Marblehead fire chief keeps watch as truck delays, costs increase nationwide

Fire Chief Jason Gilliland is keeping a close eye on a nationwide apparatus shortage that has stretched fire truck delivery times to four years and driven costs from $1.5 million to over $2 million, forcing departments to extend the service life of aging equipment.

The shortage stems from post-pandemic supply chain issues, labor shortages and rising demand across the fire service industry. Departments like Marblehead are extending vehicle lifespans, which drives up maintenance costs and increases risks to emergency response readiness.

“It’s crazy right now,” Gilliland said. “Everything’s going up. It’s costly.”

Calls keep coming 

From 2006 to 2024, the Marblehead Fire Department responded to 51,678 emergency calls — an average of 2,720 per year. Call volume rose to a record 3,605 in 2024. Medical emergencies now dominate responses, with 1,595 EMS incidents in 2024, up more than 35% from 1,170 in 2009.

The rising demand for emergency services comes as fire apparatus manufacturers face unprecedented delays. Pierce Manufacturing, Marblehead’s preferred vendor, currently has a 36- to 48-month backlog for new vehicles.

Gilliland prefers Pierce as a single-source manufacturer, citing operational advantages over competitors who assemble trucks using parts from multiple suppliers.

“So KME (fire truck company), they build a fire truck, and they’ll buy a starter from AC Delco, and another piece from somewhere else, where Pierce manufactures everything right there on site,” he said. “Everything they make is theirs, so I’m not dealing with a bunch of stuff.”

Costs balloon

Marblehead has invested some $2.5 million in apparatus-related capital over the past two decades. Major equipment purchases include a 2004 Pierce Dash pumper delivered in 2006 for $384,724, a 2013 ladder truck costing between $1 million and $1.2 million, a 2017 Pierce Enforcer pumper for $628,219, and a 2021 pumper approved but not delivered until Nov. 30, 2022 for $713,709.

Zzz The department spent $199,197 in 2023 to rehabilitate the 2006 engine’s frame and mechanical systems, extending its service life by an estimated 10 years. The 2006 truck now serves as a reserve engine, deployed only during major events or when front-line apparatus require repairs.

Town planning has shifted from 10-year replacement cycles to funding horizons of five to six years due to delivery’s delays. To stay on schedule, Gilliland said he will likely need to request ladder truck replacement funding in 2026, with expected delivery in 2030.

The regional impact extends beyond Marblehead. Topsfield Fire Chief Jen Collins-Brown, president of the Essex County Fire Chief Association, faces similar challenges.

“My town is waiting for an ambulance and an engine,” Collins-Brown said. “The engine is at least another three years out.”

Collins-Brown leads regional advocacy efforts addressing what she describes as the fire service’s most pressing challenges.

“It’s a very prominent problem in all emergency services right now,” she said. “Cancer, mental health, staffing and equipment are the primary issues we’re facing as a profession.”

Big pond, fewer fish

Industry consolidation has contributed to price inflation and supply constraints. Private equity group American Industrial Partners acquired multiple manufacturers and consolidated them under REV Group, which the International Fire & Safety Journal reports now controls 33% of the market with a $4.2 billion backlog. Market share of independent fire truck builders dropped from 85% in 2006 to 20% in 2023.

The consolidation’s financial impact is stark. In 2021, an engine one pumper cost $650,000. By 2024, the same model will exceed $1 million. Current ballpark pricing shows custom pumpers range from $850,000 to $900,000, while custom ladder trucks cost approximately $2.1 million.

Floating price contracts allow manufacturers to raise costs years after initial agreements, adding budget uncertainty for municipal planners. Key component shortages include microchips, wiring harnesses, steel and LED light components.

Marblehead participates in mutual aid agreements with nearby communities like Salem and Beverly. These mutual aid calls add wear and stress to aging vehicles already facing extended service lives.

Maintaining service readiness depends heavily on parts availability, not just vehicle replacements. When apparatus breaks down, departments cannot wait for parts to ship from manufacturers’ facilities.

“When one of our apparatuses goes down, we can’t wait for a part to be shipped from Appleton, Wisconsin,” Gilliland said, referring to Pierce’s headquarters location.

Modern fire apparatus incorporates complex technologies including electric drivetrains, hydraulic systems and advanced electronics that require what is called specialized original equipment manufacturer parts unavailable at local automotive stores. Parts availability challenges compound vehicle downtime, reducing overall fleet readiness.

Capitol Hill takes notice

Federal officials have taken notice. Sen. Elizabeth Warren launched a bipartisan investigation in April into industry consolidation. The Federal Trade Commission and Senate findings revealed anti-competitive behavior, plant closures and restricted supply chains

“While CEOs and shareholders pad their pockets,” she wrote in a letter to the International Association of Fire Fighters, “consolidation in the industry impedes firefighters’ ability to do their jobs safely and effectively, squeezes fire departments’ budgets and forces taxpayers to bear the consequences.”

Despite the challenges, Gilliland remains focused on maintaining emergency response capabilities. The department expects to evaluate ladder truck replacement needs within the next year, though funding decisions will depend on the vehicle’s condition and town finances.

“I will never ask the town voters to support the purchase of new apparatus, if the town finances dictate otherwise,” he said.

The department maintains multiple reserve vehicles to ensure continuous coverage, including a 1994 Spartan Pumper purchased for $1 from Allegiance Fire Apparatus to serve as backup during the 2023 engine rehabilitation.

For now, Marblehead continues meeting all emergency calls despite equipment challenges and rising costs.

“It’s costly,” Gilliland said, “but we’re still meeting every call.”‘

John Bender and Pete Sullivan are Marblehead Current senior project interns.