Sales of pancakes and concert tickets help, but aren't enough, for smaller Iowa communities buying increasingly expensive new fire engines.
That's because fire vehicles, that not so long ago cost hundreds of thousands of dollars, now cost millions, leaving fire departments big and small having to get creative — with fundraisers for replacements or for spare parts to keep existing equipment running.
Delivery of vehicles and gear departments may have formerly waited a year or less to receive may now take double or triple that, or longer. And the rising costs and production times have prompted the nation's largest firefighters' labor union to call the situation a public safety hazard and demand a federal probe into the fire vehicle manufacturing industry.
The Ely Fire Department, which serves a city of about 2,300 people and two townships in Linn County, ordered a new fire engine last year before it had the funding in place, said Ely City Council member Mark Becicka, one of the all-volunteer department's firefighters and emergency medical technicians.
Becicka said the department went ahead with the replacement of the more than 27-year-old Engine 294 because a delay would have made the replacement more difficult and costlier.
"We really have to balance risk versus necessity," he said.
The department's call volumes are increasing as the reliability of its current engine decreases. More small parts are wearing out, including switches for emergency lights, a tachometer that's missing a digit, leaks in a backup air compressor and a water system hose, and knobs on the water pump control panel that don't lock into place.
"We knew we couldn't afford to wait," Becicka said.
But the $950,000 fundraising goal to pay for the new engine is still far more than the department's about $150,000 annual budget, he said. Its nonprofit arm has raised about $150,000 since a kickoff event in August 2024, with an annual July 4 pancake breakfast and a Sept. 26 concert expected to bring in more.
“We just have to be more creative and patient," Becicka said.
The department has three years before it receives the new engine, at which time it would need to take out a loan to cover any remaining gap between the cost and what's been raised, he said.
Meanwhile, in Des Moines, almost 10 times the size of Ely, something has to give. The fire department needs more funding or vehicles' lifespans will have to be extended. And "we haven’t acquired more funding," said city Fire Marshal Jonathan Lund.
Edward Kelly, president of the International Association of Fire Fighters labor union, said fire vehicles' doubled prices and multi-year order backlogs are a "critical hazard in public safety," citing reports that dozens of broken-down fire trucks were unavailable during the deadly Los Angeles wildfires earlier this year.
Metro cities are paying millions of dollars but waiting years for fire trucks
Emergency vehicles don't last forever.
"Ladder trucks and engines typically last 15 to 20 years before the cost of repairs becomes too high compared to their value," said a news release about the purchase of a new ladder truck for the Johnston-Grimes Metropolitan Fire District.
The truck with a 100-foot ladder, hose and 300-gallon water tank and pump replaced a ladder truck originally purchased in 2004 for $750,000.
The new one cost more than double that — $1.7 million — and did not arrive until almost three years after it was ordered in March 2022.
Johnston-Grimes' new ladder truck is "essential for ensuring the effectiveness and safety of fire operations," the release said.
Ankeny City Council documents describe a new 107-foot ladder truck the council approved purchasing in January as the primary fire response vehicle at Ankeny Fire Department's Fire Station No. 1.
The new truck will replace a 2011 ladder truck that has had a "less-than-ideal reliability record" since it was damaged in a 2018 storm, according to a council document.
The cost: almost $2.4 million, and the new ladder truck is not expected to be ready for delivery until around 2029.
On June 9, the Des Moines City Council approved the purchase of two fire engines and a 100-foot ladder truck to replace older trucks that will be placed in reserve. The fire department's current 100-foot reserve ladder truck is 24 years old. A 2018 frontline ladder truck is ready to go into reserve, along with engines from 2008 and 2017.
"When replacing fleet vehicles, we prioritize replacement of the units with the most wear and tear, engine hours, and miles to ensure the fleet is as healthy as possible," Lund wrote in an email to the Des Moines Register.
The new engines cost nearly $1.4 million each, and the ladder truck $2.3 million. Delivery of the engines is expected after July 1, 2027, and the ladder truck's delivery is slated for at least a year later.
The prices metro cities are paying fall within the current average range for engines and ladder trucks, according to a fire vehicle manufacturing industry spokesperson: $1.2 million to $1.5 million for custom-made pumper trucks, the typical fire engines, and $1.3 million to $2 million or more for aerials, or ladder trucks, depending on the type.
Gary Pacilio, speaking for the Fire Apparatus Manufacturers Association, said the price range for a pumper about a decade ago was $600,000 to $800,000, and for an aerial, $800,000 to $1.2 million.
That change goes well beyond the rate of inflation in consumer prices alone, according to the U.S. Bureau of Labor Statistics. A $600,000 purchase in 2015 would be the equivalent of about $825,000 in 2025, for example. But that $825,000 is about $400,000 or more short of the price for a new pumper.
Why did fire vehicles become so much more expensive?
Pacilio is the executive vice president of operations for Fouts Bros. Inc., a Georgia-based manufacturer of fire apparatus including pumpers, tankers and rescue vehicles. And he is a past president of the Fire Apparatus Manufacturers Association, which represents companies that produce emergency vehicles or their components in the U.S. and Canada.
A surge in demand driven by federal money distributed to local governments during the COVID-19 pandemic exceeded manufacturers' capacities in North America. That combined with the pandemic's disruptions to parts supply chains and labor resulted in an order backlog the industry is still working through, Pacilio said.
In May, the International Association of Fire Fighters and American Economic Liberties Project, an anti-monopoly group, requested the U.S. Department of Justice and Federal Trade Commission launch an antitrust investigation into the fire vehicle manufacturing industry over concerns including consolidation, with three companies controlling about two-thirds of the market.
But Pacilio said it's misleading to consider the effects of consolidation on the industry as the only reason for inflation.
“We’re all in this together. We’re all trying to find the right path. But this influx of orders is unprecedented,” he said.
Manufacturers are planning for additional production capacity, he said, but obtaining enough skilled workers continues to be a struggle.
And he said the industry's generations-long focus on custom-made fire vehicles that are unique to each fire department — with custom chassis and positioning of storage compartments and water pump control panels, for example — adds complexity that drives up costs and production lead times.
The more complex, he said, "the harder these are to build, the more hours it requires to build them, the fewer you can get out."
Big advantages for bigger departments
Des Moines' size means it's economical to have an in-house repair garage. A superintendent and four mechanics staff the shop on Dean Avenue and they can be called out after hours and on weekends to address critical repair needs at emergency scenes.
“Our goal is to keep the cost down,” said Jim Clark, the garage's superintendent.
Des Moines' vehicles ideally see 10 years of frontline service and then spend at least five years in reserve, where, Lund said, they can be pulled back into active service when frontline units are down for repairs, or when they're needed at special events and during exceptionally busy times.
Even wrecked vehicles can have a long afterlife. There’s a room at the garage full of shelves stocked with various parts recovered from vehicles over time, including whole motors and exhaust systems.
It's not just fire engines and ladder trucks that have gotten more expensive and take longer to receive once ordered, but also ambulances and personal protective equipment.
The Ankeny Fire Department's budget presentation in January included a request for an additional $20,000 in the safety equipment budget because of "unprecedented price increases."
Des Moines' garage also can repair firefighters' respirator masks, the tools used to extricate victims from wrecked cars, and often respirator packs. A third party services the tanks that supply firefighters' air, but Clark said “99% of the time, we can repair the pack" that holds an air tank.
Des Moines also can spend more now to avoid problems later. Lund said while the city previously ordered one or two ambulances a year that would arrive in 12 to 14 months or less, because of 36-month lead times that force the extension of frontline vehicles' service, it ordered seven new ambulances in March.
Can Ely keep up?
In-house repair garages of Des Moines' scale and ordering in bulk in advance are not feasible options for many other departments, especially small ones.
In Ely, Becicka said, that capability gap highlights the fact that smaller departments don’t have the same access to funding but face the same issues of rising costs and production lead times.
The department there is reaching out to the local community and businesses for donations and applying for grants to assist with the purchase of Engine 294.
“We couldn’t do it without the community we have around us," he said, adding that it is a source of pride that the community is directly supporting the new engine through donations, not just through their taxes.
"It's helping us help them," he said.
Want to help? The Ely Fire Department's fundraising website is available at elyfire.com/meetfutureely294, and event information is available at facebook.com/elyfiredepartment/events.
Reuters contributed to this article.
Phillip Sitter covers the suburbs for the Des Moines Register. Phillip can be reached via email at [email protected]. Find outmore about him online in the Register's staff directory.