Armor: Barak Does It Better


October 9, 2023: A year ago Israel introduced the fifth version of its Merkava tank. The Merkava 5 was quietly developed, built, tested and deployed in small numbers during late 2022. This was ahead of schedule because the original delivery date was supposed to be early 2023. Like the earlier Merkava models, Merkava 5 is an improved version of the previous model and proved to be such an impressive upgrade that it was given a name; Barak.

This new version of the Merkava appeared relatively quickly after the 65-ton Merkava 4 entered service in 2005. Merkava 4 received major upgrades in 2011. Further upgrades of Merkava 4 turned out to be so extensive that this version was designated Merkava 5, which weighs the same as Merkava 4. Several hundred Merkava 4 tank deliveries will instead incorporate the Merkava 5 features and enter service as Merkava 5s. This means there will be 360 Merkava 4s and 300 Merkava 5s. The price per tank will also increase from $4.5 million for each Merkava 4 and over $5 million for each Merkava 5 Barak.

Improvements in the Merkava 5 include a more effective engine along with upgrades to the Iron Vision system that provides the commander a view of what is happening outside the tank. The new version provides a more realistic day/night view of what is outside as well as indications of where enemy fire (bullets or projectiles) hitting the tank is coming from and how best Merkava can respond. This was the result of upgrading the fire-control system. The Trophy APS (Active Protection System) has also been updated to be more effective and incorporate some of the lessons of the war in Ukraine. In addition to Iron Vision, Barak also has a much more capable fire control system featuring improved sensors that can detect and track enemy armored vehicles at night and in bad weather. The gunner can more quickly fire on any enemy tank detected no matter the weather or if Barak is on the move. All crew members have touch screens to access information on the status of Barak systems and any activity outside the tank. The improved sensors and Iron Vision enable the Barak crew to stay inside the tank during combat. Barak can operate in combat without the need for the commander to stand up and so that his head and shoulders outside the turret in order to get a better look at what’s going on. This eliminates the risk of the commander being killed or wounded, which was always bad for crew morale. Israel is a small country and has always strived to keep combat casualties as low as possible.

Israel is the smallest nation in the world to design and build its own tanks. This was the result of the 1973 Arab-Israeli War, which took Israel by surprise, and inflicted heavy losses, before Israel counter-attacked and defeated Egypt and Syria and their larger number of modern Russian tanks. Israel carefully analyzes the results of each war it fights and makes changes to deal with problems encountered. The 1973 war prompted Israel to start designing and building its own tanks.

By 1979 the 61-ton Merkava entered service and 250 were built by 1983. That was the year the first of 580 62-ton Merkava 2s entered service. Production of Merkava 2 ended in 1989. The first two Merkava models were similar in design with both using a 105mm gun. The Merkava 2 had additional armor, a five percent more powerful 950 HP engine and a 20 percent higher top speed of 55 kilometers an hour. The external 60mm mortar, mainly for firing smoke shells, was moved inside for the Merkava 2. There were a lot of other mechanical and electronic upgrades. By 1989 all the active-duty armored brigades had Merkavas and many of the reserve armored brigades as well.

Using lessons learned from the 1982 fighting in Lebanon, Israel developed a much improved 63.5-ton Merkava 3, which entered service in 1990. By 2002 680 Merkava 3s were built. The main improvements in Merkava were a 120mm main gun and much more powerful 1,200 HP engine that produced a 60-kilometers an hour top speed, faster acceleration and a more maneuverable and nimbler tank. All the armor was of a modern composite design. Fewer main gun shells could be carried; 46x120mm ones compared to 60x105mm shells in the Merkava 2. Merkava 3 could load shells faster because of a five-round mechanical drum. The fire-control system was also upgraded, as were many other components. The Merkava 3 is still used, mainly by reserve armor brigades.

In 2003 the 65-ton Merkava 4 was introduced. So far 360 of these have been produced and most have already undergone several major upgrades. Merkava 4 has improved armor, a redesigned turret, 25 percent more powerful 1,500 HP engine and a top speed of 65 kilometers an hour. Merkava 4 is even more nimble and maneuverable than Merkava 3. Merkava 4 carries 48 rounds of 120mm shells and uses a 10-round electric powered drum for quick loading. Merkava has a smoother ride because of an improved suspension system. There is also improved protection for the crew against mines and roadside bombs. By 2021 360 Merkava 4s were built.

All Merkavas feature a unique design feature; the engine is in the front. This adds more protection for the four-man crew and any passengers in the large rear compartment. That compartment can hold more 120mm shells or other supplies or up to eight passengers. Usually six infantrymen are carried, providing Merkava with its own infantry support. This is especially useful in built-up areas.

Merkava 4 underwent several major upgrades. In 2012 Israel completed equipping all the Merkava tanks in an armor brigade with the Trophy APS. In 2010 the first battalion of Merkavas was equipped with the APS. In 2011 Trophy defeated incoming missiles and rockets in combat for the first time. This included ATGMs (Anti-Tank Guided Missiles), possibly a modern Russian system like the Kornet E. This ATGM was introduced in 1994 and sold to Syria, who apparently passed some to Hezbollah and Hamas. A few weeks before the ATGM intercept, Trophy defeated an RPG warhead, an unguided rocket propelled grenade fired from a metal tube balanced on the shoulder. As it was designed to do, Trophy operated automatically and the crew didn't realize the incoming RPG and missile warheads had been stopped until after it was over. That is how APS is supposed to work.

In 2017, a ground vehicle VR (Virtual Reality) system called Iron Vision was introduced and Merkava 4 was the first tank to get it. Iron Vision meant a tank could largely dispense with tanks’ traditional dependence on the tank commander spending a lot of time with his head sticking out of the turret to get a better view of the situation. The VR helmet display helmet is worn by the tank commander and not only shows real-time video of what is outside, but also an overlay of other information or even a map. Israel pioneered the development and use of such helmets, and the F-35 stealth fighter was designed to use a VR helmet. Most modern tanks are equipped with these small external digital video cameras but Iron Vision makes the external cameras much easier to use.

In 2020 Fire Weaver fire control network software was first installed in Israeli tanks and will soon be installed in warplanes, artillery and other armored vehicles. In 2021 at least two of the four active-duty armored brigades had Fire Weaver. Once all the active-duty armor brigades have it, the six active-duty infantry brigades will receive it. Some of the 22 reserve brigades, nine of them armored, may get the system as well.

Fire Weaver takes data from existing sensors on tanks and other armored vehicles as well as artillery and warplanes and rapidly (within five seconds) lets vehicles, warplanes and artillery know which available target each combat system should fire at. This eliminates a common battlefield situation where too many weapons fire on some targets while other targets are not initially fired on at all. Currently, tank crews and artillery spotters (troops who call back to tell artillery which targets to hit) have manual procedures for picking which targets they should fire at. That often works quite well, especially during a situation where a tank unit encountering the enemy has an opportunity to fire first. Fire Weaver automates these decisions and makes more effective choices more quickly. The troops and pilots can override Fire Weaver-selected targets but tests have shown that Fire Weaver is usually quite effective in selecting the best targets for each tank, artillery unit or aircraft.

Fire Weaver is easy to implement in the Israeli military because the Israelis have already been providing their troops with better sensors and battlefield networks. For example, in mid-2019 three Israeli firms, responding to an IDF proposal for bid, showed off their versions of the proposed Carmel Concept for future armored vehicles. Three different armored vehicles; the Merkava 4 tank, Namer IFV (Infantry Fighting Vehicle) and the Eitan 8x8 APC (Armored Personnel Carrier) had proposed versions of Carmel installed. Carmel involves several existing technologies plus proposed new ones that would turn an armored vehicle into a “combat system” that would operate with, a crew of two or a robotic vehicle operated remotely (like a UAV) or autonomously, to benefit from more information about where friendly and suspected enemy forces were. This information would often be delivered in real-time. This sort of thing provides a tremendous advantage in combat.

The best example of similar (to Carmel) existing tech is used in the F-35 where numerous sensor and communications systems are controlled by software that uses data fusion. This is merging data from many sources and presenting it to the pilot in a comprehensible fashion to provide the F-35 pilot with unprecedented “situational awareness”. That means an accurate picture of where the pilot and everything else in the vicinity is. It had long been known that superior situational awareness was the key to victory in combat be it in the air, at sea or on land. Carmel proposes that manufacturers find ways to effectively combine existing tech with improved software. This would include more AI (Artificial Intelligence) to analyze sensor and situational data at high speed and either act autonomously (as ADS, or Active Defense Systems, do) or present options to the vehicle operators.

Although the Merkava was introduced in 1979, it wasn’t until mid-2006 that Israeli tanks saw their first heavy combat in 24 years. It was also the first combat for the then new Merkava 4. Actually, it was the first heavy combat for the Merkava 2 (introduced in 1983) and Merkava 3 (1989). In 1982, 180 Merkava 1s saw action during the war with Lebanon. Until 2006 Merkavas had only been used in peacekeeping and counter-terror operations with the Palestinians.

The Israelis, as they have in all past wars, collected detailed information on each tank that was hit by enemy fire. Israel won't, for obvious reasons, release all this information, but they have provided some data. "Several hundred" Merkavas were sent into southern Lebanon in 2006. Of those, ten percent were hit by enemy fire, including mines and roadside bombs. Merkava faced modern ATGMs for the first time in 2006. Only 18 tanks were seriously damaged, and only a third of those were from several hundred ATGMs fired by Hezbollah. Only two of the 18 heavily damaged tanks were destroyed, and both of those were damaged by roadside bombs. In those two cases, the tank was over the bomb when it was detonated.

The experience in Lebanon again proved that ATGMs (Anti-Tank Guided Missiles) tend to be overrated. Israel first encountered ATGMs during the 1973 war, and quickly adapted. ATGMs were much less effective in the 1982 war, and didn't do all that well in 2006 either. The Iran-backed Lebanese Hezbollah quickly learned that the Merkava frontal armor was impervious to their Kornet ATGMs. Getting side and rear shots was more difficult, and not a lot more successful. While the ATGM warhead often penetrated, the Merkava was designed to take this kind of hits and survive, and survive it did. In addition to fire extinguisher systems, the ammo and fuel are stored in such a way that secondary explosions are rare. The crew normally survives these hits, as does the tank.

One of the biggest problems with Israeli tanks in Lebanon had to do with the crews. Because of the heavy use of Israeli troops in counter-terror operations since 2000, most tank crews have spent a lot of time without their tanks, serving as security troops (light infantry). The lack of training in their tanks reduced the effectiveness of the Merkavas in Lebanon. This was not a critical factor, but it annoyed the tank crews quite a bit.

The tank crews were also peeved at the lack of protective devices, like smoke grenades on some tanks, or active defense systems like the Trophy APS. This was because so much money was diverted to counter-terror operations. While only six tanks were destroyed in Lebanon, over a hundred tank crewmen were killed or wounded by ATGMs. Hezbollah would often use a missile just to get the vehicle commander, who often was standing up, with his head and chest out of the turret hatch to get a better look at what's going on. Tank commanders would like to see some money spent on sensor systems (cameras) that enable the tank commander to get a good look around the tank, from inside the tank. The Lebanon operation was a wakeup call for the Israeli government to stop shortchanging efforts to improve their tanks.

As good as the Merkava is, there are not a lot of export customers. There was apparently only one export customer and Israel did not reveal who it was and no other public information about a foreign user has appeared so far. One difficulty with export orders is that Israel builds the Merkava itself and cannot afford large production facilities. Moreover, many key components come from the United States, which gives the Americans a veto power over who exports go to. Merkava is also very expensive, with the most modern Merkava 5 costing over $5 million each.

Israel cannot afford to keep all its Merkava in service. Currently 220 of 550 Merkava 4s are in storage, while only 160 of 730 Merkava 3s are in use, the rest in storage. There are still 370 Merkava 2s available, but all are in storage. If there is a major war, the stored Merkavas can be ready for combat in a few days, or less. These storage tanks would be used to replace tanks out of action for combat or non-combat reasons. Because the Merkava is designed to reduce crew casualties, most of the crews of damaged or destroyed tanks are available for duty within hours. While storage tanks don’t get many of the upgrades, the basic controls of Merkava were kept the same or similar from one model to another to make it easy for crewmen who started out in a Merkava 4 to operate an earlier Merkava model taken out of storage.

The success of Merkava and the need for a new APC (armored personnel carrier) to replace the current 18-ton American M113s led to the production of several hundred Namer IFVs (Infantry Fighting Vehicles). These were basically Barak tanks without the turrets. At first the chassis of the 61-ton Merkava 1 was used but the protection for the infantry and three-man Namer crew was considered inadequate. Instead, the chassis of the 65-ton Merkava 4 was used. This Namer used the Trophy APS and that seemed to provide the needed protection. The Namer is the best protected IFV in service. It is armed with a small RWS (remote controlled weapons station) containing a 30mm autocannon. There is also a 60mm mortar and a 7.62mm machine-gun that are manually operated by crew or passengers. The latest addition is two Spike ATGMs that are carried and launched from a metal pod that is inside the vehicle and raised from inside the Namer for use. The passengers and crew are seated in blast resistant seats to protect them from injury if Namer encounters a large roadside bomb or anti-tank mine. This approach proved successful when such large explosions were encountered.




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