Heavy Duty Barrier Gates | Godrej Security Solutions
Updated: Oct 7
Heavy Duty Barrier Gates: Crash-Rated Perimeter Security by Godrej (HDCR Gates)
When you are protecting a power plant, data centre, airport perimeter, warehouse, embassy or industrial campus, an ordinary gate is not enough. A fence can stop a person, but it will not stop a truck driven at speed. Godrej HDCR Gates (Heavy Duty Crash Rated Gates) are built for that threat: a sliding gate tested against vehicle impact, with the strength to stay standing.
This guide covers every feature of the product line, what each one does, and why it matters for your site.
What Is a Heavy Duty Barrier Gate?
The HDCR gate is a sliding gate on a ground track, available as manually operated or motor operated, in a single-leaf construction. It is a heavy-duty, crash-rated barrier designed to resist deliberate or accidental vehicle attacks, not just to control access.
All gates in this range are described as factory tested and built under the TESCON brand name used in the catalogue.
Crash Rating and Impact Resistance
This is the defining feature of the range.
Impact resistance of 926 kN, which the catalogue states exceeds K12-L2.
In the closed position, the gate is designed to prevent penetration by a vehicle weighing 7.5 tons hitting it at 80 km/h.
A corresponding crash test was carried out according to PAS 68 N3 (18T rated).
Why it matters: PAS 68 is an internationally recognised standard for vehicle security barriers. A crash-test-backed rating means the gate has been proven against a real vehicle impact rather than just calculated on paper. For sites that face vehicle-borne threats or ram-raid attempts, or that must meet security audit requirements, this is the most important figure on the datasheet.
Frame Construction
The frame is the backbone of the gate. The catalogue specifies the following.
Bottom Rail
Made of RHS 500/300 (rectangular hollow section).
Fitted with reflective warning tape in red, with other colours or combinations available on request.
The bottom rail is deliberately massive because it absorbs and distributes impact energy at ground level, where a vehicle strikes first. The reflective tape improves visibility day and night, which helps drivers, security staff and CCTV see the gate leaf.
Side Stiles and Top Rail
Made of RHS 120/80.
These form the vertical and upper edges of the gate, giving the leaf a rigid, box-like frame that resists twisting under load.
Vertical Reinforcement Bars
Made of RHS 80/80.
These tie the top and bottom rails together and add stiffness across the width of the gate, so force from an impact is shared across the whole leaf.
Manual Gate Option
For manually operated gates, the inside of the bottom rail can be equipped with a special tooth rack, with provision for later gate motorisation. You can start with a manual gate and upgrade to motor operation later without replacing the gate leaf, which suits phased projects and budgets.
Frame Infill
Made of rectangular bars RHS 30/20, welded between the top and bottom rail.
Maximum clear distance of 120 mm between bars.
The infill keeps the gate see-through, so security staff can see what is on the other side. The narrow 120 mm spacing keeps the barrier practical for access control and blocks easy passage through the gaps.
Posts
The posts anchor the gate to the ground, and their strength is critical in an impact.
Guide Posts
Reinforced double guide posts made of steel RR 200/100.
Concreted in 550 mm in the foundation, with a minimum foundation depth of 800 mm.
Catch Post
Stands 500 mm above road level.
Made of U 100.
Concreted in 300 mm in the foundation.
The double guide posts hold the gate leaf as it slides and carry the load when a vehicle hits. The catch post receives the leading edge of the gate when it closes. The deep concrete foundations are what allow the gate to stay anchored under heavy impact.
Supporting Structures: Rollers and Ground Track
Special steel rollers, D160, on ball bearings (lifetime lubricated), installed within the bottom rail of the gate leaf.
A special steel ground track with concrete anchors carries the gate rollers.
Heavy gates need heavy-duty movement hardware. Lifetime-lubricated ball bearings reduce maintenance and keep the gate moving smoothly despite its weight. The anchored steel track keeps the gate aligned and supported over years of daily opening and closing.
Corrosion Protection
Galvanised and plastic coated, described as suitable for maritime and extreme weather conditions, according to the 4-S-Coating process.
Standard colour: stone grey, RAL 7030.
Other colours available on request.
This matters for ports, coastal facilities, refineries, and any site with heavy rain, humidity or industrial pollution. A gate that rusts loses strength over time, and the combined galvanised and plastic coating protects both the structure and its appearance.
Motor Driven Gates
For automated access, the HDCR gate can be supplied with a complete drive unit and control package.
Drive Unit Features
Feature | What it does |
Motor of adequate size | Sized to move the heavy gate leaf reliably |
3-phase 230/400 V, 50 Hz | Standard industrial power supply |
Lockable metal housing | Protects the drive and controls from tampering |
Pinion for tooth rack | Moves the gate along the rack on the leaf |
Self-blocking at open and closed positions | Holds the gate firmly in place without relying on power |
Emergency release | Lets the gate be moved manually during a power failure or emergency |
Friction clutch | Protects the drive and mechanism from overload |
Height adjustment | Allows precise setup and alignment |
Electronic braking | Brings the gate to a controlled stop |
Integrated electrical control | Built-in control system for operation |
Optional high-speed operation: An additional frequency converter is available for a higher gate speed of approximately 0.50 m/s, useful at busy entry points where waiting time matters.
Power supply flexibility: The gate can also operate with other power supplies. Please inform the manufacturer of the power supply available on your site.
Control Equipment and Accessories
Standard accessories supplied with the motorised gate:
One key switch (Open / Close / Emergency Stop) at the motor housing, for authorised manual control and emergency shutdown.
One fail-safe rubber buffer at the front leading edge, for accident prevention. It reduces the risk of injury or damage if the gate contacts a person or object.
Two light beam units, which detect obstructions in the gate path as a safety measure.
Additional equipment, such as loop detectors, traffic lights and others, is available on request. These let you integrate the gate into a full vehicle access control system with traffic management and vehicle detection.
Standards and Compliance
The catalogue states that all TESCON gates are factory tested and comply with the acknowledged rules of technology, especially:
89/392/EWG (CE): the European machinery safety directive
BGR 232: a German guideline for power-operated windows, doors and gates
DIN EN 13241: the European product standard for industrial, commercial and garage doors and gates
Together with the PAS 68 crash test, this shows the gate has been assessed for both impact performance and operational safety.
Where Are HDCR Gates Best Used?
Based on their features, these gates suit high-risk entry points such as:
Industrial plants, factories and refineries
Ports, logistics hubs and warehouses
Power stations and utilities
Data centres and critical infrastructure
Government, defence and diplomatic premises
Airports and large campuses
Quick Specification Summary
Parameter | Detail |
Gate type | Sliding gate on ground track, single leaf |
Operation | Manual or motor operated |
Impact resistance | 926 kN (exceeds K12-L2) |
Crash test | PAS 68 N3 (18T rated) |
Stopping capability | 7.5 ton vehicle at 80 km/h |
Bottom rail | RHS 500/300 with red reflective tape |
Side stiles and top rail | RHS 120/80 |
Vertical reinforcement | RHS 80/80 |
Infill | RHS 30/20, max 120 mm clear gap |
Guide posts | Double posts, steel RR 200/100 |
Catch post | U 100, 500 mm above road level |
Rollers | D160 steel, lifetime-lubricated ball bearings |
Coating | Galvanised and plastic coated (4-S-Coating), RAL 7030 stone grey |
Drive | 3-phase 230/400 V, 50 Hz; optional frequency converter (about 0.50 m/s) |
Compliance | 89/392/EWG (CE), BGR 232, DIN EN 13241 |
Final Thoughts
The Godrej HDCR Heavy Duty Barrier Gate combines a crash-tested frame, deeply anchored posts, durable rollers, marine-grade coating and a full set of safety controls. If your premises need protection against vehicle intrusion as well as unauthorised entry, this is a strong option.
Ready to secure your site? Contact us for a site assessment, specifications and a quotation tailored to your premises.
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