U.S. Fire Administration/Technical Report Series

Special Report:

Prevention of Self-Contained 

Breathing Apparatus Failures

USFA-TR-088 / November 2001

U.S. Fire Administration Fire Investigations Program

T

he U.S. Fire Administration develops reports on selected major fires throughout the country. 

The fires usually involve multiple deaths or a large loss of property. But the primary criterion 

for deciding to do a report is whether it will result in significant “lessons learned.” In some 

cases these lessons bring to light new knowledge about fire--the effect of building construction or 

contents, human behavior in fire, etc. In other cases, the lessons are not new but are serious enough 

to highlight once again, with yet another fire tragedy report. In some cases, special reports are developed to discuss events, drills, or new technologies which are of interest to the fire service.

The reports are sent to fire magazines and are distributed at National and Regional fire meetings. The 

International Association of Fire Chiefs assists the USFA in disseminating the findings throughout the 

fire service. On a continuing basis the reports are available on request from the USFA; announcements of their availability are published widely in fire journals and newsletters.

This body of work provides detailed information on the nature of the fire problem for policymakers 

who must decide on allocations of resources between fire and other pressing problems, and within 

the fire service to improve codes and code enforcement, training, public fire education, building 

technology, and other related areas.

The Fire Administration, which has no regulatory authority, sends an experienced fire investigator 

into a community after a major incident only after having conferred with the local fire authorities 

to insure that the assistance and presence of the USFA would be supportive and would in no way 

interfere with any review of the incident they are themselves conducting. The intent is not to arrive 

during the event or even immediately after, but rather after the dust settles, so that a complete and 

objective review of all the important aspects of the incident can be made. Local authorities review 

the USFA’s report while it is in draft. The USFA investigator or team is available to local authorities 

should they wish to request technical assistance for their own investigation.

For additional copies of this report write to the U.S. Fire Administration, 16825 South Seton Avenue, 

Emmitsburg, Maryland 21727. The report is available on the Administration’s Web site at http://

www.usfa.dhs.gov/

Special Report: 

Prevention of Self-Contained

Breathing Apparatus Failures

Reported by: Adam K. Thiel

This is Report 088 of the Major Fires Investigation Project conducted 

by Varley-Campbell and Associates, Inc./TriData Corporation under 

contract EMW-94-4423 to the United States Fire Administration, Federal Emergency Management Agency.

Department of Homeland Security

United States Fire Administration

National Fire Data Center

U.S. Fire Administration

Mission Statement

As an entity of the Department of Homeland 

Security, the mission of the USFA is to reduce life and economic losses due to fire 

and related emergencies, through leadership, advocacy, coordination, and support. 

We serve the Nation independently, in coordination with other Federal agencies, 

and in partnership with fire protection and 

emergency service communities. With a 

commitment to excellence, we provide public education, training, technology, and data 

initiatives.

ACKNOWLEDGMENTS

The U.S. Fire Administration greatly appreciates the cooperation received from the following people 

and organizations during the preparation of this report:

Bruce J. Cavallari Fire Engineering Magazine

Lou Ann Harris Scott Aviation

Phil Sallaway Survivair

Nancy Schwartz National Fire Protection Association

Charles Smeby National Fire Protection Association

Richard Stein Survivair

Bruce Teele National Fire Protection Association

John Tully Scott Aviation

Ernie Younkins International Safety Instruments

TABLE OF CONTENTS

EXECUTIVE SUMMARY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Summary of Key Issues. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

INTRODUCTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Examples of SCBA Failure Incidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Catastrophic Failures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

CURRENT TECHNOLOGY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

REGULATIONS, STANDARDS, AND TESTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Federal Regulations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SCBA Testing and Certification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Breathing Air Cylinder Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

PREVENTIVE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

TRAINING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

PROBLEM TRENDS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

OTHER ISSUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

NEW CAPABILITIES FOR SCBA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Factors to Consider When Adding Capabilities. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Simplicity and Reliability. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Potential Areas of Improvement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

RECOMMENDATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

APPENDIX A: “Acidic Fluid Leads to Air Cylinder Failure”, Fire Engineering, 

November, 1996. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

APPENDIX B: Cavallari, Bruce J., “Hydrostatic Testing of Compressed Gas Cylinders”, 

Fire Engineering, October 1996. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

1

Special Report: 

Prevention of Self-Contained

Breathing Apparatus Failures

EXECUTIVE SUMMARY

Self-Contained Breathing Apparatus (SCBA) are one of the most important items of personal protective equipment used by firefighters and rescue personnel. SCBA allow firefighters to enter hazardous 

environments to perform essential interior operations including offensive fire attack, victim search, 

rescue and removal, ventilation, and overhaul. They are also used at non-fire incidents involving hazardous materials and confined spaces where there is a threat of toxic fumes or an oxygen-deficient 

atmosphere.

There have been several well-documented incidents during the past 10 years where SCBA failure may 

have been a contributing factor in the deaths or injuries of firefighters1. These incidents, coupled 

with a recognition of the importance of self-contained breathing apparatus to firefighter safety, 

prompted the United States Fire Administration to undertake this study to address any operations 

trends associated with SCBA failure incidents, and to identify potential problems requiring correction or further study.

Catastrophic failures of SCBA are characterized by the sudden and unexpected failure of any component that would subsequently expose the user to a hazardous environment, or introduce a major 

complication hindering the ability to escape from the environment. Failures of this nature are 

relatively uncommon occurrences, especially considering the very large number of route uses of 

SCBA by firefighters and rescue personnel each day. Although catastrophic failures of SCBA are rare, 

the evidence suggests that “low-order” failures of SCBA are more common. Examples of low-order 

failures include freeflowing or improperly connected regulators, improperly tightened or connected 

hoses, inadequate face-to-facepiece seal resulting in air leakage, or blown O-rings during cylinder 

changes. These problems are often attributable to operator error or inadequate preventive maintenance. Although these failures may not directly result in firefighter death or injury, they are a concern because they may reduce efficiency or hamper the coordination required for safe and successful 

operations. For example, a low-order failure may result in delayed ventilation by a truck crew, thus 

slowing the advance of the engine company which is attacking the fire.

Standards and testing procedures have been changed over time to address problems which led to 

failures and to ensure that SCBA are more durable and reliable. Nonetheless, firefighters must realize 

that catastrophic failures of SCBA are still possible. There are limits to the physical and environmental 

1

 Several of these incidents have been investigated and published as part of the United States Fire Administration’s Major 

Fires Technical Report Series. Of particular note are the reports entitled: Three Firefighter Fatalities in Training Exercise Milford, MI; 

Three Firefighters Die in Pittsburgh House Fire; and Sodium Explosion Critically Burns Firefighters Newton, MA.
2 U.S. Fire Administration/Technical Report Series

punishment that SCBA can endure. Regular inspection, upgrade, and preventive maintenance will 

lessen the potential for catastrophic failures of SCBA. The report identifies a variety of issues and 

operational aspects of SCBA failures, particularly those related to maintenance and user training. 

Suggestions for addressing these issues are included throughout the report.

SUMMARY OF KEY ISSUES

Issue Comments

Failure to Use One of the most common failures of the SCBA system (i.e., SCBA+Firefighter=System) is the 

failure to use it. Even with the current emphasis on firefighter health and safety, and the expanding knowledge of the hazards posed by the products of combustion, some firefighters still fail to 

use SCBA during interior operations in smoke-filled environments, especially during salvage and 

overhaul.

Hardware Reliability SCBA that are tested and certified according to the requirements of the NFPA 1981 (1992 and 

1197 Editions) Standard on Open-Circuit Self-Contained Breathing Apparatus for Fire Fighters are 

extremely durable and rugged. Properly used and maintained by well-trained personnel, according 

to the manufacturer’s recommendations, they should provide years of trouble-free service with little 

potential for hardware failure.

Catastrophic Failures Catastrophic failures of SCBA resulting in death or injury to firefighters are very rare considering the 

number of routine uses by firefighters each day. Even if such a failure should occur, the fail-safe 

design of the SCBA may allow it to function long enough for a firefighter to escape the hazard area.

“Low-order” Failure Some failures of the SCBA system do not directly result in firefighter death or injury, but may reduce 

efficiency and hamper fireground operations. This type of failure is relatively common and most 

often attributable to operator error, physical abuse/neglect, or inadequate preventive maintenance 

procedures. Examples include: difficult or slow donning of SCBA due to a lack of familiarity or 

infrequent practice; freeflowing regulators; blown O-rings during cylinder changes; and improperly 

connected hoses or regulators.

Operator Training Many low-order failures can be prevented through proper operator training. Before entering hostile 

environments, firefighters must be appropriately trained in all aspects of SCBA inspection and 

operation. Continued drilling and practice under realistic conditions must be emphasized until 

complete familiarity is achieved and maintained. Complete knowledge in the use and limitations of 

SCBA must become second nature to all firefighters to prevent failures.

Preventive Maintenance Regularly maintained and tested by competent, properly trained, and certified technicians using the 

appropriate tools, replacement parts, and testing equipment, following procedures recommended 

by the respective manufacturers. Fire departments should establish preventive maintenance 

programs for SCBA to ensure firefighter safety and compliance with applicable regulations. The 

1989 edition of the NFPA 1404 Standard for a Fire Department Self-Contained Breathing Apparatus 

Program can be used to provide guidance for fire department preventive maintenance and training 

programs.

Upgrades The 1992 and 1997 editions of NFPA 1981 contain realistic, updated procedures for testing and 

certification of SCBA. Several changes made in these editions were prompted by failure incidents 

mentioned in this report. Fire departments should upgrade their existing SCBA to meet the current 

edition of NFPA 1981, to minimize the risk of repeating past tragedies. SCBA that cannot be 

upgraded can be replaced with newer models.

Pushing the Edge of the 

Envelope

Despite the fact that modern, NFPA-compliant SCBA are extremely durable, the materials used in 

their construction have physical limitations. Firefighters and maintenance personnel must understand that SCBA are not indestructible, and that the potential exists to expose SCBA to factors in 

the environment that may contribute to or produce failure.
USFA-TR-088/November 2001 3

INTRODUCTION

There have been a number of incidents involving SCBA where human errors, component failures, or 

a combination of factors may have contributed to deaths, injuries, or potential injuries to firefighters 

and rescue personnel. Many of these incidents have been thoroughly investigated previously, and 

several are summarized below.

Examples of SCBA failure Incidents

Milford, MI: Three firefighters were killed when a flashover occurred during a live-burn training 

evolution in an acquired structure. Subsequent investigation of the firefighters’ SCBA provided evidence that rapid component failure (including straps and low-pressure breathing hoses) may have 

been a contributing factor in preventing their escape from the sudden change in fire conditions. 

This incident occurred in 1987, before the advent of more stringent performance and direct flame 

impingement testing procedures for SCBA certification.

Newton, MA: In 1993, 11 firefighters suffered burn injuries in an explosion that occurred while they 

were trying to extinguish a sodium fire in a metal processing plant. The firefighters were equipped 

with firefighting SCBA, some of which had older straps made of non-fire resistant materials, and 

others that had newer, fire resistant harness assemblies. The straps on some of the older units melted 

from heat exposure and released, while the units equipped with the newer straps continued to function properly. Damage to low-pressure breathing hoses and facepieces was also noted at this fire. 

Although no current SCBA can provide adequate protection from an explosion of a molten metal like 

sodium, the newer SCBA performed better in this extreme situation than older units which had not 

been upgraded to meet the (then current) 1992 edition of the NFPA 1981 standard.

Pittsburgh, PA: Three firefighters died of asphyxiation at a house fire in 1995. All three were wearing 

SCBA when they entered the house. During the investigation after the fire, the units were tested 

by the National Institute for Occupational Safety and Health (NIOSH). NIOSH found that while 

the units were functional and capable of delivering air to the users, they each failed to meet one or 

more of the performance tests required by NIOSH for certification2. Problems were noted with the 

exhalation values on the units, and also with the calibration of the low-pressure alarms. Only one 

of four tested SCBA regulators met NIOSH flow rate requirements. (The fourth was from an injured 

firefighter.) After undergoing the recommended periodic maintenance, inspection, and testing procedures, all four units met or exceeded the functional requirements. These findings help underscore 

the need for regular inspection and maintenance programs for all SCBA units. Despite these problems, investigators could not determine whether SCBA failure was a primary or contributing factor 

in the deaths of the firefighters. Since this incident, the Pittsburgh Bureau of Fire has purchased new 

SCBA and revised its SCBA maintenance and testing program.

Humboldt, CA: In March, 1996, an empty SCBA cylinder was accidentally exposed to a corrosive 

metal cleaning agent in the bed of a pickup truck while it was being transported back to the fires 

station from a training exercise. The composite cylinder was refilled and replaced on a fire apparatus. 

The cylinder failed catastrophically six days later, causing major damage to the apparatus on which it 

was stored. Fortunately, the firefighters staffing the station were in the dayroom and were uninjured 

by the blast. This incident underscores the need for training not only in the proper use of SCBA, but 

2USFA Technical Report 078, Three Firefighters Die in Pittsburgh House Fire, Pittsburgh, Pennsylvania.
4 U.S. Fire Administration/Technical Report Series

in proper care and regular inspection procedures. (An article addressing this incident is included in 

this report as Appendix A, reprinted with permission from the editors of Fire Engineering magazine.)

Detroit, MI: An empty SCBA was run-over and caught between the tandem wheels on a ladder truck 

as it left the scene of a fire, seriously damaging the backplate. After returning to quarters, firefighters 

refilled the cylinder and placed it on another SCBA mounted in a jumpseat bracket, ready for service. 

The cylinder ruptured catastrophically several minutes later, causing major damage to the cab of the fire 

apparatus. If a firefighter had been sitting in the jumpseat, the outcome would have been tragic.

At least two additional incidents, one of which resulted in a firefighter fatality, have occurred recently 

during air-refilling operations involving breathing air cylinders.

Catastrophic failures

The catastrophic failure of a SCBA is characterized by the sudden and unexpected failure of any component that would subsequently expose the user to a hazardous environment, or introduce a major 

complication hindering the ability to escape from the environment. Some examples of catastrophic 

failures are cylinder rupture, facepiece lens failure, harness failure, and complete regulator failure. 

Due to the nature of the hazards faced by firefighters and rescue personnel while using SCBA, there is 

a high probability that the occurrence of such a failure during fire or rescue operations would result 

in serious injury or death.

Catastrophic failures of SCBA are extremely rare considering the number of units currently in service, 

and the number of routine uses of these units daily. Most of the recent catastrophic failure incidents 

were caused by the rupture of breathing air cylinders exposed to an unusual stress like being run 

over or contacting a corrosive cleaning agent.

It is likely that the continued improvement of testing and certification requirements by the fire 

service and SCBA manufacturers has resulted in the low number of catastrophic failures of SCBA. 

Additionally, the incorporation of new materials in the design and construction of firefighting SCBA 

has improved durability and reliability, further reducing the incidence of catastrophic failures in 

units that are properly tested and maintained according to manufacturers recommendations.

While catastrophic failures are relatively rare, other types of failures are more common and will be 

discussed in later sections.

CURRENT TECHNOLOGY

The fire service has benefited greatly from manufacturers’ increased use of composite materials and 

aramid fibers like Kevlar®. This has increased safety and firefighter protection while enabling weight 

reductions in every element of a firefighter’s personal protective ensemble. Nowhere are these benefits more evident than in SCBA. New technologies, fibers, and designs have made SCBA stronger, 

lighter, and more durable than ever before.

Composite construction techniques and new materials have dramatically decreased the weight of 

SCBA. Steel breathing air cylinders have been replaced with cylinders constructed from aluminum 

and reinforced with glass-fiber filaments. Cylinders are reinforced with Kevlar® and other composite materials to increase strength while further reducing the weight of SCBA. The recent introduction 

of carbon-fiber breathing air cylinders for SCBA will allow further weight reductions. This improves 

safety by enabling firefighters to perform more work before requiring rest and rehabilitation. The 
USFA-TR-088/November 2001 5

ability to withstand higher pressures has made available low-profile cylinders that increase firefighters ability to maneuver and help reduce the possibility of entanglement or entrapment. Higher pressures also translate into SCBA with cylinders having up to one-hour durations. SCBA that incorporate 

these improvements have been available for several years.

The continued emphasis on firefighter health and safety has led to improvements in facepiece design, 

including a choice of different sizes to properly fit differently shaped faces), features to improve voice 

communications, and even built-in units that display information directly on the facepiece such as 

the amount of air remaining and the positive-pressure status. Facepiece fit-testing has become a 

critical component of fire department SCBA programs, and should be conducted annually, according 

to the requirements of the NFPA 1404 (1989 Edition) Standard for a Fire Department Self-Contained Breathing 

Apparatus Program.

As a result of several incidents in which harness assemblies failed due to intense heat and/or flashover conditions (e.g., those previously mentioned in Milford, MI and Newton, MA), SCBA straps 

are no longer constructed from materials such as nylon or polyester which have low heat tolerance. 

Newer straps are fire resistant and most incorporate heat-tolerant aramid fibers in their construction. 

Some strap designs are further reinforced with steel cable to ensure that the SCBA stays in place during extreme conditions. Fire departments should upgrade their straps to reduce the possibility of 

harness assembly failure during firefighting operations.

Positive-pressure regulator assemblies have become more reliable and easier to maintain with 

improved designs and the increased use of lightweight alloys and spaceage polymers. These newer 

units are more durable, resistant to failure in extreme fire conditions, and less subject to malfunction 

from adverse environmental factors such as extreme cold or heat. Many of these regulators have 

fewer moving parts and are easier and less costly to maintain than older units. Demand-type regulators are still in use, despite the fact that they do not provide adequate respiratory protection 

to firefighters and rescue personnel operating in hazardous environments. Fire departments 

that are still using demand-type SCBA should replace them as soon as possible with positivepressure type units. The use of demand-type regulators for structural firefighting is prohibited 

by 29 CFR 1910.156(f)(2) (the OSHA Fire Brigade Standard) and is contrary to the NFPA 1404 

(Standard for a Fire Department Self-Contained Breathing Apparatus Program) and NFPA 1500 (Standard on Fire 

Department Occupational Safety and Health Program) standards.

SCBA manufacturers offer a range of options including integrated PASS devices and “Buddy-Breathing” 

systems. The desirability and use of these options is an individual decision for each fire department 

and a subject of some debate within the fire service. Nonetheless, the widespread availability of 

these options is a positive sign that manufacturers are taking a renewed interest in firefighter safety 

by responding to customer requests with innovative improvements to SCBA.

When properly maintained, tested, and used by well-trained firefighters, modern SCBA that comply 

with the NFPA 1981 (1997 Edition) Standard on Open-Circuit Self-Contained Breathing Apparatus for Fire Fighters

should provide years of trouble-free service. Although SCBA have greatly improved during the past 

10 years, future advancements are on the horizon that should help to further enhance the safety of 

firefighters and rescue personnel.

Unfortunately, not all fire departments have been able to keep pace with the revised standards, and 

as a result are still using out-of-date, less functional, or improperly maintained SCBA. These SCBA 

should be upgraded or replaced to avoid the possibility of repeating past tragedies.
6 U.S. Fire Administration/Technical Report Series

REGULATIONS, STANDARDS, AND TESTING

There are a variety of regulations and standards pertaining to the respiratory protection of workers 

in hazardous environments, and specifically to fire departments.

F

There are several pertinent Federal regulations affecting SCBA. The enforcement of these regulations 

has been entrusted to several different agencies, including the National Institute for Occupational 

Safety and Health (NIOSH), the Occupational Safety and Health Administration (OSHA), and the 

Mine Safety and Health Administration (MSHA). These regulations are general in nature and apply 

to all types of respiratory protective equipment, including SCBA.

National Institute for Occupational Safety and Health (42 CFR Part 84)--On July 10, 1995, NIOSH 

made effective a “Final Rule” on respiratory protective devices in which NIOSH assumed sole responsibility for the testing and certification of most types of respiratory protection equipment for industry, including fire department SCBA. The performance-based testing and certification procedures 

incorporated in 42 CFR Part 84 replaced less stringent methods used previously.

Mine Safety and Health Administration--Until 42 CFR Part 84 became effective in July, 1995, MSHA 

had joint responsibility with NIOSH for the testing and certification of all types of respiratory protective devices, including fire department SCBA. With the publication of the “Final Rule”, MSHA is 

now responsible only for respiratory protection equipment intended for use in mining. NIOSH and 

MSHA will continue to jointly certify respiratory protective devices intended to be used in mining 

applications.

Occupational Safety and Health Administration--On January 8, 1998, OSHA promulgated revised 

regulations on respiratory protection equipment and programs. These regulations, which are contained in 29 CFR 1910.134, apply to workers in private industry, Federal government employees, and 

employees of State and local governments in the 25 States which operate OSHA-approved occupational safety and health programs. The applicability of these regulations to volunteer emergency 

responders has not yet been fully addressed in all States. 

These revised regulations contain specific provisions for fire departments with respect to respirator 

usage during interior structural firefighting, including the requirement that, “all personnel engaged 

in interior structural firefighting use SCBA respirators.”3 Furthermore, 29 CFR 1910.134 states “that 

workers engaged in structural firefighting work in a buddy system: at least two workers must 

enter the building together, so that they can monitor each other’s whereabouts as well as the work 

environment.”4

 OSHA also requires that, during interior structural firefighting operations, “there be 

at least two standby personnel outside the respirator use area, i.e., outside the fire area.”5

29 CFR 1910.134 addresses, “elements of respirator maintenance and care that OSHA believes are 

essential to proper functioning of respirators for the continuing protection of employees.”6

 Included 

3 Federal Register: January 8, 1998 (Rules and Regulations), pp. 1245

4 ibid.

5 ibid

6 ibid., pp. 1248
USFA-TR-088/November 2001 7

among these are cleaning and disinfecting, storage, inspection, and repair. Appendix B-2 of 29 CFR 

1910.134 provides specific procedures to ensure that employers, “provide each respirator wearer with 

a respirator that is clean, sanitary, and in good working order.”7

 (It should be noted that, according 

to this OSHA regulation, cleaning and disinfection procedures provided by the manufacturer may 

also be used, provided they are as effective as those detailed in Appendix B-2.)

SCBA Standards

Several industry standards have been created in addition to the Federal regulations summarized 

above. The American National Standards Institute (ANSI) and the National Fire Protection Association 

(NFPA) each have developed standards. Respiratory protection issues in general are addressed by 

ANSI and standards for fire department use have been developed by NFPA. The ANSI standards are 

voluntary, consensus-based standards that are widely used by business and industry, as are the NFPA 

standards which are specific to fire departments.

The NFPA standards are voluntary, consensus-based standards relating directly to fire department 

Self-Contained Breathing Apparatus and SCBA programs. Fire departments that adopt the NFPA 

standards are more likely to meet State or Federal regulatory requirements. Several key standards are 

summarized below.

ANSI Z88.2-1992: Respiratory Protection--This ANSI standard is primarily intended for industrial 

users of respiratory protection equipment including air-purifying particulate respirators (APRs), 

powered air-purifying particulate respirators (PAPRs), other types of filter masks, cartridge respirators, and SCBA.

NFPA 1981 (1997 Edition): Standard on Open-Circuit Self-Contained Breathing Apparatus for Fire Fighters-- 

This standard, which is approved by ANSI, contains additional requirements beyond the certification 

requirements mandated by NIOSH. This standard is specific to open-circuit type SCBA for firefighting purposes like those most commonly employed by fire departments. The standard details the 

technical requirements and testing procedures that must be followed for certification under the 

NFPA standard.

The testing requirements in the 1997 and 1992 editions of NFPA 1981 were made more rigorous 

based on evidence that SCBA certified under previous editions were subject to failure under extreme 

conditions including flashover. As a result, the new testing procedures are more reality-based, and 

should help further improve SCBA safety, reliability, and durability.

There are two features of the recently released 1997 edition of NFPA 1981 that deserve special 

mention. First is the requirement that SCBA manufacturers receive ISO 9002 certification for their 

manufacturing processes (a requirement that many manufacturers already meet). Secondly, SCBA 

receiving certification under the 1997 edition of NFPA 1981 must be equipped with at least two 

different types of low-air alarms. The two alarms must function independently (i.e., the failure of 

one alarm will not affect operation of the other) and must address different senses (i.e., an audible 

alarm could be accompanied by a visual or tactile alarm).

NFPA 1404 (1989 Edition): Standard for a Fire Department Self-Contained Breathing Apparatus Program--

This standard, created by the NFPA Fire Service Training Committee, details the requirements for a 

comprehensive fire department SCBA program including training and preventive maintenance pro7 ibid
8 U.S. Fire Administration/Technical Report Series

cedures. This standard is also approved by ANSI, and meets or exceeds the requirements of NIOSH 

and OSHA regulations.

NFPA 1500 (1992 Edition): Standard on Fire Department Occupational Safety and Health Program--This standard, 

prepared by the NFPA Technical Committee on Fire Service Occupational Safety and Health, addresses 

a variety of issues related to protective clothing and equipment. Chapter 5-3 of NFPA 1500 relates 

specifically to SCBA and contains requirements for fire department SCBA programs.

SCBA Testing and Certification

To ensure compliance with applicable Federal regulations, and to receive certification under the 

1997 edition of the NFPA 1981 standard, self-contained breathing apparatus are subjected to a battery of tests. The testing criteria included in the current edition of NFPA 1981 are designed to be 

more realistic than past tests. As a result, SCBA receiving third-party certification under the 1997 and 

1992 editions perform at a higher level than ever before required.

Several of the incidents mentioned in this report helped form the impetus for these more rigorous 

testing and certification requirements. The incidents in Milford, MI and Newton, MA, along with 

several other incidents that did not result in firefighter death or serious injury, proved that SCBA 

tested under previous editions did not perform adequately under extreme conditions like those 

found in a flashover.

The 1997 and 1992 editions of NFPA 1981 greatly improve upon previous SCBA testing methods. 

Prior to these editions of the standard, each component was tested individually, and there was little 

provision for simulating realistic fire conditions during the tests. As a result of several incidents 

involving the failure of specific components (e.g., straps, facepieces) when subjected to high radiant 

heat or flashover conditions, the standard now demands that all SCBA undergo a direct flame contact 

test. SCBA certified under the NFPA standard must continue to function while exposed to direct 

flame contact at a temperature of at least 1,742 degrees Fahrenheit for 10 seconds.

Other tests that were changed include those measuring the ease of voice communication through 

the facepiece, and the lens abrasion resistance test. These tests were modified to be more objective, 

realistic, and reproducible.

One of the most important components of the 1997 and 1992 editions of NFPA 1981 is the requirement that SCBA obtain third-party certification from a recognized, independent party (e.g., the 

Safety Equipment Institute or Underwriter’s Laboratories). Previously, manufacturers self-certified 

their product. This requirement ensures that all SCBA receiving certification undergo identical tests. 

This is accomplished by having the unit tested at an independent laboratory, or by having a representative of the certifying party at the manufacturer’s testing facility for each test.

The testing and certification requirements in the 1997 and 1992 editions of NFPA 1981 exceed the 

regulatory requirements imposed by NIOSH under 42 CFR Part 84.

Breathing Air Cylinder Testing

The testing of compressed gas cylinders, including those containing breathing air for SCBA, is regulated by the United States Department of Transportation (DOT) under CFR 49, subpart 173.34 (e).

Breathing air cylinders must be hydrostatically tested on a regular basis. Individual maintenance 

and test records for each breathing air cylinder should be kept to assist departments with meeting 
USFA-TR-088/November 2001 9

the required test intervals. Test intervals for SCBA cylinders are dependent on construction type. 

Composite SCBA cylinders must be tested at a minimum of every 3 years. Cylinders constructed 

from aluminum or steel must be tested every 5 years. All composite SCBA cylinders have a maximum 

service life of 15 years, provided they are hydrostatically re-tested on a regular basis in accordance 

with DOT regulations. At the end of the 15 year service life, composite cylinders must be removed 

from service and destroyed (to ensure that they cannot be used again). While aluminum or steel cylinders have an indefinite service life they must be carefully monitored for signs of damage, especially 

around vulnerable areas like the cylinder neck.

The above are minimum requirements. Cylinders have been subjected to atypical stresses (e.g., 

dropped from a height, run-over by fire apparatus, etc.), or exposed to chemicals such as corrosives must be immediately removed from service, purged of air, and hydrostatically tested. Failure 

to ensure that cylinders are properly hydrostatically tested as prescribed in DOT regulations may 

result in catastrophic failures that could kill or injure firefighters, as well as cause major damage to 

apparatus and facilities. The incidents in Detroit, MI and Humboldt, CA illustrate the importance of 

training personnel to recognize cylinders requiring hydrostatic testing.

Personnel tasked with filling SCBA cylinders must be aware of hydrostatic testing requirements. All 

cylinders with a current hydrostatic test must have the date of the last test either stamped on the 

cylinder neck, or prominently displayed on the body of the cylinder. Before filling a breathing air 

cylinder, it should be visually inspected for damage and checked for a current hydrostatic test date. 

Cylinders that have visible thermal or mechanical damage, or that lack a current hydrostatic test 

should never be filled. These cylinders should be purged and immediately removed from service. 

The cylinders may then be sent for hydrostatic testing by qualified personnel.

Although it seems a routine activity, extreme caution must always be exercised during air refill 

operations. Personnel tasked with refilling SCBA cylinders should be properly trained and educated 

about the potential dangers of compressed air. In addition, personnel should maintain awareness of 

any safety advisories or bulletins issued by NIOSH that pertain to SCBA. (These advisories are often 

mentioned in trade publications like Fire Engineering.) Strict procedures should be followed to ensure 

that fill-lines are not charged inadvertently, and that cylinders are filled to the correct pressure. Only 

Grade D breathing air with a low moisture content should be used to fill breathing air cylinders. 

Air samples should be regularly tested to ensure quality and prevent impurities from contaminating 

breathing air supplies. Filters should be changed at intervals suggested by the manufacturer, or more 

frequently depending on the results of air quality testing. Despite the safeguards built into most air 

refill systems, accidents can occur from improper training or carelessness.

An article in the October 1996 Fire Engineering magazine (included in this report as Appendix B, 

reprinted with the permission of Bruce J. Cavallari and Fire Engineering) answered many commonly 

asked questions regarding the hydrostatic testing and certification of compressed gas cylinders8

.

PREVENTIVE MAINTENANCE

Many of the complaints received by NIOSH about SCBA problems are directly attributable to a lack 

of, or improperly performed, preventive maintenance. Although modern, NFPA-compliant SCBA 

are both durable and reliable, they require regular inspection and maintenance to maintain these 

characteristics.

8Cavallari, Bruce J. “Hydrostatic Testing of Compressed Gas Cylinders.” Fire Engineering, October 1996: 80-82
10 U.S. Fire Administration/Technical Report Series

Every manufacturer has recommended preventive maintenance procedures for their SCBA. These 

procedures are included with the unit when it is shipped, and many manufacturers will also have a 

field service representative personally review the procedures with the fire department. The manufacturers’ maintenance recommendations should be considered a minimum. SCBA that are subjected to 

frequent use may require maintenance at more frequent intervals. Most manufacturers recommend 

annual flowtests. At least one manufacturer adds the additional recommendation of rebuiliding the 

unit every 3-6 years, or more often if subjected to frequent use.

Preventive maintenance procedures should only be performed by properly trained and qualified 

personnel who have been certified by the SCBA manufacturer as capable of safely performing such 

work. Some fire departments have a dedicated “Air Shop” where SCBA are serviced by certified technicians who are fire department employees. Other departments may send SCBA to a private firm that 

specializes in servicing their particular units. Unfortunately, many departments have not adopted the 

recommended procedures regarding routine SCBA maintenance. Routine preventive maintenance is 

the only way to ensure that SCBA will properly protect firefighters.

Another problem is posed by the so-called “midnight mechanics” who attempt to repair SCBA without the proper training, tools, or replacement parts. Although SCBA are becoming easier to maintain, they are still complex apparatus whose reliability depends upon maintenance performed by 

skilled technicians. The legal ramifications of allowing a non-certified person to repair SCBA could 

be severe should a failure occur. Knowing that all of the fire department’s SCBA units are properly 

maintained and inspected by competent personnel can also enhance the confidence and safety of the 

firefighter or rescuer who must face extreme conditions while wearing the SCBA.

Routine SCBA maintenance tasks such as daily inspection, cleaning, and disinfection are usually 

handled by field personnel, and are at integral part of overall preventive maintenance. However, care 

must be taken to ensure that they are properly performed. The use of cleaning solutions or procedures other than those recommended by the manufacturer could result in damage to the unit.

To prevent problems from occurring during daily inspection and cleaning, firefighters should be 

trained on the proper cleaning procedures and solutions to use. Firefighters should also be trained 

to recognize the signs and symptoms of problems requiring that SCBA be removed from service 

and referred to qualified service technicians. Examples of these may include: “sticky” inhalation or 

exhalation valves; leaking, cracked, or heavily abraded facepieces; frayed straps or broken buckles; 

and any signs of physical or chemical damage to the harness or cylinder. Although something like a 

frayed strap may not seem severe during a daily check, it may cause a problem for a firefighter during 

donning or doffing, especially in an emergency situation.

Some common problems with SCBA are related to their storage. SCBA should be kept as clean as 

possible, which may preclude storage on parts of fire apparatus that are exposed to weather and road 

dirt or grime. Facepieces should be stored in bags to ensure that they remain clean and ready to use. 

Particular attention should be paid to ensuring that connections are properly tightened, since road 

vibration may loosen vital connections over time.

Fire departments that do not have a comprehensive SCBA program, including preventive maintenance 

procedures, in place can become familiar with NFPA 1404, Standard for a Fire Department Self-Contained 

Breathing Apparatus Program. Using this document as a blueprint will help departments implement their 

own program to ensure compliance with regulations. More importantly, a well-designed and implemented SCBA program will help ensure that firefighters are venturing into harm’s way with safe and 

effective protective equipment.
USFA-TR-088/November 2001 11

TRAINING

As with any area of fire department operations, there is no substitute for proper training with SCBA. 

Firefighters need to be familiar with SCBA operation while performing tasks like fire attack, victim 

search, rescue, ventilation, salvage, and overhaul. Firefighters and rescue personnel should also be 

trained in routine preventive maintenance procedures like daily inspection, cleaning, disinfection, 

and cylinder changes.

Unfortunately, the tendency exists to treat SCBA as a tool more akin to an axe or pike pole than a 

vital piece of personal protective equipment. Even in busy fire departments, firefighters are likely 

to perform only a cursory check of their assigned SCBA when going on duty. In order to prevent 

“low-order” failures from occurring, it is imperative that firefighters thoroughly inspect and test 

the function of SCBA as often as possible. In a career department this should happen every day, and 

should be second-nature. A volunteer department should make SCBA inspection and practice part of 

every scheduled meeting, drill session, or training class.

SCBA training is essential for all firefighters. Basic familiarization and orientation to SCBA should 

be part of every firefighter’s initial indoctrination. Members should receive extensive training in the 

use of SCBA under low-stress conditions, as well as during simulated fireground operations. This 

training should be conducted according to recognized standards, using methodology approved by 

the appropriate fire training agency. Individual training records kept for each firefighter or SCBA 

user will help ensure that members are maintaining proficiency with SCBA.

Basic training in SCBA use should include a discussion of the limitations of SCBA, as firefighters 

need to be aware that there are situations that may be encountered where SCBA will not provide 

adequate protection, and may be subject to catastrophic failure. For example, incidents involving 

hazardous materials other than those commonly encountered at structure fires (see USFA Major Fires 

Investigation Report Sodium Explosion Critically Burns Firefighters Newton, MA.)

In addition to initial training and certification in SCBA use, continued practice and advanced training should also be addressed to ensure that firefighters maintain proficiency. Regular drills will 

improve firefighters’ familiarity and increase their comfort level with SCBA in hazardous situations. 

Some fire departments and State fire training agencies offer specialized “Smoke Diver” or “Breathing 

Equipment Specialist” courses to further develop firefighters’ SCBA skills. These are often conducted 

using a train-the-trainer format, with the goal being to train instructors to teach advanced SCBA 

skills to firefighters and rescuers in their home jurisdictions.

Firefighters can be encouraged to perform a “buddy check” with their partner prior to entering a 

hazardous environment. Each partner can quickly check to ensure that the other has SCBA properly 

donned and operational. This way, problems can be identified and corrected before they hamper 

interior operations, or injure firefighters.

PROBLEM TRENDS

As noted earlier, many of the problems that have characterized SCBA failures in the past have been 

corrected with the advent of more realistic testing procedures and tougher standards. Modern, 

NFPA-compliant SCBA are extremely rugged and durable. The National Institute for Occupational 

Safety and Health (NIOSH) receives approximately 15-20 complaints each year about potential SCBA 

problems. When a complaint is received, NIOSH begins an investigation. Many of the complaints 

are determined by NIOSH to be the result of the complainant’s unfamiliarity with, or their dislike of, 

the particular model of SCBA. About half of the investigations uncover a legitimate problem.
12 U.S. Fire Administration/Technical Report Series

Most of the problems uncovered are minor in nature. These are often quickly and easily correctable 

with a safety bulletin from the manufacturer to users of the particular model of SCBA. NIOSH may 

also issue a “Respirator User Notice” to notify users of a problem. Most often, the problem is primarily a preventive maintenance or training issue rather than an actual design or construction defect. 

However, there are some trends that appear in the verified problems:

Regulators- - One of the most common complaints about modern SCBA from all manufacturers is a 

tendency for mask-mounted regulators to unexpectedly disengage from the facepiece. NIOSH has 

investigated incidents in which the evidence suggests that the reported disengagements were primarily due to operator error, as opposed to a design defect. This type of regulator will most often 

have a positive-locking mechanism, but the mechanism will not fully engage unless the user properly inserts the regulator into the mask and engages the mechanism. Training and familiarity with 

the specific type of mask-mounted regulator in use on a particular model of SCBA should minimize 

this problem. It is important that users of SCBA with mask-mounted regulators ensure that they are 

properly engaged before entering a hazardous environment, which can be easily accomplished during a “buddy check” by the other member of the entry team. The potential for regulators to freeze 

during cold weather operations is also real, and firefighters should be aware of this possibility.

Low-air Alarms- - Another common complaint received by NIOSH is the tendency for “whistle” –type 

low-air pressure alarms to blend with background noise on the fireground. The concern is that 

firefighters experience difficulty realizing that their alarm is sounding due to the noisy environment. 

Some manufacturers have handled this concern by mounting lights on the SCBA that activate with 

the low-pressure alarm, providing a visual as well as an audible warning to the firefighter and other 

members of the entry team. As mentioned previously, the 1997 edition of NFPA 1981 requires 

that a minimum of two low-air alarms be provided on the SCBA, addressing different senses. This 

enhancement should help mitigate any problems related to low-air alarm recognition and interpretation. Still, this is primarily a training issue. Firefighters should continuously monitor their 

pressure gauges while they are in a hazardous environment. Crucial decisions on how to conduct 

interior operations can only be made with knowledge of the air status of each member of the entry 

team. Continually advancing into a structure until the low-pressure alarm sounds is an invitation 

to disaster. Firefighters should be aware of their rate of air consumption while performing strenuous fireground tasks, and must ensure that they always have enough air remaining to safely exit the 

hazardous environment if the situation deteriorates.

Facepieces- - In the past, NIOSH has received complaints about facepiece lenses becoming opaque or 

melting as a result of extreme exposure to radiant heat, particularly during live-burn training evolutions. During these evolutions, firefighters and fire instructors should be especially cautious not to 

stress the SCBA and its components past the point where failure becomes a possibility.

The majority of the complaints received by NIOSH and by individual SCBA manufacturers can be 

correlated with preventive maintenance and training issues. NFPA 1981-compliant SCBA that are 

properly maintained and used by well-trained firefighters and rescuers should provide protection 

from those hazards commonly encountered during emergency situations. Additionally, it is important that fire departments continue to upgrade their breathing apparatus to meet the most current 

edition of NFPA 1981, to prevent repeating past tragedies.
USFA-TR-088/November 2001 13

OTHER ISSUES

Pushing the Edge- - Despite the myriad tests performed on SCBA during the certification process, there 

are limitations to the amount of punishment that SCBA can survive without experiencing failure 

or malfunction. Some of those involved in the design and construction of SCBA fear that, despite 

the more realistic testing procedures adopted by the NFPA, firefighters are pushing SCBA to their 

maximum safe operating limits and beyond. Care must be taken to ensure that SCBA are not routinely pushed past the “edge of the envelope” in which they were designed to operate. Subjected to 

this type of punishment on a regular basis, even properly maintained SCBA can be expected to fail. 

Firefighters should also be aware that situations exist where SCBA will not provide adequate protection from the environment, particularly those involving certain hazardous materials.

Evaluating the Fire Environment- - There is some concern among members of the fire service community that as firefighters are increasingly well protected, they are less able to discern changes in the 

environment around them, especially with regard to changes in thermal balance, and impending 

flashover conditions. This concern has led to a fear that firefighters are venturing into conditions 

where their standard personal protective equipment cannot protect them. As a result, some research 

and development efforts are seeking to provide affordable adjuncts that could replace firefighters’ 

lost senses, and warn them to retreat as conditions become untenable.

Cold Weather- - NIOSH has received complaints about SCBA performance in cold weather. When such 

a complaint is received, NIOSH attempts to duplicate the exact conditions in which the reported 

problem occurred. With one exception, the results of these investigations were inconclusive. NIOSH 

did determine that although the regulator in one case met approval requirements, it’s design was 

susceptible to freezing in the open position. In this case, the manufacturer modified the design and 

took measures to ensure that existing SCBA units were retrofitted with the newly designed regulator. It should be noted that, although SCBA are expected and approved to perform in cold weather, 

they do have a lower temperature limit (usually -20 to -25 degrees Fahrenheit). When temperatures 

approach these extremes, the moisture content of breathing air in the cylinders becomes an important issue9

, along with the handling that SCBA receive on the fireground. Ensuring that SCBA are not 

left sitting out in the open during periods of extreme temperatures should help prevent cold-related 

problems from occurring.

Improper Modification or Use- - It is important to note that this report addresses self-contained breathing 

apparatus intended, approved, and certified for use in structural firefighting. During the approval 

and certification process, SCBA are tested as complete units (including facepiece nosecups and waist 

straps), in the manner in which they are expected to be worn (i.e., on the firefighters back, with 

straps properly applied and tightened, and with all buckles buckled). Modifications or improper 

wearing of SCBA tested in this manner may void NIOSH approval and NFPA certification.

9Although OSHA 29 CFR 1910.134 requires the use of Grade D breathing air with a -50 degree Fahrenheit dewpoint in 

SCBA, some manufacturers are more stringent and recommend the use of Grade D breathing air with a lower moisture 

content (on the order of -65 degrees Fahrenheit). Fire departments, especially those in climates where extremely 

cold temperatures are expected, should use whichever requirement is more stringent, whether OSHA’s or the SCBA 

manufacturer’s.
14 U.S. Fire Administration/Technical Report Series

Modifications to SCBA that may void NIOSH approval and result in less than peak performance of 

the unit include: the removal of nosecups (which may promote facepiece fogging in cold temperatures), cutting waiststraps, and replacing factory-installed buckles with parts from a different manufacturer. A regularly performed and effective preventive maintenance program can help identify any 

improper modifications to SCBA.

Improper or incomplete use of SCBA is another potential problem area. A common example of this 

occurs when firefighters use SCBA without having the waiststrap properly fastened and tightened. 

This practice voids NIOSH approval, may make the SCBA more difficult to wear, since the waiststrap 

is an integral part of the weight-distribution system, and can make the firefighter more prone to 

entanglement. Although “reduced-profile” maneuvers where SCBA may be temporarily removed 

from the firefighters back in an emergency situation are commonly taught, technically they too 

void NIOSH approval of the SCBA. In a more extreme example, using structural firefighting SCBA 

in confined space operations where the SCBA is not worn on the entrant’s back (although it may 

be pulled behind, pushed ahead, or suspended above the rescuer) voids NIOSH approval and can 

have severe negative consequences (NIOSH has investigated deaths where SCBA were used in this 

manner). Finally, although it seems obvious, structural firefighting SCBA are not intended for use in 

an underwater environment where SCUBA (Self-Contained Underwater Breathing Apparatus) gear 

is the appropriate choice. Although SCBA may remain functional during an accidental, temporary 

submersion, an eventuality that fire department SCBA training programs should address, they are 

neither designed nor approved by NIOSH for prolonged use in the aquatic arena.

NEW CAPABILITIES FOR SCBA

Properly performed preventive maintenance and thorough, comprehensive user training are a key to 

preventing SCBA failures. Advancing technology holds promise to further reduce the potential for 

failures under extreme conditions faced by firefighters and rescue personnel. Although technology 

cannot replace proper training and preventive maintenance, the incorporation of several recent technological advances in SCBA design may help give firefighters increased protection from situations 

commonly encounter in structure fires. Some examples of this technology are the integration of 

heat-sensing devices, Heads-Up Displays (HUDs), communications interfaces, and thermal imaging 

devices.

In order to develop an understanding about the direction of SCBA technology, general information 

on SCBA trends and developments was gathered from members of the fire service and from manufacturer’s representatives. A discussion of the trends identified during this research is presented here.

F

Future expectations for SCBA include the widespread incorporation of heads-up displays, thermal 

imagers, heat sensors, video/data links, and improved communications devices. Some of these 

items are available now, although the expense of such equipment places it out of reach for many fire 

departments.

While added capabilities such as the above are generally regarded as improvements, several critical 

issues must be considered when adding capabilities. The first is the additional weight that the device 

brings to the SCBA. Many of the recent improvements in SCBA construction were directed toward 

decreasing the weight of the unit (e.g., carbon-fiber cylinders), to reduce fatigue, strain, and increase 

maneuverability. For firefighters, every ounce of added weight is a significant factor during tactical 
USFA-TR-088/November 2001 15

operations. The value added to the SCBA by enhanced capabilities must be balanced against the need 

to keep SCBA as lightweight as possible. This is a critical safety issue as the weight of the SCBA and 

other elements of the protective ensemble contribute heavily to fatigue.

Another important issue is the impact of added capabilities on SCBA profile or bulkiness. Profile 

and weight reduction efforts have gone hand-in-hand, culminating with the recent introduction 

of carbon-fiber breathing-air cylinders that hold more air in smaller cylinders. Adding devices to 

SCBA that provide additional capabilities, but which enlarge the equipment profile, may increase the 

likelihood that firefighters will become entangled or trapped. Streamlined, low-profile SCBA help 

firefighters maintain balance by minimizing changes to their center-of-gravity. This performance 

characteristic is especially important during roof operations, while ascending or descending ladders, 

and during interior firefighting or search and rescue efforts.

Successful interior firefighting operations demand that firefighters direct their complete and total 

attention to the task at hand; a moment of indecision or inattentiveness can spell disaster. Safely performing tasks like fire attack, ventilation, or search and rescue requires that firefighters continually 

monitor the conditions around them, looking for subtle clues that may signal a dramatic change like 

flashover or impending collapse. This process of mental size-up is hindered by such things as noise, 

lack of visibility, and the overall nature of the hostile fire environment. As a result, firefighters can 

quickly become challenged by the sheet number of sensory inputs and stimuli that they are receiving. A variety of technological add-ons to SCBA have been proposed to help firefighters monitor the 

environment around them including: built-in thermal sensors, heat alarms, and heads-up displays, 

as well as communications and data links to relay information on the “big picture” to and from the 

incident commander.

While these added capabilities may positively affect firefighter communication and safety, they should 

be carefully considered not only from a physical standpoint (e.g., weight and profile) but from a 

mental standpoint, as well. While technological adjuncts may provide a wealth of useful information, they also cause additional distractions for already taxed firefighters. The beeping, blinking, 

wailing, and whistling of alarms inside an already chaotic environment places additional stress on 

firefighters, and may hinder their focus on assigned tasks, causing them to miss subtle and critical 

clues on changing fire conditions.

Added capabilities demand additional training. With respect to SCBA, the importance of thorough, 

comprehensive user training cannot be overstated. Every device added to SCBA requires that firefighters be trained in its proper use, operation, and maintenance. Failure to perform such training 

will limit the usefulness of the device.

The unpredictable fire environment, coupled with the routinely harsh treatment received by fire 

equipment daily, make it difficult to develop devices that are affordable, durable, reliable, and that 

provide consistent service. While regular preventive maintenance programs can help keep these 

devices operating properly, man “cutting-edge” devices are currently unsuitable for fire service use. 

Problems with add-ons can also result in more down-time for SCBA units, which poses a problem 

to departments with a limited number of available SCBA. To avoid having to send the entire unit for 

repair when there are problems, firefighters may disregard or not use the device, with a negative 

impact on safety.

Cost is another major factor when considering adding capabilities to SCBA. While it may be possible 

to design and construct a durable and reliable technological adjunct, such developments may not be 
16 U.S. Fire Administration/Technical Report Series

economically feasible for manufacturers unless many fire departments demand it on their SCBA. In 

turn, fire departments must also balance the value of added capabilities against the many competing 

demands on department resources.

Simplicity and Reliability

Improvements in the simplicity and reliability of SCBA may also be a way to add value and enhance 

firefighter safety. By making SCBA simpler and easier to use and maintain, failures related to inadequate training or preventive maintenance should be further reduced. Simpler, more reliable SCBA 

should also help fire departments conserve their fiscal resources by increasing service life and reducing maintenance and repair costs.

Several manufacturers contacted indicated that their major emphasis during the next decade will 

be on improving the simplicity and reliability of SCBA, as opposed to incorporating technological 

adjuncts. Particular attention will probably be directed toward using ergonomic design principles to 

enhance the “wearability” of SCBA.

Potential Areas of Improvement

Some of the improvements described here have already been incorporated in SCBA, and are currently available to fire departments wishing to upgrade or replace existing units. A variety of other 

technological advances are being studied or tested. Ultimately, it is fire departments who determine 

what improvements the manufacturers incorporate into SCBA, and at what price.

Masks and Facepieces- - Recent trends in ergonomic design have led to a variety of recent advances in 

the design and construction SCBA facepieces. Improvements have been made to enhance the clarity 

of voice communications, reduce fogging, improve peripheral vision, and provide a range of sizes to 

ensure that firefighters are properly fitted. Still, the basic shape and construction of SCBA facepieces 

has remained relatively unchanged in recent years.

Polycarbonate remains the material of choice for SCBA facepieces since it offers the best combination of thermal protection and clarity currently available. Some recent experiences with radiant 

heat transmission through the lens of polycarbonate facepieces may indicate that further research is 

needed to develop an alternative material that better resists the high radiant heat release from fires.

Some manufacturers are studying the benefits of integrating helmets and facepieces, although there 

is some question about whether or not an integrated helmet/mask system meets current NIOSH 

regulations and NFPA standards; this is due to concerns about the integrity of the face-to-mask seal 

if the helmet were struck by an object hard enough to knock it off the wearer’s head, thus potentially 

exposing him/her to a hazardous atmosphere. Such integrated helmets have long been used by the 

French Fire Service, and are the standard helmet for most French departments.

Heads-Up Displays- - Although not yet widely available, another advance being studied is a Heads-Up 

Display (HUD) for SCBA. This feature continuously provides the user with critical information on 

their life support status, without the need to divert attention to a remote pressure gauge or guess 

about whether or not their facepiece is leaking significantly enough to cause a problem. HUDs 

may also be developed to transmit information from the command post to firefighters operating in 

remote locations. At least one manufacturer currently offers a simplified version of a HUD using a 

series of lights on the facepiece to indicate remaining air pressure and positive-pressure status.
USFA-TR-088/November 2001 17

The difficulties and expense of engineering a full-featured display as part of an SCBA facepiece will 

probably preclude HUDs from being incorporated in facepieces anytime in the near future, although 

they may be marketed as add-ons that attach to the helmet. Such a device is already available from 

one company (not an SCBA manufacturer) although it is not intended for use in interior firefighting. 

The use of such a device, even if not technically part of the SCBA itself, will have an impact on the 

SCBA, especially with regard to firefighters’ field-of-vision and their ability to process SCBA-related 

information. HUDs are widely used in aerospace and military applications, and it seems likely that 

some form of these devices will be incorporated into firefighters’ personal protective ensemble in 

the future.

Thermal Imaging- - Although the value of being able to “see through smoke” is clear to firefighters, 

the cost and complexity of currently available thermal imagers make their widespread incorporation into SCBA facepieces rather unlikely, at least in the near future. As in the case of HUDs, thermal 

imaging devices will probably continue to be marketed as adjuncts that attach to the helmet. Also 

like HUDs, the thermal imaging system, while not technically part of the SCBA, may directly affect 

its performance by changing the firefighter’s field-of-vision, or by adding additional weight to the 

helmet of SCBA harness.

Communications- - Several manufacturers offer facepieces with integrated communications systems. 

These can be of different types including: voice amplifiers, two-way radio interfaces, wireless 

intercoms, or a combination. The benefit of integrated communications is easy to understand as 

fireground communication has long suffered from the difficulty of attempting to speak and be 

understood through an SCBA facepiece, often in a loud environment. The difficulty of adapting 

microphones and other hardware to work inside the SCBA facepiece has made voice clarity hard to 

achieve. The cost of these systems has also reduced their appeal, as few fire departments can afford 

to outfit all of their SCBA. While various types of integrated communications systems have been 

available for several years, they may become more commonplace as their durability and reliability 

continue to improve.

Breathing Air Cylinders- - Carbon-fiber SCBA cylinders are currently available from several manufacturers and represent a major advancement in the “state-of-the-art”. These cylinders have enabled 

weight and profile reductions without having to sacrifice the volume of air contained within the 

cylinder. As a result, firefighters can carry more air, with less weight on their backs, and less chance 

of becoming entrapped or entangled. Although breathing air cylinders with durations exceeding 

one hour are now possible, fire departments should carefully evaluate whether or not it is prudent 

to use them in the structural firefighting environment.

While carbon-fiber cylinders may feel very different from ordinary composite cylinders in terms of 

weight, they are constructed in essentially the same manner, and are still susceptible to physical and 

chemical damage or abuse.

Several manufacturers are studying ways to further reduce the profile of SCBA by using differently 

shaped containers or flexible bladders within lightweight cylinders. The problems of gaining DOT 

certification for these designs indicate that, currently, carbon-fiber represents the best available technology for SCBA cylinders.

Monitoring and Diagnostics- - An area where added capabilities are likely in the near term is in monitoring and diagnostics. The widespread incorporation of integrated PASS devices is one example of how 

monitoring technology is currently being integrated in SCBA. It is likely that the integrated PASS 
18 U.S. Fire Administration/Technical Report Series

will evolve into a “black box” that performs several different functions. Future advances will probably include the use of technology to monitor a variety of SCBA performance factors and provide an 

interface through which maintenance personnel can download diagnostic information on the unit. 

Advanced diagnostics will allow preventing maintenance to be performed based on the actual use of 

the unit in terms of hours, instead of by guidelines applied to a set of SCBA without regard for how 

often or how hard, they are used.

Sensors may also be incorporated into SCBA to measure outside temperature, and sound an alarm 

if the user enters an environment where their protective equipment may be inadequate. Firefighter 

location systems using radio or GPS (Global Positioning System) transceivers may also become commonplace in future equipment configurations.

The monitoring and diagnostic functions incorporated into future SCBA may also be able to monitor 

human performance factors like the number of breaths per minute, heart rate, skin temperature, etc., 

helping to identify problems before they can contribute to firefighter casualties.

The areas of improvement described here are general in scope and SCBA manufacturers continue 

to develop technology to enhance future SCBA. Additional research is being performed by the fire 

service in cooperation with major universities and other agencies like NASA and the Department of 

Defense. Although it is important to remember that even the most fail-safe, state-of-the-art SCBA still 

depends on firefighters for its proper operation and maintenance, technological improvements hold 

great promise for helping to prevent SCBA failures.

RECOMMENDATIONS

In summary, the following actions are highly recommended to prevent SCBA failures leading to 

firefighter injuries.

Preventive Maintenance- -Regular preventive maintenance will help ensure the safety and well-being of 

firefighters and compliance with applicable regulations. Fire departments should implement SCBA 

preventive maintenance programs. Regular maintenance by qualified personnel will help prevent 

SCBA failures and should be conducted using manufacturers recommendations as a minimum standard. SCBA subjected to extreme levels of use should be maintained and tested at more frequent 

intervals.

User Training- - Firefighters must receive comprehensive training in the use and limitations of SCBA 

before being exposed to hazardous environments. In addition to initial training, continued drill and 

practice should be conducted to maintain proficiency with SCBA. Training should also be provided 

on proper field maintenance and cleaning procedures. Thorough, ongoing user training should help 

decrease the incidence of low-order SCBA failures. Training should emphasize the limitations of 

SCBA to help ensure that firefighters do not put themselves in situations where SCBA will not 

provide adequate protection from the hazardous environment.

Problem Recognition- - Many of the problems reported to NIOSH annually are related to preventive 

maintenance or training deficiencies. Improper use or modification of structural firefighting SCBA 

may have negative consequences. Firefighters and maintenance personnel should be able to recognize potential problems that may lead to failures of SCBA or breathing air cylinders. Any SCBA or 

breathing air cylinder that has been dropped, run-over, burned, submerged, exposed to chemicals, or otherwise mistreated should immediately be purged from the service for examination 

and testing by qualified repair personnel.
USFA-TR-088/November 2001 19

Regular Upgrades- - Fire departments should upgrade or replace SCBA to meet the current edition 

of the NFPA 1981 Standard on Open-Circuit Self-Contained Breathing Apparatus for Fire Fighters. SCBA with 

demand-type regulators do not provide firefighters with adequate respiratory protection and 

should be replaced with positive-pressure type units.

Use of Standards- - The NFPA standards summarized previously in this report can be very useful to fire 

departments developing SCBA programs. Programs meeting the requirements contained in these 

standards are likely to be compliant with applicable Federal or State regulations.

Pursuit of Technology- - Fire departments should continue to encourage the development and incorporation of new technology in SCBA design and construction. The use of new materials and construction methods holds the promise of stronger, lighter, more capable SCBA providing firefighters with 

increased safety and protection from hazardous environments.

Record-keeping- - The importance of keeping accurate, up-to-date records of preventive maintenance 

actions, individual SCBA and cylinder test results, and SCBA user training cannot be overstated. Air 

quality records should also be maintained to ensure that firefighters receive clean, dry air in their 

SCBA cylinders. Accurate records can be used to show trends that may justify performing regular 

maintenance at intervals more frequent than those recommended by the manufacturer.
20

APPENDIX A

“Acidic fluid Leads to Air Cylinder failure”, 

Fire Engineering, November, 1996

Reprinted with permission from the editors of Fire Engineering.
USFA-TR-088/November 2001 21

Appendix A (continued)
22 U.S. Fire Administration/Technical Report Series

Appendix A (continued)
USFA-TR-088/November 2001 23

Appendix A (continued)
24

APPENDIX B

Cavallari, Bruce J., “Hydrostatic Testing of Compressed 

Gas Cylinders”, Fire Engineering, October 1996

Reprinted with permission from Mr. Bruce J. Cavallari and Fire Engineering.
USFA-TR-088/November 2001 25

Appendix B (continued)
26 U.S. Fire Administration/Technical Report Series

Appendix B (continued)
USFA-TR-088/November 2001 27

Appendix B (continued)