When firefighters think about PPE, flames and extreme heat naturally come to mind.
But today, two of the most dangerous threats on the fireground are heat stress and exposure to harmful fireground contaminants. Both contribute to long-term health risks and LODDs—and both are often overlooked until it’s too late.
The challenge has always been balance. More barriers can block contaminants, but they often trap heat. More turnout breathability can reduce heat stress, but firefighters have rightly questioned whether that compromises protection.
Independent testing now confirms that AeroFlex turnout gear from Fire-Dex delivers both—without compromise.
Fireground smoke is packed with fine particulate matter produced by burning synthetic materials. These particulates are small enough to penetrate traditional PPE, especially at common interface areas like the coat-pant and pant-boot. Research has shown that skin exposure to these particulates places firefighters at risk.
That’s led many to opt for extra layers or liners in their turnouts that can help block contaminants—but often at a cost. More material means more trapped heat which can lead to higher core temperatures, faster fatigue, and increased risk of heat stress.
Firefighters shouldn’t have to choose between immediate performance and long-term health.
To answer the important question, “does AeroFlex actually block particulates?” Fire-Dex partnered with RTI International, an independent nonprofit research institute with expertise in particulate exposure testing. The results of this testing were verified by UL, adding an additional layer of third-party validation.
RTI conducted controlled testing using procedures similar to the well-known FAST study. A fully geared firefighter participant entered a chamber filled with a precisely measured concentration of fine particulate matter and performed real-world fireground movements such as squatting, lifting arms, and walking.
In the testing verified by UL, the tester wore head-to-toe PPE with a specific setup:
After each test cycle, the participant followed a strict doffing procedure, then researchers carefully analyzed the amount of particulate matter found on the firefighter’s skin. The more particulates detected, the more that had penetrated the protective ensemble.
The findings were clear and significant.
No additional particulate intrusion occurred.
UL-verified results showed that complete particulate blocking was achieved without adding extra material to the coat. This is due to the sealing effect created by the SCBA straps, which tighten the turnout coat and prevent particulates from entering the pant-to-coat interface.
In short:
This testing confirms that AeroFlex blocks dangerous fireground contaminants without requiring extra material in the coat.
This matters because heat stress remains one of the leading threats to firefighter safety. Overexertion and elevated core temperatures contribute directly to medical emergencies and reduced on-scene performance.
Adding more layers to solve one problem often creates another. AeroFlex approaches the problem differently: block particulates where needed, without overbuilding the entire garment.
By avoiding unnecessary material in the coat, AeroFlex reduces the risk of added heat stress without compromising particulate protection.
AeroFlex uses a combination of strategically placed breathable zones (VaporLite panels made with extremely breathable materials that supercharge the vents) and one-way ventilation (fitted with particulate barriers to let out hot air without letting contaminants in) to reduce heat retention. These features allow hot air and sweat vapor to escape while preventing flames, heat, and particulates from entering.
The key point isn’t the technology itself—it’s the outcome: lower core temperature rise and reduced fatigue, without sacrificing protection. Independent lab testing has already confirmed that AeroFlex improves thermal performance while maintaining integrity in flame exposure.
Just as important, this recent particulate testing confirms those same vents do not allow contaminants into the garment.
AeroFlex turnout gear represents a proven evolution in firefighter PPE.
Independent testing—verified by UL—shows that AeroFlex:
Firefighters don’t lose protection to gain comfort and they don’t gain protection at the cost of performance.
With AeroFlex, departments can protect their people from both immediate and long-term threats on the fireground. AeroFlex turnouts provide proven protection—without compromise.