Compressions of electrorheological (ER) fluids have been carried out under different initial gap distances and different applied voltages. The nominal yield stresses of the compressed ER fluid under different conditions, according to the mechanics of compressing continuous fluids considering the yield stress of the plastic fluid, have been calculated. Curves of nominal yield stress under different applied voltages at an initial gap distance of 4 mm overlapped well and were shown to be proportional to the square of the external electric field and agree well with the traditional description. With the decrease of the initial gap distance, the difference between the nominal yield stress curves increased. The gap distance effect on the compression of ER fluids could not be explained by the traditional description based on the Bingham model and the continuous media theory. An explanation based on the mechanics of particle chain is proposed to describe the gap distance effect on the compression of ER fluids.