Constructing a Gas Cylinder Store

To ensure safety and compliance, gas cylinder stores must be constructed according to the requirements of AS 4332 - The storage and handling of gases in cylinders. This post discusses some of the key requirements of the Standard including the location of the cylinder stores, the physical construction, and the need for suitable ventilation systems. 

Choosing a Location for Gas Cylinder Storage 

Wherever possible, gas cylinders should be stored outside. Storing gas cylinders outside means that leaked gases often have the chance to dissipate naturally into the environment without incident. 

Compressed gases create significant hazards when stored in confined spaces. Some Class 2.2 gases present an asphyxiation risk, as the gas can quickly replace the oxygen in a room. Escaped Class 2.1 Flammable Gases can create an explosion hazard, while exposure to Class 2.3 Toxic Gases can cause serious injuries, impairments or fatalities.  

Refer to your safety data sheet and your onsite risk assessment to determine the specific hazards associated with your gas bottles.

When deciding on the best location for your cylinder store, the Standard requires that you choose a location that is: 

• Able to be fenced off and secured so unauthorised personnel cannot access the store 
• Clear of combustible materials, vegetation and foliage, as well as refuse and waste (there should be a minimum 3 metre clearance) 
• Isolated from sources of industrial heat including furnaces, operating plant, boilers, radiators, and steam pipes 
• On the ground floor 
• At least 1 metre from the building openings (windows, doors, vents, or ducting) 
• Isolated from ignition sources and the generation of static electricity 

IMPORTANT: The Australian Standard AS 4332:2004 states that an outdoor cylinder store must be free standing, with at least 40% of its wall area fully open. The gas cylinder store must also be fenced and secured against unauthorised access. 

Physical Requirements for Gas Cylinder Stores 

Are you searching for an answer to ‘How to build a gas cylinder cage?’ Or are you concerned that your gas bottle storage doesn’t meet the requirements of the Australian Standards? 

In this section of our post, we’ll be explaining the requirements that relate to the design and construction of your gas cylinder stores. 

When storing gas cylinders, you must not only think about the construction of your store, but also the position, ventilation and maintenance of the store.

Gas cylinder storage cages must be constructed from non-combustible materials. These gas bottle cages should sit on a level floor or base, to ensure stability for the gas cylinders.  

The base of the store should be paved or concreted, so that it will retain its integrity in all weather conditions. Bitumen and other soft surfaces prone to indentation are not suitable base covers. 

Storage in a Gas Bottle Cage 

Our Dangerous Goods Storage Consultants recommend purpose-built gas cylinder storage cages when keeping cylinders outside. Our gas cages are designed and constructed to meet all of the requirements of the Australian Standards, so you can ensure you’re meeting your WHS compliance obligations. 

Gas cages are often a more practical, convenient and affordable option for the storage of gas cylinders.

Here’s 10 key reasons why Storemasta gas cages can help you create a safer workplace: 

1. The Standard requires that gas bottles must be stored upright, with gas cylinders protected at all times from falling over. The gas bottle cage must have adjustable dividers, plus restraint bars and chains to secure the cylinders individually. 
2. With a robust construction, our gas bottle cage protects cylinders from damage by vehicles or being impacted from falling objects. Choose a heavy-duty cage if cylinders stores are in areas accessed by forklifts, delivery trucks, heavy equipment vehicles, or earthmoving trucks. 
3. Gas bottle cages are constructed of heavy duty steel and are finished in a corrosive resistant 2-PACK polyurethane coating. 
4. Doors on the gas cylinder stores open outwards in a way that complies with the Standard. 
5. Walls are perforated to assist with ventilation plus meet the requirements of an ‘outdoor store’. 
6. Gas cylinder cages come with compliant warning placards and safety signage. 
7. Gas cylinder storage cages are fully relocatable and can be secured to the ground. 
8. We manufacture a range of gas cylinder storage that’s suitable for the hazard class of the gas and the operations at your worksite. Different options include flammables, acetylene and O2 stores, aerosol cages, and cages to store LPG forklift cylinders. 
9. Reduce manual handling and other loading/transfer incidents by taking advantages of the fold down ramps. 
10. Gas bottle cages are completely customisable and can be paired with gas bottle trolleys, first aid stations, PPE cabinets, document boxes (for SDSs and Hazardous Chemicals Manifest), safety showers, and eye-wash stations. 

Ventilating Gas Cylinder Storage 

Due to the chemical and physical risks associated with gas cylinders, your workplace must ensure that gas cylinder storage allows for the dissipation of hazardous gases. 

The Standard explains that gas cylinder storage must provide adequate ventilation to ensure safety and compliance.  

Make sure that your gas bottle cage or store can effectively:  

• Dilute and remove gases and vapours to keep the store within safe exposure limits 
• Keep the gases within explosive range 
• Provide enough fresh air to minimise the risk of asphyxiation 
• Offer consistent air flow so that gases don’t stagnate in low lying areas 
• Direct exhaust to the outside and away from people, ignition sources and buildings openings (doors, windows, ducting) 

The Standard is very specific about the requirements of both natural and mechanical ventilation systems and Section 4.3 contains a number of schematic drawings to demonstrate how various systems must be constructed. 

IMPORTANT: As per the requirements of the Australian Standard, gas cylinder stores must have enough lighting so that the markings on cylinders, plus operational and safety equipment, can be read. Care must be taken when installing electrical fittings to ensure they will not create sparks or static electricity and cannot be impacted by the cylinders. 

Selecting Gas Cylinder Stores for Your Workplace 

For more detailed information about the requirements for gas bottle cages and gas cylinder stores, we encourage you to download our free eBook. Gas Cylinder Storage: Compliance and safety requirements unpacks the requirements in clear, easy-to-read text. You’ll also find real world examples and case studies in our eBook, which can help you apply the requirements at your own workplace.