Aerosol Storage Cages: A Practical, Code-Aware Guide

Storing aerosols safely isn’t just “put them on a shelf.”

Aerosol cans are pressurized and often use flammable propellants, so storage rules depend on what kind of aerosol it is, how much you have, how you store it (rack/pallet/solid pile), and your sprinkler protection.

Many facilities are feeling “new rules” because updated fire codes (like the International Fire Code) include dedicated aerosol requirements and jurisdictions adopt newer editions over time.

What makes aerosol cans a bigger hazard than “regular chemicals”?

Aerosol products combine two problems:

1. Pressure (cans can rupture/rocket if heated or damaged)
2. Fuel (many contain flammable propellants and/or flammable liquids)

That’s why fire codes treat aerosol storage differently than most everyday materials and why storage requirements scale with the aerosol “level,” storage height, and sprinkler design.

Which rules apply: OSHA, Fire Code, or both?

Most facilities end up needing to satisfy both:

OSHA (worker safety + hazard communication)

OSHA’s Hazard Communication standard requires employers to maintain a hazard communication program that includes labels, Safety Data Sheets (SDS), and training for hazardous chemicals. This matters because SDS guidance often drives day-to-day handling and storage practices for aerosols.

Fire codes + standards (how it can be stored in the building)

Fire protection rules are commonly driven by:

• International Fire Code (IFC) Chapter 51 (Aerosols)
• NFPA 30B (the consensus standard the IFC points to for aerosol classification and storage concepts)
• Insurer/property-loss guidance (e.g., FM Global’s aerosol storage recommendations)

Important reality check: What you “have to do” is ultimately enforced by your AHJ (Authority Having Jurisdiction—fire marshal/building official) and depends on the code edition adopted locally.

How are aerosol products classified (Level 1, 2, 3) and why does it matter?

The IFC states aerosol products are classified as Level 1, Level 2, or Level 3 in accordance with NFPA 30B.

The IFC and NFPA 30B classify aerosol products into three levels based on their fire hazard potential. This classification drives everything from storage quantities to sprinkler requirements.

The classification considers two key factors:

• Heat of Combustion (HOC) – energy released when the product burns
• Chemical Heat of Combustion (CHC) – energy per unit weight of the product

Level 1 (Lower Hazard)

• Products with lower combustion potential
• Examples: Some air fresheners, certain hairsprays with non-flammable propellants
• Most permissive storage quantities and arrangements

Level 2 (Moderate Hazard)

• The most common category for industrial aerosols
• Examples: Many brake cleaners, lubricants, spray paints, adhesive sprays
• Requires increased fire protection and more restrictive quantity limits
• This is where most maintenance and production facilities need to pay attention

Level 3 (Higher Hazard)

• Products with the highest fire severity
• Includes highly flammable contents and products in plastic containers (which add fuel load)
• Examples: Some carburetor cleaners, starting fluids, products in plastic aerosol containers
• Strictest storage limits and protection requirements

Where to find the level: Check the SDS, product technical data sheet, or packaging. If not listed, you’ll need to work with your fire protection engineer or AHJ to determine classification based on NFPA 30B test methods or manufacturer data.

Why this matters: A facility storing 100 cases of Level 2 aerosols faces completely different requirements than one storing the same quantity of Level 1 products. The difference can mean upgraded sprinklers, reduced storage quantities, or mandatory segregation.

When do you need a dedicated aerosol storage cage or segregated area?

If you’re storing more than “a few cans” (especially mixed aerosols across departments), the safest/cleanest operational approach is to create a controlled, segregated aerosol storage area.

NFPA 30B specifically references segregation approaches (including separation by interior walls, chain-link fencing, or a separation area) for certain higher-hazard aerosol storage scenarios.
And the IFC notes aerosol storage requirements depend on level, sprinkler protection, storage condition, and quantity—which is exactly where a cage/segregated area becomes the easiest way to manage compliance.

A cage is especially helpful when:

• You have multiple departments pulling aerosols (maintenance, production, shipping)
• You need controlled access and clean inventory accountability
• You need a clear “this is the aerosol area” separation for housekeeping, inspections, and fire marshal walkthroughs
• You want a scalable setup as usage grows (without creating aerosol “mini-stashes” around the facility)

How to design an aerosol storage cage setup that actually works

Physical specifications:

Size and clearances:

• Plan for 120-150% of current maximum inventory (seasonal surges happen)
• Maintain minimum 24-inch clearance below sprinkler deflectors (36 inches for ESFR)
• Allow 4-foot minimum aisle width for access and fire department operations
• Keep 3 feet clear from walls unless fire-rated separation is provided

Construction materials:

• Welded wire mesh panels (typically 2″ x 2″ or 4″ x 4″ openings)
• Steel framework with powder-coat finish to resist corrosion
• Mesh must allow sprinkler water penetration while preventing unauthorized access
• Consider grounded construction if storing products that generate static

Storage arrangement inside the cage:

• Maximum storage height: Follow your sprinkler system limits (often 12-20 feet depending on protection)
• Array size: Limit to approximately 20 x 20 feet per array with aisles between
• Keep aerosols separated by level if storing mixed classifications
• Store damaged or leaking cans in a designated quarantine area outside the main cage

Fire protection features:

• Verify sprinkler coverage extends into the cage area
• Position smoke/heat detectors if required by code
• Locate portable fire extinguishers (40-B:C minimum rating) within 50 feet
• Ensure emergency shutoff capabilities for any electrical equipment nearby

Access and operational features:

• Lockable gate with controlled access (reduces unauthorized “borrowing”)
• Clear signage: “AEROSOL STORAGE – NO SMOKING – NO IGNITION SOURCES – KEEP CLOSED WHEN NOT IN USE”
• Bin/shelf labels by product category and level
• Inventory log or RFID tracking at entry point
• Dedicated receiving/inspection area at cage entrance

Ventilation considerations:

• Natural ventilation is often adequate for storage (not dispensing)
• If mechanical ventilation is used, ensure it’s rated for flammable atmospheres
• Avoid creating stagnant air pockets where vapors could accumulate
• Consult your AHJ if storing aerosols in below-grade or enclosed areas

Documentation to maintain:

• Cage layout showing maximum storage configuration
• Sprinkler coverage map
• Product inventory by aerosol level
• SDS for all products stored
• Inspection and maintenance records

Common mistakes that cause trouble (and wasted effort during compliance panic later)

Not knowing which code edition your facility is being inspected against (IFC adoption varies)

Treating aerosols like normal cartons with no thought to level/quantity/storage height

Letting each department store “a little stash” (hard to control totals and risk)

FAQs