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thedrifter
10-11-05, 07:09 PM
October 17, 2005
Wardrobe malfunction
Army responds to wear issues affecting ACU
By Matthew Cox and Gordon Trowbridge
Times staff writers

CAMP STRYKER, Iraq — The Army Combat Uniform isn’t holding up in combat, say soldiers from the first brigade to deploy to Iraq outfitted in the new garb.

The uniform gets high marks from soldiers for its many pockets and cooler, lightweight, wrinkle-free construction. But soldiers with the Georgia National Guard’s 48th Brigade, which deployed here in May, said torn seams, ripped fabric and worn-out Velcro fasteners are commonplace with the battle attire.

“The crotches rip apart all the time,” said Spc. Tom Parsons, 27, of St. Louis, assigned to the 220th Engineer Company, attached to the 48th Brigade Combat Team.

“Most of the parts that are sewn together are likely to come apart,” said the 220th’s Pfc. David Bradbury, 25, also of St. Louis. “If this [color pattern] came in the same style as the [Desert Combat Uniform], I think I’d rather have that.”

Sgt. 1st Class Gladys Portwine, the supply sergeant overseeing the brigade’s uniform, said the ACUs were expected to last six months in a combat environment. But after about five months of wear by the 48th, including a deployment to the National Training Center in California, the Army began shipping replacements.

Army uniform experts first heard about the problems in July and immediately sent an ACU expert to Iraq for a closer inspection of the wear issues, said Lt. Col. John Lemondes, product manager, Clothing and Individual Equipment.

Since then, the Army has worked with the firms contracted to make the ACU to ensure soldier-identified weak points are fixed for future fielding.

“We have identified the shortcomings, and we have addressed them,” Lemondes said in an Oct. 7 interview.

Dave Geringer, assistant product manager, Clothing and Individual Equipment, said the ACUs were issued to the 48th in February and durability has proven to be in line with uniform experts’ projections.

The Army’s first new combat uniform since the 1980s, the ACU is to replace the woodland-patterned Battle Dress Uniform and the Desert Combat Uniform by 2007.

The fabric in the ACU is the same 50/50 nylon and cotton blend used in the DCU, except for the wrinkle-resistant treatment.

The ACU includes 18 major changes from those uniforms, including Velcro attachments for name tapes and patches; more and repositioned pockets; a camouflage pattern made up of tiny pixels designed for all environments; and a light, wrinkle-resistant fabric.

The Army issued about 500,000 sets of ACUs to deploying soldiers, but it’s unclear how many of those uniforms will develop similar problems, Geringer said.

Soldiers must rely on sew-shop fixes and replacing their uniforms through their unit supply system for now, he said.

Soldiers from the 48th raised several, issues, good and bad, concerning the new uniform.

They like the wrinkle-resistant material, which holds up even after long days in hot, unpleasant conditions. The redesigned pockets, especially the angled chest pockets and a new pants pocket on the calf, are also popular.

“Short term, it’s a great uniform,” said Spc. Michael Harrison of the 220th.

Still, durability issues dominate conversations about the outfit. Brig. Gen. Stewart Rodeheaver, the 48th’s commander, calls the ACU “the best uniform I’ve ever worn,” but concedes durability problems.

“When we got here, we got ahead of the supply chain a little bit,” said Rodeheaver, who added that officers have noticed wear on thigh cargo pockets where sidearm holsters rub against the fabric.

“They’re just not as durable,” said Capt. David Casey, a member of the 48th’s training team for Iraqi forces. “A lot of guys have had the crotches ripped.”

The crotches usually rip open along the seam that runs between the bottom of the fly and the seam that runs down the leg, Geringer said.

Fixes are underway

To mend the problem, industry will use a heavier thread for the seam, increase the amount of folded-under fabric before sewing and adjust stitching placement, Geringer said.

“The result is that we more than doubled the strength of that seam just by making those changes.”

Soldiers also have complained about Velcro material wearing out and coming loose, and about patches and other items being knocked off the Velcro when putting on body armor or removing it.

Geringer said changes have been made to the Velcro’s “hook and loop” fastener material to upgrade the way the edges are finished to improve durability.

Lt. Col. Jeff Edge, commander of the 148th Forward Support Battalion, said he switched from a thigh holster to a shoulder holster to avoid wear on his ACU pockets.

“We’ve had some durability issues,” said Edge, who noted that he nevertheless still prefers the ACU’s lighter fabric and easy care.

Despite the problems, Casey said, “There are tons of places to store stuff. And the best thing is no laundry bill. You can basically roll them up in a ball and they come out fine.”

Rodeheaver and 48th Command Sgt. Maj. James Nelson said the Army has paid attention to problems the brigade has discovered, and improvements already have been made to make pockets more durable.

Nelson, who has a monthly conversation with program officials on the uniform and other equipment topics, said he’s confident Army officials will fix the uniform.

“The second and third generations will be better,” he said. “That’s the way uniforms work — that’s the way any of our systems works.”

Matthew Cox covers the Army.

Ellie