Drums are a very common method of storing and transporting liquids, powders, and granulated solids. However, leaks and spills from drums can occur rather frequently during storage or transportation. There are several potential reasons why drums may end up leaking or spilling their contents.
Causes of Drum Leaks and Spills
There are a number of factors that can lead to leaks or spills from drums:
Improper Securing of Lids and Bungs
One of the most common reasons drums end up leaking is improper securing of the lid or bung openings. The lids or bungs are not properly tightened or fastened before the drum is moved. This allows the contents to gradually spill out through the loose openings during transport or handling. Proper securing of lids and bungs is essential to prevent leaks.
Damage During Handling
Careless or rough handling of drums can also lead to leaks and spills. If drums are knocked over, dropped, or impacted during loading/unloading or transport, the drum may become dented, warped, or cracked. This drum damage can allow the contents to leak out. Gentle handling of drums is key to preventing damage that leads to leaks.
Corrosion and Wear
Over time, drums may corrode or wear out, particularly along seams and edges. As drums age and degrade, they become much more prone to leaking. Using drums past their recommended life span greatly increases the chances of leaks due to corrosion and seam failure. Proper inspection and scheduled replacement of old drums can mitigate leaks due to wear.
Improper Stacking
If drums are stacked improperly during storage, it can result in damage to the lower drums in the stack due to the excess weight. Stacking drums too high or without protective padding between layers can dent, warp, or crack the drums and lead to leaks. Proper staggering and stacking techniques and stacking limits help prevent damage that causes leaks.
High Temperatures
Exposure to high temperatures can cause the contents of a drum to expand and build up pressure. With sufficient temperature fluctuations, this pressure buildup can push past the limits of the drum and cause leaks through seams and seals. Maintaining moderate temperatures during storage and transport helps prevent expansion leaks.
Freezing Temperatures
On the other end of the spectrum, freezing temperatures can also damage drums and cause leaks. As liquid contents freeze and expand, they can split or warp the drum. Frozen openings and bungs can crack or fail. Keeping drums from freezing helps prevent cold temperature damage.
Inadequate Venting
Without adequate venting, gasses evolved from the contents can build up pressure inside a drum. This gas pressure can push liquid out through any available seams, seals, or openings. Ensuring proper venting allows gas release without liquid escaping.
Selecting the Right Gasket Material
Choosing the suitable gasket material necessitates a deep dive into the drum’s contents and the environmental conditions it will face. It’s imperative for manufacturers and users to consult chemical compatibility charts, evaluate the operational temperature range, and consider potential exposures to UV light, ozone, and weathering. Engaging with material scientists and chemists can yield critical insights into the most appropriate material choice for a given application.
Defective Seals and Gaskets
Drums use seals and gaskets to create tight closures and prevent leaks. If these seals or gaskets are defective or degraded or of not right quality, they may not contain the contents properly. Damaged, cracked, dried out, or incorrectly installed seals/gaskets are prone to leaking and should be replaced.
Incompatible Contents
If substances are placed in a drum that are incompatible with the drum liner, it can cause the liner to weaken, degrade, or fail. Corrosive or reactive contents can eat away at drum liners, leading to leaks. Always ensure drum and content compatibility.
Exceeding Load Limits
Filling drums beyond their rated capacity can cause extensive bulging, splitting, seal failure and leaks, especially if the drums are stacked. Overloading drums puts excessive stress on the container. Following recommended filling limits helps avoid over-pressurization.
Improper Positioning During Transport
Ideally, drums should be transported upright and secured to prevent tipping or rolling. If drums are tipped on their sides or upside down during transport, weak spots in the drum can be stressed and fail, leading to leaks when righted later on.
Consequences of Drum Leaks and Spills
Drum Leaks and spills can have a number of problematic consequences, including:
- Product Loss: Leaking drums result in loss of the valuable contents, which can be very costly. Everything from raw materials to finished products can be wasted.
- Environmental Contamination: Spilled liquids or powders can contaminate soil, groundwater, or waterways, creating environmental damage. Some materials are hazardous if released.
- Cleanup Costs: Leak and spill containment, drum disposal, environmental remediation, and related costs can be very expensive. Drummed materials often require special handling if spilled.
- Regulatory Fines: Government environmental agencies may issue fines or sanctions related to spills and releases. Improper drum management can be considered a violation.
- Inventory Issues: Leaks and spills make it difficult to track and account for drummed inventory accurately. Some losses may go undetected as “shrinkage.”
- Employee Safety: Leaked materials may pose health hazards to workers if improperly contained and cleaned up. Some drummed substances require hazardous material (HAZMAT) handling.
- Reputation Damage: High-profile leaks and spills can harm a company’s reputation with the public, shareholders, or regulatory agencies. Brand image may suffer.
- Legal Liability: Drum Leaks and spills may result in lawsuits, damage claims, or other legal liabilities if property, environmental, or human health impacts result.
Preventing Drum Leaks and Spills
There are a number of best practices that can help prevent leaks and spills from drums during storage and transportation:
- Inspect drums regularly for damage, rust, or degradation and replace as needed. Do not use damaged drums.
- Ensure drum lids/bung caps are properly tightened according to manufacturer specifications. Use gaskets if required.
- Store drums on flat, solid surfaces and interlock or strap drums when stacking. Never stack drums too high.
- Handle drums gently when loading, unloading, or moving them. Avoid drops, impacts, or abrasion damage.
- Secure drums upright and immobile during transport using straps, pallet collars, chocks, or similar tiedowns.
- Maintain recommended temperature ranges during storage and transport to avoid pressure changes. Keep drums from freezing.
- Allow adequate venting for any gases emitted by drum contents to prevent pressure buildup.
- Ensure drum liners and contents are compatible and drums are not overfilled past recommended limits.
- Train employees on proper drum handling techniques, securing, stacking, loading/unloading methods, and leak/spill response protocols.
- Inspect and replace worn forklift drum handling attachments to avoid accidental punctures or damage during transport.
- Use overpack drums, pallet containment walls, or other secondary containment during storage and transport in case of leaks.
- Label drums clearly to avoid mishandling and store hazardous, flammable, or reactive drums separately.
Conclusion
Drum leaks and spills are common but preventable problems if drums are properly maintained, handled, stacked, transported with the right quality of Rubber Seal or Gasket. Following drum management best practices, conducting training, performing thorough inspections, and planning for spills can help companies significantly reduce loss, environmental impact, safety hazards, and liability from leaking drums. With appropriate drum precautions and leak response preparations, companies can safely and responsibly use drummed storage and transport.
