How to Compress a Gas Strut for Installation
In this guide, we’ll explain everything you need to know about compressing gas struts for installation. We’ll cover when compression is required, how to do it safely, and how to avoid damaging the strut or injuring yourself in the process.
Here’s what we’ll cover:
- Do you need to compress gas struts before installation
- Safety and setup tips
- Step by step compression guide
- Extra tips for a smooth installation
- Troubleshooting
- When to consider locking or dampened struts
Do You Need to Compress a Gas Strut Before Installation?
In most cases, you **shouldn’t manually compress a gas strut before installation**. Gas struts are pre-pressurised with nitrogen gas and engineered to operate within specific force tolerances. Attempting to compress one by hand, especially without the proper technique or safety equipment, can result in damage or personal injury.
Pre-compressing a gas strut might seem logical, but doing so can lead to a number of issues:
- It can **damage the seals**, causing nitrogen gas to leak and reducing the performance of the strut.
- The piston rod may become **scored or bent**, affecting both operation and lifespan.
- It can trigger sudden decompression, which may pose a **safety hazard**.
Gas struts are designed to compress under the conditions of their intended use, based on the natural range of motion of the object they’re supporting. This is why they should only be compressed **as part of the installation process, not beforehand**.
That said, there are some situations where partial compression may be needed to line up the strut with its mounting points. In these cases, compression should be done slowly, carefully, and using the correct method.
To find out more about installing gas struts, read our guide on how to install gas struts.
Safety and Setup Tips Before You Begin
Before attempting to compress or install a gas strut, take the following safety precautions:
- **Check the specifications:** ensure the strut you're using is the correct length and force for your application. (Not sure how to check this? See our guide to measuring gas struts).
- **Work in a clear area:** make sure you have space to work and that your tools are easily accessible.
- **Wear protective gear:** gloves and safety glasses are recommended, especially when working with high-force struts.
Step-by-Step: How to Compress a Gas Strut Safely
Compressing a gas strut safely during installation requires a controlled approach that works with the strut's natural movement. Here's how to do it:
1. Align the Mounting Points First
Start by fixing one end of the gas strut to the appropriate mounting bracket. This is usually the body (cylinder) end of the strut. If the strut is the correct size, the piston rod should be just a few centimetres short of the second mounting point.
2. Use Leverage, Not Force
If the piston doesn’t line up exactly, **do not try to push it in by hand**. Instead, install the gas strut to the first mounting point, and then **use the motion of the object** to bring the second point into position. The strut will compress naturally as you move the object into place.
This method uses the leverage of the installation context to compress the strut in a controlled and safe way.
3. Apply Light Pressure If Necessary
If slight compression is needed to align the second mounting point, you can apply **gentle, steady pressure** using your body weight or a padded clamp. Never use a hammer or excessive force, and always aim for smooth, even motion.
4. Secure the Second Mount
Once aligned, secure the second end of the gas strut. Double check that both ends are properly attached to the brackets or ball studs, and that the fittings are tight.
Extra Tips for a Smooth Installation
A few small details can make a big difference when it comes to getting the installation right the first time.
- Always install your gas strut with the **piston rod facing downward** to keep the internal seals lubricated and prolong the lifespan of the strut.
- If your setup includes ball joints or mounting brackets, ensure they’re **clean, rust-free, and properly aligned** before starting.
- Don’t underestimate how helpful an **extra pair of hands** can be, especially for larger installations like vehicle boots or heavy lids, where a second person can help manage the motion and alignment more safely.
Troubleshooting: What If the Strut Won’t Compress?
If you’re struggling to get the strut into place, it may be due to one of the following:
- **Incorrect size or force rating:** double-check that the strut you’re using is suitable — it’s quite easy to measure.
- **Blocked or misaligned brackets:** ensure nothing is obstructing the motion path and that the brackets are aligned correctly.
- **Gas strut fully extended:** a new gas strut will be fully extended and pressurised. Don’t try to fight it: **use the motion of the object** to bring the strut into alignment.
If it still won’t compress, contact the supplier before forcing anything.
When to Consider Locking or Dampened Struts
Some applications might call for a gas strut with additional features:
- **Locking gas struts:** these hold their position firmly and are ideal for medical equipment or adjustable furniture.
- **Dampened gas struts:** these offer slower, smoother motion ideal for kitchen cupboards or display cabinets.
These don’t require a different installation method but do keep in mind they may respond more slowly to pressure.
The Safe Way to Compress Gas Struts
In summary, in most situations gas struts **should not be compressed by hand or with tools before being fitted**. Doing so risks damaging the seals, causing nitrogen gas to leak, and may result in permanent bending or scoring of the piston rod. In some cases, sudden decompression could even be dangerous.
Instead, let the object’s own movement do the work during the installation. Fix one end of the strut and bring the second mounting point into position through **steady, controlled motion**, ideally with an extra pair of hands to help.
For help selecting the right strut or to learn more, don’t forget to check out our guides:
You can also explore our full range or contact our support team for tailored advice.