Tank renovation

Tank renovation encompasses all technical, organizational and safety-related measures required to make existing storage tanks for oil, chemicals, fuels, firefighting water or process media reliable, leak-tight and safe to operate again. It ranges from cleaning through repair and coating to decommissioning and dismantling. In practice, fugitive emissions, explosion protection, environmental protection, and the integration of suitable material- and process-specific tools are decisive. Hydraulically powered devices such as tank cutters, steel shears, combination shears, concrete pulverizers or hydraulic rock and concrete splitters – with energy supply via compact hydraulic power units – enable controlled, low-spark and low-vibration steps in concrete demolition and special demolition, during strip-out and cutting, as well as in special applications.

Definition: What is meant by tank renovation

Tank renovation is the planned repair, modernization or orderly decommissioning of tanks and their ancillary installations. The objective is to restore or ensure leak-tightness, operational safety and the protective function with respect to soil, water bodies and the surroundings. Depending on condition and purpose, it includes interior cleaning, gas-free testing, elimination of corrosion damage, installation of internal liners or leak protection systems, renewal of coatings, repair of foundations and containment basins, as well as necessary upgrades to the state of the art. For retired tanks, proper dismantling and disposal are part of the scope. In all phases, depending on material and construction, mechanical cutting, splitting and pressing methods are used; for example, concrete pulverizers and concrete or rock splitters are employed when concrete foundations, ring beams or jacket encasements must be removed.

Process and methods of tank renovation in practice

The typical project workflow is structured into plannable steps, adapted to tank type (carbon steel, stainless steel, FRP, reinforced concrete), medium and site:

• Pre-inspection and condition assessment: visual inspection, wall thickness measurements, inspection of attachments, evaluation of coatings and seals.
• Work permit and safety concept: risk assessment, explosion protection, clearance measurements, inerting if required, selection of low-spark methods.
• Emptying and cleaning: removal of residual media, sludge, deposits; internal cleaning, high-pressure methods if applicable; proper collection of rinsing media.
• Gas-free testing and clearance: verification of explosion and health hazards; continuous monitoring in confined spaces.
• Repair: local patching (e.g., welding in patch plates), crack sealing, coating renewal, installation of an internal liner or leak protection systems, strengthening of supports and foundations.
• Mechanical processing: cold cutting of openings, sampling, replacement of internals; dismantling of attachments and piping if required.
• Testing and documentation: leakage tests, layer thickness checks, visual inspections; preparation of the renovation documentation.
• Decommissioning/dismantling (if planned): safe sectioning, deconstruction and separation of material streams for disposal.

Hydraulic cutting and splitting technology enables controlled, low-vibration interventions. Tank cutters, steel shears, combination shears and Multi Cutters facilitate opening steel shells, removing manway covers and separating connected piping. Concrete pulverizers and concrete/rock splitters prove their worth when removing concrete housings, foundation rings or containment basins—especially in areas where vibration and sparking must be avoided.

Typical damage patterns and causes

Damage arises from aging, corrosion, mechanical loading, chemical exposure or insufficient maintenance. The most frequent manifestations include:

• General corrosion and pitting on steel walls, especially in the water phase or at welds.
• Delaminated, aged or chemically attacked internal coatings; blistering and underfilm corrosion.
• Cracks, settlement and spalling on concrete foundations and containment basins that impair the retention function.
• Leaking flanges, valves and manway covers; embrittlement of gaskets.
• Mechanical deformations caused by temperature changes, filling and emptying cycles, or external impacts.

The renovation strategy is guided by the cause and extent of damage: from local repair through complete recoating to conversion to an internal liner with leak monitoring. If concrete components must be strengthened or removed, depending on accessibility and member thickness, concrete pulverizers or concrete/rock splitters are used to open and separate members in a controlled manner.

Safety aspects: gas-free testing, inerting and explosion protection

Safety takes precedence, especially with flammable or toxic media. Key measures are:

1. Gas-freeing: emptying, ventilating, rinsing; clearance measurements for explosive limits, oxygen and toxic constituents.
2. Inerting: displacing oxygen with inert gases if required to minimize ignition potential.
3. Low-spark methods: cold-cutting hydraulic tank cutters, steel shears and combination shears reduce ignition risks compared with thermal methods.
4. Entry into confined spaces: rescue concept, continuous monitoring, appropriate PPE and safe access points.
5. Dust and noise reduction: mechanical methods with low emissions and low-vibration operation in sensitive areas.

For concrete demolition within integrated building structures or near live utilities, low-vibration methods are important. Concrete pulverizers and concrete/rock splitters enable controlled fractures, protecting adjacent components.

Materials and renovation procedures

Steel tanks

For steel tanks, renovation often includes removing loose layers, creating sound substrates, welding on patch plates, installing internal liners and applying chemically resistant coatings. For openings, sampling or dismantling, tank cutters, steel shears, combination shears or Multi Cutters are used. In conjunction with hydraulic power packs, these tools produce precise cuts without heat input, which improves the integrity of the surroundings.

FRP and stainless-steel tanks

For FRP, mechanical surface preparation, laminate repair and compatible resin systems are common. Stainless steel requires careful surface treatment to avoid increased corrosion susceptibility from foreign iron. Mechanical openings should be low-spark and gentle on the material; the use of hydraulic cutting tools is likewise appropriate here.

Concrete tanks and containment basins

Concrete tanks and secondary containment systems (catch basins, ring beams) require structurally and chemically suitable repairs for cracks, honeycombing or carbonated zones. Where deconstruction is required, concrete pulverizers are used for selective removal of reinforced concrete; concrete/rock splitters open massive members along defined split lines, keeping dust and vibration loads low.

Mechanical processing and deconstruction: tools and applications

The choice of mechanical methods depends on tank geometry, installation situation, material, residual media and emission targets. Relevant tools and typical applications:

• Tank cutters: opening tank shells, cutouts for manholes, segmentation for dismantling; low-spark and suitable for ATEX-hazardous areas when conditions are met.
• Steel shears and combination shears: separating pipelines, beams, ladders, attachments; versatile for strip-out and cutting.
• Multi Cutters: precision cuts on plates, sections and internals; clean cutting path without heat input.
• Concrete pulverizers: selective deconstruction of foundation rings, concrete jacketing, wall breakthroughs; good balance of power and control.
• Concrete and rock splitters (stone splitting cylinders): generating defined split joints in thick members, foundation blocks or ring beams; minimal vibration input.
• Hydraulic power packs: energy supply for the tools with reproducible parameters; important for consistent cutting and splitting quality.

These tools are used in the fields of concrete demolition and special demolition, strip-out and cutting and in special applications. For tank renovation with particularly restricted access or sensitive neighbors, compact hydraulic systems with high power density are advantageous.

Internal liners, coatings and leak protection

If the steel wall is load-bearing but corroded, installing an internal liner with leak monitoring is advisable. Alternatively or additionally, chemically resistant coatings are used. Important aspects are:

• Substrate preparation: removal of loose layers, suitable roughness, drying; controlled surface preparation.
• System selection: media resistance, temperature range, mechanical durability, repairability.
• Quality assurance: layer thickness, holiday testing, pull-off adhesion, documentation.

For concrete containment basins, crack-bridging systems or mineral reprofiling are common. Removing defective layers can be prepared with concrete pulverizers; for massive areas, concrete/rock splitters are suitable.

Decommissioning and dismantling of tanks

If continued use is not sensible, orderly decommissioning follows. Procedure:

1. Empty, clean, gas-free; capture residual media and rinsate.
2. Low-spark opening: cutouts for safe access; tank cutters or steel shears minimize heat input.
3. Segmentation: cutting into transportable sections; Multi Cutters and combination shears support separation of attachments.
4. Removal of foundations and housings: concrete pulverizers for reinforced concrete, concrete/rock splitters for massive blocks.
5. Source-separated sorting and disposal: metals, mineral fractions, coated materials handled separately.

Dismantling planning considers transport routes, noise control, vibration and dust. Hydraulic methods enable controlled steps in densely built plant areas.

Environmental and disposal aspects

A core goal of tank renovation is the protection of soil and water bodies. Therefore, enclosed working methods, sealing against runoff and proper disposal are central. Key points:

• Collection of sludges, cleaning solutions and contaminated solids in suitable containers.
• Prevention of dripping and wind drift; minimize dust sources during mechanical processing.
• Separation of material streams: metal, mineral construction materials, hazardous waste.
• Documentation of quantities and destination.

During deconstruction of containment basins or concrete foundations, a precise, selective approach helps. Concrete pulverizers and concrete/rock splitters limit collateral damage to adjacent components, reducing the amount of material that must be classified as hazardous waste.

Testing, documentation and maintenance

After completion of renovation, testing and gap-free documentation are essential. Depending on the system, this includes leakage tests, coating inspections, functional tests of leak detection systems, visual inspections and periodic repeat inspections. Maintenance includes periodic inspections, cleaning, corrosion protection upkeep and monitoring of critical zones. Clean documentation facilitates later assessments and future renovations.

Planning, interfaces and organization

Successful tank renovation integrates technical, safety and organizational aspects. Advantages include clear scheduling, coordinated lock-out concepts, coordination with adjacent trades, and a tool set tailored to the area of use. In buildings or plant areas with sensitive processes, compact hydraulic tools that generate low vibration and minimal sparks have proven their worth. If tank foundations, ring beams or wall openings must be adjusted, the combined use of concrete pulverizers and concrete/rock splitters offers a controlled approach.

Legal and normative framework

When planning and executing, the relevant legal and technical requirements must be observed. These include, in particular, regulations on water protection, handling of hazardous substances, occupational safety, explosion protection and waste disposal. Which requirements apply in each case depends on the medium, tank construction, site and use. Those responsible should check the current provisions and—where required—coordinate with authorities. Statements in this text are general in nature and do not replace binding case-by-case assessment.

Practical pointers for selecting methods

• Confined conditions and ATEX zones: prefer low-spark hydraulic tank cutters, steel shears and combination shears; ensure ventilation and clearance measurements.
• Massive concrete foundations: concrete/rock splitters to create planned split joints, concrete pulverizers for selective removal of reinforced zones.
• Vibration-sensitive environments: use mechanical, low-vibration methods; cutting and splitting instead of percussive tools.
• Documentation duties: define test and measurement points early; plan access and openings accordingly.
• Reuse instead of replacement: realistically assess load-bearing capacity and remaining wall thicknesses; select coating and internal liner systems with suitable media resistance.

The combination of systematic planning, safe working methods and suitable tools is key to renovating tanks economically and technically soundly. In many projects, the combination of a tank cutter for the vessel, steel shears for attachments, and concrete pulverizers plus concrete/rock splitters for foundations leads to a controlled, low-emission process.