Base Coat vs. Encapsaloc™ Full Coat: Understanding Spall Mitigation for Steel Body Armor

Steel core body armor remains one of the most durable and cost-effective armor options available today. Steel plates are often significantly more affordable while offering exceptional multi-hit capability and long service life.

Steel plates also resist cracking, chipping, and performance degradation from rough handling or repeated impacts. This durability is one reason many civilians, prepared citizens, and professionals continue to choose steel armor systems.

However, steel armor comes with one important consideration: fragmentation, commonly referred to as “spall.”

When a round impacts steel armor and fails to penetrate, the projectile breaks apart. Those bullet fragments must go somewhere and without proper mitigation, fragments can deflect outward along the surface of the plate at high velocity.

This is why fragmentation protection matters.

At Spartan Armor Systems®, we developed Encapsaloc™, our proprietary fragmentation mitigation coating designed specifically for steel body armor applications; not repurposed truck bed liner or generic coatings.

What Happens When a Bullet Hits Steel Armor?

Contrary to what movies often portray, bullets do not simply flatten and disappear when they strike armor.

When steel armor stops a projectile, the bullet typically fractures into smaller pieces. While much of the projectile’s energy is dissipated on impact, fragments can still travel fast enough to cause secondary injuries if not properly contained.

Most fragmentation follows the contour of the armor plate and disperses outward from the impact zone. Modern plate carriers can help reduce some risk, but relying solely on a carrier for fragmentation protection is not ideal.

That’s where dedicated fragmentation mitigation technology becomes critical.

Base Coat vs. Full Coat: What’s the Difference?

When purchasing steel armor, customers are often given two coating options:

Why Not Just Use Truck Bed Liner?

One of the biggest misconceptions in the armor industry is that all anti-spall coatings are essentially the same.

They are not.

Standard truck bed liner products are designed for abrasion resistance and surface protection; not ballistic fragmentation containment. Effective spall mitigation requires a coating engineered to withstand high-velocity projectile fragmentation and repeated impacts.

Encapsaloc™ was developed specifically for armor applications with fragmentation mitigation in mind.

Balancing Protection and Weight

Every armor setup involves balancing protection, weight, mobility, and budget.

A Full Coat of Encapsaloc™ adds additional weight compared to a Base Coat alone, but many users consider the increased fragmentation mitigation well worth it.

For users prioritizing lighter weight configurations, Spartan Armor Systems® also offers additional fragmentation mitigation solutions such as Spall Containment Sleeves.

Some customers choose:

• Base Coat for corrosion protection only
• Base Coat + Spall Sleeve for containment capability
• Full Coat Encapsaloc™ for enhanced fragmentation mitigation
• Full Coat + Spall Sleeve for maximum containment capability

The best setup ultimately depends on your mission requirements, training environment, and personal preferences.

Steel Armor in Today’s Market

Modern body armor technology has evolved significantly over the last decade. While ceramic and composite armor remain excellent choices for lightweight applications, steel armor continues to offer several unique advantages:

• Exceptional durability
• Strong multi-hit capability
• Long service life
• Cost-effective protection
• Resistance to rough handling and environmental conditions

Steel armor is not the right solution for every application, but with proper fragmentation mitigation, it remains a viable option for many prepared civilians and professionals.

Why Choose Spartan Armor Systems® Steel Body Armor?

At Spartan Armor Systems®, we continue to refine and improve our armor solutions to meet the demands of today’s users.

Our Spartan™ Omega™ AR500 and AR550 steel body armor systems are designed to provide dependable ballistic protection with fragmentation mitigation options tailored to your needs.

Whether you prioritize affordability, durability, or maximum protection, we offer configurations built to help you create the armor setup that works best for you.