Russians turn to cement armor amidst equipment shortages
A recently published report from the Russian research institute NII Stali indicates that Russians, facing significant equipment losses and a chronic shortage of high-quality gear, have decided to experiment with the construction of reactive armor (ERA). They have begun incorporating cement and sand into these structures.
NII Stali, or the Scientific Research Institute of Steel, presented an analysis of experimental tests involving armor with a mixture of sand and Portland cement. This mixture is intended to absorb some kinetic energy upon impact and act as an additional element to disperse explosion energy.
Cement and sand in Russian tanks
In theory, Russians are trying to enhance the effectiveness of the most cost-effective and readily available forms of vehicle protection, particularly for mass-produced T-62 and T-72 tanks and armored personnel carriers. In practice, however, these "reinforcements" do not compare to the explosive charges used in modern ERA modules.
Sand and cement do not detonate and only moderately dampen the impact of a projectile or shrapnel, making this modification at best a partial measure and at worst an illusory form of protection. Replacing the traditional ERA equipment with these materials could turn a tank or armored vehicle into a deadly trap for the crew. This solution not only reduces protection effectiveness but also demoralizes soldiers, who understand that their survival chances against modern weaponry are greatly diminished.
It is also concerning that these solutions extend beyond laboratory research. Experts observing the battlefield in Ukraine report that makeshift "concrete" armors do indeed appear on Russian vehicles. Some are equipped with structures resembling reactive armor but are, in reality, decoys or filled with construction mixtures.
This situation highlights issues with Russian logistics and the provision of modern components. If sand and cement are meant to replace advanced composite materials and explosive charges in ERA armor, it not only reduces effective protection but also demoralizes crews aware of their decreased survival prospects against modern weapons.
NERA as a chance for enhancing tanks?
The ongoing crisis in Russia's armored forces is also prompting engineers to create new types of non-explosive reactive armor, or NERA. This modern type of armored vehicle protection—unlike classic ERA—does not use explosive charges.
NERA operates on the mechanical reaction of material layers to an impact. It features a multi-layered structure, usually comprising metal plates and flexible inserts made of rubber, plastics, or special composites. When a projectile hits this armor, the flexible layer between steel plates undergoes rapid compression and expansion, causing a dynamic shift in the outer layers. This reaction disrupts the stability of the cumulative jet or penetrator core, significantly reducing its piercing capability.
The main advantage of NERA is the absence of explosions, allowing its use on vehicles in close proximity to friendly units—infantry, support vehicles, or in urban settings—without the risk of explosion-related side effects. It also eases maintenance and transportation, since NERA is not classified as an explosive material.
This technology is being increasingly adopted in NATO armies, with elements found in systems like Israeli Merkava tanks, modern variants of the Abrams, and European projects such as the Leopard 2A7. Notably, NERA solutions are also being developed within the Ukrainian defense industry, where local engineers are exploring alternatives to classic ERA in response to battlefield challenges, including threats from drones or tandem warheads.
