Modern naval units are increasingly confronted with asymmetric threats. In addition to conventional attacks by enemy warships or aircraft, pirates, terrorists and non-state actors are playing an increasing role. Ships are particularly vulnerable to small-calibre fire, anti-tank weapons and attacks using explosives when operating near the coast, navigating canals, or in port.
Specific features of protection systems for naval vessels
1. Material selection: corrosion protection and lightweight construction
Protective materials for naval vessels must not only meet ballistic requirements, but also:
- be corrosion-resistant, as sea water is highly corrosive to metallic materials.
- be light, so as not to increase the ship’s weight and, in turn, compromise stability
- be capable of being used in a modular form and flexibly adapted to the mission.
Image: Modular gun mount protection made of ceramic composite panels
Typical materials include ceramic composites, fibre composites or armoured steels with special corrosion protection coatings.
2. Protection of critical areas
Since the full armouring of a ship is impractical, protection focuses on particularly vulnerable areas:
- Bridge and operating rooms to protect crew and control systems.
- Ammunition storage areas to prevent secondary explosions from hits.
- Engine rooms and propulsion sections to maintain manoeuvrability.
Image: Integration into the metallic structures of the bridge
Vulnerability analyses to identify critical vulnerabilities
Detailed vulnerability analyses are necessary to ensure the best possible protection. This involves:
1. Definition and analysis of threat scenarios, e.g. which weapons and types of attack are realistic?
2. Identification of weak points in the hull and superstructure, e.g. which areas need special protection?
3. Definition and testing of protective measures. The development of a protection concept includes the targeted selection of technologies and materials, followed by individual development, design optimisation and validation. Extensive evaluations test the effectiveness of the materials and protective systems.
Particularly problematic are hits that would cause a unit kill, i.e. knock the entire ship out of action, for example by:
- A hit on the ammunition storage areas – risk of a chain reaction.
- Damage to the bridge or operations centre – loss of control.
- Destruction of the engine room – loss of manoeuvrability.
Redundant systems can be used to increase resilience. These systems protect supply lines, communication and navigation systems from secondary fragments and the effects of fire in the event of an overmatch scenario, thus significantly increasing survivability.
Summary
Protecting naval vessels against ballistic threats and RPGs presents unique challenges, as it must balance effective protection with lightweight, corrosion-resistant, and modular design. While STANAG 4569 specifies test methods for protective materials used in land vehicles, there are no standardised threat levels or protection classes explicitly defined for the maritime sector.
Targeted vulnerability analyses and the protection of critical areas such as the bridge, ammunition storage areas and engine rooms allow naval vessels to be effectively protected against asymmetric and conventional threats. However, ballistic protection is always a trade-off between weight, protection and operational flexibility, and poses a constant challenge for naval engineers and armaments experts.
Mehler Protection stands as the technology and market leader for naval protection systems in Europe. With its Multirole Armour Composite Components (M-RACC) system, Mehler Protection offers a modern, modular protection system with a low areal density, which is specially tailored to the requirements of maritime use scenarios. M-RACC systems provide reliable protection against ballistic projectiles and shrapnel as well as shaped charges and anti-tank weapons in maritime threat scenarios, tested in accordance with STANAG 4569 AEP-55, Vol. 1. The protection of critical areas of the ship, such as the bridge, operations centre, machine gun positions and ammunition storage areas, ensures the operational capability of the entire system and significantly increases the crew’s probability of survival. The individual protection solutions are designed by Mehler Protection on the basis of comprehensive threat analyses depending on the intended use and the resulting threat scenario. Based on decades of experience, Mehler Protection offers expertise as a system consultant for the design of naval protection systems and is therefore an important partner for leading shipyards in Europe and around the world.
Images and graphics: Mehler Protection, Mehler Engineered Defence GmbH (all rights reserved, 2025)
