APPARATUS: THE SHOPS
For fire departments across the country, one of the most difficult and often debated decisions is whether to continue repairing aging fire apparatus or to invest in replacements.
With budgets tight, demands high, and safety always the top priority, this choice can’t be made lightly. Knowing when to say “enough” to ongoing repairs and “yes” to new equipment is a key component of effective fleet management.
THE TRUE COST OF REPAIR
It’s common for departments to try and squeeze a few extra years out of an aging engine or ladder truck. On the surface, it might seem more cost-effective to keep repairing a vehicle that’s already paid off. However, the true cost of repair goes beyond the invoice from the maintenance shop.
Downtime is one of the most underestimated expenses. When a frontline unit is out of service—whether for days, weeks, or in extreme cases months—it forces the department to rely on reserve units, mutual aid, or delayed response. This can negatively impact service delivery and increase risk to both firefighters and the public.
Frequent breakdowns also contribute to operational fatigue. Crews lose confidence in unreliable equipment, which can affect morale and increase the stress of already difficult situations.
LIFE CYCLE CONSIDERATIONS
The National Fire Protection Association (NFPA) recommends that frontline apparatus be replaced after 15 years and reserve apparatus after 25 years. While some departments successfully stretch these numbers depending on call volume, it often comes with a trade-off in safety and performance.
Departments should be tracking the life cycle of each vehicle in their fleets, not just by years but by usage metrics—miles driven, engine hours, pump hours, and total repair costs. A good rule of thumb is this: If a vehicle’s annual repair costs exceed 10% of the cost of a new vehicle, it’s time to consider replacement.
SAFETY AND COMPLIANCE
Modern apparatus are built to higher safety and emissions standards. Older vehicles may lack rollover protection, air bags, electronic stability control, and clean diesel technology. This makes them more dangerous for crews and less environmentally responsible.
In addition, departments that want to remain compliant with NFPA standards or ISO rating criteria may find that maintaining outdated equipment works against them during audits or recertifications.
WHAT CAN BE FIXED AND WHAT SHOULDN’T
Not every repair signals the end of a truck’s useful life. Components like pumps, electrical systems, warning lights, and body panels can usually be serviced or replaced effectively. However, when repairs begin to affect core systems—frame integrity, suspension, drivetrain components, or the aerial structure—it may be a warning sign that you’re investing in a losing battle.
1 Replacing a fire truck is a major investment but, when made at the right time, it protects lives, improves service, and saves money in the long run. (Photo courtesy of author.)
Rust, especially in critical frame or suspension areas, can be a death sentence for older vehicles. That is one reason you should insist on some type of frame protection. Personally, I believe galvanized frame rails are superior. Similarly, persistent electrical issues in older wiring harnesses often become timeconsuming and costly to troubleshoot.
Another factor is parts availability. As manufacturers change pl