Gas cylinders are safe when handled correctly, but they contain compressed gases under high pressure. Improper storage, handling, or use can lead to serious incidents.

This guide covers the essential safety practices for working with industrial gas cylinders in the UK—whether you’re in a workshop, factory, or hospitality setting.

Understanding the Risks

Pressure Hazards

Cylinders typically contain gas at pressures up to 200-300 bar. If a cylinder or valve is damaged, rapid gas release can cause:

• Projectile hazards (cylinders can become missiles if the valve is knocked off)
• Blast effects from sudden gas expansion
• Cold burns from rapidly expanding gas

Asphyxiation

Inert gases (argon, nitrogen, CO2) can displace oxygen in enclosed spaces, creating an asphyxiation hazard without any warning—these gases are odourless and colourless.

Fire & Explosion

• Oxygen supports combustion and can cause materials to ignite that wouldn’t normally burn
• Acetylene is highly flammable and unstable under certain conditions
• Flammable gases mixed with air can create explosive atmospheres

Cold Hazards

Liquefied gases (CO2, nitrogen) can cause cold burns on contact with skin. Rapid gas release creates extremely cold temperatures.

Cylinder Storage Requirements

General Storage Principles

Store Upright Cylinders should always be stored and used in an upright (vertical) position, secured to prevent falling.

Secure Against Falling Use chains, straps, or cylinder stands to keep cylinders upright. A falling cylinder can damage the valve, leading to uncontrolled gas release.

Ventilated Area Store cylinders in well-ventilated areas where any gas leak will disperse safely. Never store in unventilated cellars, pits, or enclosed spaces.

Away from Heat Keep cylinders away from heat sources, direct sunlight, and naked flames. High temperatures increase cylinder pressure.

Protected from Physical Damage Store away from areas where cylinders could be struck by vehicles, falling objects, or other impact hazards.

Segregation Requirements

Different gas types should be stored separately:

Full vs Empty Cylinders Keep full and empty cylinders in separate designated areas. This prevents confusion and ensures empties are returned for refilling.

Indoor vs Outdoor Storage

Indoor Storage

• Well-ventilated area
• Away from exits and escape routes
• Fire-resistant enclosure for flammable gases
• Limited quantities based on risk assessment

Outdoor Storage

• Protected from weather extremes
• Secured compound or cage
• Away from building openings (doors, windows, air intakes)
• Clear signage

Handling Cylinders Safely

Moving Cylinders

Never Roll on the Valve Rolling cylinders is acceptable for short distances on smooth surfaces, but never roll on the valve or regulator.

Use Appropriate Equipment

• Cylinder trolleys for single cylinders
• Forklifts with appropriate attachments for multiple cylinders or pallets
• Never lift by the valve or cap

Valve Protection Keep valve protection caps in place when cylinders are not in use or being transported.

No Dropping or Striking Handle cylinders carefully. Dropping or striking can damage valves and cylinder walls.

Connecting and Disconnecting

Before Connecting:

1. Check the cylinder label matches your requirements
2. Inspect the cylinder and valve for damage
3. Ensure the regulator is appropriate for the gas type
4. Check connections for debris or damage

Connecting:

1. Remove the valve protection cap
2. Briefly “crack” the valve to clear debris (except for flammable gases)
3. Attach the regulator, ensuring correct thread type
4. Tighten connections appropriately—don’t overtighten
5. Open the cylinder valve slowly

After Connecting:

• Check for leaks using leak detection spray or soapy water
• Never use a flame to detect leaks
• Ensure the work area is ventilated

Disconnecting:

1. Close the cylinder valve first
2. Release pressure from the regulator
3. Disconnect the regulator
4. Replace the valve protection cap

Using Gas Safely

Ventilation Always work in well-ventilated areas when using gases. Even “safe” inert gases can displace oxygen in enclosed spaces.

Regulators

• Use only regulators designed for the specific gas
• Never interchange regulators between different gas types
• Check regulators regularly for damage and wear

Flow Rates Use appropriate flow rates for your application. Excessive flow wastes gas and can cause problems with the process.

Cylinder Position Keep cylinders upright during use. Never use a cylinder lying on its side unless specifically designed for that purpose.

Transport Requirements

Moving Cylinders in Vehicles

Transporting gas cylinders on public roads is subject to ADR (European Agreement concerning the International Carriage of Dangerous Goods by Road) regulations.

Basic Requirements:

• Cylinders must be secured to prevent movement
• Valves must be closed and protected
• Vehicle must be well-ventilated (not sealed car boots)
• Appropriate warning signage may be required
• Driver training may be required for certain quantities

Quantity Limits Small quantities (below ADR threshold limits) have reduced requirements, but safe handling practices still apply. Check current regulations for specific limits.

Emergency Procedures

Gas Leak

If you detect a gas leak:

1. Don’t create ignition sources – no flames, no electrical switches
2. Ventilate the area – open doors and windows if safe to do so
3. Evacuate – move people away from the affected area
4. Close the cylinder valve – if safe to approach
5. Alert others – warn people in adjacent areas
6. Contact emergency services if necessary

Fire Involving Cylinders

If cylinders are exposed to fire:

1. Evacuate immediately – heated cylinders can rupture
2. Call emergency services
3. If safe, cool cylinders with water from a protected position
4. Never approach overheated cylinders – they may burst without warning

Injury from Gas

Cold burns (from liquefied gas):

• Don’t rub the affected area
• Warm gradually with lukewarm water
• Seek medical attention for serious burns

Asphyxiation (oxygen-depleted atmosphere):

• Move the person to fresh air immediately
• Do not enter a potentially oxygen-depleted space without breathing apparatus
• Call emergency services
• Administer CPR if the person is not breathing

Cylinder Identification

UK Colour Coding

The UK follows BS EN 1089-3 for cylinder colour coding:

Important: Always check the cylinder label—colour coding can vary between suppliers and isn’t a guarantee of contents.

Cylinder Labels

Every cylinder should have a label showing:

• Gas name and formula
• Hazard symbols
• Safety phrases
• Supplier information
• Batch/fill information

Never use a cylinder with an illegible or missing label.

Legal Requirements

Health and Safety at Work Act 1974

Employers must ensure the health, safety, and welfare of employees, including safe handling and storage of hazardous substances.

COSHH Regulations

The Control of Substances Hazardous to Health regulations require risk assessment and appropriate controls for hazardous substances, including compressed gases.

DSEAR Regulations

The Dangerous Substances and Explosive Atmospheres Regulations cover the storage and use of flammable gases.

PSSR

The Pressure Systems Safety Regulations cover equipment containing compressed gas.

Risk Assessment Checklist

When working with gas cylinders, your risk assessment should consider:

• [ ] Types of gases used and their hazards
• [ ] Storage location and arrangements
• [ ] Handling and movement procedures
• [ ] Ventilation in use areas
• [ ] Emergency procedures
• [ ] Training requirements
• [ ] PPE requirements
• [ ] Inspection and maintenance of equipment
• [ ] Segregation of incompatible gases
• [ ] Quantity limits

FAQ

How often should cylinders be inspected? Visual checks before each use. Cylinders undergo formal testing on a schedule (typically every 5-10 years depending on type)—this is handled by the gas supplier for rental cylinders.

Can I store cylinders in a garage? Possibly, if the garage is well-ventilated and meets other storage requirements. Flammable gases have additional restrictions. A risk assessment should determine suitability.

What PPE do I need? At minimum: safety glasses when connecting/disconnecting, safety footwear when handling. Gloves may be needed for cold hazards or certain gas types.

Can I refill cylinders myself? No. Cylinders should only be filled by authorised, trained personnel using appropriate equipment. Illegal refilling is dangerous and a criminal offence.

What do I do with damaged cylinders? Do not use damaged cylinders. Contact your gas supplier for collection and replacement. Mark clearly as damaged.

Summary

• Store cylinders upright, secured, and ventilated
• Segregate incompatible gas types
• Handle carefully—never drop or strike cylinders
• Use correct regulators for each gas type
• Work in ventilated areas to prevent asphyxiation
• Know your emergency procedures
• Follow transport regulations when moving cylinders
• When in doubt, contact your gas supplier for guidance

Related Resources:

• Safety Data Sheets (available for each gas type)
• HSE Gas Safety Guidance
• Complete Guide to Industrial Gases