Firefighting Challenges at Crematories

With the national cremation rate increasing in North America to 50 percent or more in some states, fires at crematories are also increasing.

By Eric D. Ruggeri

Most fires associated with funeral homes and mortuaries are historically attributed to a crematory that is often installed within these facilities. With the national cremation rate increasing in North America to 50 percent or more in some states, fires at crematories are also increasing. Below are some challenges fire service responses at these unique facilities present. Most of this information has never been shared with the fire service (photo 1).

(1-2) Photos 1-2 by author; all others courtesy of the American Crematory Equipment Co.

Unless considered early in the initial design and construction phase of new funeral homes and mortuaries, cremation equipment is normally installed after the fact during facility upgrades, renovations, or changes of ownership. In some states, laws may allow crematories to operate only within or associated with cemeteries or funeral homes. Pennsylvania also allows it as a stand-alone operation within commercial/industrial districts and affiliated with a funeral home or cemetery. Depending on the state, crematories may serve the public directly or be limited to servicing only funeral homes, commonly referred to as trade-only or private crematories. Crematories can process either humans or animals, but never in the same equipment. Some funeral homes or mortuaries do operate separate cremation equipment or a facility for pets as a secondary source of income. You may have a crematory facility within your own district and not know it.

A cremator or retort, as it is called within the funeral profession, is a multichambered incinerator designed solely for the dignified final disposition by flame of human or animal remains in an appropriate container or casket. The interior chambers of cremators are manufactured with multiple layers of high-temperature insulation and lined with heavy-duty or super-duty refractory brick and concrete castings to aid in reaching and maintaining the necessary temperatures required during cremation. The best manufacturers construct their equipment with refractory material capable of enduring 3,000°F (photos 2, 3).

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The cremator itself and its fuel source are designed to engage and maintain combustion during cremation; the body of the deceased is the fuel. Larger decedents require less natural gas to cremate and typically burn hotter and faster. Although all cremation times vary, the deceased’s age, sex, and weight are the main factors used to carefully calculate the time it takes to complete a typical cremation. Cremation normally takes about two to three hours for a typical case under 250 pounds, or about 100 pounds per hour.

Most newer cremation equipment is available with automatic operating controls and sophisticated diagnostics that allow the operator to simply dial in the required data for the cremation case of the deceased for simple and error-free operation. Automatic shutdown and alarms notify the operator if the process begins to go contrary to normal operation. Older equipment without automatic controls requires the operator to preset the required air, combustion, timing, and fuel mixtures and then continually monitor and adjust the process as needed (photo 4).

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A single cremator typically costs between $120,000 and $140,000 for new entry-level equipment in North America. This does not include the extensive preconstruction permitting and planning that often require local zoning applications and variances before commencing installation. Local laws often limit where and when crematories can operate within a city. Cremators are typically preassembled at the factory; shipped on a flatbed tractor trailer; and installed on site using heavy equipment, including an industrial-capacity forklift and crane (photo 5).

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Today’s state-of-the-art cremation equipment is very fuel efficient and environmentally friendly. When operated correctly and at factory specs, the equipment produces less particulate matter out the stack than most residential fireplaces. Automatic devices closely monitor stack emissions; stacks are subject to inspection by federal, state, and local regulators. Operators must maintain accurate records and produce them when the environmental authorities inspect their facilities or risk incurring substantial fines.

In North America, the industry standard fuel is natural gas. The average cremator requires about 44 therms of natural gas to complete a typical two- to three-hour cremation on an average-size decedent, considered to be less than 250 pounds. Many states require cremations to be completed at a certain minimum operating temperature, typically between 1,400°F and 1,800°F. A 30- to 60-minute cool-down period between cremation cases is necessary to avoid equipment damage and the risk of fire.

According to Mike Burwell, chief executive officer of a crematory equipment manufacturer, 99 percent of structure fires involving crematories result from wood fatigue in the stack area at the roofline. There must be at least 10 to 12 inches of free air space around a stack; the machine and the flue must breathe. Some manufacturers think four to six inches is enough free air space between the stack and wood roof trusses (photo 6). However, he says, over time, the wood trusses or beams fatigue because of the constant exposure to radiant heat from a stainless-steel stack, which typically reaches about 110°F to 125°F during a day of continual use. Refractory-lined stacks should be replaced after 10 years of normal daily use for a typical facility that does four cremations a day. A busier facility may need to replace it sooner; a less busy facility can extend the interval. Also, Burwell does not recommend using a conical cap atop a stack, as it forces heat down onto the façade, fatiguing the structure quicker and making it more vulnerable to catching fire.

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Rushing a cremation, failing to properly operate and maintain the equipment, and failing to monitor the equipment during cremation are the typical causes of crematory fires. For example, improperly cremating obese decedents almost always results in a fire. If these cases are not cremated according to a precise set of guidelines and closely monitored, they can result in a “runaway cremation,” essentially a grease fire, the result of cremating a larger decedent (too much fuel) at too high of a temperature too quickly.

To avoid this, cremating an obese decedent should always be scheduled to be the first cremation of the working day, started inside a cool cremator that has not reached full operating temperature. A slow and controlled warmup allows the larger deceased to be properly cremated slowly over a longer time to avoid overcombustion too soon. Cremating an obese case after the cremator has reached full operating temperature or amid the day’s workload is extremely dangerous and can result in devastating consequences.

If called to a fire at a crematory resulting from a runaway cremation, allow the cremation to slowly cool down; allow the equipment operator to regain control by adjusting the cremator controls. Normally, the fire department does not need to apply any extinguishing agents to the cremation equipment in these delicate situations. Use a thermal imaging camera to monitor the building conditions to ensure no ignition of combustibles or roofing materials has occurred and stand by. The matter will almost always correct itself with immediate operator intervention. Having some sand or other absorbent material at the ready in the event the cremation spills outside of the cremation equipment is also highly recommended. Many devastating fires in funeral homes and crematories have been attributed directly to the foolish practice of leaving a cremation process unattended.

An additional cause of crematory fires is the failure to contain and eliminate radiant heat from the discharge stack to the roof, resulting from indirect or sometimes direct close contact with combustible roofing or building materials associated with the construction of the building. Stacks are typically refractory lined, constructed of black iron or stainless steel, and designed to contain and dissipate the radiant heat from the crematory equipment into the environment. If you have a fire at a crematory and it appears to have started on the roof, this may have been the case. Again, routine inspection by owners should catch this issue before a fire starts. Often, clear distinct charring, discoloration, or burn patterns will be visible on wooden roof trusses and other building materials immediately surrounding the area where the stack exits to the roof inside the building (photo 7).

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Often, the public will call the fire department to report some visible particulate (smoke) or flames exiting the stack at a crematory and assume that the building is on fire, unaware of the nature of the business. This does NOT necessarily mean that there is an actual fire emergency occurring. The typical cremation process, when completed under the proper procedures and with the equipment operating within spec, should have very little to no visible particulate or smoke. Today’s modern cremators contain a secondary after-chamber specifically used to reburn the products of combustion before discharging them into the atmosphere. Even with this, when a deceased is cremated in a heavy disaster pouch or in a highly polished wooden casket, a few seconds of black emissions may be visible exiting the stack. If it continues more than a few seconds or if the stack is emitting any visible, continual fire, there is an obvious problem warranting immediate contact with the crematory facility.

According to Burwell, “Fire department personnel responding to a fire or smoke investigation call should not rush to assume that the building is on fire simply because they view flames or heavy smoke out of the stack. They should always first make contact with the facility manager on site and inquire with them. It may be a system malfunction with a failed component in the crematory equipment dumping too much oxygen or an issue with a burner not engaging during its cycle.”

Fire personnel must never open the cremator front door and attempt to extinguish a fire in that manner, as it will severely damage the refractory lining. It may also create potential civil litigation between you, the crematory, and the funeral home, as you have interrupted and possibly ruined the solemn cremation process and the deceased’s family may sue all parties involved since the cremation was not completed in a dignified manner as prescribed by law.

Cremation equipment should regularly be inspected for maintenance according to volume but, at a minimum, once a year by an authorized factory trained technician. Failure to maintain equipment and keep its immediate operating area clean and unobstructed can result in fire. Cremation equipment produces a tremendous amount of radiant heat; combustible materials and trash should not be in the immediate vicinity. Trash should also never be burned in a cremation; it is illegal.

Cremation equipment almost always uses natural gas to operate; crematory owners must ensure that gas connections are maintained and free of leaks. If your department is called to a gas odor call near a known crematory, consider stopping by and contacting the crematory operator to confirm all is well. If it is after normal business hours, most crematories have a 24/7 on-call answering service that will forward calls to an on-call representative who can further assist you and respond to the scene.

Most modern crematory equipment manufacturers today offer optional online remote monitoring and control of their cremation equipment for their customers off site through a computer or smart device. A crematory may also have video cameras installed in the facility and on the roof to monitor stack emissions after hours or when no one is on site.

In addition to the expected bloodborne pathogens associated with working in the funeral and cremation industry, cremation equipment is extremely noisy when operating. With equipment operating at temperatures of up to 2,000°F, employees must use proper personal protective equipment to avoid burns and hearing loss.

Among the biggest fears associated with operating cremation equipment is what is not known about the deceased. Prior to cremation, any internal mechanical medical devices and implants—e.g., pacemakers and insulin pumps, which contain batteries or electronics that will explode if exposed to high temperatures—must be removed from the human remains. These items not only damage the cremator but may also injure personnel operating nearby. Crematories require a funeral director to sign off confirming that such devices have been removed prior to cremation. Also, exploding projectiles such as ammunition placed in a loved one’s clothing during a prior funeral service are also an unknown threat. For all these reasons, always staying clear of the front door of the cremator while it is operating is extremely important.

Any deceased persons who were treated for cancer with radiopharmaceutical products (chemotherapy) may still retain low levels of lutetium-77 while awaiting cremation at a crematory or funeral home. Exercise extreme care if entering a crematory unescorted or after hours. There are currently no federal laws in the United States that require medical facilities to pass this information on to funeral directors and crematory operators at the time of death. Radioactive contamination at funeral and crematory facilities is becoming a more predominant concern.

Finally, know your district. If you have a crematory in your district, meet with the operators and discuss fire preplanning and the facility’s typical daily operations. Find out where their utilities are located and what to do if called there after hours, especially if your department experiences a high smoke/odor call volume in the area of these facilities. And, most importantly, if you have a fire or emergency at one of these facilities, contact a crematory representative early on to respond to better assist you. Don’t do it alone and without any professional guidance.

Author’s note: Thanks to Philadelphia Crematories Inc. and American Crematory Equipment for their assistance in preparing this article.

Eric D. Ruggeri is a retired member of the West Chester (PA) Fire Department and a certified cremation equipment operator in the funeral industry, where he previously worked for 20 years. A police officer in Chester County for the past 34 years, he is member of the DMORT Region III Federal Disaster Response Team with the United States Department of Health and Human Services. As a death investigator with DMORT, he has been deployed to mass fatality scenes across the United States.