Floating Tank Roof Repairs - Major Operator

Our team was engaged by a major operator to deliver live floating roof repairs on three tanks, each 18 metres high and 60 metres in diameter.. Previous patch repairs had been implemented as temporary measures; however, an engineered long-term solution was required to meet regulatory requirements for uncontrolled hydrocarbon leaks.

The scope included visual inspections, corrosion and coating surveys, and NDT mapping, which identified through-wall defects, cracking, and areas of varying corrosion severity. All surface preparation and repair activities were completed as cold work, including ultra-high-pressure water jetting to remove hydrocarbons and sponge jet low-dust grit blasting to achieve an Sa 2.5 surface profile, reducing dust and blast media by approximately 90%.

Engineered composite repair systems were then applied using vacuum bagging to optimise bond strength. Technowrap™ 2K and DRS systems were installed via hand lay-up techniques, completing 115 m² of remediation and live leak sealing safely and efficiently. Each repair was bespoke engineered in accordance with ISO 24817 and API 653 requirements and designed for a 20-year service life. Following curing and QA inspection, laminate edges were whip-blasted to allow for coating tie-in.

The repairs reinstated the original structural strength of the floating tank roofs, delivering long-term asset integrity with a 20-year design life. The lightweight, cold-applied composite solution eliminated hot works, heavy lifting, and scaffold-based encapsulation, while all works were completed safely with no disruption to ongoing tank operations. The flexibility of the system and use of a small, multi-skilled team resulted in a cost-effective solution delivered within the required timeframe.