Free gas cylinder 10-year hydrostatic test record
Free gas cylinder hydrostatic test record (printable 30-point PDF). AS 2030 pressure test, expansion measurement and condemn criteria. Download free.
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Updated 26 Oct 2026
Gas Cylinder 10-Year Hydrostatic Test Record
Periodic inspection and pressure test per AS 2030 and AS 2337
1. Pre-Test External Inspection
2. Internal Inspection
3. Weight and Capacity Check
4. Hydrostatic Test Procedure
5. Post-Test Assessment
6. Marking and Certification
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Short answer
A gas cylinder 10-year test record documents a cylinder's periodic hydrostatic test: stamp details, pre-test visual inspection, test pressure, total and permanent expansion, the pass or condemn decision and destruction of failed cylinders. Test stations working to the AS 2337 series complete it at the interval the AS 2030 series sets for that cylinder. Regulation 224 of the model WHS Regulations requires inspected cylinders to carry a current inspection mark.
Checked against AS 2030.5:2026 on by the MapTrack templates team. How we check templates
Key takeaways
- The MapTrack gas cylinder 10-year hydrostatic test record contains 30 checks across 6 sections. Sections covered: 1. Pre-Test External Inspection, 2. Internal Inspection, 3. Weight and Capacity Check, 4. Hydrostatic Test Procedure, 5. Post-Test Assessment, 6. Marking and Certification.
- Tracks each cylinder by serial number with its last test date and next due date, so an out-of-test cylinder is caught before refill.
- Built around the AS 2030 requirements for periodic inspection and testing of refillable cylinders.
- The test stamp on the cylinder is the source of truth. The register exists so nobody has to read every collar to find what is due.
- A cylinder past its test date is withheld from refill until its status is verified. The register turns that rule from a hope into a check.
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What is a gas cylinder 10-year hydrostatic test record?
A gas cylinder 10-year test record documents the hydrostatic pressure test (proof test) of a refillable steel gas cylinder. Periodic inspection and testing is covered by AS 2030.5 (Filling, inspection and testing of refillable cylinders), and the interval is counted from the date of manufacture or the previous test. The test involves filling the cylinder with water, pressurising it to the test pressure stamped on the cylinder, measuring the total volumetric expansion under pressure and the permanent expansion after pressure release, and calculating the rejection ratio. A cylinder is condemned if the permanent expansion, as a share of the total expansion (known as the rejection ratio), exceeds the limit in the current edition of AS 2030.5 for that cylinder.
Composite cylinders (carbon fibre or fibreglass overwrapped) can have shorter retest intervals and a fixed service life, so check the cylinder marking and the current edition of AS 2030.5. For LPG cylinders, WorkSafe Victoria gives a 10-year test interval for most cylinders and 15 years for cylinders of 100 kg water capacity or more. This template covers the complete test record including cylinder identification, pre-test visual inspection, hydrostatic test data, expansion calculations, pass/condemn decision and disposal documentation for failed cylinders. All testing must be performed by an approved gas cylinder test station. WorkSafe Victoria notes that Standards Australia operates the approved test station scheme and that test stations must comply with the AS 2337 series.
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Benefits of using this gas cylinder 10-year hydrostatic test record
- Regulatory compliance: satisfies AS 2030 mandatory retest requirements, preventing continued use of cylinders past their safe service interval.
- Catastrophic failure prevention: gas cylinders operating at pressures up to 300 bar contain enormous stored energy. A failed cylinder can project fragments hundreds of metres, causing fatalities.
- Complete traceability: links the test result back to the specific cylinder via serial number, test station, operator and test date for full chain of custody.
- Condemn accountability: documents the condemn decision and subsequent destruction of failed cylinders, preventing condemned cylinders from re-entering service.
- Fleet management: builds a testing history for each cylinder in the fleet, enabling proactive scheduling of retests before cylinders reach their due date.
- Insurance and liability: provides evidence that cylinders in service have been tested within the prescribed interval, supporting insurance coverage and limiting liability.
Benefits of digitising forms in MapTrack
When you digitise gas cylinder checklists in MapTrack, you get:
- Field users can easily scan a QR code to complete a form on mobile. Unlimited users.
- Email the right people when a form is submitted, with an automation you set up.
- File every completed form against the asset, location or person it covers.
- Download any completed form as a PDF, with failed answers listed at the top.
- Fill in forms offline; they upload when the device is back online.
- Build conditional logic (show or hide questions based on answers).
- Take pictures or attach photos. Not possible with a paper-based form.
- Electronic signatures.
- Edit forms later without reprinting.
- Set who can view, fill in or edit forms with user roles.
- Upload a paper form (PDF, Word, Excel or a photo) and MapTrack's AI builds a digital version for you to check.
- Assign audits and send reminder emails to the people doing them.
- Keep every audit, inspection and sign-off against the asset or site it covers.
- Track corrective actions as work orders from finding to close-out, with each change in the activity log.
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What to include in a gas cylinder 10-year hydrostatic test record
This gas cylinder 10-year hydrostatic test record covers 8 key areas:
- Cylinder identification: serial number, manufacturer, date of manufacture, cylinder type (steel, aluminium, composite), gas service, working pressure, test pressure, water capacity.
- Test station details: approved test station name, approval number, address, testing officer name and qualifications.
- Pre-test visual inspection: external surface condition, neck threads, valve thread condition, heat damage evidence, corrosion assessment, dents/gouges, stamp legibility.
- Hydrostatic test data: test pressure applied (bar or kPa), duration held under pressure, total expansion (mL), permanent expansion (mL), rejection ratio calculation.
- Pass/condemn decision: pass (rejection ratio below the limit for the cylinder), condemn (rejection ratio at or above the limit, or visual defects), with clear outcome recorded.
- Post-test actions for passed cylinders: date of next retest stamped, test station stamp applied, cylinder returned to service.
- Condemn and disposal record for failed cylinders: method of rendering unserviceable (crushing, drilling, cutting), witness signature, disposal date.
- Certificate number and date of issue.
How to use this gas cylinder 10-year hydrostatic test record
- Receive the cylinder and perform a thorough pre-test visual inspection.: Record the cylinder serial number, manufacturer, date of manufacture, gas service, working pressure and test pressure from the cylinder stamp. Visually inspect the external surface for corrosion, dents, gouges, heat damage (discolouration or distortion), fire damage and general condition. Inspect neck threads and valve threads for damage. Condemn any cylinder with visual defects that compromise structural integrity without proceeding to hydrostatic test.
- Prepare the cylinder for hydrostatic testing by filling with water and connecting to the test apparatus.: Remove the valve and internal components. Fill the cylinder completely with water, ensuring all air is expelled. Connect the cylinder to the hydrostatic test apparatus (water jacket method or direct expansion method as appropriate). Verify the test equipment calibration is current and the pressure gauge accuracy meets AS 2030 requirements. Record the ambient temperature.
- Apply the test pressure, hold for the required duration and record expansion measurements.: Pressurise the cylinder to the test pressure stamped on the cylinder (typically 5/3 of working pressure for steel cylinders). Hold at test pressure for a minimum of 30 seconds (or as specified by AS 2030). Record the total volumetric expansion. Release the pressure and allow the cylinder to stabilise. Record the permanent expansion (residual expansion that does not recover).
- Calculate the rejection ratio and determine the pass or condemn outcome.: Calculate the rejection ratio as permanent expansion divided by total expansion, expressed as a percentage. If the rejection ratio is below the limit set for the cylinder in the current edition of AS 2030.5, the cylinder passes. If it equals or exceeds that limit, the cylinder is condemned. Also condemn any cylinder showing visible distortion, leakage or abnormal behaviour during the test.
- Stamp passed cylinders with the retest date and destroy condemned cylinders.: For passed cylinders, stamp the test date and test station identification onto the cylinder shoulder in the designated stamping area. Refit the valve and return to service. For condemned cylinders, render them permanently unserviceable by crushing, drilling a hole through the shoulder, or cutting. Record the method of destruction with a witness signature. Issue the test certificate.
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Get the free templateEnter your email above to download the full gas cylinder 10-year hydrostatic test record as a PDF.Back to download formHow often should you complete this checklist?
Refillable cylinders are retested at the interval AS 2030.5 sets for the cylinder type, counted from the date of manufacture or the previous test. For LPG cylinders, WorkSafe Victoria gives 10 years for most cylinders and 15 years for cylinders of 100 kg water capacity or more. Composite (carbon fibre or fibreglass) cylinders can have shorter intervals and a fixed service life, so check the cylinder marking. Cylinders exposed to fire, severe corrosion or mechanical damage require immediate retesting regardless of the scheduled interval. In MapTrack, lifecycle tracking against manufacture date ensures no cylinder in your fleet exceeds its maximum retest interval, with automated alerts as cylinders approach their due date and condemnation records for retired units.
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Frequently asked questions
Applicable regulatory standards
This template is a starting point. Check the current requirements that apply to your equipment, work and location. The template alone does not establish compliance.
| Standard | Edition | Clauses this template relies on | Source |
|---|---|---|---|
| Gas cylinders, Part 5: Filling, inspection and testing of refillable cylindersFilling, inspection and testing of refillable cylinders, the periodic test this record documents. The 2026 edition covers compressed and liquefied gases generally. | AS 2030.5:2026 | Whole instrument | Standards AustraliaSold by the publisher |
| Gas cylinders, Part 1: General requirements for pressure receptaclesGeneral requirements for gas cylinders as pressure receptacles. | AS 2030.1:2026 | Whole instrument | Standards AustraliaSold by the publisher |
| Gas cylinder test stations (AS 2337 series)Series covering gas cylinder test stations, where the test is carried out. | Multi-part series. Current parts at check date: AS 2337.1-2004, AS 2337.2-2004, AS 2337.3:2020 | Whole instrument | Standards AustraliaSold by the publisher |
| Model Work Health and Safety RegulationsPressure equipment must be inspected regularly by a competent person, and inspected gas cylinders carry a current inspection mark. | Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011) |
| Safe Work Australia (drafted by the Parliamentary Counsel's Committee) |
Gas cylinders, Part 5: Filling, inspection and testing of refillable cylinders
Edition: AS 2030.5:2026
Filling, inspection and testing of refillable cylinders, the periodic test this record documents. The 2026 edition covers compressed and liquefied gases generally.
Standards AustraliaSold by the publisher
Gas cylinders, Part 1: General requirements for pressure receptacles
Edition: AS 2030.1:2026
General requirements for gas cylinders as pressure receptacles.
Standards AustraliaSold by the publisher
Gas cylinder test stations (AS 2337 series)
Edition: Multi-part series. Current parts at check date: AS 2337.1-2004, AS 2337.2-2004, AS 2337.3:2020
Series covering gas cylinder test stations, where the test is carried out.
Standards AustraliaSold by the publisher
Model Work Health and Safety Regulations
Edition: Model WHS Regulations as at 5 December 2025 (cited within as the Work Health and Safety Regulations 2011)
Pressure equipment must be inspected regularly by a competent person, and inspected gas cylinders carry a current inspection mark.
- reg 224: Pressure equipment must be inspected regularly by a competent person; inspected gas cylinders carry a current inspection mark.
Safe Work Australia (drafted by the Parliamentary Counsel's Committee)
Each source was read at its publisher and the page checked on 26 October 2026. The publisher's current text is the authority.
Check the current source
Gas cylinder 10-year hydrostatic test record preview
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<p style="font-size:12px;font-weight:700;letter-spacing:0.05em;text-transform:uppercase;color:#071D49;margin:0;">Free template</p>
<p style="font-size:18px;font-weight:700;color:#071D49;margin:6px 0 0;">Gas cylinder 10-year hydrostatic test record</p>
<ul style="margin:12px 0 0;padding-left:18px;color:#374151;font-size:14px;line-height:1.6;">
<li style="margin:4px 0;">Cylinder identification: serial number, manufacturer, date of manufacture, cylinder type (steel, aluminium, composite), gas service, working pressure, test pressure, water capacity.</li>
<li style="margin:4px 0;">Test station details: approved test station name, approval number, address, testing officer name and qualifications.</li>
<li style="margin:4px 0;">Pre-test visual inspection: external surface condition, neck threads, valve thread condition, heat damage evidence, corrosion assessment, dents/gouges, stamp legibility.</li>
<li style="margin:4px 0;">Hydrostatic test data: test pressure applied (bar or kPa), duration held under pressure, total expansion (mL), permanent expansion (mL), rejection ratio calculation.</li>
<li style="margin:4px 0;">Pass/condemn decision: pass (rejection ratio below the limit for the cylinder), condemn (rejection ratio at or above the limit, or visual defects), with clear outcome recorded.</li>
<li style="margin:4px 0;">Post-test actions for passed cylinders: date of next retest stamped, test station stamp applied, cylinder returned to service.</li>
</ul>
<p style="font-size:13px;color:#6B7280;margin:14px 0 0;padding-top:12px;border-top:1px solid #E5E7EB;">Free <a href="https://www.maptrack.com/templates/gas-cylinder-10-year-test" style="color:#071D49;font-weight:600;text-decoration:none;">Gas cylinder 10-year hydrostatic test record</a> by MapTrack</p>
</div>Free to reuse, including commercially. This template is published under a Creative Commons Attribution 4.0 licence. Copy it, adapt it, put it on your own site or in your own docs. All we ask is that you credit MapTrack with a link back to this page. The snippet above already includes that credit, so if you use it as-is you’re covered.
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Writing about this topic? You’re welcome to quote this checklist. Here’s the wording to use so your readers can find the original.
The MapTrack gas cylinder 10-year hydrostatic test record contains 30 checks across 6 sections.
- Short attribution
- MapTrack Gas cylinder 10-year hydrostatic test record, https://www.maptrack.com/templates/gas-cylinder-10-year-test
- Reference list
- MapTrack. (2026). Gas cylinder 10-year hydrostatic test record [Checklist template]. Retrieved from https://www.maptrack.com/templates/gas-cylinder-10-year-test
Free to reuse with credit under a Creative Commons Attribution 4.0 licence. If you’d rather link straight to it, the page is https://www.maptrack.com/templates/gas-cylinder-10-year-test.
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