Safe Storage of Drums and IBCs: 6 Spill Risks Many Sites Overlook

Why Drums and IBCs Pose High Spill Risks

Drums typically store up to 205 litres, while IBCs can hold up to 1,000 litres. Due to the large volumes they contain and the frequent movement of these containers around sites, they are particularly vulnerable to damage or mishandling. 

Spills can occur during routine operations such as deliveries, forklift handling, or dispensing liquids. Without proper containment measures, even small leaks can quickly spread and reach drainage systems.

Common spill causes include:

• Forklift impact during deliveries or movement
• Corrosion or degradation of containers
• Incorrect stacking or unstable storage
• Leaks from taps, valves or seals
• Lack of suitable secondary containment

For this reason, robust storage systems and proper bunding are essential when storing liquid containers on site.

Spill Risk 1: Damaged Containers

Damaged containers are one of the most common causes of drum and IBC leaks. Steel drums may corrode over time, while plastic IBCs can crack or weaken due to weather exposure.

Forklift punctures are also a frequent cause of damage. During deliveries or routine movement around the site, forklift forks can accidentally pierce drums or IBCs, particularly in tight storage areas or where visibility is limited. Because these containers can hold up to 205 litres in drums and 1,000 litres in IBCs, even a small puncture can quickly lead to a significant spill.

If a forklift punctures a drum or IBC, the forks should be left in the container until the spill has been assessed and controlled. Removing them immediately may increase the flow of liquid and make the spill harder to contain.

Containers should be inspected regularly before use and during routine site checks.

Warning signs include:

• Corrosion or rust on steel drums
• Cracks or brittleness in plastic IBCs
• Dents or deformation in containers
• Residue around valves or seals

Any damaged container should be removed from service immediately to prevent leaks.

Spill Risk 2: Poor Secondary Containment

A major cause of environmental contamination is the absence of proper secondary containment. Without containment, even a small leak can quickly spread across a yard or warehouse floor.

This is where bunded chemical storage becomes critical.

A bund acts as a secondary containment barrier designed to capture leaks from drums or IBCs before they can reach the wider environment. 

Common solutions include:

• Drum spill pallets
• IBC spill pallets
• Bunded storage units
• Bunded dispensing stations
• Drip trays for smaller containers

These systems help prevent spills from reaching drains or surrounding land.

Spill Risk 3: Not Meeting Chemical Storage Bunding Requirements

Sites storing oils or chemicals must ensure their systems meet chemical storage bunding requirements.

In general, bunded containment should hold at least 110% of the volume of the largest container or 25% of the total stored volume, whichever is greater.

If bund capacity is insufficient, a container failure could allow liquids to escape the storage area.

Compliant bunding systems help organisations:

• Prevent liquids from entering surface water drains
• Protect soil and groundwater from contamination
• Demonstrate compliance during environmental inspections
• Reduce the impact of accidental spills

Spill Risk 4: Incorrect Stacking of Drums and IBCs

Incorrect stacking is another overlooked storage risk. Storing drums directly on top of each other without proper racking increases the chance of containers splitting or falling.

Safer storage practices include:

• Avoid stacking drums vertically unless approved racking is used
• Use bunded pallets or drum racking
• Store containers on stable, level surfaces
• Follow manufacturer stacking limits

IBCs should always be stored on secure surfaces and within suitable containment systems.

Spill Risk 5: Poor Drainage Protection

Even well-managed storage areas can experience spills during deliveries or liquid transfers. If these spills reach surface water drains, they can quickly contaminate rivers or groundwater.

Preventative measures include:

• Using drain covers during deliveries
• Installing drainage shut-off valves
• Positioning spill kits near storage areas
• Creating dedicated decanting areas

Understanding the site drainage layout is essential for effective spill prevention.

Spill Risk 6: Lack of Inspection and Maintenance

Even well-designed storage systems require regular inspection and maintenance to remain effective.

Routine checks should include:

• Checking containers for leaks or damage
• Removing rainwater from bunds or drip trays
• Ensuring storage volumes do not exceed bund capacity
• Confirming valves and taps are closed when not in use

Regular inspections help identify issues early and prevent small leaks becoming major incidents.

Do I Really Need a Bunded Oil Storage Tank?

Many site managers question whether bunded oil storage tanks are necessary.

In most cases, they are essential for storing oils or chemicals. Bunded tanks provide a secondary barrier that prevents leaks from spreading into soil or drainage systems.

Using compliant bunded chemical storage helps organisations reduce environmental risks while meeting chemical storage bunding requirements.

Improve Your Drum and IBC Storage with Expert Support

Safe drum and IBC storage depends on well-maintained containers, proper bunding and regular inspections. Addressing common risks such as damaged containers, poor stacking and inadequate containment can significantly reduce spill incidents.

If you’d like professional guidance on selecting the right drum spill pallets or designing a compliant drum storage area, please contact Spillcraft today for expert support tailored to your site requirements.