What happens if a fire extinguisher fails the hydrostatic test?

If permanent expansion exceeds 10% of elastic expansion, the cylinder has plastically deformed and cannot safely contain pressure. It must be condemned immediately. The technician must physically destroy the cylinder, typically by drilling or cutting, to prevent it from being returned to service. A replacement extinguisher must be installed at the same location.

Who is qualified to perform hydrostatic testing on fire extinguishers?

Hydrostatic testing must be performed by a licensed fire protection technician holding the relevant state or territory licence. The technician must use calibrated test equipment with current certification. AS 1851 specifies that only personnel with appropriate training, qualifications and equipment may conduct Level 4 service activities.

How does the 5-year hydrostatic test differ from the 6-monthly routine service?

The 6-monthly service (AS 1851 Level 1) is a visual and functional check covering gauge pressure, tamper seal, hose condition and mounting. The 5-year hydrostatic test (Level 4) is a pressure test that verifies the structural integrity of the cylinder itself. It requires complete discharge, internal inspection and pressurisation above normal operating pressure.

Do CO2 extinguishers require hydrostatic testing at a different interval?

Yes. CO2 extinguishers operate at much higher pressures and have thicker-walled cylinders. AS 1851 requires hydrostatic testing every 10 years for CO2 units, compared to 5 years for stored-pressure water, foam, dry chemical powder and wet chemical extinguishers. The test pressure for CO2 cylinders is also significantly higher.

How long should the hydrostatic test certificate be retained?

AS 1851 expects the hydrostatic test certificate and the underlying test record to be retained for the full service life of the extinguisher and for at least seven years after the unit is condemned or replaced. The certificate must be available to the building owner, fire authority and certifier for the Annual Fire Safety Statement (NSW) or Essential Safety Measures determination (Victoria, ACT). Where a cylinder is condemned and destroyed, retain the destruction record alongside the replacement unit history so the asset register has a clean lineage.

Free fire extinguisher 5-year hydrostatic test record

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Free fire extinguisher 5-year hydrostatic test record per AS 1851 Level 4. Internal inspection, pressure testing and pass/condemn certification.

Jarrod Milford

Commercial Director

Updated 5 May 2026

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Updated 5 May 2026

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What is a fire extinguisher 5-year hydrostatic test record?

A fire extinguisher 5-year hydrostatic test record documents the results of mandatory pressure testing on portable fire extinguishers. Under AS 1851 (Routine service of fire protection systems and equipment), all stored-pressure extinguishers must undergo hydrostatic testing at prescribed intervals to verify the structural integrity of the cylinder under pressure.

The test involves depressurising and discharging the extinguisher, conducting a thorough internal inspection for corrosion or pitting, then filling the cylinder with water and pressurising it to the specified test pressure. The technician measures both elastic expansion and permanent expansion. If permanent expansion exceeds 10% of elastic expansion, the cylinder has deformed beyond safe limits and must be condemned and destroyed. This record captures every step of the process, from initial condition assessment through to recharging and recertification, ensuring full traceability for building compliance audits and Essential Safety Measures (ESM) annual statements.

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Benefits of using this fire extinguisher 5-year hydrostatic test record

Regulatory compliance: satisfies AS 1851 Level 4 service requirements and provides documentary evidence for Essential Safety Measures (ESM) annual statements required under the National Construction Code.
Structural safety assurance: hydrostatic testing identifies weakened cylinders that may rupture under operating pressure, preventing catastrophic failure that could injure building occupants.
Clear pass/fail criteria: the 10% permanent expansion threshold provides an objective, measurable standard that removes ambiguity from the condemn-or-return decision.
Traceability and audit trail: records the technician licence number, test equipment calibration details and exact expansion measurements, creating a defensible audit trail.
Lifecycle tracking: links each test to the extinguisher serial number and date of manufacture, enabling accurate scheduling of the next 5-year test.
Site fire safety register integration: prompts the technician to update the building fire safety register immediately after testing, keeping the facility manager informed.

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What to include in a fire extinguisher 5-year hydrostatic test record

This fire extinguisher 5-year hydrostatic test record covers 10 key areas:

Extinguisher identification: asset number, serial number, type, capacity, manufacturer and date of manufacture.
Technician name and fire protection licence number.
Pre-test external condition assessment: corrosion, dents, pressure gauge, safety pin, tamper seal, hose and label.
Depressurisation and discharge confirmation with empty cylinder weight.
Internal inspection: cylinder walls, valve threads, siphon tube, internal coating.
Hydrostatic test: test pressure applied (kPa), elastic expansion (mL), permanent expansion (mL), percentage calculation.
Pass or condemn result with action taken.
Post-test recharge: correct agent, correct pressure, gauge verification, cylinder re-stamp.
Service tag attachment and fire safety register update.
Test certificate issuance confirmation.

How to use this fire extinguisher 5-year hydrostatic test record

Conduct a thorough pre-test external condition assessment.: Inspect the cylinder for corrosion, dents, bulging and damage. Check the pressure gauge reading, safety pin, tamper seal, hose condition, nozzle and label legibility. Record the extinguisher type, capacity and date of manufacture. If the external condition shows severe damage, condemn without proceeding to hydrostatic test.
Safely depressurise, discharge and disassemble the extinguisher.: Depressurise the cylinder safely following the manufacturer procedure. Discharge all remaining agent into an approved container. Remove the valve assembly and weigh the empty cylinder, recording the tare weight for comparison against manufacturer specifications.
Perform a detailed internal inspection of the cylinder.: Use a borescope or light source to examine internal cylinder walls for corrosion, pitting, scoring and thinning. Inspect valve threads for damage. Check the siphon tube and dip tube for deterioration. Examine any internal coating or lining for delamination. If significant internal damage is found, condemn the unit without proceeding to hydrostatic test.
Fill the cylinder with water and perform the hydrostatic pressure test.: Fill the cylinder completely with water, eliminating all air. Connect to calibrated hydrostatic test equipment. Pressurise to the specified test pressure and hold for a minimum of 60 seconds. Measure elastic expansion during pressurisation and permanent expansion after release. Calculate permanent expansion as a percentage of elastic expansion.
Determine the result and complete post-test actions.: If permanent expansion exceeds 10% of elastic expansion, the extinguisher fails and must be condemned and destroyed by the technician. If it passes, drain and dry the cylinder thoroughly, reassemble the valve, recharge with the correct agent to the correct pressure, verify the gauge reads in the green zone, and re-stamp the cylinder with the new test date.
Complete certification and update all records.: Attach a new service tag showing the test date and next due date. Update the building fire safety register with the test result. Issue a formal test certificate to the site fire warden or facility manager. Record condemned and destroyed units in the register with replacement details.

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How often should you complete this checklist?

AS 1851 requires hydrostatic testing every 5 years for water, foam, dry chemical powder and wet chemical extinguishers, and every 10 years for CO2 extinguishers. The clock starts from the date of manufacture stamped on the cylinder, not from the date of installation. Between hydrostatic tests, extinguishers must receive monthly visual checks and 6-monthly routine service. In MapTrack, automated scheduling reads the manufacture date from each extinguisher asset record and triggers maintenance tasks at the correct interval, ensuring no unit slips past its test-due date across all your sites.

Frequently asked questions

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS 1851 Routine service of fire protection systems and equipment
AS/NZS 1841.1 Portable fire extinguishers - General requirements
National Construction Code (NCC/BCA) - Essential Safety Measures provisions
AS 2444 Portable fire extinguishers and fire blankets - Selection and location

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