Choosing
How Much Does Body Armor Weigh: Concealable, Tactical, Assault
· 5 min read · Andrey Sokolov
A concealable vest worn under clothing weighs 1.4-2.9 kg, a tactical vest without plates 3-3.6 kg. But nobody wears an empty vest. With plates, pouches and water the weight grows two to three times, so count everything that will be on you.
How much body armor weighs: the short answer
| Type | Inside | Weight | Example |
|---|---|---|---|
| Concealable, chest and back | soft pack S2, Br1 | 1.4 kg | COYOTE |
| Concealable, all-round | soft Br1 or Br2 pack with sides | 2.6 kg in Br1, up to 2.9 kg in Br2 | DARK ARMOR M-3 |
| Plate carrier | Br1 pack with sides, plate pockets | 1.5 kg without plates | TactiX |
| Tactical | Br2 pack around the body, plate pockets | 3-3.6 kg without plates | ELITE BLACK, DARK ARMOR M-5, DELTA |
| Br5 armor plate | ceramic and UHMWPE, 250×295 mm | 2.75 kg each, 5.5 kg a pair | OBSIDIAN MAX plates |
| Assault kit | vest, neck, shoulder, arm, groin and thigh modules | 9-9.4 kg without plates, 15 kg with two Br5 plates | OBSIDIAN Basic, OBSIDIAN MAX |
Catalog weights are for the standard configuration. In a large size the packs are bigger and the vest is heavier. Check the exact weight of your size before ordering.
What makes up the weight of body armor
A vest's weight comes from four parts:
- Soft pack. The protective fabric insert. In a concealable vest it is the heaviest part. The higher the class and the larger the area, the heavier it is.
- Carrier. Fabric, lining, hook-and-loop and straps. Tactical vests also have webbing for pouches and pockets.
- Plates. The heaviest thing on a tactical vest: two Br5 plates weigh more than the vest itself.
- Modules and gear. Collar, shoulder and groin protection, side straps, pouches, water.
Take our OBSIDIAN MAX. The empty vest weighs 3.3 kg. Clip on the neck, shoulder, arm, groin and thigh modules - now 9.4 kg. Add a pair of Br5 plates - and the scales show 15 kg. So the modules add about 6 kg and the plates another 5.5. The kit's parts are described in our article on assault body armor.
Why Br2 is heavier than Br1
The Br2 test bullet is heavier and faster than the Br1 one. To stop it, layers are added to the pack. Each layer adds grams.
On DARK ARMOR M-3 the difference is about 300 g: 2.6 kg in Br1 and 2.9 kg in Br2. Under a thin shirt the thickness shows more than the weight. Br1 and Br2 compared helps you choose the class.
The material matters too. UHMWPE is a very strong polyethylene made into fibers. It is lighter than aramid (Kevlar) for the same protection. A UHMWPE pack of the same class weighs less. Our packs are UHMWPE.
How much armor plates weigh
The plate is the heaviest part of the vest. Its weight depends on three things - class, material and size:
- Ceramic on a polyethylene backing. Our Br5 plates are made this way: each weighs 2.75 kg and is 23 mm thick.
- Steel. Thinner than ceramic, but heavier at the same class.
- UHMWPE only. The lightest, but thick, and it does not stop every bullet.
Add the vest to the plates: the light TactiX plate carrier with a pair of plates comes to about 7 kg. Which plate material to choose is in ceramic vs UHMWPE.
How long you can wear heavy body armor
There is no rule for civilians on how many hours you can wear a vest. A light concealable vest of 1.4-2.9 kg can stay on all shift. An assault kit of 9-15 kg is worn only for a task: after a few hours the back and shoulders get tired.
A heavy vest is easier to wear when it fits well:
- the side straps are tight, so part of the weight moves from the shoulders to the waist;
- KAP spacer pads sit under the vest: air flows under them, and the plate presses less on the back;
- the plates sit at the right height and do not pull the vest down;
- modules you do not need today are taken off.
How to fit a vest step by step is shown in our guide to putting on a plate carrier.
What weight to choose for the task
- Every day under clothing in the city. A vest up to 3 kg is enough - a concealable Br1 or Br2 model.
- Security, patrols, call-outs. A tactical vest with all-round protection, 3-4 kg without plates. Plates if there is a threat.
- Work near the line of fire. A plate carrier or tactical vest with two Br5 plates, 7-9 kg.
- Assault. A vest with all modules and plates, up to 15 kg.
If two vests cover your risk equally, take the lighter one. A heavy vest gets taken off sooner or later and lies there doing nothing. Not sure what weight you can handle? Ask us by phone at 8 800 101-76-37, the line is free. Tell us where and how many hours in a row you will be in the vest, and we will pick a model.
Frequently asked questions
How much does light body armor weigh? Concealable vests without plates are the lightest. Our COYOTE in class Br1 weighs 1.4 kg.
How much does class 5 body armor weigh? Br5 comes from the plates. One of our plates weighs 2.75 kg, two weigh 5.5 kg. With the vest that comes to 7 to 15 kg.
Which body armor is lighter? The one with a smaller protected area and a UHMWPE pack rather than aramid. Plates add the most weight.
How much does a Kevlar vest weigh? It depends on class and area. Kevlar is a brand of aramid. At the same class it is heavier than UHMWPE; more in the materials comparison.
How long can you wear body armor? There is no rule. A light concealable vest is worn all day, a heavy kit only for the duration of a task.
