You pull out your CO2 tank to refill it for your draft system, welding setup, or beverage dispenser, and the supplier hits you with the bad news: "Sorry, your hydro test is expired. We can't fill this until it's recertified."
Now you're stuck wondering where to get a CO2 tank hydro test in Fort Wayne, how long it'll take, and: most importantly: whether your tank will even pass. If you've been storing that cylinder in a damp basement or hauling it around jobsites for years, there's a real chance it won't make the cut.
Let's break down what actually happens during hydrostatic testing, what causes tanks to fail, and the realistic timeline you're looking at here in Fort Wayne. Because when you need your CO2 system back online, two weeks feels like forever.
Hydrostatic testing: often called "hydro testing": is a pressure test required by the Department of Transportation (DOT) to ensure your CO2 tank can still safely hold gas under pressure. Every five years, your tank needs to be recertified, or it's technically illegal to refill.
Here's the process most DOT-certified facilities use, known as the Water Jacket Method:
The key here is permanent expansion. If your tank doesn't spring back to shape after the pressure is released, it's permanently deformed: and that's an automatic fail.
Think of it like stretching a rubber band. A good rubber band snaps back. A worn-out one stays stretched. Your CO2 tank needs to be the good rubber band.
Not every tank that rolls into a testing facility comes back certified. In fact, tanks fail more often than you'd think: especially if they've been sitting unused for years or exposed to rough conditions. Here's what actually causes a fail.
This is the number one killer of CO2 tanks. Rust on the exterior is bad enough, but interior corrosion is the real problem. When moisture gets inside the tank: whether from condensation, improper storage, or a leaky valve: it starts eating away at the steel from the inside out.
Corrosion weakens the tank's structural integrity. Even if it looks fine on the outside, that pitting and rust inside means it can't handle the pressure it was designed for. Testing facilities will reject a tank with significant corrosion, and there's no fixing it. Once it fails, it's done.
If you've been storing your CO2 tank in a damp garage or basement, check the exterior closely. If you see rust spots, chances are the inside isn't much better.
Dropped your tank off the back of a truck? Dented it moving equipment around? That's a problem.
Any dents, gouges, or deformations are red flags during inspection. Even if the damage seems cosmetic, it can compromise the tank's ability to withstand pressure. Fire exposure is another one: if your tank was anywhere near a fire (even if it didn't explode), the heat can weaken the metal enough to cause failure.
Visual inspection happens before the hydro test even starts. If the technician sees significant physical damage, they may reject it outright without even running the pressure test.
This is what the hydro test is specifically designed to catch. When the tank is pressurized during testing, it expands slightly: that's normal. But if it doesn't return to its original dimensions after the pressure is released, that's permanent expansion, and it's an automatic fail.
Permanent expansion means the metal has been stretched beyond its elastic limit. It's lost its ability to safely contain pressure, and there's no repair that can fix that. The tank is done.
Older tanks, tanks that have been overfilled repeatedly, or tanks that have been exposed to heat are most at risk for permanent expansion.
Here's something a lot of people don't realize: just because your tank hasn't been used doesn't mean it's still good. Tanks sitting unused for extended periods: especially in poor storage conditions: can deteriorate internally. Moisture can build up, seals can dry out, and corrosion can start without you ever noticing.
Your tank's hydro test date is stamped right on the neck, usually near the valve. It'll show the original test date and any subsequent retest dates. If it's been more than five years since the last test, you're overdue, and no legitimate supplier will fill it until it's recertified.
Let's be real: you're not getting your tank back the same day. Hydro testing in Fort Wayne typically takes 1-2 weeks, depending on the facility's workload and whether your tank needs any prep work (like valve removal or cleaning).
Here's the typical timeline:
Plan for two weeks to be safe. If you're in a rush, call ahead and ask about their current turnaround time. Some facilities can expedite for an extra fee, but don't count on same-day or even same-week service.
And if your tank fails? You're not getting it back at all: failed tanks are typically destroyed or returned to you with a hole drilled in them to prevent reuse.
So where do you actually get this done in Fort Wayne? Your best bet is to start with DOT-certified hydrostatic testing facilities. The PHMSA (Pipeline and Hazardous Materials Safety Administration) maintains a searchable database at portal.phmsa.dot.gov/rinlocator where you can enter your ZIP code and find certified testing locations near you. Look for blue icons on the map: those facilities perform full hydrostatic testing. Orange icons only do visual inspections.
You can also check with:
Here at TJ Nowak Supply, we handle CO2 tank hydro testing locally and can help you avoid the runaround. We work with Fort Wayne businesses that rely on CO2 for draft systems, welding, and other industrial applications. If you're wondering whether your tank will pass or need to get testing scheduled, we can walk you through the process and give you a realistic timeline.
Hydro testing typically runs between $18-$50 per tank, depending on size and the facility. Smaller paintball-style CO2 tanks are on the lower end, while larger industrial or beverage tanks cost more.
Here's the question: is it worth it?
If your tank is relatively new, in good condition, and stored properly, absolutely. Recertification is way cheaper than buying a new tank (which can run $100-$300+ depending on size). But if your tank is old, rusty, or has visible damage, you might be throwing money away on a test it won't pass.
Before you pay for testing, do a quick visual check:
If the tank looks questionable, it might be time to invest in a new one instead of gambling on a test.
The worst time to find out your tank needs hydro testing is when you're trying to get it refilled and you're already out of gas. Whether you're running a draft system at your restaurant, relying on CO2 for welding, or using it for any other industrial application, plan ahead.
Check your tank's test date now: it's stamped right there on the neck. If you're within six months of expiration, get it scheduled. That way, you're not stuck waiting two weeks when you actually need it.
And if you're in the Fort Wayne area and need help with CO2 tank hydro testing, reach out to us at TJ Nowak Supply. We'll make sure your tanks are tested, certified, and ready to go( without the runaround.)