What is the difference between a bump test and a full calibration?

A bump test is a quick functional check where the detector is briefly exposed to a reference gas concentration above its alarm setpoint to verify that the sensor responds and the alarms activate. It does not adjust the reading. A full span calibration exposes the sensor to a known reference gas concentration and adjusts the detector reading to match that concentration. Bump tests confirm the detector will alarm in a gas event. Full calibrations confirm the detector reads accurately across its measurement range. Both are important and serve different purposes in a gas detector maintenance programme.

How often should portable gas detectors be calibrated under AS/NZS 60079.29.2?

AS/NZS 60079.29.2 does not mandate a fixed calendar interval. It requires the operator to determine an appropriate calibration frequency based on manufacturer recommendations, the application, the environment and operational experience. In practice, most Australian workplaces perform a full span calibration every three to six months and a bump test before each use or at least daily when in active service. Some high-risk industries such as mining and oil and gas mandate daily bump tests and monthly full calibrations. Always follow your site-specific maintenance plan and review intervals if drift trends indicate more frequent calibration is needed.

What should I do if a gas detector fails calibration?

Immediately remove the detector from service and attach an out-of-service tag. Record the failure on the calibration record, noting the pre-calibration reading and the nature of the fault (excessive drift, no sensor response, error code). Do not attempt field repairs beyond sensor replacement if your organisation is trained and authorised to do so. If the sensor is replaced, perform a full calibration on the new sensor before returning the instrument to service. If the fault is not sensor-related, return the detector to the manufacturer or an authorised service centre. Update your fleet register to reflect the instrument status and ensure a replacement detector is issued to the affected work crew.

Can I use expired calibration gas?

No. Calibration gas cylinders have a certified shelf life, typically 12 to 24 months from the date of manufacture depending on the gas mixture. After the expiry date, the gas concentration may have changed due to chemical reactions within the cylinder, adsorption to cylinder walls or other degradation mechanisms. Using expired gas can result in an inaccurate calibration that either over-reads or under-reads, both of which compromise safety. Always check the cylinder expiry date before use and maintain stock rotation to avoid waste.

What records does AS/NZS 60079.29.2 require for gas detector maintenance?

The standard requires that records be maintained for all maintenance activities including calibration, bump tests, repairs, sensor replacements and any modifications to the instrument. Records should include the instrument identification, the date and type of maintenance, the reference gas details, the results (including pre- and post-calibration readings), the name of the person who performed the work, and the next scheduled maintenance date. These records must be retained for the operational life of the instrument and should be available for audit by the regulator or the site safety team.

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Free gas detector calibration record template aligned with AS/NZS 60079.29.2. Log bump tests, span calibrations and sensor drift. Download free.

Jarrod Milford

Commercial Director

Updated 3 May 2026

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What is a gas detector calibration record?

A gas detector calibration record is a formal document used to log every calibration event performed on portable and fixed gas detection instruments. The record captures the detector make, model and serial number, the target gas and concentration used for calibration, the pre-calibration reading, the post-calibration reading, the calibration gas certificate details, the technician who performed the work and the pass or fail outcome. Under AS/NZS 60079.29.2, operators of gas detection equipment in potentially explosive atmospheres must maintain calibration records that demonstrate each instrument is reading within its specified accuracy before it is deployed to a hazardous area. Gas detectors are life-safety devices. A detector that reads low may fail to alarm when a flammable or toxic gas concentration reaches a dangerous level, and a detector that reads high may trigger unnecessary evacuations and erode worker confidence in the alarm system. Maintaining a thorough calibration record ensures every instrument in the fleet is verified against a known reference gas at regular intervals, sensor drift is identified early, and any detector that fails calibration is immediately removed from service until repaired or replaced. AS 2290.3 (Electrical equipment for coal mines, Gas detecting and monitoring equipment) sets calibration requirements for gas detectors used in mining, while AS 2865 requires calibrated atmospheric monitoring for confined space work.

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Benefits of using this gas detector calibration record

Regulatory compliance: demonstrate adherence to AS/NZS 60079.29.2 calibration and maintenance requirements with a complete audit trail.
Life-safety assurance: verify that every gas detector reads within its specified accuracy before it is deployed to a hazardous area.
Sensor drift tracking: compare pre-calibration and post-calibration readings over time to identify sensors approaching end of life.
Fleet visibility: maintain a single register of all gas detectors, their calibration status and next due dates across multiple sites.
Incident investigation support: provide timestamped calibration evidence if a detector reading is questioned during an incident investigation.
Cost management: schedule sensor replacements based on actual drift trends rather than arbitrary time intervals, reducing unnecessary spares spend.

Benefits of digitising forms in MapTrack

When you digitise gas detector log / registers in MapTrack, you get:

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Automatically get alerts when faults are identified.
Link every form digitally as a PDF to the relevant asset, location or person.
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Build conditional logic (show or hide questions based on answers).
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Escalate critical hazards instantly to safety managers via push notification.
Maintain an auditable safety register that satisfies WHS regulator requests.
Correlate incident trends across sites with built-in safety analytics.

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What to include in a gas detector calibration record

This gas detector calibration record covers 10 key areas:

Detector identification: make, model, serial number, asset ID or fleet number, sensor type (catalytic bead, electrochemical, infrared, PID).
Calibration details: date, time, location, calibration type (bump test, full span calibration, zero calibration).
Reference gas details: gas type, concentration, balance gas, cylinder number, certificate number, expiry date.
Pre-calibration reading: the instrument reading when exposed to the reference gas before any adjustment.
Post-calibration reading: the instrument reading after adjustment, confirming it is within the acceptable tolerance.
Tolerance and acceptance criteria: manufacturer-specified accuracy range and the pass or fail threshold applied.
Environmental conditions: ambient temperature, humidity and atmospheric pressure at the time of calibration, as these affect sensor response.
Technician details: name, signature, competency or certification reference.
Outcome: pass, fail or pass with notes. If fail, record the corrective action taken (sensor replaced, instrument removed from service, sent for repair).
Next calibration due: calculated from the calibration interval set by the organisation in accordance with manufacturer guidance and AS/NZS 60079.29.2.

How to use this gas detector calibration record

Verify the calibration gas cylinder is within its expiry date and matches the target gas and concentration required for the detector.: Check the cylinder label for gas type, concentration, balance gas and expiry date. Cross-reference the cylinder certificate number against the supplier certificate. Never use expired calibration gas as the concentration may have shifted, producing inaccurate calibration results. Record the cylinder number and certificate number on the calibration record.
Perform a zero calibration in clean air, away from any potential gas sources, and record the zero reading.: Place the detector in a known clean-air environment or use a zero-air cylinder. Allow the sensor to stabilise and record the zero reading. If the detector does not zero correctly, note the deviation and follow the manufacturer troubleshooting procedure before proceeding to span calibration.
Apply the reference gas to the detector sensor and record the pre-calibration reading before making any adjustment.: Connect the calibration gas to the detector using the manufacturer-approved flow adaptor at the recommended flow rate. Wait for the reading to stabilise and record the displayed value as the pre-calibration reading. This value is critical for tracking sensor drift over time.
Adjust the detector to match the reference gas concentration, then record the post-calibration reading and confirm it is within the acceptance tolerance.: Use the detector calibration menu or automated calibration dock to adjust the reading. Once adjusted, re-expose the sensor to the reference gas and record the post-calibration reading. Compare the reading against the acceptance criteria (typically within plus or minus 5% of the reference gas concentration for most sensors). Mark the outcome as pass or fail.
If the detector fails calibration, remove it from service immediately, tag it as out of service and record the corrective action taken.: A failed detector must not be returned to the field. Record the failure reason (excessive drift, no sensor response, error code). Arrange repair or sensor replacement and re-calibrate before returning the instrument to service. Update the fleet register to reflect the instrument status.
Record the next calibration due date on the instrument label and in the calibration register, then return the detector to the charging station or storage location.: Calculate the next due date from the calibration interval defined by your organisation (AS/NZS 60079.29.2 recommends intervals based on manufacturer guidance and site conditions). Attach a calibration sticker to the instrument showing the calibration date, next due date and technician initials. File the completed record and update the digital register.

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How often should you complete this log / register?

AS/NZS 60079.29.2 does not prescribe a single calibration interval but requires the operator to determine an appropriate frequency based on manufacturer recommendations, the gas types being detected, environmental conditions, sensor age and operational experience. Most manufacturers recommend a full span calibration at least every six months and a bump test (functional check with reference gas) before each use or at least daily when in active service. Instruments used in high-risk environments such as confined spaces, refineries or underground mining are typically bump tested before every shift. Newly commissioned detectors should be calibrated more frequently (monthly) for the first three months to establish a drift baseline. Any detector that has been dropped, exposed to a high gas concentration, stored for an extended period or returned from repair must be calibrated before being returned to service, regardless of the scheduled due date.

Frequently asked questions

What is the difference between a bump test and a full calibration?: A bump test is a quick functional check where the detector is briefly exposed to a reference gas concentration above its alarm setpoint to verify that the sensor responds and the alarms activate. It does not adjust the reading. A full span calibration exposes the sensor to a known reference gas concentration and adjusts the detector reading to match that concentration. Bump tests confirm the detector will alarm in a gas event. Full calibrations confirm the detector reads accurately across its measurement range. Both are important and serve different purposes in a gas detector maintenance programme.
How often should portable gas detectors be calibrated under AS/NZS 60079.29.2?: AS/NZS 60079.29.2 does not mandate a fixed calendar interval. It requires the operator to determine an appropriate calibration frequency based on manufacturer recommendations, the application, the environment and operational experience. In practice, most Australian workplaces perform a full span calibration every three to six months and a bump test before each use or at least daily when in active service. Some high-risk industries such as mining and oil and gas mandate daily bump tests and monthly full calibrations. Always follow your site-specific maintenance plan and review intervals if drift trends indicate more frequent calibration is needed.
What should I do if a gas detector fails calibration?: Immediately remove the detector from service and attach an out-of-service tag. Record the failure on the calibration record, noting the pre-calibration reading and the nature of the fault (excessive drift, no sensor response, error code). Do not attempt field repairs beyond sensor replacement if your organisation is trained and authorised to do so. If the sensor is replaced, perform a full calibration on the new sensor before returning the instrument to service. If the fault is not sensor-related, return the detector to the manufacturer or an authorised service centre. Update your fleet register to reflect the instrument status and ensure a replacement detector is issued to the affected work crew.
Can I use expired calibration gas?: No. Calibration gas cylinders have a certified shelf life, typically 12 to 24 months from the date of manufacture depending on the gas mixture. After the expiry date, the gas concentration may have changed due to chemical reactions within the cylinder, adsorption to cylinder walls or other degradation mechanisms. Using expired gas can result in an inaccurate calibration that either over-reads or under-reads, both of which compromise safety. Always check the cylinder expiry date before use and maintain stock rotation to avoid waste.
What records does AS/NZS 60079.29.2 require for gas detector maintenance?: The standard requires that records be maintained for all maintenance activities including calibration, bump tests, repairs, sensor replacements and any modifications to the instrument. Records should include the instrument identification, the date and type of maintenance, the reference gas details, the results (including pre- and post-calibration readings), the name of the person who performed the work, and the next scheduled maintenance date. These records must be retained for the operational life of the instrument and should be available for audit by the regulator or the site safety team.

Applicable regulatory standards

This template aligns with the following regulations and standards:

AS/NZS 60079.29.2 - Explosive atmospheres: gas detectors, selection, installation, use and maintenance
AS/NZS 60079.29.1 - Explosive atmospheres: gas detectors, performance requirements of detectors for flammable gases
WHS Regulations 2017 Chapter 7 Part 7.1 - Hazardous chemicals
AS 2290.3 - Electrical equipment for coal mines, maintenance and overhaul
Safe Work Australia Code of Practice: Managing risks of hazardous chemicals in the workplace

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