Body Armour Guide 2024

Understanding Body armour and its Purpose

What is body armour?

Body armour is a protective system, designed to protect the wearer from death and serious injury. The system is designed to cover the wearer’s major organs and to prevent penetration from weapons. Body armour is a defensive garment formulated to hinder or mitigate harm caused by weaponry like guns, knives, blades or other pointed elements. They utilize materials that block an attack, minimizing penetration and potential injury. By offering targeted protection to vital body parts, these enhancements further reduce the risk of injury in threatening situations.  Also, body armour can act as a visible deterrent, discouraging potential attackers and deescalating confrontations

The law relating to body armour

It’s not illegal to buy or sell body armour that isn’t certified by the Home Office – the onus is on the employer to ensure the protection is adequate. Every organisation has a duty of care to protect their staff under the Health & Safety at Work Act, and this includes issuing body armour to staff that are at risk. In addition, if an incident occurs where employees are not adequately protected, an employer can face industrial tribunals and compensation, and the Corporate Manslaughter and Corporate Homicide Act allow for unlimited fines and publicity orders.

Body armour Standards

Common standards include the British the Home Office Scientific Development Branch (HOSDB) and the American NIJ, with higher levels providing increased protection against more severe threats. NIJ IIIA and other NIJ standards are American standards which don’t apply to the UK market, which is regulated by the UK Home Office. From a protection point of view, aside from a CE Mark, the HOSDB standards are the only thing to look for. Be wary of body armour ‘made to’ Home Office standards – it must be tested and certified by the Home Office – ask for a certificate to be sure. Simply calling something ‘body armour’ or a ‘stab vest’ does not mean it provides any protection – this is why the Home Office standards are essential.

Also you should look for body armour that is CE Marked. Body armour for civilian use falls under European Council Directive 89/686/EEC on Personal Protective Equipment (PPE) which states that any armour sold to civilian users must be CE approved. Only Police and Military wearers are exempt from this PPE legislation.

Protection Levels Explained

UK organisations should purchase body armour to the appropriate HG, KR and SP Home Office standards. Your risk assessment will help you ascertain which level you need, but if you speak to you supplier about the job role you’re needing the body armour for, they should be able to advise which protection level similar organizations and job roles take as a guide, but this information isn’t a substitute for your own risk assessment – just a useful reassurance.

Home Office Standards for Knife and Spike Resistance:

• KR1 (Knife Resistance Level 1) and SP1 (Spike Resistance Level 1) are the levels of stab and spike protection recommended by the Home Office for general police duties.
• KR2 (Knife Resistance Level 2) and SP1 (Spike Resistance Level 2) are the levels of stab and spike protection recommended by the Home Office for more dangerous police duties, such as armed patrol in higher risk scenarios, for example patrolling at airports or escorting prisoners.

The different levels refer to the number of Joules of energy from a knife (KR) and spike (SP) thrust that a vest can withstand, tested mechanically in Home Office laboratory conditions.

KR1 = 24 joules

KR2 = 33 joules

Home Office Standards for Ballistic protection:

• HG1 (Handgun Resistance Level 1) is the level of protection recommended by the Home Office for general police duties where handguns may be encountered. This protects from standard ammunition fired from short-barrelled handguns.
• HG2 (Handgun Resistance Level 2) is the level of protection recommended by the Home Office for higher risk scenarios for tactical firearms teams, special forces operations and situations where submachine guns may be encountered. This protects against standard ammunition fired from long barrelled handguns, 9mm carbines and submachine guns.

Standards for Syringe and Blunt Trauma protection:

There is no Home Office standard or protection level for syringe or blunt trauma attacks, and many stab vests with Home Office KR1 (knife) and SP1 (spike) certification can still be penetrated by syringes. These are serious threats that need to be protected from; an attack from a knife, spiked object or gun presents a more serious threat of death or serious injury, but blunt trauma (blows from blunt objects such as baseball bats, bricks, kicks) is a more frequent threat for many staff, and because of its very fine needle point, a syringe will penetrate the majority of conventional body armour.. To protect from these widespread and increasing threats, look for a vest with specific syringe protection, and if in doubt ask your supplier to visit you to demonstrate.

Your risk assessment will help you ascertain which level you need, but if you speak to you supplier about the job role you’re needing the body armour for, they should be able to advise which protection level similar organizations and job roles take as a guide, but this information isn’t a substitute for your own risk assessment – just a useful reassurance.

Body Armour lifespan

KR1/SP1 armour plates tend to be under warranty for 10 years, and dual purpose (KR1 and HG1) are under warranty for 5 years. Some manufacturers are able to inspect and recertify dual purpose plates for a further 5 years in some instances. If the armour plates can be removed from the vests then the outer vests are usually under warranty for 12 months.

It is worth checking with your supplier whether they offer this inspection service, and also if they offer free replacements for damage in the line of duty. Another thing to consider is their Product Liability insurance, they should be able to provide information on this for you.

Common Misconceptions about Body armour

Some individuals may mistakenly believe that body armour provides complete invincibility or protection against all types of attacks, including bullets. No body armour can protect from all threats in all circumstances and there’s no such thing as “stab proof” or “bulletproof” – body armour is stab, spike or bullet resistant to a particular protection level. Body armour is designed to protect vital organs from an attack and help dissipate the force of the attack. It is crucial to recognize the limitations and proper use of body armour to make informed decisions regarding personal safety.

A lot of people believe that to get maximum, effective protection, body armour needs to be tailored and ‘made-to-measure’. This is simply not the case. 99% of wearers can safely and comfortably wear standard sizes, as good armour can be adjusted at several points so it fits even more closely. For very tall wearers, it’s advisable to purchase armour with extra length to ensure the lower internal organs are adequately covered. For wearers outside the standard sizes and some ladies who require a ‘D’ cup fitting or larger, special sizes may be necessary both from a comfort and protection point of view, and your supplier should be able to advise on this.

Exploring the different types and designs of body armour

Armour designs:

Flexible armour plates:

These are thin, flexible sheets of high-performance fibres cut into shape and assembled in layers to give flexibility, so the plates can bend and move with the wearer. They are beneficial for those that need to wear body armour for an extending period of time and/or those that will be in and out of vehicles.

The mechanics:
Body armour plates consist of multiple layers, each serving a specific purpose in stopping or slowing down a knife blade. The outer layer acts as a sacrificial layer, designed to snag or deform the weapon and disrupt its trajectory. Underneath, the layers are arranged to provide additional resistance, reducing the weapon’s ability to penetrate the vest and reach the wearer’s body. The layered construction ensures that even if one layer is compromised, the subsequent layers offer continued protection. Examples of the types of fibres used are aramid fibers (e.g., Kevlar) or ultra-high-molecular-weight polyethylene (e.g., Dyneema). These are commonly used due to their exceptional strength and resistance. These materials possess high tensile strength and are tightly woven or laminated to create a formidable barrier against weapons. The mechanics involve the absorption and distribution of energy from an attack, reducing the force applied to a concentrated area and dispersing it across a larger surface area.

Pros:
Unrivalled flexibility, weight and manoeuvrability.
Things to look out for:
Some flexible armour plates need a sealed protective layer to keep out moisture and water (which can cause damage to the fibres) but some are laminated which makes them resistant to the effects of moisture, water and UV light, so look out for the difference.  Also, make sure that the area of complete protection extends over the whole body armour, edge to edge – some flexible armour is “feathered” at the edges, which means that the area of complete protection may only be 80% or less of the total area

Hard/Rigid Style:

These are vests or tabards that look and feel like hard plastic, with no flexibility or manoeuvrability.

The mechanics:
All body armour used to be rigid or “hardened,” but most manufacturers have moved away from this style as technology has advanced. There are still products available that are rigid and these are usually made from materials such as carbon fibre or ceramic.

Pros:
Gives the same protection levels as flexible armour plates
Things to look out for:
Rigid armour is exactly that – it can inhibit movement when it counts, so manoeuvring away from threats may be more difficult for the wearer. Comfort may also be an issue when wearing for prolonged periods of time, or if spending time in vehicles/sitting down. Rigid armour is less likely to dissipate the impact of an attack which again could impede comfort as the impact force will be concentrated on a specific point.

Vest designs:

Overt:

These are to be worn over clothing, and are used by wearers that want it to be obvious that body armour is being worn. Overt vests can give an authoritative look, and are also handy if docking stations and/or branding and badges need to be added. They can include pockets, epaulette holders and radio loops, or they can be a simple tabard design if a more subtle look is required. Overt vests are handy for those that don’t need to wear body armour constantly throughout the day and they are easy to remove.

Covert:

Covert vests are to be worn underneath clothing so are not visible to onlookers. These are used by wearers that do not require their body armour to be seen/obvious, and if the wearer needs to have body armour on at all times this is a suitable option. Whilst they are designed to be worn underneath clothing, it’s recommended that a moisture-wicking top is worn between the vest and the skin to aide with comfort and breathability.

Help with choosing body armour

1. Analyse which threats your staff are likely to encounter
   
   Carry out a risk assessment considering the threats your staff may face. This means the threats that are found in your local area (consult with the police if possible) as well as the threats that are specific to their job.
   Are your staff at risk from knives and spikes? Is there also a risk from guns? Also consider the additional threats of blunt trauma and syringes.
2. Decide which home office protection level is required
   
   Is it just protection from knives and spikes, or is protection from guns also required?
   Please note not all stab vests provide protection from syringes and blunt trauma – check in with your supplier.
3. Choose a style
   
   Are you looking for a covert or overt style? Do you need pockets and epaulettes? An authoritative or more casual design?

Other factors worth considering

Adjustment points

It is worth looking for armour that has multiple adjustment points not only to help with overall comfort but also from a protection point of view. Being able to tighten or loosen body armour at the shoulders and sides allows for it to fit more closely to the wearers body shape. Body armour that has belt loops and lumbar (back) supports also aide with comfort as they can help with even weight distribution and can prevent the unit from riding up when performing duties.

Heat and moisture management

Conventional armour has the potential to break down when exposed to rain, sun perspiration or if stored in potentially moist environments such as car boots. Non-laminated body armour needs a sealed protective layer to keep out moisture and water so it is best to look for armour that is made using a laminated textile, as not only can heat and moisture affect its performance but it will be a contributing factor to uncomfortable armour – no one wants to wear something soggy. Moisture can also come from body heat, so it’s worthwhile looking for armour that have a heat management system that keeps sweat, heat and moisture away from the body. Our advanced heat management system maximises airflow and draws sweat away from the body, helping wearers to keep cool.

Weight

When it comes to body armour there does have to be some weight to the products due to their nature but it’s best to look at the overall picture. Only Home Office certified armour ensures proper protection, and technology can’t yet produce Home Office certified body armour that’s as thin and lightweight as normal clothing. If you research the lightest weight Home Office certified armour (with syringe and blunt trauma protection, if required), as well as considering other comfort factors such as armour flexibility and heat and moisture management, you’ll be doing everything you can to ensure your staffs comfort – without jeopardising their safety.

The weight of body armour does depend on the size required, but as an approximation based on our body armour, you would be looking at about 2kg-2.4kg per vest:

Armour plates: 1.5-1.8 kg (depending upon size)

Carrier/cover 0.5-0.6kg

Full unit 2.0-2.4 kg

Sizing and adjustment advice

The best way to ensure your staff order the right size is for them to try on a vest. Your supplier should be able to arrange for a sample on request.

How to adjust

It’s important when trying on body armour to adjust the vest as much as possible to ensure the right fit. We’ve put some general information below on how to adjust body armour to ensure it’s fitted correctly as well as for maximum comfort:

• Undo all adjustment points on the side and rear as well as the stomach strap and belt straps, and main zip (if applicable). Leave any shoulder adjustments closed for the time being.
• Put the vest on and fasten the stomach strap securely around the front.
• Fasten up the belt loops. (It is recommended that your trouser belt is threaded through the belt loops when worn to help with equal weight distribution)
• Ensure the front armour panel is positioned correctly and then fully close the main zip.
• Loosen any shoulder adjustments and adjust until the bottom of the body armour is in line with the navel. Both shoulders should be adjusted evenly, then secure.
• Secure the side/rear Velcro closures so that they are close-fitting and even on both sides. (There may well be a gap below the bottom of the body armour and the top of your trousers. This is normal and allows flexibility and movement.)

Body armour should be worn tight to the body, whilst still being comfortable to wear. The first time you adjust the body armour you may find it useful to get a friend or colleague to assist you.

Additional fitting help

If you have a member of staff that has tried on their usual size and adjusted as much as possible and they are still struggling with a comfortable fit, or they have concerns about the sizing, your supplier should be able to help guide you to the size that is needed. They’ll be able to advise what measurements and information they need in order to give you advice.

Special measures and bespoke sizes

Whilst we previously offered to measure customers, over the years it has become apparent that it’s actually more accurate for wearers to try on the armour directly. This way, wearers can ensure they get a comfortable snug fit in the actual armour rather than relying on body measurements. This makes the whole process a little easier for you, as you don’t need to arrange for all staff to be available on the same day for a measuring exercise and they can try the vests on when they are next on site.

Most ‘off-the-shelf’ armour is unisex, hence it is already designed with men and women in mind however, if the wearer requires a D cup fitting or above, it is recommended that specially made female fit armour would make it more comfortable for the wearer.

Female Fit Armour

From our experience, the majority of female wearers are comfortable in standard unisex fitting due to them being highly adjustable for all body shapes and don’t feel female fit body armour is needed, but every wearer is different, so we’ve put some information below on specially made female fit body armour to help in deciding if female fit body armour is required.

The material used in our armour plates are thin flexible sheets cut into shape and assembled in layers to give flexibility, so this means we can fold the layers over to create extra room where it’s needed, rather than having ‘cups’ or a moulded shape, which is how rigid armour is made. We use the same armour plates in our female fit vests as the unisex product. They carry the same level of protection and are not thinner as we are able to fold the layers over to create the extra room, nothing is removed. As our female fit vests are not produced using cups or moulding there is no noticeable shape or outline to them. As the layers in the plates are folded over the finish is as smooth as possible, with no visible points or protrusions.

We recommend that any wearers that are unsure whether they need one should try on a stock vest to ascertain which size they need e.g. S, M, L etc and then if they feel they would like extra room in the chest we will make whichever size they need e.g. an XL Female Fit. We wouldn’t make-to-measure as it were.  It really is personal preference though and it doesn’t affect the protection level; those that are larger than a D cup don’t have to have a Female Fit and they may be perfectly comfortable without needing a special make. This is why we recommend that any wearers that are unsure whether they need one should try on a stock vest first.

Tall Fit Armour

Tall Fit vests are made in exactly the same way as our stock vests, but with additional length in the body so all vital organs are protected. For anyone over 6ft 2” we would recommend ordering a tall Fit vest to ensure that the wearer has adequate protection

The plates are designed to prevent life ending or life changing injury by covering the vital organs, and our armour is fully certified and the profile and dimensions of the panels are correct for the corresponding size, so if you’re not over 6ft 2” and still order a Tall Fit, you will not gain any additional protection and will most likely find the vest uncomfortable as it will be too long for you.

Maintenance and Care, and factors that affect body armour performance

Proper maintenance and care are essential to keep stab vests in optimal condition. Regular inspections for wear and tear, adherence to manufacturer guidelines for cleaning and storage, and prompt repairs or replacements are crucial. Stab vests should be stored in a clean and dry environment to prevent degradation of materials and ensure their reliability when needed.

Below is some information on how to care and maintain your body armour for the entirety of its lifespan

How to wash/clean your body armour:

Outer Carrier

• Remove the armour plates and machine wash up to 40°.
• It’s best to air dry the carrier flat, but they can be tumble dried on a low setting if needed.

Armour Plates

• Clean by wiping with a cloth dampened with mild soapy water
• DO NOT immerse the armour inserts in water.
• DO NOT machine wash them.

How to care for your body armour:

• Put on, take off and store your vest with care. If possible store it flat without folding, or suspend it on a clothes hanger.
• During storage do not fold or compress.
• Inspect your vest regularly and if damage is seen or suspected contact your issuing authority immediately.
• When the armour plates are removed from the carrier (such as for inspection or cleaning) they must be re-inserted with the labels facing the body side. They are marked with ‘this side next to the body’. They are also labelled ‘front’ and ‘back’ to ensure they are inserted into the correct side.
• If your vest becomes wet such as after duty in wet weather, remove the armour inserts and allow all components to dry naturally with good ventilation away from strong artificial heat.

What to look for when inspecting your armour

The following are signs that your vest needs expert attention:

• A strong crease or fold in an armour insert through it having been folded and compressed during storage and not having been stored flat or suspended on a clothes hanger
• Fire or flood damage
• Torn casing of the armour plates
• Any other signs of physical damage to the armour plates
• Labels that have become detached, or faded as to be illegible
• The armour plates are older than 10 years.