Corrosion-resistant linings: protecting stationary tanks from within

For us at SÄKAPHEN, what's out of sight should never be out of mind. That’s why stationary tanks are so important, as is their protective lining.

In industries where storage tanks are used to hold aggressive chemicals, hydrocarbons or treated water, corrosion is not just a maintenance issue, it is a critical operational, environmental, and financial risk. International estimates place the annual cost of corrosion at approximately $2.5 trillion, or around 3.4% of global GDP. In the U.S., for example, corrosion across tanks and pipelines results in estimated annual losses exceeding $440 billion; since 1984, underground storage tanks have leaked at over 500,000 sites, with average cleanup costs reaching $154,000 per incident.

Unlined or inadequately protected tank interiors are vulnerable to corrosion, erosion, fouling and contamination. Over time, this can compromise structural integrity, lead to costly plant shutdowns, or in severe cases, cause leaks and environmental incidents.

So, what can be done to minimize these issues?

Internal linings provide a barrier between the tank’s substrate and the stored media, minimizing chemical attack and helping maintain material purity. For industries that handle solvents, acids, caustics, demineralized water, or flammable liquids, selecting a suitable lining is especially critical. The applied material must resist the stored product, withstand temperature fluctuations, and often endure mechanical abrasion from solids or turbulent flow conditions.

And (re-)application can happen directly on-site, eliminating the need for transportation and minimizing downtime.

High stakes in the food industry

Take for example the project we carried out some time ago for a major company in the food and agricultural sector. At one of its facilities, where ingredients and food products are handled with strict safety standards, a stationary tank containing aggressive process waters needed re-lining for internal protection.

So we cleaned it, shot-blasted it and re-lined it.

While staying on-site.

We applied SÄKAFLAKE® 900 White 3K, our hybrid Novolac vinyl ester-based lining with excellent resistance to abrasion, highly acidic to high alkali chemicals and water vapor diffusion. The fact it is a cold-cured coating meant no oven-polymerization was needed.

For this customer, that meant fewer disruptions, no logistical headaches, and long-term protection.

A second life on-premises

Over at a European site of a global chemical manufacturer, another challenge emerged: an aging stationary tank required re-lining.

In this case, the tank was dismantled and lifted out of the plant, repaired by the maintenance technicians, and then sandblasted and recoated on site together with our authorized applicator AlpAccess.

We recommended applying SÄKAFLAKE® 900 Topcoat 3K, a green Novolac vinyl ester lining originally developed as a smooth-surface top coat but fully capable as a standalone product. Micro glass flakes enhance abrasion resistance and reduce permeability. Despite being applied at lower film thicknesses than traditional systems, it delivers robust protection against acids, bases, salt solutions, and extreme temperatures.The reduced layer thickness also means less material is used and application times are shorter, bringing a clear economic advantage without compromising on protection.

The result? A fully refurbished tank, protected from the inside out and ready to serve for years to come.

A global commitment

The global storage tank market was estimated at $23.96 billion in 2023, growing at a CAGR (Compound Annual Growth Rate) of at least 4.98% toward $37.11 billion by 2030. On a continental scale, the North American market is forecast to expand at a CAGR of 7.2%, only slightly higher than Europe, around 5.8%. At the same time, the tank protection marketacross Europe alone was valued at $967 million in 2024.

These figures clearly demonstrate the scale and economic significance of stationary tanks worldwide and the corresponding need for technically sound, cost-effective corrosion protection strategies.

SÄKAPHEN is ready to tackle the challenge.

Many leaders in their respective fields have already placed their trust in us. That reflects more than just product performance and process soundness: it means we can truly meet clients where they are… literally and technically.

We maintain our presence in every continent through long-standing partnerships with our authorized applicators, from AlpAccess (Romania) and Gruppo Donelli (Italy) in Europe to Gartner Coatings (Texas) in the US, to name only a few. Each of them has decades of experience in the in-shop and on-site application of coatings and linings for the most diverse sectors, including petrochemical, power generation, marine, and industrial. The localized presence they offer to customers, backed by SÄKAPHEN’s global expertise, makes high-performance corrosion protection accessible and responsive, especially for industries operating under tight shutdown windows or managing complex logistical requirements.

Meeting the growing needs of the market

As companies in the stationary tank industry face increasing pressure to reduce unplanned maintenance and enhance environmental compliance, proactive lining strategies are gaining importance. Whether the need is for new construction or restoration of existing assets, internal linings can provide decades of protection if properly selected and correctly applied. The products and processes offered by SÄKAPHEN, together with its trusted partners, ensure exactly that.  

As Christoph Fischer-Zernin, Commercial Director of SÄKAPHEN, puts it: “As the stationary tank market expands globally, we are scaling with it. We are investing in R&D, broadening our global footprint, and deepening partnerships with experienced applicators worldwide. This lets us meet evolving technical requirements while delivering the durability, safety, and performance our customers expect anywhere in the world.”