Storing Gasoline in Plastic Containers | Important Safety Tips

We are frequently asked whether our standard plastic containers, drums and IBCs are suitable for gasoline storage. The general consensus? Storing gasoline in general-purpose plastic drums, totes, and containers is not a good idea. Gasoline should only be stored in containers that are specifically manufactured for gasoline storage, like our Type I Safety Cans and Type II Safety Cans. Gas containers can be made of plastic or metal, but are always fortified with safety features.

Gasoline is capable of breaking down the chemical bonds that make up simple plastic containers, weakening the material’s strength and structure. Proper plastic gas cans are usually made of thick, reinforced HDPE. However, common HDPE containers like milk jugs still risk becoming soft overtime, and do not offer the necessary ventilation to eliminate fire hazards. 

How long does gas last in a plastic container? When stored properly in an approved gasoline container, the answer is about three to six months. Gasoline tends to degrade due to oxidation and evaporation, so oxygen, heat, and humidity can alter its condition. Expired or degraded gas experiences reduced combustibility. If used, it can damage internal engine components, forming gum residue and leading to blockage. Keeping your gasoline container tightly close during the storage period will preserve its condition and prevent hazardous spills.

As for how long plastic gas cans last, it is recommended to replace your gas can every 5 years if you notice any change in quality of the container: material deterioration, wear and tear, etc. 

With a flashpoint of -45ºF (-43ºC), gasoline is a highly flammable, extremely corrosive liquid. When stored in standard plastic containers, such as milk jugs or plastic drums, gasoline and other fuels can react with the chemical composition of the plastic and break down its chemical bonds. These chemical bonds hold the plastic’s polymers in place to give the plastic its structure and strength. This breakdown can also affect the fuel’s chemical composition and cause the fuel itself to become unstable and, often, unusable.

Gasoline vapors are also a concern. Any container designed to hold gasoline must be properly vented to prevent these vapors from building up. The vapor itself is flammable and the pressure can build up leading to a potentially dangerous situation if it is not stored properly. Additionally, most state and local municipalities have fire codes and regulations that must be followed to ensure safe storage. Other general safety tips include:

• Use tanks or cans that are approved to hold gasoline
• Keep gasoline and other flammable liquids away from potential heat sources (e.g., lit cigarettes, pilot lights, hot water heaters, etc.)
• Fill small engines when they’re cooled
• Do not mix gasoline with other substances
• Store gasoline in a separate building, such as a garage or shed
• Clean spills immediately with appropriate cleaning materials
• Follow state and local fire codes and regulation mandates

Due to their flammable nature, gas cans need to be stored in specific environments for optimized safety. It is recommended to keep gas cans in a separate building, such as a detached garage or shed. Gas cans should be stored in leak-proof or flammable safety cabinets, out of the reach of children and pets. The containers should be kept away from sources of ignition such as water heaters, furnaces, pilot lights, and power tools. The environment should be kept at room temperature, void of sun or any heat sources. Heat can lead to evaporation and hazardous vapor leaks, or else cause ignition.

Before you ask yourself “how long does gas last in a plastic container?”, you will need to fill your can at a gas station. Depending on the type of container you are filling, removing the lid may look differently. Take your can out of your vehicle and place it on the ground. It is crucial to avoid uneven surfaces, lined truck beds, and carpeted car floors to avoid igniting the gasoline. Insert the fuel pump nozzle into the valve of the gas container, allowing the nozzle to touch the rim so as to dissipate static electricity. Only fill the container up about 95%, allowing for room in case the gasoline expands from heat. Tightly secure the container cap or lid on the can. Wipe down the can’s exterior.

When transporting a full gas can, make sure to check that the closures are on tightly. Place the container upright in your car’s bed or trunk, away from direct sunlight. The front or back seat of your vehicle is likely exposed to too much direct sunlight. Stabilize your gas can however possible, whether with bungee cords or heavy items, so it does not tip over. It is not safe to store gasoline in a vehicle; the container should be removed as soon as you reach your destination and kept in a safe environment.

For smaller amounts of gasoline, Type I and Type II safety cans are specifically designed for this purpose.  Also known as gas cans, these containers are made of specially formulated plastic and metal that can withstand gasoline’s corrosive effects without deteriorating. The main difference between Type I and Type II cans is Type I cans have a single opening for pouring and filling, while Type II cans have two separate openings for filling and pouring. These containers are rigorously tested to achieve FM and UL approvals and should be OSHA and NFPA compliant.

To meet OSHA safety mandates for proper handling in commercial settings, gasoline must be stored in a red safety can with a yellow band to label the container with the name of its contents. This makes these cans easily identifiable and an effective way to promote safe handling. Other OSHA compliant features for safety cans include:

• A flash arresting screen
• Spring-closing lid and spout cover
• Designed to safely relieve internal pressure when subjected to fire exposure

For larger quantities of gasoline in industrial settings, specially designed storage cabinets for flammables should be used in order to meet NFPA 30 requirements.

Although storing fuel in plastic drums is not advisable, steel drums may be an option for storage of gasoline. Steel drums are extremely durable and resilient, and are composed of materials that are less likely to interact with flammable chemicals. Part #26WG55, 55 Gallon Tight Head Steel Drum, UN Rated, 2" & 3/4" Nylon Fittings, Unlined is UN rated to store flammables and includes a nylon plug that allows the drum contents to vent, reducing the risk of vapor buildup which can lead to the chance of explosion. Nylon plugs melt as the temperature rises in case of fire, which will also reduce the chance of explosion. Fuels like gasoline and diesel should also be stored under certain conditions which will keep the liquids in usable conditions. Some other considerations for diesel fuel storage include:

• Avoid contact with zinc, copper, or metal alloys that contain zinc or copper. These metals react with diesel and form unstable compounds, which means there is higher potential for dangerous chemical reactions like explosions. If such contact is inevitable, a metal deactivator additive will help.
• Avoid the presence of water. Water permits growth of fungus and bacteria, whose natural byproducts can make the fuel unstable.
• Store the fuel in ambient temperatures of 68ºF (20ºC).
• Minimize exposure to dust and dirt which contain trace elements like copper and zinc, which can destabilize the fuel.

As a packaging medium, plastic has become a key player in many industries. Often a suitable alternative to glass and metal containers, plastic containers are lightweight, durable, shatter-resistant and, in many cases, less expensive in material costs and in shipping expenses. As strong and durable as many types of plastic containers are, standard plastics do have some limitations, such as their ability to store gasoline. However, plastic containers are excellent for many other uses, with wholesale options of bottles, jars, jugs, paint cans, pails, drums, etc. for industries such as agricultural, food & beverage, chemical, industrial, pharmaceutical, and more.

It is important to consider plastic’s limitations. Standard plastic containers are not a good option for storing gasoline. Always use caution when handling flammables and always follow safety guidelines.  The proper handling of gasoline and other flammables is critical to ensure storage safety.

If you would like to find out more about the safety storage options available, please contact one of our product experts via email or call us at 630.629.6600 today!

This information has been provided as a general guide. It is the customer's responsibility to select the proper container for product and application compatibility. For more information about requirements for storing and handling flammable liquids, please consult your local, state and federal regulations.