Fuel Tank Repair: Protecting Your Fuel Systems from Risk and Downtime

Fuel storage tanks are a critical part of many industrial operations, especially in sectors where backup power or remote energy generation is required. Whether supporting mine sites, construction projects, logistics yards, or agricultural equipment, a well-maintained fuel tank ensures a consistent and safe fuel supply.

Yet, despite their importance, fuel tanks are often left unattended for long periods. This can result in corrosion, leakage, contamination, or even structural failure, which can cause significant operational delays and environmental harm.

A proactive approach to fuel tank repair is not only essential for maintaining compliance but also for extending the life of the tank and protecting the fuel it holds.

Why fuel tank integrity matters

Fuel tanks are exposed to a variety of harsh conditions. In Western Australia, for example, tanks may experience extreme heat, dust, high humidity, and salt-laden air. Over time, these environmental factors contribute to wear and tear, both internally and externally.

If a tank is left unchecked, a small issue can quickly develop into a much larger problem.

Common signs of fuel tank damage include:

• Corrosion on internal or external surfaces
• Leaking fittings or seals
• Paint blistering or rust patches
• Inaccurate fuel gauge readings
• Water contamination or microbial growth in the fuel
• Fuel usage discrepancies

These issues affect not just the performance of the tank, but also the reliability of any systems that rely on the fuel it holds. For businesses that depend on diesel-powered generators, plant equipment, or heavy vehicles, the consequences of an undetected fault can be costly.

Common causes of fuel tank damage

Fuel tanks, whether portable or stationary, deteriorate for several reasons.

Some of the most common causes include:

• Condensation inside the tank, leading to water contamination and internal rust
• Physical damage from transportation or impact on job sites
• UV exposure, which breaks down external coatings over time
• Incorrect storage, including placement on uneven or unsuitable surfaces
• Ageing seals and gaskets, which lose elasticity and may crack or fail
• Poor quality fuel, which can encourage microbial growth or sludge buildup

Regular inspections and servicing can help mitigate these risks, but once damage is identified, timely repair is essential to prevent further degradation.

What fuel tank repair involves

Fuel tank repair can range from simple part replacements to more complex structural remediation. The process always begins with a thorough inspection to assess the extent of the damage.

A standard professional repair service typically includes:

• Cleaning the tank interior to remove sludge, water, or contaminants
• Replacing worn or corroded fittings, seals, and access points
• Repairing or recoating damaged areas of the tank surface
• Testing for leaks and structural weaknesses
• Calibrating or replacing fuel level indicators and monitoring equipment
• Ensuring all work complies with Australian Standards, including AS1940 for fuel storage

It is also common to perform a pressure or vacuum test after repair, especially if the tank is used for bulk diesel storage. This confirms the integrity of the tank before it is returned to service.

When repair may not be viable

In some situations, a fuel tank may be too damaged to justify repair. This often occurs when:

• Corrosion has compromised the tank’s structural integrity
• The internal baffle system has collapsed or been obstructed
• The tank has been exposed to long-term contamination
• Parts are obsolete or no longer meet compliance standards
• The cost of repair outweighs the cost of replacement

In these cases, tank replacement may be the safer and more economical option. For operations that cannot afford extended downtime, temporary fuel tank hire may also be considered while a permanent solution is arranged.

GHASA offers both repair and replacement services across WA, along with hire options for businesses needing rapid fuel system support.

The importance of compliance

Fuel storage in Australia is regulated by a number of safety and environmental standards. Most fuel tanks must comply with AS1940: The Storage and Handling of Flammable and Combustible Liquids. Additional regulations may also apply depending on industry, location, and tank capacity.

A damaged or leaking fuel tank can pose significant environmental hazards, including soil and groundwater contamination. It can also create fire risks, especially in high-temperature zones or near ignition sources. Businesses found in breach of fuel storage regulations may face penalties or clean-up liabilities.

Working with a qualified repair provider ensures that all repairs are carried out to current compliance standards, reducing legal and safety risks.

Planning preventative maintenance

While emergency repairs are sometimes unavoidable, the most cost-effective approach to tank maintenance is prevention. Implementing a scheduled inspection and service routine can help identify early signs of deterioration and reduce the risk of unexpected failure.

Preventative measures may include:

• Annual inspections by a qualified technician
• Routine fuel quality testing
• Scheduled calibration of fuel monitoring systems
• Cleaning of tanks at fixed intervals
• Replacement of seals and fittings before failure occurs

Many businesses now include fuel tank maintenance in their broader plant servicing schedules, which helps ensure their entire power or fuel supply system remains operational and compliant.

Protect your fuel, avoid downtime with GHASA

Fuel tanks may not demand attention often, but when they do, the consequences of inaction can be severe. A reliable repair strategy not only restores functionality but also helps protect fuel quality, maintain workplace safety, and avoid unexpected downtime.

Whether your fuel tank is on a mine site, a construction project, a logistics depot, or a backup power system, keeping it in good working order is a critical part of your operation.

If you operate in Western Australia and require professional support with inspection, repair, or replacement, the team at GHASA offers local expertise and proven capability.

To learn more about GHASA’s fuel tank repair services, visit https://ghasa.com.au/fuel-tank-repairs/ or call (08) 9359 1988.