Tank liners work as a protective barrier between whatever is stored inside and the tank’s actual surface. They stop leaks, reduce corrosion and help keep liquids or sediments safe from contamination. Whether it’s water, fuel, chemicals or waste, a quality liner makes a big difference in how well a tank functions over time. But like any piece of equipment, liners don’t last forever. They face wear and tear, damage and exposure to some pretty harsh conditions.

When problems start to show, they often go unnoticed until the effects start to spread, like a slow leak or chemical reaction that compromises more than just the liner. For that reason, understanding the most common tank liner issues can help you catch trouble early and apply the right fix before it gets worse. Being aware of the warning signs gives you a better shot at keeping operations running and protecting the contents held inside your tanks.

Common Issues with Tank Liners

Tank liners don’t all fail the same way, but there are some issues that tend to pop up more often than others. These problems can develop over time or result from one specific incident. Either way, catching them early goes a long way toward avoiding more expensive damage later on.

Here are a few of the most common tank liner problems:

1. Tears or Splits

This can happen during installation or years down the track. Tears are usually caused by sharp edges inside the tank, stress from movement or shrinkage over time. Even a small split can let liquids leak through to the tank wall.

2. Punctures

Point damage like this may come from foreign objects, tools being dropped inside or sediment build-up with small rocks or debris. Punctures are often harder to spot until you notice something like a stain or damp patch on the outer tank surface.

3. Liner Shrinkage

This usually shows up when the liner appears to peel away or pull back from edges and corners. It happens when liners aren’t suited to the tank’s environment or when they’re exposed to long periods of heat or direct sunlight.

4. Chemical Degradation

Some chemicals react with liner material if there’s a mismatch between the two. Over time, this can lead to blistering, cracking or a slimy feel that signals the liner is breaking down.

5. Delamination

This is when layers within the liner start to separate. It’s often a sign of age, poor installation or chemical incompatibility. Once delamination begins, it spreads fast and can’t really be patched.

If you’re hearing odd sounds from the tank, noticing changes in water quality or spotting build-up in valves or outlets, there’s a strong chance the lining might be part of the issue.

Main Causes of Tank Liner Issues

Now that we’ve covered the most common problems, it helps to understand where they often come from. Pinpointing the trigger can help stop the same issue from happening again after it’s been repaired.

Here’s a closer look at common causes:

– Incorrect installation

If liners aren’t fitted properly, whether stretched too tight or left with creases, they’ll wear out unevenly. Poor sealing can also allow moisture to sneak in behind the liner, leading to hidden corrosion.

– Wrong material choice

Not all liners are made for the same job. Some are designed for water, others for fuel or high-temperature contents. Using one that isn’t fit for purpose leads to faster breakdowns, leaks or even full liner failure.

– Exposure to sun or heat

Tanks exposed to direct sunlight or high-heat locations can stress liners, especially if the material isn’t UV stable or made for that range of temperature. This exposure makes the liner brittle or causes it to shrink.

– Chemical reaction

If the liner material reacts with the contents of the tank, it can change texture, lose elasticity or begin forming cracks. This is common with industrial chemicals or aggressive wastewater.

– Wear and tear from abrasion

Regular movement of liquids, sludge or waste can slowly wear down the liner, especially at the base of the tank or around entry points. Sloped floors or sharp debris make this worse over time.

One example: a processing plant switched to a different type of cleaning agent without checking if it was safe for their current liners. Within weeks, several tanks showed signs of blistering near the bottom. Turns out, the cleaner broke down the liner from repeated exposure. A material upgrade and some chemical testing helped fix and prevent the same mistake from happening again.

Understanding the root of each issue gives you a better idea of how to stop it from repeating, and helps plan the kind of liner or setup your tank may need going forward.

Solutions for Each Common Issue

Once you understand what’s causing the damage, the next step is to figure out how to address it properly. Some solutions are straightforward, but others call for trained professionals who know how to work within tight tank spaces and under safety standards.

Here’s how the most common problems are usually handled:

– Tears and splits

For small tears, temporary patches can hold things together until a full repair or replacement is organised. That said, relying on patches only buys time. If the tear grows or the tank is storing something sensitive like fuel or chemicals, a proper fix is needed. Usually, that means replacing the liner or a full section of it with similar material.

– Punctures

Punctures often start as small holes but can widen with pressure from liquid movement. These need to be sealed using compatible repair materials and techniques. The area also needs to be prepped first to make sure the fix holds. Removal of any sharp nearby debris is a good idea to keep it from coming back.

– Shrinkage or peeling corners

These problems usually show that the liner wasn’t designed for the operating conditions. It’s not always possible to re-stretch a warped liner into place. In many cases, replacement with a material more suited to changing temperatures or stress zones is the safer route.

– Chemical breakdown

If parts of the liner become soft, sticky or brittle due to chemical reactions, it’s a clear warning that the material isn’t suitable for the tank’s contents. A chemical-resistant liner should replace the damaged one. Professional help is important here, since the new material needs to be matched based on exact chemical exposure.

– Delamination

There’s really no quick fix for this one. Once a liner begins to separate into layers, the problem spreads fast and affects structural support. The only real solution is to take the damaged liner out and install a new, properly bonded one.

Handling these problems is a balance between short-term function and long-term tank safety. Delaying serious repairs can cause bigger headaches later, especially if corrosion starts underneath and spreads. Bringing in the right people early makes a huge difference in the quality of the fix and the cost to restore everything.

Preventative Measures to Avoid Future Problems

You can’t stop every issue from cropping up, but setting up a few habits does extend the life of your tank liners. A bit of forward planning could save you from shut-downs or emergency repairs later on.

Useful ways to reduce liner failure include:

– Regular inspections every 6 to 12 months, depending on usage

Look for visible signs like loose seams, wrinkles, discolouration or bulging spots. Listen for bubbling or odd hissing sounds when the tank is full.

– Professional cleaning

Make sure the tanks are being cleaned with the right tools, not ones that damage or scratch the liner surface or allow chemical residues to settle over time.

– Use the correct liner for the contents

Whether the tank holds recycled water, fuel, liquid feed or sludge makes a big difference. Work with people who understand the right material for each type.

– Limit exposure to direct sunlight or open air

Tanks stored outdoors should have some shielding to block UV rays, especially when the liner isn’t designed for ongoing heat stress.

– Keep track of chemical changes inside the tank

If your operations start using new chemicals or cleaners, find out if the liners can take that kind of exposure. Don’t assume all liners can handle anything.

– Ensure proper installation the first time

Liner failures often trace back to how they were installed. Wrinkles, overstretching or poor corner seals lead to issues just months later.

Think of liner care the way you’d maintain a vehicle. The more attention you give the little things like clean hoses, clean filters and regular checks, the fewer big problems you’ll face. Tanks and their liners work much the same.

Why Staying Proactive Pays Off

Left unchecked, tank liner issues can spiral into bigger problems that affect the whole tank system. Leaks, contamination and corrosion put equipment at risk and can slow down entire operations. Once water or chemicals seep through small faults, it won’t take long before connected parts like pumps, pipes and internal supports are impacted too.

By looking out for the early warning signs and staying consistent with inspections, you put yourself in a strong position to fix issues before they cost more time or money. Getting advice when something doesn’t look right can help catch a failing liner before it forces a shutdown or cleanout. Avoiding the quick-fix mentality often leads to better tank performance and fewer surprises down the track.

The time and effort spent on liner care often pays back quietly, simply by keeping things working the way they should. Whether the tank is brand new or decades old, how it’s looked after today affects how it’ll hold up tomorrow.

For more details on keeping your tank liners in peak condition, explore the comprehensive range of services offered by ATM Tanks. You can find tailored solutions to maintain your storage system’s integrity by learning more about our expert approach to tank liners. Let our team help you protect your investment with proven, long-lasting results.