A spill pallet is one of the simplest pieces of secondary containment you can buy — and one of the most important. If you store oils, fuels, solvents or chemicals on site, a spill pallet is usually what stands between a routine drip and a reportable pollution incident. This guide explains what a spill pallet is, the main types (drum, IBC, floor and covered units), how UK guidance sets the capacity you need, and how to choose the right one.
What is a spill pallet?
A spill pallet — also called a bunded pallet, sump pallet or spill containment pallet — is a platform with a sealed sump beneath the working surface. Drums or containers sit on a removable grid; if one leaks, drips or overflows, the liquid falls through the grid and is held safely in the sump below rather than reaching the floor, drains or watercourses. In other words, it provides secondary containment: the container is the primary container, and the pallet is the back-up if that container fails.
That single function does a lot of work. It keeps your floor safe and slip-free, protects the environment, and helps you meet the legal duty to prevent pollution — which is why secondary containment is expected wherever oils and hazardous liquids are stored.
The main types of spill pallet
Drum spill pallets
The most common type, sized to hold one, two or four drums (typically 205-litre). A four-drum sump pallet is a warehouse staple. Look for forklift pockets if you need to move the loaded pallet, and a sump capacity that meets the rule below.
IBC spill pallets & bunds
Built to take one or two Intermediate Bulk Containers (the 1,000-litre caged tanks). Because an IBC holds so much liquid, IBC spill pallets have a deep sump and a dispensing area is often useful so you can decant safely. If you store a single IBC, a one-IBC bund with at least 1,100 litres of sump capacity is the usual starting point.
Floor & low-profile sump pallets
Floor sump pallets and sump flooring sit low to the ground, making it easy to roll drums on with a drum trolley or store smaller containers without a step up. Modular sump flooring lets you build a bunded floor area to whatever footprint you need.
Covered & outdoor units
For outdoor storage, covered spill pallets, storage vaults and polyethylene vaults add a lockable lid or housing that keeps rainwater out of the sump and the contents secure. Keeping rain out matters — an open sump that fills with rainwater loses the containment capacity you are relying on.
Flexible & portable bunds
Flexible portable bunds are fold-out fabric trays for temporary work, refuelling points or vehicle and plant containment. They pack down for transport and deploy in seconds, which makes them ideal for site work and maintenance.
How much capacity do you need? The 110% / 25% rule
This is the question that catches most buyers out. Under the Control of Pollution (Oil Storage) (England) Regulations 2001, and the equivalent guidance applied more widely to hazardous liquids, secondary containment should hold whichever is the greater of:
- 110% of the largest single container stored on the pallet, or
- 25% of the total volume of everything stored on it.
So a pallet holding four 205-litre drums must contain at least 110% of one drum (about 226 litres) or 25% of the total 820 litres (205 litres) — the larger figure, 226 litres, is the minimum sump capacity. Where liquids are stored in a water protection area, or where a risk assessment demands it, the requirement can rise to 100% of the total stored volume. Always let your own risk assessment set the final figure.
Materials: polyethylene vs steel
Most modern spill pallets are moulded from chemically resistant polyethylene, which won't corrode and suits a very wide range of acids, alkalis and solvents. Galvanised or coated steel units are used where heavy point loads, fire exposure or very high durability are priorities. For most oil, fuel and general chemical storage, polyethylene is the practical default; check chemical compatibility for anything aggressive.
How to choose a spill pallet
- What and how much — drums, IBCs or mixed containers, and the total volume on the pallet (this drives the sump capacity).
- Indoors or outdoors — outdoor storage needs a covered unit or vault to keep rainwater out of the sump.
- Will you move it loaded? — specify forklift pockets if so.
- Decanting — an IBC unit with a dispensing shelf makes safe transfer easier.
- Chemical compatibility — confirm the material suits your substances.
- Load rating — check the pallet is rated for the weight of full containers.
Using spill pallets safely: the three Cs
Spill response is often summarised as Control, Contain, Clean up. A spill pallet covers the "contain" stage automatically, but it only works if it is maintained: keep the sump empty and clean, inspect it regularly, remove any rainwater or captured liquid promptly and dispose of it correctly, and never let the sump sit full. Pair your containment with a spill kit so staff can deal with anything that does escape.
Frequently asked questions
What is the main purpose of a spill pallet?
To provide secondary containment — to catch and hold leaks, drips and spills from stored containers so they cannot reach the floor, drains or the environment, protecting people, the workplace and your compliance position.
What are the requirements for a spill pallet?
The sump should hold whichever is greater of 110% of the largest container or 25% of the total stored volume (rising to 100% of total volume in water protection areas or where risk assessment requires). It should suit the chemicals stored and be kept clear so the full capacity is always available.
What is the difference between a drum spill pallet and an IBC spill pallet?
Drum spill pallets are sized for 205-litre drums (one to four); IBC spill pallets are built for 1,000-litre IBCs and have a much deeper sump to match the larger volume, often with a dispensing area for decanting.
Do spill pallets need to be covered?
Outdoors, yes — a covered unit or vault stops rainwater filling the sump and reducing its containment capacity, and keeps contents secure. Indoors a standard open pallet is usually fine.
Browse our spill pallets
KC Supply stocks drum spill pallets, IBC bunds, floor sump pallets, covered vaults and flexible portable bunds. Browse the full spill containment range, or read our guide to what UK law requires on spill containment and bunding. If you store oils and chemicals in drums, see also our drum storage and hazardous storage ranges.