Gas struts are everywhere—from your kitchen cabinet to the canopy on your ute—and they do their job so well, we hardly notice them. But like any pressure-loaded mechanical device, gas struts come with a few safety considerations that should never be overlooked. Whether you’re installing new struts or replacing old ones, proper handling and installation are key to performance, longevity, and—most importantly—your safety.
Let’s go over what you should know before getting started.
1. Understand the Pressure Within
Gas struts are pressurized with nitrogen gas, often upwards of 400 to 1200 Newtons or more depending on the application. That’s enough force to hold up a heavy canopy, lid, or panel—and more than enough to cause injury if handled incorrectly.
Never attempt to open, drill into, or expose a strut to heat. They’re sealed units, and tampering can lead to a violent release of pressure.
2. Always Replace in Pairs
Even if only one strut seems worn out, it’s best practice to replace both at the same time. Uneven forces from mismatched struts can place strain on hinges, brackets, and even the panel itself.
It also helps prevent dangerous imbalances—especially relevant in car bonnet gas struts, where a failing strut can lead to sudden closure while you’re under the hood.
3. Secure the Panel Before Starting
Before removing an old gas strut, make sure the panel or lid it’s supporting is securely braced. Never rely on a weakened strut to hold it up while you work.
Use a wooden prop, locking rod, or better yet—a trusted helper to support the weight. Safety starts before the tools even come out.
4. Check Your Mounting Hardware
Even the best gas strut won’t perform well if it’s mounted incorrectly. Examine:
- Ball joints for play or rust
- Brackets for cracks or bends
- Mounting holes for wear
Replace any suspect hardware before installation. Misaligned or damaged mounting points can cause premature failure or even ejection of the strut under pressure.
5. Orientation Matters
Most struts should be installed with the body (the thicker part) pointing upward. This keeps the internal oil over the seals, reducing friction and ensuring smooth operation. Installing them upside down can lead to poor damping and early wear.
If you’re unsure, always check the manufacturer’s recommendation—or consult a specialist like Schutts Industrial.
6. Use the Right Tools—Not Force
Gas struts typically snap into place or are secured with clips or pins. Don’t hammer them into position or pry them off with brute force. A flathead screwdriver and gentle pressure are usually all you need.
Excessive force during installation can damage both the strut and the fitting, and cause injury if the pressure releases unexpectedly.
7. Don’t Modify or Overextend
Gas struts are designed for a specific range of motion. Trying to extend them further—or compress them with external force—can cause internal seal failure. Never strap, bend, or add spacers to make a strut fit. When in doubt, get a strut that’s built to spec.
Final Word
Gas struts are incredibly helpful, but they’re also high-pressure components that demand respect. A safe install ensures both reliable performance and peace of mind.
By following these safety basics—and sourcing your struts from a specialist like Schutts Industrial—you’ll avoid common pitfalls and keep your gear moving as it should. Whether you’re replacing worn-out car bonnet gas struts or installing custom units for an industrial application, safety should always come first.