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Cylinder Failure Analysis Reports

These files are documents frequently requested pursuant to the Freedom of Information Act (FOIA). The majority of documents requested under FOIA from the PHMSA Office of Hazardous Materials Safety are generated as the result of a hazardous materials accident or incident. Documents that have been released to an initial requester are then classified as public information and are not subject to FOIA.

The following files are Metallurgical Evaluation / Analysis Reports performed on Ruptured DOT-3-AL Aluminum Cylinders in the United States in order to determine the cause of the failure and its relevant to sustain load cracking. If you have any technical question (only) please contact Mr. Mark Toughiry, 202-366-4545.

Incident Date Incident Location Title of Report Download/View
March 17, 2000 Key Largo, FL Metallurgical Evaluation of DOT-3AL-3000 Cylinder J95119 3al3000.pdf1(pdf - 9.1M)
For slower Internet connections, the file has been split into two parts to aid in downloading.
Pages 1 - 15 1 (pdf - 58K)
Pages 16 - 26 1 (pdf - 2.2M)
Pages 27 - 37 1 (pdf - 1.5M)
Pages 38 - 48 1 (pdf - 2.6M)
Pages 49 - 58 1 (pdf - 2.4M)
October 4, 2000 Key Largo, FL Pneumatic Pressure Test - Key Largo Cylinder Pressure Test Report 1 (pdf - 4.3M)
For slower Internet connections, the file has been split into two parts to aid in downloading.
Pressure Test Report 1 (pdf - 1.7M)
Pressure Test Report 1 (pdf - 2.6M)
N/A Key Largo, FL Photos taken by Office of Hazardous Materials Enforcement Investigator All 131 Photos 2 (pdf - 13.7M)
For slower Internet connections, the file has been split into two parts to aid in downloading.
Photos 1 - 11 2 (exe - 1.1M)
Photos 12 - 23 2 (exe - 1.4M)
Photos 24 - 35 2 (exe - 993K)
Photos 36 - 47 2 (exe - 1.2M)
Photos 48 - 59 2 (exe - 1.6M)
Photos 60 - 71 2 (exe - 1.2M)
Photos 72 - 83 2 (exe - 1.6M)
Photos 84 - 95 2 (exe - 1.2M)
Photos 96 - 107 2 (exe - 1.2M)
Photos 108 - 119 2 (exe - 1.3M)
Photos 120 - 131 2 (exe - 1.2M)
March 4, 1996 Eureka, CA Investigation of the Failure of an SCBA Cylinder efi_jul1996.pdf1 (pdf - 2.8M)
For slower Internet connections, the file has been split into two parts to aid in downloading.
Pages 1 -20 1 (pdf - 1.8M)
Pages 21 - 27 1 (pdf - 1.0M)
March 13, 1993 Coram, NY Evaluation of Ruptured DOT-E-7235 Cylinder e7235_ruptured.pdf1 (pdf - 2.8M)
For slower Internet connections,
the file has been split into two
parts to aid in downloading.
Pages 1 - 14 1 (1.3M)
Pages 15 - 21 1 (1.5M)
May 1993 Wonderlake, IL Fractographic and Microstructural Examination of a Ruptured DOT-3AL Specification Compressed Gas Cylinder dot3al_rupture.pdf1 (7.4M)
For slower Internet connections,
the file has been split into five
parts to aid in downloading.
Pages 1 - 14 1 (639K)
Pages 15 - 25 1 (2.0M)
Pages 26 - 36 1 (2.0M)
Pages 37 - 47 1 (1.4M)
Pages 48 - 56 1 (1.2M)
May 3, 1999 Summerfield, NC Metallurgical Evaluation of DOT-E-6498-2216 Aluminum Gas Cylinder - T119168 6498_2216.pdf1 (9.3M)
For slower Internet connections,
the file has been split into five
parts to aid in downloading.
Pages 1 -1 5 1 (1.3M)
Pages 16 - 26 1 (2.1M)
Pages 27 - 37 1 (1.7M)
Pages 38 - 48 1 (2.7M)
1 (1.3M)
Pages 49 - 54 1 (1.6M)
February 4, 1998 Riviera Beach, FL Metallurgical Evaluation of DOT-E-7042-3000 Cylinder D-99604 7042_3000.pdf1 (9.9M)
For slower Internet connections,
the file has been split into five
parts to aid in downloading.
Pages 1 -1 5 1 (1.6M)
Pages 16 - 26 1 (1.9M)
Pages 27 - 37 1 (1.1M)
Pages 38 - 48 1 (2.7M)
Pages 49 - 60 1 (2.8M)
July 1996 Union City, GA Metallurgical Evaluation of DOT-3AL2015 Cylinder 3al2015.pdf1 (7.6M)
For slower Internet connections,
the file has been split into four
parts to aid in downloading.
Pages 1 -1 5 1 (1.4M)
Pages 16 - 26 1 (1.0M)
Pages 27 - 37 1 (2.5M)
Pages 38 - 50 1 (2.6M)
July 1996 Roxbury/Morristown, NJ Metallurgical Evaluation of a DOT-E-6498-2216 Cylinder 6498_2216_17916.pdf1 (6.7M)
For slower Internet connections,
the file has been split into four
parts to aid in downloading.
Pages 1 -1 5 1 (933K)
Pages 16 - 26 1 (2.1M)
Pages 27 - 37 1 (1.3M)
Pages 38 - 51 1 (2.4M)
September 9, 1997 Allegan City/Kalamazoo, MI Metallurgical Evaluation of DOT-3AL-2015 Cylinder T-57003 3al2015_57003.pdf1 (8.8M)
For slower Internet connections,
the file has been split into five
parts to aid in downloading.
Pages 1 -1 5 1 (1.5M)
Pages 16 - 26 1 (1.8M)
Pages 27 - 37 1 (1.8M)
Pages 38 - 45 1 (2.0M)
Pages 46 - 53 1 (2.1M)
June 1994 North Miami Beach, FL DOT 3AL-6351 T6 Alloy Cylinder Rupture Evaluation Tests for Mechanical Strength and Fracture Toughness 3al6351.pdf1 (1.9M)
June 1994 North Miami Beach, FL Chemical and Metallurgical Analysis of Ruptured DOT-3AL Specification Compressed Gas Cylinder 3al6351_metal.pdf1 (5.1M)
For slower Internet connections,
the file has been split into five
parts to aid in downloading.
Pages 1 -10 1 (863K)
Pages 11 - 21 1 (2.4M)
Pages 22 - 35 1 (1.8M)

1 Note: This is an Adobe.pdf file (i.e., a file that allows you to view/print the document in its original format ). In order to view and print it, you must have Adobe Reader properly configured with your browser. You may download this software FREE from Adobe's Web site Exiting PHMSA . For best viewing results, change Adobe Reader's view setting to "Fit Visible". To download the file for later viewing press Shift and click on the desired *.pdf file.

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