In high-risk industrial settings, metal building systems deliver critical resilience against explosions, fires and toxic gas releases.
Offering a cost-effective, high performance solution, these systems excel when adaptability and speed matter most. Unlike precast concrete or blast-resistant modular units, metal structures can be custom engineered to support a wide range of footprints and functions — without geometric constraints. For blast loads under 5 psi free field, they often outperform bulkier alternatives in both cost per square foot and structural performance. Their ductile nature also allows them to absorb and redistribute energy from dynamic loads such as blast waves, unlike brittle construction materials.
Beyond blast resistance, metal buildings are particularly well-suited to mitigating toxic release and fire hazards. Two main design strategies exist for multi-hazard resilience: One focuses on designing the full structural envelope. With a continuous air barrier (CAB), reinforced connections, and systems like pressurization or scrubbers, these structures can maintain integrity during a toxic release. Fire-rated panels and intumescent coatings further protect against radiant heat. When integrated into a thoughtfully designed metal building, these features create a durable, economical solution for life safety — especially where continued operation or access is vital during and after an event.
The second approach focuses on protecting the building envelope primarily for blast resistance while a dedicated internal refuge, called a "safe haven" provides a sealed, controlled space during toxic or fire events. In this strategy, the overall structure is optimized for blast loads (often at a lower cost), while the safe haven offers targeted, airtight protection for shelter-in-place scenarios. The following case study illustrates how this dual-approach strategy was successfully implemented in a facility’s Central Control Building (CCB).
Designing a safe haven for toxic threats post-explosion
Metal buildings can be designed for hazardous scenarios involving multiple hazard types that occur in rapid succession. A practical example of this can be seen in a recent Blast Resource Group (BRG) project. BRG was tasked with designing a shelter-in-place within a new CCB for a client. The client’s goal was to ensure that the CCB could serve as a safe haven for up to one hour following a blast event and potential toxic gas release. The source of the credible explosion and toxic release hazards was from the southeast.
The engineering team designated the centrally located console area within the CCB as the safe haven, while the adjacent support rooms were excluded from this designation. The console area had only one exterior wall to the north. To meet blast performance criteria, the building’s exterior envelope was designed to the American Society of Civil Engineers "Low Response" level for the expected blast loads, ensuring limited structural damage. The northern wall of the CCB was designed to stay elastic and remain undamaged in the event of a blast. This prevented damage to this wall and helped ensure that the exterior could prevent toxic ingress from the north.
Special attention was paid to strengthening critical interfaces — such as wall-to-roof and wall-to-wall junctions — to maintain CAB integrity, and additional resilience was achieved by separating the HVAC systems for the console area and support rooms, reducing the risk of toxic ingress. Full-height internal partitions were used to isolate the safe haven physically and in terms of air handling. Other safeguards incorporated into the design included positive pressurization, scrubber system, gas detection, HVAC isolation capability and PPE.
Using a metal building system lowered structural costs while meeting essential occupant protection requirements. This case study shows how, with multi-hazard design, metal buildings can offer effective, economical protection in high-risk environments. Through tailored design and integrated safeguards, they become resilient structural solutions that protect both life and property.
For more information, visit blastresourcegroup.com.
