What is Spall and Why is it Dangerous?
Spall refers to the dangerous fragments of a bullet or other projectile that can break off upon impact with hard armor plates. These high-velocity fragments can cause serious injury to the wearer if not contained.
That's where spall guards come in - they are designed to contain these fragments and protect the body armor wearer from spall injuries. But how well do they actually work? Let's take a closer look.
How Do Spall Guards Work?
Spall guards, also known as spall liners or spall coatings, are typically made from tough, flexible materials like Kevlar or Dyneema that catch and contain bullet fragments. They are built into plate carriers as a protective layer between the armor plates and the wearer's body.
Some key things to know about how spall guards function:
- Positioned to contain spall coming off the strike face of hard armor plates
- Designed to remain intact and not break apart from spall impacts
- Work in conjunction with the plate carrier and plates as part of a spall protection system
Spall Guard Materials and Construction
The effectiveness of a spall guard depends a lot on what it is made of and how it is built. Most spall guards used in body armor today are constructed from aramid fibers like Kevlar or high-strength polyethylene materials like Dyneema.
These materials are chosen for spall guards because they are:
- Extremely strong and tear-resistant to withstand spall impacts
- Lightweight and flexible to move with the wearer
- Heat-resistant to avoid breaking down from friction
- Able to catch and contain spall fragments
The way the spall guard is layered and integrated into the plate carrier also matters for spall protection. Spall guards are typically sandwiched between the strike face of the armor plate and the plate carrier fabric.
How Effective are Spall Guards?
Testing has shown that spall guards, when properly designed and integrated into body armor systems, can significantly reduce spall injuries. In some cases, good spall guards can contain up to 95% of spall fragments generated by bullet impacts on hard armor plates.
However, it's important to recognize that no spall protection is 100% effective. While spall guards substantially improve protection, they do not completely eliminate the risk of spall injuries, especially for high-velocity, armor-piercing rounds.
Spall guard effectiveness depends on factors like:
- Materials used and quality of construction
- Fit and coverage area on the armor plates
- Type of projectiles and velocities encountered
- Overall condition and integrity of the body armor system
So while spall guards are a proven way to boost protection, wearers should not consider themselves invincible. Tactics, situational awareness and keeping armor in good condition still matter.
Choosing Body Armor with Quality Spall Guards
For those who wear or rely on hard body armor plates, spall guards are an important part of protection that should factor heavily into gear selection. Look for trusted body armor brands that use top-quality, tested spall guard materials and designs.
Some things to look for in plate carriers with good spall protection:
- Kevlar, Dyneema or similar spall guards built-in
- Full coverage of plate strike faces
- Spall guards that stay in place and in good condition
- Plate pockets that snugly retain armor plates
- Overall carrier construction that supports spall guards
At PivotalBodyArmor, we only carry plate carriers with quality, built-in spall guards as part of our commitment to providing the best protection possible. Spall protection is a standard feature, not an add-on.
Real-World Impact of Spall Guards
While lab testing shows the clear protective value of spall guards, their ultimate measure is how they perform in the real world for those who wear body armor at work or in the field.
In real-world incidents, spall guards have proven themselves to be an important layer of defense. There are many cases of spall guards stopping dangerous fragments that could have otherwise caused serious injuries to law enforcement officers and military personnel after their armor plates were struck.
Spall guards offer an extra confidence factor for dangerous situations. Wearers know that in addition to their armor plates, they have a dedicated spall layer working to trap bullet fragments if the worst should happen.
This is especially important as more high-velocity and armor-piercing threats are showing up on streets. Spall guards boost protection against these dangerous rounds.
Maintaining Spall Guard Effectiveness
For spall guards to do their job, they must be properly cared for and maintained just like the rest of the body armor system. Dirty, worn out or poorly-fitting spall guards can compromise protective performance.
Tips for keeping spall guards in top condition:
- Follow manufacturer instructions for cleaning/decontaminating
- Inspect for cuts, tears, or thinning material
- Avoid bleach, solvents or harsh chemicals that degrade spall liners
- Ensure spall guards are properly seated in plate carrier after cleaning
- Replace spall guards at recommended intervals or if damaged
With proper care, quality spall guards can last for years and provide reliable spall protection over the service life of a set of armor plates. But once spall guards start to degrade, it's important to replace them ASAP.
The Bottom Line on Spall Guards
In summary, spall guards have proven themselves to be an effective and important part of modern body armor systems. While not 100% perfect, they significantly reduce the risk of dangerous bullet fragmentation injuries.
For anyone wearing or depending on hard armor plates, spall guards are a must-have protective feature to look for in a quality plate carrier setup. Good spall guards, combined with robust plates and proper wear, provide the best possible protection against ballistic threats.
Here at PivotalBodyArmor, you can trust that all our plate carrier offerings have top-quality spall protection built in. We believe in providing the highest level of protection possible to those who serve.
If you have any questions about spall guards or need help finding the best body armor setup for your needs, please reach out to our expert team. We're always happy to help.