Fuel Tank Refurbishment

Fuel tank refurbishment is the process of restoring a commercial or industrial fuel storage tank to a safe, compliant and serviceable condition without replacing it entirely. Depending on the tank's condition, this can range from rust removal, surface preparation and repainting through to complete internal tank lining, bund lining, pressure testing, integrity testing, component replacement and compliance certification.

For larger commercial tanks in reasonable structural condition, refurbishment is almost always significantly cheaper than full replacement — avoiding the cost of a new tank, installation, groundworks and disposal. For smaller tanks where the combined cost of cleaning, testing, coating and component replacement approaches or exceeds the value of the existing unit, full replacement may be the more practical option. Britteco will assess your tank honestly and advise on the most cost-effective approach.

Depending on the tank's condition and requirements, refurbishment can include: fuel removal and safe isolation, internal cleaning and sludge removal, external surface preparation, rust removal and corrosion treatment, pressure and integrity testing, application of internal and external fuel-resistant coatings and lining systems, bund lining and bund wall coating, replacement of pumps, valves, gauges and other components, installation or replacement of high level alarms, low level alarms and overfill prevention devices, and full compliance certification on completion.

Tank lining involves the application of specialist fuel-resistant coating or lining systems to the interior of a fuel storage tank — protecting the tank shell against corrosion, leaks and long-term deterioration. Internal surfaces are cleaned, dried and prepared before lining materials are applied in multiple layers using industrial-grade fuel-resistant materials. Tank lining can extend the serviceable life of an existing tank considerably and is a proven method of avoiding costly fuel leaks and environmental incidents.

Bund lining involves applying specialist fuel-resistant coatings to the bund wall and floor surrounding a fuel storage tank. Bunds are legally required under the Control of Pollution (Oil Storage) (England) Regulations 2001 to provide secondary containment in the event of a tank leak or spill. Bund lining protects the bund structure from fuel penetration and deterioration, maintaining its integrity as a secondary containment barrier and ensuring compliance with Environment Agency regulations.

Bunded fuel storage installations in England are governed by the Control of Pollution (Oil Storage) (England) Regulations 2001, which require that secondary containment is capable of holding at least 110% of the tank's capacity. Equivalent regulations apply in Scotland, Wales and Northern Ireland. Britteco provides compliance documentation on completion of all bund lining and refurbishment works.

Both options are available. In most cases, refurbishment works are carried out in-situ at your site — minimising disruption and avoiding the cost of tank transport. Where tank size, access constraints or scope of work make on-site working impractical, tanks can be transported to Britteco's own workshop facilities. The most suitable approach is determined during the initial assessment and quotation stage.

Common signs include: visible external corrosion or rust, paint deterioration or blistering, fuel contamination or sludge build-up, failed pressure or integrity tests, leaking pipework or failed valves, bund wall cracking or deterioration, non-functioning alarms or gauges, and tanks approaching the end of their expected service life. A condition assessment will confirm the extent of work required.

NDT (Non-Destructive Testing) is a method of assessing the structural integrity of a fuel tank without causing damage. Techniques include ultrasonic thickness testing and weld inspection. NDT is typically used on larger commercial tanks where a precise assessment of remaining wall thickness and structural condition is required before refurbishment proceeds — confirming whether the tank structure is sound enough to justify the investment in refurbishment.

The recommended frequency depends on tank age, condition, fuel type and regulatory requirements. Commercial fuel storage tanks should be inspected and tested periodically — and any time there are signs of deterioration, contamination or component failure. Britteco recommends an inspection and testing schedule based on the specific tank and site conditions.

Timelines vary depending on tank size, extent of work required, whether works are on-site or at our workshop, and site access conditions. A straightforward external refurbishment may be completed in a day or two; a full internal lining, bund lining and component replacement programme on a larger tank may take several days to a week or more. Britteco provides project timelines at the quotation stage.

The expected lifespan depends on the quality of work, the tank's original condition, the type of coating or lining system applied, and ongoing maintenance. A well-refurbished tank with a quality internal lining system can provide many years of continued service. Britteco advises on an appropriate inspection and maintenance schedule on completion to maximise operational life.

If structural inspection or NDT testing reveals deterioration beyond the point where lining or coating can provide a reliable long-term result, or if the combined cost of refurbishment on a smaller tank approaches the cost of a new replacement tank, full replacement and safe decommissioning may be the more practical option. Britteco will always give you an honest assessment — you will never be recommended a refurbishment that is not in your best interest.

Yes. Component replacement is a standard part of Britteco's fuel tank refurbishment service — including pumps, valves, gauges, pipework, high level alarms, low level alarms, overfill prevention alarms and other associated fuel system devices, inspected and replaced as required.

Regular bund inspections are recommended — typically every one to three years, depending on lining type, tank usage, environmental conditions and regulatory requirements. Bund integrity is critical to secondary containment compliance under the Control of Pollution (Oil Storage) Regulations. Britteco recommends a site-specific inspection schedule on completion of bund lining works.

Yes. Britteco's fuel tank refurbishment service covers commercial and industrial diesel storage tanks, heating oil tanks, generator fuel systems, gas oil tanks and bunded fuel storage installations — including sites across airports, farms, logistics depots, hospitals, MOD sites, transport depots and manufacturing plants. The same assessment, cleaning, lining and certification process applies, adapted to the specific tank type and requirements.

Yes. On completion of every fuel tank refurbishment project, Britteco provides full compliance documentation and certification — supporting audit, insurance, regulatory and operational requirements. An ongoing inspection and maintenance schedule is also recommended.

Use the enquiry button on this page and send your basic site details — tank type, estimated size, location, current condition and any known issues. Britteco will review the requirements, advise on the most appropriate treatment approach, and provide a site-specific quotation.