Blog
5 Jun 2025
Protective vests in use: Measures to protect the equipment
Ballistic protective vests are essential for protecting law enforcement personnel, especially for protecting vital organs. The manufacturer provides a warranty covering the ballistic performance of all internationally certified models of protective vests. Nevertheless, there will come a point when any protective vest will have to be replaced for a number of reasons.
This blog post summarises how to ensure that protective vests provide specified protection throughout the entire warranty period.
Basic principles of ensuring vests long-term protection
- Before using the protective vest – sized according to the wearer’s body measurements – the ballistic inserts must be slotted into place.
- The combined effect of multiple protective packages will only be achieved if all designated protective packages (e.g. hard ballistic panels and soft ballistic panels) are arranged correctly in the vest, typically with the soft ballistic panels positioned closer towards the body and the hard ballistic panels on the side facing the threat.
- Careful attention must also be paid to the orientation of the individual protective elements, as they are not all of the same design. Directions can be found on the labels of the protective inserts (e.g. ‘Body-facing side here’).
- Intended use: The protective inserts must not be used for any purpose other than that for which they are intended; otherwise the warranty may be invalidated.
- When inserting the soft ballistic packages, always check that they do not accidentally bend at any point, as this will create gaps in the protection.
- Regular inspections are required to ensure that all protective inserts are still in good condition and free of damage. Critical damage includes tears in the package covers, broken ceramic plates or PE plates with soft edges.
- Contact with sharp-edged and pointed objects should be avoided as much as possible to prevent damage to the tactical outer cover or the water-repellent covers of the protective packages.
- Objects worn or carried under the vest can become ‘secondary projectiles’ and cause injuries if a bullet strikes the vest at that point. Hard objects above a certain mass, especially metallic ones (e.g. heavy metal buttons and coins), pose a particular risk and should never be worn or carried under a protective vest.
Care and cleaning
Every ballistic of a protective vest and certified to international standards must be labelled with the care instructions that the manufacturer recommends for the ballistic components. Follow the manufacturer’s recommended care instructions, making sure that all other people who take care of the vest are aware of them as well.
Tactical outer cover
The tactical outer cover of the protective vest can be washed and cleaned. For this, the ballistic protective inserts must be removed.
All hook-and-loop fasteners, press studs and zips must be closed before placing the vest in the washing machine to avoid damaging the tactical outer cover. To prevent damage, the tactical outer cover can also be placed in a wash bag before it is laundered.
The care labels sewn into the tactical outer covers provide important information on care and cleaning. They should be observed to ensure the maximum possible service life.
If necessary, debris (such as lint, fine sand, etc.) can be removed from the hook-and-loop fasteners using a brush. Grains of sand and other dirt particles should be removed from zips as required.
Ballistic protective inserts
The protective inserts/packages must not be machine washed. This applies to soft ballistic panels that include stab protection as well as to hard ballistic panels.
The protective packages can be wiped clean with a damp cloth or sponge (using a mild soap solution if necessary). For this, as little liquid as possible should be applied. The use of cleaning agents or alcohol is prohibited. Chemical substances in cleaning agents can make the materials brittle and may impair the protective effect.
Once the protective packages have dried completely, they can be reinserted into the protective cover. Make sure the protective packages are positioned correctly when you reinsert them.
Internationally certified protective packages come with a longer warranty period than protective vest covers. For protective packages certified to the VPAM and TR protective vest standards, the ballistic performance is warranted for 10 years, as stated on the label.
Visibility elements
Visibility elements are signal yellow markings that can be attached to the protective vest to increase visibility during use. These are often labelled with inscriptions, such as ’POLICE’. To maintain their vibrancy for as long as possible, the visibility elements must be washed separately from the protective vest using liquid colour detergent. For this, a gentle wash cycle with the shortest possible running time should be selected. Hook-and-loop surfaces on the back of the signal elements should be covered wherever possible.
Inspection
The protective covering of ballistic packages (‘package cover’) should be inspected for damage regularly, or at the very least during cleaning. Examples of damage include: burst or torn package covers, impact points on the ceramic inserts or soft edges on PE plates.
Damaged inserts must be checked by qualified personnel or, if necessary, the manufacturer must be contacted.
Each protective insert has a warranty date, which must be heeded. This is indicated on the label. Once the period has expired, any further use of the product is at the buyer’s own risk.
The hook-and-loop fasteners, zips and press studs should also be checked regularly to ensure they are functioning correctly. The ballistic packages must be held securely in position. Check the vest cover regularly for damage, such as open seams or holes in the fabric. In case of damage, professional repair or replacement has to be arranged.
Storage and transport
Protective vests must be stored in a dry location. Wet protective vests need to be dried thoroughly before storing them. Protective inserts should be removed. The protective vest and inserts should be stored in a well-ventilated area.
The vests should not be subjected to unnecessary mechanical stress. For example, they should not be thrown, and no other hard or heavy items should be stored on top of them.
Storage conditions: Store at room temperature in a clean, dry, well-ventilated area; vests should be laid flat.
If necessary, the protective vest covers can also be aired briefly on a coat hanger with broad, supportive shoulders. However, this depends on the material of the tactical outer cover and the weight of the vest.
All hook-and-loop fasteners, press studs and zips must always be closed before storing and transporting the vest to avoid damaging the tactical outer cover.
Repairs
Damage to the ballistic inserts can impair the protective effect. The relevant elements must be submitted to the employer for assessment and, if necessary, sent to the manufacturer for repair.
After a bullet impact or an attack with pointed weapons, the relevant insert must be replaced. Inserts must not be reused.
Minor damage to the vest cover, such as a detached hook-and-loop fastener or an opening seam, may be repaired on site at the user’s workshops. The protection packages must be removed beforehand for safety reasons. In the event of major damage requiring repair, the manufacturer should be contacted.
Summary
The 10-year ballistic protection warranty is more than a firm promise, it is a binding obligation. The only way to maintain this protective effect throughout the entire warranty period is to care for the vest properly, inspect it regularly and store it correctly.
Before using the vest, care must be taken to ensure that all protective components are correctly integrated and arranged. No hard objects should be worn or carried under the vest. The outer cover can be washed in accordance with the care instructions, while the protective inserts may only be wiped down with a damp cloth. Visibility elements must be washed separately using a gentle cycle. Regular inspections for damage and functional closures are essential. The vests should be stored flat in a dry location, free from any pressure, weight or stress. Minor damage to the cover may be repaired on site; damaged protective inserts must be replaced or inspected by qualified personnel.
Mehler Protection, Mehler Vario System GmbH (All rights reserved, 2025)
