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How it works:

Breathing-air cylinders work under very high pressure, so they cannot remain in service indefinitely without inspection and testing. Regular pressure testing assesses whether each cylinder meets the requirements for continued service and remains safe to use, or whether damage, corrosion and age have reached the point where it must be withdrawn.

The test route depends on how your cylinder is made. Steel and aluminium cylinders are covered by BS EN ISO 18119, while composite cylinders are assessed under BS EN ISO 11623. Composite cylinders need additional checks because part of their strength comes from the fibre wrapping around the cylinder.

We begin with the cylinder’s identity and history

Every cylinder is recorded by its serial number. We also check its construction, working pressure, test pressure, previous test date and any marked end-of-life date.

These details tell us:

Which inspection and test method applies
Whether the cylinder is due for testing
The pressure it must withstand
Whether it has reached the end of its permitted service life

Your cylinder is then inspected inside and out

After the cylinder has been safely emptied, we remove the valve so the inside, neck and valve threads can be examined. Steel and aluminium cylinders are checked for corrosion, cracking, deformation and thread damage. Composite cylinders are also examined for:

Cuts and heavy abrasion
Exposed or broken fibres
Impact damage
Separation between layers
Chemical corrosion
Heat damage

Water pressure reveals whether the cylinder can remain in service

Cylinders that pass the inspection are filled with water and raised to the test pressure specified for their design.

Depending on the cylinder type, this may involve:

A hydraulic proof test, which confirms that the cylinder can withstand the required test pressure without leaking or failing

A volumetric-expansion test, which measures how much the cylinder expands under pressure and whether it returns to its original size afterwards

If too much expansion remains after the pressure is released, the cylinder has permanently changed shape and cannot safely return to service.

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Passing cylinders are dried, reassembled and certified

Once the test is complete, the cylinder is drained and thoroughly dried so that no test water remains inside. The valve is then inspected, serviced, refitted and checked. A cylinder that passes receives the required test marking and certification linked to its individual serial number. A cylinder that fails is clearly identified, together with the reason it cannot return to use.

Who the service is for

Our service is designed for fleet, workshop and maintenance managers responsible for steel, aluminium and composite breathing-air cylinders used for firefighting, industrial response, confined-space rescue, marine work or defence operations.

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Benefits: how pressure testing helps you

Pressure testing gives you a clear answer about every cylinder in your stock: which ones can remain in service, which need further attention and which must be replaced.

Avoid losing cylinders when you need them most

An overdue test can remove a cylinder from use at exactly the wrong time, so keeping your testing programme up to date reduces the risk of discovering expired cylinders immediately before training, a drill or an operational requirement.

Use each cylinder for as long as it remains safe

A cylinder does not need replacing simply because it has reached another test date. Cylinders that meet the inspection and pressure-test requirements can remain in service for another permitted period. This helps you get the full safe working life from your equipment instead of replacing serviceable cylinders unnecessarily.

Keep control of your future test dates

Certification tied to each cylinder’s serial number makes it easier to plan future testing, spread the workload across the year and maintain enough serviceable cylinders for your operational needs.

Why choose us?

Fire Safe International are a Composite Technical Systems (CTS) Partner and works with breathing-air cylinders beyond the test bench, including equipment supply and long-term fleet planning support. Our team are on call to provide specialist input when comparing cylinder specifications and planning your expenditure.

How often do cylinders need testing?

Most breathing air cylinders require a full periodic inspection and test at intervals of no more than five years. However, your exact schedule depends on the cylinder material, design specification and manufacturer’s instructions. 

Can testing be completed quickly?

Cylinders can be processed in planned batches to help reduce the effect on your operational cover. The turnaround will depend on the cylinder type, quantity, condition and whether valve servicing, remedial work or further investigation is required. We recommend scheduling testing proactively before cylinders reach their due date.

Do all cylinder types require testing?

Yes. Steel, aluminium and composite breathing-air cylinders all require periodic inspection and testing while they remain in service. 

Is replacement always necessary if a cylinder fails?

A defect involving the valve, sealing components or another serviceable part may be repairable before the complete assembly is checked again. However, a cylinder that fails because of unacceptable corrosion, cracking, permanent expansion, composite damage or another rejection criterion must be withdrawn from service.

What is hydrostatic testing?

Hydrostatic testing checks whether a cylinder can safely withstand the specified test pressure, which is higher than its normal working pressure. The cylinder is filled with water, pressurised to a specified test level and monitored for leakage or permanent expansion. 

How long does testing take?

Turnaround times depend on the number, type and condition of the cylinders and whether additional servicing or remedial work is required. We will confirm the anticipated timescale when the testing programme is arranged. This covers stripping the cylinder, internal and external inspection, hydrostatic testing, drying, valve refitting and certification.

Arrange cylinder pressure testing with Fire Safe International

To arrange cylinder pressure testing with one of our experts, please call 01743 761000 for advice, or Contact us using the form below.