How to design a chemical storage area – spill containment tubs and IBCs
Published on: 08-01-2026
1) Start with inventory and risk assessment
What do you store? Hazard classes (flammable, corrosive, toxic, oxidising), physical state, viscosity.
How and where? Number of containers (canisters, 200-litre barrels, 1,000-litre IBCs), will there be any spillage/packaging?
Environmental conditions: temperature, UV, explosion hazard zones (if applicable), floor load capacity, slopes.
Traffic and people: trolley routes, collection points, pallet trolley range, storage areas.
2) Retention principle: how much must the tray ‘catch’?
In practice, EHS increasingly uses one of two conditions for the capacity of the spill tray (you take the higher value):
≥ 110% of the volume of the largest container in the area, or
≥ 25% of the total volume of all containers in the area.
3) Material and design selection
Tray material:
HDPE/PP – acidic/alkaline solutions, most aqueous chemicals, many oils; corrosion resistant.
Painted/galvanised steel – oils, fuels; not suitable for aggressive acids/alkalis.
Stainless steel – aggressive agents, higher resistance, higher cost.
Grate:
Facilitates the placement of containers above the spilled medium. For HDPE – PE or stainless steel grate (according to compatibility).
Critical feature:
Drain plug with safety device (tap with lock/plug) – allows the medium to be safely drained into a waste container.
Integrated fork pockets – if the trays need to be relocated with a trolley.
Load capacity certification – check the maximum load (IBC vs barrels).
4) IBC – zone design
Tubs for IBCs: select models with retention ≥ 110% of the largest container (see point 2) and load capacity adapted to a full IBC (approx. 1.1–1.3 t).
Positioning: IBCs on one level (stacking only in special stacking systems), drain valve within the tray.
Spill zone: worktop/drip tray, hose rack, ball valve with safety device. Avoid makeshift hoses ‘under the trays’.
Access: min. 800–1000 mm in front for safe operation of the valve and connections.
5) Segregation and compatibility
Separate hazard classes (e.g. oxidising vs flammable; acids vs bases).
Use separate tubs for incompatible substances.
Labels and pictograms (GHS), ‘No smoking/open flame’ signs, information on maximum retention capacity.
Joint storage only for media with confirmed compatibility.
6) Floor, drainage, ventilation
Sealed flooring, without cracks; slopes should lead to the tray/not to the drain.
No drains in the retention area itself (risk of contamination entering the sewage system).
Ventilation appropriate to the nature of the medium (volatile vapours – air exchange, sometimes Ex zones).
Roofing or covers for media sensitive to rainwater/UV.
7) Ergonomics and logistics
Mark traffic paths (min. 1200 mm for pedestrians; more for trolleys) with stripes.
Bumpers/barriers next to tubs to prevent forks from hitting the tank.
Storage areas for sorbents, gloves, valve keys – always within reach.
8) Procedures: from receipt to incident
Receipt: check the label, condition of the packaging, compliance with the safety data sheet (SDS).
Daily operation: check that the grate is clean, the valve is closed, and there are no ‘bridges’ outside the tub.
Spills: sorbent kit (mats, sleeves, granules), disposal plan, emergency numbers at the workstation.
Drainage and cleaning: after an incident, pour into a marked waste container, document, wash the tub in accordance with the SDS.
9) Inspections and documentation
Weekly checklist: cracks, corrosion, condition of seals, operation of the drain plug, cleanliness of the grate.
Quarterly inspection: condition of the floor, signs and pictograms, validity of SDS, verification of retention capacity vs. current quantities.
Training: short on-the-job training for operators and foremen (handling of IBCs, sorbents, valves).
10) Most common mistakes (and how to avoid them)
Insufficient tank capacity – calculate retention according to point 2.
Inappropriate tank material – check compatibility (HDPE does not corrode, steel is not suitable for acids/alkalis).
Valve outside the tank – always inside the retention zone.
No sorbents and no plan – emergency kit ‘at hand’.
Drainage to the sewerage system – prohibited; retention = isolation.
Stacking IBCs without a system – only where the structure allows it and in accordance with the technical documentation.
Zone acceptance checklist
- Retention calculated and meets ≥ max(110% of the largest, 25% of the sum).
- Tank material compatible with media; valve within the tank.
- Grates/grating complete, stable; safe sliding.
- Segregation of incompatible substances; legible GHS pictograms.
- No drain grates in retention; sealed floor.
- Sorbent kit and response plan available on site.
- Traffic routes marked; bumpers at tubs.
- Inspection procedure and inspection log implemented.
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