Many fire departments are for the first time putting into service aerial devices, whether straight stick, platform or elevated stream. This may be the case because the area has grown to a point where an ISO assessment now requires an elevated master stream. Perhaps the agency’s response capability due to growth now requires an aerial device that either needs to be purchased and/or provided via mutual aid by neighboring departments.
Departments looking to purchase an aerial device for the first time should survey other departments’ needs and evaluate manufacturers before the specification process begins. This will be a valuable process that will result in information that can and should be used when the apparatus committee is forming the specifications.
Testing basics
The aerial device requires preventative maintenance on a regular basis that includes the visual, operational and load tests as outlined in the NFPA 1911: Standard for the Inspection, Maintenance, Testing and Retirement of In-Service Emergency Vehicles (2017 Edition)—Chapter 11: Inspection and Maintenance of Aerial Devices, and Chapter 22: Performance Testing of Aerial Devices.
One section of NFPA 1911 Chapter 22 that is often overlooked is Section 22.1.1. All inspections and tests specified in this standard, except those specifically designated as non-destructive tests (NDT), shall be conducted at the following times:
- At least annually
- After major repairs or overhaul
- Following the use of the aerial device when the aerial device could have been subjected to unusual operating conditions of stress or load
- When there is reason to believe that usage has exceeded the manufacturer’s recommended aerial device operating procedures
What this section requires is very simple: When the fire department goes out on a call with the aerial and subjects the device to unusual operating conditions to complete the call and returns to the station. Examples: The aerial was subjected to overheating when the device was elevated over a roof that collapsed and encased the aerial in fire. An ice buildup occurred while the aerial was elevated and flowing water in subzero weather. Or perhaps the aerial device was used to lift an object that was heavier than the manufacturer’s load rating.
The standard requires that the device be subjected to visual, operational and load testing if there is reason to believe that the device exceeded the tip load rating or the device was subjected to operational conditions that exceeded the design and engineering criteria. If you don’t know, call the manufacturer and determine what needs to be done. Also, make sure the manufacturer provides documentation on what needs to be done, the material required, and the process that should be performed. Make sure to include the documentation in the vehicle file when the work is completed.
Additionally, the standard is written in such a way that qualified personnel may perform these tests. The authority having jurisdiction (AHJ) determines who is qualified to perform these tests, which are only a part of the preventative maintenance program that this device should be subjected to during the course of its service life. The manufacturer has preventative maintenance programs in place that should be followed as a minimum by the department.
Note: If the fire department is going to purchase a “demonstrator” model, then the department should require that the aerial device be subjected to the aforementioned tests as a minimum. In addition, the full non-destructive tests should be performed before an aerial device is accepted by the fire department because that device has been on the road, and a fervent salesperson may have subjected the device to loads and conditions that exceed the operating parameters. Some sales personnel may have chosen to violate the parameters to show the department how “tough” the device can be.
Before and after arrival
When the device arrives at the department, it should be subjected to all the acceptance tests that are required in NFPA 1901: Standard for Automotive Fire Apparatus (2016 Edition). It is also important to have a qualified member of the department present whenever possible when these tests are being performed. Of course, preventative maintenance actually starts before the aerial device arrives at the department. Before acceptance by the department, the aerial device, including the chassis, should be subjected to visual, operational and load testing. If equipped with a pump, the pump should be tested at point of manufacture and again at point of delivery.
It was recently discovered that three pieces of apparatus built by the same manufacturer were delivered to different fire departments that never attempted an acceptance test per NFPA 1901, Section 16.13.1 Fire Pump System Certification, nor could the apparatus pass the annual fire pump service test as required in NFPA 1911 Chapter 21: Performance Testing of Fire Pumps, Wildland Fire Pumps, Ultra-High-Pressure Pumps. It should be noted that the departments were operating these pumps at 4,800-feet elevation. The pumps passed the certification at sea level, the elevation point of manufacture, and the departments accepted the apparatus based solely on the manufacturer certification tests. The pump manufacturer was called, and the department was informed that the wrong pumps were installed for that elevation. None of the departments had subjected any of the pumps to an acceptance test at point of delivery—at 4,800 feet of elevation—and also found out that the manufacturer and fire pump warranty had expired. The departments must now either spend thousands of dollars to upgrade the pumps or simply downgrade the fire pump rating.
As part of the preventative maintenance program, the chassis should be subjected to numerous inspections because that chassis is what transports and keeps the aerial device in the air and operating. The torque box, frame rails, frame cross-members and all supporting structures should undergo detailed inspections. Outriggers, ground plates and tires should all be inspected, and the drive line should go through a drive line analysis to determine if it has been installed properly. In addition, always pay attention to the Gross Vehicle Weight Rating (GVWR) and Gross Axle Weight Rating (GAWR) during the specification, construction and delivery of the apparatus, per NFPA 1901 Chapter 12.1: Carrying Capacity. This area is too often overlooked, meaning many fire apparatus are running our streets overweight. In addition, make sure to weigh all your apparatus annually per NFPA 1911 Chapter 19: Road Tests and Annual Weight Verification. As the fire service axiom goes, “Everything goes on, but nothing comes off.”
Don’t take it for granted that the aerial looks good visually and operates correctly because it may have several maintenance issues that have been overlooked or disregarded—issues that desperately need to be addressed. Ensure that the aerial device is properly maintained by trained and authorized personnel and that everything is documented.
Some time ago, a department had an aerial device fail during training. With the aerial elevated to 70 degrees and fully extended, the bolts for the wear pad shim, which had been sheared for some time, came loose and the shim fell 30 to 40 feet to the ground. Fortunately, no one was near that part of the truck, as that shim had enough energy to severely injure a firefighter.
The chief was outraged and said it was improperly engineered; however, the manufacture noted improper maintenance. During the mêlée, it was found that that the aerial device was improperly maintained, and when asked to produce the maintenance records, the department provided a single 8½ x 11 sheet of paper that included all the maintenance, repairs and annual testing over the past five years. There was only one line on that paper for the aerial device that noted, “Cleaned and re-lubed aerial.” With that, it was agreed that it was improper maintenance, and the manufacture provided the department with proper aerial maintenance and check forms for that model and also walked them through the proper steps. The manufacturer helped the department create maintenance and inspection schedules based on aerial hours. There was also an internal reorganization at the department. Documentation is as critical as doing the work itself.
In sum
Remember, if you take care of your aerial and the apparatus its “married” to, it will take care of you. Don’t let the lack of aerial maintenance, repairs and annual testing become a safety concern in your department.
