Fire trucks production in US - Pierce Manufacturing
At fire truck plant
0:03 Fire Truck Metal Fabrication Process
Parts of a fire truck body on the Pierce Manufacturing assembly line is welded.The first step in fire truck manufacturing involves several metal fabrication processes. To start, sheet metal is cut into parts using a combination of lasers, turret punches and water jets; this includes cab and body components, sub-assemblies that go into the frame-up, such as bumpers and cross members, and cab doors and sidewalls, to name a few.
Once the flat sheet metal cut-outs are completed, parts are formed according to the engineering specifications using a combination of machinery including press brakes and fully automated world-class panel bending equipment.
Once metal fabrication is complete, a fire truck begins to take shape in welding operations.

00:36 Welding Operations
Once the parts for an assembly or sub-assembly are fabricated, the welding process begins. The video below walks through the metal fabrication and welding processes in one of Pierce’s manufacturing facilities.
Pierce has several departments in the welding operation; each is tasked with a different type of part or process step. From fire truck cabs to bodies to pump structures and other subassemblies, experienced welders create customized fire truck components with precision. All welders have received the same Pierce Custom Welding Certification. This ensures quality and superior craftsmanship for all apparatus orders.

01:14 Painting Process
The fire truck painting process follows these important steps:
Sanding and surface preparation.
Chemical cleaning and treatment to remove any grease, oil or other materials.
Primer surface coat application.
Hand-sanding with fine-grit sandpaper to create a smooth surface.
Sealer primer coat to improve adhesion of base and top-coat paint.
Basecoat paint application.
Clear coat paint application to help protect the surface and increase surface longevity, durability and the glossy look.

02:53 Frame-Up, Cab and Chassis Assembly
A fire truck compartment with an open panel door is sanded to a smooth finish.During the chassis assembly phase of the fire truck build, a number of items come together in parallel, including the sub-assemblies within the frame rails, wheels and axles, engine and transmission, and the cab.
Frame-up is the process of bringing together the frame rails into a squaring fixture, installing cross members, mounting axles and suspension components, and outfitting the wheels and tires.
Once frame-up is completed, the frame assembly continues into the chassis assembly process. Harnesses are put in place and air lines and sub-assemblies for the air system are installed. The engine, radiator, cooling package and exhaust systems are also installed. As these elements come together, the cab is assembled and is almost ready to be mounted.
Cab assembly is unique because it starts from the outside and moves in. The first steps involve the assembly of the instrument panel, doors, electrical systems, insulation, walls and headliners. Once walls and headliners are installed, the interior assembly begins. Seats and EMS compartments are installed, steering systems are added and interior components begin to look more like a fire truck.
Through each stage of the assembly processes, there are quality checks along the way. This ensures that each stage of assembly is up to Pierce’s high-quality standards.
When the frame-up, chassis and cab assemblies are complete, the fire truck is almost ready for final assembly. The chassis is filled with fluids and the engine is started for the first time. At this point, the electrical system programs are loaded, and the axle steering and suspension parameters are set, along with many other final adjustments.
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04:23 Final Assembly
A Pierce employee lays beneath the fire truck cab and completes tasks associated with the final assembly process. In this step, final assembly and interior finishing begins. As the cab and chassis come together, the painted body, or back end of the fire truck, gets assembled as well. This includes the installation of harnesses, compartments, lights and doors.
Once the painted body is assembled, it is mounted on the chassis along with the water tank. From here, all of the electrical and mechanical components are installed, including cord reels, breaker boxes, body doors and any additional shelves, trays and lights.
As the truck comes together, the electrical wiring systems are connected, as are the plumbing systems. If the truck requires an aerial device, the assembly of the necessary components is also taking place at this time. As the fire truck body and aerial device are finalized, assembly and testing of those components begin.

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