Category Archives: Storage Tanks

If you’re searching for how to “Protect Your Water Storage Tanks From Corrosion“, outdoor water tank coatings, or “Water Tank Rust Treatment” you are probably searching for a company to help protect your water storage tanks. All Kote Lining Inc. helps protect all varieties of storage tanks from corrosion. This article is designed to help you understand the need for this service and also how that service is carried out. If you have any questions please feel free to call 480-966-4446.

Outdoor Water Tank Corrosion Control

Ground level and elevated water storage tanks are the main part of most water distribution systems. Not only will these vessels help to ensure that there is enough hydrostatic pressure as well as plenty of clean drinking water, but have also been landmarks for many places. Although, if they are not maintained properly, they may become a liability because of corrosion caused service interruptions and leaks.

Nowadays, the newer high performance waterborne as well as high solids coating systems are there to help combat corrosion on water storage tanks. Additionally, being able to meet VOC regulations, these eco-friendly coatings have offered applications and finish quality type of advantages over the traditional counterparts. They have formed a strong bond to the steel substrates on the newer tanks have provided better adhesion to already existing coatings on older tanks and will be compatible with protection.

By being able to know about what causes the corrosion and the characteristics of high solids and waterborne coatings, an effective and economical tank maintenance program will be able to made and then carried out.

Destructive Forces on Above Ground Tanks

All water storage tanks are susceptible to a corrosion attack. Selecting the right water tank or cooling tower coating for being able to maintain water storage tanks simply by assessing the corrosive variables that are outside and inside the structure.

Corrosion is a natural thing that has been based on the laws of chemistry, electricity, and metallurgy. The process of refining and smelting steel and iron ore are used in water tanks, then energy is added. This causes an imbalance of energy and nature works to fix this by releasing back the energy as electrons, which cause the metal to rust, or corrode and return as a form of iron oxide.

Corrosion Prevention Coatings

The exterior of the tank and the coatings are accepted as a protection method. The main function of the coating is to make a barrier that prevents moisture and chemical compounds from touching the substrate. Although the electrolyte isn’t always around in this area, ensuring that you are preventing water ingress is vital for protection. Additionally, the coating needs to have good adhesion and abrasion as well as chemical resistant properties and the ability to deal with UV radiation.

Inside of the water tank, the corrosion control approach will be different. A strong electrolyte is formed by stored water that creates a type of vehicle for ion transfers as well as current flow in the steels micro-structure. Although, coatings may be used to interrupt this type of process and help to prevent corrosion. When there is a high dielectric strength, the coating will restrict the electron passage and then prevents metal from having the solution at the anode. If electrons aren’t able to travel to cathode, the corrosion process will be stopped.

New Coating Systems

With the enactment of certain regulations that limit VOC emissions on coatings, there have been a whole new breed of protective coatings that have been made available. The new systems contain urethanes, waterborne epoxies, acrylics, high solid and mastics epoxies. Some of these coatings are better for new tanks, while others are best for existing finishes.

So, are the coatings as good as traditional solvents? Yes. Because most of the coatings are now on the market. New polymers as well as additives that make up the coatings will allow for better application environments as well as improved looks. The main key is to achieve effective control of corrosion by using certain coating systems that have the right properties for the specific tank conditions.

Exterior coatings

Polymers that have been based on acrylic chemistry have managed to prove advantages for application. These have included durability, resistance to UV light, and flexibility. Additionally, comonomers such as acrylonitrile, styrene, and acrylic coatings that have offered superior corrosion and chemical resistance. Additionally, they do possess excellent characteristics for looks because of flow properties of liquid systems without high solvent content. Acrylics can be used as a top coat or primer on the exterior of the tank and can be an attractive alternative to polyurethane and alkyd finishes.

Waterborne epoxies

These epoxies will give the convenience of water based coatings that have performance based qualities of the solvent based system. There is a crosslinking of waterborne polymers that have monomers that have carboxyl or hydroxyl groups, and the coatings will form a dense, tight, film for better corrosion protection and adhesion. They are very acidic, moisture and alkali resistant, and are able to handle abrasion. Waterborne epoxies will dry quickly to stop wash off because old dew or rain. Additionally, adding sodium nitrite will let the epoxies be resistant to flash rusting or early rusting.

High solid epoxy mastics

These offer high degrees of salt, moisture, chemical, and acid resistance which make it a good barrier coating for tanks. This is because they are compatible with intact, old paint films and provide adhesion for marginally, dry prepared substrates that requires very little surface prep. Normally, the coatings will be applied to a prior coated tank as a primer. For those tanks that have lead based alkyd finishes, these coatings give a great base coat that will prevent lifting for a good over-coating of lead particles.

High solid polyurethanes

For a lot of years, lead based alkyds were a very popular coating for the exterior of water tanks. After lead based paints were banned, polyurethane became the choice coating. Now that there are limits for VOC emissions, the high solid polyurethane has become a very widely used coating product. This can be because of their versatility.

Immersion Service Coatings – High Solid Epoxies

There are some coating types that will meet extraction test and toxicological test requirements of the NSF/ANSI standard 61 and long term corrosion protection needs of water tanks. Epoxies and vinyl’s, only the high solid epoxy has been formulated to hit the right limit for VOC emission levels. Because of this, the high solid epoxy has been used for most immersion service applications on storage tanks.

The blistering of the protective coating is a failure of immersion services. When you are lining a blister, the ability to provide corrosion resistance is diminished. If the protection isn’t monitored right, voltage levels can exceed what is needed for polarization. This will cause high levels of hydroxyl ions to form under the paint. This causes the blistering and delamination’s.

Comprehensive Tank Maintenance

Whenever the EPA declared war on pollutants, the water industry feared that the eco-friendly alternative coating systems wouldn’t help with corrosion. This misconception was put to rest with the new high solids and waterborne coating systems. These systems provide protection against corrosion and other benefits. When you examine the properties of the coatings and find the right product for applications, water authorities will be able to create effective and economical tank maintenance programs.

Phoenix Water Tank Maintenance & Coatings

All Kote Lining Inc. offers water tank coatings along with a variety of other chemical storage tank services. We can help with all of your storage tank needs in the Phoenix area with preventative tank maintenance and repair when necessary. We strive to use the best coatings in the business to extend the life of your tanks, save you money, and help preserve the tanks integrity to help protect the environment.

There are two methods by which FRP tank lining systems can be applied. There is hand lay-up and spray-up methods to install the FRP lining. Before either type of coating can be applied sand blasting has to be done to remove any debris or corrosion. This provides a clean and rough surface for the primer to be applied on. Adhesion of either system is dependent upon having that rough and primed surface.

Spray-Up Method

Glass-chopper guns are used to apply the spray-up FRP linings. The glass-chopper gun mixes to glass roving and resin components at the time of being sprayed. Dual head glass-chopper guns allow very rapid rates of depositing the coating. The average thickness of the resin at the tank bottoms are typically a quarter inch when the spray-up method is used.

Hand Lay-Up Method

While the spray-up method is quicker the hand lay-up method is the preferred method of consistency. This method produces a more consistent, and uniform layer of coating. The quality of the hand lay-up method does take more time, requires more labor, and longer time for the resin gel to dry.  While being more labor intensive this method does take less skill to apply.

To apply the lining using the hand lay-up method a heavy layer of resin is applied with brushes, rollers, or it is sprayed on. The next step is applying the glass mat to the wet resin and ensuring it is fully saturated with the resin to make sure adhesion is strong. Lastly a seal coat is applied on top of the resin and glass mat. This is only done after the resin saturated material has gelled.

FRP Lining Application Approach

Quality FRP tank coatings rely on how the lining is applied. The standardized approach for applying an FRP hand lay-up tank coating has 5 distinct phases that must be followed.

Prepare The Surface

Organic contaminants build up in steel storage tanks and must be removed. Following this the internal surfaces must be blasted with abrasive materials to prepare the inside of the tank for the primer and resin.

Applying The Primer

Immediately after the blasting is complete the dry film polyamide-cured epoxy primer is applied at a thickness of 1 to 3 mils. It is applied to prevent any contamination of the bare metal surface and to “hold” the tank in condition for the resin phase. Sharp angles in the tank, especially those at the bottom are filled in with a putty type material which includes the fibers and fillers. This putty material should of the same compound as the resin you will use for the tank to ensure proper adhesion. Any deeply pitted tanks should be resurfaced with the same fill material to create a smooth bottom.

Resin Application & Fiberglass Reinforcement

Resin is applied in a heavy layer by brush, sprayer, or roller. While the resin is still wet the fiberglass mat is laid into it and full saturation should be ensured.

The dry film thickness is decided by the full extent of the carrions on the bottom of the tank, and the source of the corrosion. Internal corrosion is controlled by a film thickness of 60 to 80 mils to help protect the bottom of the tank from internal corrosion. The exterior of the tank requires a thicker coating and will end up needing a film layer starting at 80 miles and going up to 120 mils. This helps protect the tank from the external corrosive forces.

Final Coating

A finish coat that is a resin rich layer of polyester resin is applied as the seal coat. This process helps prevent capillary action which causes wicking along the partially exposed glass fibers that stick out of the resin. Paraffin wax aids in the curing process and is added to the base resin that helps produce this seal coat.

Final Inspection

Before the tank is passed for use again an inspection should be carried out to ensure that the FRP lining has been successfully installed. A magnetic dry film tester is used to check the thickness of the dry film. Before the seal coat is applied the thickness of the bottom of the tank should be inspected with a high voltage holiday detector.

Steel Tank FRP Linings In Phoenix

If you have steel storage tanks in the Phoenix area that need to have new fiberglass tank coatings installed All Kote Lining is highly skilled, has the right techniques and is dedicated to getting the job done right quickly and the first time. Give us a call at 480-966-4446 and we can help you will your tank coating needs.

If you are responsible for an organization that uses storage tanks, corrosion is one of your concerns.  This post takes a look at how FRP linings for storage tank repairs save companies and municipalities significant money over replacing storage tank bottoms. Above ground storage tanks are notoriously corrosive which leads to leaks.  In fact the rate of corrosion at ambient temperatures in carbon steel is more than 1 mil every year.  That means that your new storage tank could leak in as little as 5 years.  Not only do leaks lead to costly repairs but can also lead to penalties for harming the environment.

Corrosion is accelerated when later rich in chlorides and soul be salts lay at the bottom of these storage tanks.  In addition to being highly corrosive on their own these elements can result in a strong electrolyte that causes corrosion to accelerate even more.  The exterior of storage tanks are also under attack from corrosion.  This is especially true for places which have stray electrical currents in the ground or are close to salt water or snow removal including salt.

As above ground tanks corrode they must either be repaired using FRP linings, the bottom repaired, or the entire tank replaced.  FRP linings or coatings are a much more cost-effective option for corroding storage tanks.  Generally, when they are used in highly corrosive environments the thickness should be no less than 60 mils.

Installing FRP Linings

For municipalities and industrial locations using above ground storage tanks the trend has been stepping away from replacing the storage tank bottoms and instead installing FRP linings.  The process of installing an FRP lining is cheaper and faster than completely replacing the tank bottom.  To install an FRP tank lining the tank must be empty, dry, primed, puttied, and include a catalyzed resin with a glass mat.  Lastly the system is finished with a sealcoat.

Thick FRP Lining Lifespan

When the correct FRP lining is selected and installed correctly it will act as a secondary bottom for the storage tank.  It is tightly bonded and will prevent leaks caused by internal corrosion for up to 20 years.  In the case that the storage tank has perforations the lining can assist in bridging these small areas and help prevent leaking.  Exterior corrosion is a concern but can be avoided by even thicker coatings of FRP  coatings.  When the thickness is increased to 120 mils an FRP lining on the inside can prevent even advanced corrosion on the exterior of the storage tank.

FRP Lining Pros & Cons

Every system is going to have pros and cons.  FRP linings are widely used as they are durable and cost effective but you should know all of the characteristics before deciding on any course of action.

FRP Lining Pros

• FRP linings offer great budget savings compared to replacing the bottom of the tank.
• FRP linings have great lifespan and can last longer than 30 years.
• FRP lining installation is faster so you won’t experience as much downtime.
• FRP linings are strong and can bridge 8” holes and over 80 psi with double laminates.

FRP Lining Cons

• Preparation is key and installers must be highly trained to complete the installation correctly.
• If pigmentation is used ascertaining the condition of the storage tank bottom is problematic.
• Potential weakness for cyclic loading which needs further research.

Hydraulic Pressure & FRP Linings

FRP linings are designed to protect and reinforce storage tanks.  They are not however designed specifically to withstand high pressure which is common in hydraulic pressure systems. In one installation FRP lining was installed and after 10 years the tank sprung a leak.  It was found that the leak was caused by bottom side corrosion.  While this is the area that the FRP lining was installed to protect it was found that the FRP was not at fault.  In fact the two holes were both about a foot in width and the only thing that had held the tank together was the FRP lining.

What Is The Pressure Limit for FRP Linings?

Studies have shown that with average temperatures common in tanks that the FRP linings will over 37 psi of strength at a single laminate thickness.  However when you double the laminate thickness the coating will withstand up to 82 psi.  As the average internal tank pressure is about 20 psi it can safely be said that FRP linins are up to the job even if hydraulic pressure is present.

Phoenix Valley FRP Lining Installation

If you are searching for a company that does FRP linings in storage tanks, All Kote Lining Inc. has all your needs covered.  We proudly install FRP linings in any size tank for both public works, industrial facilities, and other locations that have storage tank needs.  To find out how we can save you money on repairs for your storage tanks with FRP linings, please call

If you’re searching for how to “Protect Your Water Storage Tanks From Corrosion“, outdoor water tank coatings, or “Water Tank Rust Treatment” you are probably searching for a company to help protect your water storage tanks. All Kote Lining Inc. helps protect all varieties of storage tanks from corrosion. This article is designed to help you understand the need for this service and also how that service is carried out. If you have any questions please feel free to call 480-966-4446.

Outdoor Water Tank Corrosion Control

Ground level and elevated water storage tanks are the main part of most water distribution systems. Not only will these vessels help to ensure that there is enough hydrostatic pressure as well as plenty of clean drinking water, but have also been landmarks for many places. Although, if they are not maintained properly, they may become a liability because of corrosion caused service interruptions and leaks.

Nowadays, the newer high performance waterborne as well as high solids coating systems are there to help combat corrosion on water storage tanks. Additionally, being able to meet VOC regulations, these eco-friendly coatings have offered applications and finish quality type of advantages over the traditional counterparts. They have formed a strong bond to the steel substrates on the newer tanks have provided better adhesion to already existing coatings on older tanks and will be compatible with protection.

By being able to know about what causes the corrosion and the characteristics of high solids and waterborne coatings, an effective and economical tank maintenance program will be able to made and then carried out.

Destructive Forces on Above Ground Tanks

All water storage tanks are susceptible to a corrosion attack. Selecting the right water tank or cooling tower coating for being able to maintain water storage tanks simply by assessing the corrosive variables that are outside and inside the structure.

Corrosion is a natural thing that has been based on the laws of chemistry, electricity, and metallurgy. The process of refining and smelting steel and iron ore are used in water tanks, then energy is added. This causes an imbalance of energy and nature works to fix this by releasing back the energy as electrons, which cause the metal to rust, or corrode and return as a form of iron oxide.

Corrosion Prevention Coatings

The exterior of the tank and the coatings are accepted as a protection method. The main function of the coating is to make a barrier that prevents moisture and chemical compounds from touching the substrate. Although the electrolyte isn’t always around in this area, ensuring that you are preventing water ingress is vital for protection. Additionally, the coating needs to have good adhesion and abrasion as well as chemical resistant properties and the ability to deal with UV radiation.

Inside of the water tank, the corrosion control approach will be different. A strong electrolyte is formed by stored water that creates a type of vehicle for ion transfers as well as current flow in the steels micro-structure. Although, coatings may be used to interrupt this type of process and help to prevent corrosion. When there is a high dielectric strength, the coating will restrict the electron passage and then prevents metal from having the solution at the anode. If electrons aren’t able to travel to cathode, the corrosion process will be stopped.

New Coating Systems

With the enactment of certain regulations that limit VOC emissions on coatings, there have been a whole new breed of protective coatings that have been made available. The new systems contain urethanes, waterborne epoxies, acrylics, high solid and mastics epoxies. Some of these coatings are better for new tanks, while others are best for existing finishes.

So, are the coatings as good as traditional solvents? Yes. Because most of the coatings are now on the market. New polymers as well as additives that make up the coatings will allow for better application environments as well as improved looks. The main key is to achieve effective control of corrosion by using certain coating systems that have the right properties for the specific tank conditions.

Exterior coatings

Polymers that have been based on acrylic chemistry have managed to prove advantages for application. These have included durability, resistance to UV light, and flexibility. Additionally, comonomers such as acrylonitrile, styrene, and acrylic coatings that have offered superior corrosion and chemical resistance. Additionally, they do possess excellent characteristics for looks because of flow properties of liquid systems without high solvent content. Acrylics can be used as a top coat or primer on the exterior of the tank and can be an attractive alternative to polyurethane and alkyd finishes.

Waterborne epoxies

These epoxies will give the convenience of water based coatings that have performance based qualities of the solvent based system. There is a crosslinking of waterborne polymers that have monomers that have carboxyl or hydroxyl groups, and the coatings will form a dense, tight, film for better corrosion protection and adhesion. They are very acidic, moisture and alkali resistant, and are able to handle abrasion. Waterborne epoxies will dry quickly to stop wash off because old dew or rain. Additionally, adding sodium nitrite will let the epoxies be resistant to flash rusting or early rusting.

High solid epoxy mastics

These offer high degrees of salt, moisture, chemical, and acid resistance which make it a good barrier coating for tanks. This is because they are compatible with intact, old paint films and provide adhesion for marginally, dry prepared substrates that requires very little surface prep. Normally, the coatings will be applied to a prior coated tank as a primer. For those tanks that have lead based alkyd finishes, these coatings give a great base coat that will prevent lifting for a good over-coating of lead particles.

High solid polyurethanes

For a lot of years, lead based alkyds were a very popular coating for the exterior of water tanks. After lead based paints were banned, polyurethane became the choice coating. Now that there are limits for VOC emissions, the high solid polyurethane has become a very widely used coating product. This can be because of their versatility.

Immersion Service Coatings – High Solid Epoxies

There are some coating types that will meet extraction test and toxicological test requirements of the NSF/ANSI standard 61 and long term corrosion protection needs of water tanks. Epoxies and vinyl’s, only the high solid epoxy has been formulated to hit the right limit for VOC emission levels. Because of this, the high solid epoxy has been used for most immersion service applications on storage tanks.

The blistering of the protective coating is a failure of immersion services. When you are lining a blister, the ability to provide corrosion resistance is diminished. If the protection isn’t monitored right, voltage levels can exceed what is needed for polarization. This will cause high levels of hydroxyl ions to form under the paint. This causes the blistering and delamination’s.

Comprehensive Tank Maintenance

Whenever the EPA declared war on pollutants, the water industry feared that the eco-friendly alternative coating systems wouldn’t help with corrosion. This misconception was put to rest with the new high solids and waterborne coating systems. These systems provide protection against corrosion and other benefits. When you examine the properties of the coatings and find the right product for applications, water authorities will be able to create effective and economical tank maintenance programs.

Phoenix Water Tank Maintenance & Coatings

All Kote Lining Inc. offers water tank coatings along with a variety of other chemical storage tank services. We can help with all of your storage tank needs in the Phoenix area with preventative tank maintenance and repair when necessary. We strive to use the best coatings in the business to extend the life of your tanks, save you money, and help preserve the tanks integrity to help protect the environment.

Water reservoirs, damns, wastewater treatment plants, and drinking water facilities are vital to the public works of communities. When the concrete is in bad condition and water leaks it can mean that the structure allows contaminants out of or into the storage.  The contaminants can ruin water supplies and significantly impact communities.

Leaks & Contamination

Municipal or private water supplies can be contaminated through the migration of waterborne chemicals. When wastewater structures leak it can impact the environment and are especially hard to find if they are in the base of the concrete structure. With drought being a reality in so many areas of the world even small losses of drinking or agricultural water have a meaningful impact.  When any kind of water storage container needs extensive repair it means disruption to the community through downtime and expense.

Cracks & Service Interruption

Just about every concrete structure cracks due to settling, curing, seismic activity, shrinkage, or a number of other factors.  When it comes to concrete water tanks any cracking can lead to leaks and contamination.  These are the two most common factors of having downtime in operations that rely on concrete water holding structures, like wastewater or cooling towers.

Crack Prevention

Preventing cracks is clearly a priority for all operations that include water storage.  Preventing cracks and leaks comes in various waterproofing forms.  Here are few of the options on the market today:

• Installing a coating of liquid membrane by spraying or rolling which leaves a dry yet rubberized waterproof layer. The rubberized nature of these coatings helps the layer be flexible and compensate for cracks.
• Layered felt and asphalt which are built up into layers which creates a physical waterproof barrier.
• Membranes of self-adhering rubberized asphalt that make a barrier.
• Integral crystalline waterproofing can also be used to fill the spaces between parties of concrete.
• Cementitious waterproofing products brush applied to the concrete and can be mixed with optional additives which increase durability.
• Installing a sodium bentonite layer on the outside of the tank will absorb water and expanding to fill in the voids and cracks. When it fully expands it remains in the cracks to avoid additional water intrusion.

Choosing a Tank Waterproofing Option

There are a lot of products and companies offering water tank coating, how do you choose the best option for your system?  These are some of the factors that you should consider as you make decisions for your property and water storage or containment.

System Safety

Choose waterproofing coatings which are safe for the environment and are non-toxic.  When the project involves storing drinking water is especially important to choose a system which will not deposit chemicals or debris into the water.

Cost Of The System

How much the system will cost in terms of raw materials and labor hours should be weighed against the lifespan expected from each product.  Waterproofing coatings which take longer to apply will generally be more costly.

Time To Install

When you are dealing with a complex construction project or you are planning downtime for a system that a building or community relies on you need to know how long it will take to install.  Physical barriers like rubber and felt are time intensive and will require longer install times that could mean increased interruption in service.

Waterproofing Life Span

Knowing the expected life span of the waterproofing solution should play into your decision making.  Some products are designed to be permanent solutions while others have a finite life span.  Other systems eventually dry out, crack, are easily damaged, and will eventually leak and cause contamination.  Weight out how long the solution will last against the cost and service interruption.

System Flexibility

Does the system have a required installation time?  Some systems must be installed either before, during, or after the concrete is poured to create the structure.  Some systems mean having to keep the area around the water tank clear so maintenance can be done on the exterior of the water storage tank.

Heat Compatibility

Some water containment systems require the ability to withstand heated water such as in cooling tower water basins.  The heat involved in cooling tower applications must considered when choosing an option for concrete waterproofing.

Chemical Resistance

Many water storage systems like wastewater, drinking water, or the water used in cooling towers carries with it chemicals that can deteriorate concrete.  Coatings must be used which can cope with the chemicals used to treat these different types of water.

Warranty or Guarantee

When you are weighing your options for which concrete water tank waterproofing contractor or product to use you should weight the warranties or guarantee. It’s important to choose tank maintenance companies and products that warranty their work and products.

Conclusion

Ultimately each installation is different as the operations, environment, age, and condition of every tank is different. Take the time to discuss your options for your local contractor for waterproofing concrete water tanks.  Have representatives come and assess the condition of the your water tank, recommend the best solution or solutions, and then choose the one that fits your needs best.  What is best will depend on how long the system should last, if and how disruptive downtime is to the community.