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Composite Tank Repair – Case Study

In a compelling case study from 2012, a critical power generation facility faced significant challenges with a large volume storage tank experiencing uneven corrosion. The facility aimed to avoid the costly and time-consuming process of a full tank replacement. Through innovative composite repair methods, a targeted and value-engineered solution was developed. This approach allowed for the application of varying strength layers to precisely address the corrosion at different tank sections. The repair not only rectified the wall loss due to corrosion but also introduced a chemical-resistant membrane, enhancing the tank’s longevity and preventing future issues. This case study exemplifies the potential of composite tank repair to provide durable, cost-effective solutions tailored to specific structural needs, showcasing long-term durability and the effectiveness of carbon fiber systems in such applications.


We started to get into tank repair again back in 2000. Now 2012, we were approached by another customer of ours who had a large volume storage tank, that was part of the critical process at a power Gen facility. Now, this tank had varying levels of corrosion throughout the different courses, you can kind of see here they actually played with the operating level, to find the right point of where it wouldn’t leak. And they just kept moving the problem, very common issue that we see. So they said, Can you do a study to understand the issue so we can value engineer repair, and avoid the full replacement, because this tank, they were going to replace it in kind right where it stood. And what that meant was they had to tear it down and take it out of service, bring a whole new one and erected and everything you’re talking about multiple month long project to be able to complete that full rehabilitation a full replacement. So what we’re able to understand through the testing that we did was that the corrosion did vary by course. And as always showed earlier, we can take that data and value engineer the solution to provide this specific amount of strength, by course on the tank. So instead of putting a uniform number of layers everywhere, we’re able to kind of value engineer that put the right amount of strength in each location. Again, it’s fixing specifically what’s wrong with it. Furthermore, we were able to execute the install on the inside of the tank. So that allowed us to accomplish two things at the same time, one replace the wall loss that occurred due to corrosion, but to be able to provide a chemical resistant uniform membrane. And what’s interesting is when most people build new tanks, they’re already planning to blast scaffold prime and coat the interior anyway. So by inputting the HJ3 tank rep system, we’re able to replace the wall loss and prevent the problem from occurring in the future. And that’s where a lot of that long term durability testing came into play to ensure that the carbon fiber system retained its properties in immersion over time.

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