A newly released report from Russia’s NII Stali research institute reveals that, amid severe equipment losses and an ongoing shortage of high-quality gear, Russian forces have begun experimenting with improvised reactive armor using sand and cement. NII Stali—the Scientific Research Institute of Steel—analyzed tests involving a mixture of Portland cement and sand, aiming to use the materials to absorb kinetic energy upon impact and help disperse the energy from explosions.
Cement and Sand in Russian Armor
The concept is to bolster the protection of widely used, older vehicles like the T-62 and T-72 tanks, as well as armored personnel carriers, with cheap and readily available materials. In theory, these materials could enhance survivability. In practice, however, the results fall far short of modern explosive reactive armor (ERA) systems. Unlike standard ERA modules, which include explosive charges designed to disrupt incoming projectiles, sand and cement do not explode and provide only minimal resistance to shrapnel or armor-piercing rounds.
This makes such modifications largely ineffective—providing little more than the illusion of added protection. Worse still, swapping out proper ERA components for cement and sand could turn armored vehicles into death traps for their crews. Not only does this reduce the vehicle's actual defensive capability, but it also lowers morale among soldiers who understand how vulnerable they are against modern threats.
Disturbingly, these improvised "concrete" armor structures are not limited to test facilities. Observers on the front lines in Ukraine have reported seeing Russian vehicles equipped with what appears to be ERA, but is in fact filled with construction materials. These crude decoys highlight the logistical struggles facing the Russian military and their inability to supply adequate, modern components for their armored units.
NERA: A Safer, Smarter Alternative?
Russia’s armored warfare crisis has also prompted engineers to explore Non-Explosive Reactive Armor (NERA) as a potential upgrade path. Unlike traditional ERA, NERA does not use explosives. Instead, it relies on a multi-layered structure composed of metal plates and elastic materials such as rubber, plastic, or special composites. When struck by a projectile, the inner flexible layer compresses and expands rapidly, causing the steel plates to shift and disrupt the penetrative power of shaped charges or armor-piercing rounds.
The biggest advantage of NERA is its safety. Since it lacks explosive components, it can be deployed near friendly troops, in support vehicles, or in urban environments without the risk of accidental detonation. It also simplifies storage, handling, and logistics.
NERA technology is already in use by NATO forces. Elements of it are found in the Israeli Merkava, modern versions of the M1 Abrams, and European platforms like the Leopard 2A7. Ukrainian defense engineers are also exploring NERA as a more reliable alternative to traditional ERA—especially in light of battlefield threats like drones and tandem warheads, which can defeat older armor systems.
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