CORDURA® 500d is a fabric known for high abrasion resistance. In UATAC garments we use CORDURA® 500d Brookwood® USA to reinforce the knees of assault pants and the elbows of combat shirts. The reinforcement is applied to the outer layer of the garment itself, not only to the removable pads.
Why knees and elbows fail first
Crawling, kneeling, working in a fighting position or inside a vehicle concentrates load on a small area of fabric. The main weave wears through there long before the rest of the garment is used up: the trousers are still sound, but the knees are shining. For a unit that means writing off an almost new set because of two palms of fabric.
The second half of the problem is the assumption that the pads protect the knee. A pad can be taken out, and the fabric underneath still grinds against concrete.
What 500d means and why it is not «less than 1000d»
Denier is the linear density of the yarn, not a measure of the finished fabric's strength. The original CORDURA weave delivers more abrasion resistance per unit of denier than cheaper alternatives with higher numbers, and it comes out lighter and softer on the knee.
That affects comfort directly: a stiff, heavy patch on the knee restricts the leg and adds weight exactly where you feel it most.
| Material | Job | Where it is used |
|---|---|---|
| CORDURA® 500d Brookwood® USA | Abrasion resistance | Knees of trousers, elbows of combat shirts |
| Ripstop 65/35 | Tear resistance | Main fabric of the garment |
| EVA | Impact absorption | Removable knee and elbow pads |
| Double layer of base fabric | Durability when seated | Seat of the trousers |
The common mistake: thinking CORDURA is only on the inserts
With many makers the reinforcement is stitched onto the removable pad alone. Take the pad out — and people do, in heat or on long movements — and the knee is unprotected.
On UATAC garments the reinforcement sits on the outer layer of the item, so it works whether the insert is in place or not.
CORDURA and EVA solve different problems
CORDURA handles abrasion: the fabric does not wear through against rough surfaces. EVA in the removable pads handles impact: the resilient foam absorbs the shock of dropping onto a knee. One does not replace the other, and a properly built garment has both.
Common mistakes
- Comparing reinforcements by denier alone, without knowing who made the fabric.
- Assuming a stiffer patch is better — it restricts the knee.
- Expecting CORDURA to protect against cuts or punctures.
- Washing hot, which damages the finish on the base fabric around the patch.
- Ignoring the seams around the reinforcement, where wear actually starts.
What CORDURA does not do
CORDURA is not ballistic protection and will not stop a fragment or a blade. It is an abrasion fabric, not personal protective equipment. It does not make a garment waterproof either — that is the job of finishes and membranes.
Pre-purchase checklist
- Check whether knees and elbows are reinforced on the garment itself, not only on the inserts.
- Ask who makes the reinforcement fabric.
- Confirm that removable knee and elbow pads are included.
- Check that the reinforced area still lets the knee bend freely.
- Follow the washing instructions so the base fabric keeps its finish.
Frequently asked questions
Where does UATAC use CORDURA 500D?
On the knees of assault pants and the elbows of combat shirts. The reinforcement is applied to the outer layer of the garment, so it works with or without the removable pads.
Why 500d and not 1000d?
Denier measures yarn density, not fabric strength. The original CORDURA weave gives more abrasion resistance per unit of denier and is lighter and softer on the knee.
Does CORDURA protect against cuts?
No. It is an abrasion-resistant fabric. Cut and puncture protection is a separate class of materials.
How is CORDURA different from the EVA in knee pads?
CORDURA is the fabric that does not wear through; EVA is the resilient material that absorbs impact. They solve different problems and a complete garment uses both.
Can I wear the trousers without knee pads?
Yes. The knee is protected against abrasion by the reinforcement on the garment; the insert handles impact and can be removed when you want.
Author: Serhii Vynnyk, founder and CEO of UATAC. Updated: 16 September 2026.