That large plastic tote in your warehouse might not look like much of a fire hazard. Especially if it's holding something as ordinary as cooking oil or motor oil (combustible liquids).
But in a fire, that container could become a much bigger problem.
Plastic intermediate bulk containers (IBCs), commonly used to store liquids in manufacturing, maintenance, and cleaning operations, offer a convenient, economical storage solution. However, when they contain flammable or combustible liquids, they can create serious risks for your employees, property, and business operations.
Plastic and composite IBCs can fail quickly when exposed to fire, releasing hundreds of gallons of liquid. If that liquid ignites, it can spread across the floor, creating a rapidly growing pool fire.
When multiple containers are stored together, the fire can spread from one to another, potentially overwhelming sprinkler systems and causing extensive property damage and business interruption.
The consequences can be devastating. FM reports a $47 million loss involving a fire that started during the filling of a plastic IBC and spread to approximately 20 nearby containers.
And it's not just highly flammable liquids that deserve attention.
Motor oil, lubricants, and cooking oils generally have higher flash points than liquids such as gasoline. That means they require higher temperatures to ignite.
But a building fire can generate enough heat to reach those temperatures. If an IBC fails and releases its contents, the resulting liquid spill can ignite and fuel a rapidly spreading fire.
In other words, a liquid that seems relatively harmless under normal conditions can become a serious hazard during a fire.
IBC storage isn't always limited to a designated warehouse area. Containers may also be found near production equipment, in maintenance areas, or in temporary staging locations.
Focus on:
Don't assume a container is appropriate for indoor storage simply because it's approved for transporting liquids. The National Fire Protection Association (NFPA) notes that transportation approvals and fire safety requirements for storage are not the same.
1. Know what's inside
Start with an inventory of the liquids your business stores, particularly those in plastic, composite, or cardboard IBCs. Review each product's Safety Data Sheet (SDS), paying particular attention to its flash point and fire hazards.
2. Rethink where containers are stored
When practical, consider storing IBCs containing combustible liquids outside the main facility such as in an exterior storage container or designated building that’s a proper distance away from the main facility—this can be a low-cost, sacrificial building.
Keeping these materials away from critical operations can help limit damage and business interruption if a fire occurs. Outdoor storage must also meet applicable fire protection and environmental requirements.
3. Consider fire-resistant containers
Metal IBCs and steel drums offer better fire resistance than conventional plastic or cardboard IBC containers. Evaluate whether these alternatives are appropriate for the liquids being stored and your operations.
For plastic or composite IBCs, verify that containers meet applicable fire safety requirements. Standards such as UL 2368 address fire exposure testing for certain nonmetallic IBCs, but these are rarely found in-use.
4. Review your fire protection
If plastic or composite IBCs must remain indoors for production use, they should be placed in FM-approved metal containment units.
Very few sprinkler systems are designed to control fires involving large quantities of released combustible liquids.
5. Keep an eye on changing operations
A storage area that was appropriate last year might look very different today. Regularly inspect container conditions, storage quantities, temporary staging areas, and proximity to ignition sources.
Small changes in how and where liquids are stored can make a big difference in your overall fire exposure.
A fire involving IBCs can do more than damage stored materials. It can destroy equipment, interrupt production, displace employees, and leave a business facing a lengthy recovery.
Taking time to evaluate container types, storage locations, and fire protection measures can help prevent a routine storage decision from becoming a costly disruption.