TANK CORROSION
PREVENTION
CORROSION: THE UNSEEN LIABILITY IN MODERN STORAGE
CORROSION: THE UNSEEN
LIABILITY IN MODERN STORAGE
Every day, thousands of bulk storage tank installations across the United States quietly lose steel to oxidation and pitting. The process rarely makes headlines—yet the effects of corrosion erode capital budgets, elevate liability, and threaten human health when leaks contaminate soil or groundwater. On the shop floor, the problem is visible as an orange halo creeping across a tank’s surface or a dark weep line at the tank chime, but the true danger lies in unseen wall‑loss that compromises a vessel’s burst strength.
For a refinery operator, a leaking fuel tank instantly converts profit into remediation expense; for a municipality, spillage from water storage tanks undermines public trust and the local water supply. Deferred action magnifies maintenance costs, triggering costly repairs that dwarf the price of early intervention. In an era when regulators penalize spills aggressively, tank owners who delay tank corrosion prevention face a significant cost in fines and lost production. The only rational choice is proactive control anchored in science, engineering, and disciplined operations.
For a refinery operator, a leaking fuel tank instantly converts profit into remediation expense; for a municipality, spillage from water storage tanks undermines public trust and the local water supply. Deferred action magnifies maintenance costs, triggering costly repairs that dwarf the price of early intervention. In an era when regulators penalize spills aggressively, tank owners who delay tank corrosion prevention face a significant cost in fines and lost production. The only rational choice is proactive control anchored in science, engineering, and disciplined operations.
INSIDE THE CHEMISTRY OF CORROSION
INSIDE THE CHEMISTRY OF
CORROSION
Corrosion is, in effect, an electrochemical circuit established on a wet metal surface. Oxygen, moisture, and ions drive chemical reactions that convert iron to rust (oxidation). The attack accelerates on unlined mild steel and sometimes even on overstressed stainless steel, and four common causes of tank corrosion dominate:
- Residual salts from inadequate surface preparation.
- Condensation in the vapor space of underground storage tanks and aboveground storage tanks.
- Acidic by‑products of stored petroleum products or microbial colonies in diesel fuel storage tanks.
- Coating holidays at weld seams, knuckles, and especially the tank chime.
Because water bottoms accumulate at the tank floor, pitting often concentrates there, producing classic tank bottom corrosion. Stray‑current interference, sulfide bacteria, and chloride‑rich water quality further intensify attack on steel substrates and load‑bearing welds that guard a tank’s structural integrity.
Engineers have tested many protection methods—cathodic systems, corrosion inhibitors, exotic alloys—but none match the versatility of a high‑performance corrosion-resistant coating. Such membranes insulate steel from electrolytes and block the electron transfer that drives the corrosion of steel.
Engineers have tested many protection methods—cathodic systems, corrosion inhibitors, exotic alloys—but none match the versatility of a high‑performance corrosion-resistant coating. Such membranes insulate steel from electrolytes and block the electron transfer that drives the corrosion of steel.
POLYUREA AND POLYURETHANE:
ADVANCED COATINGS FOR AN AGGRESSIVE WORLD:
A modern polyurea or polyurethane protective coating hardens within seconds of leaving the spray gun, forming a seamless elastomeric shell that bonds tenaciously to carbon and stainless steel, as well as to composite laminates on fiberglass tanks. Key advantages translate directly into lower risk for asset owners:
- Layer thickness in excess of 100 mils achieved in a single pass seals pores and weld porosity around the tank chime.
- Tensile strengths exceeding several thousand psi resist impact from shifting metal components or dropped tools during turnarounds.
- 200–400 % elongation tolerates shell flexure, thermal expansion, and the slight settlement common to large‑diameter bulk storage tank foundations.
- Ultra‑low permeance blocks moisture ingress, halting under‑film attack even in harsh environmental conditions at coastal terminals and power plants.
When chemistry is tuned for potable service, the same advanced coating can protect potable water reservoirs without leaching, allowing a single technology to span diesel fuel storage tanks, oil tanks, and municipal metal water tanks. For operators of petroleum storage tanks, amp‑resistant formulations handle aromatics and crude blends, while aromatic polyurethanes suit elevated‑temperature oil storage. The result is effective corrosion protection that endures for decades with minimal touch‑up.
SURFACE PREPARATION AND
COATING—NO SHORTCUTS ALLOWED
Installing a coating is not “paint and pray.” Best practice in industrial painting begins with near‑white abrasive blasting that removes mill‑scale, rust, and salt contamination, exposing fresh metallic gray. Crews then:
- Inspect anchor profile depth to verify compatibility with the chosen coating system.
- Stripe critical welds, nozzles, and every inch of the tank chime.
- Control substrate temperature and humidity, recognizing that adverse environmental factors can create blistering or pinholes.
- Calibrate plural‑component pumps to ensure on‑ratio spray during coating application.
- Record wet‑film thickness at multiple points, guaranteeing uniform build on joints, manways, and the exterior surfaces of storage tanks as well as the interior shell.
Skipping any step undermines corrosion control and invites early failure. Industry professionals therefore link payment milestones to hold‑point inspections, emphasizing that quality surface coating is not an optional expense—it is an insurance policy against major problems.
INSPECTION, MONITORING, AND LONG-TERM STEWARDSHIP
INSPECTION, MONITORING, AND
LONG-TERM STEWARDSHIP
Even a flawless installation will fail without regular maintenance. Codes prescribe out‑of‑service internal examinations, yet leading operators supplement these rules with real‑time corrosion monitoring—LP coupons, electrical resistance probes, or guided wave ultrasonics positioned at the tank floor and near the tank chime. Combined with regular inspections, these data streams identify early signs of corrosion so repairs can occur at the right time, before wall loss compromises integrity.
A robust tank maintenance program includes:
A robust tank maintenance program includes:
- Annual holiday detection on liner films.
- Semi‑annual ultrasonic checks at high‑risk zones on both underground and ground storage tanks.
- Tracking water quality within underground tanks to limit microbial blooms in diesel service.
- Updating risk matrices so tank owners can compare maintenance costs against projected service life.
Such discipline converts “reactive” spending into planned capital and keeps the total burden of corrosion prevention measures predictable.
SECTOR-SPECIFIC SCENARIOS AND BEST PRACTICES
SECTOR-SPECIFIC SCENARIOS
AND BEST PRACTICES
Diesel fuel storage tanks dominate logistics, agriculture, and emergency‑power markets. Microbial growth, acidic waste fuel, and condensation erode bare steel quickly. Applying polyurea inside seven‑million‑gallon field‑erected units and smaller day tanks ensures continuous duty with minimal downtime. At fleet depots operating hundreds of diesel fuel storage tanks, cross‑linked polyurethane topcoats resist UV on roofs, and an aromatic‑rich elastomer guards walls and, critically, the tank chime.
Municipalities managing underground storage tanks for back‑up generators face infiltration by acidic groundwater. Hybrid polyurea linings flex with soil loads, outperforming rigid glass‑flake epoxies in maintaining a watertight envelope. Elevated water storage tanks encounter chlorine attack; an NSF‑certified polyurea solves the dilemma without compromising water quality.
Large‑diameter bulk storage tank batteries at coastal tank farms must contend with salt‑laden air, typhoon‑driven rain, and thermal cycling from product swings. Here, plural‑component elastomers combined with planned industrial painting of roofs and shell exteriors have become the consensus best practice among leading tank owners.
No matter the sector, these scenarios emphasize that corrosion damage clusters at weld toes, floor plates, manway collars, and, above all, the tank chime. Concentrating resources on those zones extends service life dramatically.
Municipalities managing underground storage tanks for back‑up generators face infiltration by acidic groundwater. Hybrid polyurea linings flex with soil loads, outperforming rigid glass‑flake epoxies in maintaining a watertight envelope. Elevated water storage tanks encounter chlorine attack; an NSF‑certified polyurea solves the dilemma without compromising water quality.
Large‑diameter bulk storage tank batteries at coastal tank farms must contend with salt‑laden air, typhoon‑driven rain, and thermal cycling from product swings. Here, plural‑component elastomers combined with planned industrial painting of roofs and shell exteriors have become the consensus best practice among leading tank owners.
No matter the sector, these scenarios emphasize that corrosion damage clusters at weld toes, floor plates, manway collars, and, above all, the tank chime. Concentrating resources on those zones extends service life dramatically.
FROM PRODUCT TO PARTNERSHIP,
ARMORTHANE CAN BE YOUR COATINGS ONE-STOP SHOP
FROM PRODUCT TO PARTNERSHIP,
ARMORTHANE CAN BE YOUR
COATINGS ONE-STOP SHOP
Selecting a lining chemistry is only the first move; the lasting win comes from aligning with a supplier that backs its materials with science, logistics, and accountability. ArmorThane fills that role by focusing on what we do best—engineering high‑solids polyurea and polyurethane formulations, moving those products through a global distribution network, and certifying applicators who meet stringent performance standards.
Tank corrosion doesn’t wait, and neither should you. Whether you’re safeguarding a new bulk storage asset, tackling a stubborn tank chime leak, or planning a long‑term maintenance program, we can deliver the high‑quality products, in‑depth training, and around‑the‑clock technical guidance you need. Call, email, or drop us a quick note through the online contact form—our 24/7 support team is ready to help you turn today’s tank corrosion challenges into tomorrow’s competitive advantage. Welcome to ArmorThane, where we protect your world—and your tanks—for the long haul.
Tank corrosion doesn’t wait, and neither should you. Whether you’re safeguarding a new bulk storage asset, tackling a stubborn tank chime leak, or planning a long‑term maintenance program, we can deliver the high‑quality products, in‑depth training, and around‑the‑clock technical guidance you need. Call, email, or drop us a quick note through the online contact form—our 24/7 support team is ready to help you turn today’s tank corrosion challenges into tomorrow’s competitive advantage. Welcome to ArmorThane, where we protect your world—and your tanks—for the long haul.
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FREQUENTLY ASKED QUESTIONS
Start with thorough surface preparation, then apply a high‑build polyurea protective coating that seals the tank chime, shell, and floor. Combine that barrier with quality corrosion inhibitors in the stored product, drain water bottoms regularly, and schedule regular inspections. This layered approach to tank corrosion prevention keeps a steel tank in service longer and avoids costly repairs.
Yes. Polyurea hardens in seconds, bonds tightly to carbon steel, flexes with temperature swings, and blocks water plus fuel additives that can undercut epoxy. For diesel fuel storage tanks, the fast‑setting elastomer builds a thicker lining in one pass, reducing downtime while maximizing tank corrosion prevention. Epoxy still works, but polyurea delivers longer life and fewer recoats.
With proper surface prep and application, a high‑build polyurea lining typically protects a steel tank for 20–30 years before major touch‑ups are needed. Service life depends on environmental factors, product chemistry, and the quality of ongoing regular maintenance. Routine inspections and small repairs can push that timeline even further, helping tank owners avoid expensive, full‑scale recoats.
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