U.S. Department of Justice

Office of Justice Programs

JUL

National Institute of Justice

Y 08

STANDARDS

Ballistic Resistance of Body Armor

NIJ Standard-0101.06

www.ojp.usdoj.gov/nij
U.S. Department of Justice 

Office of Justice Programs 

810 Seventh Street N.W. 

Washington, DC 20531 

Michael B. Mukasey 

Attorney General 

Jeffrey L. Sedgwick 

Acting Assistant Attorney General 

David W. Hagy 

Director, National Institute of Justice 

This and other publications and products of the National Institute 

of Justice can be found at: 

National Institute of Justice 

www.ojp.usdoj.gov/nij 

Office of Justice Programs 

Innovation • Partnerships • Safer Neighborhoods 

www.ojp.usdoj.gov 
ABOUT THE LAW ENFORCEMENT AND CORRECTIONS 

STANDARDS AND TESTING PROGRAM 

The Standards and Testing Program is sponsored by the Office of Science and Technology of 

the National Institute of Justice (NIJ), Office of Justice Programs, U.S. Department of Justice. 

The program responds to the mandate of the Homeland Security Act of 2002, which directed the 

Office of Science and Technology to establish and maintain performance standards in 

accordance with the National Technology Transfer and Advancement Act of 1995 (Public Law 

104–113) to test and evaluate law enforcement technologies that may be used by Federal, State, 

and local law enforcement agencies. The Homeland Security Act of 2002 also directed the Office 

of Science and Technology to establish and maintain a program to certify, validate, and mark or 

otherwise recognize law enforcement technology products that conform to the standards 

mentioned above. 

The Standards and Testing Program is a basic and applied research effort that determines the 

technological needs of justice system agencies, sets minimum performance standards for specific 

devices, tests commercially available equipment against those standards, and disseminates the 

standards and the test results to criminal justice agencies nationally and internationally. 

The Office of Law Enforcement Standards (OLES) at the National Institute of Standards and 

Technology develops voluntary national performance standards for compliance testing to ensure 

that individual items of equipment are suitable for use by criminal justice agencies. The 

standards are based upon laboratory testing and evaluation of representative samples of each 

item of equipment to determine the key attributes, develop test methods, and establish minimum 

performance requirements for each essential attribute. In addition to the technical standards, 

OLES also produces technical reports and user guidelines that explain in nontechnical terms the 

capabilities of available equipment. 

The National Law Enforcement and Corrections Technology Center (NLECTC), operated by 

a grantee, coordinates a national compliance testing program conducted by independent 

laboratories. The standards developed by OLES serve as performance benchmarks against which 

commercial equipment is measured. 

Publications are available at no charge through NLECTC. Some documents are also available 

online at https://www.justnet.org/justnet.html. To request a document or additional information, 

call 800–248–2742 or 301–519–5060, or write: 

National Law Enforcement and Corrections Technology Center 

2277 Research Boulevard, Mailstop 8J 

 Rockville, MD 20850 

 E-mail: asknlectc@nlectc.org

World Wide Web address: http://www.justnet.org

The National Institute of Justice is a component of the Office of Justice Programs, which also 

includes the Bureau of Justice Assistance, the Bureau of Justice Statistics, the Community Capacity 

Development Office, the Office for Victims of Crime; the Office of Juvenile Justice and 

Delinquency Prevention, and the Office of Sex Offender Sentencing, Monitoring, Apprehending, 

Registering, and Tracking (SMART). 

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ii 
U.S. Department of Justice 

 Office of Justice Programs 

 National Institute of Justice 

Ballistic Resistance of Body Armor 

NIJ Standard–0101.06 

Supersedes: 

NIJ 2005 Interim Requirements, Ballistic Resistance of Body Armor (August 2005) 

Also supersedes: 

NIJ Standard–0101.04 Rev. A, Ballistic Resistance of Personal Body Armor (June 2001) 

Coordination by: 

Office of Law Enforcement Standards 

National Institute of Standards and Technology 

Gaithersburg, MD 20899–8102 

Prepared for: 

National Institute of Justice 

Office of Science and Technology 

Washington, DC 20531 

July 2008 

NCJ 223054 

iii 
iv 

NATIONAL INSTITUTE OF JUSTICE

David Hagy 

Director 

John Morgan 

Deputy Director for Science and Technology 

Marc Caplan 

Chief, Operational Technologies Division 

Debra Stoe 

Physical Scientist, Operational Technologies Division 

The technical effort to develop this standard was conducted under 

Interagency Agreement 2003–IJ–R–029. 

This standard was formulated by the Office of Law Enforcement Standards (OLES) of the 

National Institute of Standards and Technology (NIST). The participants in the research and 

revision of this standard were: 

Kirk Rice, Program Manager, Weapons and Protective Systems 

Michael A. Riley, Program Manager, Weapons and Protective Systems, Testing and Evaluation 

Amanda Forster, Materials Research Engineer 

The preparation of this standard was sponsored by the National Institute of Justice. 
FOREWORD

This document, NIJ Standard–0101.06, “Ballistic Resistance of Body Armor,” is a 

minimum performance standard developed in collaboration with the Office of Law Enforcement 

Standards (OLES) of the National Institute of Standards and Technology (NIST). It is produced 

as part of the Standards and Testing Program of the National Institute of Justice (NIJ), Office of 

Justice Programs, U.S. Department of Justice. This standard is a technical document that 

specifies the minimum performance requirements that equipment must meet to satisfy the 

requirements of criminal justice agencies and the methods that shall be used to test this 

performance. This standard is used by the NIJ Voluntary Compliance Testing Program (CTP) to 

determine which body armor models meet the minimum performance requirements for inclusion 

on the NIJ Compliant Products List. In addition, manufacturers, criminal justice agencies, and 

others may use the tests described in this standard to determine whether a particular armor design 

meets their own requirements. Users are strongly encouraged to have this testing conducted in 

accordance with the NIJ CTP. Procurement officials may also refer to this standard in their 

purchasing documents and require that equipment offered for purchase meet or exceed these 

requirements. 

This document is a testing and performance standard and provides precise and detailed 

test methods. Additional requirements, processes, and procedures for CTP participants are 

detailed in the NIJ Voluntary CTP Administrative Procedures Manual. Those seeking guidance 

concerning the selection and application of body armor should refer to the most recent revision 

of the Selection and Application Guide to Personal Body Armor, NIJ Guide 100, which is 

published as a separate document and explains in nontechnical language how to select equipment 

that provides the level of performance required by a purchasing agency. 

Publication of this revision of the standard does not invalidate or render 

unsuitable any body armor models previously determined by NIJ to be 

compliant to either the NIJ 2005 Interim Requirements or the NIJ Standard–

0101.04 Rev. A Requirements. While it may not necessary to remove these 

existing armors from service, agencies are advised to always require their 

procurements to meet or exceed the most recent and up-to-date version of 

this standard. 

Personal body armor that is independently tested to this standard by 

manufacturers, purchasers, or other parties will not be considered as NIJ compliant 

unless the body armor is submitted and tested through the NIJ CTP and found in 

compliance with this standard. 

When manufacturers seek NIJ compliance of their armor to this standard and the 

armor contains unique materials or forms of construction that may not have been 

anticipated when this standard was drafted, NIJ may modify the test methods of the 

standard to take those features into account. If NIJ determines that the model meets 

the requirements of the standard, modified test methods, and the NIJ CTP, NIJ will 

include the armor on the NIJ Compliant Products List. 

v 
NIJ standards are subjected to continued research, development, testing, review, and 

revision. This standard and its successors will be re-evaluated and modified as necessary. 

Because of ongoing advancements in ballistic-resistant materials, changes to armor designs and 

manufacturing techniques, and improvements in testing methods, NIJ reserves the right to 

withhold NIJ compliance status for body armor that meets the current requirements but is 

deemed by NIJ to pose a risk to officer safety. NIJ also reserves the right to alter or modify 

existing test methods and/or requirements to address perceived weaknesses in varying designs of 

body armor submitted for inclusion on the NIJ Compliant Products List. 

Technical comments and recommended revisions are welcome. Please send all written 

comments and suggestions to the Deputy Director, Office of Science and Technology, National 

Institute of Justice, Office of Justice Programs, U.S. Department of Justice, 810 Seventh Street, 

NW, Washington, DC 20531. Before citing this or any other NIJ standard in a contract 

document, users should verify that the most recent edition of the standard is used. The most 

recent edition will be available on the Justice Technology Information Network (JUSTNET) at 

http://www.justnet.org, or write to the Director, Office of Law Enforcement Standards, National 

Institute of Standards and Technology, 100 Bureau Drive, Stop 8102, Gaithersburg, MD 20899. 

John Morgan, Deputy Director for Science and 

Technology, National Institute of Justice 

vi 
CONTENTS

Foreword......................................................................................................................................... v 

Commonly Used Symbols And Abbreviations.............................................................................. xi 

1. Purpose And Scope ................................................................................................................. 1 

2. NIJ Body Armor Classification............................................................................................... 3 

2.1 Type IIA (9 mm; .40 S&W)............................................................................................ 3 

2.2 Type II (9 mm; .357 Magnum) ....................................................................................... 3 

2.3 Type IIIA (.357 SIG; .44 Magnum)................................................................................ 3 

2.4 Type III (Rifles).............................................................................................................. 4 

2.5 Type IV (Armor Piercing Rifle) ..................................................................................... 4 

2.6 Special Type.................................................................................................................... 4 

3. Definitions............................................................................................................................... 5 

4. Sample Requirements and Laboratory Configuration........................................................... 11 

4.1 Test Samples................................................................................................................. 11 

4.1.1 Flexible Vests and Jackets.............................................................................. 11 

4.1.2 Hard Armors and Plate Inserts........................................................................ 12 

4.1.3 Accessory Ballistic Panels.............................................................................. 17 

4.1.4 Workmanship.................................................................................................. 17 

4.1.5 Labeling .......................................................................................................... 17 

4.1.6 Armor Carriers With Removable Ballistic Panels.......................................... 20 

4.1.7 Armors With Built-In Inserts or Trauma Packs.............................................. 20 

4.2 Laboratory Configuration and Test Equipment ............................................................ 20 

4.2.1 Range Configuration....................................................................................... 20 

4.2.2 Test Rounds and Barrels................................................................................. 22 

4.2.3 Velocity Measurement Equipment ................................................................. 22 

4.2.4 Armor Submersion Equipment ....................................................................... 23 

4.2.5 Armor Backing Material................................................................................. 23 

5. Flexible Armor Conditioning Protocol.................................................................................. 27 

5.1 Purpose and Scope ........................................................................................................ 27 

5.2 Pretest Parameters......................................................................................................... 27 

5.2.1 Storage of Armors........................................................................................... 27 

5.2.2 Pretest Calibrations......................................................................................... 27 

5.2.3 Test Conditions............................................................................................... 27 

5.3 Laboratory Configuration and Test Equipment ............................................................ 28 

5.3.1 General Parameters......................................................................................... 28 

5.3.2 Controls........................................................................................................... 29 

5.3.3 Test Interruption.............................................................................................. 29 

5.3.4 Procedure ........................................................................................................ 30 

6. Hard Armor Conditioning Protocol....................................................................................... 33 

6.1 Purpose and Scope ........................................................................................................ 33 

6.2 Pretest Parameters......................................................................................................... 33 

6.2.1 Storage of Armors........................................................................................... 33 

6.2.2 Pretest Calibrations......................................................................................... 33 

6.2.3 Test Conditions............................................................................................... 33 

6.3 Laboratory Configuration and Test Equipment ............................................................ 35 

vii 
6.3.1 General Parameters......................................................................................... 35 

6.3.2 Controls........................................................................................................... 35 

6.3.3 Test Interruption.............................................................................................. 35 

6.3.4 Conditioning Procedure .................................................................................. 36 

7. Ballistic Test Methods........................................................................................................... 39 

7.1 Purpose and Scope ........................................................................................................ 39 

7.2 Test Order ..................................................................................................................... 39 

7.3 Workmanship Examination .......................................................................................... 39 

7.3.1 Armor Carriers and Ballistic Panel Covers..................................................... 39 

7.3.2 Ballistic Panels................................................................................................ 39 

7.3.3 Label Examination.......................................................................................... 39 

7.4 Sampling ....................................................................................................................... 40 

7.5 Sample Acclimation...................................................................................................... 40 

7.5.1 Inserts.............................................................................................................. 40 

7.6 Fair Hit Requirements for All Ballistic Tests............................................................... 40 

7.6.1 Minimum Shot-to-Edge Distance ................................................................... 40 

7.6.2 Minimum Shot-to-Shot Distance .................................................................... 40 

7.7 Backing Material Preparation and Sample Mounting for All Ballistic Tests............... 41 

7.7.1 Backing Material Fixture Preparation............................................................. 41 

7.7.2 Mounting Armor for Ballistic Testing ............................................................ 41 

7.8 Perforation and Backface Signature Test (P-BFS) ....................................................... 43 

7.8.1 Shot Location Marking ................................................................................... 43 

7.8.2 Armor Submersion.......................................................................................... 45 

7.8.3 Test Threats for P-BFS Tests.......................................................................... 45 

7.8.4 Test Duration .................................................................................................. 45 

7.8.5 Requirements for Number of Shots and Number of Armor Samples............. 45 

7.8.6 P-BFS Test for Special Type Armor............................................................... 49 

7.8.7 P-BFS Test for Accessory Ballistic Panels..................................................... 49 

7.8.8 P-BFS Performance Requirements................................................................. 49 

7.9 Ballistic Limit (BL) Determination Test....................................................................... 50 

7.9.1 Requirements for Number of BL Tests and Test Samples ............................. 51 

7.9.2 Test Procedure Requirements......................................................................... 51 

7.9.3 Backing Material Conditioning....................................................................... 52 

7.9.4 Data Set Tabulation......................................................................................... 52 

7.9.5 Ballistic Limit Performance Requirements..................................................... 52 

8. References............................................................................................................................. 53 

APPENDIX A –Acceptable Bullets for Handloading .................................................................. 55 

APPENDIX B –Common Special Type Threats.......................................................................... 57 

APPENDIX C –Armor Sizing Templates..................................................................................... 59 

APPENDIX D –Analysis of Backface Signature Data................................................................. 65 

APPENDIX E –Analysis of Ballistic Limit Data ......................................................................... 69 

APPENDIX F –Explanatory Materials......................................................................................... 71 

viii 
TABLES

Table 1. Armor samples required for each test threat (flexible vests and jackets)....................... 11 

Table 2. Uniform thermal exposure conditions............................................................................ 33 

Table 3. Thermal cycle testing conditions.................................................................................... 34 

Table 4. P-BFS performance test summary .................................................................................. 46 

Table 5. Number of shots and fair hits on each size of new condition armor samples................. 47 

Table 6. Number of shots and fair hits on each size of conditioned samples............................... 47 

Table 7. Angle of incidence locations........................................................................................... 48 

Table 8. Baseline ballistic limit determination test summary....................................................... 50 

Table 9. Test parameters and requirements for ballistic limit test................................................ 51 

Table 10. Acceptable bullets......................................................................................................... 55 

Table 11. Special type threats of particular concern to law enforcement..................................... 58 

Table 12. Surface areas of armor sizing templates....................................................................... 59 

Table 13. Minimum allowable surface areas for production armor.............................................. 59 

Table 14. Maximum allowable surface areas for production armor............................................. 59 

Table 15. k Factors for 80 % Probability with 95 % Confidence........................................... 67 

ix 
FIGURES

Figure 1. Angle of incidence........................................................................................................... 5 

Figure 2. Examples of BFS measurements..................................................................................... 6 

Figure 3. Sample quantity and utilization for armor Types IIA, II, and IIIA ............................... 14 

Figure 4. Sample quantity and utilization for flexible armor of Type III, Type IV, and Type 

Special........................................................................................................................................... 15 

Figure 5. Sample quantity and utilization for hard armors and plate inserts of Type III.............. 16 

Figure 6. Sample quantity and utilization for hard armors and plate inserts of Type IV ............. 16 

Figure 7. Example label for test samples...................................................................................... 19 

Figure 8. Test range configuration................................................................................................ 21 

Figure 9. General pretest drop locations....................................................................................... 25 

Figure 10. Flexible armor conditioning test interruption flow chart ............................................ 31 

Figure 11. Test interruption flowchart for hard armor.................................................................. 37 

Figure 12. Proposed mechanical durability test apparatus ........................................................... 38 

Figure 13. Acceptable strapping methods..................................................................................... 42 

Figure 14. General armor panel impact locations (front and back).............................................. 44 

x 
xi 

STANDARD SPECIFIC ABBREVIATIONS

ACP = Automatic Colt Pistol LR = Long Rifle 

ANSI = American National Standards Institute LRN = Lead Round Nose 

AP = Armor Piercing NLECTC = 

BFS = Backface Signature 

National Law Enforcement and Corrections 

Technology Center 

BL = Ballistic Limit P-BFS = Perforation and Backface Signature 

CPO = Compliance Program Office RN = Round Nose 

CTP = Compliance Testing Program S&W = Smith & Wesson 

CTR = Compliance Test Report SAAMI = 

FMJ = Full Metal Jacket 

Sporting Arms and Ammunition 

Manufacturers’ Institute 

ISO = International Standards Organization 

JHP = Jacketed Hollow Point SJHP = Semi Jacketed Hollow Point 

JSP = Jacketed Soft Point SJSP = Semi Jacketed Soft Point 

COMMONLY USED SYMBOLS AND ABBREVIATIONS

A ampere H henry nm nanometer 

ac alternating current h hour No. number 

AM amplitude modulation hf high frequency o.d. outside diameter 

cd candela Hz hertz Ω ohm 

cm centimeter i.d. inside diameter p. page 

CP chemically pure in inch Pa pascal 

c/s cycle per second IR infrared pe probable error 

d day J joule pp. pages 

dB decibel L lambert ppm parts per million 

dc direct current L liter qt quart 

°C degree Celsius Lb pound rad radian 

°F degree Fahrenheit lbf pound force rf radio frequency 

diam diameter lbf⋅in pound force inch rh relative humidity 

emf electromotive force lm lumen s second 

eq equation ln logarithm (base e) SD standard deviation 

F farad log logarithm (base 10) sec. section 

fc footcandle M molar SWR standing wave ratio 

fig. figure m meter uhf ultrahigh frequency 

FM frequency modulation min. minute UV ultraviolet 

ft foot mm millimeter V volt 

ft/s foot per second mph miles per hour vhf very high frequency 

g acceleration m/s meter per second W watt 

g gram N newton λ wavelength 

gr grain N⋅m newton meter wt weight 

area = unit2

 (e.g., ft2, in2, etc.); volume = unit3 (e.g., ft3, m3, etc.) 

PREFIXES

d deci (10-1) da deka (10) 

c centi (10-2) h hecto (102

) 

m milli (10-3) k kilo (103

) 

μ micro (10-6) M mega (106

) 

n nano (10-9) G giga (109

) 

p pico (10-12) T tera (1012) 

COMMON CONVERSIONS

(See ASTM E380) 

0.30480 m = 1 ft 4.448222 N = 1 lbf 

2.54 cm = 1 in 1.355818 J = 1 ft⋅lbf 

0.4535924 kg = 1 lb 0.1129848 N.m = 1 lbf⋅in 

0.06479891 g = 1 gr 14.59390 N/m = 1 lbf/ft 

0.9463529 L = 1 qt 6894.757 Pa = 1 lbf/in2

3600000 J = 1 kW⋅h 1.609344 km/h = 1 mph 

Temperature: T°C = (T°F - 32) × 5/9 

Temperature: T°F = (T°C × 9/5) + 32 
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 xii 
NIJ STANDARD–0101.06 

FOR 

BALLISTIC RESISTANCE OF BODY ARMOR 

1. PURPOSE AND SCOPE

The purpose of this standard is to establish minimum performance requirements and test 

methods for the ballistic resistance of personal body armor intended to protect against gunfire. 

This standard is a revision of NIJ Standard–0101.04, dated September 2000. It supersedes 

the NIJ 2005 Interim Requirements, dated September 2005, NIJ Standard–0101.04, and all other 

revisions and addenda to NIJ Standard–0101.04. 

The scope of the standard is limited to ballistic resistance only; this standard does not 

address threats from knives and sharply pointed instruments, which are different types of threats 

and are addressed in the current version of NIJ Standard–0115 Stab Resistance of Personal Body 

Armor. 

Body armor manufacturers and purchasers may use this standard to help to determine 

whether specific armor models meet the minimum performance standards and test methods 

identified in this document. However, NIJ strongly encourages body armor manufacturers to 

participate in the NIJ Voluntary Compliance Testing Program (CTP) and encourages purchasers 

to insist that the armor model(s) they purchase be tested by the NIJ CTP and be listed on the NIJ 

Compliant Products List. This will help to assure that the armor models will meet the minimum 

performance standards for use by the criminal justice community. 

The ballistic tests described in this standard have inherent hazards. Adequate safeguards 

for personnel and property must be employed when conducting these tests. 

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2. NIJ BODY ARMOR CLASSIFICATION

Personal body armor covered by this standard is classified into five types (IIA, II, IIIA, 

III, IV) by level of ballistic performance. In addition, a special test class is defined to allow 

armor to be validated against threats that may not be covered by the five standard classes. 

The classification of an armor panel that provides two or more levels of NIJ ballistic 

protection at different locations on the ballistic panel shall be that of the minimum ballistic 

protection provided at any location on the panel. 

2.1 Type IIA (9 mm; .40 S&W) 

Type IIA armor that is new and unworn shall be tested with 9 mm Full Metal Jacketed 

Round Nose (FMJ RN) bullets with a specified mass of 8.0 g (124 gr) and a velocity of 373 m/s 

± 9.1 m/s (1225 ft/s ± 30 ft/s) and with .40 S&W Full Metal Jacketed (FMJ) bullets with a 

specified mass of 11.7 g (180 gr) and a velocity of 352 m/s ± 9.1 m/s (1155 ft/s ± 30 ft/s). 

Type IIA armor that has been conditioned shall be tested with 9 mm FMJ RN bullets with 

a specified mass of 8.0 g (124 gr) and a velocity of 355 m/s ± 9.1 m/s (1165 ft/s ± 30 ft/s) and 

with .40 S&W FMJ bullets with a specified mass of 11.7 g (180 gr) and a velocity of 325 m/s ± 

9.1 m/s (1065 ft/s ± 30 ft/s). 

2.2 Type II (9 mm; .357 Magnum) 

Type II armor that is new and unworn shall be tested with 9 mm FMJ RN bullets with a 

specified mass of 8.0 g (124 gr) and a velocity of 398 m/s ± 9.1 m/s (1305 ft/s ± 30 ft/s) and with 

.357 Magnum Jacketed Soft Point (JSP) bullets with a specified mass of 10.2 g (158 gr) and a 

velocity of 436 m/s ± 9.1 m/s (1430 ft/s ± 30 ft/s). 

Type II armor that has been conditioned shall be tested with 9 mm FMJ RN bullets with a 

specified mass of 8.0 g (124 gr) and a velocity of 379 m/s ±9.1 m/s (1245 ft/s ± 30 ft/s) and with 

.357 Magnum JSP bullets with a specified mass of 10.2 g (158 gr) and a velocity of 408 m/s ±9.1 

m/s (1340 ft/s ± 30 ft/s). 

2.3 Type IIIA (.357 SIG; .44 Magnum) 

Type IIIA armor that is new and unworn shall be tested with .357 SIG FMJ Flat Nose 

(FN) bullets with a specified mass of 8.1 g (125 gr) and a velocity of 448 m/s ± 9.1 m/s (1470 

ft/s ± 30 ft/s) and with .44 Magnum Semi Jacketed Hollow Point (SJHP) bullets with a specified 

mass of 15.6 g (240 gr) and a velocity of 436 m/s ± 9.1 m/s (1430 ft/s ± 30 ft/s). 

Type IIIA armor that has been conditioned shall be tested with .357 SIG FMJ FN bullets 

with a specified mass of 8.1 g (125 gr) and a velocity of 430 m/s ± 9.1 m/s (1410 ft/s ± 30 ft/s) 

and with .44 Magnum SJHP bullets with a specified mass of 15.6 g (240 gr) and a velocity of 

408 m/s ± 9.1 m/s (1340 ft/s ± 30 ft/s). 

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 4 

2.4 Type III (Rifles) 

Type III hard armor or plate inserts shall be tested in a conditioned state with 7.62 mm 

FMJ, steel jacketed bullets (U.S. Military designation M80) with a specified mass of 9.6 g (147 

gr) and a velocity of 847 m/s ± 9.1 m/s (2780 ft/s ± 30 ft/s). 

Type III flexible armor shall be tested in both the “as new” state and the conditioned state 

with 7.62 mm FMJ, steel jacketed bullets (U.S. Military designation M80) with a specified mass 

of 9.6 g (147 gr) and a velocity of 847 m/s ± 9.1 m/s (2780 ft/s ± 30 ft/s). 

 For a Type III hard armor or plate insert that will be tested as an in conjunction design, 

the flexible armor shall be tested in accordance with this standard and found compliant as a 

stand-alone armor at its specified threat level. The combination of the flexible armor and hard 

armor/plate shall then be tested as a system and found to provide protection at the system’s 

specified threat level. NIJ-approved hard armors and plate inserts must be clearly labeled as 

providing ballistic protection only when worn in conjunction with the NIJ-approved flexible 

armor system with which they were tested. 

2.5 Type IV (Armor Piercing Rifle) 

Type IV hard armor or plate inserts shall be tested in a conditioned state with .30 caliber 

armor piercing (AP) bullets (U.S. Military designation M2 AP) with a specified mass of 10.8 g 

(166 gr) and a velocity of 878 m/s ± 9.1 m/s (2880 ft/s ± 30 ft/s). 

Type IV flexible armor shall be tested in both the “as new” state and the conditioned state 

with .30 caliber AP bullets (U.S. Military designation M2 AP) with a specified mass of 10.8 g 

(166 gr) and a velocity of 878 m/s ± 9.1 m/s (2880 ft/s ± 30 ft/s). 

 For a Type IV hard armor or plate insert that will be tested as an in conjunction design, 

the flexible armor shall be tested in accordance with this standard and found compliant as a 

stand-alone armor at its specified threat level. The combination of the flexible armor and hard 

armor/plate shall then be tested as a system and found to provide protection at the system’s 

specified threat level. NIJ-approved hard armors and plate inserts must be clearly labeled as 

providing ballistic protection only when worn in conjunction with the NIJ-approved flexible 

armor system with which they were tested. 

2.6 Special Type 

A purchaser having a special requirement for a level of protection other than one of the 

above standard types and threat levels should specify the exact test round(s) and reference 

measurement velocities to be used and indicate that this standard shall govern all other aspects. 

Guidance on common special type threats and the appropriate threat velocities is provided in 

appendix B, along with a methodology for determining the correct reference velocity for other 

threats. 
3. DEFINITIONS

3.1 Absolute Humidity: The quantity of water in a given volume of air, often reported in 

grams per cubic meter. 

3.2 Accessory Ballistic Panels: Accessory panels are armor components that are detachable or 

removable from the primary body armor sample and are intended to provide comparable 

ballistic protection. Examples of accessory panels include groin, coccyx, and side 

protection panels, which are attached to or inserted into the external armor carrier but are 

not integral to the armor panels or armor sample. 

3.3 Angle of Incidence: The angle between the bullet’s line of flight and the perpendicular to 

the front surface of the backing material fixture as shown in figure 1. 

BULLET LINE OF FLIGHT 

ANGLE OF INCIDENCE 

BACKING MATERIAL FIXTURE 

ARMOR SAMPLE 

PERPENDICULAR TO FRONT 

SURFACE OF BACKING MATERIAL 

FRONT SURFACE OF BACKING MATERIAL

Figure 1. Angle of incidence 

3.4 Armor Carrier: A component of the armor sample or armor panel whose primary purpose 

is to retain the ballistic panel and provide a means of supporting and securing the armor 

garment to the user. Generally, the carrier is not ballistic resistant. 

3.5 Armor Conditioning: Environmental and mechanical conditioning of armor prior to 

ballistic testing, which consists of exposure to specified conditions of temperature, 

humidity, and mechanical damage. 

3.6 Armor Panel or Panel: The portion of an armor sample that consists of an external 

ballistic cover and its internal ballistic panel. The word “panel,” if not preceded by the 

word “ballistic,” refers to an armor panel in this standard. 

3.7 Armor Sample: One complete armor garment. Typically, a front armor panel, a back 

armor panel, and the armor carrier comprise a body armor sample. The armor sample may 

be a single wraparound style or consist of multiple parts that are worn around the body. 

3.8 Backface Signature (BFS): The greatest extent of indentation in the backing material 

caused by a nonperforating impact on the armor. The BFS is the perpendicular distance 

between two planes, both of which are parallel to the front surface of the backing material 

 5 
fixture. One plane contains the reference point on the original (pretest) backing material 

surface that is co-linear with the bullet line of flight. (If armor were not present, the bullet 

would strike this point.) The other plane contains the point that represents the deepest 

indentation in the backing material. Depending on bullet–armor–backing material 

interactions, the two points that define the locations of the measurement planes may not be 

co-linear with the bullet line of flight. Examples of how BFS is measured are shown in 

figure 2. 

Figure 2. Examples of BFS measurements 

3.9 Backing Material: A homogenous block of nonhardening, oil-based modeling clay placed 

in contact with the back of the armor panel during ballistic testing. 

3.10 Backing Material Fixture: A box-like rigid frame, with a removable back, which contains 

the backing material. The removable back is used for perforation-backface signature testing 

but is not used for ballistic limit testing. 

3.11 Ballistic Limit: For a given bullet type, the velocity at which the bullet is expected to 

perforate the armor 50 % of the time. The ballistic limit is typically denoted as the V50 or 

V50 value. 

 6 
3.12 Ballistic Panel: The protective component of an armor sample or armor panel, consisting 

primarily of ballistic resistant materials. The ballistic panel is usually enclosed in a nonremovable panel cover, which is considered part of the ballistic panel. The ballistic panel is 

normally enclosed within an armor carrier. 

3.13 Baseline Ballistic Limit: The experimentally derived ballistic limit of an armor model 

when new. 

3.14 Body Armor: An item of personal protective equipment that provides protection against 

specific ballistic threats within its coverage area. In this standard, the term body armor 

refers to that which provides coverage primarily for the torso. 

3.15 Complete Penetration: This nomenclature is no longer used in this standard. See 

“perforation.” Perforation replaces complete penetration. Although the terms partial 

penetration and complete penetration are no longer used in this standard, they may still be 

used by test laboratories for compatibility with military standards. 

3.16 Compliance Test Group: A group of armor samples submitted for testing according to this 

standard. 

3.17 Condensation: Precipitation of water vapor on a surface whose temperature is lower than 

the dew point of the ambient air. The dew point depends on the quantity of water vapor in 

the air. The dew point, the absolute humidity, and the vapor pressure are directly 

interdependent. Condensation occurs on a test item when the temperature at the surface of 

the item placed in the test chamber is lower than the dew point of the air in the chamber. As 

a result, the item may need to be preheated to prevent condensation. 

3.18 Dewpoint (or dew point): The temperature to which a parcel of air must be cooled (at 

constant barometric pressure) for water vapor present in the air to condense into water 

(dew). 

3.19 Fair Hit: The impact of a bullet on an armor panel that meets the shot spacing and velocity 

requirements of section 7.6. 

3.20 Flexible Body Armor: Body armor constructed of pliable, textile-based materials such that 

the complete system is capable of being flexed. Such systems are typically in the form of 

vests or jackets that provide greater coverage area than rigid plate armor. Generally, these 

armors provide protection against handgun threats. 

3.21 Full Metal Jacketed Bullet (FMJ): A bullet consisting of a lead core completely covered, 

except for the base, with copper alloy (approximately 90 % copper and 10 % zinc). “Total 

Metal Jacket (TMJ),” “Totally Enclosed Metal Case (TEMC),” and other commercial 

terminology for bullets with electro-deposited copper and copper alloy coatings have been 

tested and are considered comparable to FMJ bullets for this standard. 

3.22 Hard Armor or Rigid Armor: Rigid armor systems, plates, inserts, accessories, or semirigid armor systems constructed with rigid plates that are typically designed to provide 

protection against rifle threats. 

 7 
3.23 In Conjunction Armor: A combination of either two flexible armor panels or a flexible 

armor with a plate insert that is designed to provide increased stab or ballistic protection. 

For an in conjunction armor system designed with a separate flexible stab armor panel 

insert added to the flexible ballistic panel and intended to provide dual threat protection 

against stab and ballistic threats, the complete system must be tested in the end-use 

configuration to meet the requirements of this standard. If the flexible ballistic armor is 

designed to be worn separately from the stab armor panel, the flexible armor shall be tested 

in accordance with this standard and found compliant as a stand-alone armor at its specified 

threat level. 

For an in conjunction armor designed to meet the requirements of NIJ Standard–0101.06, 

the flexible armor shall be tested in accordance with this standard and found compliant as a 

stand-alone armor at its specified threat level. The combination of the flexible armor and 

hard armor/plate shall then be tested as a system and found to provide protection at the 

system’s specified threat level. NIJ-approved hard armors and plate inserts must be clearly 

labeled as providing ballistic protection only when worn in conjunction with the NIJapproved flexible armor system with which they were tested. 

3.24 In Conjunction Plate: An insert that is designed to provide increased ballistic or stab 

protection only when it is used with a particular model of a flexible armor vest or jacket. 

3.25 Insert: A removable or nonremovable unit of ballistic material that can enhance the 

ballistic performance of the armor panel in a localized area but not over the entire area 

intended for ballistic protection. Some inserts are known as trauma packs, trauma plates, 

or trauma inserts, but other forms of inserts are possible. 

3.26 Jacketed Hollow Point Bullet (JHP): A bullet consisting of a lead core that has a hollow 

cavity or hole located in the nose of the bullet and is completely covered, except for the 

hollow point, with a copper alloy (approximately 90 % copper and 10 % zinc) jacket. 

3.27 Jacketed Soft Point Bullet (JSP): A lead bullet that is completely covered, except for the 

nose, with a copper alloy (approximately 90 % copper and 10 % zinc) jacket. This bullet is 

also known as a Semi Jacketed Soft Point (SJSP). 

3.28 Lead Bullet: A bullet made entirely of lead, which may be alloyed with hardening agents. 

3.29 Maximum Velocity: The specified reference velocity for a given threat round (table 4) 

plus 9.1 m/s (30 ft/s). 

3.30 Minimum Velocity: The specified reference velocity for a given threat round (table 4) 

minus 9.1 m/s (30 ft/s). 

3.31 Nonplanar Armor: Body armor with features that prevent the armor from making full 

contact with the backing material surface. Examples include female body armor with bust 

cups and curved rigid plates. 

 8 
3.32 Panel: See Armor Panel. 

3.33 Penetration: Any impact where the projectile passes into the armor is a penetration. A 

penetration may either be a stop or a perforation. The result is considered a stop or partial 

penetration if (1) the entire projectile is captured or deflected by the armor, and (2) no 

fragments of either the projectile or the armor become embedded in the backing material. If 

any part of the projectile passes through the armor, the result is considered a perforation or 

a complete penetration. Although the terms partial penetration and complete penetration

are no longer used in this standard, they may still be used by test laboratories for 

compatibility with military standards. 

3.34 Perforation: Any impact that creates a hole passing through the armor. This may be 

evidenced by any of the following: (1) the presence of the projectile, a projectile fragment, 

or an armor fragment in the clay backing material; (2) a hole that passes through the armor 

and/or backing material; or (3) any portion of the bullet being visible from the body side of 

the armor panel. The term perforation is synonymous with the term complete penetration. 

3.35 Plate Inserts: Hard armor plates or semi-rigid plates that are intended to be inserted into 

pockets of flexible vests and jackets to provide increased protection, particularly to provide 

protection against rifle threats. 

3.36 Reference Velocity: The specified measurement velocity goal for test rounds used in 

perforation-backface signature ballistic performance tests. 

3.37 Relative Humidity: The ratio of the amount of water in a given parcel of air at a given 

temperature to the maximum amount of water that the air can hold at that temperature. 

3.38 Rigid Armor or Systems: See 3.22 Hard Armor. 

3.39 Round Nose Bullet (RN): A bullet with a blunt or rounded nose. A bullet with a generally 

blunt or rounded nose or tip, which possesses a small flat surface at the tip of the bullet, 

shall also be considered a round nose bullet for this standard. 

3.40 Semi Jacketed Hollow Point Bullet (SJHP): A bullet consisting of a lead core with a 

copper alloy (approximately 90 % copper and 10 % zinc) jacket covering the base and bore 

riding surface (major diameter), which leaves some portion of the lead core exposed, thus 

forming a lead nose or tip, which has a hollow cavity or hole located in the nose or tip of 

the bullet. 

3.41 Semi Jacketed Soft Point Bullet (SJSP): A bullet, also known as a Jacketed Soft Point 

(JSP), consisting of a lead core with a copper alloy (approximately 90 % copper and 10 % 

zinc) jacket covering the base and bore riding surface (major diameter), which leaves some 

portion of the lead core exposed, thus forming a lead nose or tip. 

3.42 Shot-to-Edge Distance: The distance from the center of the bullet impact to the nearest 

edge of the ballistic panel. 

 9 
 10 

3.43 Shot-to-Shot Distance: The distance from the center of the bullet impact to the center of 

the nearest prior bullet impact. 

3.44 Stop: The outcome of a shot where the projectile is either captured or deflected by the 

armor, with no portion of the projectile or fragments of the armor perforating the armor. 

3.45 Striking Device: A device used to establish an appropriate, flat reference surface for the 

backing material (see 3.9 Backing Material). 

3.46 Strike Face: The surface of an armor sample or panel designated by the manufacturer as 

the surface that should face the incoming ballistic threat. Also, the side of the armor 

opposite the wear face (see 3.51 Wear Face). 

3.47 Test Series: The set of all shots necessary to obtain the required number of fair hits on a 

single armor panel or plate, as defined in table 4, and the set of all shots necessary to 

generate ballistic limit response data, as defined in table 8. 

3.48 Textile-Based Materials: Materials manufactured by weaving or felting yarns into a 

fabric, or by embedding or laminating fibers in sheets of plastic film. 

3.49 Trauma Insert/Pack/Plate: See 3.25 Insert. 

3.50 Vapor Pressure: The pressure exerted by a vapor in equilibrium with its solid or liquid 

phase. 

3.51 Wear Face: The side of the armor that is worn against the body. Also, the side of the armor 

opposite the strike face (see 3.46 Strike Face). 

3.52 Yaw: The angular deviation of the longitudinal axis of the projectile from its line of flight, 

measured as close to the target as practical. 
4. SAMPLE REQUIREMENTS AND LABORATORY CONFIGURATION

For an armor model to comply with this standard, all requirements of this section shall be 

met, and the appropriate number of samples shall be subjected to the tests defined in section 5, 

section 6, and section 7. 

4.1 Test Samples 

4.1.1 Flexible Vests and Jackets 

For flexible armor in the form of concealable or tactical vests or jackets, 14 complete 

armors per test threat, sized as described in section 4.1.1.1, shall constitute the compliance test 

group. 

Types IIA through IIIA armor shall be tested with two test threats and the compliance test 

group will consist of 28 complete armors. Types III and IV armor shall be tested with a single 

test threat, and the compliance test group will consist of 14 complete armors. If special testing is 

to be performed with additional test threats, the compliance test group will require an additional 

14 complete armors for each additional test threat. 

Refer to table 1, figure 3, figure 4, and the following sections for details on the required 

sample sizes and the tests to be performed on each. Additional samples may be required if 

optional tests are to be performed or if all necessary testing cannot be completed on the standard 

compliance test group. 

4.1.1.1 Test Sample Sizes 

Two sizes are required in the compliance test group: larger sized and smaller sized. The 

sizes of the armor samples will depend on the range of the sizes over which the armor model will 

be produced. Sample armor sizing templates are provided in appendix C. Table 1 summarizes the 

quantities required for each armor template size. 

Larger sized test samples: The armor manufacturer shall determine which template size 

most closely matches the largest size of the armor model that the manufacturer will produce. 

Table 1. Armor samples required for each test threat (flexible vests and jackets) 

(Note that quantities below should be doubled for types with 2 threats [Types IIA – IIIA]) 

Armor Armor Condition Ballistic Tests 

Template 

Size 

Number 

Required New Conditioned 

PBFS Ballistic 

Limit Spare 

8 New 2 5 1 Larger 11 3 Conditioned 1 1 1 

2 New 2 - - Smaller 3 1 Conditioned 1 - - 

Total 14 10 4 6 6 2 

 11 
For each test threat, the manufacturer shall provide 11 armor samples that fit this selected 

template. These armors will be referred to as the larger sized test samples. 

Smaller sized test samples: The armor manufacturer shall determine which template size 

most closely matches the smallest size of the armor model that the manufacturer will produce. 

For each test threat, the manufacturer shall provide three armor samples that fit this selected 

template. These armors will be referred to as the smaller sized test samples. 

4.1.1.2 Sample Utilization 

Conditioned Samples: Refer to table 1, figure 3, and figure 4. From each group of 14 

armors, one small sized armor and three large sized armors shall be selected at random and 

subjected to the armor conditioning protocol described in section 5. After the selected samples 

have been conditioned, the one small sized sample and one randomly selected large sized sample 

shall be subjected to the Perforation and Backface Signature (P-BFS) test described in section 7. 

Of the remaining two large sized samples, one shall be randomly selected and subjected to the 

Ballistic Limit (BL) test described in section 7. The remaining sample is a spare. 

 New Samples: Refer to table 1, figure 3, and figure 4. From each group of 14 armors, 

two small sized armors and two large sized armors shall be selected at random and subjected to 

the P-BFS test described in section 7. Five large sized armors will be selected at random and 

subjected to the BL test described in section 7. The remaining sample is a spare. 

4.1.2 Hard Armors and Plate Inserts 

All hard armors and plate inserts shall be subjected to a 24 shot P-BFS test and to either a 

24 shot or a 12 shot BL test. All hard armors and plate inserts shall be conditioned per section 6 

prior to ballistic testing. All hard armors and plate inserts shall be no larger than 254 mm x 305 

mm (10.0 in x 12.0 in) for testing. The required number of armor samples is dependent on the 

armor type, as described in the following sections. 

4.1.2.1 Type III 

For hard armors and insert plates intended to provide Type III protection, the compliance 

test group shall consist of nine armor panels. The armor panels shall be sufficiently large to 

allow for a minimum of six shots per panel. These requirements are outlined in figure 5. Four 

armor panels will be used for the P-BFS testing described in section 7. A minimum of four armor 

panels will be subjected to the BL test described in section 7, with a minimum of 24 shots. The 

remaining armor panel is a spare and be used if necessary. 

4.1.2.2 Type IV 

For hard armors and insert plates intended to provide Type IV protection, the compliance 

test group shall consist of a sufficient number of armor panels to allow a 24 shot P-BFS test and 

a 12 shot BL test, with at least one spare armor panel. These requirements are outlined in figure 

6. For armor models capable of withstanding only a single ballistic impact, the compliance test 

 12 
group shall consist of 37 armor panels. For armor models capable of withstanding multiple 

ballistic impacts, the manufacture shall specify the number of shots to be fired at each panel, and 

the compliance test group size may be reduced accordingly. However, a maximum of six P-BFS 

shots may be taken on a single panel. The compliance test group must include one armor panel as 

a spare. 

 13 
28 armors

provided by

manufacturer

22 of larger size

6 of smaller size

8 armors

conditioned

per Section 5

6 of larger size

2 of smaller size

BL tests:

2 armors

2 larger

0 smaller Threat 2:

1 armor

1 larger

0 smaller

Threat 1:

1 armor

1 larger

0 smaller

Spare:

2 armors

2 larger

0 smaller

P-BFS tests:

4 armors

2 larger

2 smaller Threat 2:

2 armors

1 larger

1 smaller

Threat 1:

2 armors

1 larger

1 smaller

20 armors

in “as new”

condition

16 of larger size

4 of smaller size

BL tests:

10 armors

10 larger

0 smaller Threat 2:

5 armors

5 larger

0 smaller

Threat 1:

5 armors

5 larger

0 smaller

Spare:

2 armors

2 larger

0 smaller

P-BFS tests:

8 armors

4 larger

4 smaller Threat 2:

4 armors

2 larger

2 smaller

Threat 1:

4 armors

2 larger

2 smaller

Figure 3. Sample quantity and utilization for armor Types IIA, II, and IIIA 

 14 
14 armors

provided by

manufacturer

11 of larger size

3 of smaller size

4 armors

conditioned

per Section 5

3 of larger size

1 of smaller size

BL tests:

1 armor

1 larger

0 smaller

Threat 1:

1 armor

1 larger

0 smaller

Spare:

1 armor

1 larger

0 smaller

P-BFS tests:

2 armors

1 larger

1 smaller

Threat 1:

2 armors

1 larger

1 smaller

10 armors

in “as new”

condition

8 of larger size

2 of smaller size

BL tests:

5 armors

5 larger

0 smaller

Threat 1:

5 armors

5 larger

0 smaller

Spare:

1 armor

1 larger

0 smaller

P-BFS tests:

4 armors

2 larger

2 smaller

Threat 1:

4 armors

2 larger

2 smaller

Figure 4. Sample quantity and utilization for flexible armor 

of Type III, Type IV, and Type Special 

 15 
Figure 5. Sample quantity and utilization for hard armors and plate inserts of Type III 

Figure 6. Sample quantity and utilization for hard armors and plate inserts of Type IV 

 16 
4.1.3 Accessory Ballistic Panels 

All accessory ballistic panels shall be subjected to a 24 shot P-BFS test for each threat 

round. For groin and coccyx protectors, eight samples are required for each threat round, and 

each sample will be subjected to at least three shots. For other types of accessory panels, the 

required number of armor samples will be dependent on the panel size, and the number of 

impacts per test sample shall be determined by the fair hit impact spacing criteria for flexible 

armor panels. A maximum of six P-BFS shots may be taken on a single panel. 

4.1.4 Workmanship 

All armor shall be free from evidence of inferior workmanship, such as wrinkles, blisters, 

cracks or fabric tears, fraying, crazing, or chipped or sharp corners and edges. Stitching must be 

straight and secure. All samples shall be identical in appearance and manner of construction. All 

samples of flexible vests and jackets shall be sized to meet the appropriate sizing templates, and 

all armors in each size group shall be identically sized. There shall be no variance in construction 

details between individual armor samples or between any armor sample and the manufacturer’s 

documentation. 

4.1.5 Labeling 

Armor shall be durably and clearly marked (labeled) in a readable type and font size, with 

a pretest label in accordance with the requirements set forth below. An example is shown in 

figure 7. 

4.1.5.1 Ballistic Panels 

Every ballistic panel cover shall have a label. The label shall be permanently attached to 

the face of the panel. The label shall contain the following information (figure 7): 

(a) Name, logo or other identification of the manufacturer. 

(b) The rated level of protection, according to section 2 of this standard and referenced to this 

edition of the standard (i.e., Type II in accordance with NIJ Standard–0101.06). 

(c) A test ID number or model designation that uniquely identifies the armor design for 

testing purposes. 

(d) The panel size. 

(e) A sample number or serial number that uniquely identifies each armor sample. 

(f) Location of manufacture. 

(g) The date of manufacture. 

(h) Identification of the proper orientation of the ballistic panel, i.e., strike face or wear face. 

(i) A warning in 14 point or larger type and a minimum of 1 1⁄2 times larger than the rest of 

the type on the label, exclusive of the information required in (a) above, stating that the 

armor panel is a test sample that has not yet been demonstrated to provide ballistic 

resistance and that the armor panel is not intended to be worn. Printing color changes are 

acceptable but cannot be substituted for the type size requirement herein. 

These labeling requirements apply to armor samples of models that are being submitted 

for precompliance or compliance testing. 

 17 
4.1.5.1.1 Labeling Requirements for Armors Listed on the NIJ Compliant Products List 

Armor samples of models that have been listed on the NIJ Compliant Products List and 

that are being retested, lot tested, etc. shall be labeled in accordance with the requirements of the 

Compliance Testing Program (CTP). Label requirements for armors listed on the NIJ Compliant 

Products List are provided in the NIJ Voluntary CTP Administrative Procedures Manual. 

In addition to the requirements of the CTP, all armor panels of listed models shall include 

the following: 

(a) The rated level of protection, according to section 2 of this standard and referenced to this 

edition of the standard (i.e., Type II in accordance with NIJ Standard–0101.06). 

(b) Strike face or wear face. The proper orientation of the ballistic panel in the carrier must 

be clearly identified. 

(c) For Types IIA, II, and IIIA armor, a warning in type not less than 14 point and a 

minimum of 1 1⁄2 times larger than the rest of the type on the label, exclusive of the 

manufacturer identification and logo, stating that the armor is not intended to protect the 

wearer from rifle fire. 

(d) If applicable, a warning in type not less than 14 point and a minimum of 1 1⁄2 times larger 

than the rest of the type on the label, exclusive of the manufacturer identification and 

logo, stating that the armor is not intended to protect the wearer from sharp edged or 

pointed instruments. This warning may be combined with the warning in (c) above. 

4.1.5.2 Armor Carriers With Nonremovable Ballistic Panels 

Armor with ballistic panels that are nonremovable shall, in addition to the label required 

for the ballistic panel, have a label on the carrier (figure 7) that is in conformance with the 

requirements for the ballistic panels, unless the armor is so constructed that the ballistic panel 

label is not covered by the carrier. The label may be positioned in a location where it is not 

visible when the armor is worn, but it shall be easy to locate and easily readable when the armor 

is donned and doffed. 

4.1.5.3 Label Permanency and Durability 

All labels shall be sufficiently permanent and durable so that they will remain securely 

attached to the armor or carrier and be fully legible for the life of the armor. The durability of the 

label markings shall be checked with the following procedure: 

[1] A representative area of the label markings shall be rubbed by hand for 15 s with a cotton 

cloth soaked with distilled water. 

[2] The same area shall then be rubbed by hand for 15 s with a cotton cloth soaked with 

denatured alcohol (methylated spirit). 

[3] Finally, the same area shall then be rubbed by hand for 15 s with cotton cloth soaked with 

isopropyl alcohol. 

The label markings within the representative area must remain legible. 

 18 
This test shall be performed on either a stand-alone example label or on a label of a spare 

armor sample. This test shall not be performed on an armor sample that will subsequently 

undergo ballistic testing, unless approved by the armor manufacturer. 

The labels of armor samples subjected to the armor conditioning protocol in section 5

must remain legible after the conditioning has been completed; however, these samples will not 

be subjected to the durability test described in the preceding paragraphs. 

✬

✫

✩

✪

Company Name

Company Address

[Company Logo - Optional]

Warning: Test Article

This armor panel is intended for

testing. It is not intended for

personal use. It has not been

demonstrated to have any

ballistic resistance.

Do Not Wear!

Test ID:

Size:

Location of Manufacture:

Date of Manufacture: / /

Lot Number:

Sample Number:

Threat Level (NIJ 0101.06):

Warning: Test Article

This armor panel is intended for

testing. It is not intended for

personal use. It has not been

demonstrated to have any

ballistic resistance.

Do Not Wear!

** Wear Face **

This side to be positioned

against backing material.

Figure 7. Example label for test samples 

 19 
4.1.6 Armor Carriers With Removable Ballistic Panels 

Armor with ballistic panels that are removable shall be submitted for testing with cotton 

or polycotton carriers with an areal density of not more than 250 g/m2 (7.37 oz/yd2). The test 

carriers shall not have strapping, strapping attachment points, pockets for accessory plates or 

trauma packs, or any accessory mounting points, with the following exceptions: 

(a) Armors submitted for testing in conjunction with Type III or Type IV plates shall 

have the necessary pockets for the plates with which they will be tested. 

(b) Armors that are to be tested using their own strapping for mounting and support 

during the tests shall have appropriate strapping and strapping attachment points. If 

the strapping or strapping attachment materials are deemed by the CTP to have a 

significant influence on the ballistic performance, then the armor shall be treated as if 

the ballistic panels were nonremovable and should be tested in carriers of the same 

construction as will be used for production armors. 

(c) Armor carriers for samples that will undergo the conditioning protocol described in 

section 5 shall not have strapping, strapping attachment points, or any accessory 

mounting points. For armors that are to be tested using their own strapping for 

mounting and support, separate carriers may be provided for the conditioning 

protocol and ballistic testing. 

4.1.7 Armors With Built-In Inserts or Trauma Packs 

For armor models that contain built-in inserts or trauma packs, manufacturers must 

submit a detailed diagram of the location of each trauma pack. During the P-BFS test, the shot 

locations shall be adjusted so that areas other than the built-in inserts or trauma packs are tested. 

4.2 Laboratory Configuration and Test Equipment 

The armor shall be tested in a facility and with test equipment that meets the following 

requirements. 

4.2.1 Range Configuration 

4.2.1.1 Ambient Test Conditions 

The ambient conditions shall be recorded before and after each armor panel firing 

sequence (6 or 12 shots) and, unless otherwise specified, shall be as stated below. 

(a) Temperature: 21 °C ± 2.9 °C (70 °F ± 5 °F). 

(b) Relative humidity: 50 % ± 20 %. 

 20 
4.2.1.2 Range Preparation 

The test equipment will be arranged as shown in figure 8. For handgun rounds, the armor 

panel shall be mounted 5.0 m ± 1.0 m (16.4 ft ± 3.28 ft) from the muzzle of the test barrel, and 

for rifle rounds, the armor panel should be mounted 15 m ± 1.0 m (49.2 ft ± 3.28 ft) from the 

muzzle of the test barrel, with the following exception. In order to minimize the possibility of 

excessive yaw at impact, or for other range configuration reasons, the distance may be adjusted 

for each threat; however, the distance shall not be less than 4 m (13.1 ft) for any round. In the 

case of rifle rounds, if the distance is adjusted to less than 14 m (45.9 ft), the bullet yaw shall be 

experimentally verified to confirm that the angle of incidence is within 5° of the intended angle. 

The backing material fixture should be rigidly held by a suitable test stand, which shall 

permit the entire armor and backing material assembly to be shifted vertically and horizontally 

such that the entire face of the backing material can be targeted. 

4.2.1.3 Instrumentation 

Before testing, all electronic equipment will be allowed sufficient time to warm up so that 

stability is achieved. 

Location of Velocity Measurement

(center of set of light screens or

other velocity sensors)

2.5 m ± 25 mm† (8.2 ft ± 1.0 in)

Handgun Rounds: 5.0 m ± 1.0 m (16.4 ft ± 3.28 ft)

Rifle Rounds*: 15.0 m ± 1.0 m (49.2 ft ± 3.28 ft)

Length to be adjusted

to meet velocity

accuracy requirements

Test Barrel

Armor Panel

Backing Material Fixture

Start Sensor Set Stop Sensor Set

*For rifle rounds the length may be further adjusted to minimize yaw at impact; however, in such cases the

yaw at impact must be experimentally shown to be less than 5◦ and reasonably close to minimal.

†Tolerance for 0◦ shots. For 30◦ and 45◦ shots the tolerance shall be + 25 mm/- 190 mm (+ 1.0 in/- 7.5 in).

Figure 8. Test range configuration 

 21 
4.2.2 Test Rounds and Barrels 

4.2.2.1 Handloads 

Handloaded rounds will generally be necessary to achieve the required velocities 

specified for the P-BFS tests in table 4 of section 7. Actual velocities achieved shall be within ± 

30 ft/s of the specified velocity. The bullets shall be as specified in appendix A. 

4.2.2.2 Test Barrels 

The test barrels shall be ANSI/SAAMI unvented velocity test barrels (see section 8, 

References [2], [3], and [4]). No firearms will be used. The rifling of all barrels shall meet the 

ANSI/SAAMI specifications for that caliber round. Barrels shall not be shorter than the 

ANSI/SAAMI specifications; however, longer barrels may be used when necessary for achieving 

the required bullet velocity. Barrels with nonstandard chambers may also be used to allow the 

velocities required for BL testing. 

4.2.2.3 Test Barrel Fixtures 

The test barrels shall be mounted in an ANSI/SAAMI compatible universal receiver or an 

equivalent mounting fixture. The receiver/mount will be attached to a table or other fixture 

having sufficient mass and restraint to ensure accurate targeting of repetitively fired rounds. 

4.2.3 Velocity Measurement Equipment 

Test round velocities shall be determined using at least two independent sets of 

instrumentation. Fair velocity measurements are individual velocity measurements within 3 m/s 

(10 ft/s) of each other. The velocity recorded shall be the arithmetic mean of all fair velocity 

measurements. The velocity measurement instrumentation shall have a combined uncertainty of 

less than 1.0 m/s (3.3 ft/s). 

4.2.3.1 Configuration 

The velocity shall be measured at 2.5 m ± 0.025 m (8.2 ft ± 1.0 in) from the front face of 

the backing material. When a chronograph is used in conjunction with trigger screens, the 

screens shall be centered at 2.5 m ± 0.025 m (8.2 ft ± 1.0 in) in front of the front surface of the 

backing material. For angled shots only, the screens may be centered at 2.5 m + 0.025 m / 

- 0.190 m (8.2 ft + 1.0 in / - 7.5 in) in front of the front surface of the backing material. Such 

screens shall be securely mounted to maintain their required position and spacing. 

For angled shots, the positioning tolerance for the trigger screens is relaxed to allow for 

backing material supports that pivot the backing material around a fixed point such that the range 

length will decrease slightly for angled shots. All instrumentation should be positioned with the 

armor sample and backing material perpendicular to the line of fire and does not need to be 

repositioned for the angled shots. 

 22 
4.2.4 Armor Submersion Equipment 

The armor submersion equipment shall consist of a water bath sufficiently sized to allow 

at least one armor panel of the largest template size defined in appendix C to hang vertically, 

without any folds or bends, with the top edge of the armor at least 100 mm (3.9 in) below the 

surface of the water, and with at least 50 mm (2.0 in) clearance around the panel. 

The water in the bath shall be clean and shall be either potable tap or demineralized 

water. The water shall be replaced anytime there are visible impurities in the water. The water 

temperature shall be 21 °C +2.9 °C/-5.8 °C (70 °F +5 °F/-10 °F). 

4.2.5 Armor Backing Material 

4.2.5.1 Backing Material Fixture 

The inside dimensions of the backing material fixture shall be 610 mm x 610 mm with a 

depth of 140 mm (24.0 in x 24.0 in x 5.5 in). The tolerance on all dimensions is ± 2 mm 

(± 0.08 in). 

The back of the fixture shall be removable and shall be constructed of 19.1 mm (0.75 in) 

thick wood or plywood. 

4.2.5.2 Fixture Construction 

The sides of the fixture shall be constructed of rigid wood or metal, preferably with a 

metal front edge to reliably guide the preparation of the flat front surface of the backing material. 

4.2.5.3 Backing Material 

In the interest of inter-laboratory conformity, Roma Plastilina No.11

 oil-based modeling 

clay shall be used as the backing material. The backing material shall be replaced on an annual 

basis or more frequently if necessary. 

4.2.5.4 Backing Material Surface Preparation 

The clay in each backing material fixture shall be manipulated to produce a block free of 

voids, with a smooth front surface for the accurate and consistent measurement of depression 

depths. The front surface of the backing material shall be even with the reference surface plane 

defined by the fixture edges. Striking devices of sufficient length shall be used to ensure the 

reference surface is established using the edges of the clay block fixture as index points. 

For nonplanar body armor, backing material shall be built up to conform to the shape of 

the nonplanar armor. Calibration drop testing shall not be performed in the built-up area. The 

 

1

 The use of brand names in this standard does not constitute endorsement by the U.S. Department of Justice; Office of Justice 

Programs; National Institute of Justice; U.S. Department of Commerce; National Institute of Standards and Technology; Office 

of Law Enforcement Standards; or any other agency of the United States Federal Government, nor does it imply that the product 

is best suited for other applications. 

 23 
built-up backing material shall be conditioned to the same temperature as the backing material in 

the fixture. 

During preparation and post-test repair, effort shall be made to locate and remove any 

debris, including but not limited to bullet fragments and armor components introduced into the 

block during testing. 

4.2.5.5 Backing Material Conditioning 

The clay backing material shall be conditioned in its fixture using a heated chamber or 

enclosure. Actual conditioning temperature and recovery time between uses will be determined 

by the results of the validation drop test described in section 4.2.5.6. 

Additional clay, conditioned to the same initial temperature as the fixture, shall be used to 

fill voids and restore the front surface of the backing material as needed. 

4.2.5.6 Backing Material Consistency Validation 

Drop-test validation of the backing material shall be accomplished before every six shot 

P-BFS test sequence and before each 12 shot BL test sequence. During P-BFS testing, a post-test 

drop series shall also be performed immediately following the last test sequence before the 

backing material is returned to the conditioning chamber. Failure to meet drop-test depth 

requirements will result in the invalidation of all shot series since the last drop-test with 

acceptable depths of indentation, and will require that a new conditioned and drop test validated 

backing material fixture be used. Validation shall be accomplished using the equipment and 

techniques specified below: 

(a) Drop weight: Steel sphere.2

(b) Drop weight size: 63.5 mm ± 0.05 mm (2.5 in ± 0.001 in) in diameter. 

(c) Drop weight mass: 1043 g ± 5 g (2.29 lb ± 0.01 lb). 

(d) Drop height: 2.0 m (6.56 ft). 

(e) Drop spacing: Minimum of 76 mm (3.0 in) from fixture edge to indent edge and a 

minimum of 152 mm (6.0 in) between indent centers. 

Each validation drop will consist of a free release, targeted fall of the steel sphere onto 

the conditioned backing material. It is recommended that an aiming device, such as a pointing 

laser, be used to indicate the intended drop point on the backing material fixture. Five drops will 

be completed. The pretest and post-test drop positions will be located according to figure 9 and 

item (e) above. 

The arithmetic mean of the five indentation depth measurements shall be 19 mm ± 2 mm 

(0.748 in ± 0.08 in). In addition, no indentation shall be greater than 22 mm (0.866 in) or less 

than 16 mm (0.630 in). 

 

2

 A sphere, reference P/N 3606, supplied by Salem Specialty Ball Co., Inc., P.O. Box 145, West Simsbury, CT 06092, has been 

found to be satisfactory, although any steel sphere meeting the requirements listed in this section is acceptable. 

 24 
2 1

3

4

5

Figure 9. General pretest drop locations 

Depth of indentation measurements shall utilize measurement devices (± 1 mm accuracy) 

indexed to the undisturbed reference surface or the edges of the fixture, establishing the 

reference plane across the diameter of the indentation. Depending on the chosen measurement 

method, the backing material may be struck flush with the edges of the fixture to reestablish the 

reference surface prior to measuring each depth of indentation. 

Backing material temperatures shall be measured using a thermometer or thermocouple 

with a measurement accuracy of 0.5 °C (0.9 °F) or better. Temperature readings will be taken 

prior to pre and post-test drop testing at a minimum of 254 mm x 254 mm (10.0 in x 10.0 in) 

from any two fixture edges at a minimum depth of 25 mm (1.0 in) and a maximum depth of 51 

mm (2.0 in) from the backing material surface. 

A newly conditioned and drop-test validated backing material fixture shall be used for 

each threat specific, 24 shot series of firings or more frequently when drop test results dictate. 

 25 
 26 

This page intentionally left blank. 
5. FLEXIBLE ARMOR CONDITIONING PROTOCOL

5.1 Purpose and Scope 

This protocol applies to all Type IIA, II, and IIIA systems and to the flexible portion of 

Type III and Type IV armor systems. After being subjected to the conditioning protocol, flexible 

armor performance will be verified with ballistic testing as described in section 7. 

This protocol is designed to subject test armors to conditions that are intended to provide 

some indication of the armor’s ability to maintain ballistic performance after being exposed to 

conditions of heat, moisture, and mechanical wear. This protocol will not predict the service life 

of the vest nor does it simulate an exact period of time in the field. 

5.2 Pretest Parameters 

5.2.1 Storage of Armors 

To allow for equilibration, store the test samples at a temperature of 25 °C ± 10 °C (77 °F 

± 18 °F) with a relative humidity of 20 % to 50 % for at least 24 h prior to starting the armor 

conditioning protocol. This may be achieved in a controlled laboratory environment, or if 

conditions in the laboratory deviate from those specified, a chamber may be used to create these 

conditions. 

5.2.2 Pretest Calibrations 

Prior to and following each conditioning protocol, the accuracy of all instruments and test 

equipment used to control or monitor the test parameters shall be verified. The calibration 

intervals must meet ANSI or ISO guidelines for good laboratory practices. 

5.2.3 Test Conditions 

5.2.3.1 Air Temperature 

Keep the air temperature uniform, both inside the conditioning chamber and in the 

storage environment. Verify that the air temperature is uniform by using verification sensors to 

ensure that the air temperature is within ± 2 °C (± 3.6 °F) of the required temperature. Storage 

temperatures are given in section 5.2.1. 

The test temperature shall be 65 oC (149 oF). 

5.2.3.2 Relative Humidity 

Keep the relative humidity uniform and noncondensing, both inside the test chamber and 

in the storage environment. Verify that the relative humidity is uniform by using verification 

sensors to ensure that the relative humidity is within ± 5 % of the required relative humidity. The 

storage relative humidity is given in section 5.2.1. 

The test relative humidity shall be 80 %. 

 27 
5.2.3.3 Tumbling 

The drum rotation rate shall be 5.0 rpm ± 1.0 rpm. 

The drum shall be rotated through 72,000 ± 1,500 complete rotations during the test. To 

ensure that the proper number of complete rotations is obtained, a counter or totalizer shall be 

used to record the total number of rotations. The drum rotation rate may be varied within the 

given tolerance to achieve the necessary number of rotations, as long as the rate does not exceed 

the above specified tolerance. 

5.2.3.4 Test duration 

The test shall last a total of 10 d ± 1 h. 

5.3 Laboratory Configuration and Test Equipment 

5.3.1 General Parameters 

5.3.1.1 Facility Design 

Use a stand-alone or walk-in temperature and humidity chamber with the tumbling 

accessory inside. 

5.3.1.2 Monitoring Conditioning Chamber Parameters 

To provide proof of parameter level maintenance, the laboratory must keep a manually or 

electronically produced log of parameter levels. Exact parameter monitoring intervals and exact 

methods of recording parameter levels may vary for different laboratories. The technology 

involved in recording parameter levels may involve visual checks at prescribed intervals, real 

time continuous recording such as a circular chart, periodic recording on a device such as a data 

logger, or other techniques as appropriate for each individual laboratory. 

5.3.1.3 Humidity Generation 

Use steam or water injection to create the relative humidity within the test chamber as 

appropriate for the device. Set up a system to drain and discard any condensate developed within 

the chamber during the test. 

5.3.1.3.1 Water Purity 

It is essential that the water used for humidity tests not unfairly impose contaminants on 

the test samples. Chemicals commonly found in commercial water supplies, such as chlorine, as 

well as nonneutral pH, can cause unintended corrosive effects to materials. It is highly 

recommended that the water used for this test be relatively free from impurities and chemicals 

and have a pH in the range of 6.5 to 7.2. NOTE: A water resistivity of no less than 150,000 ohm 

cm is recommended. This can be produced using distillation, demineralization, reverse osmosis, 

or deionization. Many humidity chambers have a built in deionization system. 

 28 
5.3.1.4 Tumbling Generation 

Use a tumbling device to generate tumbling action during the protocol. 

The tumbler drum shall have an internal diameter of 832 mm ± 6 mm (32 3/4 in ± 1/4 in) 

and an internal depth of 651 mm ± 6 mm (25 5/8 in ± 1/4 in). The tumbler drum shall have four 

fins (ribs) running the full depth of the drum and spaced at 90o intervals about the circumference. 

Each fin shall be 114 mm ± 3 mm (4 1/2 in ± 1/8 in) high. The top edge of the fins shall be 

rounded with a minimum diameter of 19 mm ± 3 mm (3/4 in ± 1/8 in), and the width of the fin at 

the top shall be 19 mm ± 3 mm (3/4 in ± 1/8 in). The fins may be either straight or tapered. The 

base of the fin shall not be thinner than 19 mm (3/4 in) and shall not be thicker than 76 mm 

(3.0 in). The inside of the drum shall be smooth, with no sharp edges to catch, tear, or abrade the 

armor samples. The drum surface may be perforated. The drum shall have sufficient openings to 

allow air flow such that the air within the drum remains within the specified tolerances. 

The tumbling apparatus should be placed in a chamber capable of generating temperature 

and humidity during the conditioning protocol. The tumbler must maintain tolerances of 

temperature, humidity, and revolutions per minute specified in section 5.2.3. Verify the 

apparatus maintains conditions within the tolerances specified at periodic intervals throughout 

each cycle of the conditioning protocol. The tumbler and chamber must be arranged such that if 

the chamber goes out of the tolerance conditions, the tumbler rotation will cease until the 

chamber returns to its in-tolerance condition. 

5.3.1.5 Contamination Prevention 

Do not bring any material other than water into physical contact with the test armors. Do 

not introduce any material other than water into the chamber. 

Care shall be taken to prevent condensation within the humidity chamber from coming in 

contact with the armor samples. 

5.3.2 Controls 

(a) Ensure the test chamber includes measurement and recording device(s), separate from the 

chamber controllers. 

(b) Unless otherwise specified, make continuous analog temperature and relative humidity 

measurements during the test. Conduct digital measurements at intervals of 10 min. or 

less. 

(c) Use only instrumentation with the selected conditioning chamber that meets the 

accuracies, tolerances, etc., described herein. 

5.3.3 Test Interruption 

Analyze any interruption carefully. If the decision is made to continue the protocol from 

a point of interruption or to add additional time onto the protocol, and a failure occurs, it is 

essential to be able to determine the effects of the protocol interruption. The flow chart shown in 

figure 10 will assist in the determination of how to proceed if an interruption occurs. 

 29 
5.3.4 Procedure 

This procedure consists of a 24-h acclimation period to ensure all armor samples start 

with the same conditions followed by a 10-d period of temperature, humidity, and mechanical 

wear exposure. This procedure shall be performed on only one compliance test group at a time. 

[1] When a compliance test group is received, place the samples in a controlled laboratory 

environment for at least 24 h prior to beginning the test as specified in section 5.2.1. 

[2] Place the compliance test group inside of the tumbler at the specified conditions of 

temperature and relative humidity (see section 5.2.3). 

[3] Program the tumbler to rotate as specified in section 5.2.3.3. 

[4] Expose the armors to the specified conditions for the period specified in section 5.2.3.4. 

[5] Return armors to pretest conditions (see section 5.2.1). 

[6] Perform a thorough visual examination of each test sample and document any change in 

physical appearance resulting from exposure. 

[7] Armors shall remain at pretest conditions (see section 5.2.1) for a minimum of 12 h 

before transporting them to a different facility or before beginning ballistic testing. 

 30 
Flexible Armor

Conditioning

Protocol Started

and Interruption

Occurs

Is the interruption

within the tolerances

set by Section 5.2.3?

Continue the protocol.

Were the protocol

conditions above or

below specifications?

Did the conditions

return to the pretest

conditions specified

in Section 5.2.1?

Are any samples visibly

damaged due to the

deviation? Or, did the

temperature exceed 80◦C?

Or, did condensation form on

or in the specimens?

Record the deviation and

continue the protocol.

Extend the protocol for

the time that conditions

were in the pretest range.

Consult with the armor manufacturer to

determine if the protocol should be

continued or restarted with new specimens.

Yes

No

Below

Above

Yes

No

No

Yes

Figure 10. Flexible armor conditioning test interruption flow chart 

 31 
 32 

This page intentionally left blank. 
6. HARD ARMOR CONDITIONING PROTOCOL

6.1 Purpose and Scope 

This section is designed to subject hard armors or plate inserts to conditions that are 

intended to provide some indication of armor’s ability to maintain ballistic performance after 

being exposed to conditions of heat, moisture, and mechanical wear. This protocol is intended to 

apply only to rigid systems. After this armor conditioning protocol, the ballistic performance will 

be verified with ballistic testing as described in section 7. 

This protocol will not predict the service life of the armor nor does it simulate an exact 

period of time in the field. 

This protocol consists of a four step process: (1) a 24-h acclimation period to ensure all 

items at any intended climatic test location will start with the same conditions, (2) a 10-d 

uniform thermal exposure, (3) a thermal cycle exposure, and (4) mechanical durability testing. 

6.2 Pretest Parameters 

6.2.1 Storage of Armors 

To allow for equilibration of armors, store the test armors at a temperature of 25 °C ± 

10 °C (77 °F ± 18 °F) and relative humidity of 20 % to 50 % for at least 24 h prior to starting the 

armor conditioning protocol. 

6.2.2 Pretest Calibrations 

Prior to and following each armor conditioning protocol, the accuracy of all instruments 

and test equipment used to control or monitor the test parameters shall be verified. The 

calibration intervals must meet ANSI or ISO guidelines for good laboratory practices. 

6.2.3 Test Conditions 

6.2.3.1 Air Temperature 

Keep the air temperature uniform, both inside the test chamber and in the storage 

environment. Verify that the air temperature is uniform by using verification sensors to ensure 

that the air temperature is within ± 2 °C (± 3.6 °F) of the required temperature. Storage 

temperatures are given in section 6.2.1. Test temperatures are given in table 2 for uniform 

thermal exposure testing and in table 3 for the thermal cycle testing. 

Table 2. Uniform thermal exposure conditions 

Time Temperature Relative Humidity 

10 d 65 °C (149 °F) 80 % 

 33 
Table 3. Thermal cycle testing conditions 

Time (hr) Temperature (°C) Relative humidity (%) 

2 25 50 

2 15 N/A 

2 5 N/A 

2 -5 N/A 

2 -15 N/A 

2 0 N/A 

2 15 N/A 

2 30 50 

2 45 50 

2 60 50 

2 75 50 

2 90 50 

6.2.3.2 Relative Humidity 

Keep the relative humidity uniform, both inside the test chamber and in the storage 

environment. Verify that the relative humidity is uniform by using verification sensors to ensure 

that the relative humidity is within ± 5 %. Storage relative humidities are given in section 6.2.1. 

Test relative humidities are given in table 2 for uniform thermal exposure and in table 3 for the 

thermal cycle testing. 

6.2.3.3 Armor Drop Test 

A flat hardened concrete surface with a thickness of at least 76.2 mm (3.0 in) and a mass 

much greater than that expected from the weighted plate must be available for mechanical 

durability testing. 

6.2.3.4 Test Duration 

The uniform thermal exposure test shall last a total of 10 d. The thermal cycle test will 

last a total of 1 d. 

6.2.3.5 Monitoring Conditioning Chamber Parameters 

(a) To provide proof of parameter level maintenance, keep a manually or electronically 

produced log of parameter levels. Exact parameter monitoring intervals and exact 

methods of recording parameter levels may vary for different laboratories. 

(b) The technology involved in recording parameter levels may involve visual checks at 

prescribed intervals, real time continuous recording such as a circular chart, periodic 

recording on a device such as a data logger, or other techniques as appropriate for each 

individual laboratory. 

 34 
6.3 Laboratory Configuration and Test Equipment 

6.3.1 General Parameters 

6.3.1.1 Facility Design 

Use a stand-alone or walk-in humidity chamber with racks positioned such that the plates 

can be mounted in a vertical orientation (the orientation in which they will be used). 

6.3.1.2 Test Sensors and Measurements 

The laboratory must have a method of measuring and recording the temperature and 

relative humidity inside the chamber at intervals not less than once every 10 min. This can be 

accomplished by using monitoring software on the humidity chamber, an array of sensors, a 

chart recorder, or other appropriate methods. 

6.3.1.3 Humidity Generation 

Use steam or water injection to create the relative humidity within the test chamber as 

appropriate for the device. Set up a system to drain and discard any condensate developed within 

the chamber during the test. 

6.3.1.3.1 Water Purity 

It is essential that the water used for humidity tests not unfairly impose contaminants on 

the test armors. Chemicals commonly found in commercial water supplies such as chlorine as 

well as nonneutral pH can cause unintended corrosive effects to materials. It is highly 

recommended that the water used for this test be relatively clean of impurities and chemicals, 

and have a pH in the range of 6.5 to 7.2 at 25 oC at the time of test. NOTE: A water resistivity of 

no less than 150,000 ohm cm is recommended. This can be produced using distillation, 

demineralization, reverse osmosis, or deionization. Many humidity chambers have a built-in 

deionization system. 

6.3.2 Controls 

(a) Ensure the test chamber includes measurement and recording device(s), separate from the 

chamber controllers. 

(b) Unless otherwise specified, make continuous analog temperature and relative humidity 

measurements during the test. Conduct digital measurements at intervals of 10 min or 

less. 

(c) Use only instrumentation with the selected test chamber that meets the accuracies, 

tolerances, etc., described herein. 

6.3.3 Test Interruption 

Analyze any interruption carefully. If the decision is made to continue the protocol from 

a point of interruption or to add additional time onto the protocol, and a failure occurs, it is 

 35 
essential to be able to determine the effects of the test interruption. The flow chart shown in 

figure 11 will assist in the determination of how to proceed if an interruption occurs. 

6.3.4 Conditioning Procedure 

The conditioning procedure is detailed below: 

[1] When samples are received, place them in a controlled laboratory environment for at least 

24 h prior to beginning the test. 

[2] Place the armors inside of the chamber at the specified conditions of temperature and 

relative humidity. 

[3] Expose the armors to the conditions specified in table 2 for 10 d. 

[4] Perform a thorough visual examination of the test item and document any change in 

physical appearance resulting from exposure. 

[5] Expose the armors to the conditions specified in table 3 for 24 h. 

[6] Perform a thorough visual examination of the test item and document any change in 

physical appearance resulting from exposure. 

[7] Perform drop testing on the armors by attaching them with a strap, belt, or other 

nonobstructive retaining device to the front surface of 10.0 lb of P-BFS backing material. 

The backing material clay will be contoured to the back surface of the plate. If the plate is 

part of an in conjunction system, the plate shall be backed for drop testing by the in 

conjunction flexible armor design intended to be sold with the plate. This flexible armor 

design must be supplied by the manufacturer in template size NIJ–C–2. This flexible 

armor is placed between the armor and the weighted object as shown in figure 12. If the 

plate is intended to be sold as a stand-alone item, no flexible armor backing will be used 

in drop testing. A fixture similar to that shown in Figure 12 has been shown to provide 

accurate and reproducible results. For further details and specifications on this fixture, see 

the publication entitled, Description of Fixture for Hard Armor Drop Testing According 

to NIJ Standard-0101.06. At a minimum free fall height of 48.0 in (90° from horizontal) 

from the flat hardened surface and with the strike face of the armor pointing down, drop 

the weighted fixture twice. Impacts must occur at the center of the face (not at an edge). 

Following conditioning testing, the armor shall be subjected to further testing according to 

section 7. 

 36 
Hard Armor

Conditioning

Protocol Started

and Interruption

Occurs

Is the interruption

within the tolerances

set by Section 6.2.3?

Continue the protocol.

Were the protocol

conditions above or

below specifications?

Did the conditions

return to the pretest

conditions specified

in Section 6.2.1?

Are any samples visibly

damaged due to the

deviation? Or, did the

temperature exceed 80◦C?

Or, did condensation form on

or in the specimens?

Record the deviation and

continue the protocol.

Extend the protocol for

the time that conditions

were in the pretest range.

Consult with the armor manufacturer to

determine if the protocol should be

continued or restarted with new specimens.

Yes

No

Below

Above

Yes

No

No

Yes

Figure 11. Test interruption flowchart for hard armor 

 37 
 38 

 

Figure 12. Proposed mechanical durability test apparatus 3

direction of travel

122 cm 

(48 in)

flat hardened surface

weighted object, 

typically wooden or 

metal box, solidly 

attached to pivot arm 

and containing 10 lb 

backing material

hinge 

bearing

armor 

pivot arm

solid base

Not to scale

3

 From Purchase Description Personal Armor, Enhanced Small Arms Protective Insert CO/PD 04–19A 28 February 2005. 
7. BALLISTIC TEST METHODS

7.1 Purpose and Scope 

This section specifies the methods and performance requirements for ballistic testing of 

body armor and includes the formal test procedures for the Perforation-Backface Signature (PBFS) and baseline Ballistic Limit (BL) tests. The first test series is P-BFS testing and requires 

the armor to demonstrate consistent ballistic resistance to both perforation and excessive blunt 

force trauma. The second test series is BL testing and is designed to statistically estimate 

perforation performance. In addition, for flexible vests and jackets, a portion of the sample set 

will be subjected to the flexible armor conditioning protocol described in section 5. For hard 

armor and plate inserts, the entire sample set will be subjected to the hard armor conditioning 

protocol described in section 6. The conditioned samples will be subjected to ballistic testing. 

7.2 Test Order 

The ballistic test series may be performed in any order, at the discretion of the 

manufacturer. 

7.3 Workmanship Examination 

All armor samples received for compliance testing shall be inspected before testing, and 

any deficiencies shall be noted. Samples that do meet the requirements of section 4.1 shall be 

reported to both the armor manufacturer and the Compliance Testing Program (CTP) before 

testing commences. Documentary photographs shall be taken for use in deficiency notification 

reporting. 

7.3.1 Armor Carriers and Ballistic Panel Covers 

All armor sample carriers and ballistic panel covers received for compliance testing will 

be inspected for damage, material flaws, or poor workmanship as defined in section 4.1.4. 

Documentary photographs shall be taken for use in deficiency notification reporting. 

7.3.2 Ballistic Panels 

Pretest – Before testing, all armor sample ballistic panels and inserts received for 

compliance testing will be individually inspected for damage, material flaws, or poor 

workmanship as defined in section 4.1.4. 

Post-Test - Each sample’s ballistic components will be inspected immediately after 

testing to verify their construction details (layers, weave, stitching, material, etc.). 

7.3.3 Label Examination 

The complete armor sample and each part (carrier and ballistic panels) will be examined 

for conformance to the labeling requirements of section 4.1.5. 

 39 
7.4 Sampling 

Test samples will be selected according to the requirements of section 4.1.1.2. 

7.5 Sample Acclimation 

All armor samples received for compliance testing shall be stored and acclimated for a 

minimum of 24 h at ambient range conditions. 

7.5.1 Inserts 

 All armor samples will be tested in their final design and end use configuration, including 

all system components (e.g., carriers and straps), with the following exceptions. Armors with 

removable carriers that may be manufactured with more than one carrier design shall be tested 

with the minimal carrier defined in section 4.1.6. Except for plate inserts being tested as in 

conjunction armors, all removable inserts or trauma packs shall be removed from the armor 

before acclimation and shall not be tested. 

7.6 Fair Hit Requirements for All Ballistic Tests 

A test shot shall be considered a fair hit if it impacts the armor panel at an angle of 

incidence no greater than ± 5° from the intended angle of incidence, no closer to the edge of the 

ballistic panel than the minimum shot-to-edge distance, and no closer to a prior hit than the 

minimum shot-to-shot distance. 

In addition, for a P-BFS test shot to be considered a fair hit, it must meet the impact 

location requirements of section 7.8.1, and the measured velocity must either: (1) be within ± 9.1 

m/s (30 ft/s) of the reference velocity for the specified bullet; (2) be less than the minimum 

velocity and produce a perforation or an excessive BFS; or (3) be greater than the maximum 

velocity and not produce a perforation or an excessive BFS. 

7.6.1 Minimum Shot-to-Edge Distance 

The armor manufacturer shall define the acceptable minimum shot-to-edge distance for 

each armor model and each threat that will be tested against the armor. For armor types subjected 

to a single threat and for the lighter weight threat round when two threats are specified, the 

minimum shot-to-edge distance shall not be greater than 51 mm (2.0 in). For the heavier threat 

round when two threats are specified, the minimum shot-to-edge distance shall not be greater 

than 76 mm (3.0 in). Table 4 indicates which rounds are lighter weight and heavier weight. 

7.6.2 Minimum Shot-to-Shot Distance 

The minimum shot-to-shot distance shall be 51 mm (2.0 in). 

This distance may be decreased at the request of the armor manufacturer. 

 40 
7.7 Backing Material Preparation and Sample Mounting for All Ballistic Tests 

7.7.1 Backing Material Fixture Preparation 

The backing material fixture shall meet the requirements of section 4.2.5. 

The clay in each backing material fixture will be manipulated to produce a block free of 

voids and with a smooth, flat front surface for the accurate and consistent measurement of 

depression depths. The front surface of the backing material shall be even with the reference 

surface plane defined by the fixture edges. Striking devices of sufficient length shall be used to 

ensure the reference surface is established using the edges of the fixture as index points. 

For BL tests only, the removable back shall be removed from the backing material 

fixture. 

7.7.2 Mounting Armor for Ballistic Testing 

7.7.2.1 Strapping 

The armor panel shall be positioned on the backing material such that the point of impact, 

projected through the armor onto the surface of the backing material, is no closer that 106 mm 

(4.2 in) from the edge of the backing material fixture. 

Armor samples or panels shall be held in contact with the backing material and secured to 

the backing material fixture using mounting straps that conform to one of the following two 

options: 

(a) The default strapping method uses 51 mm (2.0 in) wide elastic straps, held together using 

hook-and-loop fasteners. If these straps are used, two vertical and three horizontal straps 

shall be positioned such that they do not interfere with the impact points on the armor 

panel. Figure 13, diagram A shows a typical example of strapping using this method. For 

larger armor sizes, the backing material fixture is not large enough to accommodate the 

entire armor. For these cases, extension panels shall be added to the sides of the fixture, 

as shown in figure 13, diagram B, such that the combined backing material, backing 

material fixture, and extensions form a planar surface at least 1016 mm (40.0 in) wide by 

610 mm (24.0 in) high. The extensions may be part of the backing material support 

fixture, and this configuration may be used for smaller armors. 

(b) The alternative strapping method applies to armor panels that normally would have 

strapping as an integral part of their construction. This strapping method requires the 

armor manufacturer to supply armor panels with extended strapping devices to allow the 

armor, as a unit, to be mounted on the backing material fixture. Figure 13, diagram C 

shows a typical example of strapping using this method. 

The laboratory shall record which strapping arrangement was used. 

 41 
Armor Panel

Backing Material

Elastic Straps

Backing Material Fixture

A. Standard Strapping Arrangement for Smaller Samples

Armor Panel

Backing Material

Elastic Straps

Backing Material Fixture

Extension to Fixture

Shall be coplanar with front

face of backing material

B. Standard Strapping Arrangement for Larger Samples

Armor Panel

Backing Material

Straps Provided by

Armor Manufacturer

Backing Material Fixture

C. Special Strapping Arrangement Using the Armor’s Strap Attachments

Figure 13. Acceptable strapping methods 

 42 
7.7.2.2 Remounting of Armor 

 Once the armor panel has been subjected to any ballistic tests, no effort shall be made to 

recover any bullets trapped in the armor panel, and no effort shall be made to fill in any BFS 

indentations in the test fixture backing material. When necessary, the backing material shall be 

struck to return the surface to a flat configuration; however, the BFS indentation should not be 

repaired. The armor panel shall be manipulated by hand so that any deformations in the armor 

are smoothed out. Also, the armor panel shall be repositioned on the backing material such that 

the next impact will not occur over any BFS indentation and such that the panel is supported by 

smooth clay backing material for a distance of no less than 76 mm (3.0 in) in all directions 

around the next shot location. 

7.7.2.3 Backing Material Fixture Positioning 

 The backing material fixture shall be positioned to ensure proper bullet impact placement 

and angle of incidence of the test round. For any shots requiring a nonzero angle of incidence, 

the backing material fixture shall be positioned so that the bullet line of flight is directed toward 

the vertical centerline of the armor panel at the point of impact. An exception will be made for 

armors where shots directed in a different orientation will likely be more problematic for the 

armor to stop. In these cases, for shots requiring a nonzero angle of incidence, the armor shall be 

oriented such that the shot will exploit the perceived weakness. 

7.8 Perforation and Backface Signature Test (P-BFS) 

All armor models submitted for compliance testing will undergo P-BFS testing using the 

threat rounds specified in section 2 and table 4. These impact tests measure three BFS indentions 

and demonstrate the armor’s resistance to perforation. This test series requires the use of a 

plastically deforming witness media (clay backing material) held in direct contact with the back 

surface of the armor panel. This configuration is used to capture and measure the BFS depression 

produced in the backing material during nonperforating threat round impacts. 

The number of armor samples defined in section 4.1 shall be subjected to P-BFS tests in 

accordance with the following procedures. 

7.8.1 Shot Location Marking 

Clearly mark the shot locations directly on each sample according to the following 

criteria. 

Flexible Vests and Jackets: All flexible vests and jackets shall be tested with six shots in 

the approximate pattern shown in figure 14. Shots 1, 2, and 3 shall meet the shot-to-edge 

distance requirements, but they shall not be located more than the minimum shot-to-edge 

distance plus 19 mm (0.75 in) from the edge of the panel. Shots 4, 5, and 6 shall meet the shotto-shot distance requirements, but all three shots shall be located within a 100 mm (3.94 in) 

diameter circle. For panels with sufficient area, the locations of shots 4, 5, and 6 shall be 

randomly moved to different areas on different panels. When there are no discontinuities or 

 43 
apparent weaknesses in the armor as considered below, refer to guidance from the CTP on the 

specific locations for shots 4, 5, and 6 on each panel. 

For the case of armor samples sized to Template NIJ–C–1 (smallest template) when 

tested with threat 2 only, the panel may be subjected to only five shots if space limitations 

prevent taking six shots. In this case, shots 1 through 5 shall be taken, but shot 6 may be skipped. 

In this case only, the total number of shots required for a complete P-BFS test series shall be 66 

shots per test threat. 

For armors where the construction and material thickness vary across the panel, the 

locations of shots 4, 5, and 6 shall be adjusted to exploit the weakest portion of the armor. 

For armors that have folds, seams, or other discontinuities (such as the bust cups of some 

female armors or the closures of front closing vests), additional shots shall be fired so that at 

least one shot impacts each fold, seam, or discontinuity. If a single fold, seam, or discontinuity 

extends more than one half the width or height of the armor (such as closure of a front closing 

vest), at least two shots shall impact that discontinuity. For small armors with limited shot area, 

the locations of shots 4, 5, and 6 may be varied such that one of these shots impacts the 

discontinuity. 

Hard Armors and Plate Inserts: All hard armors and plate inserts shall be tested with 

the appropriate number of shots as defined in section 4.1.2. The shots shall be placed on the 

panel in any pattern that meets the shot-to-edge and shot-to-shot spacing requirements. 

Figure 14. General armor panel impact locations (front and back) 

 44 
7.8.2 Armor Submersion 

New Flexible Vests and Jackets: All new flexible vests and jackets shall be submersed 

and tested wet. Each armor panel shall be hung vertically in a water bath meeting the 

requirements of section 4.2.4 for 30 min (+ 5 min/- 0 min) with the top edge of the armor 

positioned 100 mm ± 25 mm (3.9 in ± 1.0 in) below the water surface. For armors that are 

buoyant, weights shall be attached to the bottom edge of the armor with clothes pins or similar 

clips to allow the armor to hang vertically. After removing the panel from the water, it shall be 

hung vertically and allowed to dry for 10 min (+ 5 min/- 0 min) before mounting on the test 

fixture. All testing of the panel shall be completed within 40 min of when the panel is removed 

from the water. 

Conditioned Flexible Vests and Jackets: All flexible vests and jackets that have been 

subjected to the conditioning protocol described in section 5 shall not be submersed but shall be 

tested dry. 

Hard Armors and Plate Inserts: All hard armors and plate inserts shall be submersed 

and tested wet. When plate inserts are tested in conjunction with a flexible vest or jacket, the 

flexible component shall have previously demonstrated its full compliance with this standard at 

its appropriate level. Both the plate and the flexible vest or jacket shall be tested wet. 

7.8.3 Test Threats for P-BFS Tests 

All armors shall be tested with the appropriate threats for the armor type as defined in 

section 2 and listed in table 4. In addition, a manufacturer may specify additional special type 

threats for a particular armor model. 

7.8.4 Test Duration 

The duration of the ballistic test on each armor panel shall be no longer than 30 min, from 

the time the first shot is fired until the last shot is fired. The first shot shall be fired within 10 

min. after completion of the armor submersion cycle described in section 7.8.2. Testing shall be 

repeated if either of these requirements is not met. All test results, including the noncompliant 

test series, shall be reported. Test start and stop times shall be recorded for each test series. 

7.8.5 Requirements for Number of Shots and Number of Armor Samples 

A complete P-BFS test for an armor type consists of the total required number of fair hits 

accumulated on the required number of armor samples for each of the specified test rounds, as 

defined in table 5 for new condition armors and table 6 for conditioned armors. Each armor panel 

or plate shall be subjected to the number of fair hits specified in table 5 or table 6, as appropriate, 

using the specified test round. The shots on each panel shall be fired in order of their location 

numbers, as shown in figure 14. The angles of the shots shall be as specified in table 7. For 

flexible vests and jackets, one shot on each panel shall have an angle of incidence of 30°, and 

one shot shall have an angle of incidence of 45°. The angle of incidence for location 4 on the first 

P-BFS panel tested shall be randomly selected as either 30° or 45°, and the other angle used at 

shot location 5. For all subsequent P-BFS panels of that model, the order of the two angles shall 

alternate. 

 45 
TEST

VARIABLES PERFORMANCE REQUIREMENTS SHOT REQUIREMENTS

Hits Per Hits Per

Conditioned New Panel Maximum Panel at Shots Total

Armor Test Test Bullet Armor Test Armor Test at 0◦ BFS 30◦ or 45◦ Per Panel Panel Panels Shots Shots

Type Round Bullet Mass Velocity* Velocity* Angle Depth Angle† Panel Size Condition Required Required Required

IIA

1 4 2 6

Large New 4 24

144

9 mm 8.0 g 355 m/s 373 m/s 44 mm Conditioned 2 12

FMJ RN (124 gr) (1165 ft/s) (1225 ft/s) (1.73 in) Small New 4 24 Conditioned 2 12

2 4 2 6

Large New 4 24 .40 S&W 11.7 g 325 m/s 352 m/s 44 mm Conditioned 2 12

FMJ (180 gr) (1065 ft/s) (1155 ft/s) (1.73 in) Small New 4 24 Conditioned 2 12

II

1 4 2 6

Large New 4 24

144

9 mm 8.0 g 379 m/s 398 m/s 44 mm Conditioned 2 12

FMJ RN (124 gr) (1245 ft/s) (1305 ft/s) (1.73 in) Small New 4 24 Conditioned 2 12

2 4 2 6

Large New 4 24 .357 Magnum 10.2 g 408 m/s 436 m/s 44 mm Conditioned 2 12

JSP (158 gr) (1340 ft/s) (1430 ft/s) (1.73 in) Small New 4 24 Conditioned 2 12

IIIA

1 4 2 6

Large New 4 24

144

.357 SIG 8.1 g 430 m/s 448 m/s 44 mm Conditioned 2 12

FMJ FN (125 gr) (1410 ft/s) (1470 ft/s) (1.73 in) Small New 4 24 Conditioned 2 12

2 4 2 6

Large New 4 24 .44 Magnum 15.6 g 408 m/s 436 m/s 44 mm Conditioned 2 12

SJHP (240 gr) (1340 ft/s) (1430 ft/s) (1.73 in) Small New 4 24 Conditioned 2 12

III 1 7.62 mm 9.6 g 847 m/s - 6 44 mm 0 6 All Conditioned 4 24 24 NATO FMJ (147 gr) (2780 ft/s) (1.73 in)

IV 1 .30 Caliber 10.8 g 878 m/s - 1 to 6 44 mm 0 1 to 6 All Conditioned 4 to 24 24 24 M2 AP (166 gr) (2880 ft/s) (1.73 in)

Special - Each test threat to be specified by armor Armor performance and shot requirements shall depend on armor type. manufacturer or procuring organization.*Target measurement velocity. Fair hit measurement velocities must be within

± 9.1 m/s (

± 30 ft/s) of this value, as defined in Section 7.6. †Each armor that is to be shot at angles other than 0◦ shall be shot once at a 30◦ angle and once at a 45◦ angle.

Table 4. P-BFS performance test summary 

 46 
Table 5. Number of shots and fair hits on each size of new condition armor samples 

Armor 

Type 

Test Round 

(see table 4) 

Required 

Fair Hits Per 

Test Round 

Required 

Number of 

Complete 

Armor 

Samples 

Required 

Number of 

Armor 

Panels or 

Plates 

Required 

Fair Hits 

per Panel 

or Plate 

Maximum 

Number of 

Shots Allowed 

per Panel or 

Plate 

Required 

Total Fair 

Hits per Size

1 24 2 4 6 8 

IIA 

2 24 2 4 6 8 

48 

1 24 2 4 6 8 

II 

2 24 2 4 6 8 

48 

1 24 2 4 6 8 

IIIA 

2 24 2 4 6 8 

48 

III 1 24 4 4 6 6 24 

IV 1 24 TBD TBD 1 to 6 6 24 

Table 6. Number of shots and fair hits on each size of conditioned samples 

Armor 

Type 

Test Round 

(see table 4) 

Required 

Fair Hits Per 

Test Round 

Required 

Number of 

Complete 

Armor 

Samples 

Required 

Number of 

Armor 

Panels or 

Plates 

Required 

Fair Hits 

per Panel 

or Plate 

Maximum 

Number of 

Shots Allowed 

per Panel or 

Plate 

Required 

Total Fair 

Hits per size

1 12 1 2 6 8 

IIA 

2 12 1 2 6 8 

24 

1 12 1 2 6 8 

II 

2 12 1 2 6 8 

24 

1 12 1 2 6 8 

IIIA 

2 12 1 2 6 8 

24 

III 1 24 4 4 6 6 24 

IV 1 24 TBD TBD 1 to 6 6 24 

 47 
Table 7. Angle of incidence locations 

Armor 

Type 

Test Round 

(see table 4) 

Shot Location(s) 

for Fair Hits at 0° 

Angle of Incidence

Location(s) for Fair 

Hits at 30° or 45° 

Angle of Incidence 

Shot Locations 

for BFS 

Measurement(s) 

1 1, 2, 3, 6 4, 5 1, 2, 3 IIA 

2 1, 2, 3, 6 4, 5 1, 2, 3 

1 1, 2, 3, 6 4, 5 1, 2, 3 II 

2 1, 2, 3, 6 4, 5 1, 2, 3 

1 1, 2, 3, 6 4, 5 1, 2, 3 IIIA 

2 1, 2, 3, 6 4, 5 1, 2, 3 

III 1 All - 1, 2 

IV 1 All - 1, 2 

Before each shot, the armor panel or plate shall be positioned as described in 

section 7.7.2. 

After each shot: The bullet velocity shall be recorded. The actual location of the shot 

shall be examined to confirm that it complies with shot location requirements. The armor panel 

or plate and the backing material shall be examined to determine if a perforation occurred. All of 

the preceding observations shall be considered to determine if the shot was a fair hit, as defined 

in section 7.6. 

If impact is not a fair hit: If an impact is determined to not be a fair hit, a second attempt 

shall be made immediately to obtain a fair hit in the same general location of the preceding 

unfair hit. No more than two attempts shall be made to obtain a fair hit at any general shot 

location. The maximum number of shots on any armor panel or plate shall not exceed the 

number specified in table 5 or table 6, as appropriate. 

If more than two attempts are required to obtain a fair hit for any shot location, the test 

series on that panel shall be considered noncompliant. If the maximum number of allowable 

shots on the given armor panel/plate is exceeded, the test series on that panel/plate shall be 

considered noncompliant. Testing shall be repeated for any panel test series considered 

noncompliant. All test results, including the noncompliant test series, shall be reported. 

If impact is a fair hit: If the impact did not produce a perforation and the shot was a fair 

hit, the BFS depression depth for the locations shown in table 7 shall be measured and recorded. 

If necessary, the backing material shall be struck (as described in section 4.2.5.4) or manipulated 

to produce an acceptable surface for remounting the armor. 

7.8.5.1 BFS Measurement 

The BFS shall be measured using a device capable of 1 mm (0.04 in) or better accuracy. 

The BFS shall be recorded. All measurements necessary to determine the BFS for a shot shall 

use a common reference surface. When the measured BFS exceeds 40 mm (1.58 in), the 

 48 
measurement shall be verified by a second measurement. Additionally, when the measurements 

are not fully automated and human interaction is required with the measuring device or backing 

material, a different individual shall make the second measurement. 

7.8.6 P-BFS Test for Special Type Armor 

The materials of construction and the construction details of special type armor shall be 

examined to determine the appropriate test methodology. 

7.8.7 P-BFS Test for Accessory Ballistic Panels 

7.8.7.1 Groin and Coccyx Protectors 

Each protector shall be tested in its external carrier. Each protector shall be impacted with 

at least three evenly spaced fair hits at an angle of incidence of 0° (24 shots total). A single BFS 

depth measurement shall be taken on the first fair hit impact for each panel, for a total of eight 

BFS measurements. 

7.8.7.2 Removable Side Protection 

Removable side protection panels shall be tested in the primary armor’s external carriers 

as appropriate for each armor model designation. 

The samples shall be tested in accordance with the requirements of sections 7.6 and 7.7, 

placing as many fair hit impacts as possible, but not more than six shots, on each test sample to 

achieve a total of 24 fair hits per test caliber at the prescribed angles of incidence, per table 4. A 

single BFS depth measurement shall be taken on the first fair hit impact for each panel. 

7.8.8 P-BFS Performance Requirements 

Each test panel must withstand the appropriate number of fair hits and may not 

experience any perforations. Any complete perforation by a fair hit constitutes a failure. Fair hit 

is as defined in section 7.6. 

New Samples: Each tested size of an armor model shall either have no BFS depth 

measurements that exceed 44 mm (1.73 in), or for each threat round an estimated probability of a 

single BFS depth measurement exceeding 44 mm (1.73 in) of less than 20 % with a confidence 

of 95 %. 

The armor model shall be deemed to meet these requirements if no BFS depth 

measurement due to a fair hit exceeds 50 mm (1.97 in), and either: 

(a) All BFS depth measurements due to fair hits are 44 mm (1.73 in) or less. 

Or: 

(b) The one-sided tolerance interval for a normal distribution indicates that there is 95 % 

probability that 80 % of the test BFS measurementsfor armor samples of that particular 

 49 
model, size, condition, and test threat will be 44 mm (1.73 in) or less. In this case the 

average, Y , and sample standard deviation, s , of all recorded BFS measurements for 

armor samples of that particular model, size, condition, and test threat shall be calculated, 

and: 

1skY ≤+ mm44

For the case where there are 12 BFS measurements, 568.1 k1 = . For other quantities of 

BFS measurements, or for more details, see appendix D or Reference [9], section 7.2.6.3 

(http://www.itl.nist.gov/div898/handbook/prc/section2/prc263.htm). 

Conditioned Samples: For flexible armors that have been subjected to the conditioning 

protocol described in section 5, the BFS depth shall be recorded. However, an excessive BFS 

measurements will not constitute a failure. 

Table 8. Baseline ballistic limit determination test summary 

Armor 

Samples 

Required 

Test 

Threat 

Ballistic 

Panels 

Required 

Minimum 

Shots 

Required Minimum Penetration Results* 

Test 

Round 1 10 120 At least 60 stops. At least 30 perforations 

Type IIA 

through IIIA 

Approximately 

5 armors per 

caliber. 

Test 

Round 2 10 120 At least 60 stops. At least 30 perforations 

Type III 

4 Armors 

7.62 mm 

M80 FMJ 4 24 6 perforations, 12 stops, 6 either, velocity range of 

27 m/s (90 ft/s) 

Type IV 

2 to 12 Armors 

.30 caliber 

M2 AP 

2 – 12** 12 3 perforations, 6 stops, 3 either, velocity range of 27 

m/s (90 ft/s) 

* When the armor’s ballistic limit is sufficiently high that achieving the velocity necessary to perforate the armor is difficult or 

impossible, the test laboratory shall document that this situation has occurred. In such cases, the test will be considered 

acceptable even if the minimum number of perforations is not achieved. 

** Quantity determined by section 4.1.2.2 and panel, plate, or insert size and ability to withstand multiple impacts. 

7.9 Ballistic Limit (BL) Determination Test 

The appropriate number of armor samples, as defined in section 4.1, shall be subjected to 

BL tests. The armor’s ballistic performance will be estimated from the results. Each ballistic 

panel or plate shall be tested in accordance with the following procedures. 

 50 
7.9.1 Requirements for Number of BL Tests and Test Samples 

A complete BL test for an armor type consists of successful individual BL tests being 

conducted on the required number of armor samples specified in table 8. The armor panels or 

plates that comprise a sample shall each be subjected to a BL test using all threat rounds for 

which the armor will be certified (see table 4). 

(a) Flexible Vests and Jackets: BL testing shall be conducted on complete armor samples 

(e.g., ballistic fabric panels, covers, carriers, and strapping). Removable trauma 

inserts/packs shall not be included as part of the complete armor sample used for BL 

determination. 

(b) Hard Plates: Testing shall be conducted on complete armor samples, except when the 

armor’s Type III or IV protection is provided entirely by rigid panels, plates, or inserts. In 

those instances, only the rigid panels, plates, or inserts shall be tested for baseline BL. 

When plate inserts are tested in conjunction with a flexible vest or jacket, the flexible 

component shall have previously demonstrated its full compliance with this standard at 

its appropriate level. 

7.9.2 Test Procedure Requirements 

The angles of incidence for all shots shall be 0°. All samples shall be tested dry. 

All BL testing shall follow the basic procedures of sections 5.3.3 and 5.3.5 of MIL–STD–

662F; however, the specific test parameters in table 9 shall be adopted. For each panel, shooting 

shall continue until either 12 shots or the maximum number of shots allowed on the panel has 

been reached. For armors that are limited to less than 12 shots, the firing sequence shall be 

continued on additional panels until 12 shots are reached. After each 12 shot sequence, a new 

sequence shall be performed until the total required number of shots as listed in table 8 has been 

reached. 

Table 9. Test parameters and requirements for ballistic limit test 

Parameter Description Value 

Section Reference in 

MIL–STD–662F 

Velocity of first shot The reference velocity for the armor type and 

caliber (table 4). 5.3.3 

– 30.5 m/s (– 100 ft/s) if first shot was a 

perforation. Velocity step until first 5.3.5 

reversal. 

+ 30.5 m/s (+ 100 ft/s) if first shot was a stop. exception to 5.3.5 

Velocity step until a second 

reversal. 

± 22.9 m/s (± 75 ft/s), depending on result of 

previous shot 5.3.5 

Velocity step after second 

reversal. 

± 15.2 m/s (50 ft/s) ), depending on result of 

previous shot 5.3.5 

 51 
When the armor’s ballistic limit is sufficiently high that achieving the velocity necessary 

to perforate the armor is difficult or impossible, the test laboratory shall document this situation 

has occurred. In such cases, the test will be considered acceptable even if the minimum number 

of perforations is not achieved. 

7.9.3 Backing Material Conditioning 

The backing material fixtures shall be prepared and conditioned to the same temperatures 

as those used to conduct the P-BFS tests for that armor model. Drop test validation shall be 

performed before each 12 shot series. However, post-test validation is not necessary. The 

backing material temperature shall be recorded before and after tests on a single armor 

panel/plate. 

7.9.4 Data Set Tabulation 

All shots fired for a BL test shall be reported. The shot information shall be reported in 

the order fired and shall include, at a minimum, shot number, velocity desired, actual velocity, 

and shot outcome. 

7.9.5 Ballistic Limit Performance Requirements 

All Armors: No perforations shall occur at or below the corresponding maxium P-BFS 

fair hit velocity, which is equal to the P-BFS reference velocity plus 9.1 m/s (30 ft/s). 

New Armors: For new condition armors the BL test data shall be analyzed as described in 

appendix E, and the estimated probability of complete perforation at the corresponding P-BFS 

reference velocity must be less than 5 %. In other words, . ,05 new VV ,newref ˆ ≥

 52 
8. REFERENCES

The following references form a basis for and support the procedures described in this 

standard: 

[1] AATCC Recommended Washers and Dryers list, available from 

http://www.aatcc.org/Technical/WashDry.htm

[2] American National Standards Institute. SAAMI Z299.1–1992, Voluntary Industry 

Standards for Pressure & Velocity of Rimfire Sporting Ammunition for the Use of 

Commercial Manufacturers, 1992. 

[3] American National Standards Institute. SAAMI Z299.3–1993, Voluntary Industry 

Standards for Pressure and Velocity of Centerfire Pistol and Revolver Ammunition for 

the Use of Commercial Manufacturers, 1993. 

[4] American National Standards Institute. SAAMI Z299.4–1992, Voluntary Industry 

Standards for Pressure & Velocity of Centerfire Rifle Sporting Ammunition for the Use of 

Commercial Manufacturers, 1992. 

[5] Department of Defense. MIL-STD-662F, Department of Defense Test Method Standard, 

V50 Ballistic Test for Armor, 1997 or latest version. 

[6] Department of Defense. MIL-STD-810F, Department of Defense Test Method Standard 

for Environmental Engineering Considerations and Laboratory Tests, 2000 or latest 

version. 

[7] National Institute of Justice. NIJ Standard–0101.04, Ballistic Resistance of Police Body 

Armor, 2000. 

[8] NIST/SEMATECH e-Handbook of Statistical Methods, 

http://www.itl.nist.gov/div898/handbook/, May 2008. 

[9] U.S. Army Test and Evaluation Command. TOP 2–2–710, Test Operations Procedure, 

Ballistic Tests of Armor Materials, 1984 or latest version. 

 53 
 54 

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APPENDIX A –ACCEPTABLE BULLETS FOR HANDLOADING

Table 10 below lists the acceptable bullets for testing. For the purpose of inter-laboratory 

consistency, for threat levels IIA, II, and IIIA, only those model numbers specified in table 10 

shall be acceptable.1 For threat levels III and IV, bullets from alternate manufacturers may be 

used if they meet the specified weight, geometry, jacket, and core material requirements. 

All jacket materials shall be of copper or copper alloy (approximately 90 % copper and 

10 % zinc), with the exception of Type III, which shall be steel. 

Table 10. Acceptable bullets 

Threat 

Level Caliber 

Bullet 

Weight 

BULLET 

DESCRIPTION 

Nominal 

Bullet 

Diameter 

Acceptable 

Manufacturer 

Bullet 

Model 

Number 

9 mm Luger 8.0 g 

(124 gr) 

FMJ RN 

9 mm 

(.355 in) Remington 23558 

IIA 

.40 S&W 11.7 g 

(180 gr) 

FMJ 

10 mm 

(.400 in) Remington 23686 

9 mm Luger 8.0 g 

(124 gr) 

FMJ RN 

9 mm 

(.355 in) Remington 23558 

II 

.357 Mag 10.2 g 

(158 gr) 

JSP 

9.1 mm 

(.357 in) Remington 22847 

.357 SIG 8.1 g 

(125 gr) 

TMJ 

9.0 mm 

(.355 in) Speer 4362 

IIIA 

.44 Mag 15.6 g 

(240 gr) 

JHP 

10.9 mm 

(.429 in) Speer 

4453 

or 

4736** 

III 7.62 mm NATO 9.6 g 

(147 gr) 

FMJ – SPIRE PT BT* 

7.62 mm 

(.308 in) 

*** *** 

IV 30.06 M2 AP 10.8 g 

(166 gr) 

FMJ – SPIRE PT AP 

7.62 mm 

(.308 in) 

May be obtained from U.S. 

Military M2 AP ammunition 

* Verify that jacket is ferrous (use of a magnet is acceptable). 

** Note: These two models are the same bullet but sold in different quantities. 

*** Bullet may be obtained from U.S. military/NATO M80 ammunition, or from other manufacturers meeting the 

specifications for the projectile in the M80 cartridge. 

 

1

 The use of brand names and model numbers in this standard does not constitute endorsement by the U.S. Department of Justice; 

Office of Justice Programs; National Institute of Justice; U.S. Department of Commerce; National Institute of Standards and 

Technology; Office of Law Enforcement Standards; or any other agency of the United States Federal Government, nor does it 

imply that the product is best suited for other applications. 

 55 
 56 

This page intentionally left blank. 
APPENDIX B –COMMON SPECIAL TYPE THREATS

Table 11 lists some common threat rounds that may be problematic for some armors. 

These threats, with their accompanying test velocities, may be used in the special type testing to 

validate that a particular armor model may stop these rounds in addition to the standard threats. 

The threat rounds listed in the table are not the only rounds that can be tested in the 

special type tests. A purchaser or manufacturer may specify any round for testing with the 

special type tests. These are included in the standard only to simplify the procedure of specifying 

common special threat rounds. 

 57 
 58 

Table 11. Special type threats of particular concern to law enforcement Recommended New Armor Test Velocity (ft/s) 1150 1440 1140 1090 1040 1310 1465 1240 1115 1140 980 1340 1440 1230 1080 1080 

2140 1790 

Recommended 

Conditioned 

Test Velocity 

(ft/s)1120 1410 1110 1060 1010 1280 1435 1210 1085 1110 

950 

1310 1410 1200 1050 1050 2110 1760 

Nominal 

(Factory) 

Velocity (ft/s) 

1060 1350 1050 1000 

950 

1220 1375 1150 1025 1050 

890 

1250 1350 1140 

990 990 

2050 1700 

Diameter 

9 mm (0.355 in) 

9 mm (.355 in) 

10 mm (.400 in) 10 mm (.400 in) 

11.5mm (.451 in) 

9 mm (0.355 in) 9 mm (0.355 in) 10 mm (.400 in) 10 mm (.400 in) 

11.5mm (.451 in) 11.5mm (.451 in) 

9 mm (0.355 in) 9 mm (0.355 in) 10 mm (.400 in) 10 mm (.400 in) 

11.5mm (.451 in) 

5.7 mm (.224 in) 5.7 mm (.224 in) 

Description 

Tactical HP Tactical HP Tactical HP Tactical HP Tactical HP 

GDHP GDHP GDHP GDHP GDHP GDHP 

JHP JHP JHP JHP JHP JHP 

V-Max 

Weight 

135 gr 125 gr 165 gr 180 gr 230 gr 124 gr 125 gr 165 gr 180 gr 185 gr 230 gr 127 gr 125 gr 165 gr 180 gr 230 gr 

28 gr 40 gr 

Caliber 

9mm Luger 

.357 SIG 

.40 S&W .40 S&W 

.45 ACP 

9 mm Luger 

.357 SIG 

.40 S&W .40 S&W 

.45 ACP .45 ACP 

9 mm Luger 

.357 SIG 

.40 S&W .40 S&W 

.45 ACP 

5.7 mm 5.7 mm 

Model 

Tactical Bonded Tactical Bonded Tactical Bonded Tactical Bonded Tactical Bonded 

Gold Dot Gold Dot Gold Dot Gold Dot Gold Dot Gold Dot 

Ranger T-Series Ranger T-Series Ranger T-Series Ranger T-Series Ranger T-Series 

SS192 

SS197SR 

Manufacturer 

Federal Federal Federal Federal Federal 

Speer Speer Speer Speer Speer Speer 

Winchester Winchester Winchester Winchester Winchester 

FN 

FN/Hornady 
APPENDIX C –ARMOR SIZING TEMPLATES

The following five templates are intended for use with most models of flexible armor in 

the form of concealable or tactical vests or jackets. The same templates may be used for male, 

female, or unisex armor designs. The five templates are: 

[1] Template NIJ–C–1 (Smallest) 

[2] Template NIJ–C–2 (Small) 

[3] Template NIJ–C–3 (Medium) 

[4] Template NIJ–C–4 (Large) 

[5] Template NIJ–C–5 (Largest) 

The dimensions of these templates are shown in drawings on the following five pages, 

and the maximum and minimum areas are shown in table 12 below. Table 13 and table 14 list the 

smallest and largest allowable production armors for each of the available template sizes. 

Table 12. Surface areas of armor sizing templates 

Template 

Maximum Area 

(Largest Rear Panel) 

Minimum Area 

(Smallest Front Panel) 

NIJ–C–1 0.0939 m2 (146 in2) 0.0659 m2 (102 in2) 

NIJ–C–2 0.1354 m2 (210 in2) 0.1020 m2 (158 in2) 

NIJ–C–3 0.1835 m2 (284 in2) 0.1443 m2 (224 in2) 

NIJ–C–4 0.2393 m2 (371 in2) 0.1945 m2 (301 in2) 

NIJ–C–5 0.3022 m2 (468 in2) 0.2517 m2 (390 in2) 

Table 13. Minimum allowable surface areas for production armor 

If the smaller 

template tested is: 

The minimum area of 

production armor shall be: 

NIJ–C–1 No limit 

NIJ–C–2 0.0980 m2 (152 in2) 

NIJ–C–3 0.1399 m2 (217 in2) 

NIJ–C–4 0.1890 m2 (293 in2) 

NIJ–C–5 Not applicable 

Table 14. Maximum allowable surface areas for production armor 

If the larger 

template tested is: 

The maximum area of 

production armor shall be: 

NIJ–C–1 Not applicable 

NIJ–C–2 0.1399 m2 (217 in2) 

NIJ–C–3 0.1890 m2 (293 in2) 

NIJ–C–4 0.2455 m2 (381 in2) 

NIJ–C–5 No limit 

 59 
 60 
 61 
 62 
 63 
 64 
APPENDIX D –ANALYSIS OF BACKFACE SIGNATURE DATA

The measured backface signatures from a P-BFS test for new armor shall be analyzed to 

determine if the armor will provide adequate protection against behind armor blunt trauma. The 

requirements given in section 7.8.8 specify that either all measured BFS depths due to fair hits 

shall be 44 mm (1.73 in) or less, or if any BFS depth exceeds 44 mm (1.73 in) then there shall be 

95 % confidence that 80 % of all BFS depths will be 44 mm (1.73 in) or less. In no case may a 

BFS depth exceed 50 mm (1.97 in). 

The requirements of the second condition can be verified using a statistical tolerance 

limit (see section 8, Reference [8]). In this case, we expect a stated portion of the entire 

population of all BFS measurements to lie at or below the statistical upper tolerance limit. To 

achieve this, the population of BFS measurements is assumed to be normally distributed, and the 

upper tolerance limit, , must be less than or equal to 44 mm (1.73 in). The upper tolerance 

limit is defined as: 

YU

U += 1skYY

Here, Y is the average of all BFS measurements for armor samples of that particular 

model, size, condition, and test threat; is the sample standard deviation of the same set of BFS 

measurements; and is a factor that must be determined such that the interval covers the 

appropriate proportion, 

s

1 k

p , with a confidence of γ . 

The average, Y , is simply calculated as: 

∑=

=

N

i

Yi NY

1

1

Here, is the number of BFS measurements, and are the individual BFS 

measurements. The sample standard deviation, , is then calculated as: 

N Yi

s

∑( ) =

− − =

N

ii

i YY

N

s

2

1

1

The approximate k factor, , for a one-sided tolerance interval can now be calculated as 

(see section 8, Reference [8]): 

1 k

a

abzz

k p p −+ = − −

2

1 1

1

 65 
Here, is the normal distribution critical value that is exceeded with a probability of 

. The factors and are defined as: 

p z1−

1− p a b

( 12 ) 1

2

1

− −= −N

z

a γ ; N

z

zb p

2

2 1

1

−γ

− −=

Here, is the normal distribution critical value that is exceeded with a probability of 1−γ z

1− γ . 

For the analysis of BFS measurements according to the requirements of this standard, the 

probability that no BFS measurement exceeds 44 mm (1.73 in) must be at least 80 %, so p = 

0.80, and the required confidence is 95 %, so γ = 0.95. The critical values for the normal 

distribution can be calculated or obtained from tables in many statistical texts. For this case they 

are: 

645.1 ; −γ zz 05.01 == 1− p = zz 20.0 = .0 842

Using these results, the factors a and b can be calculated for a given number, , of 

BFS measurements. For = 12, factors a and b are: 

N

N

( ) 877.0

1122

645.1 1

2

= − a −= ; 483.0

12

645.1 842.0

2

2 b =−=

Then, the k factor, , is: 1 k

( )( ) 568.1

877.0

483.0877.0842.0842.0 2

1 = −+

k =

Other k factors, for quantities of BFS measurements that will be typical of tests 

performed to this standard, are listed in table 15. 

The allowable excessive BFS probability, 20 %, may appear to be high; however, this 

value is intended to account for both the variation in the armor’s performance, which should be 

small, and the variation in the BFS measurement due to the backing material and the backing 

material preparation. While careful treatment and preparation of the backing material by the test 

laboratory can minimize the variation due to the backing material, there will always be some 

inherent variation introduced into the test results by the backing material. The required 

probability is chosen to reduce that possibility that an acceptable armor design will fail the PBFS test due to reasonable variation in the backing material. 

 66 
Table 15. k factors for 80 % probability with 95 % confidence 

Number of BFS Measurements, N k factor, 1 k 

6 2.143 

7 1.961 

8 1.837 

9 1.745 

10 1.673 

11 1.616 

12 1.568 

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 68 
APPENDIX E –ANALYSIS OF BALLISTIC LIMIT DATA

Once the ballistic limit testing has been completed, the test results should be analyzed for 

each test threat by performing a regression to estimate what the armor’s performance will be 

over a range of velocities. In particular, the analysis should attempt to estimate the velocity 

where the probability of perforation becomes reasonably small. In general a logistic regression 

can be used for this purpose; however, other probability distributions and regression methods 

may be used when one can be shown to better estimate the performance of a particular armor 

model. 

The logistic regression may be performed on the data using the method of maximum 

likelihood to estimate the logistic parameters and , which are the estimated logistic 

constant and the estimated velocity coefficient, respectively. These parameters define the shape 

of the S-shaped logistic curve, which is defined as: 

0 β

ˆ 1

ˆ

β

( ) 10

10

1 ββ

ββ

π v

v

e

e

v +

+

+ =

Here π ( ) v is the probability of a complete perforation occurring at velocity, v. From the 

estimated logistic parameters, the ballistic limit can be determined as: 

1

0

50 ˆ

ˆ ˆ

β

− β V =

In addition, the velocity at which the probability of a complete perforation is x %, , can be 

determined as: 

Vx

ˆ

1

0

ˆ

ˆ

1

ln

ˆ

β

⎟ − β ⎠

⎞ ⎜

⎝

⎛

− = x

x

Vx

The estimated logistic parameters for a conditioned armor and its ballistic limit can be 

determined in the same method; however, care should be exercised when the analysis is 

performed on a relatively small data set, as the reliability of the estimated perforation probability 

will be poor for small data sets. 

 69 
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 70 
APPENDIX F –EXPLANATORY MATERIALS

The following information is provided as explanation for the sections indicated.

Explanatory Material for Section 2 NIJ Body Armor Classification 

The ballistic threat posed by a bullet depends on its composition, shape, caliber, mass, 

angle of incidence, and impact velocity, among other things. Because of the wide variety of 

bullets and cartridges available in a given caliber and the existence of handloaded ammunition, 

armors that will defeat a standard test round may not defeat other threats of the same caliber. An 

armor that defeats a given lead bullet may not resist perforation by other bullets of the same 

caliber having different construction or configuration. The test ammunitions specified in this 

standard represent higher velocity versions of threats that law enforcement officers may face in 

the United States, but which also are among the more difficult threats to safely stop. By testing 

armors against these threats, the armor will generally be able to stop a wide variety of similar and 

lesser threats. 

As of the publication of this standard, ballistic resistant body armor suitable for full-time 

wear throughout an entire shift of duty is available in classification Types IIA, II, and IIIA, 

which provide increasing levels of protection from handgun threats. Type IIA body armor will 

provide minimal protection against smaller caliber handgun threats. Type II body armor will 

provide protection against many handgun threats, including many common, smaller caliber 

pistols with standard pressure ammunition, and against many revolvers. Type IIIA body armor 

provides a higher level of protection, and will generally protect against most pistol calibers, 

including many law enforcement ammunitions, and against many higher powered revolvers. 

Types III and IV armor, which protect against rifle rounds, are generally used only in 

tactical situations or when the threat warrants such protection. 

Type I body armor, which was first issued during the NIJ demonstration project in 1975, 

has been removed from this test standard due to the increasing prevalence of higher powered 

threats and the increased power of most law enforcement duty weapons. While it is not yet 

necessary to remove Type IIA armor from service, agencies that are using this level of protection 

are advised to review the threats they face and to consider upgrading to a higher level of 

protection when their current armor reaches the end of its service life. 

Explanatory Material for Section 3 Definitions 

The definition of perforation was added to improve the clarity of the document and make 

the terminology consistent with international standards. Perforation replaces complete 

penetration. Although the terms partial penetration and complete penetration are no longer used 

in this standard, they may still be used for compatibility with military standards. 

 71 
Explanatory Material for Section 4 Sample Requirements and Laboratory Configuration 

4.1 Test Samples 

Ballistic limit testing is not required on smaller sized armor panels for the following 

reasons. Past research has shown that the size of the armor generally has only a small impact on 

the penetrability of the armor and that the larger armors tend to be slightly easier to perforate. 

Therefore, the larger armors are expected to perform slightly worse than the smaller armors. 

Additionally, there is not enough area on the smaller armors for good ballistic limit testing, and 

many more panels would be required for the smaller armors. 

4.1.5 Labeling 

The requirement for English on the label has been removed for the sake of allowing this 

standard to be more widely used. The requirement for use of a particular language for the label 

markings should be inserted into the appropriate conformity program or procurement 

requirements. 

4.2.2.1 Handloads 

Test laboratories are advised to consider factors that might produce variable ballistic 

results (day-to-day variations, powder lot, bullet lot, etc.), and to confirm that required velocities 

will be achieved before testing armor. For ballistic limit testing, sufficiently accurate records 

should be kept for each test threat such that the load required for particular velocity can be 

estimated with reasonable accuracy. 

4.2.2.3 Test Barrel Fixtures 

Test laboratories are advised to verify that correct velocities will be achieved, ensure that 

the test barrel has achieved thermal stability, and use an appropriate aiming system to ensure 

proper placement of the test bullet. 

4.2.4 Armor Submersion Equipment 

No formal test method is provided for measuring impurities in the water used for armor 

submersion. “Visible impurities” refers to seeing any debris, material, or particles floating in the 

water or seeing discoloration in the water. Manufacturers may request fresh water for armor 

submersion of their products. 

Explanatory Material for Section 5 Flexible Armor Conditioning Protocol 

This method may not reproduce all of the humidity effects associated with the natural 

environment, such as long-term effects of exposure to high humidity or to low humidity 

situations. This method does not attempt to duplicate the complex temperature/humidity 

environment but provides a generally stressful situation that is intended to reveal potential 

problem areas in the armor. 

 72 
Accordingly, this procedure does not reproduce naturally occurring or service-induced 

temperature-humidity time histories, nor is it intended to produce humidity effects that have been 

preceded by solar effects. It may induce problems that are indicative of long-term effects. 

Explanatory Material for Section 6 Hard Armor Conditioning Protocol 

This method may not reproduce all of the humidity effects associated with the natural 

environment, such as long-term effects of exposure to high humidity or to low humidity 

situations. This method does not attempt to duplicate the complex temperature/humidity 

environment but, rather, provides a generally stressful situation that is intended to reveal 

potential problem areas in the armor. This test method will not predict the service life of the 

armor. Accordingly, this procedure does not reproduce naturally occurring or service-induced 

temperature-humidity time histories, nor is it intended to produce humidity effects that have been 

preceded by solar effects. It may induce problems that are indicative of long-term effects. This 

method does not simulate an exact period of time in the field, nor is it intended as an absolute 

predictor of actual armor service life. 

There is no armor conditioning requirement for the in conjunction flexible armor 

portions. The plate inserts are required to undergo conditioning, and the flexible armor shall be 

listed on the NIJ Compliant Products List, indicating that they have already passed both 

conditioning and ballistic testing. 

Explanatory Material for Section 7 Ballistic Test Methods 

7.3 Workmanship Examination 

Photographs of all samples are not necessary; however, pretest and post-test photographs 

of all samples, along with photographs of any deficiencies, failures, or unusual results can 

provide useful information to both the armor manufacturer and the conformity assessment body, 

and are, therefore, preferred. Such photographic documentation may be required by either the 

manufacturer or the CTP. 

7.6.1 Minimum Shot-to-Edge Distance 

The minimum shot-to-edge distance for many test threats is now 51 mm (2.0 in), as 

opposed to 76 mm (3.0 in) in NIJ Standard–0101.03 and NIJ Standard–0101.04. This returns the 

limit to distance it was at in earlier versions of the standard. 

For the heavier threat rounds used against the Type IIA, II, and IIIA armors, the 

minimum shot-to-edge distance remains at 76 mm (3.0 in). 

The minimum shot-to-edge distance may be further reduced for a particular model at the 

request of the manufacturer. 

 73 
 74 

7.8 Ballistic Perforation and Backface Signature Testing 

Neither the clay backing material nor the backface signature depth measurement reflects 

characteristics of the human torso or its response to ballistic impact. The clay backing material 

provides a medium for making BFS measurements. 

Explanatory Material for Section 7.9.5 

While not a requirement of the current standard, the ballistic limit results may be used to 

estimate whether a conditioned or a field return has degraded to the point where its performance 

may be questionable. 

From the analysis described above, an acceptable degradation margin for aged armors, 

, can be defined as: V arg inm

This degradation margin is based on the assumption that while the armor’s performance 

will have declined, the velocity coefficient of the performance curve will have remained nearly 

the same. Once this margin has been estimated, and assuming that while the armor’s 

performance will have declined, the velocity coefficient of the performance curve will have 

remained nearly the same, a minimum allowable aged armor ballistic limit may be established. 

For aged armors the ballistic limit should not have degraded more than the degradation margin. 

Due to the limited amount of data available to determine the aged armor ballistic limit, some 

additional reduction might be allowed to account for the variation in the aged armor ballistic 

limit estimate. This leads to a minimal aged armor ballistic limit that can be defined as: 

Or: 

Care should be taken when analyzing response data from aged, and particularly fieldreturned, armors. Ballistic limit test data from armors that have not been aged in the same way 

should generally not be lumped together, and the results from any single specimen may not be 

typical of an armor model. However, if estimated ballistic limits from more than a small 

percentage of aged armors are either close to or less than the established minimum, there may be 

reason to be concerned with the armor’s long term-performance.
About the Law Enforcement and Corrections

Standards and Testing Program

The Standards and Testing Program is sponsored by the Office of Science and Technology of 

the National Institute of Justice (NIJ), Office of Justice Programs, U.S. Department of Justice.

The program responds to the mandate of the Homeland Security Act of 2002, which directed

the Office of Science and Technology to establish and maintain performance standards in 

accordance with the National Technology Transfer and Advancement Act of 1995 (Public Law

104–113) to test and evaluate law enforcement technologies that may be used by Federal, State,

and local law enforcement agencies. The Homeland Security Act of 2002 also directed the 

Office of Science and Technology to establish and maintain a program to certify, validate, 

and mark or otherwise recognize law enforcement technology products that conform to the

standards mentioned above.

The Standards and Testing Program is a basic and applied research effort that determines the

technological needs of justice system agencies, sets minimum performance standards for 

specific devices, tests commercially available equipment against those standards, and 

disseminates the standards and the test results to criminal justice agencies nationally and 

internationally.

The Office of Law Enforcement Standards (OLES) at the National Institute of Standards and

Technology develops voluntary national performance standards for compliance testing to

ensure that individual items of equipment are suitable for use by criminal justice agencies. 

The standards are based upon laboratory testing and evaluation of representative samples of

each item of equipment to determine the key attributes, develop test methods, and establish

minimum performance requirements for each essential attribute. In addition to the technical

standards, OLES also produces technical reports and user guidelines that explain in 

nontechnical terms the capabilities of available equipment.

The National Law Enforcement and Corrections Technology Center (NLECTC), operated by a

grantee, coordinates a national compliance testing program conducted by independent 

laboratories. The standards developed by OLES serve as performance benchmarks against

which commercial equipment is measured. 

Publications are available at no charge through NLECTC. Some documents are also available

online at https://www.justnet.org/justnet.html.To request a document or additional information,

call 800–248–2742 or 301–519–5060, or write:

National Law Enforcement and Corrections Technology Center

2277 Research Boulevard, Mailstop 8J

Rockville, MD 20850

E-mail: asknlectc@nlectc.org

World Wide Web address: http://www.justnet.org

This document is not intended to create, does not create, and may not be

relied upon to create any rights, substantive or procedural, enforceable at

law by any party in any matter civil or

criminal.

Opinions or points of view expressed in

this document represent a consensus

of the authors and do not represent the

official position or policies of the U.S.

Department of Justice. The products

and manufacturers discussed in this

document are presented for informational purposes only and do not constitute product approval or endorsement

by the U.S. Department of Justice.

The National Institute of Justice is a

component of the Office of Justice

Programs, which also includes the

Bureau of Justice Assistance; the

Bureau of Justice Statistics; the

Community Capacity Development

Office; the Office for Victims of Crime;

the Office of Juvenile Justice and

Delinquency Prevention; and the

Office of Sex Offender Sentencing,

Monitoring, Apprehending, Registering,

and Tracking (SMART).