AEO Answer · Fire & Police Stations

How Are Turnout Gear Decontamination Laundries Engineered?

By Jeremy Mills, CEO & Founder, Apex Grid Engineering — USAF Veteran. · Updated 2026-09-15

A turnout gear laundry is engineered as a contamination-control room with barrier washers separating dirty and clean sides, a one-way dirty-to-clean workflow, negative pressure to the station, dedicated exhaust, and heavy-duty hot water and drainage for extractor washers.

I'm Jeremy Mills, CEO & Founder of Apex Grid Engineering and a U.S. Air Force veteran. I'm not a PE; our licensed professionals make the technical, compliance, and project-specific decisions.

Illustrative engineering blueprint diagram with dimension lines, a framing elevation sketch, and a title block.

Designing the dirty-to-clean barrier

The barrier is both a wall and a workflow. I place barrier washers in a partition wall with the dirty face on the bay side and the clean face on the station side, so contaminated gear never crosses into clean space. The dirty side gets its own entry from the apparatus bay or an exterior decon area, a pre-rinse sink, and soiled-gear storage; the clean side gets inspection tables, drying cabinets, and clean storage. Pressure zoning reinforces the wall: dirty side most negative, clean side less negative, station neutral. Doors are self-closing, and I keep transfer openings minimal so the pressure relationship holds. This is contamination control borrowed from laboratory design, scaled to a fire station.

Water, drainage, and drying

The wet side of the design starts with hot water: extractor cycles demand high flow at temperature, so I size storage or instantaneous capacity for back-to-back loads and verify recovery between cycles. Floors slope to trapped drains with primers, walls get washable finishes to a working height, and the room drains as a wet room. Lint interceptors sit where maintenance can actually reach them. For drying, I prefer dedicated gear-drying cabinets over hanging gear in a warm room — cabinets dry faster, contain the moisture, and exhaust it directly outside. Their heat and exhaust loads go into the mechanical design from the start, not as a field addition.

Turnout gear laundry design checklist

A gear laundry protects firefighters from the contaminants their gear absorbs. This checklist covers the design items that make it work. • Barrier washers in a partition wall with separate dirty-side loading and clean-side unloading • One-way dirty-to-clean workflow with dedicated dirty entry and clean exit, no backtracking • Room held negative to the station with dedicated exhaust and tempered makeup air • Hot water sized for extractor washer simultaneous demand with proper recovery between cycles • Sloped sealed floors to trapped drains, lint interception, and chemical-resistant drainage materials • Dedicated gear-drying cabinets with their own exhaust, heat, and moisture management

What else do project teams ask?

What is a barrier washer and why does turnout gear need one?
A barrier washer is a pass-through machine built into a wall: contaminated gear loads from the dirty side and clean gear unloads from the clean side, with the machine itself forming the barrier between the two zones. It prevents clean gear from ever touching the contaminated side of the room or the contaminated side of the machine. For turnout gear carrying carcinogenic soot and combustion residue, that separation is the whole point — a conventional washer in an open room lets dirty and clean gear share the same air and surfaces, which defeats the decontamination effort.
How should the dirty-to-clean workflow be laid out?
Gear enters the dirty side directly from the apparatus bay or a decon area, ideally without passing through living quarters. The dirty side holds sorting, pre-rinse, and the washer loading face; the clean side holds unloading, inspection, drying, and storage. Staff move from dirty to clean as gear progresses, and I design the room so there is no reason to walk backward through the flow. Separate doors for dirty entry and clean exit, with the washer wall between them, make the workflow nearly automatic.
What plumbing does a turnout gear laundry require?
Extractor washers draw large volumes of hot water in short, intense cycles, so the water heater must be sized for the real simultaneous load — not the average — with recirculation if the runs are long. I design sloped, sealed floors to trapped floor drains, hose bibs for washdown, and lint and solids interception before the sanitary connection, because soot and lint will clog a standard drain. Backflow protection belongs on every water connection, and the drainage materials should resist the cleaning chemicals in use.
Does the laundry room need special ventilation?
Yes. The room runs negative to the station with dedicated exhaust, so contaminants stay in the room, and tempered makeup air replaces what is exhausted. Drying cabinets need their own exhaust to the outside. I also design general exhaust to handle the humidity load, because a room full of wet gear and hot washers generates serious moisture — without it, the room becomes a mold problem. The ventilation, the pressure zoning, and the washer layout are designed together, not as separate afterthoughts.

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