South Africa-based Booyco Engineering is supplying specialised heating, ventilation and air conditioning (HVAC) systems to global defence-industry customers.

The company’s recent projects include the design and manufacture of cooling systems for radar jamming shelters as well as for military amphibious vehicles.

“We engineer our systems to suit the particular demands of complicated military equipment, designed for the harshest conditions while still meeting onerous specifications,” says Booyco Engineering executive director Grant Miller.

The company highlights a recent project in which its custom-engineered solutions are being fitted to specialised hard-skinned radar jamming shelters - manufactured in South Africa by ADG Mobility for export. Built on an ISO-container footprint, the shelters house sensitive electronic systems, radar-interference technology and ballistic protection rated to withstand light arms fire.

“This environment creates severe thermal and electromagnetic demands,” explains Miller. “Not only must the HVAC system maintain stable internal temperatures for both personnel and electronics, but it must do so while complying with rigorous electromagnetic interference standards.”

Booyco Engineering says it designed the system in accordance with US military standards 461F, which governs electromagnetic interference in military environments, in order to meet the demanding electromagnetic compatibility requirements.

“When you are dealing with radar-related systems even small emissions can compromise performance - so the HVAC unit itself must be part of the protection strategy,” he says. “Acoustic considerations are also important, to ensure a quiet working environment; our system therefore operates at around 50 dB, significantly quieter than a typical office unit.”

To meet the extreme thermal specifications imposed by the shelters, the HVAC system is engineered for operating temperatures from -40 °C to 55 °C, with a maximum cooling output of 9 kW and heating of approximately 6.5 kW. The HVAC design must also be able to accommodate the shock and vibration demands of mobile military platforms, aligning with both MIL-STD-810G and the AECTP-400 requirements for mechanical stresses.

“These shelters are mounted on military trucks that move over rough terrain, so the system must endure the same treatment,” Miller says. “It is not a plant room system; it has to survive real military deployment.”

Other features of the system include chemical, biological, radiological and nuclear (CBRN) filtration as well as cyclonic dust filtration for high particulate environments. There are also built-in test functions and sensors such as onboard CO2 monitoring and advanced digital scroll compressors that ensure tight thermal stability for sensitive equipment.

In a separate contract with a southeast Asian government, Booyco Engineering is supplying a dedicated HVAC solution for a latest generation 8x8 amphibious infantry fighting vehicle. Rated for operation between -10 °C to 49 °C, the HVAC unit integrates CBRN filtration and advanced environmental protection.

“The CBRN system protects occupants of the vehicle from harmful gases or chemical agents,” Miller explains. “The filtration activates and removes harmful particulates and gases through high efficiency particulate air and carbon filters to protect both the crew and the vehicle’s electronics.”

The company asserts that it has successfully developed systems that withstand exceptionally harsh climatic and operational conditions. In amphibious applications, for instance, humidity and salinity - as well as rapid thermal shifts and continuous vibration - create a uniquely demanding environment for climate-control systems, adds Miller. The project includes a full prototype as well as several pre-production units to undergo qualification testing.