Corrosion is one of the most common and costly issues affecting large water storage tanks. Whether a tank is made from steel, concrete, GRP, or lined materials, corrosion can gradually damage the structure, reduce water quality, and shorten the tank’s service life. Understanding water tank corrosion problems is essential for facility owners who want to maintain a safe, efficient, and reliable storage system.
This guide explains what corrosion is, why it happens, the early warning signs to look for, and how it affects the performance of your water tank.
What are Water Tank Corrosion Problems?
Water tank corrosion problems occur when the interior or exterior surfaces of a tank begin to break down due to chemical reactions, moisture exposure, or environmental conditions. Over time, corrosion can weaken the tank walls, cause leaks, contaminate stored water, and lead to expensive repairs.
Corrosion may appear as surface rust, pitting, scaling, discoloration, coating failure, or structural weakening. While steel tanks are most commonly affected, all types of water tanks can experience deterioration if they are not properly maintained.
Common Causes of Corrosion in Large Water Tanks
Corrosion can develop for many reasons. Some of the most common causes include:
1. Constant Water Exposure
Continuous contact with water—especially untreated or high-mineral water—creates ideal conditions for corrosion.
2. Chemical Reactions
Chlorine, salts, and certain minerals in the water can react with tank surfaces, accelerating material breakdown.
3. Environmental Factors
Humidity, extreme temperatures, and industrial surroundings can damage exterior surfaces and coatings.
4. Poor Maintenance or Infrequent Inspections
Tanks that are not inspected regularly are more likely to develop unnoticed corrosion issues that worsen over time.
5. Coating or Liner Failure
Protective coatings and linings wear down with age. Once protection fails, corrosion can begin rapidly.
6. Sediment Accumulation
Sediment at the bottom of the tank can hold moisture and bacteria, contributing to localized internal corrosion.
Understanding these causes helps facilities take preventive steps before corrosion becomes a costly problem.
Early Signs of Water Tank Corrosion
Spotting corrosion early can prevent serious damage and expensive repairs. Some of the most common warning signs include:
- Rust stains or discoloration on internal or external tank surfaces
- Peeling, flaking, or blistering coatings
- Water discoloration (brown, orange, or cloudy water)
- Metal pitting or rough patches inside the tank
- Wet areas or moisture seepage around the tank base
- Unusual odors or taste changes in stored potable water
- Visible cracks or structural weakness in concrete tanks
- Leaks, even small ones, which can indicate deeper corrosion
If any of these signs appear, it’s important to investigate promptly.
How Corrosion Impacts Your Water Storage System
Corrosion is more than just a visual problem—it affects the entire performance of a storage system. Here are the main risks:
1. Structural Damage
Corrosion weakens the tank walls and roof over time. Severe corrosion can lead to cracks, holes, panel failure, or even full structural collapse in extreme cases.
2. Water Contamination
As tank materials break down, contaminants may enter the water supply. This affects water quality and can be especially dangerous in potable water systems.
3. Leaks and Water Loss
Corrosion often leads to leaks, which waste stored water, increase operating costs, and cause damage to surrounding structures.
4. Reduced Capacity and Efficiency
Sediment and corrosion buildup reduce the effective volume of the tank and place extra strain on pumps and connected systems.
5. More Frequent Repairs
Left untreated, corrosion spreads quickly. What starts as a small patch of rust can turn into major repair work, taking the tank out of service unexpectedly.
6. Shortened Tank Lifespan
Without proper monitoring, corrosion can force early replacement of an otherwise functional tank—resulting in major capital expenses.
Understanding these impacts emphasizes why early detection and prevention are essential.
Best Practices to Prevent Water Tank Corrosion
While corrosion cannot always be avoided completely, there are proven methods to minimize its impact:
- Regular tank inspections to monitor coatings, linings, and structural condition
- Cleaning and removing sediment to reduce corrosive buildup
- Maintaining protective coatings or liners so the tank surface stays isolated from water
- Controlling water chemistry to prevent aggressive reactions
- Monitoring for leaks to catch early signs of deterioration
- Vent and roof maintenance to limit humidity and internal condensation
Implementing these preventive measures helps keep water tanks in safe and reliable condition.
When Should You Inspect Your Water Tank?
Most tanks should be inspected at least once every one to two years, depending on their age, usage, and the type of water they store. Inspections help identify early corrosion problems, measure coating or liner wear, and ensure the tank remains compliant with industry standards.
If corrosion has already developed, a refurbishment may be necessary to restore the tank’s condition.
Conclusion
Water tank corrosion problems can significantly impact the safety, performance, and longevity of a storage system. By understanding what causes corrosion and recognizing early warning signs, facility owners can take proactive steps to protect their assets. Regular inspections, proper maintenance, and timely refurbishment help prevent serious deterioration, ensure safe water quality, and extend the overall lifespan of large water tanks.
