Tank Leak Repair: A Complete Guide (with GIFs and Video)

Learn How to Stop and Repair a Live Leak

INTRODUCTION TO LIVE LEAK REPAIR

Live leak and through-wall defects on tanks are one of the major concerns in industrial operations. Tanks often suffer from corrosive content, and tough operating conditions, which contribute to internal corrosion, metal loss and wall thinning. This can eventually result in the leakage of hazardous materials, leading to production delays, environmental damage, and health and safety risks. Asset owners have traditionally relied on conventional methods such as welding and brazing for tank leakage repair. However, such  tank leak repair methods lead to consequential problems including bi-metallic corrosion in welds and seams, extended downtime, and unsafe environment for maintenance personnel.

Tank Leak Repair

This blog post demonstrates an effective tank leak repair solution with Belzona 9611 (ES Metal), a rapid-curing putty. For more permanent tank leak repair, Belzona recommends a cold-bonding technique using a preformed metal plate and Belzona 1161 (Super UW-Metal) as a bonding agent to overcoat the putty. Asset owners can carry out this emergency repair while tanks remain online, enabling the operations to continue with minimal disruption and minimizing environmental damage. This application method can quickly repair water tank leaks or even address fuel tank leaks as Belzona 1161 is a surface-tolerant paste-grade material. It is specifically designed for applications on oily and wet surfaces, making it ideal for challenging operating conditions.

Supplies and Tools Required for Tank Leak Repairs

Step-by-Step Guide: How to Repair a Water Tank Leak with Belzona 9611

STEP ONE: SURFACE PREPARATION

Prepare the surface by using a grinding file and remove any dirt, grease, and other contaminants around the live leak area.

STEP TWO: PREPARE BELZONA 9611

Cut off the required amount of Belzona 9611 and knead it in gloved hands until a uniform grey color is achieved.

STEP THREE: APPLY BELZONA 9611

Use the Belzona applicator to force the mixed material into holes and firmly apply pressure

STEP FOUR: ALLOW THE PRODUCT TO CURE

Use a stud and a ratchet strap to secure the material in place until cured.

STEP FIVE: REMOVE THE STUD ONCE CURE

Overcoat with Belzona 1161 for More Permanent Repair

STEP ONE: PREPARE THE SURFACE

Roughen the area around the leak with a grinder to prepare for plate bonding.

STEP TWO: CLEAN THE REPAIR AREA

STEP THREE: MIX BELZONA 1161 (Super UW-METAL)

Mix Belzona 1161 as per the instructions for use until the uniform color is achieved.

STEP FOUR: APPLY BELZONA 1161 ONTO TANK

Apply Belzona 1161 directly onto the prepared tank surface. Press down firmly to ensure maximum contact with the surface.

STEP FIVE: APPLY BELZONA 1161 TO THE PLATE

STEP SIX: FORM A BUILD UP

Form a buildup approximately 0.25 in (6mm) towards the center of the metal plate.

STEP SEVEN: POSITION PLATE ON TANK

Push the plate into position, pressing firmly in the middle to push the material towards the outside to prevent air entrapment.

STEP EIGHT: REMOVE EXCESS

Remove excess material immediately and use a Belzona applicator to contour the edges of the plate with Belzona 1161.

STEP NINE: REMOVE TAPE

Remove the tape once the application is complete.

CHECK OUT OTHER SOLUTIONS FOR METAL TANK REPAIR

How to Repair a Riveted Tank with Belzona

Tank and Vessel Metal Loss Repair: Fast and Easy with Belzona 1161

VIDEO: How to Stop and repair a live leak