The 55 Gallon Drum has been the backbone of industrial storage and transportation for decades. Whether in the form of a 55 Gallon Steel Drum, a Plastic 55 Gallon Drum, or other types of gallon barrels, these containers have become essential for moving liquids, solids, and hazardous materials across industries. But as businesses evolve, so do their storage needs. The heavy, rigid design of the traditional 55 Gallon Barrel Metal container comes with safety risks, inefficiencies, and hidden costs. Today, more companies are recognizing the benefits of switching to innovative alternatives like Gorilla Drum.
This page explores how long steel drums last, what alternatives exist, and the differences between lined and unlined steel drums. It also explains why Gorilla Drum is the smarter option for businesses seeking both cost savings and improved safety.
How long do steel drums last?
The lifespan of a 55 Gallon Steel Drum is highly variable, depending on use, handling, and the environment in which it is stored. In ideal conditions—indoors, protected from moisture, and used with non-corrosive materials—a steel drum may last several years. However, in most industrial settings, conditions are far from perfect, and the effective service life is much shorter.
Environmental factors that affect lifespan
Moisture, temperature fluctuations, and outdoor storage significantly reduce the longevity of a fifty five gallon drum. Even with proper coatings, steel is prone to rust when exposed to water or humid environments. In outdoor storage yards, corrosion can begin within months, particularly at the seams and chimes where paint or coatings may be thinner. Once rust develops, the structural integrity of the 55 Gallon Barrel Metal container is compromised, making it unsafe for continued use.
Extreme temperatures also accelerate wear. High heat can weaken protective linings, while freezing conditions may cause brittleness in seals or increase the risk of deformation when drums are stacked. These factors highlight why many steel drums are cycled out of service earlier than expected.
Impact of contents on durability
What goes inside a steel drum matters just as much as where it is stored. Corrosive chemicals, acids, and solvents quickly degrade unlined barrels, while food or pharmaceutical products may require epoxy or phenolic linings to prevent contamination. Even lined drums have a limited lifespan, as linings eventually crack, peel, or wear away after repeated fills. For businesses that frequently buy 55 gallon drums, this leads to ongoing replacement cycles and higher costs.
Non-corrosive products, such as oils or lubricants, may extend a drum’s service life, but physical wear from handling still shortens its usefulness. Dents, punctures, or warped lids are common in warehouses and during transport, all of which reduce safety and usability.
Safety concerns and handling risks
From a safety standpoint, the heavy weight of a 55 Gallon Steel Drum creates risks throughout its lifespan. Even when empty, these containers are cumbersome, requiring forklifts, drum lifters, or other equipment. When full, they can weigh over 400 pounds, making manual handling impractical and dangerous. Accidents such as drops, spills, or tipping are not uncommon, and as drums age, the risk increases due to weakened structural integrity.
Average service cycle
In practice, many industries retire steel drums after just a few uses, particularly if they are storing hazardous or high-value materials. For less critical applications, drums may last longer, but frequent inspections are required to ensure safety and compliance. On average, a 55 Gallon Drum Container might serve effectively for one to five years, but this range varies widely depending on use and environment.
Why alternatives last longer
The ongoing need to replace steel drums is one of the primary reasons businesses are moving toward modern alternatives. Gorilla Drum, made of recyclable polypropylene, avoids the corrosion, weight, and handling issues of steel. At only 7.5 pounds unfilled, it is easy to manage while maintaining the same 55-gallon capacity. Collapsible design also reduces damage risks during storage and transport. For companies evaluating long-term cost and safety, Gorilla Drum delivers a lifespan advantage that steel simply cannot match.
What is the alternative to steel drums?
For decades, the 55 Gallon Steel Drum has been the go-to choice for industries needing durable containers for liquids, powders, and solids. Its rigid metal construction made it dependable for many applications, but it also introduced challenges: heavy weight, susceptibility to rust, difficult handling, and inefficient use of space. Over time, these limitations have led businesses to seek better solutions.
Plastic drums as a partial alternative
One of the first alternatives was the Plastic 55 Gallon Drum. These gallon barrels offered resistance to corrosion and were lighter than steel versions, making them easier to handle in some situations. They became popular in food-grade applications, pharmaceuticals, and industries where rust contamination was a concern. However, while they solved some problems, plastic drums remained rigid and bulky. Whether full or empty, a fifty five gallon drum made of plastic consumed the same amount of storage space, and like steel, they still required forklifts or dollies to move when filled.
The rise of collapsible polypropylene drums
The true breakthrough in drum design comes from collapsible polypropylene containers like Gorilla Drum. Designed as a full-capacity alternative to traditional gallon barrels, Gorilla Drum weighs only 7.5 pounds when unfilled, compared to more than 40 pounds for a 55 Gallon Barrel Metal container. Despite being lighter, it maintains the same 55-gallon volume, providing identical functionality without the drawbacks.
Collapsibility is one of its most revolutionary features. When empty, Gorilla Drum folds flat, allowing up to 80 units per pallet and more than 4,000 per truckload. In contrast, rigid steel or plastic drums allow only about 208 units per truck. This means freight costs are dramatically reduced, warehouse space is used more efficiently, and fewer trucks are required to transport the same number of containers.
Safety and compliance advantages
Gorilla Drum is also engineered with safety in mind. Features like lift loops, reinforced zippers, dolly straps, and labeling windows simplify handling and reduce the risk of injury. Certified for hazardous and non-hazardous materials under UN/DOT standards, it offers the same compliance as traditional 55 Gallon Drum Containers but in a more user-friendly design. For workers and managers alike, this reduces both the physical strain of handling drums and the risks of spills or contamination.
Long-term value
While companies may initially look to buy 55 gallon drums made of steel or plastic due to familiarity, the long-term costs of replacements, storage, transport, and handling quickly outweigh the benefits. Gorilla Drum provides not just an alternative but an upgrade—combining efficiency, safety, and sustainability.
What is the difference between lined and unlined steel drums?
When businesses consider a 55 Gallon Steel Drum, one of the first decisions they face is whether to use a lined or unlined version. Both types of gallon barrels are widely available, and while they share the same fifty five gallon drum capacity, their design makes them better suited for different applications. Understanding these differences helps companies avoid costly mistakes, maintain safety, and ensure compliance with industry standards.
Lined steel drums
A lined 55 Gallon Barrel Metal container is manufactured with a protective interior coating. This lining is typically made of epoxy or phenolic resins, designed to serve as a barrier between the contents and the steel walls of the drum. The purpose of the lining is to prevent chemical reactions, corrosion, or contamination.
Lined drums are commonly used for:
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Food and beverage storage: Preventing contamination from direct contact with bare metal.
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Pharmaceuticals and healthcare products: Protecting sensitive materials from trace metal leaching.
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Chemicals: Especially those that are corrosive or reactive with steel, which could otherwise damage the drum and compromise safety.
While lined drums extend usability in certain applications, they are not indestructible. Over time, the lining can peel, crack, or wear away, particularly if exposed to abrasive contents or repeated cleanings. Once the lining is compromised, the drum loses its protective benefits and must be replaced.
Unlined steel drums
An unlined 55 Gallon Drum Container has no internal coating and is simply raw steel inside. These are generally used for non-corrosive materials such as oils, lubricants, or some industrial solids that will not react negatively with bare metal. Because there is no lining, they are often less expensive to manufacture and purchase.
However, the tradeoff is vulnerability to rust or corrosion when exposed to moisture or reactive chemicals. For companies that buy 55 gallon drums in unlined versions, careful consideration of the stored material is critical. Using an unlined drum with incompatible contents could lead to product contamination, environmental hazards, and safety risks.
Shared limitations of both types
Despite their differences, both lined and unlined steel drums share the same core challenges: they are heavy, rigid, and costly to transport. A 55 Gallon Steel Drum weighs more than 40 pounds empty and requires forklifts or specialized equipment to move when filled. In addition, neither lined nor unlined designs address the inefficiencies of space consumption in warehouses or during shipping. Whether a business chooses lined or unlined, they are still constrained by the drawbacks of traditional gallon barrels.
Modern alternatives
Instead of choosing between lined and unlined, many businesses are turning to alternatives like Gorilla Drum. Made from recyclable polypropylene, Gorilla Drum avoids the risks of corrosion entirely and eliminates the need for interior linings. It provides the same fifty five gallon drum capacity but with a collapsible, lightweight design that saves space, reduces costs, and simplifies handling.
For organizations evaluating whether to buy 55 gallon drums, Gorilla Drum represents a modern solution that delivers all the benefits of lined and unlined steel drums without their limitations. For a more detailed comparison, see the Complete Guide To Choosing The Right 55 Gallon Drum Alternative.
Cost benefits of switching from steel drums
The financial benefits of moving away from steel drums are significant. Companies that buy 55 gallon drums repeatedly incur costs not only from purchase but also from shipping, storage, and disposal. Heavy steel drums add weight to shipments, increasing fuel consumption. Their rigid design consumes valuable warehouse space even when empty. Once corroded or dented, they must be recycled or scrapped, adding another cost.
With Gorilla Drum, these expenses are reduced. The collapsible design allows for more efficient storage and transportation, lowering freight costs and freeing up warehouse space. The lightweight build reduces labor and equipment requirements, cutting operational expenses. Over time, businesses see measurable savings while also achieving sustainability goals.
Safety benefits of switching from steel drums
Safety is another area where Gorilla Drum outperforms traditional gallon barrels. Handling heavy 55 Gallon Steel Drums puts workers at risk of injury from lifting, rolling, or transporting the containers. Spills and leaks are also more likely when drums corrode or are mishandled.
Gorilla Drum mitigates these risks with a lightweight frame that is easy to handle. Workers no longer need forklifts or heavy equipment for every movement. Built-in lift loops and dolly straps provide safer ways to move the containers. The collapsible design reduces clutter, lowering the chance of accidents in storage areas. For companies prioritizing worker safety and compliance, Gorilla Drum represents a smarter solution, offering streamlined handling, reduced physical strain, and safer workflows that protect employees while improving operational efficiency. Its innovative design empowers businesses to reduce injury rates, minimize downtime, and create safer, more organized workplaces that directly support productivity and cost savings.
Final thoughts
The fifty five gallon drum has long been the industry standard, but its limitations are becoming harder to ignore. Steel drums are heavy, costly to transport, and prone to corrosion. Even lined versions wear out over time. Plastic alternatives reduce some risks but remain rigid and inefficient. In addition, both types consume valuable warehouse space even when empty and require significant equipment for handling. Over time, the costs of replacements, storage, and labor add up, creating financial and operational strain for businesses across multiple industries. Gorilla Drum offers a better path forward: a collapsible, lightweight, and recyclable solution that meets all the needs of a 55 Gallon Drum Container without the downsides, delivering safer handling, long-term durability, improved logistics efficiency, and measurable cost savings.
For businesses looking to improve safety and reduce costs, Gorilla Drum is the clear choice. To learn more about how Gorilla Drum can benefit your operations, call +1 800-758-8079 today.