Fiberglass Tank Inspection

Updated: Feb 26
Introduction
Fiberglass tanks are complex structures made from multiple layers of different
materials to achieve a balance between strength, weight, and corrosion protection. 
Starting from the inside – out, a typical filament wound fiber reinforced plastic
(FRP) tank consists of an inner surface, interior layer, structural layer, and outside
layer.  The inner surface is commonly 10-20 mils thick resin rich layer. The
interior layer is in the 100 mil range and contains 20 to 30 % chopped glass for
strength. As its name implies, the structural layer carries most of the product
related stress and contains 60-70% continuous strand filament winding. The
outside layer is a resin rich surface layer with added coating(s) for ultraviolet
protection and corrosion resistance.

Figure 1. Fiberglass tank cross-section.

Quality Control Inspection

Quality control (QC) inspections will vary depending on end user requirements. A
common requirement is a 3-stage inspection process.  The first inspection is
commonly performed at the completion of the corrosion barrier and before
structural winding occurs. The second inspection is performed after the tank is
removed from the mandrel and before any nozzles are attached. The third
inspection is performed prior to shipment of the tank.  These inspections are
generally performed by an independent inspector with at least 5 years of
experience with FRP vessels. The QC visual inspections are performed to ASTM
and ASME standards [1-2].  Different quality levels are defined in these documents
along with different repair thresholds. For example, a construction specification
may define a Level 1 liner inspection with 10% repair allowed and Level 2 in the
structure with 10% repair allowed.
After the tank has completed a successful hydrostatic test, some contracts require
that the tank shall undergo a mechanical integrity test using Acoustical Emission
Test (AE Test) in accordance with the latest version of ASTM E 1067 [4].

Internal and External Inspections

A thorough fiberglass tank inspection of interior and exterior surface is typically
required every 5 years per state or tank owner guidelines.  There are many different
types of fiberglass tank defect with most presented in in ASTM and RTP
standards.  Inspector safety and is a very important consideration during the
internal inspection. Proper fiberglass tank pre-inspection safety steps must be taken
to assure that the tank is clean and free from any chemicals and air quality
acceptable. The FRP tank interior is accessed through a ground level or roof
manhole. Special attention is given to the FRP tank penetrations which may
include erosion, corrosion, mechanical, and environmental related deterioration.
Example fiberglass tank defects are shown in Figure 2.

Figure 2. Advanced cracking on fiberglass tank floor.

Fiberglass Tank Hardness Testing
Fiberglass tank surface hardness readings on the interior liner are recommended
post manufacturing and in-service.  FTPI 2007-1, Recommended Practice for the
In-service Inspection of Aboveground Atmospheric Fiberglass Reinforced Plastic
Tanks and Vessels [5] recommends 12 separate readings with the highest and
lowest discarded.  The average of the remaining values should be within 10% of
the manufacturer’s specification. DEREKANE® resins manufactured by Ashland
Inc. is a common liner product with FRP tank liner Barcol hardnesses in the 30-40
range.

The device is intended for handheld testing of hardness fiberglass tank liners.  The
liner hardness is tested by placing the indenter point and leg on level surface. The
indenter is pressed down firmly on the surface and the peak reading is noted from
the indicator. FRP tank hardness reading should be spaced at least 1/16th of an
inch away from previous readings. A fiberglass tank Barcol hardness reader is
shown in Figure 3.

Figure 3. Fiberglass tank Barcol Hardness reader.

Fiberglass Tank Strain Measurement

Many different loading conditions must be considered during fiberglass tank
design including external and internal pressure, weight of the vessel, superimposed
static loads, attachments, environmental and thermal. At 5-year intervals, it is
recommended to acquire fiberglass tank hoop strain measurements to assess the
load baring capacity of the tank. Strain gages are installed a different elevations
while the tank is empty. The tank is then filled to capacity and the hoop strain is
recorded. The maximum allowable hoop strain is 0.002 microstrain with values
typically in the 30 to 120 microstrain range.  As the tank ages, hoop strain does
tend to increase due to the general aging of the structural layer. Example hoop
strain data is shown in Figure 4.

Figure 4. Fiberglass tank hoop strain measurement.

Fiberglass Tank Acoustic Emission Testing

Acoustic emission testing of fiberglass reinforced plastic (FRP) tanks is performed
post-fabrication and in-service.  The tests are performed to ASTM E1067-07:
Standard Practice for Acoustic Emission of Fiberglass Reinforced Plastic Resin
(FRP) Tanks/Vessels. Acoustic Emission (AE) is used to inspect new and in-
service FRP tanks for; resin cracking, fiber debonding, fiber pullout, fiber
breakage, delamination, bond failure in assembled nozzles and manways.
FRP tanks are tested with acoustic emission by filling with water or product in
incremental steps to 50%, 75%, 87% and 100% capacities. As the tank is filled any
active flaws will emit acoustic emission in the 150 kHz range waves which are
picked up by acoustic emission sensors. An example acoustic emission sensor is
shown in Figure 5.
Figure 5. An acoustic emission sensor installed on a fiberglass tank.

Thermographic Inspection of Fiberglass Tanks

An infrared (IR) camera is a non-contact device that detects infrared energy (heat)
and converts it into thermal image. As a fiberglass tank is filled with product
during a hydrostatic or acoustic emission test, a thermal gradient is created through
the FRP tank wall which consists of multiple layers, between which, delaminations
may occur.  Similarly, repair patches from fabrication or in-service fiberglass tank
repairs may also be observed during the acoustic emission testing. An example
fiberglass repair or delamination is shown in Figure 6. The area is outlined by a
dark red area approximately 6” x 4” in area in the fiberglass tank thermographic
image.
Figure 6. Thermographic image of a delamination or previously unknown repair
in a fiberglass tank shell. 
References
ASTM D2563-08: Standard Practice for Classifying Visual Defects in Glass-
Reinforced Plastic Laminate Parts.  ASTM D2583: Standard Test Method for
Indentation Hardness of Rigid Plastics by Means of a Barcol Impresser.ASME
RTP-1-2007, “Reinforced Thermoset Plastic Corrosion-Resistant
EquipmentASTM’s E1067-07: Standard Practice for Acoustic Emission of
Fiberglass Reinforced Plastic Resin (FRP) Tanks/Vessels.FTPI 2007-1
Recommended Practice for the In-service Inspection of Aboveground Atmospheric
Fiberglass Reinforced Plastic Tanks and Vessels.