Case Study: Innovative Tank Roof Rehabilitation Using STOPAQ Solutions
In industries that rely heavily on large storage tanks—such as oil and gas, chemicals, and water treatment—maintaining the integrity of these assets is critical for both operational efficiency and safety. However, when faced with severe corrosion, extensive damage, and the challenge of carrying out repairs while the tank remains in service, many conventional methods simply don’t offer viable solutions. This was the scenario we encountered with a client facing a severely corroded tank roof, where traditional approaches like sandblasting and painting were not an option.
In this case study, we demonstrate how STOPAQ’s innovative repair solutions were used to successfully rehabilitate the tank roof, all while the tank remained fully operational—without any downtime.
The Challenge: Severely Corroded Roof with Limited Options
The tank in question was in a critical state of corrosion, with holes and visible damage compromising the structural integrity of the roof. These issues threatened not only the safety of the tank but also the entire system's operation. To make matters worse, the tank could not be emptied or degassed due to lack of storage capacity elsewhere.
This restriction ruled out several common repair methods, such as:
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Sandblasting to remove corrosion
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Painting for corrosion protection
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Welding and full roof replacement due to the need for the tank to remain in service
Given these constraints, we had to develop an alternative approach that could be executed while the tank continued to operate, ensuring minimal disruption for the client.
Solution Development: A Customized Repair Strategy
After conducting a thorough assessment of the situation and consulting closely with the client, our team designed a customized repair strategy that focused on cold repair techniques—methods that could be applied without the need for the tank to be emptied or degassed. The solution we ultimately implemented involved a combination of adhesives, steel plate reinforcement, and STOPAQ Wrappingband EZH—a specialized corrosion prevention material.
Step 1: Reinforcing the Roof with Cold Repair Techniques
The tank roof had sustained significant damage, particularly in certain critical areas. To address this, we used specialized adhesives and steel plates to patch up holes and reinforce weakened areas of the roof. The cold repair method was essential, as it allowed us to work on the tank without having to shut it down or drain it.
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Steel Plates were strategically placed over the holes to provide structural reinforcement and prevent further damage.
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Adhesive application ensured that the steel plates adhered securely to the roof, preventing corrosion from spreading further.
Step 2: Selecting the Right Corrosion Protection: STOPAQ Wrappingband EZH
With the porous nature of the steel roof, it was important to select a material that could conform to irregular surfaces and offer robust protection against further corrosion. After careful consideration, STOPAQ Wrappingband EZH was chosen for this challenging application.
STOPAQ Wrappingband EZH is a versatile, high-performance anti-corrosion material known for its ability to:
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Adapt to irregular surfaces, such as the uneven contours of the tank roof
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Provide a long-lasting, durable seal against the elements
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Offer excellent adhesion to both steel and other materials, even in harsh conditions
Step 3: Cleaning and Surface Preparation
Before the application of STOPAQ Wrappingband EZH, it was crucial to thoroughly clean the tank roof to ensure optimal adhesion and the effectiveness of the repair. The steps included:
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Removal of oil contaminants: Using a water-based degreaser to eliminate any oil, grease, or other contaminants that could affect adhesion.
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High-pressure cleaning: A high-pressure ATEX-compliant jet was used to clean the roof, remove loose debris, and eliminate any remaining corrosion or contaminants from the surface.
This cleaning process ensured that the substrate was properly prepared and ready for the application of the corrosion protection materials.
Step 4: Applying STOPAQ Wrappingband EZH
Once the tank roof was properly cleaned and dried, the application process began. STOPAQ Wrappingband EZH was applied in strips across the roof, particularly over the welds, seams, and reinforced areas where the steel plates had been added. This ensured that additional layers of protection were applied to the most vulnerable parts of the roof.
Key application considerations:
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Field joint coatings were used to increase the overall thickness and durability of the coating.
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Critical areas, such as air and gas vents, were given special attention, with extra layers applied to provide additional shielding from fumes and environmental stressors.
Step 5: Finishing Touch: Flexible Water-Based Acrylic Paint
As a final step, the entire roof was coated with an approved flexible, water-based acrylic paint. This finishing layer provided both aesthetic enhancement and mechanical protection, allowing for light foot traffic and further safeguarding the surface from environmental exposure.
The Result: A Successful, Cost-Effective Solution
In just three days, our two-person team, under the supervision of an experienced contractor and a trained STOPAQ technician, completed the repair process. The results were impressive:
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The tank roof was fully rehabilitated, with strengthened areas, reinforced holes, and long-lasting protection against further corrosion.
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The tank remained in service throughout the entire repair process, with no downtime or disruption to the client’s operations.
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The cost-effective nature of the repair process provided the client with significant savings, as traditional tank emptying, sandblasting, and painting were not required.
The client expressed complete satisfaction with the outcome, praising the rapid turnaround, the seamless application process, and the cost-effectiveness of the STOPAQ solution.
Key Takeaways: The Value of STOPAQ Solutions
This case study underscores several important points:
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Cold Repair Techniques: These methods allow for repairs to be carried out without the need for tank downtime, making them ideal for critical assets where uninterrupted service is a priority.
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STOPAQ Wrappingband EZH: Its versatility, durability, and ability to conform to irregular surfaces make it an excellent choice for complex corrosion protection challenges.
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Efficiency and Cost-Effectiveness: In just three days, a two-person team was able to carry out a full tank roof rehabilitation, providing long-term protection while avoiding the costs and delays associated with traditional repair methods.
At the heart of this project was our commitment to delivering innovative, tailored solutions that not only meet the client’s technical needs but also align with their operational requirements. By leveraging the latest in corrosion protection technology and repair techniques, we were able to extend the lifespan of this asset, delivering peace of mind for the customer and ensuring the tank’s ongoing reliability.
Conclusion: Protecting the Future of Industrial Assets
In today’s fast-paced industrial landscape, downtime is costly, and asset longevity is more important than ever. The successful rehabilitation of this tank roof demonstrates the power of STOPAQ solutions in addressing complex challenges and providing sustainable, long-term solutions for critical infrastructure.
Whether you're facing severe corrosion or need to carry out a repair while your equipment remains in service, STOPAQ has the expertise and products to ensure your assets are protected for the long haul.
If you’d like to learn more about our corrosion protection solutions or need help with a specific asset repair challenge, don’t hesitate to reach out. Let’s talk about how we can help you protect the future of your operations.
