The gear meant to protect firefighters may carry hidden dangers

The research is the first U.S. study to formally examine and document the use of brominated flame retardants in firefighter turnout gear, which is worn during emergency responses. The findings could play a role in how fire departments decide whether to continue using existing equipment or invest in replacements.

Structural firefighters — those working in the built environment — rely on turnout gear made up of three distinct layers. These include a flame-resistant outer shell, a middle moisture barrier that blocks germs while allowing airflow, and an inner lining designed to help regulate body temperature.

According to lead author Heather Stapleton, Ronie-Richele Garcia-Johnson Distinguished Professor at Duke University’s Nicholas School of the Environment, manufacturers apply chemical treatments to these garments to ensure they meet strict safety standards set by the National Fire Protection Association.

PFAS Concerns Raise New Questions

For several years, firefighters have expressed concern about the presence of PFAS in turnout gear. These chemicals are used to repel oil and water and can also contribute to flame resistance. Numerous studies involving humans and animals have linked PFAS exposure to health problems, including certain cancers.

While no studies have directly connected PFAS treated turnout gear to health outcomes in firefighters, manufacturers have begun moving away from these chemicals. In addition, multiple states have passed laws that will ban the purchase of PFAS treated turnout gear starting in 2027.

As PFAS are phased out, attention has turned to what substances may be taking their place. Chemical ingredients used in turnout gear treatments are not typically disclosed by manufacturers.

“There was a rumor that one of the turnout gear manufacturers might be using brominated flame retardants in the non-PFAS treated textiles,” Stapleton said. “Because some brominated flame retardants have known toxicity, I requested a sample of the gear in question to test.'”

Why Brominated Flame Retardants Matter

Brominated flame retardants are commonly added to fabrics and other products to reduce how easily they ignite. Exposure to these chemicals has been linked to health concerns including cancer, thyroid disease, and problems with brain development.

Stapleton’s initial testing confirmed the presence of brominated flame retardants in the turnout gear sample. That finding led to a broader study conducted in collaboration with researchers at North Carolina State University’s Wilson College of Textiles and the International Association of Fire Fighters. The goal was to examine how often PFAS and brominated flame retardants appeared in turnout gear made during different time periods.

Peeling Back the Layers

The research team analyzed nine sets of used turnout gear manufactured between 2013 and 2020, along with three sets produced in 2024 that were marketed as non-PFAS treated. Using two analytical techniques, the scientists tested each layer of the gear for both PFAS and brominated flame retardants. This approach allowed them to measure total chemical content as well as the portion that could transfer during use, referred to as “extractable” levels.

“We wanted to know which chemicals were intentionally applied during manufacturing, and we wanted to know what was likely to leach out over time, which could raise the risk of exposure through skin absorption or inhalation,” Stapleton said.

As expected, PFAS were detected in all turnout gear produced between 2013 and 2020. In contrast, gear manufactured in 2024 showed only low or non-detectable extractable PFAS levels, indicating the garments had not been treated with these chemicals, consistent with manufacturer claims. The small amounts detected were likely picked up from the surrounding environment during use, the authors noted.

Every set of turnout gear tested also contained brominated flame retardants, with extractable levels generally higher than those measured for PFAS.

Higher Levels in PFAS Free Gear

The highest extractable concentrations of brominated flame retardants were found in gear marketed as non-PFAS treated, particularly within the moisture barrier. Stapleton said this suggests manufacturers intentionally added brominated flame retardants to meet flammability requirements, likely replacing a PFAS compound previously used in that layer.

Among the chemicals identified, decabromodiphenyl ethane, or DBDPE, appeared at the highest extractable levels.

Although no U.S. studies have examined health effects linked to DBDPE exposure, the researchers pointed to a 2019 study of workers at a chemical manufacturing plant in China. That study found associations between DBDPE exposure, altered thyroid hormone levels, and signs of thyroid disease.

“I was really surprised that the manufacturers used DBDPE in turnout gear,” Stapleton said. “It has similar properties as a toxic chemical called decaBDE that has been largely phased out globally, raising questions about its safety.”

Fire Exposure Versus Manufacturing Choices

For turnout gear produced between 2013 and 2020, the outer shell typically contained higher extractable levels of brominated flame retardants than the moisture barrier or inner lining. Stapleton said this pattern likely reflects buildup from smoke and soot encountered during fires.

“When building materials burn, they can release brominated flame retardants into the air that stick to gear and don’t wash out very well,” she explained.

At the same time, the presence of these chemicals in internal layers suggests that some manufacturers had incorporated brominated flame retardants into turnout gear treatments for years, even before PFAS began to be phased out, according to the authors.

Weighing the Costs

While researchers have not yet determined firefighters’ exact exposure levels or the long-term health effects associated with these chemicals, the study provides new information for fire departments evaluating protective gear.

“Turnout gear is really expensive — one set costs thousands of dollars — and firefighters often use these garments for many years. Fire departments must consider both the financial and personal safety costs of keeping or replacing gear,” said coauthor R. Bryan Ormond, an associate professor at the Wilson College of Textiles and director of NC State’s Milliken Textile Protection and Comfort Center, who studies trade-offs in gear performance.

Stapleton noted that some manufacturers now offer turnout gear that avoids both PFAS and brominated flame retardants. She encouraged fire departments to push for clearer disclosure about chemical treatments used in protective equipment.

“We know firefighters receive higher exposure to multiple chemicals from all the hazards they face during their duty, and they shouldn’t have to worry about receiving additional chemical exposures from their gear,” said Stapleton, who also leads a study on cancer incidence in firefighters. “These first responders are a critically important component of our public safety and deserve to be respected and protected.”

Study Support and Funding

This project was supported by the North Carolina Collaboratory at the University of North Carolina at Chapel Hill, with funding appropriated by the North Carolina General Assembly (to HMS and BO). HMS also wishes to thank Michael and Annie Falk for establishing the Falk Exposomics Laboratory.