Burn Building Design: Which Lasts Longer, Steel or Concrete?

Planning a new fire training building is the ultimate long-term investment for a fire department. The material you choose today can affect the building's performance for decades.

Steel and concrete are both used in burn building design, but they don't perform the same under live-fire training conditions. While concrete is often viewed as the more durable option, that isn't always the case once repeated fire training enters the equation.

Before moving forward with a new burn building, it's worth your budgeting dollars to take a close look at how each material performs over the long term.

What Makes Burn Building Design Different?

Burn buildings face conditions that most commercial structures never experience. They're intentionally subjected to repeated abuse throughout their service life.

That environment includes:

• Heating and cooling: Live-fire training exposes the structure to repeated thermal cycles throughout its service life.
• Water exposure: Fire suppression and post-training cleanup introduce moisture after every training evolution.
• Long service life: Many burn buildings remain in service for decades. The material selected today can influence maintenance and repairs for years to come.

Construction is only one part of the investment. As a burn building ages, maintenance and repair costs become part of the overall cost of ownership.

How Does Cost Compare?

Cost is often the first question departments ask when planning a new burn building design. That makes sense. The building’s performance over time can also affect what it costs to own.

Steel Burn Buildings

Steel burn buildings generally cost less to construct than comparable concrete structures. In many cases, departments that initially consider concrete choose steel after comparing project costs.

A lower up-front investment can also leave more room in the budget for training props, accessories, or future expansion.

For departments working with a fixed budget, those savings can create more flexibility during the planning process. Rather than scaling back the project, they may have the opportunity to invest in additional training features that support both current and future training needs.

Concrete Burn Buildings

Concrete burn buildings generally cost about 40% more than comparable steel structures. For some departments, that difference alone can influence which type of facility is financially feasible.

Concrete has a long history in building construction, so it's understandable why many departments consider it early in the planning process. A burn building, however, operates under different conditions than most commercial structures.

Remember, the purchase price is only the beginning.

How Do Steel and Concrete Respond to Live-Fire Training?

Concrete has long been associated with strength and durability. In a burn building, repeated live-fire training introduces conditions that can affect steel and concrete in very different ways.

Concrete and masonry:

• Absorb moisture between training exercises.
• Experience internal steam pressure once temperatures exceed 212°F.
• Undergo repeated stress as that cycle continues over years of training.
• May require additional maintenance as the structure ages.

Steel:

• Does not absorb moisture.
• Avoids the internal steam cycle.
• Can be protected from oxidation with a hot-dip galvanized coating.
• Has a proven track record of long-term performance.

Moisture is one of the biggest differences between the two materials. In an unconditioned burn building, concrete and masonry can retain water used during exercises. As temperatures rise, that moisture turns to steam and places additional stress on the material from within.

Steel doesn't absorb moisture, but it can oxidize if left unprotected. That's why any training tower supplier you work with should hot-dip galvanize every structural steel component. The galvanized coating creates a barrier between the steel and oxygen, helping extend the life of the structure.

The first metal burn tower is still fully operational after 46 years. (We know because we built it.) That longevity demonstrates what properly protected steel can deliver in a live-fire training environment.

What Should You Expect Over the Life of a Burn Building?

A burn building is expected to support firefighter training for decades. As you compare steel and concrete, think beyond construction and consider what ownership may look like years down the road.

Questions worth asking include:

• How much maintenance will the building require over the next 20 to 40 years?
• How could future repairs affect training schedules?
• Which material is better suited for repeated live-fire training?
• What will it cost to keep the facility in service over its lifetime?
• Will the building continue to meet our department's training needs as they evolve?
  
  

Choosing the Right Burn Building Design

Every department approaches burn building design with different priorities. The right choice depends on how the facility will be used and what you expect from it over the coming decades.

By understanding how steel and concrete perform in a live-fire environment, you can move forward with greater confidence and choose a burn building design that fits your department's long-term plans.

Keep Learning

Every project starts with good information. Visit our blog for more articles on burn building design and training facilities.