How Are Padlocks Attack-Tested for Security Ratings?

When choosing a padlock, the security rating is often the most important factor. Insurance companies frequently require locks to meet specific standards, and those standards are based on how well a padlock can withstand real-world attacks. To earn these ratings, padlocks must undergo rigorous strength and durability testing before they are released to the market.

How Manufacturers Test Padlock Security

Major lock manufacturers, such as ABUS, Squire and Abloy, operate dedicated testing facilities. These aren’t simple “pull tests.” The padlocks are subjected to controlled, repeatable attack simulations that mirror the tools and methods a thief might use.

Common tests include:

• Impact testing to simulate repeated hammer strikes

• Force twisting using mechanical levers similar to crowbars

• Cutting and bolt cropping tests on shackles and bodies

• Weather and corrosion resistance tests for outdoor and marine use

• Pick and manipulation resistance of the cylinder or combination mechanism

This ensures the lock doesn't just look strong — it performs under realistic attack conditions.

The ABUS Test Facility Demonstration

In the video below, we visited the ABUS strength testing facility in Germany to see the process firsthand. Engineers demonstrated:

• A hammer swing machine that strikes the lock repeatedly with high force

• A long-arm torque tool that applies rotational force to simulate twisting a lock off a gate or hasp

These tests help determine whether a padlock meets specific insurance grades such as CEN 3, 4, 5 or 6. Higher grades must withstand significantly greater force and multiple forms of attack.

Understanding What the Results Mean

It’s important to remember:

• A higher CEN grade does not just mean “slightly stronger” — each step up represents a very large jump in resistance.

• Two padlocks of similar size may perform very differently under attack.

• A padlock that appears heavy or “chunky” may not necessarily meet any tested security grade.

Choosing a properly rated lock gives confidence that it has been engineered to survive realistic break-in attempts.

When to Choose a Tested, Rated Padlock

Rated padlocks are recommended for:

• Business premises

• Storage units

• Commercial gates

• Boats and coastal equipment

• High-value machinery

• Sites where insurance compliance is required

If your insurer has specified a minimum rating, always ensure the lock clearly states its tested grade.