Refurbish or Replace? That Is the Question? Fire Apparatus Magazine

Scott Poulton
Jul 11
5 min read

July 11, 2025

Fire departments across the country are grappling with a pivotal decision: Should they refurbish aging vehicles or replace them altogether?

With extended lead times—often ranging from 24 to 48 months—and limited funding, many departments are opting for refurbishment as a more cost-effective solution to meet their operational needs. But, is it the right choice for your department? This article explores the challenges departments face in making this decision, examining lead times, costs, and how refurbishment can extend the life of a fire apparatus.

THE EVOLVING STANDARDS FOR REFURBISHING FIRE APPARATUS

In 2024, a significant change in fire apparatus standards occurred with the “Emergency Response and Responder Safety Document Consolidation Plan.” National Fire Protection Association (NFPA) 1912, Standard for Fire Apparatus Refurbishing, is no longer a standalone document. Instead, it has been integrated into the newly consolidated NFPA 1910, Standard for the Inspection, Maintenance, Refurbishment, Testing, and Retirement of In-Service Emergency Vehicles and Marine Firefighting Vessels.

This new standard incorporates NFPA 1911, Standard for the Inspection, Maintenance, Testing, and Retirement of In-Service Emergency Vehicles; 1925, Standard on Marine Fire-Fighting Vessels; and 1071, Standard for Emergency Vehicle Technician Professional Qualifications, to focus on the inspection, maintenance, and retirement of fire vehicles.

Although this article focuses primarily on fire apparatus refurbishment, understanding these updated regulations is essential when considering how to handle an aging apparatus.

REFURBISHING A 2006 SEAGRAVE PUMPER

Imagine this scenario: The chief of the XYZ Fire Department has just been informed that funding for a new replacement engine has been cut from the town’s budget. Faced with this unexpected challenge, the chief must now explore a more budget-friendly solution—refurbishment.

The truck committee initially considered several factors when specifying the needs for a new engine, including vehicle safety, operational efficiency, and technology upgrades. These same factors now apply to refurbishment decisions, with particular attention to the condition of the apparatus’s “good bones”—the frame, drivetrain, pump, and body. After conducting an extensive inspection of the 2006 Seagrave pumper, it was determined that the rig had a solid drivetrain and a good frame, though there was minor corrosion along the body and frame rails.

1 An extensive inspection of this 2006 Seagrave pumper revealed that the rig had a solid drivetrain and a good frame, though there was minor corrosion along the body and frame rails, making it a candidate for refurbishment. (Photo by Scott Poulton.)

The department outlined a scope of repairs that would extend the life of the vehicle by another five to 10 years. After receiving proposals from three contractors, the department awarded a refurbishment contract. Several weeks into the breakdown and inspections, it was confirmed that the scope of repairs was accurate, and no unexpected costs had emerged, even avoiding the need to use the department’s 30% contingency fund.

TWO LEVELS OF REFURBISHMENT

NFPA 1910 defines two main levels of refurbishment: Level I and Level II.

Chapter 3.3.194.1* states that Level I refurbishing is “the assembly of a new fire apparatus by the use of a new chassis frame, driving and crew compartment, front axle, steering and suspension components, and the use of either new components or components from an existing apparatus for the remainder of the apparatus.” If components like the drivetrain remain unchanged, they must be thoroughly inspected for damage, wear, and stress cracks. Chapter 30.1 says that fire apparatus refurbished to Level I standards shall meet the requirements of the applicable chapter of NFPA 1900, Standard for Aircraft Rescue and Firefighting Vehicles, Automotive Fire Apparatus, Wildland Fire Apparatus, and Automotive Ambulances, unless specified otherwise in Chapter 30.

Chapter 3.3.194.2* states that Level II refurbishing is “the upgrade of major components or systems of a fire apparatus with components or systems that comply with the applicable standards in effect at the time the original apparatus was manufactured.” Chapter 31.1* states that all new or upgraded components used in Level II refurbishing shall meet the requirements of the applicable chapters of NFPA 1900, unless otherwise specified in Chapter 31.

Both levels have distinct advantages and challenges, and the choice between the two depends on the extent of the necessary repairs and the department’s goals.

THE PROS OF REFURBISHING

When considering refurbishment over replacement, the most influential factor for most departments is budget. Here are several compelling advantages of refurbishment:

Refurbishing an apparatus is typically much more affordable than purchasing a new one.
Departments with limited funding can extend the lifespan of their apparatus without breaking the bank.
Refurbishment allows departments to delay the cost of replacement, keeping finances more flexible for other needs.
Refurbishment upgrades outdated components, improving the vehicle’s overall performance and reliability.
Enhanced technology integration, from improved pumps to modern safety features, reduces the risk of breakdowns and operational delays.

Refurbishment upgrades outdated components, improving the vehicle’s overall performance and reliability.

Departments can tailor refurbishments to meet their specific operational needs, upgrading features that may have been unavailable when the apparatus was first built.
Valuable equipment can be retained, particularly in cases where replacing it would be too costly or difficult.
Refurbishment projects typically take three to six months, allowing departments to get their vehicles back on the road relatively quickly, compared with the extended waiting periods for new builds.

The Cons Of Refurbishing

While there are many advantages, refurbishment also has its drawbacks, including the following:

Even after refurbishment, the vehicle’s lifespan is finite, and it may not be a long-term solution for growing or evolving departments.
There’s always the potential for unforeseen structural or mechanical problems to arise during refurbishment, leading to unexpected costs.
Even with upgrades, refurbished apparatus may not be able to incorporate the latest technology and features available in new vehicles.
Integrating new technology with older components can be difficult, potentially leading to issues with compatibility and compliance with newer safety standards.
The quality of refurbishment work can vary depending on the contractor, and departments may lack experience in evaluating refurbishment options and contractors.

Ultimately, each department must assess its unique needs and budget before making a decision on refurbishing a rig. Refurbishment may be the ideal solution for smaller departments with limited funding, minimal usage, and low call volumes, provided the apparatus has a solid maintenance record.

Departments must consider the vehicle’s condition and reliability and the department’s long-term needs when determining whether refurbishment or replacement is the best option. Consider the department’s projected growth and evolving operational needs over the next decade and ensure any choice made aligns with the department’s goals for performance and public service.

Whether you choose to refurbish or replace, it’s crucial to make an informed decision based on the unique needs of your department. Both options have their merits, but the decision should always center on safety, reliability, and the long-term operational success of your fire department.

RAY SAJDAK is a lieutenant (ret.) with the Bristol (CT) Fire Department, where he served on its apparatus replacement committee. His career in the fire service also includes 20 years as the chairman of the apparatus committee for the Portland (CT) Volunteer Fire Department. He is a managing partner with Fire Apparatus Consultants, LLC.

SCOTT POULTON is a firefighter and apparatus operator for the Bristol (CT) Fire Department, where he serves on the department’s apparatus replacement committee. His career in the fire service also includes 37 years as a volunteer firefighter with the Terryville (CT) Volunteer Fire Department, where he cochairs the department’s apparatus replacement committee. He is a managing partner with Fire Apparatus Consultants, LLC.