1. Introduction to Cash-in-Transit Vehicles
The worldwide use of cash has orchestrated a huge industry “Cash-in-Transit” over the past century. Vehicles that protect against robbery during transit are commonly referred to as “cash-in-transit vehicle” or the abbreviation “CIT vehicle.” Valuables, another branch for applications of those cash-in-transit vehicles, are divided into different types such as those that can be worn by the person or those that are bulky and must be carried by staff. Today, the cash-in-transit job is more precisely defined as “staff escorting money being handled from receipt.”
These armed banking “engagement” vehicles have lots of variations (armored, bulletproof glass, bullet-resistant glass, armed employees). The term “CIT vehicle” rarely applies for class B4 armored CIT vehicles, actually high-standard protection vehicles. In addition to the introduction of either light or precision weapons into the vehicles, the desired weight of those armored suffered an additional increase by having to build in heavier armor and then greater protection. This increase in weight has resulted in the acquisition of a new standard chassis. Since the mid-1950s, cash-in-transit vehicles have played a crucial role in urban security on the streets for transporting huge wealth of the people from banks to their business, and investors under an agreement of trust worth billions to give much anticipated security and safety during the transport of fully armed CIT vehicles to prevent the loss of banks’ spillover. In this way, highly technical security in society has been bolstered for its cash-based banking system. Armored vehicles evolved significantly before the World War and had, for example, more than full-machine-gun armament in the form of the armored car. However, for the time being, vehicles were not popular for trips to banks and communities. After the mid-1930s, following a review of the shoot-out authorities, the plane-truck Fokker F.III was the first specialized vehicle designed for the transport of bank loot on a road with limitations to being utilized almost at nighttime for safety and security.
1.1. Purpose and Importance
Cash-in-transit vehicles, also known as armored trucks, are highly specialized vehicles that are designed to meet certain very specific demands. A cash-in-transit vehicle is designed with various levels of armor or security measures in order to safely and securely transport goods, money, and valuables. ATMs require frequent “refilling” with cash, businesses frequently need to make large deposits, and banks themselves must transport money from one branch to another or otherwise need to safely move large quantities of currency from one location to another for various reasons. Most government authorities require the companies who engage in providing such services to do so with an armored vehicle so that the cash or other valuables are not subject to theft while in transit. Of course, with currency not only being paper but also the fact that it is easy to carry, the threat of someone taking cash from someone else is ever present.
In addition to moving actual cash, it is also common to move coinage in a cash-in-transit vehicle. A $5,000 bag of quarters, for example, will weigh 1,000 lbs. Coin is heavy, so many armored vehicles have means by which to assist heavy lifting. For example, a small crane/navigational winch may be installed on the vehicle. Many cash-in-transit vehicles are painted in such a way as to be easily identifiable and can often have warning labels or lights to identify themselves as such. The armored vehicles are designed to resist attempts at simple theft with opportunistic smash and grab shortcuts, such as hammer attacks or lock picking. As a result, all cash-in-transit vehicles have at least some form of secure lock or electronic combination or key code to unlock the cargo area of the vehicle. The fact that the vehicles are resistant to theft has an effect that is also related to the crimes of larceny and theft; that is, major crimes of larceny typically require a higher worth item to be stolen. Given the design of cash-in-transit vehicles, it is inevitable that the value of the goods cargo area will surpass the statutory threshold for major theft charges.
1.2. Historical Background
As already mentioned, the evolution of cash-in-transit vehicles has followed the development of security processes and requirements to satisfy them. Cash-in-transit vehicles were originally formed to serve bank customers who needed to deposit cash and for carrying cash from one bank to another that was short of cash. It was not until the later years of the Roman Empire that the rotation of cash from the already rich bank to the poor bank brought the idea of theft of money into being. The first security system for cars in use by the banks was devised by a hospital administrator who in 1736 hired a guard with a gun and a mounted horse to accompany a car from Whitechapel to a bank in London at night. This system, enhancing the guardsmen’s protection with improved armor and closing in on the car interior, was still standard protection in 1920 when the tanks protecting World War I were converted into the first armored cars.
The first armored car for cash-in-transit was built in 1920 by the W. J. Greaves Company to provide a service when British banks first began to trade on the continent. Those continental banks wanted guns, armaments, and systems as reliable as the fantastically efficient German blitzkrieg. Thus security cars came into service at a time when the extraordinary development of handguns and cannon had produced barrels with defective deco packings, firing everything from hot metal balls to iron fragments, and effective ammunition that shattered barriers, repeated a precise pattern, and warheaded with armor-piercing balls. Those early armored cars also were initially armed.
2. Armoring Standards and Regulations
Specifying the form, design, quantity, and location of armor for a CitV is a delicate process, especially if the vehicle has to be considered as armored for any standard level. If we are talking about armor for a commercial armored car firm, the full armoring option should always be evaluated. However, it should be taken into account that non-armored fleets are always more economically advantageous and politically correct.
Two are the most consolidated standards referred to at the international level: the NFPA 472 and the National Institute of Justice with its Standard 0108.01 (NIJ). There are also the STANAG 4569 and the European Standard EN 1063. To our knowledge, the EN 1063 standard can be completely used to properly define and regulate patient transport vehicles. It defines, indeed, three levels of protection for light vehicles against no-dedicated targeting, also offering specific values of the hurt injury assessment. The NIJ and the STANAG standards, instead, are referred to weapons with military ballistic characteristic: dedicated assaults, targeted ammo, accurate aiming. In this paper, only the oldest-mentioned standards are considered. The standard details the levels of armor protection, the required tests and specifies the testing procedure to determine the resultant V50 ballistic limit, which shall then be used as a measure of armor effectiveness.
2.1. NIJ Standard 0108.01
The National Institute of Justice (NIJ) primarily focuses on research, development, and evaluation in criminal justice. NIJ’s facility in Rockville performs testing of armor materials used in the construction of cash-in-transit vehicles. They are the most widely recognized agency in the US when it comes to authorizing the levels of security in armored vehicles, and others in the field often use their standards even if the vehicle is not being manufactured in the United States. The previous standards (NIJ Standard 0108.01, promulgated on April 19, 1985) for armored vehicles are the ones that Matterhorn uses to determine which vehicles can be used for their trucks based on armoring levels.
This standard establishes a methodology to certify the performance of materials as well as establishing NIJ’s classifications of bullet-resistant materials. This standard was developed in conformity with the American National Standards Institute (ANSI) Essential Requirements. The NIJ armor standard provides the performance level for most ballistic-resistant materials combined with bullet-resistant glazing and armored vehicles used by police and also by private security agencies. The standard provides a classification to evaluate bullet-resisting characteristics of a given armor material/system against certain handgun/caliber and rifle caliber. Three skeletal structures or crude drawings of inherent points target the impacts: shots shall not be deliberately adjusted after striking the armor. If these shots exceed the areas limits, they should be disregarded as missed shots and repeated.
2.2. European Standard EN 1063
The standard EN 1063, “Glass in building – Security glazing – Testing and classification of resistance against bullet attack”, superseded the similar standard EN 1063:1999, issued in 1999 by the European Committee for Standardization (CEN). The European Standard EN 1063, published in January 2000 as CEN/TRA document 1063, provides standardized tests, procedures, and performance prerequisites for the classification of transparent armor (or “glazing”) for use in buildings. Transparent armor evaluated under the standard includes laminated glass and certain impact-resistant plastic products. The intent behind EN 1063 is to determine transparent armor resistance level classifications which provide a test-based means of resisting penetration and blunt force trauma into an area shielded by the transparent armor.
The specific requirements and classifications within the EN 1063 standard focus on the vehicle features most likely to be targeted by violent PACIT robberies: transparent armor (especially bullet-resistant glass), heavily armored exterior doors, and bullet-resistant fascia. Though EN 1063 obviously does not address other aspects of vehicle security, such as safe storage of valuables, the standard is a significant step in protection for the cash-in-transit industry. The standard ensures that the industry-developed armored features are sufficiently capable of resisting PACIT attacks and retaining their structural integrity after such attacks. In short, if the armored features on a cash-in-transit vehicle are built and installed to an appropriate EN 1063 resistance level classification, the integrity and resistance of the features to penetration and blunt force trauma will be maintained after an attack with defined levels of hand grenade threats.
3. Types of Armoring Materials
Variety of materials are being used in order to ensure a high level of protection against ballistic, explosive, and forced entry attacks on CIT vehicles, and they are steel, composites, and glass. Traditional material used in CIT vehicles is steel. This material allows for quality defense against forced entry attacks, rifle shots, and airborne threats. However, CIT vehicles were not equipped with good ballistics, which forced Security Solutions to add additional protection by adding composites and ceramic materials.
Because a significant amount of steel is required for the construction of the entire CIT vehicle, and the vehicle weighs around 7,000-13,000kg, the CIT vehicle needed a powerful engine, which also increased the weight and fuel consumption of the vehicle. To reduce the weight of the CIT vehicle, manufacturers are increasingly using composite materials, which have the same features as steel but at lower weight for CIT constructions. Composites offer a level of protection equivalent to steel materials with the same thickness, with a minimum of 24% weight savings. There are also steel and aluminum grades that provide good protection and also contribute to reduced fuel consumption. But composites, and therefore CIT vehicles built with composites, are not widely accepted in practice, as they are most often wanted to be real solid and cannot be sacrificed for the safety of employees who transport money. Composites are freely moving in ballistic tests; however, in the real world, the martial defense of the CIT vehicle is acceptable. However, in some parts of the vehicle, such as the engine compartment, CIT vehicles have metals that are not the defense and are made of non-ballistic materials, in some parts, CIT vehicles have suitable armored vehicle roofs and bulk-top layers. Effectively protected by this careful balance, the CIT vehicles are fully competed in the hazardous environment.
3.1. Steel
Steel is an alloy of iron and carbon and may contain small amounts of silicon, manganese, sulphur, and phosphorus. The addition of these elements refines the steel quality by making it stronger, more adaptable, and resistant. Steel is commonly used as an armoring material in lower-level threats of armoring applications as it has better bendability and less cost compared to other armoring materials. Steel does not tend to become brittle at low temperatures and is thus less sensitive to supplying. It has an energy absorption mechanism for the further gathering of shock loads, especially with impact. It is usually used as a spall liner together with Twaron, Spectra, and Dyneema, thus becoming a better spalling bilayer solution.
Types of Steels: Two types of steel are usually used as armoring materials. They are Constructional Steel and High Hardness Armor Steel. Steel continues to be the material of choice for security-driven vehicles. It can be readily applied through constructional steel or high hardness armor steel for various security levels, most commonly BR4 – BR7. Steel constructional steel is the basic steel available off from the mill apart from minimal heat treatment in the manufacture of protection in the XWF division. The steel aspect is that it is easy to process in accordance with the manufacturer of the vehicle and is usually used in thinner layers when added in the armoring division.
4. Application Area for Armoring: Steel armor is highly recommended for armoring against bullets, robbery, assault, hand grenades, and machine gun levels. It is used in cash-in-transit (CIT), armored personnel carriers, and civilian security vehicles. It is used for bullet resistance in the engine compartment area, vehicle cabin, and other parts such as fenders, front bumper, and external surface of the vehicle.
3.2. Composite Materials
Nowadays, an essential compositing element used in cash-in-transit vehicles is composite materials. They have a relatively high strength-to-weight ratio compared to polymers, which makes them suitable for armoring light armored vehicles as they contribute to an increase in payload while remaining within the permissible Gross Vehicle Weight (GVW). The advantage of composite materials is related to higher design flexibility, resulting in improved protection. For example, thin-walled hollow sections exposed to explosive loading. Using advanced materials in combination with other lightweight solutions, such as ceramic or aluminum, can significantly reduce the vehicle’s moving inertia and influence further maneuverability. The multi-threat protection of cash-in-transit vehicles should be provided at a minimum for the entire vehicle periphery, while the more vulnerable parts (like doors) at higher levels.
Relevant works on the armor research of cash-in-transit vehicles or light armored vehicles were noticed. However, the focus was mainly on carburized armor (steel) and alumina ceramic as separate materials. The combined and integrated solution, which is described in this paper, was unfortunately absent. This solution utilizes a ceramic tile and an internal steel fiber mesh with a polymeric matrix. To confirm the effectiveness of this system, the FG-1 blank and armor-piercing incendiary (B-32 API) projectiles were used in a multi-layer configuration. Perforation analysis was conducted on the tile and polymeric matrix, the polymeric matrix and the steel fiber mesh, and the steel fiber mesh and covered section. The cover materials considered were aluminum 2024, 5083 aluminum, and mild steel. The projectile impact event interacting with the armoring wall was analyzed using a dynamic nonlinearity FEM support software, specifically the commercial package LS-DYNA ver. 971.
4. Design Features of Armored CIT Vehicles
Bulletproof glass is always used in the cab. The purpose of using bulletproof glass in the cab is that it can completely or partially replace the reinforced armor area. When being attacked, it can withstand chambered bullets, plastic explosives, hand grenades, and other attacks from close range. Moreover, it can maximize the protection of the armored personnel carrier and does not affect normal observation and getting on and off. Bulletproof glasses are usually fabricated with multiple layers of glass and optical plastic (usually polycarbonate) sandwiched together in a manner that gives the desired protection. The proper design is to create a layered buffer that mitigates the explosion pressure. The automotive bulletproof glass with high strength, light weight, and good bulletproof performance is a transparent composite laminated glass bonded together via high-temperature pressure with qualified blotter and an ultra-thin layer of membrane EVA (ethylene-vinyl acetate).
Armored vehicles often use run-flat tires to keep the vehicle mobile and protected in the case of any of the tires being punctured. There are now many companies in the industry engaging in designing and manufacturing the run-flat tire system for armored vehicles. The working principle is that it can continue to work for a limited period of time after being punctured. The inner support ring and the outer tire are mounted on the outside of the wheel by means of a secure clamping ring. Armored personnel carriers were initially fitted with run-flats featuring a rubber core. However, these were found to be a serious combat hazard resulting in many fire-related deaths to servicemen. Today’s modern run-flat tires have an integrated ring of hard rubber which, while suffering the same rapid compression under load as the core-only systems, comes at a far lower cost in terms of suffering a loss in protection. Much of the packaging technology used in run-flat tire systems comes from the F1 racing car industry. This kind of run-flat wheel has been used for military light weapons carrier vehicles, especially for military armored vehicles in Iraq and Afghanistan. The processing technology and performance of automobiles and armored vehicle run-flat tires have had full access to European Community Certification and also provide related products to the United States and other military industries. For armored vehicles with a certain weight, run-flat tires are recommended so that they can continue to operate safely even with flat tires.
4.1. Bulletproof Glass Cash-in-Transit Vehicles
Cash-in-transit vehicles are armored to a variety of specifications, primarily targeting protection against gunfire, explosions, and ramming. In order to build these vehicles with the ability to handle a variety of threat levels, CIT vehicles must contain specialized components. Bulletproof glass is one of the most crucial components of the CIT vehicle, as it enables visibility facing out of the vehicle while also ensuring that the cash and guards within remain safe from violent criminals. This section will focus on the features of bulletproof glass in CIT vehicles.
Bullet-resistant glass, also known as bulletproof glass or ballistic glass, is a type of glass that is constructed using a combination of materials in order to provide any given level of protection from gunfire. This glass is manufactured so that it may respond to materials, such as bullets, with different forms of resistance, including deformation or absorption of the impact, splaying towards the direction that energy from the projectile is coming from, or even spallation such that splinters of glass are not thrown towards the protected individuals. The primary role of the bullet-resistant glass present in CIT vehicles is to provide visibility of the environment that lies outside of the vehicle to the driver, while ensuring that individuals within the CIT vehicle face protection from those who seek to rob or harm them as they are carrying cash. Bulletproof glass is not only used in CIT vehicles; it is also used in VIP vehicles, premium multi-level houses, portable cabins, bridges, large offices, and in many other applications to provide security. In addition, it is used for protection from kidnappings, terrorist threats, and other criminal acts. Bulletproof glass is quite different from normal glass, as it provides resistance to various types of ballistic impacts.
4.2. Run-flat Tires Cash-in-Transit Vehicles
Run-flat tires are known to have reinforcements which can carry the car’s load without the need for air pressure. In case of a puncture, run-flat tires can carry the car with enough speed. In this scenario, a vehicle whose tire has sustained damage can be more helpful. In case of an ambush attack, vehicles carrying cash and valuable can move out of the threat environment with high speeds without being stuck in the road because of the firearm damage on the tires. Run-flat tires directly affect the resilience against unscheduled features, which therefore will demand increased cost. Run-flat tires can be replaced directly with the tires used in civil vehicles. However, the military industry vehicles usually use run-flat tires as military standard to achieve resistance against unscheduled situation. Run-flat tires can be made up of solid rubber based on a core of the wheel, or they may use a support ring system. These devices are heavily engineered to take large overloads. Some of the requirements for such tires are defined below.
Run-flat tires or run-flat tire systems are an important aspect in CIC vehicles, especially when they operate in conjunction with the usage of lightweight add-ons, as will be used for the underbelly protection level. Both pass-flat tires and support ring system tires are mentioned and ensured to be impact tested. The high inertia (140 kJ) drop tower is used for the bead unseating test. The armored cash-in-transit vehicles’ wheels are equipped with run-flat systems. The main functionality of this feature is to continue to move the vehicle eventually in case of the tire being shot and damaged without loss of control. The vehicle should lose mobility rather than its security capability if tires are shot. The runners are tested on the ground on a paved platform. The arresters can also be tested along with the tires or they can also be tested separately. Also, the vehicle equipped with runners can be driven throughout the tests, which are held on a paved platform.
5. Maintenance and Testing Protocols Cash-in-Transit Vehicles
The heavy armoring of cash-in-transit vehicles is provided by certified manufacturers who need to adhere to specific standards with regards to materials, armoring design, and installation procedures. However, given the inherent mobility of the vehicles, continual vigilance needs to be exercised to ensure that these vehicles continue to provide a level of security to its personnel. Failure to maintain armored structural integrity or fix any damages to the armored vehicle in a timely manner could compromise the safety of the crew and security of the cargo. Areas where damage (especially related to ballistic or blast protection) should receive extra attention as soon as any potential threat is identified by the crew. Also, to ensure that the vehicle has the maintenance performed on it in line with the expected procedures, numerous periodic inspections by MROs are required on this vehicle.
The primary purpose of this specification is to outline those practices and procedures that should be used to maintain the balance of performance that should be expected from certified armored vehicles. The specification is split into two main sections: the first relates to the maintenance of the armored features and the second is concerned with the testing methods and procedures that are to be used to ensure the armored features are fit for purpose. The testing procedures for armored vehicles will be covered separately under a separate specification in Section 7. Maintenance is also part of maintaining the warranty of an armored vehicle, which should have specific sections dealing with armored components. Moreover, it is the duty of the inside MRO to ensure that any damage to an external armored component is repaired effectively.
