Materials in ModuleGuard

The security industry has long relied on heavy-duty materials to ensure high resistance against attacks. But in today’s world, sustainability demands a smarter approach—one that optimises material use without compromising strength.   

At Gunnebo Safe Storage, we believe that engineering excellence and sustainability must go hand in hand. By integrating advanced material science and structural simulations into our development process, we rethink and reimagine every day the way security solutions are built. One such example is our ModuleGuard T2 strongrooms and vault doors that uphold the highest security standards while reducing environmental impact. 

Engineering a More Sustainable ModuleGuard 

Recent projects in the retail and residential sectors have highlighted the need for lighter yet highly secure solutions. In particular, strongrooms installed on upper floors require weight-efficient designs, while the pharmaceutical industry demands security solutions that align with stringent compliance standards. At the same time, the evolution of our manufacturing capabilities made it the right moment to re-engineer our modular panels and vault doors, ensuring we provide a full range of security solutions that meet modern customer needs. 

Through in-depth structural analysis and advanced simulations, our R&D team identified key areas where material efficiency could be improved while maintaining maximum security. This led to an optimised panel composition, reducing reliance on traditional materials such as concrete and steel by incorporating alternative, more sustainable materials like wood. 

Ilaria Lavermicocca, Sustainable Materials R&D Engineer at Gunnebo Safe Storage, says:  

“Engineering and material research play a crucial role in shaping a more sustainable future. Continuous research and innovation are key to reducing environmental impact across our industry.” 

By refining our approach, we have achieved significant performance and sustainability gains in our ModuleGuard panels: 

• Weight Reduction: The new Grade I panels weigh around 60 kg/m², making them ideal for upper-floor installations. As a newly introduced grade in the ModuleGuard range, there is no previous Grade I for comparison. It extends our offering with a lighter yet certified security solution. 

• High-Performance Security: Grade III panels remain around 136 kg/m² while delivering superior resistance. 

• Certified Protection: Fully tested and certified under EN 1143-1 standards for Grade I, III, and IV with optional ballistic resistance up to FB2 (pistol). 

• Enhanced Fire Resistance: Meets EN 1363-1 and EN 1634-1 standards, ensuring a minimum of 60 minutes of fire protection. 

• Lower Carbon Footprint: The Global Warming Potential (kgCO2-eq) calculated for the raw materials of the new Grade III design is 56% lower than the old version. This improvement was achieved by reducing steel use by 50% and replacing processed wood board (MDF) with unprocessed wood beams. In addition, the new Grade IV design has a 48% lower Global Warming Potential (kgCO2-eq) than its predecessor, primarily due to a 70% reduction in the impact of concrete. 

Sustainability Through Engineering Innovation 

Every design decision in the ModuleGuard strongroom and vault door reflects our commitment to environmental responsibility while ensuring the highest levels of protection. Myriam Bevillon, Head of R&D, Quality and Sustainability, says: 

"The development of ModuleGuard has been the first where we’ve considered sustainability just as important as the weight and cost targets set by the product manager. This was a good learning curve, and moving forward, we will implement more systematic methods to eco-design our products” 

Francesco Mariano, 3D CAD Design Engineer, who managed the project, concludes: 

“This project was a true team effort, and its success is a testament to the hard work and commitment of everyone involved. We faced challenges along the way, but through collaboration and determination, we turned them into opportunities for growth and innovation. Seeing it come to life has been amazing, and I look forward to what’s next.”