A Hybrid Approach: Fire Training That Works

How combining hands-on experience with tech-enhanced methods improves fire response readiness.

• By David Kopf
• May 01, 2025

Effective fire training goes beyond classroom lectures and compliance checklists. To prepare workers for emergencies—whether it’s a Class A blaze involving paper and wood, or a Class B fire fed by flammable liquids—safety professionals must offer practical, scenario-based instruction. That’s where a hybrid approach, combining traditional hands-on training with the latest technological tools, can help employees retain critical fire response skills and boost workplace preparedness. 

These were some of the insights shared during the March 11 webinar, “Mastering Fire Safety: Class A and B Fire Training,” hosted by Occupational Health & Safety Magazine. The presentation featured Kevin Shea, a veteran firefighter and technical rescue expert, and Matt Gardner, Director of Marketing at LION Group Inc., who shared effective training strategies. The full webinar archive is available at ohsonline.com/webinar. 

The Power of Hands-On Fire Training 

When it comes to fire response, theory has its limits. “The best training is the training people will actually do,” Gardner emphasized. That means replacing passive instruction with physically engaging exercises. 

Hands-on training—whether live fire drills or extinguisher exercises—allows employees to build muscle memory. This is especially important for high-pressure incidents where panic can override logic. By practicing fire extinguisher use, evaluating escape routes, and responding to alarms in real time, workers become more confident and capable. 

Shea, a retired FDNY firefighter, explained that the effectiveness of hands-on training comes down to its realism. “People don’t rise to the occasion; they fall to their level of training,” he underscored. Shea said that in his experience, both in municipal firefighting and industrial settings, confidence under pressure is forged in drills that replicate the stress and constraints of real emergencies. 

Live fire training still has a role to play, particularly for fire brigades or facilities with significant Class B hazards such as petrochemicals or LP gas storage. But as Gardner noted, these scenarios require more logistics and risk management.  

“Live fire is valuable, but it’s the most difficult to achieve—it requires safety measures, weather coordination, and often creates a mess,” he said. “It’s also the least inclusive. Some people are afraid to participate in that kind of training.” 

That’s why many companies are leaning into hybrid methods, starting with digital or simulated training before progressing to full-scale fire exercises. 

Building Confidence Through Technology 

As training needs have evolved, so too have the tools. Safety technology providers now offer a suite of tech-enhanced training aids, including digital fire simulators and virtual reality (VR) headsets. These resources allow safety managers to run realistic drills in low-risk, controlled environments. 

“Products like our Bullseye simulator let you practice right next to the equipment that could cause a fire—like a plastic extruder or a kitchen range—without needing to go outside or deal with a mess,” Gardner explained. “And you can do it again and again. That repetition builds muscle memory.” 

Virtual reality tools add another layer of realism. Using VR systems, employees can enter a fully immersive environment where they must assess the fire type, choose the right extinguisher, and react accordingly.  

“In VR, you can teach lessons you’d never be able to safely replicate in real life,” Gardner explained. “For example, in a kitchen fire scenario, the extinguisher doesn’t work until you turn off the gas source. That kind of interactivity leaves a lasting impression.” 

Plus, because the VR experience can be projected on a screen, safety teams can use it as a collaborative learning tool. “Everyone in the room watches and learns from the scenario—even if only one person is wearing the headset,” he added. 

According to Shea, the technology isn't just effective—it’s essential for today’s complex fire risks. However, it also has to reflect real-world scenarios.  

“Some facilities have electrical hazards, others store lithium-ion batteries, some are in confined spaces like manholes or water tanks. There’s no one-size-fits-all solution,” he said. “But no matter the environment, training must reflect real hazards.” 

Tailoring Training to the Facility 

One major takeaway from the webinar was the importance of understanding your facility’s unique risks and tailoring training accordingly. 

“Start with your material safety data sheets. What flammable materials are on site? What’s the fire history at your location?” Gardner advised. “From there, build a plan that meets both OSHA compliance and your operational realities.” 

Shea encouraged companies to go further. “Partner with your insurance provider. Ask what hazards they’re most concerned about. And talk to your employees—many of them are volunteer firefighters or EMTs. You might already have the foundation for a great internal brigade.” 

For sites with confined spaces, for example, safety officers must ensure atmospheric testing, proper ventilation, and clear egress routes. “Too often, people assume a space is safe without checking it. You need to monitor the air—every time,” Shea said. 

Gardner added, “Confined space training is one of the most overlooked areas. Simply talking about it isn’t enough. People need to physically train with the equipment they’d use in an emergency.” 

Closing the Training Gaps 

Technology can also help fill in critical training gaps. VR tools allow safety managers to simulate fires that are difficult or dangerous to reproduce live, such as lithium-ion battery incidents or electrical panel explosions. And digital training platforms offer portability for remote or distributed teams. 

“If your goal is to train thousands of employees quickly, digital simulators are efficient,” Gardner said. “If your goal is to prepare for fear and chaos, VR or live fire might be better. Choose the tool that matches your mission.” 

He also encouraged safety pros to test tools before fully committing. “Use a contractor to run a few trainings. See how your team responds. Then decide what’s worth investing in.” 

And if the budget is tight? Start small. “Take fire extinguishers off the wall and go outside. Practice using them,” Shea recommended. “It’s low-cost, but high-impact.” 

The Bottom Line: Make Training Stick 

Whether it’s a paper fire in the breakroom or a gas-fed blaze in a repair bay, every employee needs to understand how to respond—and feel confident doing it. That takes training that’s interactive, repeated, and relevant. 

“OSHA lays out the basics, but it’s up to us to go beyond the minimum,” Gardner said. “The work you do now is what keeps people safe when it counts.” 

As Shea put it: “If we can just get people to practice regularly, using the right tools, in the right way—that’s how we make fire safety work.” 

This article originally appeared in the April/May 2025 issue of Occupational Health & Safety.