It’s impossible right now to have a conversation about fire apparatus or equipment and not talk about costs and wait times. But, that’s back at the firehouse after a call or during preventive maintenance, and the focus is usually on those of us on the bay floor.
I recently spoke at a meeting of the Montgomery County (PA) Engineers and provided an update on where we are in the industry right now, and one of the things I stressed is that no matter the manufacturer (in this case, of fire apparatus), all of them are doing as much as they can to eat away at their record backlogs so lead times will ultimately come down. But, what I couldn’t answer then is the “why” for all this. We’re about five years out from when we started hearing about COVID-19 and four years since 2020 ended. Why are we still experiencing the lead times, etc? To understand that, we need to understand the challenges our fire service industry suppliers are experiencing and how those challenges can impact our purchasing decisions during 2025.
INFLATION AND SUPPLY CHAIN
The waters through which fire industry suppliers navigate include continued supply chain challenges (although they have eased, they still exist), labor, inflation, as well as finding new product opportunities. “Despite what many would perceive to be a boon market for fire service suppliers,most are facing a number of challenges from continued supply chain to employee attraction and retention challenges,” says Paul Darley, president and CEO of Darley.
“In addition to the looming 2027 emission changes, the long lead time has had some negative impact on manufacturers, dealers, and fire department customers. Specifically, trucks sold over the past few years were priced at prehigh inflationary prices, resulting in eroding margins due to the inflation impact on deliveries that average about three years.” He states that fire apparatus manufacturers are faced with limited facilities, aging workforces, and a skilled labor shortage. “Dealers and sales reps, most of whom are compensated on commissions after the delivery of the truck, face business and personal cash flow challenges,” Darley adds.
Bob Schulz, president of Pierce Manufacturing, says that while supply chain pressures have eased in recent years, occasional disruptions happen, particularly with critical components and specialty materials. He also cites workforce development and the demand for sustainable, technologically advanced apparatus as challenges. “Inflation remains a significant factor, driving up costs for both raw materials and labor, which directly impacts apparatus pricing,” he says. To address the supply chain and inflation challenges, Pierce has expanded its supplier network, according to Schulz, to create more redundancy and flexibility to ensure it has multiple sources for critical components. “Additionally, we’ve invested in strategic inventory management to mitigate disruptions, allowing us to maintain steady production even when supply chains are strained,” he adds.
According to Roger Parker, Rosenbauer America director of sales, North America, “In building a new fire apparatus, the potential disruption can be surprises with various aspects of the supply chain that result in material delivery delays to our manufacturing operations. Generally there remains a fair amount of fragility and uncertainty with various aspects of different parts and components,” he says. “It can range from PTOs to axles, and frankly it only takes one issue from a given supplier to have a major impact on the final build of a customer’s truck. We have a dedicated supply chain team who work diligently to address this, and it remains a daily focus to manage through and honor delivery commitments to our customers.”
LABOR
When the topic of fire apparatus delivery times comes up, many people will turn to the current backlogs all apparatus manufacturers have right now. But, Mike Adams, executive vice president, Ziamatic, says, “One thing to keep in mind is that the backlog for fire trucks has stayed the same for most of 2024. However, moving forward, it should improve slightly in the next year or two. The main factors are that new truck sales are down considerably this year vs. the same time last year. But, there are still two factors that can delay vast improvement on catching up. They are supply chain and labor force issues. Most, if not all, builders I’ve talked to need additional employees.”
Larry Daniels, senior director, global sales, REV Fire Group, adds, “As with most fire departments and businesses I talk with, one of the biggest challenges facing our manufacturing industry is labor. The labor force has changed over the past four or five years. It’s a less experienced workforce, and the tenure rate at our businesses is not what it used to be.” REV has implemented additional training for its employees, Daniels says, “making sure that we are providing the highest quality mission-critical vehicles to our dealer partners and fire departments around the world.”
Schulz also cites workforce development as a challenge and says that Pierce has invested heavily in training and retention programs to maintain its production quality and capacity as demand for highly skilled labor in manufacturing increases. “At Pierce, we’ve found success in building partnerships with technical schools and creating internal training pathways to address this.” One avenue is its expanded apprenticeship and upskilling programs that not only help recruit new talent but also empower Pierce’s existing team to grow their skills andadvance within the company. “This has allowed us to increase capability while maintaining our high standards for craftsmanship and quality.”
PRODUCT DEVELOPMENT
Another challenge for fire service product suppliers has to do with product development—currently developed new products as well as products yet to come. Keith Creely, vice president, Ziamatic, says that a big challenge at Ziamatic is finding new product opportunities. “Finding opportunities is the first step,” he says. “The second challenge is to develop a product that fulfills a specific need. The product must also be efficient in function and cost. This is why we always encourage our customers to communicate to us so that we can provide answers when it comes to superior equipment access and mounting.”
At Whelen Engineering, one challenge is getting a product out onto fire apparatus once the product is developed. With the lead times the way they are right now, when Whelen comes out with a new emergency lighting model, for example, it is a challenge to get that new model onto recently ordered rigs at the time of introduction. So, a truck is ordered with one model, but department representatives might attend a show like FDIC International and see the new product but not be able to get it on the rig they just ordered. Then, that rig will be in service for up to 20 years. Getting the new product into circulation can be challenging. And by the time the truck is built, there could be yet another update. “Technology’s changing every year,” says Paul Deming, national sales manager, fire and EMS sales, Whelen Engineering. “Work closely with your dealer to see how those technologies can be adapted to a truck that’s in a long backlog.”
At Pierce, meeting the demand for sustainable, technologically advanced apparatus has introduced new challenges in product development, according to Schulz. “Fire departments are increasingly looking for vehicles that not only meet operational needs but also align with environmental, sustainability, and safety/health goals,” he says. “This shift requires continuous innovation to design apparatus that leverage alternative power sources, such as electric or hybrid systems, without sacrificing performance or safety.”
LOOKING TO 2025
Some of the challenges noted above will influence purchasing decisions during 2025—inflation being one considerable factor. “As fire departments plan their purchases in 2025, they will likely be influenced by a combination of financial and operational factors,” says Schulz. “First, the lingering effects of inflation mean departments must plan carefully around higher-than-historic apparatus costs.” For departments that have relied on large purchases, Schulz says they may look to diversify their strategies, which could include phased purchasing plans, lease-to-own options, or exploring refurbishment programs. Simplifying the fleets by investing in multifunction apparatus is another option for 2025.
REV brands have worked to mitigate longer lead times by reducing complexity without compromising customization for fire apparatus. The result was the S180 fire apparatus, which is highly customizable but can hit the production floor and go through the line much faster, according to Daniels. “Similar to the S180, E-ONE has introduced its Select Series: preengineered 78- and 100-foot aerial apparatus that have much quicker production rates,” says Daniels. “Fire departments can circumvent long lead times by considering preengineered units such as the Select Series and S180.”
Darley adds that as we move into 2025, fire departments need to accelerate their capital expenditure process within the confines of community budgets. “With fewer ready reserve fire apparatus, fleet managers and fire chiefs will need to have longer- term fleet replacement planning.”
“I think you’ll see a lot of fire departments looking at available stock trucks, from OEMs as well as stock units from fire apparatus dealers,” says Parker. “This is due to the relatively persistent long lead times for new truck order timeframes based on existing production backlogs. Additionally, the continued price increases due to inflation can cause a department to look at more immediate purchase options vs. the risk associatied with future longer deliveries.”
Technological and environmental considerations will also play a role in purchasing decisions next year, according to Schulz. “Many municipalities are pushing for more sustainable apparatus, so departments are seeking alternative energy vehicles,” he says. “However, the cost and infrastructure requirements for charging stations can make this a complex decision. Departments need to balance their immediate operational needs with long-term sustainability goals.”
THE MILLION-DOLLAR QUESTION
While lead times have leveled over time, they are still above the normal market. The number of fire apparatus orders at the end of 2024 will be down compared with 2023, and fire service equipment providers are optimistic that lead times will continue to get better in 2025. “Fire departments should begin to see more consistent lead times, provided there are no unforeseen disruptions,” says Schulz. “However, departments should still expect some extended timelines for more specialized or custom-built apparatus. We advise departments to plan proactively, engage early in the purchasing process, and work closely with their dealers to set realistic expectations.”
Parker says, “Based on what we see through the first six months of this year for our entire industry, the number of fire apparatus orders at the end of 2024 will likely be down compared with 2023. This is most likely just a settling of the market to a more typical demand level that existed prior to the pandemic in 2020.” He adds, “On a fully custom truck, depending on product type and configuration, the average lead time is within approximately two years.”
Daniels adds, “While the market is starting to normalize to preCOVID, prepandemic levels, the levels are still above the normal market. We believe once we reach a normal market, customers will look to purchase a smaller quantity of units vs. the past couple of years when customers were ordering several trucks or more at one time due to the multiyear backlogs.
We expect customers will soon start to follow their normal budgeting replacement and buying cycles. In the meantime, we continue to look at ways to improve efficiency and throughput through our designs and operations.”
Pierce has also continued to work to improve its production capacity. “Continued investments in our facilities and workforce have allowed us to scale up production capacity,” says Schulz. “We’ve added a substantial amount of team members but have also increased automation in key processes to supplement and support our workforce, reducing bottlenecks and enhancing efficiency without compromising quality.”
Darley says that while the number of fire apparatus ordered will be down in 2024, there are still backlogs that will continue at least into 2026. “While OEMs are taking measures to increase capacity, it will be at least a couple of years before new customer- ordered fire apparatus lead times decrease significantly,” he says. “The EPA emission changes will compound the problem.”
EPA CHANGES
Darley says there are still issues relative to mounting SCRs, pumps, and other components on apparatus once the EPA changes are implemented on engines that go into fire apparatus. “Most OEMs still do not have enough complete engineering data from engine suppliers to design around these potential challenges,” he says, adding that as a pump manufacturer, the company still does not have engine curves from one engine manufacturer.
Daniels says that the EPA changes will have a far-reaching impact. “We know that there will be more components to the engine, and the aftertreatment system will get larger, which will have an impact on cab and chassis design,” he says.
Parker says, “The biggest thing we’ve got going into 2025 is to do all the prototype and the beta testing on the new engines. Our first beta engine is supposed to be here in May 2025 to start fitting that into the cab, start doing all the testing, and all the configurations.”
In terms of what some of those changes might look like, Parker says there are going to be two aftertreatment systems. On a normal pumper, the right front lower compartment will probably be raised someplace between 3 and 6 inches. “You’ll have a wasted space because of the height of the canister,” he remarks. “You’re going to lose some compartment space, and there’s just no other way of getting around it.” It’s not going to look different, he says, but when a firefighter opens the compartment door, there will be a little shelf.
Schulz says Pierce is working closely with engine manufacturers to minimize packaging impacts and ensure it not only meets the new standard but maintains performance and reliability. “While it’s too early to fully understand the complete impact of these changes, we expect a shift toward greater integration of hybrid technologies and further advancements in electric powertrains,” he says. “These changes could lead to a rethinking of engine design, size, and placement within apparatus, potentially impacting weight distribution and the overall layout of the vehicle.”
ADVICE FOR 2025
Advice for purchasing in 2025 revolves around starting early in the process, being forward thinking, communicating with suppliers, choosing the right dealer, and being patient.
“My advice to fire departments considering new fire apparatus over the next few years is simple: Start the process early. Plan 36 to 48 months in advance,” says Darley, who also suggests reaching out to dealers that may have a limited inventory of stock trucks available for quicker delivery if a department has an emergency need.
Schulz suggests that fire departments approach procurement with both flexibility and forward thinking in mind. “The market continues to evolve, and with new technologies, sustainability requirements, and regulatory changes on the horizon, departments need to consider not only their immediate needs but also how their apparatus will perform and evolve over the next decade,” he says. He also believes departments should work closely with their dealer representatives to “explore all options, whether that involves leasing, refurbishment, or phased purchase,” he says. He also says fire departments should prioritize longterm relationships with their suppliers.
Parker stresses acting now and also returns to the EPA topic. “If you want an engine without the new EPA features, now is the time to do it. I tell everybody, the sooner you work on it, the better off you’re going to be and the quicker you’ll get it. If you’re going to have the budget in 2026, you have to start talking about it now.” Additionally, he says, “Many of the challenges related to the COVID- 19 pandemic have improved. For those departments planning major purchases in 2025 and beyond, make sure you identify dealers and OEMs you can trust. Remember that you are specifying a truck with today’s current technology. that technology may change with delivery times that are greater than two to three years. Being forward thinking and working with your OEM can be very helpful throughout the process.”
Deming again stresses starting early, particularly with new products. “Make sure with long lead times that you look at all the technology that’s out there,” he says. “Build that truck for 25 to 30 years and remember you’re building it four years or three years from now, before it even hits the community. Talk to your suppliers. Talk to your dealer. Talk to your OEM about what emerging technology is out there that you should be leaning forward with to make sure that you make the right decisions when building that long-term vehicle.”
Creely says that departments planning purchases should let their vendors help provide the information needed to make informed decisions on tool and equipment mounting purchases. “Most departments do things differently,” he says. “We pride ourselves on the versatility and quality of our product designs. We will support our customers before, during, and after their purchases.”
Finally, Daniels says, “Be patient with lead times and be sure to work with a reputable dealer and manufacturer that you know and trust.”
Many of the challenges related to the COVID-19 pandemic have subsided or have lessened to a degree. For those departments planning major purchases in 2025 and beyond, make sure you use dealers and vendors you can trust and that you know well, but remember that you are likely specing a truck with today’s technology-technology that is likely to change by the time you take delivery. Be flexible and remember that your product suppliers are doing everything they can to return to the “normal marketplace” Daniels mentions above.
CHRIS Mc LOONE, editor in chief of Fire Apparatus & Emergency Equipment, is a 31 -year veteran of the fire service currently serving as a safety officer and is a former assistant chief with Weldon Fire Company (Glenside, PA). He has served on past apparatus and equipment purchasing committees. He has also held engineering officer positions, where he was responsible for apparatus maintenance and inspection. He has been a writer and an editor for more than 30 years.
