Fuel containers and closing components must first meet the requirements outlined in CARB CP-501, TP-501, TP-502, and EPA regulation 40 CFR 59.623.

Prior to testing, each container must be subjected to:

Low temperature exposure (0°F or -17.8°C) for 8 hours

High temperature exposure (140°F or 60°C) for 8 hours

250 opening and closing cycles

Inspection to ensure that there are no leaks or damage to the container

In order for a fuel container to be considered child resistant, it must be tested with children ages 42-51 months according to the protocol detailed in ASTM F2517.  Testing is performed to ensure that young children are unable to access potentially dangerous substances.  Each container is tested with a minimum of 50 children and a maximum of 200 children to determine the effectiveness of the container and the closures on the container (see Summary of Testing Protocol for further details).

Conversely, the container and its closures must also be tested with adults (ages 18-70 years) to make sure it is not too difficult for them to use.  For this portion of testing, at least 90% of the adults tested must be able to successfully open and re-close all of the closures and use the fuel container two sequential times within the allotted test period.

Summary of Testing Protocol

A full description of the fuel container testing protocol summarized below can be found in ASTM F2517.

Child Testing Protocol

A child panel is needed for each closure.

Each test is made up of 1 to 4 panels of 50 children between the ages of 42 and 51 months.

Panels are divided into 3 groups according to age:

30% between the ages of 42 and 44 months

40% between the ages of 45 and 48 months

30% between the ages of 49 and 51 months

The number of boys and the number of girls in each group must be approximately 50%/50% (regulation allows for +/-10% variation).

No more than 20% of the children may be from a single test site.

All children must be healthy with no disabilities or injuries that could potentially affect their ability to test the container.

Each child may test up to two containers.  If a child tests two containers, the containers must have different closure types.

Children are tested in pairs in a room that is well-lit, free of distractions, and is familiar to them, or in a central location in which they feel comfortable, by a tester who administers the test to no more than 30% of the sample.

To begin, the tester gives each child a container that is one-quarter full of water and asks them to try to open it without any instruction.  Each child has 5 minutes to try to open the container.  The tester uses a stopwatch to document the amount of time it takes for the child to open the container.

If a child opens the container, the test is counted as a failure and he or she is not tested further.  If the second child has not been able to open the container successfully at this point, they are allowed to continue for the remainder of the allotted test period.

If a child (or children) does not open the container within the allotted 5 minutes, the tester demonstrates how to open the container.  The child is then given an additional 5 minutes to try to open the container.  If the child is able to open the container within this period, this is also counted as a failure.  Each closure is tested with a panel of children.

Pass/Fail Criteria:

A test is determined a failure if a child is able to access the liquid in the container through any of the openings, whether the opening procedure was demonstrated to the child or not.

For a container to pass in the first panel of 50 children, three or fewer must be able to open the container during the first 5 minutes (before the tester demonstration), and 5 or fewer during the second 5 minutes (after the demonstration).  Conversely, if 11 or more children open the container in the first 5 minutes, or if 15 or more open the container within the full 10 minutes, the container fails.  In both cases, no further testing is necessary.

In the first panel of 50 children, if 6-14 open the container within the allotted 10 minutes, a second panel of 50 children must be tested.  Depending upon the results of the second round of testing, the container may pass, fail, or require another panel.  Testing stops after the 4th panel regardless of the passing rate.

Senior Adult Testing Protocol

For this test, one panel of 100 adults between the ages of 18 and 70 years old is used.  Each participant is required to read and sign a consent form and attest to having used a gas can in the preceding two years.

Panels are divided into 3 groups according to age:

No more than 20% of the adults may be from a single ZIP code, city, or town to allow for geographical diversity.

Participants must have no obvious physical or mental disabilities.

Each adult is tested individually by a tester who administers the test to no more than 35% of the sample.

To begin, the tester gives the participant a container that is filled 15% to 35% of its rated capacity with water, the closures are secured, and have been inverted to check for leakage.  At any time during the test, an adult test panel participant is allowed to consult instructions provided with the container and digitally available as indicated on the container. The participant is allotted 5 minutes to open and re-close all of the closures on the container correctly. The tester uses a stopwatch to document the amount of time it takes for the participant to open and re-close the container.

If the participant is able to open and close all of the closures on the container within this time period, he or she must be able to do so a second time with another identical container during a subsequent 1 minute dispensing closure phase; and ending with a 1 minute filling closure phase.  In each phase the participant is given tasks to complete.

If a participant is unable to open the first container in the allotted 5 minutes, he/she is asked to open and close two non-child-resistant containers. The participant is allotted 1 minute per container. Those who are unable to open/close the non-child-resistant containers are excluded from the panel and replaced by additional participants.

Pass/Fail Criteria:

A test is determined a failure if the adult is unable to open and reclose all of the closures on the container within the allotted test period.

For a container to pass, at least 90% of the adults tested must be able to properly open and re-close the container during the first 5 minutes and open and close the container again in the subsequent 1 minute dispensing closure phase; and 1 minute closure phase.filled 

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