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How do many industries safely store and transport a wide range of chemicals and liquids? One answer lies in the use of plastic fabricated tanks. These versatile tanks offer numerous benefits, such as durability, low maintenance, and chemical resistance, making them ideal for a variety of applications.
In this article, we will delve into the world of chemical storage tanks, exploring the advantages, materials, and customization options available, as well as their various applications in industries such as chemical storage and wastewater treatment. By the end, you will have a more thorough understanding of plastic fabricated tanks and their advantages.
Plastic fabricated tanks stand out due to their exceptional durability. They are constructed from durable and robust materials including:
All of these materials are commended for their toughness and ability to resist chemicals. They each possess unique characteristics such as temperature tolerance or UV resistance, enabling the selection of the most suitable plastic for a specific application.
Another advantage of plastic fabricated chemical storage tanks lies in their minimal maintenance needs. The materials used in their construction, such as high density polyethylene and polypropylene, contribute to their strength and chemical resistance. Fittings installed on fabricated tanks can be selected of the same material as the tank walls, ensuring material homogeneity throughout the entire system, reducing the chance of cracks at joins between the tank and inlets / outlets.
Furthermore, customisability is a strong advantage of fabricated chemical storage tanks. They aren't made using moulds, therefore allowing many design customisations in shape and size and optional extras, such as rated lifting lugs.
Dual wall chemical tanks can also be designed with an inner wall material selected for its durability against contact with the stored chemical and the outer wall material chosen for its ability to withstand the chemical tanks environmental conditions, such as high temperatures and UV exposure. The gap between the two walls can serve as a bunding area or be filled with optional insulation for added strength and thermal insulation.
Plastic tanks are much lighter than metal counterparts and with rated lifted lugs added to the design; installation is much easier. This is a significant advantage in scenarios where quick installation is required or where access to the installation site is limited. The reduced weight of plastic tanks also means less strain on supporting structures and foundations, potentially saving on infrastructure costs. Additionally, the inclusion of rated lifting lugs in the design not only facilitates easier installation but also provides a secure and safe method for tank transportation. This can be particularly beneficial in industries where tanks need to be regularly moved or transported between different locations.
As a result of these benefits, fabricated tanks can be manufactured with a design life of up to 25 years.
Polypropylene (PP) and high-density polyethylene (HDPE) are the most popular choices for industrial tank construction.
HDPE offers excellent abrasion and corrosion resistance, making it an ideal choice for industrial chemical storage tanks. HDPE provides:
PP offers excellent impact, chemical and abrasion resistance with an operating temperature of up to 90˚c. Standard PP doesn't offer UV resistance, however having a higher operating temperature makes it more suitable than PE in some applications.
These qualities make HDPE and PP ideal for the safe storage of various substances. Fusion has manufactured chemical storage tanks from sheet HDPE up to 40mm and PP in similar thicknesses. When selecting a thickness, variables such as seismic forces and wind loads are taken into consideration.
The size and capacity of plastic fabricated tanks are adaptable to specific applications, with a maximum height of 10 meters, factoring in specific gravities. Round tanks, in accordance with DVS 2205, should have a diameter not exceeding 4 meters and a height not exceeding 6 meters, ensuring a suitable range of chemical storage capacities.
Compared to rotomolded plastic tanks, plastic fabricated tanks present distinct advantages. rotomolded plastic is created using rotational molding, which involves heating and rotating plastic powder in a mold to form various plastic products.
While the heating and molding process of rotomolded tanks allows the plastic to coat the mold, it can result in varying wall thickness, potentially leading to weaker areas on the tank. In contrast, fabricated chemical storage tanks from Fusion are constructed from plastic sheets that undergo butt welding and extrusion welding. These sheets have a consistent thickness and are available in various sizes to cater to specific chemical storage needs.
Rotomoulded tanks are created using specific moulds, which inherently limits their size and shape to the dimensions and configurations of the available moulds. This means that the customization of these tanks is somewhat restricted, offering less flexibility for unique or specific applications. On the other hand, plastic fabricated chemical storage tanks do not face such limitations. These tanks are custom-made from plastic sheets, allowing for a wide range of sizes and shapes to be achieved. This bespoke approach ensures that fabricated tanks can be precisely tailored to suit specific applications, offering a significant advantage over their rotomolded counterparts.
Rotomolded tanks are typically constructed from low-density polyethylene (LDPE), a type of plastic known for its flexibility and toughness. However, the LDPE walls are often paired with HDPE fittings. The differing material densities and expansion/contraction rates can create stresses at joins which can cause cracks and leaks. On the other hand, plastic fabricated tanks have the advantage of being crafted from a wider range of materials, including high-density polyethylene (HDPE) and polypropylene (PP). The fittings used on fabricated chemical tanks are generally made from the same material as the tank walls, ensuring consistency in the tank's construction and significantly reducing the likelihood of cracks at joins.
In conclusion, while rotomolded tanks have their place in the market due to their cost-effectiveness and suitability for water storage, when it comes to industrial storage, fabricated tanks generally outperform them and lead to significant cost savings the in long run. Fabricated tanks offer a longer lifespan and require minimal to no maintenance, provided they are used for their intended application. This makes them a more advantageous choice for complex industrial applications requiring robust, durable, and highly customizable storage solutions.
The latest Australian Standard for the storage and handling of corrosive substances identifies that "rotationally moulded polyethylene tanks larger than 5m³ can have a service life of only 5 to 7 years and should be inspected frequently." (AS3780-2023 The Storage and Handling of Corrosive Substances, Section 6.7.3 Tank Design and Construction (subsection d)).
Provided a thermoplastic tank fabricated from sheet is operated using to its manufactured specifications, they can achieve a design life of up to 25 years; far more than the standard allows for rotationally moulded tanks.
Thermoplastic tanks are furthermore not mandated to be inspected within the standard. Fusion recommends that inspections do occur for Fusion fabricated tanks to ensure safety to people and the environment, however they will likely require less frequency than a rotationally moulded tank.
Lastly, the standard states rotationally moulded tank inspections "shall include evidence of cracking, leakage and connections and for tanks becoming out-of-round due to load cycling and/or temperature variations" (AS 3780-2023 The Storage and Handling of Corrosive Substances, Section 6.7.3 Tank Design and Construction (subsection d)). Fusion plastic fabricated chemical storage tanks are far less susceptible to these issues as homogenous materials are used throughout.
Plastic fabricated industrial tanks are widely utilized across various industries, including:
Plastic fabricated industrial tanks, with their chemical resistance and durability, offer immense benefits for chemical storage solutions. Some advantages of plastic fabricated chemical storage tanks depend on the chosen material, however these can include:
Given their durability and low maintenance attributes, industrial chemical storage tanks crafted from plastic materials are optimal for wastewater and process water management. Polyethylene and polypropylene are the primary materials employed in water treatment tanks, with external steel frames providing support if required. The use of plastic fabricated tanks in wastewater treatment plants offers numerous advantages, including their ability to withstand harsh chemicals and resist corrosion, ensuring a long service life.
A primary advantage of plastic fabricated tanks is the flexibility they offer for customization to meet specific needs. Customisation options include capacity and size options, as well as fittings and accessories. These tailored solutions allow for precise specifications and ensure that the tanks are suitable for various applications, from chemical storage to wastewater treatment.
For example, single-wall tanks and double-wall tanks offer different capacity and size options to suit specific needs. Additionally, fittings and accessories such as valves, pumps, level indicators, and other components can be customized to enhance the functionality and performance of the tanks. This level of customization ensures that plastic fabricated tanks can be adapted to a wide range of industrial applications, providing reliable and efficient storage and transport solutions.
The design of plastic fabricated chemical tanks can be varied in terms of capacities and sizes to fulfill specific requirements. Common capacity options include:
1,000L (1kL)
5,000L (5kL)
10,000L (10 kL)
20,000L (20 kL)
30,000L (30 kL)
40,000L (40 kL)
50,000L (50 kL)
60,000L (60 kL)
70,000L (70 kL)
80,000L (80 kL)
When selecting a plastic fabricated chemical tank, it is essential to consider the specific capacity and size requirements of the application. Fusion is capable of providing assistance with these specific size requirements and material selection. This ensures that the tank can safely store and transport the intended substances, whether it be chemicals, water, or other liquids, while also fitting within any space constraints and/or environmental considerations.
To boost the functionality and performance of Fusion plastic fabricated tanks, fittings and accessories can be tailored to specific needs. These options include:
Tank fittings
Manways and lids
Ball valves
Level controls
Pumps
Couplers
Hoses
Baffles
Welded-in fittings
By selecting the appropriate fittings and accessories, Fusion can ensure that Fusion plastic chemical tanks are well-suited for their specific applications, whether it be chemical storage, water treatment, or any other industrial process.
For example, a chemical storage facility may require specialized fittings to safely transport hazardous chemicals, while a wastewater treatment plant may need specific pumps and level controls to manage the treatment process efficiently. By customizing fittings and accessories, plastic fabricated tanks can be tailored to meet the unique needs of each application, providing a reliable and efficient storage solution.
The production of plastic fabricated tanks incorporates sheet fabrication techniques and rigorous quality control measures, ensuring adherence to industry standards. These tanks are generally manufactured from sheet polypropylene or high-density polyethylene, with various methods being employed in the production process such as:
Quality control plays a vital role in the manufacturing process, safeguarding the safety and durability of the end product. For example, Fusion Plastics is a renowned Australian plastic fabricated tank manufacturer and is certified to ISO 9001, the international standard for quality management. This level of quality assurance ensures that plastic fabricated tanks are reliable and long-lasting, making them a popular choice across various industries.
In the production process of plastic fabricated tanks, quality control and compliance play a pivotal role in ensuring safety and durability. By adhering to strict quality control measures and industry compliance standards, Fusion can ensure that Fusion plastic fabricated tanks are reliable and safe for their intended applications. This level of quality assurance gives customers confidence in the performance and longevity of their plastic fabricated tanks, making them a popular choice for many industries. Fusion chemical storage tanks are manufactured according to DVS 2205 standards and undergo quality inspections and hydrotesting as standard to ensure leak free, strong and long lasting chemical storage.
The selection of the appropriate plastic fabricated tank takes into account both chemical compatibility and environmental considerations. The relationship between the plastic tank and its contents is of paramount importance when storing chemicals, as the type of chemical, its concentration in solution, and the temperature at which it is stored all contribute to deciding the type of plastic that is suitable for containing it. To guarantee secure storage of chemicals, it is essential to consult a chemical compatibility guide when selecting a storage tank.
Environmental considerations, such as temperature and UV exposure, should also be taken into account when selecting a plastic fabricated tank. Temperature can influence the strength and longevity of the tank, as well as the chemical resistance of the material. UV exposure can cause the plastic to degrade over time, potentially leading to cracks and leaks.
By considering these factors, companies can select the most appropriate plastic fabricated tank for their specific application, ensuring a reliable and efficient storage solution.
Fusion can provide assistance when choosing the most suitable plastic for specific applications. Contact us today with your specific application.
A chemical compatibility guide aids in identifying the suitable material for a particular chemical storage application. This crucial resource assists in selecting the most suitable material for a given chemical storage tank application, ensuring that the tank can safely store and transport the intended substances.
Chemical compatibility guides can be found online. Some offer slightly differing results and should be used as a guide only. A great resource for researching compatibilities is Simchem by Simona (requires free registration to use). By consulting these resources, companies can ensure that their plastic fabricated tanks are suited for their specific applications and operations, whether it be chemical storage, water treatment, or any other industrial process.
Important environmental factors like temperature and UV exposure should be taken into consideration while choosing a plastic fabricated tank. Temperature can affect the strength and longevity of plastic fabricated tanks, in addition to the chemical resistance of the material. For example, a tank storing chemicals in a hot environment may require a different material than one storing chemicals in a cooler environment.
Case studies exemplify the successful integration of plastic fabricated tanks across various industries such as chemical storage facilities and wastewater treatment plants. These real-world examples demonstrate the versatility and effectiveness of plastic fabricated tanks, as well as their ability to provide reliable and efficient storage solutions across a range of applications. Fusion's case studies can be viewed online and also a vast photography set of Fusion's prior work can be viewed on our Flickr.
From chemical storage facilities to wastewater treatment plants, Fusion chemical storage tanks have proven to be a valuable asset in numerous industries.
Plastic fabricated tanks offer numerous benefits, such as durability, low maintenance, and chemical resistance, making them ideal for various industries and applications. By understanding the advantages, materials, and customization options available, as well as considering factors such as chemical compatibility and environmental considerations, companies can select the appropriate plastic fabricated tank for their specific needs. With successful implementations across various industries, including chemical storage facilities and wastewater treatment plants, plastic chemical storage tanks have proven to be a valuable and reliable storage solution for countless applications.
Fusion can provide assistance when choosing the most suitable plastic and create designs for specific applications. Contact us today with your specific application.
All material have their issues, steel can corrode and is heavy, plastic can melt and degrade; however many of these issues are resultant from either cost-cutting measures or incorrect choice of material for the chosen application. Fusion does not manufacture plastic water tanks, particularly for domestic applications as custom fabricated tanks are too cost prohibitive for these applications. Generally plastic water tanks for residential water storage are made from LDPE, are thin walled and made using a rotomoulding manufacturing process to keep costs down. As a result of the thin wall and material, these tanks can be prone to photo-oxidation, which weakens them and reduces their longevity. Signs of photo-oxidation include discolouration, cracking, chalking, sheen loss, brittleness, and even catastrophic failure. Fusion tanks are manufactured to suit specific applications using thick plastic sheet and DVS standards. If continued usage is within the intended application we offer a design life of up to 25 years.
The short answer is yes. They're lightweight and can provide long term water storage with food-grade safe, BPA-free polyethylene plastic so they're safe for storing drinking water.
Polypropylene and high-density polyethylene are the primary materials used for plastic fabricated tanks. More information about these materials is available above within in this article.
Fusion plastic fabricated tanks offer more customization, higher strength and crack resistance and considerable longevity. They are therefore generally and a better fit for many industrial applications compared to rotomolded plastic tanks.
