Intermediate bulk containers, commonly referred to as IBC totes, offer an efficient and practical solution for the storage and transportation of liquids, chemicals, and other raw materials. However, safely moving IBC totes require precision, appropriate equipment, and a thorough understanding of proper lifting techniques to avoid spills, injuries, and liability risks. Let’s dive into some essential tips for safely moving IBC totes, helping businesses streamline their logistics while maintaining worker safety and efficiency.
Inspect IBCs for Damage
Before moving any IBC tote, inspect the container thoroughly by checking for visible damage such as dents, leaks, defects or compromised seals. Ensure lids are fully tightened to the appropriate torque specification. Then, verify that all valves, fittings, gaskets, and other components are secure and in good working condition. If parts need replacing or welding repairs are required, the tote should be emptied and thoroughly cleaned before performing any tank maintenance. Make these necessary repairs as soon as possible to avoid downtime. Routine inspections are a critical component of IBC tank maintenance, ensuring container safety and structural integrity.
Choose the Right Equipment
Using appropriate equipment and tools for moving, stacking, and unloading IBC totes is key to avoiding accidents and worker-related injuries. Forklifts, pallet jacks, or cranes may be necessary depending on the tote’s design, gross weight, and size. Some IBCs have pallet bases with 2-way fork access, while others, like metal IBCs, have stackable leg positioners with three- and 4-way fork entry options. Forklift operators should also pay special attention to the “No Forks This Side” decal to prevent damage to the discharge valve.
Use Proper Lifting Techniques
Lifting IBCs requires precision and proper lifting techniques to prevent damage to the tote, its contents, and the environment from unnecessary hazards. Always position forklifts and pallet jackets centrally beneath an IBC tote, ensuring the fork tines are fully engaged before lifting. Equipment operators also need to account for uneven weight distribution when lifting and maneuvering, which can vary based on the IBC’s design and drain configuration. For example, stainless-steel IBC totes with side drains are heavier on the valve side than those with center drains. Additionally, straps and certified slings can be securely attached to totes with heavy-duty lifting lugs for controlled movement by crane.
Label Containers Clearly
Clear labeling and placarding is critical for DOT-compliant shipments of hazardous materials. IBC totes must have visible labels and markings (as required by the U.S. Department of Transportation per Title 49 CFR) including the UN symbol, IBC design type code, manufacture date, capacity, tare weight, and testing/inspection dates. Proper and accurate labeling not only complies with regulations but also informs employees on how to safely and effectively respond to emergencies.
Avoid Overfilling
Improper handling and overfilling of IBC totes can result in damaged containers, injuries, and operational downtime. Totes constructed from polyethylene, for example, will have different fill capacities and pressure limits than those built with stainless steel. Always adhere to the recommended fill levels provided by the manufacturer/supplier.
Consider Transportation Modes
When considering transportation modes, especially with movements involving hazardous liquids and chemicals, ensure the route complies with all DOT guidelines ahead of IBC shipment. Road transport via flatbed truck or enclosed trailer (i.e., dry vans) offers a reliable option that satisfies DOT requirements; however, it’s highly recommended to confirm local, state, and regional guidelines to avoid delays or missed deliveries. With the ever-evolving regulatory landscape, being informed about updates to domestic and international guidelines ensures that your operations remain compliant—and without disruption.
Secure IBCs for Transport
Securing IBC totes for transport is an essential step for DOT compliance. Factors like transportation mode and load distribution will determine if IBCs can be double stacked to optimize storage space, or if they require ratchet straps or load bars to prevent shifting during transit. If pressure build-up is a concern, ensure all venting procedures are followed. Properly secured shipments reduce the risk of incidents and potential damage to totes, valves, and fittings.
Monitor Locations During Transit
Monitoring tote locations during transit is possible with advanced IBC tracking technologies such as GPS and cellular units. Once installed on the container, robust data becomes available including real-time movements, trip frequency, utilization rates, and more. Real-time monitoring ensures that IBC totes and the valuable products stored arrive in optimal condition, while also enhancing inventory management and business operations through informed, data-driven decisions.
Regularly Service IBC Totes
It’s important to regularly service IBC totes, especially those being reused to transport hazardous liquids and chemicals. Leftover residue from previous shipments can lead to cross-contamination of new contents if not properly cleaned. Additionally, weld seams, valves, and gaskets can degrade over time. With thorough IBC tank cleaning and maintenance services along with routine quality checks, on-site personnel can quickly address structural integrity concerns and replace broken fittings. This proactive approach to tote maintenance prevents unexpected leaks and spills during transport.
Perform Periodic Testing
To ensure safety and continued use, UN/DOT-certified IBC totes must receive periodic testing and recertification. This can include leakproofness, thickness and pressure testing, as well as visual internal & external inspections for cracks, warpage, corrosion or other defects that might render the IBC unsafe for transportation. By staying on top of IBC recertification, you can avoid operational delays from tote rejections due to non-compliance.
Plan for Emergencies
Even with the best precautions in place, emergencies can happen. Have an emergency response plan in-place to address potential chemical spills, leaks, or accidents during transport and unloading. Ensure facilities are equipped with spill kits and that employees know the appropriate steps to contain and report incidents. Preparedness minimizes the impact of emergencies and ensures a swift, effective response.
Hazardous Materials Training for Personnel
All personnel who perform tasks with; could be exposed to; and/or handle hazardous materials will need to complete initial and recurring training required by the Occupational Safety and Health Administration (OSHA). Through HAZWOPER certification, staff will learn how to comply with hazardous waste operations and emergency response regulations in accordance with OSHA standards. In addition, employees should understand proper lifting techniques, equipment usage, and the specific handling requirements for different materials. Providing clear procedures and ongoing training fosters a strong safety culture within your organization.
Leveraging IBC Tanks for Efficiency
Using IBC tanks in your supply chain offers both flexibility and efficiency, but their safe movement is critical to their effectiveness. Incorporating best practices, such as regular testing and inspections, proper equipment usage and secure transport methods, ensures that these versatile containers deliver maximum value. Whether you’re moving temperature-sensitive liquids or hazardous materials in Packing Groups II and III, following these tips supports safety, compliance, and operational success.
