Cracks in tanks might seem like small issues at first, but they can grow fast if left alone. A minor line across the wall could turn into a bigger split that puts your entire system at risk. Once water starts to leak or pressure inside changes, everything from water quality to structural strength is affected. Staying on top of cracks before they spread is a smart move that avoids bigger trouble down the track.
This article focuses on what leads to tank cracks, how to spot early signs, and why it’s worth fixing them as soon as possible. If you’ve ever heard odd noises coming from your tank, seen unexplained damp patches, or noticed a sudden drop in water pressure, those might be more than just quirks. Here’s a look at what causes cracking and how it gets worse if ignored.
Common Causes Of Tank Cracks
Tanks are built to carry and hold large amounts of water or other fluids for years, but a lot can affect their lifespan. Knowing what causes cracking helps prevent future issues and guides better maintenance schedules.
One main cause is material fatigue. Tanks go through regular pressure changes as they fill and empty, and over time, this repeated stress can weaken even the strongest walls. Cracks often show up in the same trouble spots like corners, seams, or around supporting fittings.
Weather has an impact too. When tanks heat up during the day and cool down overnight, they expand and contract. This cycle puts stress on the surface and leads to hairline fractures. This is more common in places with temperature swings and mostly affects concrete or fibreglass tanks.
Poor maintenance can also bring on cracking. If seals and linings get worn or if sediment builds up at the base, the tank becomes more prone to damage. Water with chemicals or minerals can erode older tank walls faster, especially if issues go unchecked for too long.
Other causes to keep in mind:
– Shifting soil under the tank: Uneven foundations create extra stress points and cracking during movement.
– Incorrect installation: If the base isn’t level or fittings aren’t aligned, pressure builds up and cracks form early.
– Poor-quality materials: Tanks must match their intended purpose. Using a plastic tank in high heat or thin linings for chemical storage shortens the tank’s life.
These issues don’t usually appear overnight. Most cracks develop slowly, out of sight, and take time to work their way to the surface. Regular inspections are the main defence.
Signs Your Tank Has Cracks
Catching signs of cracks early is a big help. A small issue sorted right away is far easier to manage than one left to grow. Some warning signs are obvious, but others can only be spotted during proper maintenance checks.
Here’s what to look out for:
1. Visible surface cracks
Hairline fractures on the tank’s inside or outside are clear signs something is wrong. If lines keep showing up in the same areas, it likely means weakening beneath the surface.
2. Water leakage
If you’ve noticed puddles forming suddenly at the tank base or fittings showing signs of moisture when the tank is full, cracks might be to blame. These leaks can come and go, which makes timing the inspections important.
3. Unusual tank noises
Popping or snapping sounds aren’t normal. If the tank isn’t being used and you hear sounds of shifting or water moving, it could point to pressure changes caused by splits behind the liner or wall.
4. A drop in water pressure
If there’s a sharp decrease in pressure during regular use, a hidden crack could be letting liquid escape or the structure might be starting to give way.
Taking these signs seriously avoids more serious damage later. We’ve come across tanks where minor symptoms were brushed off until full repairs were needed, resulting in days of downtime and risk of contamination.
The Dangers Of Ignoring Tank Cracks
Leaving cracks unchecked doesn’t just lead to bigger leaks. It brings on a range of trouble that affects safety, product quality and the tank system itself.
As cracks spread, the cost of repair grows. What might have been a quick patch can turn into a job needing full section replacements or even tank replacement. Cracks can also weaken nearby surfaces. Water seeping out under pressure often damages pads or metal brackets nearby, adding to costs.
There’s also the risk of contamination. When tank walls crack, outside air, bacteria or soil can mix with what’s inside. In cases like drinking water or chemical storage, this could shut down the whole system for cleaning and testing. If the crack goes deep and reaches through past a liner, contents can end up leaking into the surrounding environment.
Ignoring cracks can even lead to fines in some industries. If the tank stores hazardous material or is part of a regulated system, leaks could lead to breaches of environmental or safety rules. These not only add unexpected expenses but can damage a business’s reputation and delay operations.
Steps To Repair Tank Cracks
Once a crack is found, the repair process starts with a detailed inspection. Proper visuals of internal and external surfaces help map out the damage. Focus should be on areas where seams meet, locks join or previous fixes were done. Once full inspection is complete, the right repair approach can be selected.
Here are the most common repair options:
– Patch repairs
Small cracks can often be covered using approved sealants or fitted liners. These are fast, cost-effective fixes for non-structural damage.
– Section replacements
If a crack is tied to older materials or faulty construction, replacing a full section is more reliable than a simple cover-up.
– Welding or bonding
Best for fibreglass or metal tanks. This method fuses broken areas together to restore full strength and stop pressure faults from spreading.
One of the biggest mistakes is trying to patch cracks without checking for other hidden weak spots. DIY efforts often miss the actual cause of the damage or the extent of the strain inside the tank. A hidden crack might look like a single line, but pressure maps often show stress spreads out behind the visible break.
After the repair, follow-up is key. Regular inspection after a fix helps spot if the area struggles again, especially during the next seasonal change. Maintenance checks catch stress points early and give peace of mind that the repair holds up under use.
Preparing For Future Cracks
To reduce the need for repeated repairs, it helps to make your tank system stronger moving forward. This doesn’t only mean replacing old parts—it means building a clear plan for care and upgrades.
Start with a regular maintenance calendar. This might include pressure testing, resealing or periodic camera inspections. Doing this before signs appear saves time and avoids panicked repairs when things go wrong.
For older systems showing repeated cracks, a few upgrades can go a long way. Better lining materials, improved seals and stronger base supports all give the tank a fresh chance at long-term use. In areas with heavy sun or weather exposure, insulation or protective coatings help slow down wear.
External pressure should be considered too. If the soil shifts seasonally or machinery moves close to the tank, reinforced foundations or buffer zones can be added. These small steps lower chances of new cracks forming from outside forces.
Keeping Your Tanks In Top Shape
Cracks aren’t just ugly surface flaws—they’re warnings. Whether they come from stress, age or missed maintenance, catching cracks early often means the difference between quick repairs and major costs.
Tanks that are looked after tend to perform longer and safer. Regular checks, paired with reliable repair and upgrade options, take guesswork out of tank care. Staying alert to early signs, using the right repair approach and thinking ahead about future risks help avoid repeat issues. Keep your tanks ready to serve for years by giving cracks the attention they deserve when they first appear.
When it comes to ensuring the longevity of your tank, dealing with repairs quickly is a key aspect. If you’re noticing any signs of wear, don’t hesitate to explore your options. For professional and effective tank repairs, ATM Tanks offers a thorough approach that addresses the root of the issue, preventing future problems and protecting your investment. Keep your system running smoothly by staying on top of maintenance and taking action at the first sign of trouble.
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