Which quantity and clearance limits to apply before fuel is stored
Five specific limits govern how much flammable liquid you can store and where you can keep it on the site.
Key takeaways for how much flammable liquid may be stored on a construction site
Act on these limits before fuel is stored.
- Confirm the can is an approved container or portable tank before any storage or handling.
- For 5 gallons or less, use an approved safety can or a Department of Transportation approved container unless the liquid is highly viscid and stays in the original shipping container.
- Keep stored fuel out of exits, stairways, and other paths people normally use.
- Store no more than 25 gallons in a room outside an approved storage cabinet.
- Store no more than 60 gallons of Category 1, 2 and/or 3, or 120 gallons of Category 4, in any one storage cabinet.
First, you must use approved containers and portable tanks for any storage and handling of flammable liquids, according to Legal Information Institute. Second, for quantities of 5 gallons or less, you must use approved safety cans or Department of Transportation approved containers, unless the material is highly viscid and used in its original shipping container, according to Legal Information Institute. Third, flammable liquids shall not be stored in areas used for exits, stairways, or normally used for the safe passage of people, according to Legal Information Institute. Fourth, no more than 25 gallons of flammable liquids may be stored in a room outside of an approved storage cabinet, according to Legal Information Institute. Fifth, not more than 60 gallons of Category 1, 2 and/or 3 flammable liquids or 120 gallons of Category 4 flammable liquids shall be stored in any one storage cabinet, according to Legal Information Institute. Additionally, when using Category 1, 2 or 3 flammable liquids, there must be no open flames or other sources of ignition within 50 feet of the operation, unless conditions warrant greater clearance, according to California Department of Industrial Relations. These limits apply to the specific jurisdictions named in the sources. Check the container type, the total quantity in the room, the quantity in the cabinet, and the distance from ignition sources before you store fuel. If a limit does not apply to your specific state or site conditions, verify the local code. Do not store fuel in an exit path. Do not use an unapproved container for 5 gallons or less. Do not exceed the cabinet capacity for your specific category. Record the container size and location in your daily log.
Which containers the pages allow for small quantities
For quantities of 5 gallons or less, the federal rule states that approved safety cans or Department of Transportation approved containers shall be used for the handling and use of flammable liquids, according to Legal Information Institute. The same federal page notes that this requirement does not apply to flammable liquid materials which are highly viscid, meaning extremely hard to pour, which may be used and handled in original shipping containers, according to Legal Information Institute. The general storage rule on that page specifies that only approved containers and portable tanks shall be used for storage and handling of flammable liquids, according to Legal Information Institute.
In California, the rule requires that approved safety cans or Department of Transportation approved containers shall be used for the handling and use of flammable liquids and liquids with a flashpoint greater than 199.4oF (93oC) in quantities of 5 gallons or less, according to California Department of Industrial Relations. The Washington State rule states that you must use approved metal safety cans, or department of transportation approved containers for the handling and use of flammable liquids in quantities 5 gallons or less, according to Washington State Legislature. The Washington page adds that this does not apply to those flammable liquid materials which are highly viscid, meaning extremely hard to pour, which may be used and handled in original shipping containers, according to Washington State Legislature.
When checking a container on site, verify if it is an approved safety can or a Department of Transportation approved container. If the liquid is highly viscid, the original shipping container may be used for handling and use, as noted by the federal and Washington pages. Do not use ordinary drink bottles or unapproved vessels for these quantities. Record the container type and the liquid's viscosity status in your daily log to confirm compliance with the specific page that applies to your jurisdiction.
The open-room limit and the cabinet limits, named by publisher
The federal rule printed in the Electronic Code of Federal Regulations states that no more than 25 gallons of flammable liquids shall be stored in a room outside of an approved storage cabinet, according to Legal Information Institute. This same 25-gallon limit for rooms outside an approved cabinet appears in the California Code of Regulations, Title 8, Section 1930, according to California Department of Industrial Relations. The Washington Administrative Code also specifies that you must not store more than 25 gallons of flammable liquids in a room outside of an approved storage cabinet, according to Washington State Legislature. These three sources align on the maximum quantity permitted in a general room setting when the liquid is not contained within a designated cabinet.
For storage inside a cabinet, the federal regulation distinguishes between liquid categories. It states that not more than 60 gallons of Category 1, 2 and/or 3 flammable liquids or 120 gallons of Category 4 flammable liquids shall be stored in any one storage cabinet, according to Legal Information Institute. The California rule provides a similar split for cabinet storage, noting that of the total allowed, not more than 60 gallons may be of Category 1, 2 and 3 flammable liquid, according to California Department of Industrial Relations. Washington mirrors the federal distinction in its cabinet rule, stating that you must not store more than 60 gallons of Category 1, 2, or 3 flammable liquids or 120 gallons of Category 4 flammable liquids in any one storage cabinet, according to Washington State Legislature.
When checking your site, verify which category your specific solvent or gasoline falls under before calculating the cabinet total. The 60-gallon and 120-gallon figures are not interchangeable; they apply to different categories of liquids as defined by the respective sources. The California text specifically limits the Category 1, 2, and 3 portion to 60 gallons within the total cabinet allowance.
A filled reference table of each publisher's flammable-liquid rule
The following table lists the federal container, room, and cabinet limits plus the California 50-foot clearance. Each row cites the exact rule from the source document to ensure the supervisor applies the correct jurisdictional standard.
| Publisher | Limit Type | Value | Source Quote |
|---|---|---|---|
| Legal Information Institute | Small-quantity container rule | 5 gallons | "Approved safety cans or Department of Transportation approved containers shall be used for the handling and use of flammable liquids in quantities of 5 gallons or less" Legal Information Institute |
| Legal Information Institute | Open-room storage limit | 25 gallons | "(1) No more than 25 gallons of flammable liquids shall be stored in a room outside of an approved storage cabinet." Legal Information Institute |
| Legal Information Institute | Cabinet limit for Categories 1-3 | 60 gallons | "(3) Not more than 60 gallons of Category 1, 2 and/or 3 flammable liquids... shall be stored in any one storage cabinet." Legal Information Institute |
| Legal Information Institute | Cabinet limit for Category 4 | 120 gallons | "...or 120 gallons of Category 4 flammable liquids shall be stored in any one storage cabinet." Legal Information Institute |
| California Department of Industrial Relations | Ignition clearance for use | 50 feet | "(c) Category 1, 2 or 3 flammable liquids may be used only where there are no open flames or other sources of ignition within 50 feet of the operation" California Department of Industrial Relations |
Illustrative example of checking a room and a cabinet
Picture one open room and one cabinet, with round figures only. The room holds 10 gallons outside the cabinet, under the 25 gallon open-room limit. The cabinet holds 50 gallons of Category 1 liquid, under the 60 gallon limit for Category 1, 2 and/or 3. A second cabinet holds 105 gallons of Category 4 liquid, under the 120 gallon limit. The use spot is 55 feet from any open flame, beyond the 50 foot clearance. These figures are only an illustration of how to compare a count with those limits.
Ignition clearance and what the British page requires instead of a gallon limit
When using Category 1, 2, or 3 flammable liquids on site, the California Code of Regulations, Title 8, Section 1935. Use of Flammable Liquids, states that these liquids may be used only where there are no open flames or other sources of ignition within 50 feet of the operation, unless conditions warrant greater clearance, according to California Department of Industrial Relations. This 50-foot distance applies specifically to the use of these liquids and is not a storage limit for containers. If your job involves welding or cutting near fuel, you must check the distance from the fuel operation to any ignition source.
In the United Kingdom, the approach differs because the regulations focus on risk control rather than a specific gallon limit. The Dangerous Substances and Explosive Atmospheres Regulations 2002 (DSEAR) require employers to control the risks to safety from fire, explosions and substances corrosive to metals, according to Health and Safety Executive. These duties cover employers and the self-employed to protect people from these risks to their safety in the workplace, and to members of the public who may be put at risk by work activity, according to Health and Safety Executive. Instead of a fixed quantity limit, you must identify the dangerous substances on your site and implement controls to manage the fire and explosion risks they pose.
For supervisors managing multiple sites, it is important to distinguish between the specific clearance required for use in California and the broader risk control duties in the UK. The 50-foot rule is a hard limit for the operation itself, while the UK regulations require a systematic approach to identifying and controlling hazards. Both approaches aim to prevent fires and explosions, but they do so through different mechanisms.
A blank line for today's container, quantity, and storage spot
Record the specific fuel can you inspect on site today. Mark whether your can meets this requirement. The same source states that flammable liquids shall not be stored in areas used for exits, stairways, or normally used for the safe passage of people, according to Legal Information Institute. Check if your storage spot blocks any exit path.
Fill in the container ID and quantity for the can you are checking. Note if it is an approved container and where it sits. If it is in an exit path, move it to a compliant location.
| Container | Quantity | Approved | Storage spot |
|---|---|---|---|
| Example | small can kept closed | yes | open room away from the exit |
Today, inspect one can, complete the blank row, and write the result in the daily log. If someone will weld nearby, read the hot-work handoff first, and see extinguisher travel rules.
FAQ about storing flammable liquids on site
What container does the federal page require for 5 gallons or less?
Approved safety cans or Department of Transportation approved containers shall be used for the handling and use of flammable liquids in quantities of 5 gallons or less, according to Legal Information Institute. This requirement does not apply to flammable liquid materials which are highly viscid (extremely hard to pour), which may be used and handled in original shipping containers, according to Legal Information Institute. Check the label on your current can to confirm it meets this approval standard.
How much may sit in a room outside a cabinet?
No more than 25 gallons of flammable liquids shall be stored in a room outside of an approved storage cabinet, according to Legal Information Institute. Verify your total quantity before placing any new containers in the open area.
How much of Category 4 may sit in one cabinet on the federal page?
Not more than 120 gallons of Category 4 flammable liquids shall be stored in any one storage cabinet, according to Legal Information Institute. This limit is distinct from the 60-gallon cap for other categories. Ensure your cabinet selection matches the specific category of liquid you are storing.
What ignition distance does the California use page name?
Category 1, 2 or 3 flammable liquids may be used only where there are no open flames or other sources of ignition within 50 feet of the operation, according to California Department of Industrial Relations. Conditions may warrant greater clearance, according to California Department of Industrial Relations. Measure this distance from the point of use to any potential ignition source.
What does the British page require instead of a gallon limit?
This regulation focuses on risk control rather than specifying a maximum storage volume in gallons. Review your emergency plan to ensure it addresses these specific risks.