Repair or Replace? What Should You Do With Leaking Storage Tanks?

A leaking storage tank is never a minor problem—especially when the tank holds fuel, chemicals, process water, or other critical materials. Facility managers and maintenance teams are often faced with a tough decision: should you repair the leak or replace the tank entirely? The right answer depends on several key factors, including the extent of the damage, regulatory requirements, operational needs, and budget. This guide will help you weigh the options and choose the smartest, safest, and most cost-effective solution for your operation.

When Is Storage Tank Repair the Best Option?

• Leak is Localized or Minor:
  If the damage is confined to a specific area—such as a single weld, joint, or wall section—targeted repairs can restore integrity without the cost and downtime of a full replacement.

• Tank is Structurally Sound:
  If the tank still has good overall wall thickness and passes structural inspections, advanced repair methods can reliably stop leaks and reinforce weak spots.

• Fast Turnaround or Minimal Downtime:
  Emergency on-line leak repair, composite wraps, and engineered coatings/linings from RAK can often be applied with the tank in service, allowing you to minimize disruptions and avoid extended shutdowns.

• Regulatory Compliance:
  Professional repair solutions can meet EPA, OSHA, and industry standards—especially when performed by certified specialists using approved materials and methods.

When Should You Consider Tank Replacement?

• Extensive Corrosion or Wall Loss:
  If multiple leaks, severe thinning, or widespread corrosion are present, full replacement may be the safest and most cost-effective option long-term.

• Aging or Outdated Tank Design:
  Tanks that no longer meet current design codes, have compromised foundations, or are showing signs of fatigue may be better replaced than repaired.

• Repeated Repairs or Recurring Leaks:
  If you’ve repaired the same tank multiple times in recent years, it may be time to invest in a new asset for better reliability and lower ongoing maintenance costs.

• Compliance or Capacity Upgrades Needed:
  Sometimes, changing regulations or operational needs require a newer tank with higher capacity, improved coatings/linings, or enhanced features.

Modern Repair Solutions for Leaking Storage Tanks

• On-Line Leak Repair:
  RAK Industrial Services specializes in emergency on-line leak repair—stopping leaks fast, even in pressurized or hazardous tanks, without removing them from service.

• Carbon Fiber and Composite Wraps:
  Advanced composites reinforce and seal areas of wall loss or mechanical damage, restoring tank integrity and preventing future leaks.

• High-Performance Coatings & Linings:
  Installing or restoring internal linings (epoxy, vinyl ester, plural component, NSF 61) creates a seamless, chemical-resistant barrier for long-term tank protection.

• Trowel-Applied and Specialty Linings:
  For spot repairs or tanks with complex geometries, trowel-applied systems offer durable, targeted protection.

Assessment Steps Before Deciding

• Inspect the Damage:
  Use ultrasonic testing, visual inspection, and thickness measurements to evaluate the extent and location of leaks or corrosion.

• Identify the Cause:
  Determine whether the leak is due to corrosion, impact, lining failure, or another root cause—addressing the cause is key to preventing recurrence.

• Consult a Professional:
  Have experts like RAK conduct a site assessment. We’ll provide clear recommendations and cost comparisons based on your tank’s condition, regulatory needs, and operational priorities.

Why Choose RAK Industrial Services?

RAK brings decades of experience in leak assessment, composite repairs, coatings and linings, and turnkey tank rehabilitation. We help you make informed, cost-effective decisions—matching the solution to your goals, budget, and compliance requirements. Our emergency response ensures leaks are contained fast, minimizing risk and downtime.

Repair or replace? The answer depends on your tank’s condition, compliance needs, and business priorities. With modern repair technologies and rapid response, many leaks can be safely and effectively fixed—saving you time, money, and hassle. When replacement is the better choice, RAK can help you plan and execute the transition with minimal disruption.