FIERF Forging Competion 2024

PROJECT:  Halligan Bar


Do you think you have what it takes to forge the strongest Halligan Bar? Join the 2024 Forging Competition challenge to creatively design and forge a functioning version of a Halligan bar – a multipurpose tool used by firefighters to gain access to building spaces, vehicles, and for a multitude of other emergency uses.

Designed by and named for New York City Fire Department First Deputy Chief Hugh Halligan in 1948, the Halligan consists of a bar with claw or fork, a blade (wedge or adze), and a tapered pick.  Some feature a sliding weight for hammering the bar into a gap to facilitate prying.

Teams do not have to stick closely to the traditional design of the Halligan bar but can modify or optimize the design to improve its utility while performing the functions that the Halligan bar is used for by firefighters.

Each bar will be put through a series of tests appropriate to the application.  You can expect your bar to be tested in prying, punching, twisting, and striking.  All submissions should include your Halligan bar, a project video and technical report documenting the design and manufacturing process.


  1. Student teams who will design, build, and test their Halligan Bar. At least one member must be a current college student.  Teams are limited to 8 members.
  2. A university faculty sponsor to help the team.
  3. An industrial partner familiar with forging.
  4. Including one high school student on the team is encouraged. If the team has a high school student, they should also submit an addition to their report from the student about what they learned, less than two pages.

Click the red button below to register your team. If you would like to fill out a paper registration form, click here.

Click the button below to review the entry requirements and technical report guidelines.

Industry Partnerships:

FIA Member companies are invited to participate as industry partners for student teams. Industry partners are asked to work with a team of competing students to provide guidance, materials, and information about forging.

If your company is interested in being an industry partner, please contact Amanda Dureiko at [email protected] to be connected with a competing team.

Schedule of Events: Registration deadline extended

Ongoing   Proposed teams, and preliminary plan due. 

Friday, March 29, 2024   Project video, technical report, and Halligan Bar due.

Thursday, April 25, 2024*    Performance testing and awards in Milwaukee, WI.

*For the testing on Thursday, April 25, teams, and mentors are highly encouraged to attend and compete with their Halligan Bar.


Each Halligan Bar entry will be eligible for 5 awards and a Grand Prize:

  1. Best design and process
  2. Best authentic Halligan Bar design for the form, fit and functions, but the team can use any materials they wish for their entry
  3. Best forging
  4. Best project video documenting the project
  5. Best performance based on testing and expert evaluation