High-Strength, Corrosion-Resistant Composite Tank Repair and Reinforcement
Tanks can fail for various reasons, depending on the service conditions.
With experience in industries ranging from Nuclear Power to Oil and Gas, Advanced FRP Systems offers long-lasting, maintenance-free, structural reinforcement solutions for tanks damage caused by corrosion, erosion, mechanical damage, or chemical attack.
We help create the best repair solution, minimizing the disruption to your business operations while helping you avoid time-consuming and costly tank replacement.
State-of-the-art storage tank repair and reinforcement service
Corrosion damage can be most extreme in areas under insulation with limited accessibility or hidden away from the daily view. Corrosion under insulation can quickly cause through-wall failures.
We have tank repair solutions for insulated tanks, tanks that operate at elevated temperatures, water tanks, crude oil tanks, and many more. Our highly chemically resistant composites can withstand microbially influenced corrosion, acid attack, black and white liquor, bleach, caustics, and many more aggressive chemicals.
For the most badly corroded, eroded, or damaged tanks we offer a full structural composite system featuring high-strength, aerospace-grade, US-made carbon fiber composites. A structurally independent tank can be built inside the footprint of your existing tank.
For tanks that have isolated corrosion, even through-wall failures, a composite repair solution is engineered to enhance the strength of the existing tank wall and seal off any leaks while preventing further corrosion from occurring.
Compliance with industry standards
Composite repairs are governed by several standards including the ASME PCC-2 and the ISO 24817 standards that address leak repairs and provide relevant design equations. Composite repairs are compliant with many API, DOT, ASME, and AWWA standards.
Why Carbon Fiber Is The Right Choice
Carbon Fiber:
- Is light-weight and has 10x the strength-to-weight ratio of carbon steel
- Does not corrode, even in high salinity, low pH or in the presence of oxidizers
- Bonds to a wide range of substrates, including carbon steel, aluminum, stainless steel, concrete, fiberglass, and even wood.
- Designed to withstand temperatures up to 375°F, making it suitable for high-temperature assets and assets that experience thermal cycling.
- Cures at ambient temperature and allows tanks to go back to service quickly after repairs.
- The time required for the tank repair is minimal with no downtime required for external repairs
Installing a carbon fiber composite inside of an existing tank will completely eliminate further corrosion of the substrate by acting as a thick-film barrier coating.
Spot repairs – for tanks experiencing isolated corrosion or erosion, even with through-wall failures, a carbon fiber composite patch may be the best solution. This patch can be installed quickly and efficiently and provides a high-strength, chemical-resistant barrier compatible with a wide range of high-performance coatings.
Sectional repairs – for tanks experiencing larger scale corrosion limited to certain areas, we recommend sectional repairs with carbon fiber composite. Sectional repairs can be performed on tank floors, walls, and/or roofs and they provide structural reinforcement, leak prevention and mitigation, and long-term corrosion prevention.
Full tank enhancement – for tanks experiencing systemic corrosion that are still structurally sound, we can perform repairs with composite technology to augment the strength, fix leaks, and prevent degradation with our composite carbon fiber technology.
Structurally independent tank – for tanks experiencing extreme degradation and needing a complete rebuild, we can use our composite technology to help you avoid replacing your tank. Using the existing tank as a mold, a composite carbon fiber tank can be built within the existing tank, structurally certified by a third-party engineer as a free-standing structure, to meet and/or exceed all the original design parameters of your tank.
Chemical
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Oil & Gas
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Pulp & Paper
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Water & Wastewater
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Mining
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Power Generation
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Traditional Repair Process vs Carbon Fiber Repair
Traditional tank repair options for a tank with through-wall failures or significant corrosion damage involves welding steel plate to the surface. This hot work can be difficult and time-consuming and damages any coatings in the heat-affected zone. Moreover, after the installation of the steel plate, the entire repair area must be properly coated to prevent future damage from corrosion.
Using a composite carbon fiber reinforcement system is a great alternative to a welding plate. The application of carbon fiber has no hot work, and the non-metallic reinforcement does not corrode like metals.
Due to resistance to corrosion, increased strength in comparison to steel, longevity, ease of application, and cold curing, carbon fiber-based composites are becoming a popular technology for industrial tank repairs.
Because of carbon fiber’s ability to fit a variety of shapes, it can be used to repair any damage to a tank, no matter the size or severity, location in the tank, or operating conditions. From small patches for holes with leaks to a complete rebuild and replacement of a tank, carbon fiber can be engineered to provide an ideal tank repair solution. Advanced FRP has designed our composite solutions to provide optimal performance without the need for an elevated temperature post-cure.
Internal applications of Carbon fiber-based composites also prevent internal corrosion and erosion from continuing, extending the longevity of your critical assets.
Tank wall repair with carbon fiber
Full tank enhancement with carbon fiber
Carbon fiber repairs of the vent pipe, tank roof and top seam
Customized Composite Tank Bottom Repair
Many tanks experience corrosion on the floor and floor-to-wall joint; this is especially prevalent in hydrocarbon storage tanks. Customized composite tank bottom repairs are a cost-effective and easy-to-install tank repair option that provides a long-term life extension. Our composite system even allows API-required ultrasonic thickness analyses to be performed on the host tank right through the composite.
For tanks that do not have uniform degradation across the entire tank surface but still leak, spot repairs for areas that are below the minimum wall thickness threshold or for through-wall failures can often be performed.
Industry Applications
- Power Generation
- Oil & Gas
- Chemical Manufacturing
- Pulp & Paper
- Water & Wastewater
- Mining
Chemical Manufacturing
With extensive immersion testing in a wide range of chemicals and reagents, our team of experts understands the chemistry of our polymers and knows how to protect your tanks even with less common chemicals or combinations of chemicals.
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Oil & Gas
We offer resistance to the most common fracking chemicals. We can repair well wastewater even with bolted tanks or extreme microbially influenced corrosion (MIC).
Our solutions for natural gas, sour crude, and refined products like gasoline, diesel, and jet fuel can withstand aggressive solvents like benzene and acetone.
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Pulp & Paper
Advanced FRP Systems offers easy-to-install, economical, and long-lasting repairs for the most aggressive tank environments and helps you provide your plant with more reliability at a fraction of the cost.
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Water & Wastewater
Our composite reinforcement solutions are compatible with raw sewage and aeration areas and can stop microbially induced corrosion (MIC).
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Mining
When combining high wear conditions to extreme pH exposure, it’s crucial to choose the right solution. When nothing “off the shelf” will do, contact us to design a customized solution that fits your needs and budget.
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Power Generation
From FGD systems to condensate tanks, our team of experts can perform a reliable, maintenance-free tank repair within your outage window.
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Before and After
A hydrochloric acid storage tank was experiencing significant corrosion, especially in the vapor zone and on the roof of the tank. Several through wall failures were found and the smell of Hydrochloric acid was noticeable near the tank.
A chemically resistant, carbon fiber reinforcement system was installed over the tank roof. The system prevents any further external corrosion, provides a vapor-tight seal to prevent the escape of hydrochloric acid, and structurally reinforced the roof.
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