His armor kept soldiers safe in Iraq

DOVER, N.H. --Karl Hannan knows how to stop a bullet, and for that the Army is grateful. Before the Department of Defense figured out how to armor vehicles in Iraq, Hannan was the man on the ground, inventing a system of steel plates that could be clipped onto vehicles to protect soldiers. Hannan, an engineer and retired Army Reserve officer, earlier this year was awarded the Bronze Star, one of the military's top medals, for his invention. Last year, former Secretary of Defense Donald Rumsfeld recognized Hannan on a list of heroes for his lifesaving work. Hannan, of Pittsfield, was only two months into his 2004 tour in Tikrit, Iraq when a commanding officer asked him to design something to protect tractor trailers hauling supplies. The trucks "had no protection whatsoever," Hannan recalled. His invention, 6 mm plates of hardened steel were unique because they could be clipped, rather than bolted to vehicles. They tested well, too. "When I actually shot a weapon at the material, it actually stopped the bullet," he said. Soon Hannan and a team of servicemen were working around the clock, armoring as many vehicles as they could. As word spread, he traveled to Baghdad, Mosul and Kuwait to outfit vehicles. He also shared his designs and drawings in books and CDs. At its peak, Hannan's team was armoring 254 trucks a day. He estimates more than 2,500 military and civilian trucks received the protection. "His engineering expertise really emphasized how well-versed he was in coming up with the different angles and the stress factors that were needed," said Wayne Cote, Hannan's supervisor in Iraq. "They withstood quite an impact." Hannan retired from the Army Reserve's Devens, Mass.-based 323rd Maintenance Co. five months after returning form Iraq in February 2005.

Karl Hannan, Sales Engineer. Karl has 22 years as a machinist and a mold maker. Karl is also an instructor in machine shop technology and CNC programming. Karl holds a degree in Mechanical Engineering and a Master's degree in Manufacturing Engineering. khannan@eptam.com

Chief Warrant Officer Hannan

Northfield employee designed armor that saved lives in Iraq

NORTHFIELD — A Pittsfield soldier who earned a Bronze Star in Iraq for designing armor protection kits which have saved several lives received a hero’s welcome when he returned to his position at Eptam Plastics on Monday.

Applause from more than 60 employees greeted Chief Warrant Officer 3 Karl Hannan when he was presented with a plaque by Jeff Hollinger, company president, for his "dedication and efforts in defending our country."

The plaque, which is highlighted with two American flags, was presented during a surprise ceremony in front of his fellow employees.

Hannan is a member of the 323rd Maintenance Company (DS) GSE Platoon, based at Fort Devens, Mass. He is a maintenance technician with the unit which supports heavy trucks (five tons or more.)

Hannan had received the Bronze Star from his company commander, Capt. James Davis, during a ceremony at Fort Drum, N.Y. upon his return to United States two weeks ago.

Hannan, according to the Bronze Star citation, designed and manufactured a clip-on armor plating kit to protect soldiers in the heavy trucks. The kits included armor plating for the driver’s and passenger’s door and the floorboard.

He made engineering prints for several types of trucks and showed other soldiers in his unit and other units how to make the kits. He also trained six Iraqi nationals how to cut, weld, read blueprints and manufacture the armor.

His idea is credited with saving 29 lives to date.

The citation also states that his armor plating is the only type of its kind in Iraq in that it is a clip-on and not bolted to the body, and will not damage the vehicles.

"CW3 Hannan’s exceptional performance and devotion to duty are in keeping with the highest traditions of the military service and reflects distinct credit upon himself, the 323rd Maintenance Company (DS) and the United States Army," the citation states.

"I don’t believe I deserve this. I was just doing my time and my job. If I could save just one life and send him or her back home, it was worth it," Hannan said .

Hannan who has served in the U.S. Army Reserves for 25 years, knows the armor plating works.

"I came under four attacks myself," he said.

His unit was stationed at Tikrit, Iraq, for 14 months.

This was not his first tour of duty. He was in the Persian Gulf War when he was a member of the 82nd Airborne.

Hollinger said he and company employees are very proud of Hannan. He is the senior engineer on the firm’s research and development team.

"We are very proud of Karl and the fact that he saved lives. He gave up more than a year of his life and lived in a bombed-out building, sleeping on a cot. He is an excellent employee. It’s nice having him back," Hollinger said.

Hannan and his wife, Louise, live in Pittsfield.

Eptam Plastics is a plastic fabricator. The firm produces items for the private sector, the medical field and the military.

Part of Hannan’s design duties includes working with the manufacturers of military equipment, Hollinger said.

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