Why Old Gear Is More Expensive Than You Think

It can be tempting for departments—especially those with tight budgets—to push another year or two out of turnout gear, hoses, or radios.

But the reality is that outdated fire equipment carries hidden costs: safety risks, legal liability, insurance complications, and higher long-term replacement expenses.

This guide explores the true cost of outdated gear and provides practical strategies to stretch your department’s budget while keeping crews protected.

 

The Safety Risks of Outdated Fire Equipment

PPE Degradation

• Turnout gear exposed to heat, smoke, and chemicals loses protective qualities over time.
• NFPA recommends replacing PPE every 10 years—even if it looks “fine.”
• Old gear increases risks of burns, toxic exposure, and heat stress.

Tool & Hose Failure

• Cracked hoses can fail during suppression, putting both firefighters and civilians in danger.
• Rusted or fatigued tools break under pressure, slowing critical rescues.

Communication Breakdowns

• Older radios may not meet NFPA 1802 standards, leading to dead zones, interference, or outright failures during emergencies.

 

The Financial & Legal Risks

Higher Insurance Costs

Departments with outdated gear may see higher insurance premiums or face denied claims after an incident.

Liability Exposure

If an injury occurs while using outdated or non-compliant gear, municipalities or leadership may be held legally responsible.

Replacement Costs Spike

Delaying purchases often means bulk replacements all at once, which is far more expensive than scheduled rotations.

 

How to Stretch Your Fire Department Budget

1. Prioritize PPE First

Always budget for PPE replacement before tools or station upgrades. Without compliant PPE, firefighters cannot safely operate.

2. Rotate Purchases Strategically

Replace 20–25% of gear annually rather than waiting for full sets to expire at once. This smooths out budget impact.

3. Apply for Grants

Programs like FEMA’s Assistance to Firefighters Grant (AFG) can cover large purchases of PPE, SCBAs, or radios.

4. Buy in Bulk (or Partner with Neighboring Departments)

Ordering multiple sets of turnout gear, hoses, or helmets often earns discounts. Smaller volunteer stations can partner with nearby agencies to place joint orders.

5. Maintain What You Have

• Use washer-extractors to properly clean turnout gear.
• Store equipment in gear racks instead of sunlight or damp spaces.
• Perform annual hose and ladder testing.
  Small maintenance steps extend usable life and save thousands.

FAQ: The True Cost of Outdated Fire Equipment

1. How long does firefighter turnout gear last?

According to NFPA 1851 standards, turnout gear must be retired 10 years from the date of manufacture, regardless of condition. Heavy use, exposure to fire, and poor storage can shorten its safe lifespan.

2. What are the risks of using outdated fire equipment?

Outdated gear increases risks of gear failure, toxic exposure, burns, communication breakdowns, and liability if an injury occurs during operations.

3. Can outdated PPE increase insurance costs?

Yes. Many insurance providers evaluate whether departments use NFPA-compliant gear. Outdated PPE or equipment may lead to higher premiums or even denied claims after an incident.

4. How can small departments afford to replace equipment?

Volunteer and rural fire departments can apply for FEMA Assistance to Firefighters Grants (AFG), rotate purchases gradually, and partner with neighboring departments to place bulk orders for discounts.

5. What is the best way to extend the life of fire equipment?

Regular cleaning, inspections, and proper storage are key. For example, turnout gear should be washed in a washer-extractor after exposure to smoke or contaminants, and hoses should undergo annual testing to prevent failures.

Final Thoughts: Don’t Let “Outdated” Become Dangerous

The true cost of outdated fire equipment isn’t just dollars—it’s lives, liability, and operational readiness. By prioritizing safety, applying for grants, and purchasing strategically, departments can stretch limited budgets without putting crews at risk.

At FirePenny, we’re committed to helping both volunteer and career departments find the right gear at the right price. From NFPA-compliant PPE to trusted tools and radios, we make smarter purchasing possible.