Sylvie Willis
The longevity of a boat's fuel tank depends on several factors, including the material it is made of, the quality of the installation, and the maintenance carried out by the owner. Plastic fuel tanks, for example, are immune to corrosion, which is the leading cause of metal tank failure, but they are not used in large tanks due to strength and fire safety concerns. On the other hand, metal tanks, such as aluminum and stainless steel, are susceptible to corrosion in certain conditions, especially when exposed to saltwater. While some sources suggest that fuel tanks can last up to 100 years if built and maintained properly, others recommend regular inspections and replacements to ensure safety.
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What You'll Learn
Plastic tanks are immune to corrosion
Plastic boat fuel tanks have become increasingly popular, with 98% of vehicles in Europe and 75% in the US fitted with them in 2016. This shift from steel tanks is largely due to the improved fuel efficiency and design flexibility that plastic tanks offer.
Plastic tanks are lightweight, which contributes to better fuel efficiency. They are also versatile in form, allowing engineers to design them to fit any available space in the undercarriage. This is in contrast to the traditional steel tank, which often requires the vehicle to be designed around its rigid shape and fixed specifications.
One of the key advantages of plastic fuel tanks is their immunity to corrosion. Metal tanks, on the other hand, are susceptible to corrosion from various factors, including road salt, debris, mud, and water. Water vapour forming on the inside of a half-empty metal fuel tank, for example, can cause it to rust from the inside out. Plastic tanks, however, are non-corrosive and do not suffer from this issue.
The corrosive effect of certain chemicals is also a concern when it comes to fuel tank materials. Metal can be corroded by most corrosive chemicals, releasing flammable hydrogen gas. Plastic storage tanks, such as those made from polyethylene, offer a safer alternative as they do not contain any corrodible metal and therefore do not produce hazardous fumes. Cross-linked polyethylene, in particular, has superior tensile and impact strength due to the bonding and linking of plastic molecules, making it even more resistant to corrosive materials.
The durability of plastic tanks in the face of corrosion is further supported by observations from industry professionals. Tech Editor Drew Frye, a licensed API tank inspector, has inspected countless steel and aluminium tanks and found that after 15 years of service, serious damage due to corrosion is common. Plastic tanks, however, are immune to this type of degradation. This is evident in aging and corrosion studies, where gasoline and diesel samples in metal tanks generate gum and discolour, while those in plastic tanks remain relatively stable.
In summary, plastic boat fuel tanks offer a corrosion-resistant alternative to traditional metal tanks. Their non-corrosive nature, combined with their lightweight and design flexibility, has contributed to their widespread adoption in the automotive and boating industries.
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Fuel tanks can last 100 years if built properly
Fuel tanks can last a long time, but there are many factors that determine their longevity. The material used, installation, maintenance, and exposure to corrosive elements all play a role in how long a fuel tank will last.
Plastic fuel tanks, for example, are immune to corrosion, which is the leading cause of metal tank failure. They are widely used in small boats and passenger cars, with over 95% of the market share. However, they are not used in large tanks due to strength and fire safety concerns.
Aluminum tanks have been popular for 20 to 30 years, but they are susceptible to corrosion, especially from saltwater. Stainless steel tanks are also an option, but they are prone to pitting and crevice corrosion in marine environments.
To ensure a long-lasting fuel tank, proper installation and maintenance are key. Keeping the tank dry and regularly checking for leaks are essential. While it is difficult to determine an exact lifespan, some fuel tanks have been known to last for several decades, with a few even reaching a half-century or more.
Therefore, with proper construction, maintenance, and attention to potential issues, it is reasonable to expect that fuel tanks can last for an extended period, potentially reaching or exceeding 100 years.
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Ethanol is destroying fibreglass tanks
Plastic fuel tanks have become nearly universal among small boats, commanding over 95% of the market. They are immune to corrosion, which is the leading cause of death for metal tanks. However, ethanol is causing issues with fibreglass tanks.
Ethanol is a powerful agent that breaks down sludge, sending it through the engine and fuel filters. This is causing particular issues for fibreglass tanks in vintage boats, where the resin used in the tank construction is incompatible with ethanol. The resin dissolves, passes through the fuel filters, and re-cures on the valves, causing pushrod failure. The tank ultimately fails, and gasoline leaks into the bilge, creating a significant risk of explosion.
BoatU.S. believes that reformulations made to gasoline in the Long Island Sound area, which replaced MTBE (Methyl Tertiary-Butyl Ether) with a 10% concentration of ethanol, is causing the additive to "attack" the resin in old fibreglass tanks. The result is weakened tank walls and bottoms, with the potential to leak.
One boat owner with a vintage Bertram boat found that although there was a significant amount of sludge in the tank, there were no signs of the tank being compromised. They suggest that the issues may be caused by the age of the tanks, with ethanol breaking up 30+ years of sludge build-up. They also point out that the older fuel fill lines and feed lines to the engine are not compatible with ethanol-added fuels.
It is important to note that not all boats with fibreglass tanks are experiencing issues with ethanol fuel. One boat owner has used a mix of up to 25% ethanol in cold weather without any problems. However, it is the responsibility of the boat owner to research the compatibility of their tanks with the fuel available, as serious damage can occur when using incompatible fuels.
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Salt, contaminated water, sludge, corrosion, and stray currents cause tank decay
Salt, contaminated water, sludge, corrosion, and stray currents can all contribute to the decay of boat fuel tanks.
Saltwater is a significant cause of corrosion in boat fuel tanks. Saltwater can infiltrate the fuel system and engine, causing corrosion in concealed areas. To combat this, it is essential to wash saltwater boats with soap and freshwater after each use, paying special attention to metal components. Additionally, flushing the boat's engine with freshwater for at least five minutes is crucial to removing saltwater remnants from the cooling system.
Contaminated water can also lead to corrosion and sludge buildup in fuel tanks. Water can enter fuel tanks through condensation, leaks, or during filling. This can lead to the separation of water-soluble components from the fuel, contributing to sludge formation. Water contamination can also cause bacterial microbial growth, further degrading the fuel and leading to corrosion. Regularly dewatering tanks at outlet pipes and keeping fuel tanks full can help prevent water build-up and reduce the risk of corrosion.
Sludge, a mixture of solid or semi-solid deposits, water-soluble components, rust, and other contaminants, can accumulate in fuel tanks over time. Sludge buildup can clog fuel filters and lines, reduce fuel efficiency, and cause engine performance issues, eventually leading to engine failure if left unchecked. Regular maintenance, including cleaning and fuel testing, is essential to minimise sludge formation and its associated problems.
Corrosion itself is a significant contributor to fuel tank decay. It can occur in concealed areas, such as inside the fuel system and engine, making it difficult to detect. Sacrificial zinc anodes are often used to protect metallic components from corrosion, but they must be regularly inspected and replaced if corroded. Regular maintenance and visual inspections of connections, wiring, and other components are crucial to identifying and addressing corrosion early on.
Stray currents can also contribute to fuel tank decay, especially in metal tanks. When stray currents pass through the fuel, they can cause electrolytic corrosion, leading to the degradation of the tank and its components. This can be mitigated by proper grounding and bonding of the fuel system to prevent stray currents from passing through the fuel tank.
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Metal tanks corrode over time
The longevity of boat fuel tanks depends on the material they are made of. Metal tanks, for example, are susceptible to corrosion, which is the leading cause of their demise. Corrosion is another word for rust, the breakdown of metal due to an electrochemical reaction. In a water tank, this occurs when an electrical current flows through the water from one point on the inner surface to another. As a result, the metal dissolves into the water, leading to corrosion of the tank's surface. This process can cause leaks and discolouration in the tank wall.
Several factors influence the rate of corrosion in metal tanks, including the type of metal, its use, and the environmental conditions it is exposed to. For instance, galvanic corrosion occurs when two different metals are combined, causing degradation in the weaker metal. Additionally, saltwater, contaminated bottom water, sludge, and stray currents can accelerate corrosion in metal tanks.
To mitigate corrosion in water tanks, two primary methods are employed: coating the inner wall of the tank with paint and cathodic protection. Paint forms a physical barrier between the tank wall and the water, preventing the flow of electrons and subsequent corrosion. However, the coating must match the design and application of the tank and be regularly inspected and maintained. Cathodic protection, on the other hand, involves introducing electrical currents from external sources to counteract normal corrosion reactions. While effective, this method only protects the area of the tank interior where water comes into direct contact with the metal tank wall.
In contrast to metal tanks, plastic fuel tanks are immune to corrosion. They are widely used in small boats and passenger cars, accounting for over 95% of the market. Plastic tanks offer a longer lifespan by eliminating the corrosion issues associated with metal tanks. However, it is worth noting that the durability of plastic tanks in larger applications may be limited by strength and fire safety concerns.
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Frequently asked questions
Plastic boat fuel tanks are immune to corrosion, unlike metal tanks. However, they are not used in large tanks due to strength and fire safety concerns. Plastic tanks have become nearly universal among small boats and passenger cars, with over 95% of the market share. There is no definitive answer to how long they last, but one source mentions that a plastic tank on a 1983 Grady boat was intact at 21 years of age.
Plastic tanks are not used for large boats due to strength and fire safety concerns. Additionally, one source mentions that the compartment of a boat with a plastic tank always smelled of gasoline.
Metal boat fuel tanks can last anywhere from a few years to a few decades, depending on the material used and various environmental factors. Aluminum tanks have been popular for 20 to 30 years, but they can corrode over time, especially if exposed to saltwater. Stainless steel tanks are also susceptible to pitting and crevice corrosion in marine environments. A US Coast Guard study found that the average life expectancy of aluminum tanks was only 20 years, with some failures in less than a year.
