Turnout Gear Structure

The Fire Suit Composite System 

You may be surprised to learn that the assembly of turnout gear (bunker gear, turnouts, fire incident gear, specialized PPE) is quite complex. Every set of gear is made of three layers; together those layers make up the fire suit composite system. Each layer is required in order to meet NFPA guidelines:

• the outer shell
• the moisture barrier
• the thermal liner

All three layers have a unique purpose in the build of the suit. The materials that make each layer also play a vital role in the suits overall functionality. Check out our Material Selection Guide to learn more about the differences in materials.

The combination of materials impact: 

• Weight of the turnout gear
• Body temperature regulation
• Flash over threshold
• Puncture resistance/strength
• Agility while suited up

The Outer Shell

As the very first line of defense, the outer shell is the hardest working layer. This layer gives the gear the iconic image that comes to mind when thinking of firefighters. But, it must meet a lot of demands in order to qualify and is held to very high standards to be certified with the NFPA. 

This layer must provide protection against abrasions and punctures while being flame-resistant. The material must also be durable enough to withstand many years of proper washing cycles and be resistant to tearing, but not so resistant that a firefighter couldn’t tear themselves free in an emergency.

Moreover, it needs to be as lightweight as possible while simultaneously providing excellent thermal protection and being strong enough to support any patches, accessories, pockets, and any other equipment needed while staying in compliance with all NFPA guidelines. 

It’s definitely tough criteria to meet, so being sure to select the proper fabric is important. All outer shells possess differentiating attributes that are influenced by the chemistry of the fibers, the blends, and the weave. When selecting the proper fabric for your department, you want to look out for a lightweight and durable option with ample thermal protective properties.

Our suggestion: Check out TECGEN71 outer shell material.

The Moisture Barrier 

The moisture barrier is the layer of protection found in the middle of the composite system. This layer is constructed of a two-layer membrane, one layer being a porous polymer film and the other being a flame-resistant, non-woven fabric.  

The primary role is to provide protection against penetration of the chemicals, water & other liquids, and bloodborne pathogens that firefighters regularly come into contact with. This is accomplished through the membrane’s micropores acting as a filtration system. The pores are bigger than a molecule of steam, but smaller than a drop of water, allowing the sweat to be pulled away from your body but simultaneously not allowing any other fluids in. 

 The secondary role of this layer is to provide proper insulation and thermal protection, which then aids the comfort of the suit as a whole. Not all membranes will provide the same level of thermal protection. Some membranes are made of polyurethane or polyester, and although these perform similarly in terms of managing the moisture within the suit, it is worth noting that neither of them have the thermal protection qualities of ePTFE (expanded polytetraflouroethylene). 

When selecting the proper material to use for this layer, look for an ePTFE membrane coupled with a fabric that uses Nomex or Kevlar non-woven or woven from spun fibers for enhanced comfort. All moisture barriers offered by Fire-Dex proudly boasts bi-component ePTFT membrane for superior protection. 

Our suggestion: Stedair 3000 or Stedair 4000

The Thermal Liner

The thermal liner is the innermost layer of the composite system, the fabric that you see as you slip the jacket on, the only one that comes into contact with direct skin – and therefore, considered an absolutely critical part of the turnout gear system. 

When coupled with the moisture barrier, this layer is responsible for about 70% of the thermal protection of the whole suit. The main goal it serves is to minimize the amount of heat transfer from the firefighting scene to the body of the firefighter. It does this by trapping air pockets between layers of fabric, allowing the wearer to absorb less moisture and remain drier, thus improving breathability as it wicks the moisture away. 

A unique function that the thermal liner also serves is to aid in reducing the amount of friction that is created when donning and doffing the gear. The smoother the liner, the faster a firefighter is able to don their garment and the quicker they can respond. As an added benefit, the smoother, softer, and more lightweight the liners are, the more comfortable and soft they feel on the skin. 

We understand how to select the proper thermal liner to compliment your preferred moisture barrier. For more information on the available materials for moisture barriers, visit our Material Selection Guide.

Our favorite: CoreCXP 1-layer or CoreCXP 2-layer

Our Gear Process

Turnout gear is never a one-size-fits-all situation. Every department, budget, and need is unique. This means that every spec is different and not many situations play out the same way. Our sales team is educated on all aspects of the turnout gear process from building the spec, to providing the quote through the fitting and ordering process. Then, we stay up to date on all the details for each order during the production process, keeping you informed along the way.  

Item	Expected Lead Time
Custom Turnout Gear (including Our Gold Standard)	26 - 30 weeks
FXM Standard Turnout	12 - 16 weeks
TECGEN51 Fatigues (Standard and Deluxe)	12 - 16 weeks
Helmets	12 weeks
Hoods	There is a significant supply chain delay with the materials needed to produce these hoods. At this time, Fire-Dex does not have assessment of accurate lead times. They are fulfilling the orders as quickly as the supply chain allows. Expect at least 10 weeks. Towards the later part of 2023, we hope and expect this should improve.
Boots (both styles)	Quick Ship Items – 3 to 5 Business days
Gloves (both styles)	Quick Ship Items – 3 to 5 Business days

Fittings + Terms and Conditions

Once accepted by the Fire Department, a fitting meeting will be scheduled. Any firefighter being fitted for gear will need to attend to try on the sizing gear and will be required to sign for their sizing choice.  The gear specification also will be reviewed and signed off by both Front Line Services, Inc and the Fire Department.   

Quotes are always valid for 30 days unless otherwise specified on the quotation. Shipping is never included in the quote, unless it is requested by the fire department. 

Sizing Information

Turnout Coats/Jackets	Available in even chest sizes only, sizes 32-74. Jacket sizes are designed accommodate station wear or other clothing underneath. This means that the jacket you receive will have an exterior measurement greater than the size ordered. Chest sizes and jacket lengths are customized at no additional charge.
Sleeve Lengths	Standard sleeve lengths are based on the chest size of the coat. Custom sleeve lengths can be measured in 1” increments. Sleeve length is customized at no additional charge.
Turnout Pants	Available in even waist sizes only, sizes 28-68. Pant sizes are designed to accommodate station wear or other clothing underneath. Turnout gear pants should be measured at the point on the body where pant waist will be worn. The measurement ordered will be the size of the interior of the waistband. Waist sizes are customized at no additional charge.
Inseam Lengths	Standard inseam length is 29”, regardless of waist size. Inseam changes can be made in 1” increments. Custom inseams are provided at no additional charge.
TECGEN51 Fatigue Jacket	Available in size Small (33”-36”) through size 7X (69” – 72”). Each size has 4” increment before next size. Sleeve lengths come standard in accordance with the chest size. Option to add 1” extra on the sleeve length at no charge, additional customizations to the sleeve length (longer or shorter, increments of 2” only, addtl $65 custom cut charge).
TECGEN51 Fatigue Pant	Available in size Small (27” – 30”) to 7X (62”-65”). Each of the other sizes have a 4” increment before the next size. Inseam length is custom between 26” and 36” at no additional charge.

Returns and Exchanges

Fire-Dex does not maintain inventory of finished product. All custom items purchased are non-returnable. 

Front Line Services, Inc will offer an exchange of any new and unused current Fire-Dex gloves or boots due to sizing and fit for a direct replacement of the same item which does fit more optimally. We do not offer refunds on any gear or gear accessory orders. 

All gear, whether custom or standard is considered a custom made-to-order product and is not eligible for return, exchange, or refund. 

Warranty

Fire-Dex warrants it’s protective clothing products to be free from defects in workmanship for the serviceable life of the products when used by appropriately trained personnel following proper fire fighting procedures and when the product’s warning, use and care instructions are followed. Please contact us with any warranty concerns.