Sort your cylinders out: A guide to safe gas cylinder storage

In this article, Mike Brodie, MD of Chemstore Engineering, outlines some essential principles for safe, compliant gas cylinder storage.

Understanding gas cylinder storage

Gas cylinders are never truly empty unless brand new or post-inspection - residual gas, even in small amounts, can still be hazardous. A cylinder is considered in storage when it is not in use, not connected to equipment, and not actively being transported. Proper storage ensures cylinders remain secure, upright, and protected from environmental and mechanical damage. This guide does not cover cylinders in use, those in transit, offshore storage, or cryogenic vessels, as these require specialised handling procedures.

Key hazards

Gas cylinders present significant risks due to their weight, instability, and high internal pressure. A minor incident—such as a cylinder toppling over—can cause injuries, while a damaged valve can lead to dangerous gas leaks or even explosions. Corrosion weakens a cylinder’s structure, increasing the risk of failure, while heat exposure can cause rapid gas expansion, leading to catastrophic rupture. Proper storage mitigates these risks and ensures a safer work environment.

Location and Layout

Whenever possible, store gas cylinders outdoors to benefit from natural ventilation. If indoor storage is necessary, it must comply with strict ventilation requirements to prevent gas buildup. Storage areas should be planned to maintain a safe distance from emergency exits, high-traffic areas, and other hazardous materials while allowing easy access for handling and retrieval. Risks associated with manual handling and equipment use should also be minimised.

Security and Access

Unauthorised access to gas cylinder storage poses both safety and security risks. To prevent theft, vandalism, and tampering, cylinders should be stored in secure enclosures with restricted access for trained personnel. Locked gates, monitored access points, and properly secured cylinders using racks, chains, or pallets help prevent tipping. Clear emergency access routes must be maintained at all times.

Ventilation and Fire Safety

Adequate ventilation is essential for safe gas cylinder storage. The best solution is an outdoor area with open or ventilated sides. If using an enclosure, proper airflow must be ensured to prevent hazardous gas accumulation. Where natural ventilation is insufficient, mechanical ventilation should be installed. Fire-resistant partitions should separate different gas types, with a minimum 30-minute fire resistance rating, increasing to 60 minutes in high-risk areas. Regular fire safety assessments and staff training on emergency response procedures for gas leaks and fires are crucial.

Handling and Training

Safe handling prevents injuries and accidents. Cylinders should be moved using appropriate equipment such as trolleys or forklifts rather than rolled or dragged. Manual handling should be minimised to reduce strain and injury risk. All personnel must be trained on hazard identification, safe handling, and emergency response procedures. Workers handling fluorinated gases must obtain specialist certification per regulatory requirements.

Common mistakes in gas cylinder storage

Many businesses make critical errors in gas cylinder storage. One common mistake is using a mesh cage with no roof, nor a raised floor, allowing rain or ground water exposure to increase corrosion and weakened cylinder integrity. Another issue is failing to consider the storage location and surroundings. The British Compressed Gases Association Guidance Note GN41 outlines required separation distances and construction standards, recommending concrete enclosures with walls and a roof to prevent cylinders from becoming projectiles. Storing incompatible gases together is another common mistake; multi-gas storage solutions can be misleading, and expert consultation is necessary. The British Compressed Gases Association (BCGA) Code of Practice 44 (CP44) provides essential guidelines on the safe storage of gas cylinders and should be referred to for detailed regulatory compliance.

Conclusion

Proper gas cylinder storage is essential for workplace safety, regulatory compliance, and operational efficiency. By following best practices for storage, security, ventilation, and training, businesses can significantly reduce risks and prevent costly incidents.

For tailored storage solutions and expert guidance, contact Chemstore UK’s team of specialist engineers today. For a more detailed guide on gas cylinder storage, visit: www.chemstore.co.uk/gas-cylinder-storage