This Advanced Military load carriage for Ethiopian army, help full for New Ethiopian Military Force that will intended to Modernize and have effective good Performance. This project Done by Mr. Fikadie Arega, when He was attending His MSc of Fashion Technology in Bahir Dar University.

1. Bahir Dar University
Ethiopian institute of Textile and Fashion Technology
DESIGN AND DEVELOPMENT OF IMPROVED MILITARY LOAD CARRIAGE EQUIPMNET
FOR ETHIOPIAN ARMY
CASE STUDY ON WEST REGION COMMAND HEAD QUARTER
Prepared by: Fikadie.A
June 2018
Thesis Final presentation
Advisor: Dr. Rotich K. Gideon
Bahir Dar
University
Ethiopian institute of Textile
and Fashion Technology
1

2. The outline of the presentation
 Abstract
 Introduction
 Problem statement
 Objective
 Literature review
 Methods & materials
 Data analysis
 Product Comparison
 Implantation
 Feed back
 Conclusion
 Recommendation
 Project limitation
 Reference
2

3. Abstract
 Designing and developing improved
military load carriage Equipment for
Ethiopian army.
 This Case study was designed for 94
soldiers as a sample size among total 8,000
numbers of soldiers as a target population.
 and random sampling is used to select the
participant of those 94 soldiers.
 questionnaires prepared to gather the
required data.
3

4. • The study shows that 62% soldiers were carried their external load
by assault load carriage system.
• and 48% of the soldiers were carried external load on the range of
21-25kg.
• 29% of the soldier were challenged by load distribution problem of
the carriage equipment”.
• but the other problem which related to design of the load carriage
equipment like load mobility, load suspender (strap), and load
bearing system (fasteners, closures) problem have considerably
challenged.
Cont.…
4

5. Introduction
 Load carriage can be defined as the external
load comprising items critical to tactical and
operational mission success.
 Focuses on the Ergonomically principle of
Human body load carriage system.
 studying the existing product material Quality
and replace it with good quality material.
5

6.  Military personnel to be capable of moving
their body mass plus an external load.
 The individual’s load is increasing with
advancing technologies and personal
protective equipment.
 Backpacks, shoulder straps, and belts can
enhance comfort and efficiency.
 Load carriage system must have consider
Ergonomic principles and Equipping material
functionality.
BACKGROUND OF THE
STUDY
6

7.  Load carriage is an external load comprising
items critical to tactical and operational
mission success.
 key element for dismounted military
operations.
 Reducing total loads, modifying
equipment and improving load
distribution.
 directly connected with the design of the
load carriage system.
 The study use domestically available
material to improve the existing one.
JUSTIFICATION OF THE PROJECT
7

8.  Do not sufficiently meet the
requirements.
 Has less engineering principles, result
several injuries and fatigues.
 Not manufactured locally, which can
apply human load carriage ergonomics
principles.
PROBLEM STATEMENT
Load carriage mag pouch
The existing Ethiopian
Military load carriage
equipment
8

9. General objective
 Design and develop improved military load carriage
Equipment for Ethiopian Army by conducting case study
on West region command head quarter.
OBJECTIVE
Specific objective
 Analysis the exiting load carriage equipment design and
materials.
 Integrate solar power system on the load carriage
system.
 Make Ethiopia capable to manufacture its own improved
military load carriage equipment with available materials.
9

10.  Well-designed load carriage systems can
enhance the likelihood of mission
accomplishment by reducing localized
stress and fatigue, so minimizing
performance decrements and injuries.
 So designing and developing load
carriage equipment system for One’s
state will be significant to contribute on
the strength of defense force
performance.
SIGNIFICANCE OF THE STUDY
10

11.  Limited from designing to
developing product.
SCOPE OF THE STUDY BENEFITS AND BENEFICIARIES
Benefits
 Increase the nation’s military
performance
 Improving the health, safety, and
comfort of soldiers as a Nation.
Beneficiaries
Ethiopian defence Institute
the sellers ( Manufacturers)
Soldier
developer
11

12.  According to Delaney Cassidy (2017) ,
 As of 2014, - 27 million active armed forces in
the world.
 With limited access to transportation, they rely
on their bodies to carry heavy supplies and
equipment.
Necessity of external load carriage
12

13.  According to J. Drain (2012)
 It is a universal requirement for military
personnel to carry an external load.
 Military operations often require
dismounted personnel to move, on
foot, through various climates and
terrains for long and continuous
periods.
Cont.…
13

14.  According to J. Drain (2012)
 The individual’s load is increasing with
advancing technologies and personal
protective equipment.
 Excessive external load may adversely impact
upon an individual’s physical capability
(mobility) and health (survivability, thermal
burden).
Effect of heavy loads
 Robin (2012 )
 Recently soldiers are carrying more load than
ever before, there is potential for the injuries
and death.
14

15. Load carriage systems
 According to Joseph (2004)
 Load carriage on some parts of body can
more comfortable than carriage on other parts
of the body.
 Load-carriage systems like backpacks,
shoulder straps, and belts can enhance
comfort and efficiency.
15

16.  Stewart (2009)
Proposed that most efficient way to carry
load as close to the body’s center of mass as
possible.
Cont.…
 Delaney Cassidy (2017)
 Currently two methods of load carrying available
to US soldiers.
 All-Purpose Lightweight Individual-Carrying
Equipment (ALICE).
 The ALICE pack utilizes an external frame to hold
the pack away from the body.
16

17.  Delaney Cassidy (2017)
 Modular Lightweight Load-Carrying
Equipment (MOLLE) pack.
 This improved pack utilizes an external
frame and a load bearing vest.
 In addition to improving carrying
functionality with customizable packs
 MOLLE utilizes improved padding and
strap adjustments that allow for better load
distribution.
Cont.…
17

18. Cont.…
Delaney Cassidy (2017)
Requirements and features that are
necessary to design an improved
load carriage system.
 Lightweight
 Adjustable: to adapt the wide
range of Users and varying load
ranges.
 Durable:
 Optimize load distribution:
essentially optimizes load
distribution to different parts
of the body to minimize
injury and fatigue.
18

19. Literature Gap
 Most of the literature studies about the ergonomics
principles and material selection for military purpose.
 But they aren’t discuss about how easily achieving human
load carriage ergonomics principles.
 And material selection, that is relatively good for military
purpose as the capabilities of one’s developing countries,
Particularly for Ethiopia.
19

20. Problem
formulation
Literature
survey
Data
Collecting
Primary data
Secondary data
Study & testing
Material of the
Product
Understand &
analyzing the
existing products
Designing
the products
from customer
Data analysis
Product
developing
Implementation
Documentation
METHODS & MATERIALS
20

21. Research design
 Explorative and Descriptive research methods
Source of data
 The study uses primary and secondary source
of data’s.
Data analysis methods
Qualitative Analysis
Quantitative Analysis
21

22.  From total population of 8,000 soldiers, 94 personnel was selected for
sample size, by using the formula,
𝒏 ∘ =
𝒛 𝟐 𝒑𝒒
𝒆 𝟐
Proportion of population size =50% at 95%
confidence interval, error (z). q= 1-p
no= 94,
N=8,000(Number of total soldier).
𝒏 =
𝒏𝒐
𝟏 + (𝒏𝒐 − 𝟏)/𝑵
= 94 Soldiers
Since, From 94 respondent 1 solider have no given the question
response
Sample size selection
22

23. MATERIALS
 Canvas fabric (1)
 1” width Velcro (2)
 plastic zipper (3)
 Snap button (5)
 Elastic cord (6)
 heavy weight sewing thread (7)
 plastic fasteners and adjustable ring (8)
 straps, rigger belts (9)
 Polyurethane foam board (10)
 Eye let(11)
 Military 3D Mesh fabric (12)
 elastic band (13)
1
12 9
6
7
13
11
10
2
5
3
8
23

24.  solar panel (1)
 Smart phone power bank (2)
 Solar power storage(3)
 portable smart (4)
phone data cable (5)
Cont.…
1
3
2
4
24

25.  In order to Comparing the existing product material with New
recommended material, scientific testing is basic.
 Material Testes, like
 Structure test
 Strength test
 Permeability test
 Serviceability test
 Handling test
For the case of this project ,
• GSM
• Tensile strength
• Tear strength
• Air and water permeability test
• Snagging test
• Abrasion test
• Seam slippage test
Required testing parameters.
25

26. The Current load carriage System
• The current load carriage system of the
Ethiopian defense force particularly the ground
force is hip belt load carriage system.
• This is made from nylon-polyester and Cotton
textile materials and it produced as straps, belts
and other webbing products.
• The hip belt load carriage system loads their
armament equipment all around the hip by the
mechanism of hanging (suspending).
Military Harness (Military Suspender)
Military belt
26

27. Cont.…
27

28. The Current load carriage System
 The current load
carriage system is
Assault load
carriage
equipment .
 Load their military
equipment all
around the hip by
the mechanism of
hanging
(suspending) on
the hip belt.
NO, Item(load Equipment) Unloade
d weight
(kg)
Loaded
weight (kg)
Dimension(size)
(cm)
1 AK47- Semi automatic machine gun
3.47
4.025 88 cm (35’’)
2 AK47, Cal, 7. 62 x 39mm, 30 rounds
magazine
0.37 0.925 L=22, W=7
3 RGD-5 grenade 0.0310 0.420 L=11.7 , d= 5.8
4 Weapons oil 0.009 0.034 5 x 2.5 x 8.25
5 Water bottle(canteen) 0.391 1.337 13(L)x9(W)x17.5(H
)
6 AK47, Cal, 7. 62 x 39 mm Bullets 0.0163 0.0254 7.62 × 39 mm
The current Ethiopian dismounted military personnel
equipment
28

29. No, Item(load Equipment) Loaded Body
part
Location of
load equip.
No,
Equipmen
t
Equipmen
t weight
kg
1. AK47- Semi automatic
machine gun
Shoulder Right
shoulder
one 4.025
1. AK47, Cal, 7. 62 x 39mm,
30 rounds magazine
One side hip hip 3 2.77
1. RGD-5 grenade Both side hip hip 2 0.84
1. Weapons oil One side hip hip One 0.68
1. Water bottle(canteen) One side hip hip One 1.337
1. AK47, Cal, 7. 62 x 39 mm
Bullets
One side hip hip 90 2.16
1. Back Pack Back Shoulder
and hip
one 13.188
1. Total external load 25 kg
Cont.…
 The national defense
force institute expected
that the foot soldiers
can have load 25kg as
average when they are
completely equipped
the common
combating and
sustainment
equipment.
The current Ethiopian dismounted military
personnel individual load mission planning.
29

30. No, Material tests (type) Canvas test result Leather test result
1 GSM 588 g/m2 1249 g/m2
2 Tensile strength test  903 N (92.04 kg)
 10.95 % elongation
 13.1 second
Weft
Relatively stronger than
Canvas,
(slide out from griper) 1079 N (110.1 kg)
 19.89 % elongation
 23.9 sec Warp
3 Tear test  48.41 N Weft Not available, but expected
that relatively stronger
than canvas.
More than 64 N warp
4 Air permeability test 1.89 cm3/cm2 sec Not permeable
5 Water repellency test 100 ISO 5 ( very good repellency) Not available (Expected
that, not permeable but
wet)
6 Snagging test ISO 4 ( good resistance) Not available( only for
fabric)
7 Abrasion test Rating 4 with photographic standard Not available
8 Seam slippage test Not available
Cont.…Material tests Results
30

31. 0%
9%
64%
27%
what equipment you were
carried?
body armor, helmet
food and water
webbing, weapon systems,
ammunition, power sources,
radio
all
0% 10%
12%
14%
36%
28%
How many times participate on
dismounted Operation, (trains, and
mountains)? None
One time
Two times
Three times
Four- seven times
 The data analysis is dome based on the data from questionnaires, existing
military equipment study and lab test results.
 expected that, all the data make the study realized and help to make accurate
decision on the designing and developing project.
DATA ANALYSIS
From
questionaries'
31

32. 0%
19%
27%48%
6%
0% 0%
0%
0%
How many load were weight the total
equipment?
10kg
10-15kg
15-20kg
21-25kg
26-30kg
31-35kg
36-40kg
41-45kg
Above 45 kg
Cont.…
62%
0%
0%
30%
8%
0%
what load carriage system you were carriage the
equipment?
Assault system
MOLE webbing
system
Tactical vest system
Back pack system
Hip loading system
Other system
(……………)
32

33. 29%
22%18%
25%
0%
6%
0%
What problem you have seen on the load
carriage system with respect to design
consideration?
Load distribution
problem
Load suspension(strap)
problem
Load bearing system
problem
Load mobility problem
Insufficient load carriage
system problem
Over loaded carriage
problem
Other………
Cont.…
 In addition all these question,
on the questionnaire there
was free space for comment
and ideas.
 Most the respondent
comment the
questionnaires'', basic and
important to address the
issue”.
 And rise other issues like
fitting problem of the load
carriage equipment system.
33

34. Cont.…
 The researcher summaries' the data
analysis from questionaries' ,
 Almost all dismounted military personnel
of “West region command Head quarter”
are men and their age fall on the range of
41-45 years.
Most of them average body mass fall on
the range of 61-65 and serve for more
than 17 years.
On their past operation event they carry
mission planning loads 21-25kg weighed,
 their load carriage equipment
were assault system which means
hip belt with shoulder suspender
straps and webbings.
During operation the common
problem of load carriage equipment
system, was load distribution.
But other problems also relatively
happen like sliding the load, load
suspension problem, load bearing
fastener problem and over load
problems.
34

35. Cont.…From Material
tests'
 From the material test result,
 the selected canvas fabric can perform the
requirement of the military application.
 The testing result shows that canvas fabric
have good snagging resistant ability, good
water repellency property, less GSM, less stiff
and relatively good air permeable property,
than leather.
 But relatively leather have strength and good
tear resistant property than canvas.
 In addition this canvas can easily treated with
different finishing like, water repellant, ant-
microbial treatment,
 Make it suitable for making the load carriage
equipment.
35

36. Cont.…
From the existing military equipment studies,
 data shows there is unbalanced load
distribution.
 The existing load carriage clearly have
ergonomics problem.
36

37. Cost Analysis
 The cost of improved load carriage equipment is 2765.33 Birr and its
price with 17 % price markup is 3180.12 Birr.
 While the existing load carriage equipment is 1840 Birr.
 The functionality and quality dimension of the improved product is much
more different from the existing.
 That is why the cost difference is wide
 This comes from the additional feature of the improved product.
 Particularly integration of solar system on the product
 And selection of quality material responsible for increasing cost of the
improved product.
37

38.  Depending this analysis the researcher trying to design
and develop improved load carriage equipment for
target groups.
 The load carriage system that would designed and
developed, was military tactical vest with customable
multi -purpose pouch, back pack.
38

39.  Can detachable with all customable and
adjustable load components.
 All around the tactical vest there is straps for
ease to detach any load carriage components
 The main construction material is Canvas
fabric.
 The design Considering Ergonomic
principles.
 The color of the product is green.
 Integrate with solar system
Advanced load carriage tactical
vest
Detachable
load
component
s
Improved Military Load Carriage Equipment Design
Description
39

40. Design of the Improved individual Military load carriage
equipment
AI and Ps 3D CAD design of the Tactical Vest
40

41. Technical specification sheet
Product order type:- Thesis project Pattern No.:- 001
Style No.:-MFTR00109 Gender: - Male
Item: - Tactical Military Vest Size Range: - M (Customable)
Product Description: - Tactical Military
Vest with detachable components and
solar system integration.
Product Line: - Load carriage
equipment
No. of patterns pieces: - depend on
details
Season: - all season
41

42. Pattern making
No. Measurement Tol. +/-
inch
Tactical Military Vest
1 Chest circumference 38 ½
2 Center front Length 28 ¼
3 Center Back length 21 ¼
4 Hip circumference 40 ½ ½
5 Shoulder girth 19 ½
6 Front hip girth 21
7 Side panel width 3 ½ ¼
8 Shoulder padding width 3
9 Armhole depth 14 ¼
10 Neck drop 6
Back pack
Width 15
length 22 ½
Depth 13 42

43. Marking and Cutting
Canvas fabric marking
Aluminum marking
3D Spacer mesh knit fabric marking
Canvas fabric marking
43

44. Sewing
44

45. Component assembling
45

46. Completed product ( Tactical Vest)
Side view
Front & Back
Top & bottom
Solar panel
46

47. Detachable backpack
Front & back view Side view Top view
Profile view47

48. Grenade pouch
Water canteen pouch
Ak-47 mag pouch
First aid Med kit
Radio pouch
Striking face plate pouch
Shoulder pad
Side closure
Back comfort
Load suspender strap
Bottom load secure strap
48

49. Shoulder strap D-ring
Shoulder strap free D-ring
Shoulder strap webbing
Adjustable chest strap
Shoulder strap comfort
Tringle load distributor
3D-spacer mesh knit fabri
Shoulder strap adjuster buckle
Gusset tacked strap
Power bank pouch
Shoulder strap insertion spa
Shoulder comfort
reinforcement
Shoulder strap webbingSolar panel
Back lower
pocket
Back upper pocket
Detachable backpack
Details
Solar cable port
49

50. Implementation
 The implementation of
the improved load
carriage product is done
by try-on four soldiers
who are from Logistics,
communication and
security department.
 They were test the
comfortability,
adjustability and
functionality of the
(source,
http//www.
Soldier
combat
field dress
military
uniforms
Ethiopia-
Ethiopian
army).
(sourc
e,
Author
)
50

51. Cont.…
Completed product on the giant body 51

52. Comparison of the existing and improved load carriage equipmen
No, Comparison Existing LCE Improved
LCE
Reason
1 Comfort ability Not comfortable Good comfort -ergo-Design
-Polyurethane
2 Design aspect Simple design Advance
design
-detachable concept
-adjustment concept
3 Financial
aspects
Less cost Higher cost -additional feature and value
4 Durability Durable Good durable - Quality Material with good
arrangement (Integration)
5 Weight of
products
Lower Higher - carriage capacity
6 Purpose Unique Multi –function - Design flexibility
- Usage mechanism
7 Treatment Untreated Treated - water repellent
52

53. Cont.…Existing LCE
Improved LCE
- Hip belt
- Grenade pouch
- Mag pouch
- Shoulder
strap(harness)
- Reserve bullet
pouch
- First aid pouch
- Water canteen
pouch
- Leather, cotton
- Grenade pouch
- Mag pouch
- Shoulder strap
(comfort)
- First aid med kit pouch
- Water canteen pouch
- Solar panel
- Striking face plate
pouch
- Power bank & storage
- Shoulder and back
comfort
- Buckle, Zipper, Velcro,
hook
- 3D spacer mesh knit
fabric
- Treated Canvas
- Webbing and strap
- Polyester lining
Distribute loads on
different body parts
(shoulder, hip, chest,
back and front) and all
load equipment can
detachable.
Distribute load
only on
shoulder, &
hip.
53

54. Feedback
 Collected from different departments (Logistics, communication
and security) of west region command heads quarter
 They also gave some details for applying the product for
Ethiopian army like, the color (camouflage) should have the
same with uniform.
 Other specific requirements related with load carriage
equipment need detail research.
 And they also gave their appreciation for this advanced load
carriage equipment overall product feature.
54

55. 55
Conclusion
 The current Ethiopian
military load carriage
equipment have need
improvement on its multi-
aspect (material selection,
design, and usage
mechanism).
 Modifying equipment and
improving load distribution
 Equipment modifications reduce
strain by allowing pressure and
load to be distributed to other
body locations.
 Appropriated changes on body
part lead to lower energy
consumption,

56. 56
 The load, carriage on some parts of body can more comfortable
than carriage on other parts of the body.
 Load-carriage systems like backpacks, shoulder straps, and
belts can enhance comfort and efficiency.
 Well-designed load carriage systems can enhance the likelihood
of mission accomplishment.
 By reducing localized stress and fatigue,
 Minimizing performance decrements and injuries.
Cont.…

57. 57
 The improved load carriage
equipment product was
designed and developed by
applying all the above
concepts.
 In general the improved product for One’s state
(Ethiopia) will be good and significant to
contribute on the strength of defense force
performance.
Cont.…

58. 58
Recommendati
on
 The hostile effects of load carriage equipment can be
decreased by modifying equipment and improving load
distribution.
 They reduce localized stress and fatigue, accordingly
minimizing performance decrements and injuries.

59. 59
Cont.…
Reduce load carriage problem and related issues:
 Use comfort material (polyurethane).
 Selecting quality material
 Apply load carriage concept (keep body center of mass).
 Design human ergonomic consideration
 Use load carriage fastener mechanism (buckle, hook, Velcro).
 Distribute the load on load efficient body part (Hip, chest, shoulder,
back)
 Securing load component with webbing and strap secure system.

60. 60
Project
Limitation
When studying this research, there was some
critical problems, budget (financial) problem,
fortunately the budget which funded from
sponsored Institute not gave to the researcher,
this result sever influence on the realization of
project.

61. References
Bernard F. Griffard and Professor John F. Troxell, Enhancing Professional Military Education in the Horn
of Africa, the Ethiopian
Defense Command & Staff College Initiative, Volume 13-09, August 2009.
Chris Brady, Derrek Lush and Tom Chapman, A Review of the Soldier's Equipment Burden, (December
2011).
Delaney Cassidy, Kimberlee Kocienski, Emma Healey and Ben Pulver, Improved Backpacking Load
Carriage System, March 22, 2017.
J. Drain, R. Orr, R. Attwells and D. Billing. Human Protection and Performance Division Defense Science
and Technology Organization, DSTO-TR-2765Load Carriage Capacity of the Dismounted Combatant - A
Commander's Guide Australia( 2012).
Johnson RC, Pelot RP, Doan JB, Stevenson JM: The effect of load position on biomechanical and
physiological measures during a short duration march, 2001.
61

62. 62