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15 May 2025
A Comparison of International Ballistic Standards
Ballistic standards specify protection levels and the associated testing and certification procedures. These standards offer a flexible framework that can adapt to new threats and technological developments. Some serve as international benchmarks for body armor, ensuring the conformity of materials, designs, and products that provide protection against firearms.
The leading examples are the NIJ standards in the United States, the VPAM guidelines in Europe and national frameworks such as CAST and TR.
This blog post presents these four leading standards, explores their structures, and highlights the key differences among them.
In this blog post:
NIJ standard 0101.07
The NIJ Standard 0101.07 is the current standard from the National Institute of Justice in the United States for body armour ballistic resistance. This standard sets out the minimum requirements and test methods for protection against firearms ammunition, in particular handguns and rifles. This revised version replaces the previous NIJ Standard 0101.06 and has been developed to respond to changing threats and technological developments. The NIJ Standard 0101.07 represents a significant advance in the development of protective equipment. Increased reliability and adaptability to modern threats are achieved through the introduction of new protection levels, improved testing methods and closer alignment with international standards. The new protection levels include:
Threats with handguns (NIJ HG1 and HG2):
- NIJ HG1: Formerly Level II, it is designed for protection against 9 mm Luger FMJ RN projectiles and .357 Mag JSP projectiles.
- NIJ HG2: Formerly Level IIIA, it offers enhanced protection even against threats such as .44 Mag JHP and 9 mm Luger FMJ RN projectiles.
Rifle threats (NIJ RF1, RF2 and RF3):
- NIJ RF1: An upgrade from the previous Level III, which protects against threats such as the 7.62 x 51 mm M80 Ball NATO FMJ and the 5.56 mm M193 BT.
- NIJ RF2: Provides protection against 5.56 mm M855 BT, in addition to the threats covered in RF1.
- NIJ RF 3: The highest level under this standard, which corresponds to the previous level IV, is designed to stop armour-piercing projectiles such as the .30–06 M2 AP. The new guideline includes specific adaptations for protective equipment designed for women. In addition, the shooting position has been redefined to better simulate potential vulnerabilities.
The NIJ Standard 0101.07 represents a significant development in ballistic protection standards. It takes into account the dynamic and complex nature of the threats faced by operators and reaffirms the need to improve safety through rigorous testing and certification of body armour.
A detailed overview of the NIJ 0101.07 update can be found in our blog post.
VPAM standard
VPAM (Vereinigung der Prüfstellen für angriffshemmende Materialien und Konstruktionen) is an organisation dedicated to researching, testing and developing ballistic-resistant materials. Its guidelines provide detailed classifications and assessments of ballistic protection systems, helmets and other protective equipment.
The VPAM standards categorise the resistance of materials against various threats into 14 protection classes.
- Class 1: Suitable for .22 Long Rifle Lead Round-Nose projectiles, tested at a velocity of 360 ± 10 m/s.
- Class 2: Protects against 9×19 mm Parabellum Full Metal Jacket Round-Nose projectiles at 360 ± 10 m/s.
- Class 3: Provides protection against 9×19 mm Parabellum Full Metal Jacket Round-Nose projectiles at 415 ± 10 m/s.
- Class 4: Designed to stop .357 Magnum Jacketed Soft Point projectiles at 430 ± 10 m/s and .44 Magnum Jacketed Hollow Point projectiles at 440 ± 10 m/s.
- Class 5: For .357 Magnum Full Metal Jacket projectiles at a velocity of 580 ± 10 m/s.
- Class 6: Protects against 7.62×39 mm projectiles with soft steel core at 720 ± 10 m/s.
- Class 7: Covers 5.56×45 mm SS109 projectiles at 950 ± 10 m/s and 7.62×51 mm Full Metal Jacket projectiles at 830 ± 10 m/s.
- Class 8: Designed for 7.62×39 mm API BZ projectiles at 740 ± 10 m/s.
- Class 9: Protects against armour-piercing 7.62×51 mm projectiles at a velocity of 820 ± 10 m/s.
- Class 10: Suitable for 7.62×54 mm R API projectiles at 860 ± 10 m/s.
- Class 11: Designed for 7.62×51 mm AP projectiles at 930 ± 10 m/s.
- Class 12: Protects against 7.62×51 mm Swiss P AP projectiles at 810 ± 10 m/s.
- Class 13: Designed for 12.7×99 mm (.50 cal) projectiles at 930 ± 10 m/s.
- Class 14: Protects against 14.5×114 mm API projectiles at 911 ± 10 m/s.
The VPAM stanards are essential for improving the safety and operational effectiveness of police, military and civilian personnel across Europe. Their detailed classification of protection levels and specific ballistic threats provides a clear framework for developing, testing and certifying body armour. This helps to ensure that protective equipment meets the highest safety and effectiveness standards against a wide range of ballistic threats.
Find out more in the blog VPAM.
Technical guidelines
The Technical Guideline (TR) is the key German standard for certifying body armour, particularly for use by the police, military and security forces. It sets high quality and safety standards, which are continuously updated through regular revisions and adjustments in response to emerging threats. This ensures that the TR remains a vital component of personal protective equipment.
The TR distinguishes five safety classes (SK), which depend on the calibre, the type of projectile and the velocity:
- Protection class SK L: Calibre: 9×19 mm, projectile type: FMJ/RN/SC, impact velocity: 360 m/s ± 10 m/s
- Protection class 1 (SK 1): Calibre: 9×19 mm, projectile type: FMJ/RN/SC, impact velocity: 415 m/s ± 10 m/s
- Protection class 2 (SK 2): Calibre: .357 Magnum, projectile type: FMs/CB, impact velocity: 580 m/s ± 10 m/s
- Protection class 3 (SK 3): Calibre: .223 Remington & .308 Winchester, projectile type: FMJ/PB/SCP & FMJ/PB/SC, impact velocity: 950 m/s ± 10 m/s & 830 m/s ± 10 m/s
- Protection class 4 (SK 4): Calibre: .308 Winchester, projectile type: FMJ/PB/HC, impact velocity: 820 m/s ± 10 m/s
Due to the detailed classification of protection levels against specific threats, the TR plays a decisive role in managing the development and testing of ballistic protective clothing.
Further information at the blog TR.
CAST standard
The Centre for Applied Science and Technology (CAST) standard is the British reference for ballistic protective equipment, specifically developed for police and security forces in the United Kingdom. This standard outlines the minimum requirements and testing methods for protection against ballistic threats, knives, and spike weapons.
The CAST standard categorises protection into different classes based on the type of threat and the corresponding test procedures:
These classes relate to protection against firearms.
- H01 Protection against 9 mm at a velocity of 365 m/s
- H02 Protection against 9 mm at a velocity of 430 m/s
- H03 Protection against 7.62 mm NATO munition at a velocity of 830 m/s
- H04 Protection against .308 Winchester at 820 m/s
Knife and spike weapon protection classes
- KR1 Protection against knives with a maximum penetration depth of 8 mm at an energy of 24 J
- KR2 Protection against knives with a maximum penetration depth of 8 mm at an energy of 33 J
- SP1 Protection against spike weapons with a maximum penetration depth of 0 mm at an energy of 24 J
- SP2 Protection against spike weapons with a maximum penetration depth of 8 mm at an energy of 33 J
Life cycle monitoring is carried out periodically to ensure that protective vests maintain their required protective performance throughout their life cycle.
The HOSDB/CAST standards are critical to ensuring that British police officers are equipped with ballistic protective equipment that addresses the particular threats posed by ballistic projectiles and cutting weapons in the UK. The standards focus on reducing the risk of internal injuries caused by blunt force and ensure that body armour meets high safety and performance standards throughout its life cycle.
Further information at the blog CAST.
Summary
In summary, each of these standards has specific requirements and test methods that are tailored to regional threat scenarios and operational conditions.
The NIJ standard is particularly well established among U.S. authorities and in the military industry worldwide. The various protection levels offer coverage against a wide range of threats, including light handguns and armour-piercing ammunition.
VPAM emphasises high testing standards with multiple impact points and European ammunition, making it a leader, particularly in vehicle protection.
The BKA’s technical guidelines are practical and specifically tailored to everyday police operations in Germany. They combine ballistic protection with cut and stab resistance, placing emphasis on wear comfort, traumatic effects and psychophysiological suitability.
The CAST standard is highly focused on urban police use. It considers typical threats such as shotguns, handguns, and improvised weapons. The tests are designed to be rigorous, focusing on maximum recoil energy and injury risk.
These standards play a crucial role in their respective regions by ensuring that protective gear meets local needs and addresses specific threats, while also contributing to the global understanding of ballistic protection and safety.
In conclusion, our examination of global ballistic standards reveals that they are much more than just technical specifications. They are dynamic, continuously evolving systems that demonstrate a commitment to the safety and protection of those on the front line, whether they are police officers, military personnel or civilians. From the NIJ standards in the United States to the VPAM guidelines in Europe and beyond, these frameworks are used to evaluate and guarantee the effectiveness of ballistic protective equipment. They also symbolise the global effort to adapt to an ever-changing threat landscape.
Images and graphics: Mehler Protection (all rights reserved, 2025)
