Creating a Safer Workplace: 10 Tips for Proper Drum Handling

Industrial drums can be dangerous if not handled correctly. Improper lifting or moving techniques can lead to strains and long-term injuries. In some cases, the drum can move out of control if handled carelessly. These incidents can seriously injure employees and damage equipment or the workspace. 

Providing employees with tools, resources, and training to move drums safely is essential to protecting their long-term health and safety. Not only does it protect the employees and the drum contents, but it also improves employee confidence and productivity. Let’s walk through the importance of drum handling safety, and some key steps to preventing drum handling injuries. 

Drum handling safety is key to protecting employees from preventable injuries, including strains, cuts, fractures, and chemical exposure. Enforcing proper drum handling guidelines not only keeps workers safe, but also improves warehouse efficiency. When fewer injuries occur, employees spend less time recovering, which helps maintain productivity. Safe practices also help employers meet Occupational Safety and Health Administration (OSHA) requirements and avoid compliance issues.

Prioritizing workplace safety is key to maintaining a productive work environment. Safe practices are essential to preventing drum handling injuries and accidents, which come with high costs for lost time and repairs.

Improper drum handling can lead to a wide range of injuries. Over time, poor handling techniques can cause musculoskeletal disorders, often affecting the spine or back, shoulders, or neck. Workers may also bruise, break, or fracture their fingers if their hands get trapped between drums or pallets. In more severe cases, accidents can result in crushed limbs or chemical burns.

Improper drum handling can lead to expensive consequences, including employee injuries, product loss, and damaged equipment. Without proper training or drum handling equipment, employees face a higher risk of accidents. Injuries can result in workers’ compensation claims and decreased warehouse efficiency. Poor practices may also violate OSHA drum handling guidelines, leading to expensive fines.

In addition to safety risks, improper techniques can damage warehouse equipment, floors, and the drums themselves. Dropping, churning, or rolling a heavy drum can quickly cause it to dangerously move out of control. Using the wrong drum handling equipment, like a forklift without the right attachments, can cause costly repairs and spills. These mistakes risk both employee safety and warehouse efficiency.

Before handling a drum, employees should be certain that they have the appropriate PPE. They should also check the drum and the area around it to ensure that moving the drum is safe and smooth.

PPE is a key factor to drum handling safety. The correct tools can protect warehouse employees from a wide variety of injuries. Employees should always wear the appropriate PPE for their tasks. Safety footwear, such as steel-toed boots, is essential. A hard hat should be worn when moving drums at or above head height. 

When handling chemicals or other hazardous material, employees must protect their skin and eyes. Employees should wear gloves, as drums may be coated in dangerous residues. Eye protection is also important when working with chemicals that could splash. If a drum contains materials that could release harmful vapors or dust, a respirator may be necessary. Ultimately, the content inside the drum will determine the exact PPE needed. 

Before moving a drum, assess three things: the drum contents, the drum exterior, and the work area.

First, review the Safety Data Sheet (SDS) to understand what is inside the drum and what kind of PPE is necessary. Employers should ensure that labels are accurate, visible, and reflect the contents and dangers inside.

Next, look for signs of damage on the drum, such as loose parts, burrs, or leaks. Also ensure that the drumhead is tightly secure on the drum. When applicable, check the bung seal of the drum. Never grab the bung while moving, as it can break or slip.

Finally, check that there is enough space to move the drum safely, and choose the best method or equipment to do so. Plan the route in advance and remove any potential hazards.

There are various ways to create a safe environment when working with industrial drums. The following tips offer guidance into what steps can be taken to make your workplace safer for all employees.

Using proper drum handling equipment can reduce the risk of strains and injuries caused by manual handling. To work safely, employees must understand which tools to use, and how to use them correctly. They should consider the specific needs of the job, including the drum’s size and weight. Harsh conditions, such as cold or corrosive substances, can also influence tools used.

Forklifts can safely lift heavy drums only when used with the right attachments designed to secure the container. Without this protection, the forks can puncture the drum. 

For overhead lifting, drum lifters provide a stable, controlled grip that reduces the likelihood of accidents. Employees should always use lifting equipment when working with stacked drums.

When moving filled drums, drum trucks are the safest option. Manually rolling can lead to a loss of control and significant physical strain.

Drum-specific pallets also offer better stability compared to standard pallets, allowing for safer storage and transport. Spill containment pallets provide extra safety within the workplace, catching any leaks or spills.

While drum handling equipment is essential for safe operations, it is important to recognize that each tool has limitations. Employees must be trained to understand what each piece of equipment is for and how to use them properly. They should also be able to recognize the maximum weight the equipment can safely handle. 

Employers should clearly label all equipment with its rated weight capacity to create clear references for employees. As a general rule, a tool’s weight capacity must be greater than the weight of the drum being moved. Warehouses should provide drum handling equipment that can handle a wide range of drum weights. At least one tool should handle the heaviest drum stored in the warehouse.

Proper drum handling techniques help protect both employees and drum contents. Only trained employees should manually handle drums, as they can get out of control quickly.

“Walking” or rolling a drum should be done by one employee, and only for short distances. This method can be safely done if the container is empty and the path is clear. One hand is placed high on the drum chime, and the other is placed low. From there, they can begin rolling the drum slowly. As one hand reaches the top of the drum, the employee should lift their lower hand and switch positions quickly. 

Workers should be trained to never slide their hands along the drum, as they can get cuts from its surface. They should also avoid sliding their feet as they move. Instead, they should side-step while staying close to and ahead of the drum to maintain control.

“Breaking” a drum refers to the process of getting the drum moving from a stationary position. Employees should understand how to move drums safely based on their surroundings and the condition of the drum. Only trained employees should perform these techniques, as improper handling can increase the risk of accidents or injuries.

1. Pushing: This is the best method to use when there is plenty of room to work. Place hands on the drum’s chime, about shoulder width apart. Lower shoulders and use legs to push forward until the drum reaches its balancing point.

2. Pulling: Pulling is best suited for situations where drums are stored close together. Place both hands on the drum chime, with one hand close, and the other along the far side. Before moving the drum, check finger placement to avoid any pinch points between drums. Brace one foot across the bottom chime, with the other directly behind it for support. Once hands and feet are in place forming a straight line, pull back on the drum.

3. Drag/Pull: This method is best used when there is little room to maneuver the drum. Place hands on the drum chime about shoulder width apart. One foot should be against the bottom of the container, and the other in line with it for support. Shift weight to the back foot, and pull and drag the drum a few inches to the left and right.

4. Push/Pull: The push/pull method is used when the drum is located beside a wall. Place one hand on the far side of the drum chime to pull, and the other on the wall to push. 

Drums are more challenging to stack than boxes because of their round shape. Employees must be trained on safe stacking methods to prevent accidents. They should never stack or remove drums by hand. Instead, employees should use the proper equipment to ensure safe lifting techniques for drums. Before stacking, employees should confirm all drum closures are on tightly to prevent leaks. 

When stacking drums, they should be arranged on pallets, keeping spacing uniform and heights even. This creates a stable surface for the next pallet layer. A pallet should always be used between each layer. The maximum height of stacked drums is ultimately determined by the drum contents, including its specific gravity and combustibility. 

Flammable and combustible materials have stricter height limits. These drums are required to have relieving style plugs, and warehouses must have sprinklers.

Employees should understand when tasks can be done safely alone, and when they should work with a partner. In most situations, drum handling should be done in pairs. Working with a partner reduces the amount of force each person must exert, lowering physical strain. One exception, however, is when a drum needs to be rolled. In these situations, one employee should handle the drum to maintain full control over its direction.

Accidents can happen during drum handling, even when safety procedures are followed. Staying alert and knowing when to get out of the way is critical for safety. A dropped or out-of-control drum can cause severe damage. When a worker sees a drum fall, they must get out of the way quickly to avoid injury. Employees should wait until the container stops moving before responding to any spills or damages.

Ergonomic drum handling aims to reduce physical strain and prevent worker injury. It involves using tools and equipment designed to reduce awkward movements, excessive force, and repetitive strains. These tools are built to support workers, rather than requiring workers to adapt their bodies to heavy or awkward loads. 

Manually moving drums can be dangerous because of their weight and size. Workers are often forced into awkward bending, twisting, or reaching motions that strain various body parts. Over time, these actions can lead to chronic musculoskeletal problems. Providing ergonomic drum handling equipment not only protects employees, but also improves overall workplace efficiency. 

By preventing drum handling injuries, companies experience less downtime, fewer disruptions, and lower the risk of product loss. Additionally, these tools can increase employee confidence in their work, leading to faster and smoother handling processes. 

Proper training and clear procedures are important to maintaining a safe workspace. Drum handling requires specific knowledge, including safe lifting techniques for drums and equipment control. Employees should also have clear training on all relevant safety regulations and procedures. 

Investing in training and certification programs helps ensure that workers are properly prepared to handle drums safely. Many programs cover equipment operation, maintenance and inspection, hazard identification, and emergency response. Programs with hands-on training, assessments, and classroom instruction give employees well-rounded preparation to work safely.

Maintaining a clean and organized workspace is essential to keeping a safe workspace. Ignored debris and spills can cause future slips or trips. Keeping the workplace clean can assist in preventing these kinds of accidents. 

The Occupational Safety and Health Administration (OSHA) provides detailed guidance on how to protect workers from injury. OSHA drum handling guidelines, found in Code 1910.120(j), outline safety requirements for hazardous environments. This includes proper container labeling and employee PPE, in addition to many other safety regulations. Code 1910.120(j)(5) further addresses the protective measures employers must take when working with shock-sensitive materials. This includes enhanced PPE and continuous communication during handling. It is best to read the code to identify which regulations apply to your employees’ work.

In addition to OSHA guidelines, employers must also take proactive steps to reduce risks in potentially explosive environments. Equipment used in these areas should be designed to prevent sparking. Mild steel drums can rust over time, increasing the chance of sparks. Drums used in these environments should be kept free of rust.

Metal-on-metal contact, especially with mild steel, should be avoided, as it has a high chance of sparking. Stainless steel can be used to cover corners, edges, and hardware to reduce this risk. Fully stainless steel drums offer a safer option, but can still spark under the right conditions, so they must be handled with similar caution. 

Static electricity is also capable of creating dangerous sparks. To prevent static buildup, use earthing chains and clamps to help ground equipment. Any large sections of plastic or other man-made materials should be anti-static. The wheels on equipment should also be anti-static or have some other way of releasing electrical charges safely.

Having a safe workplace creates a conducive environment for all employees. Not only does it boost employee confidence and job satisfaction, but it also increases productivity and efficiency. However, more work must go into maintaining a safe workplace.

There are several ways to improve overall workplace safety. Employees manually handling drums should receive proper training on a regular basis. The workplace should also be well-lit, clean, and organized to help prevent additional accidents.

Regular risk assessments are also important. These reviews help identify potential hazards, reducing the chance of workplace injuries. Employees should go over each assessment to make sure their work aligns with the established standard operating procedures (SOPs).

At The Cary Company, we offer a wide range of industrial drums  to suit your industry needs. We also offer various kinds of equipment for drum handling safety to protect both your employees and your products. 

Still have questions about proper drum handling? 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.