Maintenance and Cleaning Best Practices for Safer, Longer-Lasting Gear

bunker gear

Proper bunker gear maintenance protects you from burns AND cancer. Contaminated gear exposes you to carcinogens, reduces protective performance, and fails prematurely. Understanding decontamination protocols, inspection requirements, and NFPA 1851 compliance keeps you safer and extends gear life significantly.

In this guide, you'll learn:

  • Why immediate decontamination is critical

  • How to perform field and advanced cleaning

  • What carcinogen exposure risks exist

  • Required inspection procedures

  • How departments maintain NFPA 1851 compliance

  • When to repair vs replace gear

Why Is Gear Decontamination So Important?

Quick Answer: Fire contaminants contain proven carcinogens that absorb through skin, off-gas in stations and apparatus, and reduce gear protective performance. Immediate field decontamination followed by advanced cleaning removes cancer-causing chemicals, maintains gear effectiveness, and protects you and your family from exposure. Firefighters have significantly higher cancer rates, making decon protocols life-saving.

The Cancer Connection

Alarming statistics:

  • Firefighter cancer rates 9% higher than general population

  • Cancer is leading cause of firefighter line-of-duty deaths

  • 60% of firefighter deaths are cancer-related

  • Most cancers are exposure-related and preventable

How contamination causes cancer:

  • Carcinogens absorb through skin contact

  • Off-gassing creates respiratory exposure

  • Cross-contamination spreads to apparatus, stations, homes

  • Repeated low-level exposure accumulates over career

  • Improper cleaning leaves carcinogens in gear

Common carcinogens in fire smoke:

  • Polycyclic aromatic hydrocarbons (PAHs)

  • Benzene and toluene

  • Formaldehyde

  • Diesel exhaust particles

  • Heavy metals

  • Volatile organic compounds (VOCs)

Performance Impacts

How contamination reduces protection:

  • Soot blocks moisture barrier breathability

  • Chemicals degrade aramid fibers

  • Contaminants absorb and conduct heat

  • Reflective trim loses visibility

  • Materials lose flame resistance

  • Seams weaken from chemical exposure

Measured performance loss:

  • Thermal protection reduced up to 30%

  • Breathability decreased significantly

  • Tear strength compromised

  • Moisture barrier effectiveness reduced

  • Overall TPP rating lowered

What Is Field Decontamination?

Quick Answer: Field decontamination is immediate gross contamination removal at the fire scene before entering apparatus or stations. Use brushes, wipes, or hose spray to remove soot and debris from outer shell. Bag gear separately for transport. Field decon reduces 70-90% of contamination and prevents cross-contamination to apparatus and stations.

Field Decon Procedures

Immediately after fire operations:

Step 1: Remove gross contamination

  • Brush off heavy soot and debris

  • Use soft brush on outer shell

  • Pay attention to high-contact areas (shoulders, knees, sleeves)

  • Work in designated decon area away from clean zones

Step 2: Wipe down surfaces

  • Use decon wipes on outer shell

  • Focus on neck, wrist, and waist areas

  • Clean gloves, boots, and helmet

  • Don't forget SCBA facepiece

Step 3: Bag contaminated gear

  • Place gear in designated bags

  • Separate from clean equipment

  • Label if multiple sets present

  • Transport separately from personnel

Step 4: Wash exposed skin

  • Face, neck, hands, wrists

  • Use soap and water or wipes

  • Before eating, drinking, or tobacco use

  • Remove contact lenses if worn

Field Decon Equipment

Essential tools:

  • Soft-bristle brushes (avoid wire brushes that damage fabric)

  • Decon wipes (specifically designed for turnout gear)

  • Portable decon bags or bins

  • Hand washing station or wipes

  • Hose spray for heavy contamination (cool water only)

What to avoid:

  • High-pressure washing (damages moisture barrier)

  • Hot water in field (sets stains)

  • Harsh chemicals or solvents

  • Wire brushes or abrasive tools

  • Contaminating clean areas

Why Field Decon Matters

Benefits of immediate action:

  • Removes 70-90% of surface contamination

  • Prevents off-gassing in enclosed spaces

  • Reduces skin absorption time

  • Protects apparatus from contamination

  • Easier advanced cleaning later

  • Establishes good safety culture

How Do You Perform Advanced Cleaning?

Quick Answer: Advanced cleaning uses specialized extractors and ISP-approved detergents following NFPA 1851 guidelines. Clean gear after every fire exposure using front-load extractors only, manufacturer-approved products, proper water temperature (maximum 105°F), and appropriate drying methods. Never use household washers, bleach, or high heat.

Advanced Cleaning Requirements

NFPA 1851 mandates:

  • Advanced cleaning after every contamination exposure

  • Use of ISP (Independent Service Provider) or in-house capabilities

  • Proper equipment and approved cleaning products

  • Trained personnel performing cleaning

  • Documentation of all cleaning events

Frequency requirements:

  • After every fire exposure (mandatory)

  • Routine cleaning every 6 months minimum (even without fire exposure)

  • More frequent in high-use departments

  • Before annual advanced inspection

  • After any suspected contamination

Proper Cleaning Process

Step 1: Pre-inspection

  • Check for damage requiring repair first

  • Document gear condition

  • Remove loose debris

  • Close all closures (zippers, hook and loop)

  • Turn gear inside out if manufacturer allows

Step 2: Washing

  • Use front-load extractors only (top-loaders damage gear)

  • Load properly (don't overload, typically 2-3 sets per cycle)

  • Use ISP-approved detergent (never household laundry soap)

  • Water temperature: Maximum 105°F (40.5°C)

  • Appropriate cycle time per manufacturer instructions

  • Extra rinse cycle to remove all detergent

Step 3: Drying

  • Hang dry preferred method

  • Tumble dry on low heat only if needed (maximum 105°F)

  • Never high heat or direct sunlight

  • Proper ventilation to prevent mildew

  • Allow complete drying before storage

  • Verify all components dry (especially moisture barrier)

Step 4: Post-cleaning inspection

  • Verify cleanliness achieved

  • Check for damage discovered during cleaning

  • Document cleaning date

  • Return to service or send for repair

What NOT to Do

Prohibited practices:

  • Household washing machines (damage gear)

  • Bleach or harsh chemicals (degrade fibers)

  • Fabric softeners (reduce flame resistance)

  • Excessive water temperature (damages moisture barrier)

  • High heat drying (melts components)

  • Dry cleaning solvents (damage multiple layers)

  • Pressure washing (forces contaminants deeper)

Approved Cleaning Products

ISP-approved detergents:

  • Specifically formulated for turnout gear

  • Remove particulates and organic compounds

  • Don't degrade protective materials

  • Maintain fabric breathability

  • Leave no harmful residues

Common approved brands:

  • GEAR WASH Supreme

  • FireSafetix Gear Wash

  • Morning Pride Gear Wash

  • Globe Manufacturing Gear Cleaner

Why approval matters:

  • Standard detergents leave residues

  • Some products damage aramid fibers

  • Unapproved cleaners void warranties

  • Performance can be compromised

What Are Required Inspection Procedures?

Quick Answer: NFPA 1851 requires three inspection levels: routine (after each use), advanced (annually by qualified person), and specialized (for repair evaluation). Document all inspections. Retire gear at 10 years from manufacture or sooner if damaged beyond repair. Regular inspection identifies problems before they cause injuries.

Routine Inspection (After Each Use)

Firefighter performs after every use:

Outer shell check:

  • Tears, cuts, punctures, or abrasions

  • Char, melting, or heat damage

  • Seam separation or thread damage

  • Missing or damaged hardware

  • Reflective trim condition

  • Contamination level

Closure inspection:

  • Zipper function and alignment

  • Hook and loop effectiveness

  • Snaps and buckles secure

  • Storm flaps positioned correctly

Interface areas:

  • Coat/pants overlap adequate (8-12")

  • Wrist and ankle closures functional

  • Collar seals properly

  • DRD (Drag Rescue Device) secure

Documentation:

  • Note any concerns

  • Report damage immediately

  • Remove from service if needed

  • Record inspection completion

Advanced Inspection (Annual)

Qualified person performs annually:

Comprehensive evaluation:

  • All routine inspection items in detail

  • Moisture barrier integrity testing

  • Thermal liner condition assessment

  • Seam strength evaluation

  • Thread condition throughout

  • Label and identification verification

  • Remaining service life determination

Moisture barrier testing:

  • Visual examination for damage

  • Light test for pinholes

  • Hydrostatic testing if available

  • Any failure requires immediate action

Thermal liner assessment:

  • Check for compression or damage

  • Verify proper attachment

  • Assess loft and insulation value

  • Look for mold or mildew

Documentation requirements:

  • Complete inspection form

  • Photograph damage areas

  • Record findings in gear file

  • Make repair or retirement recommendations

Specialized Inspection (For Repairs)

When repair needed:

  • Evaluate if repair feasible

  • Determine repair type needed

  • Assess cost vs replacement

  • Verify repair maintains NFPA compliance

Who can perform:

  • Manufacturer authorized repair facilities

  • ISP certified repair technicians

  • In-house programs meeting NFPA 1851

  • Never unauthorized alterations

When Should Gear Be Repaired vs Replaced?

Quick Answer: Repair minor damage to outer shell, closures, and hardware. Replace gear with moisture barrier failure, extensive thermal damage, major structural damage, or approaching 10-year retirement. All repairs must be performed by qualified personnel using approved materials. Document all repairs.

Repairable Damage

Can typically be repaired:

  • Small tears or holes in outer shell (under certain size limits)

  • Broken zippers or hardware

  • Detached reflective trim

  • Minor seam separation

  • Worn wristlets or collars

  • Damaged pockets or storm flaps

Repair requirements:

  • Use manufacturer-approved materials

  • Maintain NFPA compliance

  • Document repair with date and description

  • Re-inspect after repair

  • May require re-certification testing

Non-Repairable Damage

Requires retirement:

  • Moisture barrier failure or extensive damage

  • Large tears in thermal liner

  • Extensive charring or melting

  • Severe seam failure affecting multiple panels

  • Contamination that cannot be cleaned

  • Damage exceeding manufacturer repair limits

  • Gear at or near 10-year retirement date

NFPA 1851 retirement:

  • 10 years from date of manufacture (on label)

  • Not from purchase date or issue date

  • Earlier if damaged beyond repair

  • Document retirement

  • Remove from service immediately

  • Destroy or clearly mark as unusable

How Do Departments Maintain NFPA 1851 Compliance?

Quick Answer: Establish written procedures, train personnel on inspection and cleaning, maintain proper equipment, document all activities, track gear age and service life, provide adequate gear inventory allowing rotation, and conduct regular compliance audits. Assign a program manager and follow NFPA 1851 standard comprehensively.

Required Program Elements

Written procedures for:

  • Field decontamination protocols

  • Advanced cleaning schedules and methods

  • Routine inspection requirements

  • Advanced inspection procedures

  • Repair and retirement criteria

  • Documentation requirements

  • Storage and handling

Training requirements:

  • All firefighters on routine inspection

  • Qualified persons for advanced inspection

  • Cleaning personnel on proper procedures

  • ISP certification for repair technicians

  • Regular refresher training

  • New member orientation

Equipment needed:

  • Front-load extractors (proper capacity)

  • Approved cleaning products

  • Proper drying facilities

  • Inspection tools and forms

  • Storage areas (clean, dry, protected)

  • Field decon supplies

Documentation Requirements

Must document:

  • Issue date and firefighter assigned

  • All cleaning events (dates and who performed)

  • All inspections (routine and advanced)

  • All repairs (what, when, who, materials used)

  • Any damage or concerns noted

  • Retirement date and reason

Record retention:

  • Maintain throughout gear life

  • Retain after retirement per department policy

  • May be required for workers' comp claims

  • Demonstrates OSHA compliance

  • Proves due diligence

Program Management

Assign program manager:

  • Oversees entire PPE program

  • Ensures NFPA 1851 compliance

  • Schedules inspections and cleaning

  • Maintains documentation

  • Coordinates repairs and replacements

  • Conducts training

  • Performs audits

Adequate inventory:

  • Minimum two sets per firefighter

  • Allows rotation during cleaning

  • Backup sets for damaged gear

  • New gear ordered before 10-year retirement

  • Multiple sizes available

What Are Common Maintenance Mistakes?

Quick Answer: Common mistakes include delaying cleaning, using household washers and detergents, ignoring small damage, poor documentation, storing contaminated gear improperly, and continuing to use gear beyond 10-year limit. These mistakes increase cancer risk, reduce protection, violate OSHA requirements, and create liability.

Critical Errors to Avoid

1. Delayed cleaning

  • Waiting days or weeks to clean after fires

  • Allows carcinogen absorption

  • Makes cleaning harder

  • Degrades materials

  • Increases health risks

2. Improper cleaning methods

  • Using home washing machines

  • Household laundry detergent

  • Excessive heat

  • Improper loading

  • Insufficient rinsing

3. Ignoring damage

  • "Small tears don't matter" mentality

  • Not reporting damage promptly

  • Continuing to use compromised gear

  • Delaying repairs

  • Missing moisture barrier failures

4. Poor documentation

  • Not recording cleaning dates

  • Missing inspection findings

  • No repair documentation

  • Unknown gear age

  • Inadequate records for compliance

5. Improper storage

  • Storing contaminated gear in living quarters

  • No protection from sunlight

  • Poor ventilation causing mildew

  • Compressed storage damaging thermal liner

  • Mixed with clean equipment

6. Exceeding service life

  • Using gear beyond 10-year limit

  • Not tracking manufacture dates

  • Continuing with failed moisture barriers

  • Ignoring retirement criteria

How Does Proper Maintenance Extend Gear Life?

Quick Answer: Regular cleaning maintains protective properties and prevents material degradation. Prompt repairs address minor issues before they become major. Proper storage protects from UV damage and mildew. Following manufacturer guidelines optimizes performance and longevity. Well-maintained gear lasts full 10-year service life while poorly maintained gear may fail in 3-5 years.

Maintenance Benefits

Performance preservation:

  • Maintains thermal protection ratings

  • Preserves moisture barrier effectiveness

  • Keeps reflective trim visible

  • Retains fabric strength and flexibility

  • Sustains breathability

Longevity enhancement:

  • Prevents premature material breakdown

  • Catches small repairs before major damage

  • Reduces contamination degradation

  • Protects against UV deterioration

  • Avoids mildew and mold damage

Cost effectiveness:

  • Full 10-year service life achieved

  • Fewer mid-life replacements needed

  • Reduced repair costs

  • Better budget predictability

  • Demonstrates good stewardship

Safety improvement:

  • Reliable protection throughout service life

  • Reduced cancer exposure risk

  • Consistent performance

  • Fewer unexpected failures

  • Enhanced firefighter confidence

What Should Individual Firefighters Do?

Quick Answer: Perform routine inspection after every use, participate in field decon immediately after fires, report damage promptly, follow department cleaning schedules, properly store your gear, track your gear's age, and never use damaged or contaminated gear. Your health depends on consistent maintenance practices.

Personal Responsibilities

After every fire:

  • Participate in field decon completely

  • Perform routine inspection

  • Report any damage discovered

  • Place gear in proper cleaning queue

  • Shower and wash exposed skin

  • Change clothes before leaving station

Regular duties:

  • Follow department inspection schedules

  • Properly store gear between uses

  • Know your gear's manufacture date

  • Attend training on maintenance

  • Follow all SOPs

  • Never bypass procedures

Know when to say no:

  • Don't use damaged gear

  • Don't skip decon for convenience

  • Don't ignore small problems

  • Don't wear gear past 10 years

  • Don't take contaminated gear home

Self-Protection Practices

Reduce exposure:

  • Remove gear as soon as safe

  • Shower within one hour of exposure

  • Change into clean clothes

  • Never wear contaminated gear unnecessarily

  • Don't eat, drink, or use tobacco until cleaned

  • Keep gear away from living areas

Frequently Asked Questions

How soon after a fire should gear be cleaned?

Field decontamination should happen immediately before leaving the scene. Advanced cleaning should occur within 48 hours, sooner if possible. The longer contamination remains, the more carcinogens absorb into materials and the harder cleaning becomes.

Can I take my bunker gear home to wash it?

No. Household washing machines don't properly clean turnout gear and can damage protective layers. You also risk exposing your family to carcinogens. All gear should be cleaned at department facilities or by certified ISPs using proper equipment.

What if my department doesn't have an extractor?

Contract with an Independent Service Provider (ISP) certified for turnout gear cleaning. Many fire equipment dealers offer cleaning services. NFPA 1851 compliance requires proper cleaning regardless of in-house capabilities.

How do I know if my moisture barrier is compromised?

Visual inspection may reveal tears or holes. If you feel wet during operations, the barrier has failed. Annual advanced inspection includes moisture barrier testing. Any suspected failure requires immediate evaluation by qualified personnel.

Can gear be cleaned too often?

Properly performed cleaning using approved methods and products does not damage gear. Clean after every fire exposure plus routine cleaning every 6 months minimum. More frequent cleaning is acceptable and recommended for high-use departments.

What happens if I don't clean my gear?

You face increased cancer risk from carcinogen exposure, reduced thermal protection (potentially causing burns), failed inspections, OSHA violations, and gear degradation requiring early replacement. Proper cleaning protects your health and extends gear life.

Who pays for gear cleaning?

Departments are responsible for providing proper cleaning per OSHA requirements. This includes in-house equipment and supplies or contracted ISP services. Proper maintenance is a cost of operations, not an optional expense.

Final Recommendations

Establish strong habits:

  • Field decon after EVERY fire exposure

  • Advanced cleaning within 48 hours

  • Routine inspection after each use

  • Prompt damage reporting

  • Proper storage always

  • Track gear age and service life

Department responsibilities:

  • Implement comprehensive NFPA 1851 program

  • Provide proper equipment and training

  • Maintain adequate gear inventory

  • Document all maintenance activities

  • Enforce cleaning and inspection requirements

  • Budget for proper maintenance and timely replacement

Culture change needed:

  • Contaminated gear is not a badge of honor

  • Cleanliness promotes safety and longevity

  • Cancer prevention is everyone's responsibility

  • Compliance protects firefighters and departments

  • Proper maintenance is professional standard

Remember: Your bunker gear protects you from burns during fires and cancer after fires. Proper maintenance through regular cleaning, inspection, and timely repair or replacement keeps you safer throughout your career. Make gear maintenance a non-negotiable priority.

Shop Bunker Gear and Maintenance Supplies at Fire Safety USA

Browse Bunker Gear & Turnout Coats →

Fire Safety USA carries complete NFPA 1971-compliant bunker gear and maintenance supplies to support your gear care program.

Our selection includes:

  • Complete coat and pant sets

  • Replacement components

  • Gear cleaning products

  • Decontamination supplies

  • Storage solutions

  • All sizes available

Maintenance supplies available:

  • ISP-approved cleaning detergents

  • Decon wipes and brushes

  • Gear bags for transport

  • Inspection forms and tools

Why Choose Fire Safety USA:

  • Family-owned since 1982

  • Expert guidance on gear selection and care

  • Competitive pricing with department discounts

  • Fast shipping nationwide

  • Support for NFPA 1851 compliance

Questions about gear maintenance, cleaning products, or establishing compliance programs? Contact our specialists at 1-877-699-3473.