What you need to check when storing LPG in your workplace

LPG is commonly used in New Zealand workplaces for forklifts, heating, and other equipment. Because LPG is a hazardous substance, you must store it safely and in compliance with the Health and Safety at Work (Hazardous Substances) Regulations 2017.

You might have a couple of spare bottles for a forklift, or something more substantial. Regardless, you need to consider the risks of a leak. This article outlines the key considerations to check, ranging from legal requirements to practical storage considerations. You may want to take a walk around your premises and check that everything looks fine.

1. Know Your Obligations as a PCBU

The WorkSafe LPG in industry guidance helps PCBUs understand your legal duties and what controls are required.

Your responsibilities include:

• Ensuring the safe storage of LPG cylinders and piping
• Providing training and information for workers who handle or could be exposed to LPG (this includes dangerous goods handler or forklift LPG training, plus fire extinguisher training, as mandated by WorkSafe.
• Applying the correct controls based on how much LPG you store.

2. Check How Much LPG You Can Store Indoors and Outdoors

WorkSafe’s guidance includes specific quantity limits for LPG storage depending on building type and location:

Indoor storage limits:

• Standalone commercial buildings:
  Maximum of 10 kg of LPG per 10 m² of floor area, up to a total of 100 kg.
  Each cylinder must be no larger than 10 kg.
• Buildings attached to others:
  A maximum of 20 kg indoors regardless of floor area (e.g., two 9 kg cylinders).
• Factory or warehouse spaces:
  Up to 45 kg per 50 m² of floor area, capped at 180 kg total, with cylinder sizes up to 45 kg.

Outdoor storage:

• If you hold more than 100 kg of LPG across your site, all cylinders must be stored outside in a compliant location.

Knowing these limits helps you comply with regulatory requirements and plan your storage areas effectively.

3. Ensure Safe Physical Storage Conditions

Cylinder orientation and security

• Always store LPG cylinders upright with valves on top; horizontal storage can compromise safety. Even though your forklift cylinders are used horizontally, they should be stored vertically.
• Secure cylinders so they cannot be easily knocked over, tampered with, or accessed by unauthorised people when they are not in use. For example, in a locked cage, or chained up.

Clear surroundings

• Keep storage areas free from combustible materials like rubbish, weeds, or packaging.
• Ensure ignition sources such as open flames, heaters, and electrical equipment are well separated from LPG.

Ventilation

• Storing LPG indoors demands adequate ventilation to prevent gas build-up in the event of a slow leak.
• Ventilation must allow any escaping gas to disperse safely rather than accumulate at ground level.
• Refilling and storage areas should have places the leaked LPG can collect without being dispersed.

Labelling and signage

• Where more than 50 kg is stored indoors (or 250 kg outdoors), you must display clear flammable gas warning signs.
• Signs should be durable, easy to see, and located where they can’t be obscured.

4. Fire Protection and First Aid

You must ensure adequate fire safety controls:

• A 2 kg dry chemical fire extinguisher must be available if more than 50 kg of LPG is on site.
• First aid facilities and trained first aiders must be available to respond to LPG-related incidents – these can be things like frostbite from ‘cold burns’, or inhalation injuries.
• Your team must have had fire extinguisher training.

These checks are part of ensuring your workplace can respond effectively if something goes wrong.

5. Compliance Certification and Notifications

Depending on the total amount of LPG stored, you may need additional compliance measures:

• If your site stores more than 100 kg but less than 300 kg, you must have a location compliance certificate or compliance plaque.
• For 300 kg or more, a location compliance certificate from a certifier is required.
• If planning to store over 100 kg of LPG for the first time at a site, you must notify WorkSafe at least five working days beforehand.

These protocols ensure that hazardous storage is independently checked and verified as safe under the Regulations.

Regular Checks Prevent Bigger Problems

Storing LPG safely requires knowing your legal limits, maintaining clear and safe storage conditions, labelling appropriately, and providing fire and first aid protections. Regular checks ensure your workplace remains compliant with NZ health and safety requirements, and helps to prevent LPG-related incidents.