# Fire Apparatus Manufacturer’s Association 

# Fire Apparatus Duty Cycle White Paper

FAMA Technical Committee Chassis Subcommittee

Roger Lackore - Pi erce Manufacturing

August 10, 2004Apparatus Use White Paper 08-10-04.doc 8/10/2004 2 

## Contents

Purpose........................................................................................................................ ................................... 3 Methods........................................................................................................................ .................................. 3 Definition of Terms ............................................................................................................ ............................ 3 PART I - Survey of Fire Chiefs................................................................................................. ..................... 4 Description.................................................................................................................... ........................ 4 Respondent Profile............................................................................................................. ................... 4 Type of Department ............................................................................................................. ............ 4 Population Served .............................................................................................................. .............. 4 Demographics Served ............................................................................................................ .......... 4 Topography of Region Served .................................................................................................... ..... 5 Average Apparatus Per Department by Type ....................................................................................... ..... 5 Apparatus in service per department............................................................................................ .... 5 Chassis Type (new est apparatus) ................................................................................................ ..... 5 Life Expectancy................................................................................................................ ......................... 5 Years Expected in Activ e Service (Average)................................................................................... 5 Years Expected in Reserv e Service (Average)................................................................................. 5 Annual Apparatus Usage ......................................................................................................... .................. 5 Total Miles Driven In Last 12 Months........................................................................................... .. 5 Total Engine H ours (Average) ................................................................................................... ...... 5 Hours at Idle Per Week ......................................................................................................... ........... 6 Life Expectancy by Demographics................................................................................................ ............ 6 Years of Apparatus in active se rvice (Average Expected) ............................................................... 6 Years of Apparatus in reserve se rvice on (Average Expected) ........................................................ 6 Years of total service lif e (active plus reserve) .............................................................................. .. 6 Apparatus Use by Demographics .................................................................................................. ............ 6 Miles driven (las t 12 months).................................................................................................. ......... 6 Engine hours (las t 12 months).................................................................................................. ........ 6 Runs per Week .................................................................................................................. ............... 7 Idle Time (hou rs per week) ..................................................................................................... ......... 7 PART II - Engine Du ty Cycle Ex traction......................................................................................... .............. 8 Description.................................................................................................................... ............................. 8 Results ........................................................................................................................ ............................... 9 Population of Engine ECMs Interrogated ......................................................................................... .... 9 Average Apparatus Miles Per Year by Demographic........................................................................... 9 Average Engine Hours Per Year By Demographic............................................................................. 10 Average Pump Hours Per Year By Demographic............................................................................... 10 Average Aerial Hours Per Year By Demographic .............................................................................. 11 Time Spent at Engine Sp eed by Demographic.................................................................................... 11 Time Spent at Engine Load by Demographic ..................................................................................... 12 Average Engine Load ............................................................................................................ ............. 13 PART III - Vehicl e Data-Logging................................................................................................ ................ 14 Description.................................................................................................................... ........................... 14 Results ........................................................................................................................ ............................. 14 Urban Career Department Apparatus Results ..................................................................................... 1 4 Rural Volunteer Departme nt Apparatus Results................................................................................. 15 National Cumulative Projections for Custom Apparatus........................................................................... ... 16 Data Source.................................................................................................................... .......................... 16 Results ........................................................................................................................ ............................. 16 All Domestic Fi re Apparatus .................................................................................................... .......... 16 Custom Fire Apparatus .......................................................................................................... ............. 17 Acknowledgements ............................................................................................................... ....................... 18Apparatus Use White Paper 08-10-04.doc 8/10/2004 3 

### Purpose

This paper has been created by the Chassis Technical Committee of the Fire Apparatus Manufacturer’s Association for the follow purpose:

• Provide guidance to fire apparatus manuf acturers on the life expectancy and use profile for major types of fire apparatus.

• Estimate the average engine duty cycle in a fire apparatus.

• Provide a tool for engine manufacturers to use when estimating the impact of fire apparatus engine emissions.



### Methods

• Survey of Fire Chiefs

• Instrumentation of selected vehicles to log data on use profiles

• Engine Data Collection



### Definition of Terms

Urban Area served by the fire department is obviously metropolitan and consists of high-density housing, industr ial, or retail structures.

Suburban Area served is mainly single fam ily housing, light retail or light industry. Could be outskirts of metropolita n areas or smaller communities.

Rural Area served is small towns and lo w density population regions that would include significant distances between the station and the structures being protected.Apparatus Use White Paper 08-10-04.doc 8/10/2004 4 

### PART I - Survey of Fire Chiefs

Description

In January 2004, Pierce Manufacturing conducted an independent quantitative research survey through Added Value Inc . that was designed to prov ide information on the usage patterns for fire apparatus. Among the info rmation sought through this survey were the following topics:

• Department demographics

• Number of apparatus by type

• Average number of runs per week

• Average length of run

• Average miles driven per year

The methodology for the research survey was as follows:

• A one-page questionnaire was developed consisting of 15 closed-end questions.

• A list of 1200 fire chiefs representing a cross-section of the U.S. was created.

• A code number was printed at the bo ttom of each questionnaire to allow Added Value Inc. to track responses.

• All Questionnaires were mailed with a pos tage-paid return en velope, and a cover letter from Pierce Manufacturing

. • The cutoff date for the survey receipt was February 23, 2004.

The response rate for the survey was 30% 

### Respondent Profile

Respondents who were fire chiefs or assistant fire chiefs 69%

Type of Department Career fire departments 30% Volunteer departments 45% Combination career/ volunteer 25%

Population Served 50,000 or less 82% 50,000 to 100,000 11% 100,000 or more 7%

Demographics Served Urban 25% Suburban 46% Rural 48%Apparatus Use White Paper 08-10-04.doc 8/10/2004 5 Topography of Region Served Relatively Flat 58% Hilly 36% Mountainous 14%


### Average Apparatus Per Department by Type

Apparatus in service per department Pumper 5.8 Aerial 1.5 Rescue 2.5

Chassis Type (newest apparatus) Custom Commercial Pumper 77% 23% Aerial 93% 7% Rescue 46% 53%


### Life Expectancy

Years Expected in Active Service (Average) Newest Pumper 17 Newest Aerial 19 Newest Rescue 15

Years Expected in Reserve Service (Average) Newest Pumper 12 Newest Aerial 10 Newest Rescue 9


### Annual Apparatus Usage

Total Miles Driven In Last 12 Months Newest Pumper 4,501 Newest Aerial 3,663 Newest Rescue 4,898

Total Engine Hours (Average) Last 12 Months Hours per Week Newest Pumper 655 12.6 Newest Aerial 413 7.9 Newest Rescue 705 13.5Apparatus Use White Paper 08-10-04.doc 8/10/2004 6 Runs (Average) Runs per Week Runs per Year Newest Pumper 15 780 Newest Aerial 10 520 Newest Rescue 16 832

Hours at Idle Per Week Newest Rescue 10 Newest Pumper 9 Newest Aerial 7 

### Life Expectancy by Demographics

Years of Apparatus in active service (Average Expected) Urban Suburban Rural Newest Pumper 15 16 18 Newest Aerial 18 19 21 Newest Rescue 13 15 16

Years of Apparatus in reserve service on (Average Expected) Urban Suburban Rural Newest Pumper 10 11 14 Newest Aerial 9 10 13 Newest Rescue 7 7 11

Years of total service lif e (active plus reserve) Urban Suburban Rural Newest Pumper 25 27 32 Newest Aerial 27 29 34 Newest Rescue 20 22 27 

### Apparatus Use by Demographics

Miles driven (last 12 months) Urban Suburban Rural Newest Pumper 7,629 4,992 3,034 Newest Aerial 5,083 3,492 2,155 Newest Rescue 7,534 6,087 3,946

Engine hours (last 12 months) Urban Suburban Rural Newest Pumper 873 572 496 Newest Aerial 540 403 279 Newest Rescue 714 648 745Apparatus Use White Paper 08-10-04.doc 8/10/2004 7 Runs per Week Urban Suburban Rural Newest Pumper 29 16 8 Newest Aerial 13 11 5 Newest Rescue 31 16 11

Idle Time (hours per week) Urban Suburban Rural Newest Pumper 11 10 6 Newest Aerial 8 7 5 Newest Rescue 13 9 8

Run Length (Round-Trip) Miles Urban 4.9 Suburban 5.4 Rural 7.6Apparatus Use White Paper 08-10-04.doc 8/10/2004 8 

### PART II - Engine Duty Cycle Extraction
Description

With the advent of electronically controll ed diesels, engine manufacturers have incorporated data logging capability into the Electronic Control Modules (ECM) of the engines. Both Detroit Diesel and Cummins engines have the ability to log duty cycle activity and output the results in the form of percent of time spent at varying loads and engine speeds.

The accessibility of this logged data varies between engine models, dates of manufacture and the extent to which the customers may ha ve extracted data al ready. Despite these issues, the researchers were able to access data on engines from a wide spectrum of apparatus types and department demographics . The resulting data provides good insight into the manner in which the average fire apparatus is used.

Because the format of data between engine manufacturers, engine models, and ECM versions is not identical, this paper condenses the results into six buc kets. The percentage of time the engine operates at vari ous speeds is reported as follows:

Low Speed 1000 rpm or less Medium Speed Between 1000 rpm and 1800 rpm High Speed 1800 rpm and above

The percent of time the engine operates at vary ing loads is reported as a percentage of maximum load

Low Load 0 – 10% Medium Load Above 10% and below 90% High Load 90 – 100%

Time spent at negative values of torque (engi ne braking) is included with the low load values.Apparatus Use White Paper 08-10-04.doc 8/10/2004 9 

### Results
Population of Engine ECMs Interrogated

Average Apparatus Miles Per Year by Demographic

Apparatus Type Number of Apparatus Sampled Average Months of Service in Extraction Record
Pumper 51 26

Aerial 21 31

Rescue 4 14

Grand Total 76 26

Demographic Apparatus Type A verage of Miles Per Year

Rural Pumper 2,352 Aerial 1,866 Rescue 2,756 Rural Total 2,347 Suburban Pumper 6,068 Aerial 3,479 Rescue 4,992 Suburban Total 5,403 Urban Pumper 6,126 Aerial 6,514 Rescue 9,222 Urban Total 6,478 

### Grand Total 5,222Apparatus Use White Paper 08-10-04.doc 8/10/2004 10 

### Average Engine Hours Per Year By Demographic

Average Pump Hours Per Year By Demographic

Demographic Apparatus Type A verage of Eng Hrs

Rural Pumper 301

Aerial 204
Rescue 301
Rural Total 295 Suburban Pumper 1,364 Aerial 1,133
Rescue 367 Suburban Total 1,272 Urban Pumper 1,107 Aerial 2,379 Rescue 1,686 Urban Total 1,681 

### Grand Total 1,244

Demographic Apparatus Type A verage of Pump Hrs
Rural Pumper 70
Rural Total 70 Suburban Pumper 168
Aerial 59
Suburban Total 135 Urban Pumper 93
Aerial 141
Urban Total 111


### Grand Total 117Apparatus Use White Paper 08-10-04.doc 8/10/2004 11 

### Average Aerial Hours Per Year By Demographic

Time Spent at Engine Speed by Demographic Demographic Apparatus Type A verage of Aerial Hours Per Year

Rural Aerial 63
Rural Total 63
Suburban Aerial 64
Suburban Total 64

Urban Aerial 72
Urban Total 72


### Grand Total 69

Apparatus Type Demographic A vera g e Time at

Low RPM A vera g e Time at Medium RPM Avera g e Time at High RPM
Pumper Rural 63% 27% 11%
Suburban 71% 23% 6%
Urban 62% 32% 5% Pumper Total 66% 27% 7%

Aerial Rural 73% 19% 9%
Suburban 68% 27% 5%
Urban 73% 22% 5%
Aerial Total 71% 23% 5%

Rescue Rural 51% 42% 7%
Suburban 77% 17% 7%
Urban 57% 32% 11%
Rescue Total 61% 30% 9%
Grand Total 67% 26% 7%Apparatus Use White Paper 08-10-04.doc 8/10/2004 12 

### Time Spent at Engine Load by Demographic

Apparatus Type Demographic A verage Time at

Low Load A verage Time at Medium Load Average Time at High Load

Pumper Rural 61% 36% 3%
Suburban 54% 44% 3%
Urban 73% 24% 3% Pumper Total 62% 35% 3%

Aerial Rural 83% 11% 6%
Suburban 37% 58% 5%
Urban 53% 42% 5%
Aerial Total 50% 45% 5%

Rescue Rural 59% 39% 2%
Suburban 78% 22% 0%
Urban 44% 51% 5%
Rescue Total 56% 41% 3%
Grand Total 58% 38% 3%Apparatus Use White Paper 08-10-04.doc 8/10/2004 13 

### Average Engine Load

The Average Engine Load was determined by multiplying the percent load, by the percent time at load, then by the total HP, and summing up the results. This gives an average power load for each sample apparatus. The following chart summarizes the average power by each power rating, and finally provides and average power load for the entire sample population.

Apparatus Type HP A verage Power

Load (HP)

Pumper 315 44
330 49
350 51
365 51
370 68

400 51
430 90
435 106

475 111
500 118 Pumper Total 73

Aerial 330 42

430 81

470 124 500 128 Aerial Total 104 Rescue 350 32 430 107 500 96 Rescue Total 86 

### Grand Total 82Apparatus Use White Paper 08-10-04.doc 8/10/2004 14 

### PART III - Vehicle Data-Logging

Description

Operational data was gathered by installi ng GPS based data logging equipment on two sample apparatus. This record ing equipment was installed fo r a span of three weeks on each vehicle and measured the time spen t accelerating, decelerating, pumping, and at idle. Engine speed was also measured. Th e first apparatus was a pumper located at the busiest station of a major metropolitan depart ment. The second apparatus was located at the station of a volunteer departme nt in a rural bedroom community.

Most of the information obtained here is duplic ated with a much larg er population in the Engine Duty Cycle Extraction section. Th e unique information obtained in this portion of the study is the percentage of time the a pparatus spends accelera ting or decelerating while driving, and a more detailed view of the engine speeds during pumping.

The percent of time the appara tus operates at various condi tions is defined as follows:

Acceleration +1.5 mph per second or greater Deceleration -1.5 mph per second or less Steady Speed Between +1.5 and –1.5 mph per second



### Results

The result of this section of the study are provided for reference purposes only. The results are not statistically significant since only two truc ks are involved and only three weeks of data was collected for each vehicle. The rural apparatus only operated for 15 hours over the three week time frame and of th at was only actually dr iving for a total of three hours. It responded to one car fire which accounts for the pumping hours.

The urban pumper probably provides a more useful profile since it accumulated 64 hours of engine-on time over the thre e week period. The annualized data agrees fairly well with what we might expect of a busy metropolitan station. 

### Urban Career Department Apparatus Results

Urban Pumper Percent of Time Acceleration 7.2 % Deceleration 6.8 % Steady Speed 13.6 % Stopped with Engine Running (Pump Off) 66.6 % Pumping 5.8 %Apparatus Use White Paper 08-10-04.doc 8/10/2004 15 Urban Pumper Hours per Year Acceleration 80 Deceleration 77 Steady Speed 151 Stopped with Engine Running (Pump Off) 747 Pumping 64 Total 1123



### Rural Volunteer Department Apparatus Results

Rural Pumper Percent of Time Acceleration 1.5 % Deceleration 2.0 % Steady Speed 18.5 % Stopped with Engine Running (Pump Off) 61.4 % Pumping 16.4 %

Rural Pumper Hours per Year Acceleration 4 Deceleration 5 Steady Speed 46 Stopped with Engine Running (Pump Off) 152 Pumping 41 Total 247Apparatus Use White Paper 08-10-04.doc 8/10/2004 16 

### National Cumulative Projections for Custom Apparatus

Data Source

FAMA reports each year on the number of a pparatus sold by apparatus type (Pumper, Aerial, Rescue). This data is sent by each fire apparatus OEM to a third-party organization that tallies the results and reports the total numbers without revealing the break-down by manufacturer. This eliminates any incentive for over or under reporting, and provides what we believe to be reasona bly accurate data on the fire apparatus population. These numbers are inflated because they include export sales, but they are understated by the small number of OEMs w ho are not members of FAMA or do not report. We believe that these reporting errors balance fairly equally and that the values reported here can be used for gross estimates with a reasonable degree of confidence.



### Results
All Domestic Fire Apparatus

Year Commercial Pumper Custom Pumper Aerial Rescue Specialty Total

1997 1425 1570 605 408 735 4743

1998 1328 1535 590 520 805 4778

1999 1561 1561 657 513 900 5192

2000 1523 1865 712 446 1016 5562

2001 1416 1755 648 447 1028 5294

2002 1321 1977 584 588 1008 5478

2003 1277 1701 537 548 1028 5091Apparatus Use White Paper 08-10-04.doc 8/10/2004 17 

### Custom Fire Apparatus

The number of Custom Chassis Appara tus can be estimated as follows:
100% of Custom Pumpers (as reported by FAMA ) 100% of Aerial Apparatus (Nearly every Aerial is built on a custom chassis) 20% of the Rescue Apparatus 10% of the Specialty Apparatus

Year Custom Chassis Apparatus

1997 2330

1998 2310

1999 2411

2000 2768

2001 2595

2002 2779

2003 2450Apparatus Use White Paper 08-10-04.doc 8/10/2004 18 

### Acknowledgements

I wish to thank all the fire service personnel who assisted in this project. Hundreds of Chiefs responded to our survey, or gave permission to inspect their apparatus. The gathering of this data involved many visits to fire stations where I was allowed to take their apparatus out of service while the data was collected. I have never visited a fire station where I was not welcomed and treated with curtsey. Perhaps a friendly attitude is a natural characteristic of those who put their life on the line to protect others. Whatever the reason, I find it a pleasure playing a small part in a profession filled with such kind people

. – Roger Lackore, Pierce Manufacturing

Special thanks to the following departments for their help during the engine analysis phase of the project:

Anderson, Indiana Appleton, Wisconsin Big Bend Vernon, Big Bend, Wisconsin Black River Falls, Wisconsin Central County Rescue, Missouri Chicago, Illinois Cleveland Township, Indiana Countryside, Illinois Delefield, Wisconsin Denver, Colorado DePere, Wisconsin Dover, Pennsylvania Eagle River FPD, Colorado East Troy, Wisconsin Fivepointville, Pennsyvania Freedom, Wisconsin Ft Atkinson, Wisconsin Glenwood Springs, Colorado Greenville, Wisconsin Hand In Hand, Pennsyvania Harris Township, Indiana Howard, Wisconsin LaGrange, Wisconsin Lakeville, Indiana Liberty, Pennsylvania Lincoln, Pennsylvania Lincolnshire, Illinois Los Angeles, California Madison, Wisconsin Marshall, Wisconsin Mesa, Arizona Milwaukee, Wisconsin Mishawaka, Indiana Monona, Wisconsin Mount Pleasant, Wisconsin Mukwonago, Wisconsin North Shore, Wisconsin Plymouth, Indiana Portage Township, Indiana Racine, Wisconsin Riverside County, California Seymour, Wisconsin Sheboygan, Wisconsin South Milwaukee, Wisconsin Sugarland, Texas Tualitan Valley, Washington Union Township, Indiana Vail, Colorado Warran Township, Indiana West Grove, Pennsylvania Willowstreet, Pennsylvania