Proactive Containment Upgrade for IBC Chemical Storage
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The Challenge
As Environmental Manager, Chris was accountable for ensuring full compliance with hazardous substance storage requirements across site operations. A significant portion of the site’s chemicals were stored in 1,000L Intermediate Bulk Containers (IBCs), positioned on secondary containment bunds.
Over time, these bunds, constructed with internal steel reinforcement frames were experiencing accelerated degradation. Exposure to harsh environmental conditions, combined with the corrosive properties of the stored chemicals, resulted in progressive structural failure due to rust.
This presented a critical risk scenario:
- Compromised structural integrity of containment systems
- Potential collapse of IBC units
- High-consequence chemical spills (up to 1,000L per unit)
- Environmental contamination and regulatory non-compliance
The site required a durable, long-term containment solution that would eliminate corrosion risk and enhance operational safety.
The Hazero Approach
Hazero engaged directly with the site through an on-site assessment, taking a consultative approach to understand both the operational environment and risk profile.
Rather than a like-for-like replacement, Hazero identified an opportunity to re-engineer the containment strategy. The recommendation was to phase out the existing steel-reinforced bunds and transition to purpose-built, high-performance containment systems.
Hazero specified:
- Replacement with Single and Double IBC Spill Pallets
- Construction from 100% polyethylene for superior chemical resistance
- Elimination of all steel components to remove corrosion pathways
- Standardised containment platforms to improve handling and consistency
This approach aligned with Hazero’s broader philosophy: designing out risk at the source, rather than managing its consequences.
The Outcome
The implementation delivered immediate and long-term improvements across safety, compliance, and operational efficiency.
Risk Elimination
- Removal of corrosion-prone steel components
- Significantly reduced likelihood of structural failure and chemical release
Long-Term Durability
- Polyethylene construction provides resistance to both environmental exposure and aggressive chemicals
- Extended service life with minimal maintenance requirements
Improved Operational Safety
- Flat, stable load-bearing surfaces simplified IBC handling
- Reduced manual handling risks during loading and unloading
Compliance Confidence
- Strengthened alignment with hazardous substance storage standards
- Reduced environmental liability exposure
Hazero as Your Containment Partner
This project demonstrates Hazero’s role beyond product supply, acting as a solution provider focused on risk mitigation, compliance, and long-term performance.
By combining technical expertise, on-site assessment, and purpose-built containment systems, Hazero enables organisations to proactively manage hazardous substance risks and create safer working environments.
Creating Safer Working Environments
At Hazero, our mission is Zero Hazards. We partner with organisations across New Zealand to design and implement solutions that safely store, contain, control, and manage hazardous substances.
If you would like support reviewing your current containment systems or identifying areas of risk, our team is available to assist.
Contact Hazero
📞 0800 688 844
✉️ help@hazero.co.nz
On-site assessments are available nationwide.
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