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Injury, Int. J.

Care Injured 47 (2016) 1932–1938

Contents lists available at ScienceDirect

Injury
journal homepage: www.elsevier.com/locate/injury

Determining the dimensions of essential medical coverage required by


military body armour plates utilising Computed Tomography
J. Breezea,* , E.A. Lewisb , R. Fryerc
a
Academic Department of Military Surgery and Trauma, Royal Centre for Defence Medicine, Birmingham Research Park, Birmingham B15 2SQ, United
Kingdom
b
Defence Equipment and Support, Ministry of Defence Abbey Wood, Bristol, BS34 8JH, United Kingdom
c
Platform Systems Division, Defence Science & Technology Laboratory, Portsdown West, Fareham, Hampshire PO17 6AD, United Kingdom

A R T I C L E I N F O A B S T R A C T

Introduction: Military body armour is designed to prevent the penetration of ballistic projectiles into the
Keywords: most vulnerable structures within the thorax and abdomen. Currently the OSPREY and VIRTUS body
Anthropometric
armour systems issued to United Kingdom (UK) Armed Forces personnel are provided with a single size
Plate
Ballistic
front and rear ceramic plate regardless of the individual’s body dimensions. Currently limited
Body armour information exists to determine whether these plates overprotect some members of the military
Anatomy population, and no method exists to accurately size plates to an individual.
Coverage Method: Computed Tomography (CT) scans of 120 male Caucasian UK Armed Forces personnel were
Military analysed to measure the dimensions of internal thoraco-abdominal anatomical structures that had been
Bullet defined as requiring essential medical coverage. The boundaries of these structures were related to three
potential anthropometric landmarks on the skin surface and statistical analysis was undertaken to
validate the results.
Results: The range of heights of each individual used in this study was comparable to previous
anthropometric surveys, confirming that a representative sample had been used. The vertical dimension
of essential medical coverage demonstrated good correlation to torso height (suprasternal notch to iliac
crest) but not to stature (r2 = 0.53 versus 0.04). Horizontal coverage did not correlate to either measure of
height. Surface landmarks utilised in this study were proven to be reliable surrogate markers for the
boundaries of the underlying anatomical structures potentially requiring essential protection by a plate.
Conclusions: Providing a range of plate sizes, particularly multiple heights, should optimise the medical
coverage and thus effectiveness of body armour for UK Armed Forces personnel. The results of this work
provide evidence that a single width of plate if chosen correctly will provide the essential medical
coverage for the entire military population, whilst recognising that it still could overprotect the smallest
individuals. With regards to anthropometric measurements; it is recommended, based on this work, that
torso height is used instead of stature for sizing body armour. Coverage assessments should now be
undertaken for side protection as well as for other non-Caucasian populations and females, with
anthropometric surveys utilising the three landmarks recommended in this study.
Crown Copyright ã 2016 Published by Elsevier Ltd. All rights reserved.

Introduction structures requiring coverage need to be articulated. These are


medical judgments dependent on, for example, distance from a
Body armour is a type of protective equipment worn by military medical facility and the types of threats requiring mitigation.
personnel designed to prevent or reduce injury from ballistic Coverage can then be modified by means of a risk-based analysis
projectiles penetrating structures within the thorax and abdomen that includes human factors considerations such as comfort, fit,
[1]. To optimise the design of body armour; the anatomical equipment integration and interoperability [2].
A recent multidisciplinary review identified the anatomical
structures of the thorax and abdomen which if damaged would
likely lead to death within 60 min without definitive surgical
* Corresponding author at: ST6 Registrar Maxillofacial (Head and Neck) Surgeon,
Academic Department of Military Surgery and Trauma, Royal Centre for Defence
intervention: these are the heart, great vessels, spleen and liver [1].
Medicine, United Kingdom. Such essential medical coverage is currently provided to UK Armed
E-mail address: johno.breeze@gmail.com (J. Breeze). Forces in the form of single sizes of front and rear OSPREY plates

http://dx.doi.org/10.1016/j.injury.2016.06.010
0020-1383/Crown Copyright ã 2016 Published by Elsevier Ltd. All rights reserved.
J. Breeze et al. / Injury, Int. J. Care Injured 47 (2016) 1932–1938 1933

Fig. 1. The OSPREY hard armour plates providing the front (left) and rear (right) components of thoraco-abdominal essential medical coverage currently provided to UK
Armed Forces personnel.

(Fig. 1); these plates cover all of the aforementioned structures in the literature describing whether or not internal organs simply
with the exception of the most inferior portion of the abdominal scale proportionally with increased height. Both liver and spleen
aorta and inferior vena cava from front and rear angles (Fig. 2). size have been shown to increase with height but the relationship
Coverage of this area was not possible for ergonomic consider- shows poor correlation [10–20]; in other structures such as the
ations; for example hard armour is rigid and therefore may limit pancreas and aorta diameter, taller people have proportionally
the adoption of certain postures, such as sitting within a vehicle. smaller structures than shorter people [21,22].
Anthropometric surveys of military personnel have the poten- Previous research into helmet and neck coverage demonstrated
tial to provide data to size and scale body armour to an individual that utilising hard tissue (i.e. bone) landmarks for coverage
[3–6]. These in turn could be supplemented by assessments on assessments are more reproducible than soft tissue landmarks as
computerised geometric representations of human anatomy, they do not alter with changes in the subject’s body mass [23,24].
provided the anatomical structures were accurately scaled An example for the thoraco-abdominal region is the umbilicus
(Fig. 2) [7–9]. The most comprehensive anthropometric study of (belly button), which is commonly believed to be a surface
UK Armed Forces personnel to date was undertaken by QinetiQ, landmark representing the bifurcation of the aorta (i.e. the lower
and measured 2470 subjects (2159 male, of which 1395 were border of essential medical coverage) [25–27]. The closest bone
Caucasian and 924 of these were Army or Royal Marine personnel). landmark to this is the superior border of the iliac crest of the hip,
[4]. However the only relevant values in these existing anthropo- but this has never been measured in military anthropometric
metric surveys, in terms of body armour coverage, is the stature surveys before. The only relevant palpable bone landmark for
(standing height) of an individual; this is because, prior to this thoraco-abdominal coverage that has been measured in such
study, no evidence exists to link the remaining external measure- previous anthropometric surveys is the suprasternal notch [3,6].
ments to internal anatomical structures. In addition, no work exists The suprasternal notch is a potentially useful landmark as it has

Fig. 2. Front (a) and rear (b) OSPREY body armour plates superimposed upon a computerised geometric representation of those internal anatomical structures requiring
essential medical coverage, positioned as fitted in current UK issue carrier. It should be noted that the inferior parts of the vessels not covered by the plates are still covered by
soft armour.
1934 J. Breeze et al. / Injury, Int. J. Care Injured 47 (2016) 1932–1938

been described as being just above the most superior point of the
arch of the aorta (i.e. the upper border of essential medical
coverage) [25–27], and has been used for a number of years to
position ceramic plates in UK body armour vests. As such, torso
height – defined as suprasternal notch to iliac crest (most vertical
points when viewed in horizontal axial plane) – could be related to
essential medical coverage of the thorax and abdomen.
The aims of this research were to determine the size, location
and variation of internal anatomical structures within a military
population from CT scans of UK Armed Forces personnel. These
internal anatomical structure location could then be related to
external bone landmarks to enhance fitting and sizing. Finally the
aim was to exploit the measurements obtained from CT scans to
provide evidence for the size and shape of body armour plates to Fig. 4. A demonstration of how the horizontal distance between the most lateral
optimise the anatomical coverage they provide. points of the liver and spleen were determined from a contrast CT scan. This
distance is the lower horizontal component of essential medical coverage (Distance
Method H).

Contrast CT ‘trauma' scans of 120 consecutive UK Armed Forces The height measurements were compared to data derived from the
personnel evacuated to the Queen Elizabeth Hospital Birmingham QinetiQ anthropometric study [4] using a two tail z-test with a
(QEHB) between 17 June 2009 and 19 March 2013 were analysed. significance level of p = 0.01 to ascertain whether this was a
Stature (vertex of scalp to sole of feet) of these individuals upon representative sample.
admission to hospital was determined, as recorded by a nurse The vertical and horizontal distances between specific soft
using a tape measure or using their military identification card. tissue and bone landmarks were determined from the CT scans
These scans were taken as part of the trauma call protocol for all (Fig. 3). Vertical distances were determined by measuring the
injured service personnel in Afghanistan as part of their initial distance between horizontal planes taken at most superior and
assessment. Analysis of these scans was approved by the Medical inferior points of that structure. Horizontal measurements were
Directorate of the Defence Medical Services. recorded as the distance between the most lateral points of each
Scans were excluded if there was any damage to structures anatomical structure (Figs. 4 and 5). Slice thicknesses prior to 16
within the thorax or abdomen as well as any in whom stature July 2010 were 1.0 mm and 3.0 mm; after this date 1.25 mm slices
information was not available. To increase the statistical strength were used.
of any conclusions made, only scans of male Caucasians were used.

Fig. 3. A pictorial representations of the measurements made from CT scans using an anatomically accurate three- dimension computer geometrical model.
J. Breeze et al. / Injury, Int. J. Care Injured 47 (2016) 1932–1938 1935

that the CT scan sample was representative. Both total height and
torso height were found to be normally distributed. Calculated
distances derived from CT between thoracic and abdominal
anatomical structures were arranged into percentiles (Table 3).
The three surface (bone) landmarks were able to accurately
represent the position of each underlying soft tissue structure
(Table 4). For example the position of the suprasternal notch
ranged from 20 mm below the aortic arch to 27 mm above it (with a
mean distance of 9 mm above the arch). In 107/120 (89%) CT scans,
torso height (Distance G) was larger than essential vertical
coverage (Distance D). Stature demonstrated poor correlation to
all of the components of essential medical coverage i.e. as height
increases the size of coverage does not necessarily increase. Torso
height demonstrated the best correlation to essential vertical
Fig. 5. Maximum heart diameter was determined to the left (Distance K) and right coverage, but poor correlation to the horizontal parameters
(Distance J) of the midline (dashed line). The heart can be seen to sit more to the left (Table 5); this means that as torso height increases, the vertical
of the midline. component of coverage increases proportionally. There was poor
correlation between stature and torso height (R2 = 0.011), meaning
The most superior point of the arch of the aorta (i.e. the upper that those taller individuals do not necessarily have greater torso
border of essential medical coverage) was related to the supra- height than shorter individuals.
sternal notch (distance i, Fig. 6). The bifurcation of the aorta (i.e. the Within the population sampled, the vertical component of
lower border of essential medical coverage) was related to the essential medical coverage (Distance D in Fig. 3 and Table 1), had a
superior border of the iliac crest in the mid clavicular plane range of 111 mm between the minimum value (305 mm) and
(distance iii). In addition the lower border of the liver was related maximum value (416 mm). This suggests that if a single height of
to the lower border of the ribcage in the mid clavicular plane body armour plate is used then this could overprotect a large
(distance ii). Stature (distance N) and torso height (suprasternal proportion of the population. For example, a plate height based on
notch to superior border of the iliac crest, distance G) were the vertical component of essential medical coverage from the
correlated using linear regression analysis to both the vertical and 50th percentile soldier in this study (353 mm) could theoretically
horizontal components of essential medical coverage. overprotect the shortest soldier by 48 mm.
The horizontal components of essential medical coverage did
Results not correlate with either total or torso height i.e. as height
increased the horizontal components of coverage did not
The clinical heights of the 120 soldiers sampled in this study necessarily increase and often decreased. This finding means that
ranged from 1690 mm to 1930 mm (Table 2). The heights at each should multiple widths of plate be required, another method of
percentile were compared to the 924 Army and Royal Marine sizing them is required other than torso height, such as measuring
Caucasian male subjects from the 2007 QinetiQ anthropometric waist circumference. However, there was little variation in these
survey which ranged from 1600 mm to 2014 mm [4]. Using a two horizontal components of coverage across the population.
tail z-test with p < 0.01 the null hypothesis was rejected suggesting Therefore choosing a single plate width for the lower horizontal

Fig. 6. Relating the horizontal components of essential medical coverage to surface bone landmarks; i = arch of the aorta to suprasternal notch (1), ii = lower border of the liver
was related to the lower border of the ribcage (2), iii = bifurcation of the aorta to iliac crest (3). Note the distances are not to scale to enhance visual clarity.
1936 J. Breeze et al. / Injury, Int. J. Care Injured 47 (2016) 1932–1938

Table 1
Measurements made from CT scans to potentially scale the structures comprising essential medical coverage.

Serial Description
A Vertical distance between horizontal planes taken at most superior and inferior levels of spleen (ie spleen height).
B Vertical distance between horizontal planes taken at most superior and inferior levels of liver (ie liver height).
C Vertical distance between horizontal planes taken at most superior and inferior points of aortic arch and liver respectively.
D Vertical distance between horizontal planes taken at most superior point of aortic arch and bifurcation of abdominal aorta.
E Vertical distance between suprasternal notch to horizontal plane taken at lowest point on ribcage in mid clavicular plane.
F Vertical distance between horizontal planes taken at lowest point on ribcage in mid clavicular plane and upper border of iliac crest
G Vertical distance between horizontal planes taken at suprasternal notch and upper border of iliac crest.
H Horizontal distance between vertical planes taken at most lateral points of liver and spleen
I Horizontal distance between vertical planes taken at right heart border and left heart border (ie heart width)
J Horizontal distance between vertical planes taken at right heart border and midline
K Horizontal distance between vertical planes taken at left heart border and midline
L Vertical distance between horizontal planes taken at suprasternal notch and upper border of liver
M Vertical distance between horizontal planes taken at upper border of liver and lower border of ribcage
N Vertical distance between horizontal planes taken at vertex of scalp and sole of feet (ie stature)

Table 2
Percentile ranges of statures derived from QinetiQ anthropometric survey in 2007 compared to those from this study (height measured by nurse on admission).

Percentile Army and marine Caucasian males only (QinetiQ survey) mm Caucasian males only (this study) mm (Distance L)
5th 1680 1700
25th 1734 1750
50th 1777 1790
75th 1822 1823
95th 1889 1900

Table 3
The distances between structures measured from the 100 CT scans in this study arranged into percentiles. Each measurement is arranged into percentiles and means
independently, not grouped on percentiles for a fixed measure.

Size grouping Soft tissue measurements Hard tissue measurements

A B C D H I J K L M E F G
5th percentile 59 125 234 315 246 111 30 72 99 144 266 40 342
25th percentile 85 147 256 336 257 123 35 83 116 160 285 57 358
50th percentile (Median) 99 161 279 353 268 130 41 91 127 174 300 71 371
75th percentile 109 173 297 370 278 139 45 99 137 186 314 88 385
95th percentile 124 189 318 393 294 150 50 111 156 207 336 106 411
Mean 98 161 277 353 269 131 40 91 124 176 300 72 373

component (Distance H) could be valid; for example basing it on


the value for the 95th percentile in this population (294 mm) Discussion
would theoretically overprotect the 5th percentile (246 mm) by
48 mm. Relating essential medical coverage to total height and torso height

Currently all UK Armed Forces personnel are provided with a


single size of front and rear ceramic body armour plate regardless
of that individual's body dimensions. The plate is enclosed within
Table 4 the carrier of the body armour vest that is usually fitted to an
Reproducibility of bone landmarks to determine the boundaries of underling soft individual’s total height. The UK VIRTUS personal armour system is
tissue structures (cross reference with Fig. 6). an important improvement from previous systems in that the
Bone versus soft tissue landmarks Mean (mm) Range (mm)
armour fitting is based on torso height instead of total height
(stature). The definition of torso height with respect to VIRTUS is
Distance suprasternal notch is above aortic arch (i) 9 20 to +27
Distance rib cage is below lower border of liver (ii) 14 47 to + 50
suprasternal notch to umbilicus (belly button). However the
Distance iliac crest is below aortic bifurcation (iii) 11 18 to + 43 umbilicus is a soft tissue landmark and will change in position with
weight gain or loss. The iliac crest is a stable bone landmark and
should be used preferentially. As essential medical coverage

Table 5
Correlation (R2) of distances between anthropometric distances and components of essential medical coverage.

Coverage Correlation with total height (N) Correlation with torso height (G)
Vertical essential medical coverage (D) R2 = 0.041 R2 = 0.531
Upper horizontal essential medical coverage (I) R2 = 0.022 R2 = 0.039
Lower horizontal essential medical coverage (H) R2 = 0.009 R2 = 0.032
J. Breeze et al. / Injury, Int. J. Care Injured 47 (2016) 1932–1938 1937

demonstrated the best correlation to torso height, it is therefore Further it is recommended that coverage should not be reduced
recommended that torso height is used in future anthropometric further than the lower border of the ribcage in the mid clavicular
surveys and for coverage assessments. plane. The use of this bone landmark instead of just the lower
border of the liver was particularly important as the position of the
Use of surface bone landmarks to determine the boundaries of lower border of the liver was variable within the population
essential medical coverage sampled. The shape of the resultant plate will be determined not
only by anatomical coverage but also by ergonomic acceptability.
Accurate scaling and sizing of plates on a user requires surface This may potentially therefore result in different shapes for the
bone landmarks which can be related to the positions of the front and rear plates as is the case with the current OSPREY plates.
underlying structures requiring coverage (Fig. 6). This study
suggests that from horizontal angles the upper border of essential Limitations
medical coverage is level with the suprasternal notch (landmark 1),
as it was located a mean of 9 mm above the aortic arch (the upper There are limitations in this initial study. The structures
border of essential medical coverage). The lower border of determined as requiring essential medical coverage are based
essential medical coverage should be level with the upper border upon the assumption of 60 min to definitive medical care and if
of the iliac crest (landmark 3), which was located a mean of 11 mm that timeline changes this may necessitate review of those
below the bifurcation of the aorta. Torso height (distance G) will be structures. The sample size of 120 subjects was limited by the
larger than vertical essential medical coverage in 89% of the number of available CT scans. The CT scans of male Caucasians were
population, and therefore using torso height should improve the analysed to maximise the sample size and therefore the results are
confidence in providing adequate protection. not necessarily applicable to other populations (i.e. non-Cauca-
sians and females). The measurement of internal anatomical
Potential coverage shapes structures while the patient is supine (lying flat) could cause small
differences in the position of internal structures compared to a
In order to visualise the potential plate size and shape required standing subject; this will be a limitation for the foreseeable future
to provide essential medical coverage (heart, great vessels, liver as imaging currently available (CT or MR) that can make such
and spleen), these structures have been identified within an measurements can be performed whilst standing is extremely
anatomical model. When the boundaries were defined within this limited. Again the use of bone landmarks as proxy markers for the
model, essential medical coverage from front and rear horizontal boundaries of these soft tissue structures should overcome this
angles would require a cross-shape (Fig. 7a). The upper coverage limitation. Finally this study only considered coverage from front
width is linked to heart diameter in the coronal plane; however and rear projections; consideration also needs to be given to the
this showed the greatest variation between subjects and it is the protection required from other angles (i.e. from either side of the
anatomical structure with greatest mortality [28]. Hence increas- body) and elevations (i.e. not horizontal trajectories), along with
ing the upper coverage width (eg utilising values for the 95th human factors constraints as mentioned previously.
percentile) would increase the confidence in its medical effective-
ness (Fig. 7b). The lower section of the coverage in Fig. 7a and b is Recommendations
clearly visually different from existing and traditional hard armour
(Fig. 1); but the ergonomic necessities for movements such as A number of recommendations can be made from this study.
bending or sitting preclude complete coverage of the lower parts of There was strong evidence to suggest that in future, ‘torso height’
the great vessels by hard armour. To enable maximal coverage to (i.e. suprasternal notch to iliac crest) should be used as a basis for
the abdominal aorta, human factors assessments should be determining armour coverage as well as correctly fitting such
undertaken to establish the extent to which this area can be armour to an individual. The acceptable size of front and rear body
protected while still allowing acceptable movement (Fig. 7c). armour plates that provide the recommended area of anatomical

Fig. 7. Potential coverage shapes related to bone anthropometric landmarks using the geometric representation; a) 1 = essential medical coverage, b) 2 = increased upper plate
width, c) 3 = sequentially reduced coverage height and demonstrating how edges could be rounded.
1938 J. Breeze et al. / Injury, Int. J. Care Injured 47 (2016) 1932–1938

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