Types of Armored Steel Used in Vehicles – Ballistic & Military Grades Guide

Types of Armored Steel Used in Vehicles – Ballistic & Military Grades Guide

Types of Armored Steel Used in Vehicles

From military tanks to civilian bulletproof cars – Understanding ballistic steel grades (Updated 2026)

What is Armored Steel?

Armored steel, also known as ballistic steel or armor plate, is a high-hardness alloy specially engineered to withstand bullets, shrapnel, fragments, and sometimes explosive forces. It achieves this through extreme hardness (measured in Brinell Hardness Number – BHN), combined with toughness to prevent cracking on impact.

There are two primary categories:

  • Military-grade ballistic armor – Certified to strict standards like MIL-DTL-46100, MIL-A-12560, or STANAG 4569
  • Abrasion-resistant (AR) steels – Often used in civilian armoring or as cost-effective alternatives (e.g., AR500, AR550)
M1A2 SEPv3 Abrams Main Battle Tank in action M1E3 Abrams pre-prototype – next-generation tank development M1 Abrams main battle tank side view

Common Types of Armored Steel – Comparison Table

Grade / Spec Category Typical Hardness (BHN) Common Thickness Main Applications Protection Level (examples)
MIL-DTL-46100 Military High Hardness Armor (HHA) 477–534 0.1" – 2" Tanks, APCs, MRAPs, add-on kits High-velocity AP rounds, sniper threats
MIL-A-12560 Military Rolled Homogeneous Armor (RHA) 330–410 Up to 12" Tank hulls, blast-resistant structures Fragments, lower-velocity projectiles, explosions
AR500 Abrasion Resistant (civilian/military crossover) 470–540 0.2" – 1" Civilian armored vehicles, body armor, targets Handguns to 7.62mm FMJ (multi-hit in thicker plates)
AR550 / AR600 Ultra-High Hardness Abrasion Resistant 525–650 Thinner possible Lightweight VIP vehicles, high-threat armoring Rifle rounds, some AP threats (weight savings)
Proprietary (Armox, Quardian, Hardox ballistic grades) Commercial Ballistic Steels 477–600+ Varies Armored sedans, cash-in-transit vans, police vehicles B4–B7 / VPAM levels (handguns to 7.62 AP)
Important: Military grades require official ballistic certification and toughness testing. AR steels are primarily for wear resistance and may not always meet full ballistic specs unless independently tested.

Popular Grades in Real-World Use

1. MIL-DTL-46100 – Military Workhorse

The go-to for modern armored fighting vehicles. Provides excellent protection against high-velocity threats while remaining weldable and formable.

2. AR500 – Civilian & Budget-Friendly Choice

Widely used in private security vehicles and DIY armoring due to its balance of cost, availability, and performance against common rifle rounds.

3. AR550/AR600 – Lightweight High-Performance

Higher hardness allows thinner plates, reducing weight in executive armored cars without sacrificing protection.

Ballistic steel plating with spall protection coating Close-up of armored vehicle steel plating Detailed view of armored steel plate surface

Examples in Civilian Armored Vehicles

Bulletproof civilian SUV with armored steel integration Modern civilian armored vehicle exterior Armored Cadillac Escalade ESV – luxury protection

Key Factors When Selecting Armored Steel

  • Threat Level: Match hardness and thickness to expected threats (handgun vs. rifle vs. AP)
  • Weight Penalty: Harder steels allow thinner/lighter protection but can be more brittle
  • Weldability/Formability: Critical for vehicle integration; extreme hardness can cause cracking
  • Certification & Testing: Military needs certified plates; civilian often uses tested commercial equivalents
  • Cost & Availability: AR500 is most affordable and readily available
MIL-DTL-46100 armor steel plate example Humvee with added MIL-46100 armor plating AR500 / PRO500 ballistic steel plate for vehicles

Armored steel continues to evolve, with next-gen developments like the M1E3 Abrams pushing boundaries in protection and weight reduction. Choosing the right grade is essential for effective, reliable vehicle armor.

Stay protected. 🛡️

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