A U.S. study has found brominated flame retardants in firefighter turnout gear, including in newer models marketed as PFAS-free. Published on December 16 in Environmental Science & Technology Letters, the research reports that some of these flame retardants appear at higher extractable levels than PFAS in certain gear layers, raising fresh questions about potential health risks to firefighters.
Firefighter turnout gear, essential for protection during emergencies, is typically made up of three layers: a flame-resistant outer shell, a middle moisture barrier that blocks germs while allowing airflow, and an inner thermal layer designed to help regulate body temperature. According to Duke University, manufacturers apply chemical treatments to these textiles so they can meet safety standards developed by the National Fire Protection Association.
For several years, firefighters and researchers have raised concerns about per- and polyfluoroalkyl substances (PFAS), which are used in turnout gear to repel oil and water and can contribute to flame resistance. Numerous human and animal studies have linked PFAS exposure to health problems, including certain cancers and thyroid disease. Multiple U.S. states have passed laws that will prohibit the purchase of PFAS-treated turnout gear starting in 2027, prompting manufacturers to shift toward alternative chemistries.
The new study, led by Heather Stapleton of Duke University's Nicholas School of the Environment and published December 16 in the journal Environmental Science & Technology Letters, is described by Duke and ScienceDaily as the first U.S. research to formally document the use of brominated flame retardants in firefighter turnout gear.
The research team, which included scientists from Duke University and North Carolina State University's Wilson College of Textiles, analyzed nine sets of used turnout gear manufactured between 2013 and 2020 and three sets produced in 2024 that were marketed as non-PFAS treated. Using two analytical techniques, they tested each of the three layers of the gear for both PFAS and brominated flame retardants. This allowed them to measure the total amount of chemicals present and the fraction that could be extracted from the textiles, an indication of what might transfer during use through skin contact or inhalation.
PFAS were detected in all turnout gear manufactured between 2013 and 2020. In contrast, gear made in 2024 showed only low or non-detectable extractable PFAS levels, which the authors say indicates the garments had not been intentionally treated with PFAS, consistent with manufacturer claims. Small amounts that were found are thought to have come from environmental contamination rather than the manufacturing process.
Every set of gear in the study also contained brominated flame retardants, and the extractable levels of these compounds were generally higher than those measured for PFAS. The highest extractable concentrations of brominated flame retardants were reported in the 2024 gear marketed as non-PFAS treated, particularly in the moisture barrier layer. The authors say this pattern suggests that some manufacturers may have added brominated flame retardants to help the gear meet flammability requirements as PFAS were phased out from that layer.
Among the brominated flame retardants identified, decabromodiphenyl ethane (DBDPE) occurred at the highest extractable levels. The study notes that no U.S. research has directly examined health effects from DBDPE exposure in firefighters, but cites a 2019 study of workers at a chemical manufacturing plant in China that 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, according to accounts from Duke University and outlets summarizing the study. She added that the compound has similar properties to decaBDE, a brominated flame retardant that has been largely phased out globally due to toxicity concerns.
For most gear manufactured between 2013 and 2020, the outer shell contained higher extractable concentrations of brominated flame retardants than the moisture barrier or inner lining. Stapleton said this pattern likely reflects accumulation from smoke and soot encountered during fires: when building materials burn, they can release brominated flame retardants into the air that adhere to gear and do not wash out easily.
At the same time, the presence of brominated flame retardants in the internal layers of some older sets suggests that certain manufacturers had been incorporating these chemicals into turnout gear treatments well before PFAS began to be phased out, the authors report.
Brominated flame retardants as a class have been associated in prior research with cancer, thyroid disease and neurodevelopmental or developmental problems. However, the Duke-led team emphasizes that firefighters' specific exposure levels to the substances identified in this study and any resulting health effects are not yet established and will require further investigation.
The findings nonetheless have practical implications for departments weighing gear purchases. "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 NC State's Wilson College of Textiles who studies trade-offs in gear performance, in comments released by Duke.
Stapleton said some gear suppliers have now begun offering garments that avoid both PFAS and brominated flame retardants. She and her coauthors have called for greater transparency from manufacturers about the chemical treatments used in turnout gear so that departments and firefighters can make more informed decisions. "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," she said in Duke's summary of the research.
The study was conducted in collaboration with the International Association of Fire Fighters and is part of a broader effort by the Duke team to understand and reduce chemical risks facing firefighters.
