Snapshot
Over the last 20 years, Flowco has delivered pre and post bury installation tank testing at hundreds of fuel sites across Australia. From major national retailers through to independent operators, our precision tank and line testing program has become the standard for ensuring new sites achieve compliance first time. By verifying underground tanks, lines, containment and controls both before backfill and again prior to commissioning, we help our clients reduce risk, protect opening dates and hand over projects with complete confidence.
The situation
Fuel retailers, contractors and independent operators across Australia face the same challenge when building or upgrading sites: how to ensure that newly installed underground assets are watertight, compliant and ready for commissioning. Over two decades, Flowco has been engaged by every major fuel brand as well as hundreds of independent operators to provide that assurance. By delivering a two-stage testing program — pre bury when assets are accessible, and post bury once construction is complete — we have helped sites of every scale avoid costly rework, safeguard critical opening dates and achieve compliance on the first attempt.
Our method
Flowco employs a precision tank and line testing method that sets the benchmark for accuracy and reliability. Capable of detecting leaks as small as 95 millilitres per hour, it is significantly more sensitive than regulatory requirements. Unlike other systems, our method allows both tanks and lines to be tested dry, meaning full integrity can be verified before fuel is introduced. This ensures defects are identified early, when they are easiest and cheapest to repair.
During each test, data points are recorded at a frequency of up to 1,000hz, capturing the most accurate picture of system performance under stabilised conditions. Results are temperature-compensated and digitally monitored to guarantee repeatability, free from environmental interference.
Every test is then reviewed, analysed and reported by qualified engineers, not just field technicians, to ensure the integrity of the analysis. This combination of advanced technology and professional oversight eliminates false passes or false failes, provides fast and defensible outcomes, and delivers compliance reports that withstand scrutiny from regulators, insurers and corporate stakeholders.
See an overview of our testing methodology here: How Installation Testing Works
Benefits of the Flowco methodology
Pre bury installation testing
Pre bury testing is one of the most important steps in protecting the long-term integrity of a fuel system. Flowco’s certified precision test is the only method available that can be carried out dry, giving project teams complete confidence before a single litre of fuel is introduced. The benefits fall into three key areas:
1. Early detection of defects
Material flaws, porous welds, manufacturing issues or poor installation practices are all identified before the tanks and lines are buried. Detecting these issues early prevents them from being locked underground where they are harder to find and much more expensive to resolve.
2. Easier and more cost-effective rectification
Because the assets are still fully accessible, rectification work can be carried out immediately and with minimal disruption. Repairs at this stage are straightforward and inexpensive compared to the excavation, demolition and downtime that would be required if problems are discovered after backfill.
3. Confidence before burial
A passing test before backfill gives builders, retailers and contractors complete assurance that the system being buried is watertight and compliant. This creates a strong foundation for the remainder of the project, protects budgets from overruns and builds confidence with all stakeholders.
Post bury installation testing
Once the system has been backfilled and concreted, additional risks are introduced. Heavy construction traffic, soil settlement and compaction forces can place stress on joints, seals and containment structures. Post bury installation testing verifies that the underground system has maintained its integrity through this process. The benefits fall into three key areas:
1. Verification after construction stress
Backfill and concreting can cause movement or damage to fittings and seals. Post bury testing ensures that tanks, lines and containment have held their integrity after construction is complete, providing a final check before the site goes live.
2. Prevention of costly delays
Identifying and addressing issues at this stage prevents last-minute surprises during commissioning. By confirming system integrity before fuel is introduced, sites avoid unplanned excavation, project hold-ups and costly rectification work at the eleventh hour.
3. Compliance evidence for handover
The post bury installation test provides a defensible evidence pack, including test data, calibration certificates and photographic records, all mapped against AS 4897 and AS 1940. This gives retailers, regulators, insurers and corporate stakeholders absolute confidence at the point of handover.
Read more here: Tank and Line Testing
Results
Flowco’s two-stage testing has delivered consistent results across hundreds of projects nationwide. By applying our precision tank and line testing both before and after backfill, we have repeatedly eliminated rework, prevented commissioning delays and provided clients with defensible evidence of compliance. Major retail networks and independent operators alike have benefitted from the same outcome: underground systems that pass first time, projects that stay on schedule and sites that open with complete confidence.
Reducing project risk with Flowco
Flowco’s precision tank and line testing method is more sensitive than the regulatory minimum and has been proven in the field for over two decades. Our technicians are trained to AS 4897 and AS 1940 requirements, and every result is backed by traceable calibration and photographic verification. Reports are delivered in plain language with clear outcomes, giving our clients the certainty they need to proceed without hesitation.
Client feedback
“Flowco’s two-stage approach meant we had no surprises at commissioning. The evidence pack gave us complete confidence in the outcome.” – Project Manager, National Fuel Retailer
Flowco has helped hundreds of projects open on time by eliminating underground risk through pre and post bury testing. To discuss how our precision tank and line testing can safeguard your next project, contact our team today.
