Sand drives Army to ditch Velcro on pants

WASHINGTON — The Army is ripping space-age Velcro from its uniforms and replacing it with the humble button, which turns out to be tailor-made for the rigors of Afghanistan.
Hook-and-pile tape — the generic term for Velcro— strains to keep jam-packed cargo pants pockets closed. And when the Taliban attacks, the last thing soldiers need to worry about is spilling their gear.


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Soldiers told superiors that Velcro didn't suit their needs, and the Army began testing alternatives last year, said Debi Dawson, an Army spokeswoman. In August, the Army will begin issuing new pants to soldiers heading to Afghanistan.

"When concerns surfaced in surveys that the hook-and-pile tape was not holding under the weight of full pocket loads, the Army evaluated several solutions," Dawson said. Velcro has been part of the latest Army combat uniform since it was introduced in 2004.

Dirt and rocks also clog the pile portion of the fastener. That requires soldiers to clean it regularly. An Army website offersthis helpful hint: a soldier's small weapons cleaning brush has been "working very well" in removing dirt and sand.

"This is the latest proof that dust and debris are the biggest enemy for the U.S. military," said Loren Thompson, a military analyst at the Lexington Institute and a consultant to defense contractors. "Taliban attacks come and go, but dust is constant in Afghanistan. Dust will impede the function of anything."

Sgt. Kenny Hatten cut to the heart of the matter in this posting on an Army website, urging the military to go back to the future:

"Get rid of the pocket flap Velcro and give us back our buttons," Hatten wrote. "Buttons are silent, easy to replace in the field, work just fine in the mud, do not clog up with dirt and do not fray and disintegrate with repeated laundering."

Somebody, apparently, was listening.

Snaps and buttons were identified as possible fixes for failing Velcro. The Army surveyed 2,700 soldiers who tested prototypes, and 60% said they preferred buttons and 29% liked snaps. Just 11% wanted to keep Velcro, according to the Army. In the end, the Army decided to substitute three buttons for Velcro on the cargo pockets of its pants.

It's cheaper, too. The Army will save 96 cents per uniform when it swaps buttons for Velcro, Dawson said.

The new-and-improved uniforms will still have plenty of Velcro, the sticky fabric popularized during spaceflights. (Astronauts used it to keep pens and other items from floating in the weightless environment.) Velcro remains on the cuffs of sleeves. It's also used for nameplates and patches.

Hatten's ideal uniform might save the Army a few more pennies.

"I don't mind the insignia Velcro on the sleeve pockets, but why would I need Velcro for my name tape and U.S. Army tapes?" he asked. "Am I going to change my name and join a different army? Why not let us sew these items on the uniform, along with the patrol cap? That's cheaper, more durable and reduces the possibility of having your uniform items stolen or tampered with."

The Army, Dawson said, hears soldiers like Hatten. It's aware of continuing complaints about Velcro and will take them into account when redesigning uniforms in the future.

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