10 Common Mistakes to Avoid When Storing Chemicals in Drums

Storing chemicals in drums requires careful planning, proper equipment, and ongoing attention to safety. Careful organization and handling techniques are essential to protecting employee safety and product integrity. 

However, when best practices are overlooked, even minor accidents can become severe situations. In this article, we cover ten common chemical storage mistakes and outline how to store chemicals in drums safely, including preventing accidents, maintaining compliance, and protecting both employees and products. 

Warehouses lacking proper spill containment supplies face a higher risk of serious accidents when storing chemicals in drums. Chemical spills can cause significant harm depending on the materials involved, including property damage, fire or explosion risk, and water contamination. 

The Environmental Protection Agency (EPA) requires warehouses with hazardous materials in bulk storage to use secondary containment systems. These systems are designed to prevent spills from spreading. They must hold 10% of the total chemical volume, or the full volume of the largest container, whichever is greater. 

Spill containment tools, such as pallets and berms, play an important role in preventing the spread of chemical spills from drums. Quickly containing chemicals helps stop small incidents from becoming a more serious safety or environmental issue.

Many chemicals are often reactive with certain storage materials or other substances. Ignoring chemical and drum storage compatibility can create dangerous situations, including health hazards for employees.

Choosing the proper material to use should take into account the type of chemical being stored and the conditions it will be stored in. 

Steel drums are a popular choice for storing chemicals because of their strong durability. They are excellent for outdoor use, as they provide protection against any impacts, fire, and UV radiation. However, metal drums can quickly degrade, with rust or corrosion caused by reactions with certain chemicals. 

High density polyethylene (HDPE) drums are nonreactive with many chemicals, making them an alternative for chemical storage. Plastic drums, however, do not offer the same resistances to impacts or fire, making them more prone to punctures, cuts, or extreme temperature fluctuations. Unlike steel drums, HDPE also risks stress-cracking, plasticization, and oxidation.

Ensuring that the equipment and surrounding surfaces are resistant to the chemicals being stored is also important. Understanding drum storage compatibility is essential to protecting employees, facilities, and products. Some substances can erode certain materials, weakening containers or containment systems over time. Drums, pallets, and warehouse flooring should be resistant to chemicals to prevent damages and reduce hazards from leaks or spills.

Storing incompatible chemicals in the same area can result in dangerous reactions if a leak or spills occurs. Even when materials are stored in separate drums, accidental spills can allow chemicals to mix.

Proper chemical segregation helps reduce the risk of severe accidents. This may involve distancing incompatible materials within warehouses, using fire-rated walls, or investing in approved chemical storage cabinets for smaller quantities.

Improper drum inspections increase the risk of preventable accidents. Over time, drums can develop rust, leaks, and various other kinds of damages that compromise their integrity.

When these issues go unaddressed, they can result in chemical spills, worker injuries, and environmental harm. Conducting routine inspections helps identify early signs of wear or damage, aiding in preventing chemical spills from drums.

Where drums are stored, and how those areas are set up, can affect the long-term safety of both the containers and their contents. Ignoring necessary steps in storage location setup can lead to various chemical storage mistakes.

Some chemicals require temperature control to remain stable. High temperatures can cause certain materials to react or degrade, while freezing conditions may damage drums. Fluctuating temperatures can also lead to container “breathing”, where harmful vapors can escape. 

For temperature-sensitive chemicals, climate-controlled storage areas are essential for maintaining consistent temperatures and humidity levels, protecting both the product and the container.

Outdoor drum storage presents additional risks, including potential impact damage from vehicles, debris, and severe weather. Drums stored outside should be made from corrosion-free materials and designed to withstand environmental exposure. 

Protective covers such as hard tops can protect drums from severe weather. Drum pallets are also important outdoors, as they keep containers elevated and prevent submersion during heavy rain or flooding.

Many hazardous chemicals emit harmful fumes that can become dangerous if trapped in an enclosed space. Without proper ventilation, these fumes can increase the risk of fire, explosion, or asphyxiation. 

Mechanical ventilation systems are essential when storing or handling these kinds of chemicals. A proper system must prevent the accumulation of hazardous vapors, while also avoiding the creation of a hazardous environment elsewhere.

Inadequate or missing signage increases the risk of mixups, mishandling, and accidental exposures when storing chemicals in drums. Clear, consistent signage helps workers quickly identify where certain materials are stored and what hazards they present. Each drum and storage area should be clearly labeled with the chemical and appropriate hazard warnings.

The Occupational Safety and Health Administration (OSHA) has set requirements for how to store chemical drums safely, specifically through hazardous material communication. Standard 1910.1200, or the Hazard Communication Standard, requires visible labels, accessible Safety Data Sheets (SDS), and proper employee training. Failure to clearly communicate chemical hazards not only puts workers at risk, but can also lead to regulatory fines and compliance violations.

Neglecting drum cleaning and routine maintenance can result in avoidable damages. Residual chemicals left in reused drums may contaminate new materials, creating unexpected reactions, safety hazards, or environmental issues. Thoroughly cleaning drums between uses helps prevent unwanted cross-contamination.

Regular inspections and maintenance while storing chemicals in drums is also essential to protecting employees and products. Damaged drums can lead to leaks or spills, potentially causing an unsafe workspace. Identifying and addressing corrosion or structural issues early is key to preventing chemical spills from drums.

Skipping or delaying employee training increases the risk of preventable chemical storage mistakes. All workers who handle chemical drums must receive thorough training, including safety procedures, emergency response, and spill cleanup. 

Regulations, best practices, and materials evolve. Keeping employees informed with up-to-date, relevant training helps reduce risks and creates a safer work environment.

Unauthorized access to chemical storage areas can lead to costly damages and serious safety risks. While security needs differ by facility, restricting access to these areas with wire mesh security gates and similar barriers can help reduce accidents, tampering, or theft.

Even with proper precautions, chemical storage mistakes can still happen. Without a spill prevention, control, and countermeasure (SPCC) plan, a minor accident can quickly become a serious situation. 

Facilities handling hazardous chemicals should have a clear emergency response plan, including chemical containment, clean-up, and evacuation procedures when necessary.

All employees should be familiar with these protocols. Appropriate spill clean up supplies must be accessible so workers can handle any spills or incidents quickly.

Preventing chemical storage mistakes starts with a commitment to safety, regulation guidance, and consistent maintenance. Clear procedures, proper equipment, and ongoing inspections all help in reducing risks. Keeping these best practices in mind can aid in preventing accidents:

- Stay up-to-date on current regulations and training, including emergency response procedures.

- Invest in spill containment supplies, proper ventilation systems, and compliant hazard communication.

- Remain aware of drum storage compatibility and storage requirements, including temperature control and security. 

By prioritizing education, preparedness, and consistent maintenance, your workspace, employees, and products can remain protected.

At The Cary Company, we understand the importance of using the right equipment while storing chemicals in drums. With a wide selection of drums and drum accessories, our experts can help find the perfect solution for your facility’s needs.

Still have questions about how to store chemicals in drums safely? Contact one of our product specialists available to answer any questions and recommend products for you. Give us a call at 630-629-6600 or email us at sales@thecarycompany.com.