Guide to Spill Containment Pallets

Businesses that store or handle hazardous liquids such as oils, chemicals, or fuels are required to implement appropriate spill containment measures to prevent environmental contamination and workplace hazards. The Health and Safety Executive (HSE) strongly recommends the use of secondary containment systems, such as spill containment pallets, as a ‘second line of defence’ in the event of leaks or container failure.

Under the Control of Pollution (Oil Storage) Regulations 2001, oil storage containers over 200 litres must be provided with suitable secondary containment. In practice, this typically includes bunded storage solutions or drip trays designed to capture and control spills before they reach drainage systems or the environment. Similar spill containment requirements are widely applied across industries storing hazardous chemicals, not just oils.

Key compliance expectations include:

• Secondary containment systems must typically hold at least 110% of the largest container or 25% of the total stored volume (whichever is greater)

• Spill containment pallets and bunded systems must be appropriately sized to capture full leaks with a safety margin

• Sites storing more than 200 litres of oil or hazardous liquids are generally required to use bunding or equivalent containment measures

• Regular inspections, maintenance, and staff training are essential to ensure ongoing compliance and safe operation

Failure to meet spill containment requirements can result in enforcement action, financial penalties, and significant environmental damage, making correctly specified spill containment pallets a critical part of safe hazardous material storage.

Spill containment requirements depend on the industry, the type of liquids stored, and how materials are handled on site. 

Different sectors, such as chemicals, manufacturing, logistics, and utilities, face varying risks, from corrosive substances to flammable liquids, all of which require compatible spill containment pallets.

The potential size and frequency of a spill also influence system selection. Larger volumes or regular decanting operations increase the need for higher-capacity containment, while smaller containers still require safe capture of leaks during handling and storage.

Material handling practices, including forklift movement, drum storage, and transfer activities, should also be considered to reduce spill risk. In all cases, spill containment requirements must be assessed to ensure the chosen system provides adequate secondary containment and supports safe day-to-day operations.

The correct spill containment pallets depend on the materials being stored and the required spill containment requirements.

Steel spill containment pallets are suitable for flammable and water-polluting liquids such as oils and lacquers. Plastic or stainless steel options are better suited for aggressive chemicals like acids and alkalis due to their higher corrosion resistance.

Spill containment requirements vary depending on where and how hazardous liquids are stored. Choosing the right type of spill containment solution helps ensure safe handling, regulatory compliance, and efficient site operations.

Indoor containment

Indoor solutions, such as spill containment pallets and bunded racking systems, are commonly used in warehouses and production areas. They are designed to safely capture leaks within enclosed environments and are ideal where materials are frequently handled or stored in smaller quantities.

Outdoor containment

Outdoor containment systems, including larger bunded platforms and storage depots, are used where bulk storage is required or indoor space is limited. These systems must be weather-resistant and provide secure secondary containment to meet spill containment requirements in exposed environments.

Permanent containment

Permanent installations are fixed systems integrated into the site infrastructure, such as built-in bunded areas or purpose-designed storage zones. They are typically used for long-term storage of hazardous liquids and offer high-capacity containment for consistent, high-volume operations.

Portable containment

Portable solutions, including mobile spill containment pallets and temporary bunds, offer flexibility for changing site layouts or temporary storage needs. They are particularly useful for maintenance work, short-term projects, or areas where storage requirements frequently change.

When selecting the appropriate spill containment pallets for your application, it is essential to review the safety data sheets (SDS) for each substance. These provide key information on chemical properties, safe storage requirements, and transport considerations, helping you ensure full compliance with spill containment requirements.

To support this decision-making process, we have compiled a media resistance list covering a wide range of commonly stored substances. This allows you to quickly identify compatible pallet materials based on chemical resistance and application.

As a general guide, steel spill containment pallets (1.0038) are suitable for many non-corrosive substances. However, for aggressive chemicals such as acids and alkalis, polyethene or stainless steel spill containment pallets are required to ensure safe and compliant storage:

1) Painted (WN 1.0038) or galvanised (1.0242) steel
2) Stainless steel 1.4301 (V2A)
3) Polyethylene (PE)
4) Galvanised sump pallets are not suitable for the storage of the following liquids: organic and inorganic acids, sodium bicarbonate, caustic potassium carbonate solution as well as other alkali hydroxides, chlorinated hydrocarbons, amine, nitro compounds, acid chlorides and other chlorides, phenol, aqueous alkaline solutions, nitrile.

As we previously mentioned, it's important that spill pallets are able to hold 110% of the maximum capacity of the largest tank or drum in use. This is a legal requirement when storing certain hazardous substances outside, and good practice in general when dealing with hazardous substances in any industrial setting.

Please bear in mind that the weight of the materials you are using will affect which spill pallet is appropriate for your needs. Spill pallets have a maximum load capacity that should not be exceeded. Should you need to discuss this further you can speak to one of our technical experts on +44 1952 811 991.

There are a wide range of storage solutions available for the safe containment of spills and leaks. You may also want to consider spill decking and containment racking if you are looking to bund whole areas, or it may be more suitable to use spill trays and pallets if you only need to bund individual 60 and 205 litre drums and IBCs.

Spill containment pallets can be fitted with a range of accessories to improve safety, handling, and response in the event of a leak, helping support spill containment requirements in daily operations.

DENIOS recommends the SpillGuard® hazardous substance leakage warning system, which can be used with any spill containment pallet and provides acoustic and visual alarms for at least 24 hours once activated.

For safer handling, accessories such as drum lifters and drive-on ramps help improve loading efficiency and reduce manual handling risks. To find the right configuration for your site and ensure full compliance with spill containment requirements, get in touch with the DENIOS team on +44 1952 811 991 for expert advice or view our full spill pallet range.