Understanding Blast Overpressure (BOP) and the Role of B3’s Blast Gauge in Soldier Safety

Why Blast Overpressure Matters, and DoD Policy

Blast Overpressure (BOP) is an invisible, yet destructive force caused by explosions of all sizes that poses significant risk to military and law enforcement personnel. It can lead to traumatic brain injuries (TBI) and long-term brain health complications. Recognizing the gravity of this risk, the Department of Defense (DoD) has taken steps to reduce BOP-related injuries, recently issuing an August 8, 2024 memo that directs units to establish processes for managing brain health risks from BOP by giving them a guideline of 4 psi to initiate risk management [Reference: DoD August 8, 2024 Memo]. However, most leaders lack a critical tool to enable them to effectively follow the policy: a way to know if their troops have exceeded the 4-psi guideline.

Mitigating the risk of blast overpressure requires accurate and timely data on blast exposure. The BlackBox Biometrics (B3) Blast Gauge® System, an AirBoss Defense Group (ADG) product, was developed in conjunction with the US Government specifically for this purpose. Most commonly deployed as a three Gauge set, these small, highly ruggedized sensors provide real-time monitoring of individual BOP exposures experienced by the warfighter. The Blast Gauge System empowers users, medics, and leaders to follow the DoD policy, reduce exposure without diluting training, and help keep servicemembers safe and in the fight.

ADG believes that persistent monitoring of BOP exposure with commercial off the shelf (COTS) wearable sensors like the proven Blast Gauge System is essential not only for protecting the warfighter but also for complying with recent DoD policies. The August 8, 2024 memo directs military units to establish internal processes for managing brain health risks from blast exposure, and the Blast Gauge can be instrumental in enabling units to follow these directives. It automatically captures, stores, and can be configured to transmit data to a cloud-based system of an organization’s choice, such as DOEHRS-IH. This ensures comprehensive record-keeping that supports policy compliance and enables better long-term tracking and understanding of individual risk.

Moreover, SOCOM’s 19-01 memo “Comprehensive Strategy for Special Operations Forces Warfighter Brain Health” mandates the use of B3’s Blast Gauge System, specifically by National Stock Number, “if and when available” to monitor BOP exposure* [Reference: SOCOM Brain Health Policy 19-01]. The memo continues: “USSOCOM personnel with blast exposure that exceeds moderate and severe thresholds which causes a yellow or red indicator light on the blast gauge will be evaluated by medical personnel at the earliest possible opportunity.” The Blast Gauge has been proven in the field, making it a key asset in helping military leaders meet their obligations. Without accurate monitoring, servicemembers cannot reasonably adhere to the DoD’s 4 psi BOP guideline or SOCOM’s brain health memo, putting their health at risk and compromising their ability to remain effective.

Proven, Real-World Success of the Blast Gauge

The Blast Gauge System has been trusted and used by all branches of the DoD, more than 20 foreign partner militaries, over 200 law enforcement organizations around the world, and dozens of critical research programs to detect, record, and analyze blast overpressure in some of the most challenging training and operational environments in the world. Thanks to this extensive use and wide deployment among the US military, B3 has observed numerous examples of troops adopting safer behavior thanks to the information captured by the Blast Gauge System.

One of the best examples comes from a combined arms exercise with an elite unit of the US Army. Blast waves can be unpredictable due to reflections and rebounds, and during full-tempo, live-fire events, it can be difficult to know exactly where it is safest to stand. During this exercise, the Blast Gauge identified the moment a Carl Gustav Assistant Gunner experienced an unexpectedly high exposure of 16.1 psi — well above the 4-psi safety guideline – due to weapon positioning and the unique topography of the training site. Thanks to the Blast Gauge, medics were immediately alerted to the potential risk and conducted a Military Acute Concussion Evaluation (MACE). Otherwise, the Soldier’s exposure would not have been identified. While the Soldier passed the MACE, the data revealed an area for improvement: a safer position for the assistant gunner to stand. By adjusting the Soldier’s position in subsequent exercises, his exposure to dangerous overpressure levels was significantly reduced. The Soldier later shared this story with his peers, improving positioning and likely reducing future exposures across the unit.

In a second notable illustration, US Army Ranger mortarmen during a training exercise who were exposed to repeated BOP from firing their 81mm and 120mm mortars [Reference: Military Medicine, 188(3-4), e771 (2023)]. By analyzing the data collected by the Blast Gauge, the unit identified higher-than-average blast exposures on some crew members due to the surrounding environment and individual positioning. This information allowed the group to modify their training protocols to effectively reduce exposure levels in future training events. These changes helped protect the individual Soldiers and enhanced overall unit readiness, all without impacting mission performance.

Still another example involved the M777 artillery system wherein data collected by Blast Gauges helped identify a crew member suffering from unusually high blast overpressure levels. Upon closer inspection, experts discovered that a crew member was positioned further forward than necessary resulting in the highest  exposures of the crew. By moving the crewman to a safer location where he could still effectively do his job, his BOP exposure was dramatically reduced without any disruption to training or weapon system effectiveness* [Reference: Frontiers in Neurology, 2023. “Monitoring and Risk Mitigation of Blast Overpressure and TBI in Military Training”].

The importance of the Blast Gauge extends even beyond its role in field operations. An article published in support of the DoD’s policy memo and 4 psi guideline by S. Sloley and S. Turner shows that nearly half of the research used by the DoD in its policy development directly used or relied on individual exposure data, and all of it was gathered by the Blast Gauge [Reference: Shock Waves, 2024. “Evaluating evidence supporting the relevancy of 4 psi as a blast overpressure value associated with brain health and performance outcomes following low-level blast overpressure exposure.”] This widespread trust and use by the research community underscores how essential the Blast Gauge has been in shaping modern military policies on blast overpressure safety.

The insights gained from using the Blast Gauge are critical in reducing BOP exposure to help prevent long-term injuries and ensure military operational readiness. These examples demonstrate how the Blast Gauge provides critical data that enables real-time adjustments, helping to minimize blast overpressure exposure and improve warfighter safety.

Global Efforts in Blast Monitoring: Australia’s Progress

As the U.S. military makes significant progress in addressing the risks of blast overpressure—including Congressional interest in monitoring, cataloging, and mitigating exposure—other nations, like Australia, are also advancing policies to protect their military personnel.

In Australia, significant progress has been made in establishing policies to protect military personnel from the dangers of BOP. One of the most notable developments is the Royal Commission into Defence and Veteran Suicide, which recently put forth Recommendation 61, calling for a comprehensive brain injury prevention program that focuses on understanding and mitigating the impact of repetitive low-level blast exposure [Reference: Royal Commission into Defence and Veteran Suicide, Recommendation 61, 2024].

Recommendation 61 outlines the creation of a program aimed at several key goals: 

• Monitoring and assessing environmental exposure to blast overpressure.
• Recording traumatic brain injury (TBI) exposure in both serving and ex-serving members of the military.
• Developing neurocognitive programs to treat and manage brain injuries caused by blast exposure.

This recommendation signals a shift in global awareness, recognizing the need for products like the Blast Gauge System to help monitor and assess BOP exposures to promote long-term health and operational readiness. Australia’s push for the inclusion of blast monitoring policies mirrors the U.S. military’s focus on BOP mitigation and further emphasizes the global relevance of tools like B3’s Blast Gauge in monitoring and reducing blast exposures in real time.

Protecting Troops and Enhancing Readiness

The B3 Blast Gauge System is a proven solution that can enhance safety, support compliance with DoD, SOCOM, and Australian policies, and help prevent long-term health risks by minimizing unnecessary BOP exposure. By providing real-time, accurate data on individual blast overpressure exposure, the Blast Gauge enables military leaders to follow these policies and make informed decisions that protect troops without sacrificing training effectiveness.

Recent developments in the U.S. Congress have shown increased interest in monitoring, cataloging, and mitigating blast overpressure exposure among military personnel. This growing support underscores the importance of using reliable tools, like the B3 Blast Gauge, to enhance troop safety and operational readiness.

As new military policies on blast exposure continue to develop, ADG believes that the Blast Gauge will remain at the forefront of wearable blast monitoring technology and ensure these guidelines are met while contributing to the safety and long-term health of warfighters worldwide.