I’m not big into military surplus but occasionally I come across gear purpose-built for military units that I can put to good use as a civilian. After last year’s winter vortex debacle, I’ve been researching cold weather gear. Depressing I know, but winter is coming and I want to be better prepared. That’s when I came across the Protective Combat Uniform or “PCU”. PCU is a 16 piece, 7 Level clothing system that was developed for USSOCOM starting in 2001 after soldiers complained that they were “freezing their ass off” in the Hindu Kush mountain range in Afghanistan.
Beyond Tactical PCU Level 5 Soft Shell
ADSTactical was given the first contract (ADS also was eventually awarded the contract for the US Army’s GEN III ECWCS). Below is an excerpt from a DVD talking about the system.
Here’s a summary of the Seven Levels:
Level 1
A durable, silkweight Polartec Power Dry fabric worn next to the skin wicks away moisture and dries fast. It consists of a crew neck T-shirt and boxer shorts, or is available inlong-sleeve top with invisible zipper and pants, built for comfort and minimal weight.
Level 2
A long-sleeve shirt and pants made from Polartec Power Dry fabric are worn next to the skin for extra warmth in extreme conditions, but still wicks away moisture quickly from skin and dries fast. An inserted side panel of Polartec X-Static fabric enhances fit and flexibility. The top has a front 15-inch zip for extra venting and a soft lining around the collar. Comfort features include an articulated side seam on the pants to minimize chafe on the kneecap.
Level 3
An insulative mid-layer jacket made from Polartec Thermal Pro High Loft fabric is water-repellent yet breathable. It is worn as an outer jacket in mild temperatures or as a heavy insulative layer in extreme cold. Seamless shoulders minimize chafe, which are then lined for extra warmth and padding for heavy pack straps.
Level 4
The soft windshirt is made from an encapsulated microfiber that repels water but also breathes for a variety of conditions. It is designed to pair with a next-to-skin layer for intense activity in cooler temperatures or with the Level 5 soft shell as a mid-layer. It stuffs into its own pocket for easy packing.
Level 5
The key to the entire system, this soft shell fabric jacket and pants are made with fibers encapsulated with silicone that are highly stretchable, windproof, water repellant and breathable (EPIC by Nextec). They are paired with Level 1 or 2 next-to-skin layers, ready for any cold weather aerobic activity.
Level 6
A lightweight waterproof and coated nylon hard shell is slightly oversized to fit easily and quickly over gear. The jacket features water-resistant zippers and armpit zips for maximum ventilation, pocket openings to quickly access inside layers and a hood that incorporates a stiff brim. The pants borrow the same design from Level 5 but provide waterproof protection.
Level 7
For extreme conditions, this lightweight, loft-insulated level in a jacket, vest and pants has the feel of down but retains its warmth when wet. Silicone-encapsulated fabric sheds water and is paired with Primaloft insulation for maximum warmth while the liner pulls away moisture.
The whole thing was pretty ambitious. Since 2002, other companies have been sourced to manufacture pieces from the various levels including Beyond Tactical, Blackhawk! Industries, Insport, Patagonia, Propper, Ready One, and Steps Inc. The Patagonia versions are especially sought after. Some are out of production, but they can still be found from secondary sources. The Ontario Geardo blog put together a Buyer’s Guide that I found particularly helpful. He’s also tested some of the clothing from the different companies. Definitely worth a look. Kwikpoint also published a step-by-step visual user guide that provides detail on the levels, shows how to combine the layers in different conditions, care instructions, and other useful information.
I’ve heard that this winter might be as bad or worse than last year. If you need some warm clothing and you like Milspec quality gear then the PCU system might be a good place to start.
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