How High Can You Stack IBC Totes?

IBC totes are a vital part of many industries, offering a convenient and efficient solution for storing and transporting liquids and bulk materials. However, when it comes to stacking these containers, safety and efficiency are key considerations. In this article, we’ll explore how high can you stack IBC totes, factors influencing stacking height, and best practices for ensuring safe and effective storage.

What Is an IBC Tote?

IBC (Intermediate Bulk Container) totes are large, industrial containers typically used to store and transport liquids or powders in bulk. Made of durable materials such as plastic or metal, BCs come in various sizes, but the most common is the 1,000-litre container. They are widely used in industries like food processing, chemicals, pharmaceuticals, and agriculture.

Knowing how high you can stack IBC totes, or how many IBC totes you can stack in a given environment, is crucial to maximising storage space while maintaining safety and preventing damage. The stacking height varies depending on the container’s design, condition, and the material inside.

Manufacturer’s Stacking Recommendations

To ensure safety, manufacturers provide clear guidelines for stacking IBC containers. Generally, the maximum stacking height for IBC totes is between 3 and 4 containers high. Exceeding this height can place undue pressure on the lower containers, leading to potential structural failure.

If you’re using reconditioned IBCs from Recontainers Direct, broadly-speaking you can keep to this rule even when using reconditioned IBC’s. This is because our reconditioned IBCs exhibit the same structural integrity as a brand new IBC – anything that falls below this standard is taken out of circulation and repurposed.

We’d hope so, but there’s no guarantee that another supplier has the same high standards for quality as we do. That being the case, reconditioned IBCs of unknown origin may have different (lower) stacking limits than new IBC’s due to pre-existing wear and tear being factored in. Always inspect these containers for signs of damage before stacking to determine how many IBC totes you can stack safely in your storage area.

Factors Affecting Stacking Height

The stacking height of IBC totes isn’t one-size-fits-all; it depends on several factors. Here are the main elements that influence how high can you stack IBC totes:

• Weight Distribution: IBC containers can hold various materials, from liquids to powders. The weight of the contents does play a significant role in how high you can safely stack IBC totes, and it’s recommended that you don’t stack IBC’s that are holding something more than two high.
• Container Condition: You should always verify that any IBCs you intend on stacking are in good condition. The older an IBC is, the more likely it is to be in poor condition so new IBCs will, in general, be more suitable for stacking than reconditioned IBCs. However, it is the overall condition and not the age that you should use to determine suitability for stacking. If you see any clear defects or deformities in a tank, don’t stack it.
• Storage Environment: Indoor and outdoor storage conditions can influence the stability of stacked IBCs. In outdoor settings, exposure to weather conditions can make certain types of incidents more likely (e.g. empty tanks stacked outside are more likely to blow over in strong winds).

Safety Guidelines for Stacking IBC Totes

When stacking IBC totes, safety should always be the top priority. Here are some essential safety guidelines:

• Stable Surface: Always stack IBC containers on a level, firm surface. This helps prevent tipping or collapsing, especially when the containers are full. Palletized IBCs are an excellent solution to enhance stability.
• Use of Bunded Storage and Spill Kits: Bunded storage systems can help prevent spills and increase stability when stacking IBCs. They are particularly useful in industries dealing with hazardous materials. Incorporating spill kits into your stacking practices ensures that you are prepared for any accidents, and complying with any applicable health and safety regulations.

Best Practices for Stacking IBC Totes in Different Environments

When it comes to stacking IBC totes, the environment plays a crucial role in determining how high can you stack IBC totes. Here are some best practices for different settings:

• Indoor Storage: Ideal for stacking 3-4 high, as indoor environments provide more control over conditions like wind, terrain, and ground conditions.
• Outdoor Storage: Outdoor storage can expose IBC totes to the elements, which increases the risk of IBC deterioration and / or stack instability. Our recommendation is to only stack IBCs 4-high outdoors if there is sufficient cover from heavy winds, and limit stacking to 2-3 high if suitable cover / protection is not present. 
• Warehouse Stacking: In warehouse environments, using pallet racking systems designed for IBC totes can help maximize storage space while keeping the containers organized and accessible. Under-rack bunds are a further useful addition to this kind of setup, as they’ll help contain any spills that do occur.

If you’d like further advice on safe stacking practices for IBCs, contact Recontainers Direct today.