Restoring Underground Fuel Tank Integrity Without Full Replacement Flowco Delivers Cost-Effective FRP Lining Solution to Extend Tank Life

After a Precision Tank Test failure a was client faced the prospect of replacing an underground fuel tank due to suspected leakage and localised corrosion, Flowco Australia approached the problem differently. Rather than immediately proceeding with excavation and full tank replacement — a process that would cause significant operational downtime and incur major capital expense — Flowco recommended a smarter, more sustainable path forward.

Problem

The site had reported unusual water ingress and suspected loss of product from an underground petroleum storage tank (UPSS). Initial assumptions by third parties suggested the tank was at end-of-life and would require complete replacement to comply with environmental and safety regulations. With limited access to the tank and operations that could not afford significant downtime, the client needed an urgent yet reliable solution.

Flowco’s Approach

Flowco initiated a detailed site inspection and condition assessment, leveraging its specialist diagnostic expertise. The assessment revealed that while the tank exhibited localised corrosion, it remained structurally sound overall. This finding shifted the discussion from replacement to repair and opened up an opportunity to reduce cost, complexity, and disruption.

The Two-Step Remediation Strategy

1. Precision Tank Integrity Testing
Flowco conducted certified precision tank testing using industry-leading methods to confirm that the detected leak was isolated and suitable for in-situ repair. This testing not only validated that the tank was structurally capable of remaining in use, but also helped map the precise extent of internal degradation.

2. Internal FRP (Fibreglass Reinforced Polymer) Lining
Following testing, Flowco installed a high-performance internal FRP lining system. This internal coating sealed corroded surfaces, reinforced structural areas subject to wear, and provided a new leak-proof inner wall. The liner bonded seamlessly to the existing tank walls, creating a corrosion-resistant barrier and restoring the tank’s compliance with relevant environmental regulations.

Key Outcomes

• Capital Cost Savings
  The client avoided full tank replacement, saving up to 60% compared to the cost of new tank excavation and installation.

• Minimal Site Disruption
  All repair works were completed without excavation, allowing the client to maintain site operations with only minor interruptions.

• Extended Asset Life with Warranty
  The completed system included a 10-year warranty, ensuring long-term protection, compliance, and peace of mind.

• Sustainability Benefits
  By restoring rather than replacing the tank, Flowco helped the client reduce construction waste and the carbon footprint associated with new tank manufacturing and installation.

Why This Matters

In many cases, underground fuel tanks are prematurely removed due to incomplete diagnostics or default assumptions around corrosion. Flowco’s evidence-led strategy demonstrates that with the right expertise and proven engineering methods, these critical assets can be safely restored — providing both environmental and economic benefits.

Learn More

To learn more about Flowco’s tank and line testing or internal tank lining services, visit our Tank & Line Testing page.

Request a Quote

If your site is experiencing suspected tank leakage, contact us today for a site-specific assessment and quote: flowcoglobal.com/contact