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The Lifecycle of AFFF From Production to Disposal

Following aqueous film-forming foam (AFFF) from the manufacturing process to its sale and use reveals the number of people at risk of exposure throughout its life cycle. Everyone in this chain must follow best practices to limit contact with the foam and protect others down the line from unsafe handling. Major flaws in safety measures in the early production stages have only been magnified by relaxed protection protocols in other phases of the life cycle.

Production of AFFF

The chemicals in AFFF do not exist naturally in the environment and cannot be grown or harvested. These substances are produced through synthesized methods that introduce fluorine atoms into carbon to create a new compound. The surfactants are tested before they are ready for market. Limiting these tests to the performance of these substances was a huge misstep in the manufacturing cycle of AFFF.

Historically, 3M used a unique process to manufacture the components of the fluorosurfactants in its AFFF. The composition produced was found to degrade into perfluorooctanesulfonic acid (PFOS), among the most hazardous ‘forever’ chemicals. This electrochemical fluorination process ceased after 2001, but countless manufacturing employees and firefighters were already exposed to PFOS. Though the primary foam in use today was produced using “safer” methods and contains short-chain PFAS rather than long-chain PFOS, all of these chemicals impact biological functions that increase the risk of cancers and other diseases due to AFFF exposure.

Procuring AFFF

Once aqueous firefighting foam met performance requirements, it was put on the market for commercial sale. While the Department of Defense now restricts the purchase of AFFF, millions of gallons of this dangerous suppressant still exist in military hangers, on naval ships, at municipal fire stations, and at other emergency response facilities. Even if the foam isn’t purchased from the manufacturer, a firehouse can receive equipment and resources, including AFFF concentrate, from another fire station through a mutual aid contract.

A firehouse manager or commander purchasing or acquiring firefighting foam needs to research it thoroughly before settling on a solution. Questions to ask before procuring a firefighting foam include:

  • Is it for training, or for emergency response?
  • Do the likely fire hazards require AFFF or will an alternative provide safe results?
  • Is the suppression equipment compatible with the foam type?
  • Is a two-foam approach safer than using AFFF alone?
  • What is the life span of AFFF and how much will outlast our needs?

Management for AFFF Discharges 

Discharging AFFF is the most hazardous function during the life cycle of the foam. Data from the Environmental Protection Agency notes nearly 900 reported spills and releases of PFAS foam over the last 30 years. If concern over events from decades ago seems trivial, remember that these chemicals are persistent enough to outlast nearly any timeline.

Best practices should be established for any firehouse or military base using AFFF, to manage the effects of accidental releases and leaks. Protocols for preventing AFFF discharges should include:

  • Inspecting suppression equipment, hoses, and holding tanks for signs of wear and leakage
  • Prompt replacement of any malfunctioning equipment
  • Training for proper notification procedures when a leak is suspected
  • Enforcement of wearing personal protective equipment to prevent exposure

Ending the AFFF Life Cycle

Because AFFF stays in human tissue and the environment long after exposure, its life cycle doesn’t have a clear end. The only way to prevent direct exposure for future generations is to switch to alternative firefighting foams. Many acceptable substitutes are available for commercial use, and the performance of these is expected only to improve as the manufacturers home in on safe, high-quality formulations.

While the efficacy of firefighting foams produced in the U.S. has always been strictly regulated, we can only hope that the safety of these chemicals will now be bound to similar standards. Holding legacy manufacturers accountable for the damages done is the first step to change and recovery for the countless firefighters and families affected by AFFF.