What happens if corrosion develops in a tank holding untreated wastewater? The outcome could be calamitous for people and the environment. Storage tank corrosion is a persistent challenge for industries that rely on bulk liquid storage, from oil and gas to water treatment to chemical processing. Corrosion can lead to structural failures, safety hazards, and expensive repairs without proper protection.
The good news? Advancements in coatings and linings are transforming how these industries prevent corrosion in storage tanks. Explore these real-world solutions and expert insights from CoatingsPro Magazine to help find effective solutions for preventing corrosion and extending the service life of storage tanks.
Why is preventing corrosion in storage tanks so challenging?
Storage tanks are exposed to environmental and chemical stressors that accelerate degradation, including:
- Moisture and oxygen exposure – leads to oxidation and rust formation
- Chemical reactions – cause material breakdown and internal corrosion
- Temperature fluctuations – expand and contracts materials and create microcracks
- High rates of coating failures – accelerate deterioration
Proactive corrosion prevention strategies like those listed here can enhance safety, asset longevity, and environmental compliance while reducing costly downtime.
In extreme conditions, traditional epoxy coatings don’t always stand up to heavy, long-term use. However, newer ceramic coatings are making protection easier. CoatingsPro has highlighted real-world examples of chemically bonded phosphate ceramic (CBPC) coatings that protect wastewater storage tanks in harsh environments. Ceramic coatings are particularly effective in industries with extreme conditions, because they offer superior resistance to ongoing wear and tear.
Unlike traditional polymer and rubber-type linings, CBPC coatings chemically bond with the substrate, making it nearly impossible for corrosion promoters to get behind the coating. (Surface preparation and application are key to this longevity.) This is especially useful for tanks that hold wastewater and liquids containing sand and sediment that would chip and scratch traditional linings.
Considerations with ceramic coatings:
- Surface preparation is critical to ensure adhesion and long-term performance. Follow the manufacturer's instructions to get the best results.
- Ceramic coatings create a durable, corrosion-resistant barrier against aggressive chemicals and environmental exposure.
- CBPC coatings have been proven to extend tank lifespans in real-world applications.
Water storage and pipes present unique challenges because coatings and linings must be safe for use with potable water. They must be free of xylene, toluene, ethylbenzene, and oxsol while meeting stringent environmental regulations. In these cases, using a newer corrosion-resistant epoxy lining is crucial. CoatingsPro has been covering the latest developments in new formulations of water tank epoxy linings. In one example, a high-solids epoxy phenalkamide lining has enhanced corrosion protection in municipal water storage tanks.
For municipalities and industries that rely on long-term water storage, a certified epoxy lining is a vital first step toward achieving maximum corrosion prevention plus environmental compliance. Newer formulations are available at 89% solids, which makes them easier to apply with sprayers than traditional 100% solids formulations.
Considerations with epoxy linings for water storage:
- Regulatory compliance – Epoxy linings must meet drinking water safety standards.
- High durability – The epoxy must resist long-term exposure to water and chemicals.
- Seamless application – Modern formulations reduce the risk of coating failures and extend maintenance cycles.
Despite the best-laid plans and expertly applied coatings, localized damage can still occur, especially at seams and weld joints. A two-component epoxy paste can restore and protect these potentially weak areas in these cases. The perimeter of oil storage tanks are particularly vulnerable to localized damage because they are often exposed to water, chlorides, sulfides, and high operating pressure.
Two-component, high-strength epoxy paste is modified with fibers and ceramics to ensure lasting strength. It typically has non-sag and quick-setting properties so it can be used for urgent repairs when it’s not feasible to embark on a full recoating project. Early detection and targeted repairs will prevent corrosion from escalating into major structural issues.
Considerations with localized epoxy repairs:
- Localized repairs can prevent small corrosion spots from spreading.
- Surface preparation is key – Proper cleaning and application ensure long-lasting adhesion.
- Epoxy solutions are ideal for sealing gaps and reinforcing weak points.
Want to learn more about localized protection or storage tank corrosion prevention in general? Learn more about our materials protection Courses and Certification Programs.