Tailoring turnout gear to risk: evolving firefighter safety

In a recent podcast discussing firefighter turnout gear, a term used that particularly resonated with me was ‘multi-mission garments’. As an Industrial Firefighter with over four decades in the field, I have observed an array of turnout gear innovations during this time. Textile technology has made substantial strides, offering significant improvements in features and benefits from a diverse range of global suppliers. However, these in the main have centred on the typical structural turnout gear design and limited differentiation in turnout gear tailored to specific risk exposures and the environments in which they are employed.

Typically, Industrial firefighters are equipped with ‘structural’ firefighting turnout gear, which, while robust, may not always align with the unique demands of their operational settings. This turnout gear is generally certified to conform to international standards like NFPA 1971 derived in the US and EN 469 in the UK and Europe. While other regional and national certifications exist, these two are predominantly recognized as de facto standards globally.

This article aims to refresh your understanding of the anatomy of structural firefighting turnout gear, examining its main composition and the role each layer plays. We will also touch briefly on the standards mentioned above and the performance assurance they provide. We also question the need for a more diverse ‘risk-based’ approach in designing firefighter turnout gear. Such an approach would ensure that the firefighting turnout gear is specifically tailored for the many challenging operations conducted and the wide range of environments in which firefighters work.

Essentials defined: key attributes of effective turnout gear

Turnout gear, also known as bunker gear, is primarily designed to protect against burn injuries and heat stress and is composed of several layers, which include an outer shell, a moisture barrier and a thermal liner. Also termed ‘bunker gear’ the name originally referred to the fact that the trousers and boots are traditionally kept by the firefighter’s bunk in the fire station so they can be quickly donned when responding to an emergency call. Let’s look at some of the main attributes of good-quality turnout gear:

Flame and heat resistance: protects against direct flame impingement and extreme thermal radiation.
Breathability: ensures efficient heat and moisture transfer to reduce heat stress and exhaustion.
Durability and abrasion resistance: provides resilience in harsh conditions, enhancing gear longevity.
Flexibility and ergonomic fit: facilitates freedom of movement for various firefighting tasks.
Moisture, chemical & pathogens: offers defence against water, chemicals and other liquids, preventing steam burns, toxins and disease.
Lightweight design: aims to reduce fatigue during prolonged operations.
Quick donning and doffing: enhances response efficiency in emergencies.
Visibility and reflectivity: includes reflective elements for improved visibility and safety.
Utility features: equipped with pockets and compartments for essential tools and items.

Let’s look at the three most important layers of structural turnout gear and what they each functionally bring to the protection of the firefighter.

Triple shield: exploring the three layers of structural turnout gear

The outer shell

The outer shell plays an important role for firefighter defence and is typically made from materials like Nomex, Kevlar and PBI with the objective of protecting against direct flame impingement. This flame-resistance requires the material to self-extinguish and prevent further combustion of the outer garment. The shell requires durability with a need for high tear and tensile strength to maintain integrity in abrasive conditions.

The outer shell must have a durable water repellent (DWR), this is provided by the application of synthetic coatings whilst still maintaining breathability. Features such as flexibility allow free movement and ensure overall safety and functionality.

The colour of the outer shell is a personal choice; however, the trend is toward lighter colours to reduce radiative impacts and provide ease of determining the cleanliness of the garment. Lastly UV resistance is vital as UV can seriously degrade the performance of material over time and this deterioration is not visible to the human eye.

The moisture barrier

In structural firefighting gear, the moisture barrier is crucial, located between the outer shell and the thermal liner. It prevents external moisture like water from entering while allowing sweat to evaporate, keeping firefighters dry and protected from steam burns and contaminants.

The moisture barrier’s effectiveness hinges on its waterproofness and breathability. It must stop liquid penetration and allow perspiration to escape, reducing heat stress and increasing comfort. Its vapour permeability is vital for moisture transfer, and it must resist chemicals and bloodborne pathogens for safety.

Composed of a microporous film (PTFE ePTFE, PU) and non-woven aramid, the barrier combines liquid and vapour resistance with strength. A good moisture barrier balance protection with the turnout gear’s comfort and functionality, ensuring firefighters’ safety and effective performance.

Thermal liner facecloth combination

In structural firefighting turnout gear, the thermal layer plays a fundamental role in insulating firefighters from intense heat. Typically, the thermal liner is made from heat-resistant materials such as aramids and flame-resistant modacrylics, this thermal layer is often constructed in a quilted fashion, enhancing its ability to trap air, which has excellent insulating qualities.

Key to its functionality is its integration with the innermost layer the facecloth that sits closest to the skin. The facecloth, typically soft and flame-resistant, augments comfort, aids in ease of donning and helps in moisture management by wicking sweat away from the body. This collaboration between the thermal layer and the facecloth provides not only protection from extreme temperatures but also comfort through moisture control and reducing chafing during prolonged wear.

Together, they offer a balanced combination of efficiency, flexibility, durability and breathability, allowing firefighters to perform their duties effectively while safeguarding against heat stress and burns.

Meeting the mark: standards in firefighting gear

NFPA 1971 and EN469 are pivotal standards for turnout gear, ensuring the highest protection and functionality levels. NFPA 1971 demands over 40 tests for gear, assessing flame resistance, heat insulation and durability. This rigorous testing simulates elements of firefighting conditions, and certification confirms the gear’s reliability and performance in real-world situations. However, the current practice of using structural turnout gear as a one-size-fits-all solution is being questioned.

One example of this change is wildland firefighting. Specific standards like NFPA 1975 and EN 16073 focus on lightweight, mobile gear with enhanced abrasion and tear resistance, acknowledging the distinct challenges of wildland environments. Similarly, NFPA 1951 and EN 16689 address gear needs for technical rescue scenarios, such as road accidents and urban search and rescue, ensuring protection, functionality and comfort.

Firefighters engage with fire in just about 30% of callouts, highlighting the need for gear tailored to their varied roles. The recognition of this diversity is driving the demand for new turnout gear designs that can meet global firefighting challenges. Looking ahead, we may see new standards emerging, likely influenced by market trends and innovations in turnout gear and technical textiles, better suited to the multifaceted nature of today’s firefighter.