'Cool' new ride equals cooler temperatures for Palletized Load System engineers

Courtesy Photo | The cool air from the air conditioning vents in the Palletized Load System truck is...... read more read more

Courtesy Photo | The cool air from the air conditioning vents in the Palletized Load System truck is directed towards the window, which potentially results in excessive temperatures.  see less | View Image Page

BAGHDAD, IRAQ

11.24.2008

Courtesy Story

926th Engineer Brigade

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By Capt. Angela Smoot
926th Engineer Brigade

CAMP LIBERTY, Iraq – One of the most vital pieces of equipment to any engineer element, outside of the engineering equipment itself, is the Palletized Load System truck. Its compact size makes maneuvering easy, and its flat-rack system allows the securing of construction equipment and building materials. The flat-rack also allows loads to be lowered without the use of a forklift.

Multi-National Division Baghdad engineers were utilizing the PLS trucks when they began running into issues. Due to the high desert temperatures during daytime operations, Soldiers of the 46th Engineer Combat Battalion (Heavy), riding in the vehicles, wearing all of their protective equipment, began suffering from heat exhaustion.

The 46th ECB is assigned to the 926th Engineer Brigade, Multi-National Division – Baghdad.

Once the challenge was identified, immediate action was taken to correct the problem.

"Ice filled coolers, cold drinks and specialized cooling towels were added to each vehicle's packing list in addition to the tons of water the Soldiers were ordered to carry on missions," said 1st Lt. Jane Capra, equipment platoon leader, Headquarters Support Company, 46th ECB (H), who is a native of New Market, N.H. "Those measures were not enough. It was just too hot in the cab of the trucks and more had to be done."

At this point, the think tank grew and new strategies were discussed in order to improve the situation.

"The maintenance staff of the 46th ECB (H) identified the condenser as the main component to cooling a vehicle and decided that was a good place to start with vehicle modifications," said Master Sgt. Kevin Fletcher, 46th ECB (H) battalion motor sergeant, who is a native of Thibodaux, La. "The temperature of the doors and surrounding metal were very hot to the touch also. So we decided there needed to be better insulation throughout the vehicle."

Coordination with various maintenance agencies resulted in the acquisition of a stick-on insulation, which was installed throughout the cab. The team also used lessons learned from living in comparable desert climates back in the United States.

"I used to live in Arizona and recalled a number of the residents had light-colored cars and others frequently painted their roofs white to deflect heat," added Chief Warrant Officer Richard Pinkerton, battalion maintenance technician, who is a native of New Orleans.

Utilizing that information, the roof of the cab and the top of the air-conditioning condenser unit were painted white.

"Looking over the vehicle, we observed that the air vents flowed directly towards the window, which would reach in excess of 130 degrees," said Staff Sgt. Fredrick Counter, maintenance foreman, 46th ECB (H), who is a native of Columbia, S.C. "Obviously, after the cool air hit the window, it would heat up. We decided to design an insulated box to deflect air onto the driver and passenger, where it would be much more beneficial."

After making those adjustments, the team conducted several tests and found that each modification decreased the temperature in the cab – cumulatively by 20 to 30 degrees. Now it was time to conduct the road tests in full combat gear.

The first road test was conducted on Camp Liberty, where the data showed the temperature in the cab was significantly cooler due to the modifications. Next, it was time for the real test. The team took the modified vehicle on a convoy operation over rough terrain, driving a distance for several hours, all while pulling a construction load.

"Our first test run went well, but we discovered that the coolant hose would fall into the fan and get cut," stated Pinkerton. "This caused the air to run warm of course. So we needed to make some adjustments by re-routing the hoses and using brackets to hold them in place."

After making that final modification, the team had the right combination of adjustments to solve their overwhelming heat problem in the PLS truck. Even though the air temperature was significantly decreased, he added, leaders must still remember that the cooling system is designed to cool air relative to outside temperature and not down to a set temperature.

On sweltering days in Iraq, when temperatures exceed 100 degrees, the PLS cab temperature is still very warm and leaders must aggressively check their Soldiers for evidence of heat-related injuries.

The team of 46th ECB (H) engineers and maintenance leaders used their ingenuity and practical solutions to make vehicle modifications that will potentially help lessen the possibility of future heat injuries.

These practical solutions and simple modifications are now being distributed to various military maintenance publications.