The purpose of this study was to examine physical work performance, energy cost, and physiological fatigue in military personnel during simulated operational conditions. Using a within-subject, repeated-measures design, 34 military personnel volunteered to undergo two experimental conditions: with body armor (BA+) and without BA (BA-). Subjects walked on a treadmill for 30 minutes and completed a physical performance battery during each of two sessions, which were separated by > or = 5 days. Subjects with BA+ as compared with BA- had significantly greater increases in: oxygen uptake (VO2) at slow (16.8 +/- 1.5 vs. 18.8 +/- 1.7 mL x kg(-1) x min(-1)) and moderate paces (34.8 +/- 3.9 vs. 40.8 +/- 5.0 mL x kg(-1) x min(-1)); blood lactate at a moderate pace (4.0 +/- 2.4 vs. 6.7 +/- 2.6 mmol/L); heart rate at slow (107 +/- 14 vs. 118 +/- 16 beats per minute) and moderate paces (164 +/- 16 vs. 180 +/- 13 beats per minute); and ratings of perceived physical exertion at slow (8.4 +/- 1.5 vs. 10.4 +/- 1.8) and moderate paces (14.3 +/- 2.3 vs. 16.7 +/- 2.1). Physical tasks were significantly affected by BA: under BA+, men performed 61% fewer pull-ups and women's hang time was reduced by 63%; stair stepping was reduced by 16% for both men and women. BA significantly impacted the physical work capacity of militarily relevant tasks. Specifically, wearing BA significantly increased VO2 when walking at both slow and moderate paces. The potential for physical exhaustion is high and performance of physical tasks is markedly impaired when wearing BA.